Printronix p7000 Maintenance Manual

Maintenance Manual
Printronix P7000 Series of Line Matrix Printers

P7000 Series of Line Matrix Printers
Maintenance Manual
177705-001B
Trademark Acknowledgements
Trademark Acknowledgements
ANSI is a registered trademark of American National Standards Institute, Inc.
Centronics is a registered trademark of Genicom Corporation.
Chatillon is a trademark of John Chatillon & Sons, Inc.
Code V is a trademark of Quality Micro Systems.
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.
Java is a trademark of Sun Microsystems.
LinePrinter Plus is a registered trademark of Printronix, Inc.
Linux is a registered trademark assigned to Linus Torvalds.
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 and PSA3 are trademarks of Printronix, Inc.
QMS is a registered trademark of Quality Micro Systems.
SureStak is a trademark of Printronix, Inc.
Torx is a registered trademark of Camcar/Textron Inc.
UNIX is a registered trademark of The Open Group.
Utica is a registered trademark of Cooper Power Tools.
Warranty And Copyright Information
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.
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 © 2005, Printronix, Inc.
ENERGY STAR
The Environmental Protection Agency ENERGY STAR® Computers program is

a partnership effort with manufacturers of data processing equipment to
promote the introduction of energy-efficient personal computers, monitors,
printers, fax machines, and copiers to help reduce air pollution and global
warming caused by electricity generation.
Printronix, Inc. participates in this program by introducing printers that reduce
power consumption when they are not being used. As an ENERGY STAR®
Partner, Printronix has determined that this product meets the ENERGY STAR®
guidelines for energy efficiency.
NOTE: The ENERGY STAR® emblem does not represent EPA endorsement of
any product or service.
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 provide 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 instructions, 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 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 Fules. 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.
European Union (EU) Conformity Statement
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 option cards not authorized by Printronix.
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 devices.
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.
Properly shielded and grounded cables and connectors must be used in order
to reduce the potential for causing interference to radio and TV
communications and to other electrical or electronic equipment. Such cables
and connectors are available from Printronix authorized dealers. Printronix
cannot accept responsibility for any interference caused by using other than
recommended cables and connectors.
Industry Canada Compliance Statement

This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A conform á la norme NMB-003 du

Canada.
Statement of CISPR 22 Edition 2 Compliance

Attention: 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.
Japanese VCCI Class A
Taiwan
Warning: This is a Class A product. In a domestic environment this product

may cause radio interference in which case the user will be required to take
adequate measures.
Australia/New Zealand
Attention: This is a Class A Product. In a domestic enviroment this product
adequate measures.
Korea
China
Declaration: This is a Case A Product. In a domestic environment this
product may cause radio interference, in which case the user may be required
to take practical actions.
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.
Der Außteller der Konformitätserklärung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gerät erfüllt die Schutzanforderungen nach EN 55022 und

EN 55024 Klasse A.
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
European Union (EC) Electromagnetic Compatibil-
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.
European Union (EC) Electromagnetic Compatibility

Directives
This product conforms to 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 option cards
not authorized by Printronix.
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen EMVG
vom 9.Nov.92 das EG-Konformitätszeichen zu furhren.
Properly shielded and grounded cables and connectors must be used to
reduce the potential for causing interference to radio and TV communication
and to other electrical or electronic equipment. Printronix cannot be
responsible for any interference caused by using other than recommended
cables and connectors.
This product has been tested and found to comply with limits for Class A
Information Technology Equipment according to CISPR 22/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.
Warning: This is a Class A product. In a domestic environment this product
adequate measures.
Dieses Gerät erfüllt die Bedingungen der EN 55022 Klasse A. Für diese
Klasse von Geräten gilt folgende Bestimmung nach dem EMVG:
Geräte dürfen an Orten, für die sie nicht ausreichend 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 vom 9.Nov.92, Para.3, Abs.4)
Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost
noch nicht veröffentlict worden.
Chapter
Table Of Contents
1 Maintenance Overview ....................................... 17

Printronix P7000 Printers..................................................................... 17
Order The Correct Spares............................................................. 18
How To Identify A P7000 Printer ................................................... 18
H-Series Printers ........................................................................... 20
Zero Tear Pedestal (ZTP) Printers ................................................ 20
Printer Configuration Code............................................................ 20
Forms Handling ............................................................................. 21
Important Maintenance Notes.............................................................. 22
Notices .......................................................................................... 22
About This Manual............................................................................... 23
How To Use This Manual .............................................................. 24
Safety Notices...................................................................................... 25
Hinweise zur Sicherheit ....................................................................... 25
Controls And Indicators ....................................................................... 26
Electrical Controls ......................................................................... 26
Mechanical Controls...................................................................... 28
Tools And Test Equipment .................................................................. 30
Plugging In The Printer ........................................................................ 31
Printronix Customer Support Center.................................................... 31
Printronix Supplies Department..................................................... 32
Maintenance Training For Printronix Products .................................... 32
2 Preventive Maintenance ..................................... 33

Cleaning The Printer............................................................................ 33
Cleaning The Outside Surfaces........................................................... 33
Cleaning The Shuttle Frame Assembly ............................................... 35
Cleaning The Card Cage Fan Assembly ............................................. 36
3 Troubleshooting.................................................. 37
Introduction .......................................................................................... 37
Troubleshooting Aids ........................................................................... 37
Start Here... ......................................................................................... 38
Troubleshooting Display Messages..................................................... 39
List Of Messages .......................................................................... 39
Troubleshooting Other Symptoms ..................................................... 107
11
Table of Contents
General Symptom List................................................................. 108

Communications Failures .................................................................. 132
Diagnostic Printer Tests..................................................................... 134
Selecting And Running Diagnostic Printer Tests ........................ 135
Boot Diagnostics Menu...................................................................... 140
Factory Menu..................................................................................... 143
Hex Code Printout ............................................................................. 146
How To Print A Hex Dump .......................................................... 147
ASCII Character Set .......................................................................... 149
Soft vs. Hard Reset............................................................................ 150
The Power On Sequence .................................................................. 151
Controller Board Handshake Sequences .................................... 152
DC Software Initialization And Power Up .................................... 155
4 Adjustments and Tests ..................................... 157

Introduction ........................................................................................ 157
Adjustments and Tests................................................................ 157
Preparing The Printer For Maintenance ............................................ 158
Returning The Printer To Normal Operation...................................... 159
Belt, Paper Feed Timing, Adjustment ................................................ 160
Belt, Platen Open, Adjustment........................................................... 162
Paper Scale Alignment ...................................................................... 164
Platen Gap Adjustment...................................................................... 166
Ribbon Guide Alignment.................................................................... 168
Paper Out Adjustment ....................................................................... 170
Hammer Phasing Adjustment ............................................................ 173
Loading Flash Memory ...................................................................... 175
Loading Software With The Firmware Download Utility .............. 175
Loading Through Parallel Or Serial Port Using DOS .................. 177
Loading Software If Flash Contains Only Boot Code.................. 178
Loading Software Through The NIC ........................................... 180
Reprogramming the Security Key...................................................... 182
How To Reprogram The Security Key ........................................ 182
Coil Temperature Adjustment ............................................................ 184
Dynamic Paper Tension Adjustment ................................................. 185
Tractor Belt Tension Adjustment ....................................................... 187
Shuttle Electrical Short Check ........................................................... 188
Hammer Bank Power Cable Shorts Test........................................... 189
Cable Shorts Test .............................................................................. 190
Main Wire Harness Test Diagnostic .................................................. 192
Power Supply Operational Check...................................................... 193
12
Table of Contents
5 Replacement Procedures
And Illustrated Parts Lists...................................... 197
Organization Of This Chapter ............................................................ 197
Section I: Replacement Procedures .................................................. 198
List Of Removal / Installation Procedures ................................... 198
Belt, Paper Feed Timing ............................................................. 200
Belt, Platen Open ........................................................................ 201
Circuit Breaker ............................................................................ 202
Connector Coupling Shrouds ...................................................... 203
Control Panel Assembly .............................................................. 205
Controller Board .......................................................................... 206
Cover Assembly, Hammer Bank / Ribbon Mask ......................... 208
Cover Assembly, Shuttle ............................................................. 209
Cover Assembly, Top, Pedestal Models ..................................... 210
CT Board ..................................................................................... 211
Dashpot ....................................................................................... 212
Fan Assembly, Cabinet Exhaust ................................................. 213
Fan Assembly, Card Cage .......................................................... 214
Fan Assembly, Hammer Bank..................................................... 215
Hammer Spring Assembly........................................................... 216
Integrated Print Management Sensor ......................................... 218
Magnetic Pickup (MPU) Assembly .............................................. 219
Memory and Security Key ........................................................... 220
NIC (Network Interface Card) Assembly ..................................... 222
Paper Feed Motor ....................................................................... 223
Paper Ironer ................................................................................ 224
Paper Path .................................................................................. 225
Platen .......................................................................................... 226
Platen Open Motor ...................................................................... 230
Platen Stop Assembly ................................................................. 232
Power Supply Board ................................................................... 233
Resistors, Terminating ................................................................ 234
Ribbon Drive Motor ..................................................................... 236
Ribbon Guide Assembly (L/R)..................................................... 237
Shaft, Splined .............................................................................. 238
Shaft, Support ............................................................................. 240
Shuttle Frame Assembly ............................................................. 241
Spring, Extension, Hammer Bank ............................................... 243
Static Brush, Pedestal Printer ..................................................... 244
Switch Assembly, Paper Detector ............................................... 246
Switch Assembly, Platen Interlock .............................................. 247
13
Table of Contents
Tractor (L/R) ................................................................................ 248

Section II: Illustrated Parts Lists ........................................................ 249
Illustrations of Printer Components ............................................. 249
6 Principles Of Operation..................................... 291

Line Matrix Printing ............................................................................ 291
Printing Rates .................................................................................... 294
Printing Mechanism ........................................................................... 294
Shuttle Frame Assembly.................................................................... 295
Hammer Bank Assembly............................................................. 295
Shuttle Drive Motor ..................................................................... 295
Paper Transport System.................................................................... 297
Ribbon Transport System .................................................................. 298
Integrated Print Management System ............................................... 299
Operation .................................................................................... 299
The Ribbon Log........................................................................... 302
Logical Control Of The Printer ........................................................... 303
Control Panel ..................................................................................... 304
Controller Board................................................................................. 305
Data Controller ............................................................................ 307
Engine Controller ........................................................................ 309
Power Supply Board .......................................................................... 311
AC Power .................................................................................... 311
DC Power .................................................................................... 311
Printer Interface ................................................................................. 312
Graphics ............................................................................................ 312
A Wire Data ......................................................... 313
B Abbreviations.................................................... 359
C Metric Conversion Tables ................................ 367
D SureStak™ Power Stacker .............................. 369

Contents ............................................................................................ 369
Introduction ........................................................................................ 370
Stacker Operation.............................................................................. 370
Stacker Problems .............................................................................. 375
Stacker First Inspection............................................................... 375
Stacker Confidence Check.......................................................... 376
Stacker Motor Check................................................................... 377
Removing The Power Stacker ........................................................... 380
Installing The Power Stacker ............................................................. 386
14
Table of Contents
Replacing The Constant Force Spring............................................... 397

Replacing The Timing Belts............................................................... 399
Replacing The Roller Drive Shaft ...................................................... 402
Illustrated Parts Breakdown............................................................... 405
List of Illustrations ....................................................................... 405
E Zero Tear Pedestal (ZTP) ................................ 417

Contents ............................................................................................ 417
Overview............................................................................................ 417
Performance Limitations .................................................................... 417
Control Panel Menus ......................................................................... 419
Operation ........................................................................................... 420
Adjust The Paper Guides ............................................................ 420
Load Paper.................................................................................. 421
Set The Tear Bar Distance.......................................................... 422
Set The Top Of Form .................................................................. 423
Position The Paper Out Sensor .................................................. 424
Illustrated Parts Lists ......................................................................... 425
Illustrations of ZTP Printer Components ..................................... 425
F Paper Specifications And Forms Design.......... 441

Introduction ........................................................................................ 441
General Paper Specifications ............................................................ 442
Paper Guidelines ............................................................................... 443
Terms And Definitions ................................................................. 443
Environmental Considerations .................................................... 445
Form Types ................................................................................. 445
Form Weight................................................................................ 445
Form Thickness........................................................................... 445
Form Evenness ........................................................................... 445
Tractor Pin Engagement ............................................................. 445
Methods Of Forms Attachment ................................................... 446
Chaff Content .............................................................................. 447
Form Design Checklist....................................................................... 448
Summary ........................................................................................... 451
Storage And Handling ................................................................. 451
G Maintenance Manuals For P5000 Printers ...... 453
15
Table of Contents
16
1 Maintenance Overview
Printronix P7000 Printers

P7000 printers are the latest Printronix line matrix printers to feature PSA3™
(Printronix System Architecture, third generation). This innovative printer
architecture puts all data and printer control electronics on the PSA3
controller board. Up to 32 MB of flash memory on this board permits rapid
access to stored printer control languages (emulations) and very fast
processing of print data. A variable-speed shuttle and micro-step paper feed
control enable P7000 printers to print a wide range of horizontal and vertical
dot densities, making these printers ideal for high-volume print jobs.
The controller board, card cage, and some parts of the ribbon drive system in
P7000 printers are new designs and are not electrically or mechanically
compatible with earlier Printronix line matrix printers. (For maintenance
information about earlier Printronix printers, see page 453.)
The principal differences among the various P7000 models are the number of
hammers on the hammer bank, whether the printer is mounted on a pedestal
or housed in a floor cabinet, and the maximum possible print speed. In this
manual, all items described apply to all models except where noted. (See
Table 1 on page 19.)
Although technically sophisticated, a P7000 printer is easy to use. The
mechanical controls that the operator can adjust are colored blue for quick
identification. The operator can select every printer function either at the
printer control panel or by sending control codes to the printer in the data
stream from the host computer. For added security—and to protect special
printer configurations—the operator can program which key combination
locks and unlocks the ENTER key on the control panel.
Optional Features Enhance Graphics

The PGL® and VGL Printronix emulations, bundled together as IGP®, are
easy to use but highly versatile graphics programming languages that load
into the printer’s memory and simplify the creation of graphic images. The
PSA3 architecture enables multiple emulations and graphic options to be run
without additional graphic processors or protocol converters. Depending upon
the model, various types of paper stacker are available to handle any
throughput requirements. (See “Forms Handling” on page 21.)
17
Chapter 1 Printronix P7000 Printers
Order The Correct Spares

When you replace worn or damaged printer components, make sure you
order the correct spares for the model you are servicing. The next section
shows you how to identify a P7000 printer.
How To Identify A P7000 Printer

A P7000 printer has a black or gray finish and the PSA3 logo on the printer
cover. Every printer also has a model number, which is an alphanumeric code
that identifies the printer type, its housing, and its maximum rated print speed.
The model number and serial number of the printer are on the identification
label next to the input/output ports at the rear of the printer. Figure 1 shows
how to inpret a model number.
Housing Code:
0 = Pedestal
2 = Floor Cabinet
H = H-Series printer
ZT = Zero Tear Pedestal (option)
Printronix Line P7003H
Matrix Printer
P7000 Printer
Speed Rating:
03 = 300 lines per minute (lpm)
05 = 500 lpm
06 = 600 lpm
08 = 800 lpm
10 = 1000 lpm
15 = 1500 lpm
20 = 2000 lpm
Figure 1. How to Interpret a Model Number
Table 1 lists the models in the P7000 series. Remember that the speeds
listed are the highest attainable under controlled test conditions. The speed of
printing for “real world” print jobs is affected by the interaction of many
variables and varies from print job to print job. For more information, see
“Printing Rates” on page 294.
18
How To Identify A P7000 Printer
Table 1. P7000 Printers
Maximum
Model Number Enclosure Hammer Bank
Print Speed
P7003H 300 lpm Pedestal 60 Hammers
P7003HZT 300 lpm Zero Tear 60 Hammers

Pedestal
P7203H 300 lpm Cabinet 60 Hammers
P7005 500 lpm Pedestal 28 Hammers
P7005ZT 500 lpm Zero Tear 28 Hammers

Pedestal
P7205 500 lpm Cabinet 28 Hammers
P7006HZT 600 lpm Zero Tear 102 Hammers

Pedestal

Pedestal

Pedestal
19
Chapter 1 Printronix P7000 Printers
H-Series Printers
H-Series models print the ideogrammic symbols used in China, Hong Kong,
South Korea, and Taiwan. (See Table 2.) These Kanji/Hanzi/Hangul printers
are indicated by the letter H in the model number suffix. (See Figure 1 and
Table 1.) H-Series printers have specially designed platens and unique
shuttle assemblies which are not interchangeable with any other Printronix
printers.
Table 2. H-Series Character Sets
Character Set Where Used
GB China
BIG-5, with an additional 3000 Cantonese characters Hong Kong
BIG-5
TCA
DCI (1st and 2nd segments) Taiwan
DCI (3rd segment)
CNS
KSC 5601 South Korea
Zero Tear Pedestal (ZTP) Printers

Zero Tear Pedestal (ZTP) printers are pedestal models equipped with special
hardware and software that permits them to print small jobs or single sheets
without losing a sheet between print jobs. The printer automatically presents
the current print line to a tear bar when it finishes printing and presents the
perforation of the last form printed to the tear bar. When it receives more data
from the host computer, the printer pulls the form down to the print station and
resumes printing.
ZTP printers are covered in Appendix E (see page 417).
Printer Configuration Code

Every printer also has a configuration code which specifies the printer’s
cabinet type, controller board revision level, V8 ASIC revision level, and
MECA ASIC revision level. The configuration code is included in the
configuration printout. Figure 2 shows how to interpret the printer’s
configuration code.
V8 ASIC Revision Level

Cabinet Type:
F = Floor Cabinet MECA ASIC
Revision Level
P = Pedestal Model FH05AF
Controller Board Revision Level.
H = PSA3 board
Figure 2. How to Interpret the Printer’s Configuration Code
20
Forms Handling
Forms Handling
Pedestal Models
Pedestal models provide access to printed forms from the top cover with a
tear-at-perforation edge for ejected forms or a paper exit at the rear of the top
cover. Pedestal printers also have a wireform paper tray attached to the front
of the pedestal and a wireform catch basket attached either to the back of the
pedestal or to the back of the printer top cover.
Cabinet Models
Cabinet models can be equipped with four kinds of paper stacking device:
• The fixed paper fence is a wireform divider that separates the source
paper stack from the printed output stack, and is used in combination with
hanging chains that guide printed forms downward.
• For improved performance at higher print speeds, the chains are used
with a moveable fence called the “passive paper stacker,” which can be
positioned to match the form’s length.
• The front access paper stacker consists of a shelf that holds the input
paper and a sliding tray that receives the printed forms. The sliding tray
pulls forward, permitting the user to both load and unload paper from the
front of the printer. This option is helpful in locations where access to the
rear of the printer is limited or impossible.
• For more demanding applications, an optional power stacker is available.
(The power stacker is covered in Appendix D on page 369.)
These devices are summarized in Table 3.
Table 3. Paper Stackers Used On Cabinet Models
Passive Front Power

Fixed Paper
Printer Paper Access Paper
Fence
Stacker Stacker Stacker
P7205 Standard Option Option Option
P7210 Not Used Standard Option Option

21
Chapter 1 Important Maintenance Notes
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 assembly or platen has been replaced with a new or
rebuilt unit, or
2) you are instructed to do so in a troubleshooting procedure.
• Never bend or try to adjust (“tweak”) the hammer springs. The
hammer springs are precisely aligned and the hammer tips are delicate.
Always handle hammer springs by the thick mounting base.
• Use only the ribbons specified in the User’s Manual. Using ribbons
not made by Printronix can lead to degraded print quality, expensive
damage to the printer, and can void the owner’s warranty.
• Never close the forms thickness lever (platen lever) too tightly.
Closing the forms thickness lever too tightly can lead to smeared print,
degraded print quality, paper jams, and damage to the platen and shuttle
assembly.
Notices
For your safety and to protect valuable equipment, always read and comply
with all information highlighted under notices.
The heading of a notice indicates the kind of information it contains, as
explained below:
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: Tips for efficient operation, maintenance, and troubleshooting.
22
About This Manual
This is a field service maintenance manual, intended for use by trained
service personnel. It is designed so that you can quickly locate the
maintenance information you need to restore the printer to operation.
This manual does not explain how to install, operate, or configure the printer.
For that information, refer to the Quick Setup Guide and the User’s Manual.
This manual does not explain how to program application software for
operation with the printer. Programming information for the printer languages
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 Interface Card 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
emulation (CT).
• 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
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.
23
Chapter 1 About This Manual
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 on page 22.)
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 / CLEAR key.
Messages that appear on the LCD (Liquid Crystal Display) are set off by
quotation marks (“ ”).
Example: Press the ON LINE / CLEAR key. “OFF LINE” appears on the LCD.
Control panel key combinations are indicated by the + (plus) symbol.
Example: Press = + >.
means press the key and the key at the same time.
IMPORTANT The Safety Notices on page 25 apply at all times when you are working
on a P7000 printer. Please read them now.
24
Safety Notices
WARNING Always disconnect the AC power cord from the printer or power source
before performing any maintenance procedure. Failure to remove power
could result in injury to persons or damage to equipment. If you must
apply power during maintenance, you will be instructed to do so in the
maintenance procedure.
WARNING Always disconnect the AC power cord before cleaning the printer.
WARNING To prevent injury from electric shock, wait at least one minute after
shutting off power before removing the power supply circuit board.
Wear a properly grounded static wrist strap when handling the power
supply board. Handle the board by the sides. Do not touch components
or flex the board during removal/installation.
WARNING Over time, the upper edge of the paper ironer can become sharp. To
avoid cutting yourself, handle the paper ironer on the sides.
WARNING Hold the printer cover securely while disengaging the dashpot.
Hinweise zur Sicherheit

VORSICHT Bevor Sie anfällige Wartungsarbeiten durchführen, müssen Sie zuerst
immer das Netzkabel aus der Steckdose ziehen. Wird das Netzkabel
nicht herausgezogen, können Verletzungen oder Geräteschäden
entstehen. Falls die Wartungsarbeit Stromzufuhr erfordert, wird im
Wartungsablauf darauf hingewiesen.
VORSICHT Ziehen Sie das Netzkabel aus der Steckdose, bevor Sie den Drucker
reinigen.
VORSICHT Um Verletzungen durch Elektroschocks zu vermeiden, warten Sie

mindestens eine Minute nach Stromausschaltung, bevor Sie die
elektrische Schaltkarte entfernen. Bitte immer einen geerdeten,
statischen Handgelenkriemen tragen, wenn Sie die elektrische
Schaltkarte handhaben. Halten Sie die Karte nur an den seitlichen
Auswurfshebeln. Während des Herausnehmens/Installierens dürfen die
Komponenten der Karte nicht berührt oder gebogen werden.
VORSICHT Die obere Kante der Papierschiene wird mit der Zeit scharf. Halten Sie
die Schiene deshalb an den Seiten, damit Sie sich nicht schneiden.
VORSICHT Behalten Sie die Druckerabdeckung sicher im Griff, wenn Sie das
Gasfederpaket entfernen.
25
Chapter 1 Controls And Indicators
Controls And Indicators

Electrical Controls
Switch or Active Active

Function
Indicator Online Offline
Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker.
Status Indicator On when the printer is online, off when the printer is offline. Flashes to indicate a fault or
warning.
LCD Liquid Crystal Display. Displays printer status messages, fault messages, and menus which
permit user to set various configurations.
ON LINE / Toggles the printer online and offline. Clears the printer after a fault is corrected and returns
CLEAR the printer to offline state. Pressing CLEAR silences the audible alarm (if enabled).
PAPER Prints any data in the buffer then moves paper to the next Top Of Form as defined by the
ADVANCE currently active form length.
VIEW / Cabinet: moves last data printed to the tractor area for viewing. “Printer in View” displays.
EJECT Press UP or DOWN key to move paper vertically in 1/72 inch increments. (Refer to the Up
and Down key functions.) Press VIEW/EJECT again to move the paper back to the adjusted
print position.
Pedestal: moves bottom of last printed form to the tear bar position. “READY TO TEAR/
EJECT TO RETURN” displays. Press UP or DOWN key to move the paper vertically in 1/72
inch increments. (Refer to the Up and Down key functions.) Press VIEW/EJECT again to
move the paper to the top of the next available form.
CANCEL Clears all data from the print buffer (if enabled in the MAINT/MISC menu).
Displays next higher level of a configuration menu. In VIEW mode, moves paper up 1/72
inch. (See VIEW / EJECT key.)
Displays next lower level of a configuration menu. In VIEW mode, moves paper down
1/72 inch. (See VIEW / EJECT key.)
Displays the next option in a configuration menu.
Displays the previous option in a configuration menu.
SET TOF Moves paper downward from TOF (Top Of Form) alignment mark to the print station and sets
this as the first line of print on a page, independent of forms length. If there are data in the
buffers, the printer slews to the page position where printing left off and prints the data.
PRT CONFIG Prints the current printer configuration.
JOB SELECT Allows selection of the active configuration or print mode (typeface) of the printer. The
functionality of this key depends on the current setting of the “Job Select/Print Mode” under
the “MAINT/MISC” menu. (Refer to the User’s Manual.)
ENTER Enters an option displayed on the LCD into the printer’s non-volatile memory. Starts and
stops printer tests, sets a value, or prints the configuration. This key is locked and unlocked
by a user-selectable key combination. (Refer to the User’s Manual.)
= + ON LINE When pressed in offline state, if data are in the printer buffer the printer goes online, prints
one page, then returns to offline. Can be repeated until the end of a print job. Only one page
(IPDS emulation prints each time you press = + ON LINE. If no data are in the printer buffer, the printer is
only) placed in online mode. (This key combination does not work if the printer is in the fault state.)
;+ < Resets the printer by reloading the power-up configuration and resetting the internal state.
26
Electrical Controls
Rotated 180 Degrees

A B
C
C (Off) (On) A
B
Power Switch
Arrow Keys Status Indicator

LCD
B
SET TOF
PRT
CONFIG
JOB ON LINE/ PAPER VIEW/

SELECT CLEAR ADVANCE EJECT CANCEL
ENTER
Figure 3. Electrical Controls
27
Chapter 1 Controls And Indicators
Mechanical Controls
Control or Indicator Function
Paper Supports Help prevent paper jams by supporting inner sections of paper. They
are positioned manually by sliding them along the shafts.
Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. This
lever must be fully opened (raised) to load paper, unload paper, and
move paper with the vertical position knob.
Forms Thickness Indicates the relative thickness of forms and paper. Align pointer with
Pointer and Scale A for thin (single-part) forms, B for thicker forms, and so on.
Forms Thickness Lever The forms thickness lever closes the platen to the relative thickness
and Platen Stop of the paper. The platen stop returns the platen to the lever
adjustment made by the user.
Tractors (2) Hold and feed paper. Used to set side margins and position the paper
horizontally.
Tractor Locks (2) Lock tractors in position.
Vertical Position Knob Used to set top of form or the first line to be printed. Open the forms
thickness lever and rotate this knob to move paper vertically.
Ribbon Loading Path Instructions showing how to load the ribbon correctly.
Diagram
Paper Scale A horizontal scale graduated in tenths of an inch, useful for setting
paper margins and counting text columns. (See below.)
1 inch
1 10 20
0.1 inch Column

Number
28
Paper
Supports
Right Tractor
Left Tractor
Tractor Lock
Tractor Lock
Vertical
Position
Knob
Forms
Thickness
Lever and
Scale
Platen Stop
Assembly
Ribbon Loading
Path Diagram
Figure 4. Mechanical Controls
29
Chapter 1 Tools And Test Equipment
Tools And Test Equipment

For field level maintenance of the printer, you will need these tools:
Adapter, 1/4 in. hex to 1/4 in. square, Utica® HW-18
Alcohol, anhydrous
Allen Wrench, 1/16 inch
ESD Wrist Strap
Feeler Gauge, Flat, 0.010 inch
Field Kit, Tester, P5 Power Supplies, Generic, (P/N 178083-001)
Force Gauge, (Chatillon™ NY, Gauge-r, 0-20 lb., CAT 719-20)
Force Gauge, “Fish Scale” type, 0-16 oz.
Hardware Kit, P5XXX Mech, ZTP (P/N 178573-001)
Hex bit, 3/16 in., torque screwdriver
Lubricant, Bearing (Printronix P/N 101805-001)
Nut Driver, 1/4 inch
Nut Driver, 5/16 inch
Nut Driver or Open End Wrench, 7/32 inch
Open End Wrench, 5/16 inch
Pliers, Grip Ring, External
Screwdriver, flat tip
Screwdriver, Phillips, #1
Screwdriver, Phillips, #2
Screwdriver, Torque, Utica TS-35
Tie Wraps, 4 inch and 8 inch
Torx® T-10, T-15 Driver
30
Plugging In The Printer
In compliance with international safety standards, a P7000 printer is equipped
with a three-pronged electrical plug on the power cord. When this power cord
is plugged into a correctly wired AC power outlet, the ground conductor
ensures that the printer chassis is at ground (earth) electrical potential.
WARNING Failure to properly ground the printer can result in electrical shock to
the operator.
Never use adapter plugs that have no grounding prong. Never remove
the grounding prong from the power cable plug. If an extension cord is
required, make sure it is a three-wire cable with a properly grounded
plug.
Printronix Customer Support Center

The Printronix Customer Support Center offers technical support with:
• Installation
• Configuration and setup
• Loading supplies and operating the printer
• Specifications of the proper ribbons, forms, and paper
• Answers to post-sale service support questions
IMPORTANT Please have the following information available before you call the
Printronix Customer Support Center:
• Model number of the printer
• Serial number (located on the back of the printer)
• Installed options (i.e., interface and host type if applicable to the problem)
• Configuration printout (Press PRT CONFIG on the control panel, then
press ENTER)
• Is the problem with a new installation or an existing printer?
• Description of the problem (be specific)
• Good and bad samples that clearly show the problem (faxing of these
samples may be required)
Americas (714) 368-2686
Europe, Middle East, and Africa (31) 24 6489 410
Asia Pacific (65) 6548 4114
http://www.printronix.com/public/servicessupport/default.aspx
31
Chapter 1 Maintenance Training For Printronix Products
Printronix Supplies Department

Contact the Printronix Supplies Department for genuine Printronix supplies.
Americas (800) 733-1900
Europe, Middle East, and Africa (33) 1 46 25 1900
Asia Pacific (65) 6548 4116
or (65) 6548 4182
http://www.printronix.com/public/supplies/default.aspx
Maintenance Training For Printronix Products

Printronix offers Product Maintenance Training Classes designed to enhance
the knowledge of service personnel. Taught by experienced professional
instructors, these classes include:
• Theory of operation
• Hands-on work with the products
• Diagnosis of equipment failures
• Preventive and corrective maintenance requirements and procedures
Customized classes designed to meet specific needs are also available upon
request. Call Customer Training at (714) 368-2332 or visit the Printronix web
page at www.printronix.com.
32
2 Preventive Maintenance
Cleaning The Printer

The printer is designed to require very little maintenance. Aside from normal
replenishment of paper and ribbons, the only preventive maintenance
necessary is periodic cleaning. Periodic cleaning, especially of the ribbon
guides and ribbon path, contributes to increased printer life and reliability, and
helps sustain superior print quality.
Because operating conditions vary so widely, the user must determine how
often to clean the printer. But, since there is no guarantee that the user will
clean the printer regularly, you should clean the printer every time you are
called to service it.
NOTE: A cabinet model printer is illustrated in this chapter, but the cleaning
procedures presented here pertain to all models.
WARNING Always disconnect the AC power cord before cleaning the printer.
CAUTION Do not use abrasive cleaners, particularly on the window.

Do not drip water into the printer. Damage to the equipment will result.
Do not spray directly onto the printer when using spray solutions. Spray
a cloth, then apply the dampened cloth to the printer.
Do not vacuum circuit boards.
Cleaning The Outside Surfaces

1. Set the printer power switch to O (Off).
2. Disconnect the AC power cord from the printer or the power source.
3. Remove the paper.
4. Remove the ribbon.
5. Dampen a clean, lint-free cloth with water and a mild detergent or window
cleaning solution. Make the cloth damp, not wet. Wipe down the outside
surfaces of the printer.
6. Dry the outside surfaces with a clean, lint-free cloth.
7. Open the printer cover.
8. Using a soft-bristled, non-metallic brush (such as a toothbrush), brush
paper dust and ribbon lint off the tractors, shuttle cover assembly (air
shroud), base casting, and ribbon guides. Vacuum up the residue.
(Figure 5.)
9. Wipe the splined shaft with a soft cloth.
33
Chapter 2 Cleaning The Outside Surfaces
CAUTION To avoid corrosion damage, use only alcohol when cleaning printer
mechanical elements and make sure the cleaning solution contains no
water.
10. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides.
11. Vacuum up dust and residue from the lower cabinet.
12. Wipe the interior of the lower cabinet with a clean, lint-free cloth
dampened with water and a mild detergent or window cleaning solution.
13. Dry the cabinet interior with a clean, lint-free cloth.
14. Clean the shuttle frame assembly, as described in the next section.
Tractors
Splined Shaft
Shuttle Cover
Assembly
(Air Shroud)
Base Casting
NOTE: A cabinet model is Forms Thickness

shown here, but the Lever
procedure is the same for
pedestal models.
Ribbon Guide
Figure 5. Where to clean inside the cabinet or top cover.
34
Cleaning The Shuttle Frame Assembly
1. Remove the shuttle cover assembly (page 209).
2. Remove the shuttle frame assembly (page 241).
3. Remove the paper ironer(s) (page 224).
4. Moisten a clean, soft cloth with alcohol. Wipe the paper ironer(s) to
remove lint, ink, and paper residue.
5. Install the paper ironer(s) (page 224).
6. Remove the hammer bank / ribbon mask cover assembly (page 208).
CAUTION The ribbon mask is easily bent. When handling and cleaning the ribbon
mask be careful not to crease or kink it.
7. Moisten a clean, soft cloth with alcohol. Wipe the hammer bank cover and
ribbon mask to remove lint, ink, and paper residue. Clean the holes in the
cover strips.
CAUTION Do not use solvents or liquids to clean the hammer tips. Clean the
hammer tips gently—too much pressure can chip them.
8. Using a stiff, non-metallic brush (such as a toothbrush), gently brush the
hammer tips to remove lint and ink accumulations. (Figure 6.) Vacuum up
any residue.
Hammer Tip
Figure 6. Cleaning the Hammer Tips
CAUTION The hammer bank contains a strong magnet. To prevent damage to the
hammer tips, do not let the hammer bank cover assembly snap into
place as the hammer bank magnet attracts it. Any impact of the cover
against the hammer bank can break hammer tips.
9. Install the hammer bank / ribbon mask cover assembly (page 208).
10. Install the shuttle frame assembly (page 241).
11. Install the shuttle cover assembly (page 209).
12. Clean the card cage fan assembly, as described in the next section.
35
Chapter 2 Cleaning The Card Cage Fan Assembly
Cleaning The Card Cage Fan Assembly

1. Cabinet Models: Remove the paper path (page 225).
Pedestal Models: Remove the top cover assembly (page 210).
2. Vacuum the card cage fan assembly and surrounding areas to remove
paper particles, dust, and lint. (Figure 7.)
3. Install the ribbon.
4. Cabinet Models: Install the paper path (page 225)
Pedestal Models: Install the top cover assembly (page 210).
5. Return the printer to normal operation (page 159).
NOTE: A cabinet model is

shown here, but the
procedure is the same for
pedestal models.
Card Cage Fan
Figure 7. Cleaning the Card Cage Fan Assembly
36
3 Troubleshooting
Introduction
This chapter lists fault messages and general symptoms, and provides
procedures for troubleshooting printer malfunctions.
NOTE: Because you must operate the printer to check its performance and
sometimes you may have to reconfigure it, always have the User’s
Manual handy when you troubleshoot. This manual does not cover
printer operation or configuration.
Troubleshooting Aids
Troubleshooting is faster and more effective if you understand the equipment
and make use of all available tools.
This manual has a number of troubleshooting aids to help you isolate printer
malfunctions:
• “Start Here” Logic Tree ............................................................... page 38
• Troubleshooting Display Messages............................................ page 39
• Message List............................................................................... page 39
• Troubleshooting Other Symptoms ............................................ page 107
• General Symptom List .............................................................. page 108
• Communications Failures ......................................................... page 132
• Diagnostic Printer Tests............................................................ page 134
• Boot Diagnostics Menu............................................................. page 140
• Factory Menu............................................................................ page 143
• Hex Code Printout .................................................................... page 146
• ASCII Character Set ................................................................. page 149
• The Power On Sequence ......................................................... page 151
• Appendix A: Wire Data ............................................................. page 313
37
Chapter 3 Start Here...
Start Here...
Are you here because of an Go to Troubleshooting Display

error message? YES Messages, page 39.
NO
Power on the printer and

observe the control panel for
the following sequence of
events (retry as required):
1. All black squares appear on Did the status
the display. indicator lamp
2. Display goes blank. come on and Printer initialized
3. The following messages After about 10 ONLINE appear successfully.
YES seconds did YES on the display? (If YES Other symptoms
appear on the display, in this
order: the fans come default is are listed in
on? OFFLINE, status Table 5 page
B00 STATUS: SDRAM indicator will not 108.
DETECTION 33MHZ NO come on.)
B01 STATUS: 8245 NO

SDRAM TEST 32MB
B51 STATUS: XX% Go to Printer

LOADING does not
initialize, page
114.
B30: STATUS INITIALIZING...
Power on the printer.

Did steps 1, 2, and 3 occur?
NO
Press ON LINE.
Press PRT CONFIG. Go to the Control
Did the fans come on after YES Press ENTER.
10 seconds? YES Panel section of
Does machine Table 5 page 108.
configuration
NO print?
NO
The Control Panel

is not functioning
(Table 5 page 108)
—OR—
Printer does not
initialize, page 114.
Did ANY of steps 1 thru 3 Are there black Go to Black squares

occur? YES squares on the YES on control panel
control panel? display, page 111.
NO
NO
Go to No power, and
control panel is blank, Go to Printer does not
and card cage fan is not initialize, page 114.
running, page 113.
38
List Of Messages
Troubleshooting Display Messages

WARNING Always disconnect the AC power cord from the printer before doing a
maintenance procedure. Failure to do so could result in injury to you or
damage to equipment. If you must apply power during maintenance, you
will be instructed to do so in the maintenance procedure.
Three kinds of messages appear on the Liquid Crystal Display (LCD):
• Status messages
• Configuration menus with associated options
• Fault messages
Most fault messages are cleared from the LCD by correcting the fault
condition then pressing the CLEAR key.
Some fault messages can only be cleared by shutting down and restarting the
printer. These fault messages are indicated by an asterisk (*) after the
message.
If printer logic circuits detect a fault condition, three things happen:
• The status indicator on the control panel flashes on and off.
• The audible alarm beeps if it is enabled. (Press CLEAR to silence the
alarm.)
• The control panel LCD displays a fault message.
List Of Messages
Find the message in the Message List below and follow the suggested
procedure. After correcting an error, press the CLEAR key to clear the
message and place the printer in the offline state.
If an error is not cleared, the printer will try to print again but will display the
error message until the error is cleared.
Table 4. Message List
Message Explanation Solution
06 HOST REQUEST Status message: in the CT Not a printer problem.

emulation, the host
computer or printer
controller requires attention.
08 HOLD PRINT Status message: in the CT Press ON LINE.
TIMEOUT emulation, the printer was
offline more than 10 minutes
and the “Intervention
Required” parameter is set
to “Send to Host.”
39
Chapter 3 Troubleshooting Display Messages
8.5V POWER FAIL * 8.5 Volt Power Failed. 1. Cycle power. If the message
Internal power failure. appears, do the power supply
operational check (page 193). If
the power supply fails the check,
replace it. If it passes the check,
go to the next step.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
shuttle frame assembly.
15 COMM CHECK Communication Check: a 1. Power off the printer. Reseat the
message that appears in the twinax host data cable
CT emulation meaning the connection and twinax I/O cable
line is not active on a twinax connection at the CT board.
interface. 2. Disconnect the twinax auto-
termination cable from the printer.
Test the cable for the resistances
shown in Appendix A. If the
resistances are incorrect, replace
the twinax auto-termination cable.
3. Power on the printer. Send a print
job to the printer. Verify that all
other devices on the twinax line
are working properly. (Refer to
line problem determination
procedures, as recommended by
the host system.)
4. If the message is gone, the host
has reestablished communication
with the printer. If all other twinax
devices work properly and the
message still appears, replace
the CT board. Record the
defective board.
40
List Of Messages
15V CTL FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print job
again. If the message appears,
remove the hammer bank logic
cable, inspect it for damage, and
test it for continuity. (See
Appendix A.) Replace the
hammer bank logic cable if it is
damaged or fails the continuity
test.
2. Cycle Power. Run the print job
download the emulation software
again (page 175).
3. Cycle power. Run the print job
replace the flash memory.
4. Power on the printer. Run the
print job again. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
5. Check the resistance of
connectors P106/LRIB M and
P107/RRIB M. (Refer to the Main
Wire Harness Test Tables in
Appendix A.) If ribbon motor
resistance is not correct, replace
the motor and/or the intermediate
cable, if installed.
appears, do the power supply
22 INVALID ADDR Invalid Address: poll time- Have the system administrator make
out on the twinax interface sure the printer address is correct.
indicating the unit address is
not recognized by printer.
41
23.5V CTL FAIL* 23.5 Volt Controller Failed: a 1. Cycle Power. Run the print job
voltage failure on the again. If the message appears,
controller board. download the emulation software
again (page 175).
31 PAPER OUT In the CT emulation with a 1. Load paper. Run a print test. If
TIMEOUT coax interface, a time-out the message appears, replace
message is sent to the host the paper detector switch
if paper is not loaded within assembly.
10 minutes after CLEAR 2. Run a print test. If the message
was pressed to clear a paper appears, replace the controller
out fault. board. Record the message and
42
List Of Messages
32 PAPER JAM In the CT emulation with a 1. Clear the paper jam. Press
TIMEOUT coax interface, a time-out CLEAR.
message is sent to the host 2. Press PAPER ADVANCE
if paper motion has not several times and check that
occurred for 10 minutes after forms feed without erratic motion,
CLEAR was pressed to noise, or pin-hole damage. If
clear a paper jam fault. forms do not feed, go to Paper
feeds poorly, page 125. If forms
feed, go to step 3.
3. Press VIEW once and check that
forms move up. Make sure the
forms thickness lever is not set
too tightly.
4. Press VIEW again and check that
the forms thickness lever rotates
and the paper moves down. If the
forms thickness lever does not
rotate and/or the paper does not
move down, refer to Reverse
paper feed: platen does not
open, page 127.
5. Check the paper tension between
the tractors. Adjust the right
tractor so that it does not pull
paper too tightly or leave it too
loose. The right tractor should
hold the paper under slight
tension.
6. Check the dynamic paper
tension.
7. Inspect the ribbon mask for
bends or deformation that block
the paper path or prevent paper
from exiting the pedestal top
cover. Replace a damaged
hammer bank cover assembly.
8. Check the condition and tension
of the platen open belt. Adjust the
platen open belt. Replace the belt
if it is damaged.
43
32 PAPER JAM 9. Inspect the tractors and tractor

TIMEOUT (continued) door springs for damage,
excessive wear, and equal door
closing tension. If either tractor is
worn, damaged, or exhibits
uneven door closing tension,
replace both tractor assemblies.
10. Check the condition and tension
of the paper feed belt. Adjust the
paper feed belt. Replace the belt
if it is damaged.
11. Check the platen gap. Adjust the
platen gap if necessary.
12. Clean the paper motion detector
with a cotton swab and alcohol.
At the control panel, set the paper
motion detector (PMD) fault
setting to DISABLE. Load paper.
Run a print test and observe how
the paper feeds. If the message
If the message does not appear,
replace the paper detector switch
assembly and set the paper
motion detector (PMD) to
ENABLE.
33 PLATEN OPEN In the CT emulation with a 1. Load paper. Close the forms
TIMEOUT coax interface, the forms thickness lever. Press CLEAR.
thickness lever has been 2. Run a print test. If a platen open
open for at least one minute. or close platen message
appears, power off the printer.
Remove the paper path or
pedestal top cover. Disconnect
connector P107 from the
controller board. Check continuity
of the platen interlock switch
cable from P107 to the switch.
Replace the platen interlock
switch assembly if it fails
continuity test.
3. Run a print test. If a platen open
or close platen message
44
List Of Messages
34 RIBBON STALL In the CT emulation with a 1. Set the forms thickness lever to
TIMEOUT coax interface, the ribbon match the thickness of the paper
has not moved for 10 being used, but not too tightly.
minutes after CLEAR was 2. Inspect the ribbon guides for ink
pressed to clear the ribbon buildup, which can inhibit ribbon
drive fault. movement. Clean the printer.
3. Inspect the hammer bank cover/
ribbon mask for bending or
damage. Replace if bent or
damaged.
4. Check the platen gap: if too
small, it can inhibit ribbon
movement. Adjust the platen gap.
5. Power off the printer. Remove the
paper path or pedestal top cover.
Disconnect P106 and P107 from
the controller board. Check the
resistance of LRIB M in P106 and
RRIB M in P107. (Refer to the
Main Wire Harness Test Tables
in Appendix A.) If ribbon motor
resistance is not correct, replace
the motor. If the resistance is
correct, disconnect the ribbon
motor cables from the motors and
check continuity. Replace a cable
if it fails the continuity test.
6. Power on the printer. Run a
diagnostic print test. If the
RIBBON STALL message
45
48V CIRCUIT* Either the power supply is 1. Make sure the power supply
See User Manual not generating a proper 48 board is correctly connected to
Volts or the controller board the controller board.
is not detecting a 48 Volt 2. Power on the printer. If the
output from the power message appears, do the power
supply board. supply operational check (page
193). If the power supply fails the
check, replace it. If it passes the
check, go to the next step.
defective board.
48V PWR FAIL* 48 Volt Power Failed: an 1. Power off the printer. Remove the
internal power failure. paper path or pedestal top cover.
Check that power supply
connector P101 is fully seated in
connector J101 on the controller
board.
2. If the printer has the CT board,
make sure it is correctly seated in
the controller board.
hammer bank logic cable
assembly (P108) and the power
cable assembly (P105). (Refer to
Appendix A.)
message appears, do the power
supply operational check (page
193). If the power supply fails the
check, replace it. If it passes the
check, go to the next step.
defective board.
message appears, replace
46
List Of Messages
733 DP FIFO Busy* There is a timing problem in 1. Cycle Power. Run the print job
the Engine Controller again. If the message appears,
firmware. download the emulation software
again (page 175).
ACCESS NULL PTR* Access Null Pointer: The 1. Cycle power. Run the print job
processor tried to access a again. If the message appears,
pointer that contains nothing download the emulation software
(null). again (page 175).
replace the controller board.
Record the message and return it
with the defective board.
ACTIVATE LOST The printer detects a twinax 1. Power off the printer. Disconnect
protocol communication the AC power cord from the
error and reports the error. printer. Reseat the twinax host
data cable connection and the
twinax I/O cable connection at the
CT board.
2. Disconnect the twinax auto-
termination cable from the printer.
Test the cable for the resistances
shown in the Main Wire Harness
Test Tables in Appendix A. If
resistances are not correct,
replace the twinax auto-
termination cable.
3. Connect the power cord to the
printer. Power on the printer.
Send a print job to the printer. If
the message appears, replace
the twinax cable.
4. Send a print job to the printer. If
the message appears, go to
Communications Failures,
page 132.
47
A TO D OVERRUN* Analog to Digital Overrun. Cycle power. Run the print job again.
The analog-to-digital If the message appears, replace the
converter overflowed. controller board. Record the message
and return it with the defective board.
B00 STATUS: SDRAM Status message: the printer No action required.
DETECTION 166MHZ has begun its boot-up
routines and is checking for
the presence of SDRAM.
B01 STATUS: 8245 Status message: printer No action required.
SDRAM TEST 32MB boot-up routines are testing
SDRAM.
B10 ERROR: Boot-up routines did not 1. Cycle power. If the message
NO DRAM DETECTED* detect the presence of the appears again, power down and
SDRAM DIMM. check that there is an SDRAM
DIMM installed on the controller
board. If not, install the SDRAM.
If so, reseat the SDRAM DIMM.
2. Power up the printer. If the
SDRAM DIMM.
defective board.
B11 ERROR: SDRAM failed the boot 1. Cycle power. If the message
RAM TEST FAILED* initialization test. appears again, reseat the
SDRAM DIMM.
SDRAM DIMM.
defective board.
B12 ERROR: The printer does not see a There is no program in printer
PROGRAM MISSING* program in flash memory. memory. Download an emulation.
B13 ERROR: The printer is not compatible Load the correct emulation software
NOT COMPATIBLE* with the downloaded option(s) for this printer.
program.
48
List Of Messages
B19 ERROR: This message indicates an Cycle power. If the message appears
DC RETURNED* incorrectly assembled and again contact the printer
tested machine. manufacturer and report this
message.
B20 STATUS: 00% Status message informing No action required.
DOWNLOAD MODE the operator that software is
being downloaded through
the printer’s parallel port
using the three-key
download activation (page
178). The percentage
indicates the approximate
amount loaded into the
printer.
B21 STATUS: Status message informing No action required.
PRINTER RESET the operator that the printer
is undergoing a system
reset.
B22 ERROR: Flash memory has not 1. Cycle power. If the message
DECOMPRESS SIZE* passed boot initialization appears again, reseat the flash
tests. SIMM.
flash SIMM.
defective board.
B23 ERROR: Flash memory has not 1. Cycle power. If the message
DECOMPRESS CKSUM* passed boot initialization appears again, reseat the flash
tests. SIMM.
flash SIMM.
defective board.
B30 STATUS: Status message: the printer No action required.
INITIALIZING... is running its initialization
routines after startup and
successful memory tests.
49
B35 STATUS: Status message: the DC on Cycle power. If the message appears
WAITING FOR EC the controller board is again, replace the controller board.
STATUS waiting for communication Record the message and return it
with the EC. If this message with the defective board.
does not clear within a few
seconds there is an
electrical or electronic
problem on the controller
board.
B40 ERROR: SDRAM Flash memory has not 1. Cycle power. If the message
EEPROM CKSUM BAD* passed boot initialization appears again, reseat the flash
tests. SIMM.
flash SIMM.
defective board.
B41 ERROR: DIMM The DRAM DIMM installed 1. Cycle power. If the message
MEMORY NOT SDRAM* on the controller board is not appears again, reseat the
Synchronous DRAM SDRAM DIMM.
(SDRAM). 2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
defective board.
B42 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message
ROWS NOT ALLOWED* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
50
List Of Messages
TOO MANY BANKS* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
NOT 64 BITS WIDE* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
IS WRONG VOLTAGE* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
51
HAS MIXED SIZES* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
LARGER THAN 256M* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
# LOGICAL BANKS* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
52
List Of Messages
LOGIC COMB BANKS* tests detect incorrect appears again, reseat the
SDRAM. SDRAM DIMM.
and size.
defective board.
B51 STATUS: XX% Status message: printer No action required.
LOADING boot-up routines are loading
printer system software into
flash memory and SDRAM.
B54 ERROR: SDA The SDRAM or a PCI card is 1. Cycle power. If the message
LINE STUCK LOW shorting out the serial data appears again, reseat the
bus on the controller board. SDRAM DIMM.
and size.
defective board.
B55 SEND PROGRAM Status message: the printer No action required.
TO EC is loading the engine
controller program into the
engine controller.
53
BARCODE DAMAGED The sensor detects a bar 1. If the bar code label appears
Reverse Ribbon code, but it is not complete. damaged, reverse the ribbon
This fault condition is spools on the ribbon hubs. If the
entered into the Error Log bar code label appears
(not the Ribbon Log). undamaged, clean the sensor
lens with a damp cloth or swab.
2. Make sure the forms thickness
lever is not too tight, which can
restrict ribbon motion. Loosen it if
necessary.
3. Press Clear and run the print job
again. If the message reappears,
replace the ribbon.
replace the sensor.
BARCODE MISSING The ribbon sensor does not 1. Verify that the bar code labels
Install New RBN detect the presence of the and ribbon sensor are present
ribbon spool, indicating a and undamaged. If the labels are
missing label or a damaged missing, replace the ribbon. If the
sensor. (This fault condition labels are present and
is entered into the Ribbon undamaged, clean the sensor
Log as “Ribbon Not lens with a damp cloth or swab.
Recognized.”) 2. Press Clear and run the print job
again. If the message reappears,
replace the ribbon.
replace the sensor.
BUFFER OVERRUN The print buffer has 1. Verify that the printer matches the
overflowed on a serial host serial interface configuration
interface. The printed output settings for Data Protocol, Baud
may contain random * Rate, Data Bits, Stop Bits, Parity,
(asterisk) characters. Make Data Terminal Ready, and
a configuration printout. Request to Send. Set printer
serial interface parameters to
match those of the host.
page 132.
54
List Of Messages
CLEAR PAPER JAM Paper jam. 1. Inspect the paper path for jams.
Clear jams. Load paper.
2. Press PAPER ADVANCE
several times and check that
forms feed without erratic motion,
noise, or pin-hole damage. If
forms do not feed, go to Paper
feeds poorly, page 125.
If forms feed, go to step 3.
3. Press VIEW once and check that
forms move up. Make sure the
forms thickness lever is not set
too tightly.
4. Press VIEW again and check that
the forms thickness lever rotates
and the paper moves down. If the
forms thickness lever does not
rotate and/or the paper does not
move down, refer to Reverse
paper feed: platen does not
open, page 127.
5. Check the paper tension between
the tractors. Adjust the right
tractor so that it does not pull
paper too tightly or leave it too
loose. The right tractor should
hold the paper under “slight”
tension.
6. Check the dynamic paper
tension.
7. Inspect the ribbon mask for
bends or deformation. Replace if
damaged.
8. Check and adjust the platen open
belt. Replace the belt if it is
damaged.
9. Inspect the tractors and tractor
door springs for damage,
excessive wear, and equal door
closing tension. If either tractor is
worn, damaged, or exhibits
uneven door closing tension,
replace both tractor assemblies
55
CLEAR PAPER JAM 10. Check the condition and tension

(continued) of the paper feed belt. Adjust the
paper feed belt. Replace the belt
if it is damaged.
11. Check and adjust the platen gap.
12. Clean the paper motion detector
with a cotton swab and alcohol.
At the control panel, set the paper
motion detector (PMD) fault
setting to DISABLE. Load paper.
Run a print test and observe how
the paper feeds. If the message
If the message does not appear,
assembly and set the paper
motion detector (PMD) to
ENABLE.
CLEARING PROGRAM Status message: emulation No action required.
FROM FLASH software successfully loaded
into printer RAM and the
checksum matched. The old
program is now being
deleted from flash memory.
56
List Of Messages
CLOSE PLATEN The forms thickness lever is 1. Load paper. Close the forms
open. thickness lever.
Disconnect connector P107 from
the controller board. Check
continuity of the platen interlock
switch from P107/PLO to the
switch. Replace the switch
assembly if it fails the continuity
test. (Refer to Appendix A, Switch
Assembly, Platen Interlock.)
3. With the forms thickness lever
closed (position A), hold a 0.011
inch (0.028 cm) feeler gauge
between the switch and the body
of the forms thickness lever,
gently press down on the switch,
and tighten the two screws.
4. Check and adjust the platen open
belt. Replace the belt if it is
damaged.
5. Disconnect connector P106 from
the controller board. Check the
resistance of connector P106/
PLAT M. (See the Main Wire
Harness Test Tables in Appendix
A.) Replace the platen open
motor if it fails the resistance test.
6. Run a print test. If the message
57
CTL VOLT FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print job
15 V failure on the controller again. If the message appears,
board. download the emulation software
again (page 175).
DIAGNOSTIC Status message: the printer No action required.
PASSED passed its memory and
hardware initialization tests.
DP FIFO Busy* There is a timing problem in 1. Cycle Power. Run the print job
the Engine Controller again. If the message appears,
firmware. download the emulation software
again (page 175).
58
List Of Messages
DRVR CIR BAD* Driver Circuit Bad: the 1. Cycle power. If the message
hammer coil count test appears, press CLEAR.
failed. 2. Power off the printer. Remove the
shuttle cover. At the shuttle frame
assembly, disconnect the
hammer bank logic and power
cables. Power on the printer. If
“HB NOT INSTALLD” appears on
the LCD, replace the shuttle
frame assembly. If “HB NOT
INSTALLD” does not appear on
the LCD, replace the controller
board.
E00 EXE @ ADDR0 An illegal or unsupported 1. Cycle Power. Run the print job
See User Manual instruction was attempted in again. If the message appears,
the application program. load the latest emulation software
(page 175).
record the display message and
send it to your next higher
support facility.
E01A TYPE 0x40 An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E01B TYPE 0x60 An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
59
E02 MACHINE CHK An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E03A DSI HASH L An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E03B DSI HASH S An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E03C DSI BAT PL An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
60
List Of Messages
E03D DSI BAT PS An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E03E DSI CXIWX An illegal or unsupported 1. Cycle Power. Run the print job
See User Manual instruction was attempted in again.If the message appears,
(page 175).
support facility.
E03F DSI CXOWX An illegal or unsupported 1. Cycle Power. Run the print job
the application programn. load the latest emulation software
(page 175).
support facility.
E03G DSI ECXIWX An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
61
E03H DSI ECXOWX An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E04A ISI NO TRA An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E04B ISI DIRECT An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E04C ISI PROTEC An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
62
List Of Messages
E06 NOT ALIGNED An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E07 ILLEGAL INS An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E08 FLOATINGPNT An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E12 SYSTEM CALL An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
63
E13 TRACE INT An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E16 ITRANS MISS An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E17 DLOAD MISS An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E18 DSTORE MISS An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
64
List Of Messages
E19 BREAKPOINT An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E20 SYS MANAGE An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E30 DEBUGGER An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E31A EVENT O BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
65
E31B EVENT 1 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E31C EVENT 2 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E31D EVENT 3 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E31E EVENT 4 BP An illegal or unsupported 1. Cycle Power. Run the print job
See User Manual instruction was attempted in again.If the message appears,
(page 175).
support facility.
66
List Of Messages
E31F EVENT 5 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E31G EVENT 6 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E31H EVENT 7 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E32A CND 0 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
67
E32B CND 1 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E32C CND 2 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E32D CND 3 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E32E CND 4 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
68
List Of Messages
E32F CND 5 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E32G CND 6 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E32H CND 7 BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E33 WRITE BP An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
69
E34 TRACE CMPLT An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E99 UNKNOWN INT An illegal or unsupported 1. Cycle Power. Run the print job
(page 175).
support facility.
E Net Test Unavailable The ethernet PCBA did not Cycle power. Wait for “E Net Ready”
initialize correctly. to display, then retry operation. If it
still fails, replace the ethernet PCBA.
ERROR OCCURRED An interim message that Wait. When the asterisk (*) stops
FLUSHING QUEUES * displays while the printer rotating, a different fault message will
discards host data it cannot appear: troubleshoot the final
use because a fault message.
condition exists. While this
message displays, the
asterisk (*) rotates.
ERROR: DC PROGRAM The printer cannot find the 1. Download the program again
NOT VALID data controller program or (page 175).
the validation checksum is
2. If the message appears, replace
corrupt.
the flash memory SIMM.
ERROR: DRAM AT The printer found a defective 1. Replace the DRAM DIMM.
ADDRESS XXXXXXXX memory location. 2. Power on the printer. If the
defective board.
70
List Of Messages
ERROR: EC PROGRAM The printer cannot find the 1. Download the program again
NOT VALID engine controller program or (page 175). If the message
the validation checksum is occurs again, replace all flash
corrupt. memory SIMMs.
2. Power on the printer. Download
the emulation. If the message
ERROR: EC STOPPED Where XXXX is a number 1. Power off the printer. Remove the
AT STATE XXXX from 0000 to 0010. The flash memory SIMM and SDRAM
Engine Controller has DIMM. Inspect the SIMM and
stopped and is in the state DIMM sockets on the controller
identified by the number board. If any socket pins are bent
displayed. If the EC stops at or damaged, replace the
state 0000 at power-up, controller board.
replace the controller board. 2. Install the flash SIMM and
Record the message and SDRAM DIMM, making sure they
return it with the defective are fully and correctly seated.
board. Power on the printer. Download
the emulation (page 175). If the
flash SIMM.
appears, replace the SDRAM
DIMM.
ERROR: FLASH The printer encountered an Download the program again (page
DID NOT PROGRAM error trying to program flash 175). If the message occurs again,
memory. replace the flash memory.
ERROR: FLASH The printer could not find Check flash memory on the controller
NOT DETECTED flash memory. board. If present, reseat the flash
SIMM; if missing, install flash SIMM.
71
ERROR: LOCKED SN= Where nnnnnnnnnnnnnnnn 1. Remove the SPX from the Debug
nnnnnnnnnnnnnnnn is the serial number of the Port.
printer’s security key. The 2. Cycle printer power.
SPX gets “locked” to the
printer as the first part of the
security key reprogramming
process. The “lock” consists
of copying the printer’s
security key serial number
into the flash memory of the
SPX, which prevents the
SPX from being used on
other printers. It also
enables the customer to
retry upgrading the same
printer if the SPX was
removed before
reprogramming is complete.
ERROR: NO DRAM The printer could not find 1. Check SDRAM on the controller
DETECTED any DRAM. board. If present, reseat SDRAM
DIMM; if missing, install SDRAM.
defective board.
ERROR: NVRAM The non-volatile SRAM on Replace the controller board. (Do
FAILURE the controller board has NOT attempt to replace NVRAM.)
failed. Record the message and return it
with the controller board.
ERROR: PROGRAM The printer requires more Add DRAM or use a smaller
NEEDS MORE DRAM DRAM in order to run the emulation program.
downloaded program.
ERROR: PROGRAM The printer requires more Add flash memory or use a smaller
NEEDS MORE FLASH flash memory in order to run emulation program.
the downloaded program.
ERROR: PROGRAM The printer is not compatible Use the correct emulation software
NOT COMPATIBLE with the downloaded option(s) for this model printer.
program.
ERROR: PROGRAM The printer does not see a There is no program in printer
NOT VALID program in flash memory. memory. Download the emulation.
72
List Of Messages
ERROR: SECURITY The security key is not 1. Check the security key at
KEY NOT DETECTED present or has failed. connector J9 on the controller
board. If the key is absent, install
the correct key. If a security key is
present, replace it.
defective board.
ERROR: SHORT AT Hardware failure in SDRAM 1. Download the program again.
ADDRESS XXXX or controller circuitry.
2. If the message occurs again,
ERROR: WRITING Hardware or software fault in 1. Replace flash memory.
TO FLASH flash memory.
2. If message occurs with new
memory, replace the controller
ERROR: WRONG The printer received the 1. Power off the printer. Download
CHECKSUM complete program but the the program again from the
checksum did not match. beginning. If the messages
The data may have been appears, replace the DRAM.
corrupted during download. 2. Download the program using a
new software diskette. If the
messages appears, replace the
flash memory.
3. Download the program. If the
messages appears, replace the
defective board.
ERROR: WRONG OEM The SPX inserted in the 1. Remove the SPX from the Debug
OR PRINTER TYPE debug port is not intended Port.
for this model printer or this
2. Cycle printer power.
OEM.
ETHERNET DETECTED Status message indicating No action required.
that the PrintNet ethernet
interface has established
communication.
73
ETHERNET Status message that No action required.

INITIALIZING indicates that the internal
Network Interface Card is
processing the boot
procedure. (May occur with
older versions of
microcode.)
EXCESS RIBBON WEAR Status message that Install a new ribbon.
Install New RBN displays when ribbon
reaches the end of its
service life, whether the
Integrated Print
Management System is
enabled or not.
74
List Of Messages
EXHAUST FAN FLT Exhaust Fan Fault. Sensors 1. Cycle power. If the message
cannot detect current in the appears, press CLEAR.
fan circuit. 2. Check that the exhaust fan is
connected to exhaust fan cable
connector J307. Connect the fan
cable connector.
paper path. Disconnect connector
P107 from the controller board.
Test connector P107/EHF for
shorts or opens. (See the Main
Wire Harness Test Tables in
Appendix A.) Replace
components that fail test.
4. Make sure connector P107/EHF
has a good connection at J107 on
5. Inspect for obstructions of
airways and vents. Check for
items beneath the printer
blocking cabinet vents. Remove
obstructions. Make sure cabinet
exhaust fan vents are not
blocked.
6. Power on the printer. Check for
fan operation. If the message
appears or the fan does not work,
replace the exhaust fan.
defective board.
75
FIRMWARE ERROR Application software tried to 1. Cycle power. Run the print job. If
perform an illegal printer the message appears, download
function or damaged the emulation software again
memory is detected on the (page 175).
controller board. If the 2. Cycle power. Run the print job
message appears at power- again. If the message appears,
up, replace the controller replace the flash memory.
board. Record the message
and return it with the 3. Cycle power. Run the print job
defective board. again. If the message appears,
still appears, there is an
application software error. Use
your local support procedure to
request assistance.
FM HEADER ERROR Frame Header Error. Not a printer problem. The system
Application software has administrator should correct
violated header parameters. applications data or configuration.
FRAMING ERROR The printed output may 1. Make a configuration printout. Set
contain random ! printer serial interface parameters
(exclamation point) to match host configuration
characters. settings for Data Protocol, Baud
Rate, Data Bits, Stop Bits, Parity,
Data Terminal Ready, and
Request to Send.
page 132.
GRF CHK ERROR Graphic Check Error: in the Press CLEAR then press ON LINE.
PRESS STOP CT emulation over a twinax
interface, the printer
received a non-printable
character.
76
List Of Messages
H00: PCI SLOT ? The controller board is not 1. Cycle power. If the message
See User Manual communicating with a PCI appears, power down and reseat
card. This could indicate a the PCI card.
bad PCI card, poor 2. Power on the printer. If the
connection, or problem in message appears, move the PCI
the PCI bus. card to the other PCI slot.
PCI card.
defective board.
H01: PCI J12 The controller board is not 1. Cycle power. If the message
See User Manual communicating with the PCI appears, power down and reseat
card in PCI slot J12. This the PCI card.
could indicate a bad PCI 2. Power on the printer. If the
card, poor connection, or message appears, move the PCI
problem in the PCI bus. card to PCI slot J13.
PCI card.
defective board.
H02: PCI J13 The controller board is not 1. Cycle power. If the message
See User Manual communicating with the PCI appears, power down and reseat
card in PCI slot J13. This the PCI card.
could indicate a bad PCI
card, poor connection, or
message appears, move the PCI
problem in the PCI bus.
card to PCI slot J12.
PCI card.
defective board.
77
<Online, etc. ... .> This is a status message, 1. Advise the user to move the
Half Speed Mode not an operational state. The printer to cooler, cleaner location.
controller samples the 2. Check the kinds of print jobs the
operating temperature of key user is running: look for very
components of the print dense graphics and layouts.
mechanism. When higher Advise the user to run jobs in
than normal temperatures smaller batches.
are sensed, the print speed
is automatically reduced by 3. Power off the printer. Remove the
50% and the message sent paper path or pedestal top cover.
the LCD. When the Check all fan cable connections.
components cool down, the 4. Power on the printer. Verify that
print speed returns to 100% all fans operate. Replace any fan
and the message clears. that does not operate.
Periodic appearance of this 5. Inspect vents and fan airways for
message is normal for obstructions. Look underneath
extremely dense print jobs, cabinet models for items blocking
such as “All Black” plot. If the cabinet exhaust vents.
this message often appears, Remove any obstructions from
the printer may be operating vents and airways.
in a severe environment. A
severe environment has an 6. Install the paper path or pedestal
ambient temperature at or top cover. Load paper. Run the
above 40° Celsius (104° “All E’s” print test for 5 to 10
Fahrenheit) or is dirty minutes. If the message appears,
enough to clog air vents. The replace the shuttle frame
printer must never be run at assembly.
ambient temperatures 7. Run the “All E’s” print test for 5 to
greater than 40° Celsius 10 minutes. If the message
(104° Fahrenheit). Inspect appears, replace the controller
the printer environment for board. Record the message and
severity, and if the printer is return it with the defective board.
located in such an 8. If the printer is a P7220, set the
environment relocate it to a coil temperature (page 184).
cooler, cleaner area.
HAM. COIL OPEN* Hammer Coil Open. 1. Cycle power. If the message
Electrical malfunction of one appears, replace the shuttle
or more hammer coils. frame assembly.
2. Power on the printer. Run a print
test. If the message appears,
78
List Of Messages
HAMMER COIL BAD Hammer coil(s) number #, #, 1. Cycle power. If the message
#, #, #, #, ... etc. etc. failed the current test at appears, replace the shuttle
power-up. Check that the frame assembly. Record the
hammer bank cables are message and return it with the
connected. defective assembly.
message appears, replace
defective assembly.
HB NOT INSTALLD* Hammer Bank Not Installed. 1. Install the shuttle frame
Self-test routines do not assembly.
detect hammer coils at 2. Remove the paper path or
printer start-up. Power off pedestal top cover. Verify that the
the printer. Verify that the hammer bank logic cable is
shuttle frame assembly is connected to connector J108 on
installed. the controller board and to the
hammer bank logic cable.
defective board.
79
HMR BANK FAN FLT Hammer Bank Fan Fault. 1. Cycle power. If the message
Sensors cannot detect appears, press CLEAR. If the
current in the fan circuit. message does not clear, go to
step 2.
the controller board. Test
connector P107/HBF for shorts or
opens. (Refer to the Main Wire
A.) Replace components that fail
test.
3. Make sure P107/HBF has a good
connection at J107 on the
controller board.
airways and vents. Remove
obstructions.
defective board.
ILL EXT BUS ACC* Illegal External Bus Access. 1. Cycle power. Run the print job
Firmware error on the again. If the message appears,
again (page 175).
ILL INST ACCSS* Illegal Instruction Accessed. 1. Cycle power. Run the print job
again (page 175).
80
List Of Messages
ILLGL OPR ACCSS* Illegal Operand Accessed. 1. Cycle power. Run the print job
again (page 175).
Incompat E-Net The ethernet NIC for a Remove the installed NIC and
Remove NIC thermal printer has been replace it with the correct card for this
installed in this printer. printer.
Incompat WLAN The wireless NIC for a Remove the installed NIC and
Remove NIC thermal printer has been replace it with the correct NIC for this
installed in this printer. printer.
INTAKE FAN FAULT Sensors cannot detect 1. Cycle power. If the message
current in the card cage fan appears, press CLEAR. If the
circuit. message does not clear, go to
step 2.
the controller board. Test
connector P106/CCF for shorts or
opens. (Refer to the Main Wire
A.) Replace components that fail
test.
3. Make sure P106/CCF has a good
connection at J106 on the
controller board.
airways and vents. Remove
obstructions.
defective board.
81
INTERRUPT UNUSED This message is generated 1. Cycle power. If this message

VECTOR 00 when the controller board occurred once and never again,
gets an interrupt it does not you can ignore it. If the message
understand. The problem reappears or appears
can be created by electrical consistently check the grounding
noise, by a software of the printer. If the machine is
problem, or by a hardware correctly grounded, replace the
problem. controller board.
2. Power on the printer. Cycle
power. If the message appears,
suspect an application software
error. Request assistance from
your local support group. Install
the original controller board.
INVALID ACTIVATE The printer detects a twinax 1. Reseat the twinax host data cable
protocol communications connection and the twinax I/O
error and reports the error. cable connection at the CT board.
Power off the printer. 2. Disconnect the twinax auto-
Disconnect the AC power termination cable from the printer
cord from the printer. Check or from the last device on this
the twinax host data cable twinax port. Test the cable for the
and twinax I/O cable resistances shown in the Main
connection at the CT board. Wire Harness Test Tables in
Appendix A. If resistances are not
correct, replace the twinax auto-
termination cable.
the twinax cable.
page 132.
82
List Of Messages
INVALID COMMAND The printer detects a twinax 1. Reseat the twinax host data cable
protocol communications connection and the twinax I/O
error and reports the error. cable connection at the CT board.
Power off the printer. 2. Disconnect the twinax auto-
Disconnect the AC power termination cable from the printer.
cord from the printer. Check Test the cable for the resistances
the twinax host data cable shown in the Main Wire Harness
and twinax I/O cable Test Tables in Appendix A. If
connection at the CT board. resistances are not correct,
replace the twinax auto-
termination cable.
the twinax cable.
page 132.
LO DRV. SHORT* Lower Driver Short. 1. Cycle power. If the message
Circuit(s) on the hammer appears, press CLEAR. If
bank or in the hammer bank message does not clear, replace
power cable are shorted to the hammer bank logic cable and
ground. the hammer bank power cable.
defective board.
83
LOAD PAPER The printer is out of paper. 1. Load paper. Press CLEAR. If
message does not clear, go to
the next step.
2. Check for black or colored
backing on the paper being used
in printer. The paper out detector
is optical and may not detect
paper with a black or dark
backing facing the detector. Try
paper with a white or light back. If
paper with white/light back works
and black/dark paper does not,
with the optional black back forms
switch assembly. (See page 276,
item 3.)
Remove the barrier shield
(cabinet model) or the barrier
shield and paper guide (pedestal
model). Check that the paper
detector switch assembly is
securely mounted in its bracket.
4. Check that connector P106/PMD
is fully seated in connector J106
on the controller board.
5. Load paper. Power on the printer.
Replace the paper detector
switch assembly if message
appears.
6. Load paper. Power on the printer.
Replace the controller board if
message appears. Record the
defective board.
LOADING PROGRAM Status message: the new No action required.
FROM PORT XX% emulation program is
loading into printer RAM.
XX% indicates how much of
the program has loaded.
84
List Of Messages
LOADING PROGRAM The printer has deleted the No action required.

INTO FLASH previous program from flash
memory and is loading the
new program into flash
memory.
NEW SPX DETECTED The printer detects an SPX Press the ENTER key. The following
PRESS ENTER in its debug port and the actions occur:
SPX is valid for this printer.
1. The SPX copies the printer’s
security key serial number into its
flash memory.
2. The printer reprograms its
security key with the information
stored in the SPX.
3. The printer verifies that the key
was programmed as intended.
4. The SPX overwrites itself so that
it cannot be used again.
NON VOLATILE Large emulations reduce the 1. If the message appears at power-
MEMORY FAILED amount of space available up, replace the flash memory.
for saving configurations,
2. If the message appears while
which means that
saving a configuration, the printer
sometimes fewer than 8
is out of memory and will not save
configurations can be saved.
that or subsequent
If this message appears
configurations. (Previously saved
when saving a configuration,
configurations are still okay.)
it means the printer is out of
memory. Previously saved 3. If the message appears after
configurations will still be replacing/increasing memory,
available, but the one that replace the controller board. (Do
was “saved” when the NOT attempt to replace NVRAM.)
message appeared is not in
memory. If this message
appears at power-up, it
means the flash memory is
defective.
OLD RIBBON The sensor detects a ribbon Install a new ribbon.
Install New RBN that was previously declared
to be at the end of its service
life (message 146 or 302).
ONLINE Controller Unit Not Enabled. Check cable connection and host
28 CU NOT ENAB Poll time-out error. The system. (Refer to line problem
printer was not polled for determination procedures, as
one minute across a coax recommended by the host system.)
interface.
85
ONLINE Link-level code test detects Replace the CT board. Record the
8344 FAILED a hardware failure on the CT message and return it with the
board. defective board.
ONLINE Controller Unit Timed Out. Check cable connection and host
CU TIMED OUT The printer was not enabled system. (Refer to line problem
for one minute or more on a determination procedures, as
coax interface. recommended by the host system.)
PAP BAD TABLE* Paper Bad Table. The paper 1. Cycle power. Run the print job
feed process on the again. If the message appears,
controller board has a download the emulation software
corrupted table. again.
PAP BSY TOO LNG* Paper Busy Too Long. 1. Cycle power. Run the print job
again (page 175).
2. Run the print job again. If the
message appears, power off the
printer. Remove the paper path or
pedestal top cover. Make sure
connectors P106 and P107 are
fully seated on the controller
board. Make sure the MPU cable,
the hammer bank logic cable, and
the hammer bank power cable
are undamaged and have good
connections. Replace as
necessary. (Refer to Appendix
A.)
appears, replace the shuttle
frame assembly.
86
List Of Messages
PAP FD DRVR CIR* Paper Feed Driver Circuit. 1. Cycle power. If the message
See Manual The paper feed driver circuit appears, replace the controller
on the controller board is board. Record the message and
drawing too much current. return it with the defective board.
paper feed motor.
PAP FIFO OVERFL* Paper First In First Out 1. Cycle power. Run the print job
Overflow. Firmware error on again. If the message appears,
the controller board. download the emulation software
again.
87
PAP FIFO UNDRFL* Paper First In First Out 1. Cycle power. Run the print job
Underflow. Firmware error again. If the message appears,
on the controller board. download the emulation software
again.
2. Run the print job again. If the
message appears, power off the
printer. Remove the paper path or
pedestal top cover. Make sure
connectors P106 and P107 are
fully seated on the controller
board. Make sure the MPU cable,
the hammer bank logic cable, and
are undamaged and have good
connections. Replace as
necessary. (Refer to Appendix
A.)
3. Check hammer phasing. Try
using a lower phasing value;
sometimes this message
indicates too high a hammer
phase value.
frame assembly.
88
List Of Messages
PAP ILLGL ST* Paper Illegal State. Firmware 1. Cycle power. Run the print job
error on the controller board. again. If the message appears,
again.
PAP INCMPL ENER* Paper Incompletely 1. Cycle power. Run the print job
Energized. Firmware error again. If the message appears,
again.
PAP INVLD CMD* Paper Invalid Command. 1. Cycle power. Run the print job
again.
PAP INVLD PARM* Paper Invalid Parameter. 1. Cycle power. Run the print job
again.
89
PAP NOT SCHED* Paper Not Scheduled. The 1. Cycle power. Run the print job
paper feed process is not again. If the message appears,
scheduling on the controller download the emulation software
board, and the printer cannot again.
feed paper. 2. Cycle power. Run the print job
replace the MPU cable assembly.
frame assembly.
PAP NT AT SPEED* Paper Not At Speed. 1. Cycle power. Run the print job
again.
PAP UNEXP INT* Paper Unexpected Interrupt. 1. Cycle power. Run the print job
again.
90
List Of Messages
PARAMETER ERROR Illegal parameter value 1. Press CLEAR then press ON

received in a command code LINE.
over a coax/twinax interface. 2. Run the print job that generated
the error message. If the
message appears, check the host
data for invalid characters.
3. Ask the system operator to verify
that the printer’s Device ID is set
to the correct emulation with
respect to the host configuration.
4. Run the print job that generated
message appears, go to
page 132.
PARITY ERROR The printed output may 1. Verify that the printer matches
contain random ? (question host serial configuration settings
mark) characters. Make a for Data Protocol, Baud Rate,
configuration printout. Data Bits, Stop Bits, Parity, Data
Terminal Ready, and Request to
Send.
the serial data cable.
page 132.
4. If the printer is in a twinax
environment, check the error log
for parity error entries and inspect
the customer’s cable hook-ups.
Connect all communications
cables correctly.
the twinax auto-termination cable
(“T” connector).
the CT.
91
PLAT INV CMD* Platen Invalid Command. 1. Cycle power. Run the print job
again.
PLAT INV PARM* Platen Invalid Parameter. 1. Cycle power. Run the print job
again.
PLAT INV STATE* Platen Invalid State. 1. Cycle power. Run the print job
again.
PLEASE WAIT... Status message: the printer No action required.
RESET IN PROGRESS finished loading the program
into flash memory and is
automatically resetting itself.
POWER SAVER MODE This is a status message. No action required. (To revive the
The printer is in low-energy printer from power saver mode press
idle state, all fans and higher the PAPER ADVANCE key.)
voltages are off, only +5Vdc
logic circuits are active.
92
List Of Messages
POWER SUPPLY HOT The printer has sensor 1. Inspect printer environment for
circuits that sample the severity. Advise the user to move
operating temperature of key the printer to cooler, cleaner
components of the power location.
supply. When higher than 2. Check the kinds of print jobs the
normal temperatures are user is running: look for very
sensed, print speed is dense graphics and layouts.
automatically reduced. If the Advise the user to run jobs in
printer runs at reduced smaller batches.
speed for an extended
period of time, the POWER 3. Power off the printer. Remove the
SUPPLY HOT message is paper path or pedestal top cover.
sent to the LCD and printing Check that the plastic power
stops, allowing printer supply guard/air deflector is
components to cool down. correctly positioned over the
Pressing the CLEAR key power supply board. WARNING:
resumes the print task. DO NOT TOUCH THE POWER
Check the operating SUPPLY, but hold your hand
environment. A severe close enough to check for heat
environment is one with an radiating off the power supply
ambient temperature at or board. If the power supply is
above 40° Celsius (104° noticeably hot, let it cool down,
Fahrenheit) or is dirty then replace it.
enough to create blockage 4. Check that all fan cables are
of the cabinet fan vents. The connected.
printer must never be run at 5. Inspect vents and fan airways for
ambient temperatures obstructions. Look underneath
greater than 40° Celsius cabinet models for items blocking
(104° Fahrenheit). If the the cabinet exhaust vents.
printer is located in such an
environment, relocate it to a 6. Install paper path or pedestal top
cooler, cleaner area. cover. Load paper. Power on the
printer. Run the “All E’s” print test
for 5-10 minutes. If the message
93
PRINTER HOT This message indicates 1. Controller board sensors report

internal temperatures over high temperatures on the board.
60° Celsius (140° Inspect printer environment for
Fahrenheit). Print jobs will severity. Advise the user to move
not create such the printer to cooler, cleaner
temperatures, so location.
immediately determine that 2. Power off the printer. Remove the
the fans are operating and paper path or pedestal top cover.
that all air vents are Check that all fan cables are
unobstructed. It is crucial connected.
that the exhaust vents on the
floor of the cabinet remain 3. Inspect vents and fan airways for
unblocked, since hot air from obstructions. Look underneath
inside the printer is vented cabinet models for items blocking
through the cabinet floor. the cabinet exhaust vents.
Nothing must be stored Remove any obstructions from
under the printer. Then vents and airways.
check the operating 4. Install paper path or pedestal top
environment. A severe cover. Load paper. Power on the
environment is one with an printer. Run the “All Black” print
ambient temperature at or test for 1/4 page. If the message
above 40° Celsius (104° appears, replace the controller
Fahrenheit) or is dirty board. Record the message and
enough to create blockage return it with the defective board.
of the cabinet fan vents. The
printer must never be run at
ambient temperatures
greater than 40° Celsius
(104° Fahrenheit). If the
printer is located in such an
environment, relocate it to a
cooler, cleaner area.
PROTECTED INSTR* Protected Instruction. 1. Cycle power. Run the print job
again.
PWR SUPP VOLT* Power Supply Voltage. The Replace the power supply board.
power supply has failed.
94
List Of Messages
QUEUE OVERRUN In the CT twinax emulation, 1. If the message appears, replace

the print buffer has the CT board. Record the
overflowed. Send a print job message and return it with the
to the printer. defective board.
the twinax data cable and the
twinax auto-termination cable
assembly (“Smart T”).
RESTORING Normal download No action required.
BOOT CODE initialization message.
REMOVE USED SPX Status message: An SPX is 1. Remove the SPX from the Debug
THEN PRESS ENTER depleted because it has Port.
successfully reprogrammed 2. Press the ENTER key. The
the security key on the printer will reboot itself.
controller board.
RIB INVLD CMD* Ribbon Invalid Command. 1. Cycle power. Run the print job
See User Manual Firmware error on the again. If the message appears,
again.
RIBBON AT END POINT Integrated Print Install a new ribbon.
Change Ribbon Management System
software has determined
that the ribbon is out of ink.
RIBBON UNDER 2% Status message indicating Install a new ribbon.
Change RBN Soon the Integrated Print
Management System is
enabled and the ribbon ink
level is 2%.
95
SCS COMMAND In the CT emulation, the 1. The printer clears the error.
ERROR printer received undefined 2. Run the print job that generated
control character (hex 40). the error message. If the
message appears, verify that
there are no invalid control codes
in the host data.
3. Ask the system operator to verify
that the printer’s Device ID is set
to the correct emulation with
respect to the host configuration.
4. Run the print job that generated
message appears, go to
page 132.
SECURITY VIOLATION Security code of the security 1. Remove the paper path or
key at J9 on the controller pedestal top cover. Check that
board does not match the the security key is correctly
code of the firmware on the installed.
controller board. 2. Install correct key for the
customer’s emulations.
SECURITY KEY NOT The security key is not 1. Check the security key at
DETECTED present or has failed. connector J9 on the controller
board. The security key is a 3-pin
jumper connector. If it is absent,
install the correct key. If a key is
present, replace it.
defective board.
SF ERROR Structured Field Error. Not a printer problem. Have the
Application software has system administrator correct
violated structured data field applications data or configuration.
parameters.
96
List Of Messages
SHUT DRVR CIR* The shuttle driver circuit on 1. Power down the printer. Remove
See User Manual the controller board is the paper path or top cover to
drawing too much current. gain access to the card cage.
Make sure the shuttle data and
power cables are undamaged
and have good connections at the
shuttle and the controller board.
defective board.
SHUTL INV CMD* Shuttle Invalid Command. 1. Cycle power. Run the print job
again.
SHUTL INV PARM* Shuttle Invalid Parameter. 1. Cycle power. Run the print job
again.
SHUTL OVR SPEED* The shuttle is oscillating too Adjust the gap between the MPU and
rapidly. the shuttle motor flywheel to 0.010 ±
0.001 inch (0.254 ± 0.025 mm). (See
page 268.)
97
SHUTTLE JAM The shuttle is not moving or 1. Set the forms thickness lever to
is moving at the wrong match the thickness of paper, but
speed. Check the forms not too tightly.
thickness lever: if it is set too 2. Check and adjust the platen gap.
tightly, it can slow the shuttle
enough to trigger the fault 3. Inspect the ribbon mask for
message. deformation that snags and
interferes with shuttle movement.
Correctly install the hammer bank
cover assembly or replace a
deformed cover assembly.
appears, power off the printer.
5. Remove the shuttle cover and
paper path or the pedestal top
cover. Inspect the shuttle
mechanism for obstructions.
Check that all cables are
attached at the shuttle and the
controller board. Make sure the
MPU cable is not pinched. (Refer
to the Interconnection Diagrams
in Appendix A.) Reseat all cables.
Check the resistance of the MPU
at connector P107. (Refer to the
in Appendix A.) Replace the MPU
if it fails the test.
7. Run a shuttle test and observe
shuttle movement. If the shuttle
oscillates too slowly, adjust the
gap between the MPU assembly
and the flywheel to 0.010 ± 0.001
inch (0.254 ± 0.025 mm). Torque
the 7/16 inch MPU clamp screw
to 18 ± 1 inch-pounds (2.03 ±
0.11 N•m).
appears, replace the MPU and
the MPU cable assembly.
98
List Of Messages
SHUTTLE JAM 9. Run a print test. If the message

(continued) appears, replace the controller
frame assembly.
SHUTTLE STALL See SHUTTLE JAM (page See SHUTTLE JAM (page 98).
98).
SHUTTLE TYPE The shuttle type was not 1. Power down the printer. Remove
NOT SUPPORTED* detected at power-up. the paper path or top cover to
gain access to the card cage.
Make sure the shuttle data and
power cables are undamaged
and have good connections at the
shuttle and the controller board.
defective board.
SOFTWARE ERROR* Application software tried to 1. Cycle power. If the message
CYCLE POWER perform an illegal printer appears, power off the printer.
function or damaged logic 2. Disconnect the input data line
circuits were detected on the from the host computer. Power
controller board. on the printer. If the message
appears, download the emulation
software again (page 175).
replace the controller board. If the
message is gone, there is an
application software error.
Request assistance from your
local support group.
SPX FOUND, ERROR: The controller board does 1. Remove the SPX from the Debug
KEY NOT DETECTED not have a security key. Port.
2. Power down the printer.
3. Install the security key.
99
SPX NOT NEEDED The user has attempted to 1. Remove the SPX from the Debug
OPTIONS ENABLED use the SPX to turn on Port.
printer options that are 2. Cycle printer power.
already enabled. In such a
case the SPX does not copy
the security key serial
number into its memory and
does not deplete itself.
STACK OVERFLOW* Firmware error on the 1. Cycle power. Run the print job
controller board. again. If the message appears,
again.
STACK UNDERFLOW* Firmware error on the 1. Cycle power. Run the print job
controller board. again. If the message appears,
again.
100
List Of Messages
STACKER FAULT Two situations can trigger 1. Open the cabinet rear door and
this message: check for obstructions preventing
1. The stacker elevator is elevator movement. Remove any
obstructed while attempting obstructions.
to move up or down. The 2. Power on the printer. Operate the
message will always occur if power stacker and check that:
the user presses the a) all motors are operating,
ELEVATOR UP key on the b) the paddles are rotating,
stacker control panel to c) the elevator moves smoothly
move the elevator and the and without obstruction,
elevator is blocked so that it d) the timing belts are
cannot move to the top of its undamaged and the belt pulleys
travel. are not slipping,
2. Controller hardware tells e) the extension springs are
firmware that an over- attached and undamaged (not
current condition exists. This bent or stretched),
will only occur if the f) the drive rollers are not
controller board or the damaged,
stacker motors are bad. g) the constant force springs are
tightly mounted and undamaged.
Tighten pulley setscrews and/or
replace damaged components as
necessary.
3. Adjust the stacker rails if they are
not vertical and parallel.
4. Check the stacker limit switches.
(See page 118.) If the limit
switches are OK, go to the next
step.
5. Disable the power stacker unit
under the Printer Control menu.
(Refer to the User’s Manual.) If
the message occurs, replace the
controller board and download
new function code.
paper path. Disconnect stacker
cables from the controller board,
stacker assy, and the stacker
control panel (see Figure 77,
page 387). Check cables for cuts,
breaks, or damaged pins. Check
continuity of cables. (See
Appendix A.) Replace cables that
are damaged or fail continuity
test. If the cables are OK, replace
the stacker motors.
101
STACKER FULL Status message: the power 1. Unload the stacker.

paper stacker is full. 2. Check the stacker limit switches.
(See page 118.) If the limit
switches are OK, go to the next
step.
stacker assembly, and the
stacker control panel (see
Figure 74, page 384). Check
cables for cuts, breaks, or
damaged pins. Check continuity
of cables. (See Appendix A.)
Replace any cable that is
damaged or fails continuity test.
102
List Of Messages
STACKER JAM This message is triggered if 1. Open the cabinet rear door and
there is paper inside the check for obstructions preventing
throat of the stacker elevator movement. Remove any
elevator, but the elevator is obstructions.
not moving. 2. Check that the wheel of the
stacker paper motion detector
rests against the rear brace of the
paper throat. Also make sure the
wheel rotates freely. If necessary,
gently bend the brace toward the
paper motion detector wheel until
the wheel contacts the brace.
Clean the stacker paper motion
detector.
3. Power on the printer. Operate the
power stacker and check that:
a) all motors are operating,
b) the paddles are rotating,
c) the elevator moves smoothly
and without obstruction,
d) the timing belts are
undamaged and the belt pulleys
are not slipping,
e) extension springs are attached
and not bent or stretched),
f) drive rollers are not damaged.
Tighten setscrews and replace
damaged components as
necessary.
stacker assembly, and stacker
control panel. Check cables for
cuts, breaks, or damaged pins.
Check continuity of cables. (See
Appendix A.) Replace any cable
that is damaged or fails continuity
test.
103
TCB CORRUPTED* Task Control Block 1. Cycle power. Run the print job
Corrupted. Firmware error again. If the message appears,
again.
TCP Port Busy Error message reported by 1. Power on the printer.
the Printer Manager when
2. If the printer is online, press the
ethernet interface option is
ON LINE key to place the printer
installed. The network
offline.
address given in the printer
properties was reached, but 3. On the control panel, press the
the printer port is “busy.” = + > keys to unlock the ENTER
When the port setting is key.
“Serial” the printer manager 4. Press the = + > + ; + < keys
software cannot interact with simultaneously to enter the
the ethernet card, although Factory Menu.
the card will respond to other
TCP/IP utilities. 5. Press < until you reach the
PRINTER MGMT menu, then
press >.
6. Press < until you reach the
“Diagnostics Port” option, then
press >.
7. Press < until you reach “Debug
ethernet”, then press ENTER.
8. Press ON LINE to return the
printer to the online state.
9. Save the changes and set up a
new power-up configuration, if
necessary. The Printer Manager
should now be able to access the
printer. For other communication
errors, print out the E-Net Test
Page (page 138) and verify the IP
address, subnet mask, gateway
address, and TCP port settings.
104
List Of Messages
UNDEF INTERRUPT* Undefined Interrupt. 1. Cycle power. Run the print job
again.
UNDFNED OPCODE* Undefined Opcode. 1. Cycle power. Run the print job
again (page 175).
UNKNOWN RBN1 The sensor detects a bar Install a new ribbon.
Install New RBN code, but the ribbon model is
not permitted on this printer.
UNKNOWN RBN2 The sensor detects a bar Install a new ribbon.
Install New RBN code, but the region code
does not match the printe
UP DRV. SHORT* Upper Driver Short. Hammer 1. Cycle power. If the message
driver circuits on the appears, press CLEAR. If the
controller board are shorted message does not clear, replace
to ground. the hammer bank logic cable and
assemblies.
defective board.
105
WAITING FOR This status message No action required.

ETHERNET ADAPTER appears when the printer is
first powered on if the
optional ethernet NIC is
installed. An ethernet
adapter must be detected
early in the power up
sequence so the printer can
tell the adapter it has been
detected and continue with
its own power up sequence.
Compared to the printer, the
ethernet adapter takes a
long time to complete its
internal diagnostic tests, so
the boot code allows the
adapter to power up in
parallel with the printer to
reduce its effect on overall
boot time
106
List Of Messages
Troubleshooting Other Symptoms

WARNING Always disconnect the AC power cord from the printer before doing a
maintenance procedure. Failure to do so could result in injury to you or
damage to equipment. If you must apply power during maintenance, you
will be instructed to do so in the maintenance procedure.
Use standard fault isolation techniques to troubleshoot malfunctions not
indicated by display messages. These techniques are summarized below:
1. Ask the operator to describe the problem.
2. Verify the fault by running a diagnostic printer test or by replicating the
conditions reported by the user.
3. Look for a match in the General Symptom List, which begins on page
108. If you find a match, go to the troubleshooting procedure and follow
the numbered instructions.
4. If you cannot find the symptom in the General Symptom List, use the
Half-Split Method to find the malfunction:
a. Start at a general level and work down to details.
b. Isolate faults to half the remaining systems at a time, until the final
half is a field-replaceable part or assembly. (Troubleshooting aids are
listed on page 37.)
5. Replace the defective part or assembly. Do not attempt field repairs of
electronic components or assemblies. Most electronic problems are
corrected by replacing the printed circuit board assembly, sensor, or
cable that causes the fault indication. The same is true of failures traced
to the hammer bank: replace the entire shuttle assembly because it is not
field repairable.
6. Test printer operation after every corrective action.
7. Reinstall any parts you replaced earlier that did not solve the problem.
8. Stop troubleshooting and return the printer to normal operation when the
reported symptoms disappear.
107
Chapter 3 Troubleshooting Other Symptoms
General Symptom List

Table 5 is a list of possible printer problems that are not indicated by
messages on the LCD. Troubleshooting procedures are included for each
symptom.
If you encounter a problem that is not listed in Table 5, troubleshoot using the
Half-Split Method described on page 107.
Table 5. General Symptom List
Symptom Solution
Communications Failures See page 132.
Ribbon
Ribbon folding or feed 1. Make sure the ribbon is correclty installed and the ribbon
problems spools are fully seated on the ribbon hubs.
2. Check that the ribbon runs between the ribbon mask and
hammer bank cover. Check that the hammer bank cover is
Installed correctly.
3. Check that the ribbon spools are not rubbing against the
shuttle cover assembly. Install the shuttle cover assembly
correctly, so that the spools do not rub against it.
4. Inspect the paper print path for paper chaff, ink residue,
and debris. Clean the shuttle frame assembly.
5. Power on the printer. Run a print test and observe ribbon
movement across the left and right ribbon guides. Adjust
the right and left ribbon guides if necessary.
6. Observe ribbon movement at both left and right ribbon
posts as the metal end strip crosses each ribbon post. If
the metal strip moves past either post without reversing
the direction of the ribbon, power down the printer.
Remove the paper guide assembly or pedestal top cover.
Reseat connectors P106/LRP and P107/RRP on the
controller board.
7. While shorting across each ribbon post with the ribbon
metal strip or a screwdriver, check for continuity in
connector P106/LRP pins 10 and 12, and connector P107/
RRP pins 14 and 16. (Refer to the Main Wire Harness Test
Tables in Appendix A.) Replace a ribbon post that fails the
continuity test.
8. Check the platen gap. Adjust if necessary.
108
Symptom Solution
Jams
CLEAR PAPER JAM 1. Power off the printer. Remove the paper path or pedestal
message instead of LOAD top cover. Remove the barrier shield (cabinet model) or
PAPER when printer is out of the barrier shield and paper guide (pedestal model).
paper Check that the paper detector switch assembly is securely
mounted in its bracket. Clean the paper detector switch if
necessary.
2. Check that connector P106/PMD is fully seated in
connector J106 on the controller board.
3. Load paper. Power on the printer. Replace the paper
detector switch assembly if either message appears.
4. Inspect the paper ironer. If the paper ironer has slipped up
into the print line, reposition the paper ironer.
5. Load paper. Power on the printer. Replace the controller
board if either message appears. Record the message
and return it with the defective board.
CLEAR PAPER JAM 1. Remove the paper path or pedestal top cover. Make sure
message will not clear and connector P107/PAPR M is fully seated in connector J107
paper does not move on the controller board.
2. Check the condition and tension of the paper feed timing
belt. Adjust the paper feed timing belt. Replace the belt if it
is damaged.
3. Check the dynamic paper tension.
4. Load paper. Power on the printer. Press PAPER
ADVANCE and VIEW several times and check that paper
moves correctly in both directions. Replace the paper feed
motor if the message appears or the paper moves
erratically.
5. Power on the printer. Press PAPER ADVANCE and VIEW
several times and check that paper moves correctly in
both directions. Replace the controller board if the
message appears or the paper moves erratically. Record
the message and return it with the defective board.
109
Symptom Solution
CLEAR PAPER JAM 1. Power off the printer. Remove the paper path or pedestal
message will not clear but top cover. Check that connector P106/PMD is fully seated
paper moves in connector J106 on the controller board.
2. Remove the barrier shield (cabinet model) or the barrier
shield and paper guide (pedestal model). Check that the
paper detector switch assembly is securely mounted in its
bracket. Clean the paper detector switch if necessary.
3. Check that the paper detector switch assembly is securely
mounted to the mechanism base. Tighten the two screws
securing the paper detector switch assembly to the
mechanism base.
4. Check that the motion detector wheel rotates. Replace the
paper detector switch assembly if the wheel does not
rotate.
5. Load paper. Power on the printer. Replace the paper
detector switch assembly if the message appears.
6. Load paper. Power on the printer. Replace the controller
board if the message appears. Record the message and
110
Symptom Solution
Control Panel
Black squares on control 1. Power off the printer. Remove the paper path or pedestal
panel top cover. Disconnect the control panel cable from the
panel and from J110 on the controller board. Check
continuity of the cable. (See Appendix A.) Replace the
control panel cable if it fails continuity test. Connect the
cable. Power on the printer. If the symptom appears,
replace the control panel.
2. If the printer has the CT board, make sure it is correctly
seated in the controller board.
3. Power off the printer. Make sure the flash memory is
seated properly in J10 and J11 on the controller board.
Regardless of memory configuration, J10 must be used.
4. Power on the printer. If black squares appear on the LCD,
the flash memory could be blank. Replace the flash SIMM
in J10 with a new flash SIMM with the boot program
installed.
5. Power on the printer. If the symptom appears, replace the
control panel.
6. Power on the printer. If black squares appear on the LCD,
replace the controller board. Record the message and
return it with the defective board. If the LCD displays
characters correctly, download the emulation software
again (page 175).
Control panel blank 1. Power off the printer. Remove the paper path or pedestal
top cover. Check all cable connections into the controller
board; make sure the control panel cable is seated in
3. Power on the printer. Inspect the control panel display and
cooling fans. If the control panel is blank and the cooling
fans come on, replace the control panel cable assembly
and/or the control panel, as required.
4. Power on the printer. If the control panel is blank and the
fans do not come on, replace the controller board.
111
Symptom Solution
Control panel keys do not 1. Power on the printer. Check the operation of the control
work panel keys. Replace the control panel assembly if the keys
do not work.
2. Power on the printer. Check the operation of the control
panel keys. Replace the control panel cable assembly if
the keys do not work.
3. Power on the printer. Check the operation of the control
panel keys. Replace the controller board if the keys do not
work.
Control panel display shows 1. Remove the paper path or pedestal top cover. Check
garbled, broken characters cable connections into the controller board. Make sure the
control panel cable is seated in connector J110 on the
controller board.
2. Make sure the SDRAM DIMM is seated properly in its slot
on the controller board. Reseat and re-latch the SDRAM
DIMM.
3. Power on the printer. Inspect the control panel display. If
the control panel shows broken characters, replace the
SDRAM.
112
Symptom Solution
Power Failures
No power, and control panel 1. Check that the AC power outlet has power. Restore AC
blank, and card cage fan not power if necessary.
running 2. Unplug the printer AC power cord from the printer (leave it
plugged into the power outlet) and check for AC power at
the printer end of the cord. If there is no power through the
AC power cord, replace it. Plug the AC power cord into the
printer and power outlet.
3. Remove the paper path or pedestal top cover. Verify that
the AC-In power cable and the AC power input cables are
connected to the on/off switch-circuit breaker. (See
Figure 47, page 278.) Make sure all ground connections
are clean and tight.
4. Check that AC-in power cable connector P1 is connected
to J1 on the power supply board. Reseat the connector.
5. Check that power supply cable connector P101 is
connected to J101 on the controller board. Reseat the
connector.
6. Check all cable connections on the controller board.
8. Disconnect AC-in power supply cable connector P1. Set
the circuit breaker to 1 (on). Measure AC voltage at pins 1
and 2 of connector P1. If no voltage, replace the circuit
breaker. If there is voltage, replace the power supply
board.
113
Symptom Solution
Printer does not initialize NOTE: Power-on initialization is explained on page 151.
1. Power off the printer. Remove the paper guide or pedestal
top cover. Reseat all cable connectors on the controller
board, especially connectors P106 and P107.
2. Check the shuttle for electrical shorts (page 188).
3. If the printer has the CT board, verify that the user is
running CT emulation software. If the printer does not
have the CT board, go to step 7.
4. If the printer has the CT board, check that the user has
enough flash memory installed to handle the emulation
software. (See Figure 27 on page 221, and the Boot
Diagnostics Menu on page 140.) Install flash memory and
download emulation software if necessary.
6. Power on the printer. If the fans run but the printer does
not initialize, replace the CT board.
7. Power on the printer. If the fans do not run and the printer
does not initialize, do the power supply operational check
(page 193). If the power supply fails the check, replace it.
If it passes the check, go to the next step.
8. Power on the printer. If the fans run but the printer does
not initialize, replace the controller board.
9. Power on the printer. If the problem persists, replace the
10. Power on the printer. If the problem persists, replace the
control panel and cable.
114
Symptom Solution
Power Stacker
Printer does not detect 1. Check that the power stacker is enabled under the Printer
presence of power stacker Control menu. (Refer to the Setup Guide.) If the power
stacker enable/disable option does not appear in the
menu, go to the next step.
2. Open the rear cabinet door. Check that the ON/OFF
indicator lamp is lit. If the ON/OFF indicator is not lit, go to
step 3. If the ON/OFF indicator is lit, press the ON LINE
key and check that the ON LINE indicator lights. If the ON
LINE indicator comes on, the stacker is detected by the
printer. If the ON LINE indicator does not come on, go to
step 4.
3. a) Power off the printer.
b) Unfasten the cable clamp holding the stacker control
panel cables.
c) Disconnect the stacker power cable from the back of the
stacker control panel. (See Figure 74, page 384.)
d) Locate pin 1 of connector P106. (See the cable
assembly drawing in Appendix A.)
e) Power on the printer.
f) At connector P106 check for +48 volts DC between pins
1 and 2 and +5 volts DC between pins 3 and 4. If the
voltages are correct, replace the stacker control panel. If
the voltages are not correct, power off the printer, remove
the paper path, and disconnect the stacker power cable
from the controller board. (See Figure 77, page 387.)
Check the continuity of the stacker power cable between
P105 and P106. If the cable fails the continuity test,
replace it. If the cable is OK, replace the controller board.
4. Power off the printer. Remove the paper path. Disconnect
stacker cables from the controller board, stacker
assembly, and the stacker control panel (see Figure 74,
page 384). Check cables for cuts, breaks, or damaged
pins. Check continuity of cables. (See Appendix A.)
Replace any cable that is damaged or fails continuity test.
Reconnect all stacker cables to the controller board,
stacker, and stacker control panel.
5. Power on the printer. Check that the ON LINE indicator
lights on the stacker control panel. If the ON LINE indicator
does not light, replace the stacker control panel.
6. Power on the printer. Check that the ON LINE indicator
lights on the stacker control panel. If the ON LINE indicator
does not light, replace the controller board.
115
Symptom Solution
Stacker “chatters” at upper or 1. Power off the printer. Unload paper. Open the rear cabinet
lower limit door and check that stacker motion is not obstructed by
the control panel cable or other obstruction. Remove
obstruction or reroute the stacker control panel cable as
necessary.
2. Verify that the stacker rails are vertical and parallel. Adjust
the stacker rails if necessary: they must be vertical and
parallel.
3. Move the elevator up and down by hand and check that
the limit switches are being tripped at the highest and
lowest limits of elevator travel.
4. Power on the printer. Operate the power stacker. (Refer to
the Operator’s Guide.) While the stacker is operating,
check that:
a) all motors are operating,
b) the paddles are rotating,
c) the elevator moves smoothly and without obstruction,
d) the timing belts are undamaged and the belt pulleys are
not slipping,
e) the extension springs are attached and undamaged (not
bent or stretched),
f) the drive rollers are not damaged,
g) the constant force springs are tightly mounted and
undamaged.
Tighten pulley setscrews and/or replace damaged
components as necessary.
116
Symptom Solution
Stacker does not stack 1. Check for and remove obstructions preventing elevator
properly movement.
2. Check for misaligned stacker rails. Adjust the stacker rails
if they are not vertical and parallel.
3. Power on the printer. Operate the power stacker. (Refer to
the Operator’s Guide.) While the stacker is operating,
check that:
a) all motors are operating
b) the paddles are rotating
c) the elevator moves smoothly and without obstruction
d) the timing belts are undamaged and the belt pulleys are
not slipping
e) the extension springs are attached and undamaged (not
bent or stretched)
f) the drive rollers are not damaged
g) the constant force springs are tightly mounted and
undamaged
Tighten pulley setscrews and/or replace damaged
components as necessary.
4. Check the stacker limit switches. (See page 118.) If the
limit switches are OK, go to the next step.
5. Check the stacker motors. (See page 119.) If the stacker
motors are OK, go to the next step.
6. Remove the paper path. Disconnect stacker cables from
the controller board, stacker assembly, and the stacker
control panel (see Figure 74, page 384). Check cables for
cuts, breaks, or damaged pins. Check continuity of cables.
(See Appendix A.) Replace any cable that is damaged or
fails continuity test. Reconnect all stacker cables to the
controller board, stacker, and stacker control panel.
Stacker elevator does not See “Stacker does not stack properly”
move
Stacker elevator moves by 1. Power off the printer. Inspect all stacker LEDs for dust,
itself chaff, or dirt. (See Figure 100 through Figure 102, page
410 through page 414.) Clean the stacker LEDs and the
sight tubes in the LED mounts.
2. Power on the printer. If the stacker elevator moves by
itself, replace the stacker LEDs. (See Figure 100 through
Figure 102, page 410 through page 414.)
117
Symptom Solution
Stacker limit switch check NOTE: This procedure tests the upper and lower limit
switches on the right vertical rail. These magnetic
switches are normally closed. You can quickly check
Right Vertical Rail their functionality with a small, powerful magnet.
Upper Limit You will usually be referred to this procedure from

Switch other troubleshooting procedures. When you have
Elevator completed this check procedure, return to the
Disable procedure that sent you here.
Switch 1. Power on the printer. Open the rear cabinet door. Unload
the power stacker.
2. Press the Elevator Disable Switch and manually lift the
elevator all the way to the top of its travel.
3. Position a small, powerful magnet between the belt and
vertical rail so that it is in front of the exposed face of the
lower limit switch. Tape or otherwise secure the magnet in
position so that your hands are clear of the vertical rail and
elevator.
a. With the magnet secured next to the lower limit switch
press the ELEVATOR DOWN key on the stacker
control panel.
b. If the elevator does NOT move, the lower limit switch
is OK. Remove the magnet and go to step 4.
c. If the elevator moves, release the ELEVATOR DOWN
key, power down and unplug the printer, and replace
the lower limit switch.
4. Press the Elevator Disable Switch and manually move the
elevator all the way down to the bottom of its travel.
Lower Limit Switch 5. Position a small, powerful magnet between the belt and
vertical rail so that it is in front of the exposed face of the
upper limit switch. Tape or otherwise secure the magnet in
position so that your hands are clear of the vertical rail and
elevator.
a. With the magnet secured next to the upper limit switch
press the ELEVATOR UP key on the stacker control
panel.
b. If the elevator does NOT move, the upper limit switch
is OK. Power down, unplug the printer, remove the
magnet, and return to the procedure that sent you to
this check procedure.
c. If the elevator moves, release the ELEVATOR UP key,
power down and unplug the printer, and replace the
upper limit switch.
118
Symptom Solution
Stacker motor check NOTE: This procedure tests the four stacker motors and their
cables. You will usually be referred to this procedure
from other troubleshooting procedures. When you
have completed this procedure, return to the
procedure that sent you here.
1. Power off the printer.
2. Open the rear cabinet door.
3. Unfasten the cable clamp holding the stacker control panel
cables.
4. Disconnect stacker rail cable connector P107 from
connector J3 on the back of the stacker control panel.
(See Figure 74, page 384.)
5. Disconnect stacker frame cable connector P102 from
connector J4 on the rear of the stacker control panel. (See
Figure 74, page 384.)
6. Locate pin 1 of connector P102 and connector P107. (See
the cable assembly drawings in Appendix A, page 350 and
page 353.)
7. Check both cables for pin damage, continuity, and shorts.
8. Check all motors for 15.2 ± 1.5 Ohms on both phases.
(Refer to the power stacker control panel PCBA pinout
drawing on page 331.)
9. Replace any cable that is damaged or fails continuity test.
Replace any motor that fails the resistance test.
Stacker not operating See “Printer does not detect presence of power stacker,” page
115.
119
Symptom Solution
Print Quality
Characters or dots are 1. Check the forms thickness lever: if it is set too loose or too
missing, smeared, too light, tightly print quality can be affected. Set the forms
or too dark. thickness lever to match the thickness of the paper being
used.
2. Check the paper tension between the tractors. Adjust the
right tractor so that it does not pull paper too tightly or
leave it too loose. The right tractor should hold the paper
under “slight” tension.
3. Inspect the shuttle frame assembly for print chaff, debris,
or ink residue that could be causing the problem. Clean
the shuttle frame assembly.
4. Check the ribbon for folds or tears. Check that the ribbon
guides are tight and the ribbon tracks straight across them.
Rewind or install new ribbon. If the ribbon does not track
straight across the ribbon guides, adjust the ribbon guides.
If the ribbon guides are loose, tighten them. If the ribbon
guides are damaged, replace them.
5. Power off the printer. Remove the shuttle cover. Remove
the shuttle frame assembly. Inspect the ribbon mask for
bends or deformation that adversely affect paper feeding.
Make sure the hammer bank cover assembly is correctly
installed on its mounting pegs. Check the shuttle frame
assembly for broken hammer springs, hammer tips, or
contaminations. Replace any damaged hammer spring
assemblies. Replace the hammer bank cover assembly if
it is deformed or damaged.
6. Check the platen gap. Adjust the platen gap if necessary.
7. Remove the paper guide assembly or pedestal top cover.
Make sure Connectors P105 and P108 have good
connections on the controller board. Make sure
connectors P04 and P05 have good connections at the
shuttle frame assembly. Reseat connectors P04, P05,
P105, and P108.
8. Power on the printer. If the problem still occurs, replace
the hammer bank logic cable and the hammer bank power
cable.
9. Power on the printer. If the problem still occurs, replace
the shuttle frame assembly.
10. Power on the printer. If the problem still occurs, do the
power supply operational check (page 193). If the power
supply fails the check, replace it. If it passes the check, go
to the next step.
11. Check the shuttle for electrical shorts (page 188).
120
Symptom Solution
Characters or dots are 12. Power on the printer. If the problem still occurs, replace
missing, smeared, too light, the controller board.
or too dark. (continued.)
Characters are compressed Adjust the tension of the tractor belts (page 187).
on first line of a form
Horizontal misalignment of 1. Take the printer offline and print a test pattern of All H’s. If
characters (Dots or characters shift left or right from line to line, there might be
characters move left or right a proportional spacing problem. If the pattern of H’s prints
from dot row to dot row or line correctly (that is, all the columns line up), contact your
to line) support group or configuration help desk, because a
configuration change may be necessary. If the pattern of
H’s did not print OK, go to the next step.
2. Check the hammer phasing. Adjust hammer phasing if
necessary.
4. Inspect the shuttle frame assembly area for ink residue,
paper chaff, or debris. Clean the shuttle frame assembly.
5. Check the MPU gap. Using a feeler gauge, adjust the gap
between the MPU assembly and the flywheel to 0.010 ±
0.001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch MPU
clamp screw to 18 ± 1 inch-pounds (2.03 ± 0.11 N•m).
6. Power on the printer. Run a print test. If the symptom is not
gone, replace the MPU.
gone, replace the controller board.
gone, replace the shuttle frame assembly.
121
Symptom Solution
Randomly misplaced dots 1. Power off the printer. Check the platen gap. Adjust the
platen gap if necessary.
On the left rear wall of the card cage, make sure the nut
which secures the line filter ground line and the AC In
Power Supply cable lead to the ground stud is tight. (See
3. Disconnect the AC power cord and check the ground
leads for continuity. Replace the AC power cord if it fails
continuity test.
4. Make sure the printer is plugged in to a grounded power
outlet. Power on the printer. Run a print test. If the problem
occurs, replace the hammer bank logic cable.
5. Power on the printer. Run a print test. If the problem
occurs, replace the flash memory and SDRAM. Download
the emulation software again.
occurs, replace the controller board.
occurs, do the power supply operational check (page 193).
If the power supply fails the check, replace it. If it passes
the check, go to the next step.
occurs, replace the shuttle frame assembly.
122
Symptom Solution
Vertical misalignment of 1. Load paper. Press PAPER ADVANCE and check that
characters: paper feeds smoothly. Press VIEW to verify that paper
1. Dots or characters move moves in both directions. Check the forms thickness lever:
up or down from dot row to if it is set too loose or too tightly print quality can be
dot row or line to line affected. Set the forms thickness lever to match the
2. Incorrect spacing from dot thickness of the paper being used.
row to dot row or line to line 2. Check the condition and tension of the paper feed timing
3. Characters randomly belt. Adjust the paper feed timing belt. Replace the belt if it
compressed and/or enlarged is damaged.
3. Check the platen gap. Adjust the platen gap.
4. Inspect the tractors and tractor door springs for damage,
excessive wear, and equal door closing tension. If either
tractor is worn, damaged, or exhibits uneven door closing
tension, replace both tractor assemblies.
Make sure connector P107/PAPR M is fully seated in
7. Load paper. Power on the printer. Run a print test. If the
problem occurs, replace the paper feed motor.
8. Run a print test. If the problem occurs, replace the
controller board.
9. Run a print test. If the problem occurs, replace the power
supply board.
123
Symptom Solution
Printer Operation
Downloads consistently fail NOTE: Most download problems are detected by software
during the procedure and communicated by LCD
messages. If downloads fail consistently with no
messages or with erratic messages, suspect a
hardware failure.
1. Power off the printer. Remove the paper path or pedestal
top cover. Check the I/O cable connections from the host
to the printer. Check the parallel cable connection at J112
on the controller board. Inspect all cables for damaged,
bent, broken, or burnt pins. Replace any damaged cables.
Reconnect all I/O cables; make sure all connections are
clean and tight.
2. Remove the flash SIMM. Inspect the SIMM sockets on the
controller board. If any socket pins are bent or damaged,
3. Check that customer has the right size SIMM for the
emulation. (See page 220) Install the SIMM that support
the emulation software.
4. Power on the printer. Download the emulation (page 175).
If the download fails, activate the Boot Diagnostics Menu
(page 140) and run MISC. TOOLS MENU / RUN
MEMORY TESTS. If memory fails test, replace the
SDRAM. If memory tests OK, replace the flash SIMM.
Boot code won’t copy 1. Power off the printer. Remove the flash SIMM. Inspect the
flash SIMM socket on the controller board. If any SIMM
socket pins are bent or damaged, replace the controller
board.
2. Make sure the blank SIMM is the same size as the SIMM
to be copied. Install the SIMM, making sure it is fully and
correctly seated. Power on the printer. From the Boot
Diagnostics menu, select and run MISC. TOOLS MENU /
COPY BOOT CODE. (See page 140.) If the
DESTINATION NOT DETECTED message appears, the
blank SIMM is not a type supported by the boot code on
the original SIMM. If SOURCE LARGER THAN
DESTINATION appears, the blank SIMM is not large
enough to contain the code on the original SIMM. If the
SIMM does not copy or the ERROR WRITING TO FLASH
message appears, replace the blank SIMM.
3. Power on the printer. From the Boot Diagnostics menu,
select and run MISC. TOOLS MENU / COPY BOOT
CODE. If the new SIMM does not copy, replace the
controller board.
124
Symptom Solution
Paper feeds poorly 1. Check the forms thickness lever: if it is set too tightly paper
feeding can be affected. Set the forms thickness lever to
match the thickness of the paper being used.
2. Power off the printer. Remove paper. Inspect the paper
feed path for obstructions that could snag paper. Clear
paper feed path of any obstructions.
3. Inspect the tractors and tractor door springs for damage,
excessive wear, and equal door closing tension. If either
tractor is worn, damaged, or exhibits uneven door closing
tension, replace both tractor assemblies.
is damaged.
7. Remove the shuttle frame assembly and check the
following:
a. Inspect the hammer bank cover assembly for ribbon
debris, paper debris, or other foreign matter. Make
sure the four foam spacers on the ribbon mask are
properly seated. If the ribbon mask or hammer bank
cover is damaged or deformed, replace it.
b. Inspect the paper ironer for distortion or misalignment.
Reposition or replace it if necessary.
c. Make sure the paper guides are properly seated on
the splined and support shafts.
d. Make sure the paper entrance guide pivots freely with
minimal down force. Reposition the springs or the
guide if necessary.
e. Check for correct position and function of the paper
motion detector assembly. Reposition or replace if
necessary.
8. Inspect the paper path from above (below the paper
ironer), and from below (above the paper entrance guide),
for debris, foreign matter, or anything that could inhibit
paper motion. Correct as necessary.
10. Remove the paper path. Make sure connector P107/PAPR
M is fully seated in connector J107 on the controller board.
Check for a good paper feed motor connection to J103 on
125
Symptom Solution
Paper feeds poorly 11. Load paper. Power on the printer. Press PAPER
(continued) ADVANCE and VIEW several times and check that paper
moves in both directions. Replace the paper feed motor if
paper does not move in both directions.
several times and check that paper moves in both
directions. Replace the controller board if paper does not
move in both directions.
Power on “hang” condition 1. Remove the paper path or pedestal top cover. Reseat all
cable connections to the controller board and the power
supply board.
2. Power on the printer. If the printer “hangs,” replace the
controller board.
3. Power on the printer. If the printer “hangs,” replace the
power supply board.
Printer does not print from the 1. Check the host data cable connection at the rear of the
host printer. Attach the data cable to the printer interface.
2. Make a configuration printout. Verify that the printer
matches host interface settings. Set printer interface
parameters to match those of the host.
3. Power on the printer. Send a print job from the host. If
printer does not print and the interface is RS-232,
interchange the wires to pins 2 and 3. (This is the most
common cause of an inoperative RS-232 cable.) Verify
that the host and printer have the same baud rate, number
of data bits, number of stop bits, and parity. Configure the
host for XON/XOFF if possible, since this requires the
least complex cable.
4. Power on the printer. Send a print job from the host. If the
printer does not print from the host, replace the data and
interface cable assemblies.
5. Remove the paper path or pedestal top cover. Check all
cable connections on the controller board. Reseat all cable
connectors on the controller board.
6. Power on the printer. Send a print job from the host. If the
printer still does not print from the host, replace the
controller board.
126
Symptom Solution
Printer does not print self 1. Power off the printer. Remove the paper path or pedestal
tests top cover. Disconnect the control panel cable from
connector J110 on the controller board. Disconnect the
control panel cable from the control panel. Check
continuity of the control panel cable assembly. Replace
the control panel cable assembly if it fails continuity test.
2. Connect the control panel cable assembly to J110 on the
controller board and to the control panel. Load paper.
Power on the printer. Run a self test. If the self test does
not run, replace the control panel assembly.
3. Power on the printer. Run a self test. If the self test does
not run, replace the controller board.
Reverse paper feed: platen 1. Raise the forms thickness lever and check that the platen
does not open opens. If the platen opens with difficulty, inspect for and
remove jams or obstructions.
2. Check the condition and tension of the platen open belt.
Adjust the platen open belt. Replace the belt if it is
damaged.
4. Power off the printer. Remove the paper guide assembly.
Disconnect connector P106 from the controller board.
Check the resistance of connector P106/PLAT M. (Refer
to the Main Wire Harness Test Tables in Appendix A.)
Replace the platen open motor if it fails the resistance test.
several times and check that paper moves in both
directions. Replace the controller board if the platen does
not open during paper reverse.
127
Symptom Solution
TOF is lost repeatedly 1. Check that the customer is setting the forms length to
match the size paper used. Set the forms length to match
the length of paper being used.
2. If the customer is using multi-part forms, check that the
forms thickness lever is not being set too tightly. Set the
forms thickness lever to match the thickness of paper and
provide satisfactory print quality, but not too tightly.
is damaged.
5. Remove the paper path or pedestal top cover. Make sure
connector P107/PAPR M is fully seated in connector J107
on the controller board. Connect P107/PAPR M to J107 on
6. Power on the printer. Load paper and set TOF. Press
PAPER ADVANCE and VIEW several times and check
that paper returns to TOF. Replace the paper feed motor if
paper does not return to TOF.
several times and check that paper returns to TOF.
Replace the controller board if paper does not return to
TOF.
128
Symptom Solution
Ribbon
Folding or feed problems with 1. Check that both ribbon spools are fully seated on the
a ribbon ribbon hubs.
2. Check that the ribbon runs between the ribbon mask and
hammer bank cover. Check that the hammer bank cover is
Installed correctly.
3. Check that the ribbon spools are not rubbing against the
shuttle cover assembly. Install the shuttle cover assembly
correctly, so that the spools do not rub against it.
4. Inspect the paper print path for paper chaff, ink residue,
and debris. Clean the shuttle frame assembly.
5. Clean the ribbon guides.
6. Power on the printer. Run a print test and observe ribbon
movement across the left and right ribbon guides. Adjust
the right and left ribbon guides if necessary.
7. Observe ribbon movement at both left and right ribbon
posts as the metal end strip crosses each ribbon post. If
the metal strip moves past either post without reversing
the direction of the media, power down the printer.
Remove the paper guide assembly or pedestal top cover.
Reseat connectors P106/LRP and P107/RRP on the
controller board.
8. While shorting across each ribbon post with the ribbon
metal strip or a screwdriver, check for continuity in
connector P106/LRP pins 10 and 12, and connector P107/
RRP pins 14 and 16. Replace a ribbon post that fails the
continuity test.
9. Check and adjust the platen gap.
129
Symptom Solution
Shuttle
Shuttle does not move 1. Power down the printer. Remove the shuttle cover. Check
the MPU gap. Adjust the gap between the MPU assembly
and the flywheel to 0.010 ± 0.001 inch (0.254 ± 0.025 mm).
Torque the 7/16 inch MPU clamp screw to 18 ± 1 inch-
pounds (2.03 ± 0.11 N•m).
2. Check that the MPU cable is connected to J03 on the
mechanism base. Check that the shuttle motor cable is
connected to J02 on the mechanism base. Connect the
MPU and the shuttle motor cables.
3. Remove the paper path or pedestal top cover. Check that
the shuttle motor drive cable is connected to J116 on the
controller board.
5. Inspect the ribbon mask for bends or deformation that
snag and interfere with shuttle movement. Make sure the
hammer bank cover assembly is correctly installed on its
mounting pegs. Reinstall the hammer bank cover
assembly. Replace a damaged or deformed hammer bank
cover assembly.
6. Check continuity of the shuttle motor drive cable
assembly. Replace shuttle motor drive cable assembly if it
fails continuity test.
7. Power on the printer. Run a Shuttle Slow or Shuttle Fast
test. If the shuttle does not move, replace the shuttle frame
assembly.
test. If the shuttle does not move, replace the power
supply board.
test. If the shuttle does not move, replace the controller
board.
130
Symptom Solution
Shuttle is noisy 1. Check the bolts securing the mechanism base to the base
pan. Tighten the mechanism base mounting bolts if they
are loose enough to permit movement of the mechanism
base.
2. Remove the shuttle cover. Check the shuttle frame
assembly mounting/clamp screws for looseness. Torque
the 5/32 inch socket head clamp screws to 30 ± 2 inch-
pounds (3.39 ± 0.23 N•m). Torque the center captive 5/32
inch socket head screw to 30 ± 2 inch-pounds (3.39 ± 0.23
N•m).
3. Inspect the shuttle area for loose hardware. Tighten loose
hardware.
4. Check that the hammer bank cover assembly is correctly
installed, that it has not slipped off the mounting pegs.
Check that the ribbon mask has not partially separated
from the hammer bank cover. Check for debris trapped
between the ribbon mask, hammer bank cover, and
hammer bank. Clean the shuttle frame assembly and
hammer bank cover assembly if you find debris. Replace
the hammer bank cover assembly if you find any damage
to the ribbon mask or hammer bank cover.
5. Power on the printer. Run a shuttle test. Replace the
shuttle frame assembly if it is noisy or rattles.
131
Chapter 3 Communications Failures
Communications Failures
Many host-printer communications problems are complex. With the exception
of a defective interface cable, most communications problems are not a result
of a hardware failure. They usually result from an incompatible configuration
of the host computer system, network (LAN, print server, controller,
multiplexer, etc.), or the printer. Sometimes the print application program itself
is at fault.
If you have limited communications experience, and the cause of the problem
is not readily apparent, do the following:
1. Print out the printer configuration, including the E-Net Test Page if the
customer is using the ethernet interface.
2. Obtain a copy of the Device Host Configuration if possible.
3. Call your support group for assistance in problem analysis.
If you cannot obtain support, or you have experience solving host-printer
communications problems, the following additional information is provided.
You can quickly check the ASCII portion of the printer logic by sending a plain
text file from a PC to the printer via the parallel or serial port. For a description
of each of the ASCII interfaces, refer to the User’s Manual.
Table 6. Communications Problems
Problem Interface Possible Causes & Solutions
Fails to print from host Parallel • Interface cable defective

-or-
• Host/Network configuration
Prints incorrect characters
-or- • Printer logic
Prints extra characters • Terminating Resistors
-or-
Drops characters
Serial • Host/Printer interface cable pinouts incompatible

• Host/Printer/Network configuration
• Set DTR and RTS both True
• Interface cable defective
• Printer logic
Twinax • Interface cable defective
• Host-Printer definition
• Controller/Network configuration
• Printer logic
Coax • Interface cable defective

• Controller/Network configuration
• Printer logic
132
Table 6. Communications Problems
Ethernet • Interface cable defective

• Host/Printer/Network configuration
• Printer logic
Ethernet PCBA responds Ethernet 1. Open a telnet session using the IP address of
to “ping” and “telnet” the ethernet card.
utilities, and can print from 2. Enter these commands:
“ftp”, but card cannot be config http on
accessed by a browser. save
reset
3. Wait up to two minutes for the ethernet card to
complete a reset cycle.
4. Close the telnet session.
You should be able to access the ethernet card

now through a browser by using the IP address
as a URL, as for example http://xxx.xxx.xxx.xxx
NOTE: If the ethernet card cannot be accessed by
the Printer Manager, do the steps listed
under “TCP Port Busy” on page 104.
Ethernet PCBA responds Ethernet 1. Open a telnet session using the IP address of
to “ping,” “telnet,” and “ftp” the ethernet card.
utilities, but will not
2. Enter these commands:
communicate from the host
start fox prn
computer.
stop prn
3. If the fox test prints, the host computer is not
configured properly.
133
Chapter 3 Diagnostic Printer Tests
Diagnostic Printer Tests

A set of printer tests is included in the DIAGNOSTICS configuration menu for
use as diagnostic tools. Use these tests to check the print quality and basic
operation of the printer. You will also use some of the tests in some
adjustment procedures. The diagnostic tests are summarized below:
• Shift Recycle — A “sliding” alphanumeric pattern useful for identifying
missing or malformed characters, improper vertical alignment, or vertical
compression.
• All E’s — A pattern of all uppercase letter E’s useful for identifying
missing characters, misplaced dots, smeared characters, improper
phasing, or light/dark character variations.
• E’s + TOF — A pattern of all E’s repeated for ten lines and followed by a
form feed to the top of the next page. This test is useful for identifying
paper motion or paper feed problems.
• All H’s — A pattern of all uppercase letter H’s useful for detecting missing
characters or dots, smeared characters, or improper phasing.
• All Underlines — An underline pattern useful for identifying hammer
bank misalignment.
• Shuttle Slow — Exercises the shuttle and ribbon mechanisms at low
speed. You can also use this test to check ribbon tracking and reversing.
• Shuttle Fast — Exercises the shuttle and ribbon mechanisms at high
speed. You can also use this test to check ribbon tracking and reversing.
• Shuttle Only — Runs the shuttle mechanism with no ribbon movement.
• Phase Printer — A hammer timing test that permits you to adjust the
hammer phase value. The hammer phase value is a timing parameter
that controls the vertical alignment of dots in character printing. The
numerical units are relative, they do not represent a physical
measurement or value. There is no “correct” value or range. The factory
prints the initial phase value on the casting of the shuttle assembly, next
to the motor housing. Use this value as your starting point when adjusting
hammer phasing.
• Paperout Adj. — Prints a vertical comb pattern. You use this pattern
when you do the end of forms (paper out) adjustment procedure. The
comb pattern lets you measure the number of dot rows from the
completion of a paper out fault to the end of the paper.
• Burnin Test — Do not use. This test is used by the printer manufacturer
to burn in the printer prior to shipment and has no value as a maintenance
tool.
• Print Error Log — Prints the current log of errors. Most non-routine faults
(ribbon stall, voltage faults) are stored in the error log.
• Clear Error Log — Clears all entries from the error log.
• Adapter Test — Prints the ethernet adapter statistics stored in the
ethernet adapter (if present).
134
Selecting And Running Diagnostic Printer Tests
• Ethernet Test — Prints the ethernet statistics stored on the ethernet

interface (if present). See page 138.
• Acoustics — A test used by the manufacturer to measure acoustic
properties of the printer. This test has no value as a maintenance tool.
• Demo — Prints representative lines of the various CPI available and
some sample bar codes.
• Dice 5 — Prints all dot positions, creating a solid black band across the
page. Used to detect dark and light hammer springs.
• Print Ribbon Log — Prints a list of the ribbons that have been used in
the printer.

NOTE: You must set TOF after running any diagnostic test.
Step Press LCD Result Notes
1. Make sure the printer is on. Raise the printer cover.
2. Load paper.
3. Set TOF. (Refer to the User’s Manual.)
4. ON LINE/CLEAR OFFLINE The printer must be

QUICK SETUP offline to run a print
test.
5. ENTER SWITCH Unlocks ENTER key

UNLOCKED and control panel.
+
OFFLINE
QUICK SETUP
6. OFFLINE
DIAGNOSTICS
UNTIL
7. DIAGNOSTICS
Printer Tests
135
8. DIAGNOSTICS
Test Width
UNTIL
9. Test Width
Full Width*
10. Test Width Cycle through

X choices. X = Full
OR Width or X = 80
columns.
11. ENTER Test Width Test width is

X* selected.
12. DIAGNOSTICS
Test Width
13. DIAGNOSTICS
Printer Tests
UNTIL
14. Printer Tests

Shift Recycle*
15. Printer Tests Cycle through the

All E’s choices.
OR
16. ENTER Printer Tests Starts test.

All E’s*
17. ENTER Printer Tests Stops test.

All E’s*
136
18. ENTER SWITCH Locks the ENTER

LOCKED key and control
panel.
+
19. ON LINE/CLEAR ONLINE Places the printer in

LinePrinter+ online mode.
20. Examine print quality. Characters should be fully formed and of

uniform density.
137
Printing The Ethernet Test

NOTE: You must set TOF after printing the Ethernet Test.
2. Load paper.
4. ON LINE/CLEAR OFFLINE The printer must be

QUICK SETUP offline to run a print
test.
5. ENTER SWITCH Unlocks ENTER key

UNLOCKED and control panel.
+
OFFLINE
QUICK SETUP
6. OFFLINE
DIAGNOSTICS
UNTIL
7. DIAGNOSTICS
Printer Tests
8. Printer Tests
Shift Recycle
9. Printer Tests
Ethernet Test
OR
10. ENTER Printer Tests Starts printing.

Ethernet Test*
11. ENTER Printer Tests Stops printing.

Ethernet Test
138
12. ENTER SWITCH Locks the ENTER

LOCKED key and control
panel.
+

139
Chapter 3 Boot Diagnostics Menu
Boot Diagnostics Menu

Printer boot-up software contains a “Boot Diagnostics” menu that you can
access by holding down two keys while powering on the printer. This menu is
not intended for the end user, but provides useful information for
manufacturing and maintenance personnel.
The boot diagnostics menu is a multi-level menu that operates the same way
as the user menus. The menu structure is shown in Figure 8 on page 141.
Activating The Boot Diagnostics Menu

1. Set the printer power switch to O (off).
2. On the control panel, press and hold down ; + >.
3. While holding ; + > , set the printer power switch to 1 (on).
4. When “BOOT DIAGNOSTICS / PRESS ENTER” appears on the LCD,
release the ; >
+ keys and press the ENTER key. Menu options are
shown in Figure 8.
Exiting The Boot Diagnostics Menu

Method 1: Use the exit option in the Boot Diagnostics Menu
1. Using the arrow keys, move to the DIAGNOSTICS MENU / EXIT
DIAGNOSTICS menu option. (Refer to the menu map on page 141.)
2. Press the ENTER key. The printer goes into startup initialization.
(B30: STATUS INITIALIZING...)
Method 2: Cycling power
2. Wait 15 seconds.
3. Power on the printer.
140
BOOT DIAGNOSTICS
>= Down Arrow Key
PRESS ENTER <= Next Arrow Key
ENTER
DIAGNOSTICS MENU
VERSION CONTROL <
>
<
VERSION MENU VERSION MENU VERSION MENU VERSION MENU
BOOTCODE VERSION < \SOFTWARE VERSION < HARDWARE VERSION < V8 ASIC VERSION
ENTER ENTER ENTER ENTER
BOOT/PPC V2.00A 09/12/04 HARDWARE VERSION V8 VERSION=F

03-Nov-03 363329 13:22:29 HURRICANE II MECA VERSION=F
VERSION MENU
EC VERSION
ENTER
EC V3.06M
12-Sep-03
DIAGNOSTICS MENU
FILE SYSTEM
<
A
Continued on
> next page
FILE SYSTEM MENU < FILE SYSTEM MENU FILE SYSTEM MENU
< - VIEW FILES - > FILE STATISTICS < OPTIMIZE FILES
ENTER > ENTER
OPTIMIZING
FLASH FILES
< - VIEW FILES - > VIEW FILES
93779.sf < FILENAME
FILE STATS MENU

<
FILE STATS MENU FILE STATS MENU FILE STATS MENU FILE STATS MENU FILE STATS MENU
BYTES AVAILABLE < BYTES USED < UNOPTIMIZE BYTES < TOTAL ERASE CYCL < # DELETED FILES NUMBER OF FILES
ENTER ENTER ENTER ENTER ENTER ENTER
BYTES AVAILABLE BYTES USED UNOPTIMIZE BYTES TOTAL ERASE CYCL # DELETED FILES NUMBER OF FILES
3010918924 1288242676 0000000000 0000000000 0000000000 0000000000
Figure 8. Boot Diagnostics Menu
141
Chapter 3 Boot Diagnostics Menu
A DIAGNOSTICS MENU
MISC. TOOLS <
DIAGNOSTICS MENU
EXCEPTION VIEWER <
DIAGNOSTICS MENU
EXIT DIAGNOSTICS
From previous
page > > ENTER
B30: STATUS
>= Down Arrow Key INITIALIZING...
<= Next Arrow Key
MISC. TOOLS MENU MISC. TOOLS MENU MISC. TOOLS MENU MISC. TOOLS MENU
AMOUNT OF MEMORY < COPY BOOT CODE < ERASE ALL NVRAM < CACHE CONTROL
<
ENTER ENTER ENTER >
SDRAM SIZE 032MB BOOT CODE COPY ERASE ALL NVRAM
FLASH SIZE 004MB HAS COMPLETED COMPLETED
CACHE CONT. MENU CACHE CONT. MENU CACHE CONT. MENU CACHE CONT. MENU CACHE CONT. MENU
DATA CACHE OFF < INSTRN CACHE OFF
< DATA CACHE ON < INSTRN CACHE ON < ALL CACHE ON
ENTER ENTER ENTER ENTER ENTER
DATA CACHE HAS INSTRUCTION DATA CACHE HAS INSTRUCTION ALL CACHE
BEEN DISABLED CACHE DISABLED BEEN ENABLED CACHE ENABLED HAS BEEN ENABLED
MISC. TOOLS MENU MISC. TOOLS MENU

RUN MEMORY TESTS < STATUS DISABLE
ENTER
>
<
RAM TEST MMU OFF SHOW STATUS MENU SHOW STATUS MENU
EC=NO DC=WR S2=B SHOW STATUS OFF SHOW STATUS ON
ENTER ENTER
EXCEPTION MENU EXCEPTION MENU EXCEPTION MENU

VIEW EXCEPTION < WHERE IT OCCURED < PPC INSTRUCTION
ENTER ENTER ENTER
NO EXCEPTION OCCURRED AT b1 0x0001E368

HAS OCCURRED ADDRESS 001E4B48
Figure 7. Boot Diagnostics Menu (continued)
142
Factory Menu
Printer software contains a Factory menu that you can access by holding
down the four arrow keys when the printer is in the offline state. This menu is
not intended for the end user, but is used by manufacturing and maintenance
personnel to set or change certain operational perameters.
The factory menu is a multi-level menu that operates the same way as the
user menus. The menu structure is shown in Figure 9 on page 144.
IMPORTANT If you do not know the purpose for a setting or value in the Factory
Menu, DO NOT change it. Default menu values set at the factory are
indicated by an asterisk ( * ) next to the value.
Entering The Factory Menu

1. Plug the AC power cord into the printer and the power source.
3. The printer must be offline to do this procedure. If the printer is online,
press the ON LINE key. “OFFLINE / QUICK SETUP” will display.
4. On the control panel, press the = >
+ keys to unlock the ENTER key.
“ENTER SWITCH UNLOCKED” briefly displays. (If “LOCKED” displays,
simply press = >
+ again. This is the default key combination. The lock/
unlock key combination can be programmed by the user. If = >
+ does
not unlock ENTER, get the new key combination from the user.)
5. Press = > < ;
+ + + to enter the factory menu. (Press all four keys at
the same time.) “Factory / Set Coil Temp” appears on the display. Menu
options are shown in Figure 9.
6. Before exiting the factory menu, press the = + > keys to lock the ENTER
key.
Exiting The Factory Menu

Press ON LINE to exit the Factory menu.
143
Chapter 3 Factory Menu
Factory Factory Factory

>= Down Arrow Key
Set Coil Temp < PRINTER MGMT < Demo Count <= Next Arrow Key
Press ENTER to select or
ENTER > > activate.
PLEASE WAIT... Demo Count

(See also the procedure 1*
on page 184.)
2 (Use < to view options.)
5
10
Continuous
PRINTER MGMT PRINTER MGMT PRINTER MGMT PRINTER MGMT

Diagnostic Port < Debug Port Cfg < Clear Password < Reboot w/Factory
> > ENTER ENTER
A Done Printer reboots with

Factory configuration.
Continued on
next page
Diagnostic Port
Disable * < Diagnostic Port
Serial
>
Serial Serial Serial Serial Serial

Select Port < Baud Rate < Word Length < Stop Bits < Parity <
> > > > >
Select Port Baud Rate Word Length Stop Bits Parity
Debug * 9600 BAUD * 8* 1* None *
Host (Use < to 19200 BAUD 7 (Use < to 2 (Use < to Odd (Use < to
view options.) 38400 BAUD view options.) view options.) Even view options.)
57600 BAUD
115200 BAUD
2400 BAUD (Use <
to
4800 BAUD view options.)
Serial Serial Serial Serial

Modem < Modem NVM < Modem Status < Dial Method
> > > >

Modem Modem NVM Modem Status Dial Method
Disable * Enable * Enable * Tone *
Enable Disable Disable Pulse

(Use < to (Use < to (Use < to (Use < to
view options.) view options.) view options.) view options.)
Figure 9. Factory Menu
144
>= Down Arrow Key

<= Next Arrow Key
Press ENTER to select or
A
From previous activate.
page
Debug Port Cfg Debug Port Cfg Debug Port Cfg Debug Port Cfg
Baud Rate < Word Length < Stop Bits < Parity
> > > >

Baud Rate Word Length Stop Bits Parity
9600 BAUD * 8* 1* None *
19200 BAUD 7 (Use < to 2 (Use < to Odd (Use < to

38400 BAUD view options.) view options.) Even view options.)
57600 BAUD
115200 BAUD
2400 BAUD (Use < to
4800 BAUD view options.)
Figure 8. Factory Menu (continued)
145
Chapter 3 Hex Code Printout
Hex Code Printout

A hex code printout (or “hex dump”) prints every ASCII data character
received from the host computer, and lists its corresponding two-digit
hexadecimal code. (See Figure 10 below.) You can use hex dumps as an aid
in troubleshooting data reception problems.
In a hex dump every printable character is printed both as its assigned symbol
and as its hex equivalent. Every unprintable (ASCII control) character is
printed out as a period (.) and its hex equivalent. If the printer is using a
parallel interface, the letter “p” before a hex code indicates an active Paper
Instruction (PI) line, and a blank space before a hex code indicates an inactive
PI line.
To convert an ASCII character to its corresponding hex code, or vice versa,
refer to the ASCII code chart on page 149. To make a hex code printout, refer
to the procedure on page 147.
Figure 10. Sample Hex Dump
146
How To Print A Hex Dump
2. ON LINE/CLEAR OFFLINE
QUICK SETUP
3. ENTER SWITCH Unlocks the ENTER

UNLOCKED key and control panel.
OFFLINE
QUICK SETUP
4. OFFLINE
MAINT / MISC
UNTIL
5. MAINT / MISC
Hex Dump Mode
6. Hex Dump Mode Default

Disable*
7. Hex Dump Mode Cycle through choices.

Enable
OR
8. ENTER Hex Dump Mode Asterisk (*) indicates

Enable* choice is active.
9. ENTER SWITCH Locks the ENTER key

LOCKED and control panel.
147
Chapter 3 Hex Code Printout

11. Send a file from the host computer. the printer outputs a hex dump. Refer to
the ASCII chart on page 149.
12. When the hex dump is complete, take the printer offline and change the Hex
Dump Mode back to Disable. Follow the steps outlined above and select
Disable.
148
ASCII Character Set
B7 0
B6 0
B5 1
BITS
KEY B4 B3 B2 B1
33 OCTAL equivalent
1 0 1 1 ESC 27 DECIMAL equivalent
1B HEX equivalent
ASCII Character Name
B7 0 0 0 0 1 1 1 1
B6 0 0 1 1 0 0 1 1
B5 0 1 0 1 0 1 0 1
BITS COLUMN
B4 B3 B2 B1 ROW 0 1 2 3 4 5 6 7
0 20 40 60 100 120 140 160
0 0 0 0 0 NUL 0 DLE 16 SP 32 0 48 @ 64 P 80 96 p 112
0 10 20 30 40 50 60 70
1 21 41 61 101 121 141 161
0 0 0 1 1 SOH 1
DC1 17
! 33
1 49
A 65
Q 81
a 97
q 113
(XON)
1 11 21 31 41 51 61 71
2 22 42 62 102 122 142 162
0 0 1 0 2 STX 2 DC2 18 " 34 2 50 B 66 R 82 b 98 r 114
2 12 22 32 42 52 62 72
3 23 43 63 103 123 143 163
0 0 1 1 3 ETX 3
DC3 19 # 35 3 51 C 67 S 83 c 99 s 115
(XOFF)
3 13 23 33 43 53 63 73
4 24 44 64 104 124 144 164
0 1 0 0 4 EOT 4 DC4 20 $ 36 4 52 D 68 T 84 d 100 t 116
4 14 24 34 44 54 64 74
5 25 45 65 105 125 145 165
0 1 0 1 5 ENQ 5 NAK 21 % 37 5 53 E 69 U 85 e 101 u 117
5 15 25 35 45 55 65 75
6 26 46 66 106 126 146 166
0 1 1 0 6 ACK 6 SYN 22 & 38 6 54 F 70 V 86 f 102 v 118
6 16 26 36 46 56 66 76
7 27 47 67 107 127 147 167
0 1 1 1 7 BEL 7 ETB 23 ' 39 7 55 G 71 W 87 g 103 w 119
7 17 27 37 47 57 67 77
10 30 50 70 110 130 150 170
1 0 0 0 8 BS 8 CAN 24 ( 40 8 56 H 72 X 88 h 104 x 120
8 18 28 38 48 58 68 78
11 31 51 71 111 131 151 171
1 0 0 1 9 HT 9 EM 25 ) 41 9 57 I 73 Y 89 i 105 y 121
9 19 29 39 49 59 69 79
12 32 52 72 112 132 152 172
1 0 1 0 10 LF 10
0A
SUB 26
1A
* 42
2A
: 58
3A
J 74
4A
Z 90
5A
j 106
6A
z 122
7A
13 33 53 73 113 133 153 173
1 0 1 1 11 VT 11 ESC 27 + 43 ; 59 K 75 [ 91 k 107 { 123
0B 1B 2B 3B 4B 5B 6B 7B
14 34 54 74 114 134 154 174
1 1 0 0 12 FF 12 FS 28 44 < 60 L 76 \ 92 l 108 | 124
0C 1C , 2C 3C 4C 5C 6C 7C
15 35 55 75 115 135 155 175
1 1 0 1
13 CR 13 GS 29 - 45 = 61 M 77 ] 93 m 109 } 125
0D 1D 2D 3D 4D 5D 6D 7D
16 36 56 76 116 136 156 176
1 1 1 0 14 SO 14 RS 30 . 46 > 62 N 78 ^ 94 n 110 ~ 126
0E 1E 2E 3E 4E 5E 6E 7E
17 37 57 77 117 137 157 177
1 1 1 1 15 SI 15 US 31 / 47 ? 63 O 79 _ 95 o 111 DEL 127
0F 1F 2F 3F 4F 5F 6F 7F
149
Chapter 3 Soft vs. Hard Reset
Soft vs. Hard Reset

Soft Reset
A soft(ware) reset clears printer memory then loads the power-up
configuration set by the user. (If no power-up configuration has been set by
the user, the factory default configuration is loaded.) It is called a soft reset
because no hardware is tested. All diagnostic and initialization tests are
bypassed and memory is simply refreshed with the power-up printer
configuration.
The printer must be offline to do a soft reset:
1. Press the ON LINE key to put the printer in the offline state.
2. Press the ; + < keys simultaneously.
The LCD will display “Standby / Soft Reset” while the printer loads the power-
up configuration.
Hard Reset (“Cycle Power”)

A hard(ware) reset is a power shutdown and restart that runs all initialization
and diagnostic routines. This is also called “cycling power.”
2. Wait 15 seconds.
3. Set the printer power switch to 1 (on).
NOTE: A hard printer reset causes the +48V power supply (fans, motors,
etc.) to shut down in 1 to 5 seconds, depending on the amount of
memory installed on the controller board.
150
The Power On Sequence

This section describes the normal sequence of events from the time the
power switch is set to 1 until ONLINE (or OFFLINE, if so configured by the
user) appears on the LCD.
Use this sequence as a reference baseline to help you isolate problems that
occur before the printer completes its bootstrap and initialization routines.
At power up printer software turns on the amber status LED at the rear of the
card cage. (Figure 11.) If a hardware problem is detected at power up the
amber LED will blink continuously.
At power up printer hardware also turns on the green LED. (See Figure 11.) If
a problem is detected with the software stored in the printer’s flash memory
both the amber and green LEDs will blink alternately.
Under normal conditions, both LEDs remain on continuously.
Green LED
Amber LED
Figure 11. The Controller Board Status LEDs

The rest of the power on sequence consists of two sets of routines:
1. DC hardware initialization (controller board handshake sequences)
2. DC software initialization and power up
The routines are listed below, in order of occurrence.
151
Chapter 3 The Power On Sequence
Controller Board Handshake Sequences

• Processor Alive — The green LED marked CR1 on the controller board
is turned on to indicate that the processor received a valid reset vector
and the first instructions to the processor are correct. CR1 is used to
report all DC errors and states.
• Test V8 Data Bus — A walking zero and one test verifies that all 32 data
lines from the V8 bus to the processor are connected. If a bad line is
detected, a 4-1-1-XX blink code is sent to the LED on the controller,
where XX is the data line plus 1. (For example, a bad data line 8 would
blink as 4-1-1-9.)
• Initialize V8 ASIC — The boot code detects the processor type and sets
up the internal registers of the V8 ASIC.
• Initialize Debug Serial Port — The boot code checks the validity of the
debug serial parameters in NVRAM; if they are valid, it sets the baud rate,
data type, and which messages should be sent out the debug port. If the
values in NVRAM are not valid, boot code initializes NVRAM to 9600
baud, 8 data bits, one stop bit, no parity bit, and standard messages.
• Turn On Instruction Cache — The instruction cache is turned on to help
speed up memory tests and the entire boot process.
• Enable DRAM Controller — A DRAM controller is built into the V8 ASIC.
DRAM must be refreshed a few times to operate correctly. To speed the
boot process, the refresh rate is temporarily increased. The message
“TESTING HARDWARE PLEASE WAIT” is sent to the LCD, during which
time the refreshes run and finish. At this point, the fans start. After
sending the message, the refresh rate is set to the proper rate and DRAM
is ready to be tested.
• Test I/O Clock — The V8 ASIC has two clocks for internal timing, a
processor clock and an I/O clock. The processor clock cannot be checked
because the processor will not run without it, but the I/O clock can be
checked. The I/O clock is used for sending data to the control panel and
to get the time for DRAM refreshes. If the boot code detects a problem
with the I/O clock, the error blink code 4-3-4 is sent to the diagnostic LED
on the controller board.
• Read Control Panel Keys — The control panel keys are read to
determine if the user is requesting that the printer be placed in download
mode, diagnostic mode, or debug SIMM disabled. If ON LINE and
PAPER ADVANCE are pressed during start-up, the printer is placed in
download mode. If the ; and > keys are pressed during start-up, the
printer is placed in diagnostic mode. If any other combination of keys are
pressed, the debug SIMM is disabled. Key states are put in an internal
register in the V8 ASIC.
• Detect DRAM — The V8 ASIC supports up to four banks of DRAM
totalling up to 32 Megabytes. Boot code detects how much DRAM is
located in each bank, and relocates the banks to create one contiguous
block of DRAM. The size and location of each bank is then displayed on
the debug terminal through the debug serial port.
• Test DRAM — DRAM is tested by writing a pseudo-random number
sequence to all the DRAM, then reading the pattern back to verify it
152
Controller Board Handshake Sequences
against what was originally written. If an error is detected, the message

“ERROR: DRAM AT ADDRESS XXXXXXXX” is displayed on the LCD.
When finished, the DRAM test sets all memory to zero.
• Inform the EC Processor — The first 8 Kilobytes of DRAM are reserved
for the EC processor, which must be notified when DRAM is ready to be
used. This is done by putting the message “DCS1” in the ECDC
communications register in the V8 ASIC.
• Detect Ethernet Adapter — An ethernet adapter must be detected early
in the power up sequence so the printer can tell the adapter it has been
detected and continue with its own power up sequence. An ethernet
adapter takes a long time to complete its internal diagnostic tests, so the
boot code allows the adapter to power up in parallel with the printer to
reduce its effect on overall boot time.
• Load Boot Messages — The boot code scans flash memory for OEM
boot messages and loads them into DRAM. The manufacturer’s boot
code is the same for all OEMs, and contains a set of default messages.
Boot messages for specific OEMs are stored in the DC code, not the boot
code.
• Load Boot Code into DRAM — Flash memory cannot be accessed
while flash is being detected, cleared, or programmed. This prevents boot
code from running in flash because the opcodes cannot be fetched. This
is solved by copying the program into DRAM and executing the program
out of DRAM. The boot code is position-independent in order for the
program to operate at a different address. The interrupt vector table is
also move to DRAM and the vectors are changed to reflect the new
address.
• Detect Flash — The boot code supports many different kinds of flash
memory, permitting any mixture of flash in the four memory banks. The
only requirement is that flash must exist in bank 0 and have boot code
programmed on it. The boot code displays flash configuration,
manufacturer’s part number, size, and start address out the debug serial
port.
• Display V8 Registers — The boot code displays the values of the V8
registers out of the debug serial port.
• Check for Pedestal — Boot code uses the control panel to determine if
the printer is a pedestal or floor cabinet model. Boot code needs to know
the difference so the exhaust fan fault can be disabled on a pedestal
model. “FAN DISABLED” is printed out at the debug serial port of a
pedestal model.
• Check for Download Mode — Boot code checks whether the ON LINE
and PAPER ADVANCE keys were pressed at power up. If so, the printer
enters download mode. If not, the printer continues the boot routines.
• Check for Diagnostics Mode — Boot code checks whether the
; and > keys were pressed at power-up. If so, the printer enters the Boot
Diagnostics menu. If not, the printer continues the boot routines.
• Check for Remote Download Mode — Boot code checks if the user
remotely requested the printer to enter download mode. If so, the printer
enters download mode. If not, the printer continues boot routines.
153
• Check for Flash Optimize — Boot code checks if the user requested the
flash file system to be optimized at power up. If so, flash memory is
optimized at this time. If not, the printer continues boot routines.
• Check EC Program — The EC calculates a checksum of the program
stored in its flash memory. If there is problem with its program, the EC
puts the message “nopg” in the ECDC communications register. If the
boot code detects this message, it displays “ERROR: EC PROGRAM
NOT VALID” on the LCD. If the EC processor does not respond within
three seconds, the boot code sends “EC STOPPED AT STATE XXXX” to
the LCD, where XXXX is one of these states:
State Description
0000 Power up
0001 Enter checksum calculation
0002 Enter copy download code from FLASH into shared DRAM
0003 Enter programming FLASH mode

0004 Erase EC FLASH
0005 Program FLASH
0006 Finish programming FLASH
0007 Enter initialization of EC serial debug
0008 Enter EC firmware task initializations
0009 Enter power up coil diagnostic

000A Start running normal EC firmware
• Check Security Key and NVRAM — The chip select for NVRAM comes
from the security key. If the key is not installed, NVRAM cannot be
accessed, so the key is tested before NVRAM. If the security key is not
detected, boot codes displays “SECURITY KEY NOT DETECTED”. If a
security PAL is detected, boot code checks for the presence of NVRAM. If
NVRAM is not found, boot code displays “ERROR: NVRAM FAILURE”.
• Test for Powerup File — Boot code checks for a DC executable file
called powerup.sbr. If found, it executes the file, then returns to boot
routines. If the file is not found, boot routines are resumed. If any key was
held down during power up, boot code does not look for the powerup file
and continues the boot sequence.
• Automatic EC Update — Boot code checks whether the automatic EC
update feature is enabled by the DC program. If so, it looks for a copy of
the EC program in the Flash File System. If it has a copy, it compares the
program in EC flash to the program in the Flash File System, and updates
the EC program if they are different. If the automatic EC update was not
enabled, or if any key was held down during power up, automatic EC
update is skipped and the boot sequence continues normally.
154
DC Software Initialization And Power Up
• Debug SIMM — The debug SIMM contains fast static RAM that
automatically replaces the flash memory. Boot code checks for the debug
SIMM and, if found, copies the contents of flash memory into the SIMM,
then re-maps the address of the SIMM to the location of flash. This allows
breakpoints and single-stepping from the MTOS® debugger. When the
debug SIMM is found, boot code displays “DEBUG SIMM ACTIVATED”
on the panel and out the debug port.
• Verify DC Program — Boot code calculates a checksum at every power
up to verify that the program has not been corrupted. If the checksum
does not match, boot code displays “ERROR: DC PROGRAM NOT
VALID”.
• Check Security — The security check verifies that the security key
supports the software that is loaded in flash memory. If the key does not
support the software, boot code displays “SECURITY CODE
VIOLATION”.
• Check Required DRAM — Boot code checks whether the amount of
DRAM required to run the DC program is larger than the amount of
DRAM in the printer. If so, it displays the message “ERROR: PROGRAM
NEEDS MORE DRAM”.
• Tell EC Processor to Finish Booting — Boot code informs the EC
processor that everything is okay and can finish booting up.
• Diagnostics Passed — If all tests pass, boot code displays
“DIAGNOSTICS PASSED”. At this point, the ribbon motors engage. Boot
code then jumps to the start address of the DC software.
• Display DC Program Information — Boot code sends the following
information out the debug port: the compile time, date, and the address it
will jump to start the DC program.
• Waiting Ethernet — If boot code earlier detected an ethernet adapter, it
places the message “WAITING FOR THE ETHERNET ADAPTER” on the
LCD so the user will not think the printer has crashed.
• Jump Back into Flash and Clear DRAM — Boot code jumps back into
flash memory, then clears the DRAM that held the boot code.
• Jump to MTOS — Jump to start initialization of the MTOS (Multi-Tasking
Operating System).
DC Software Initialization And Power Up

The final part of the power up sequence is initialization and startup of the DC
software, which occurs in the following order:
• Clear Uninitialized RAM Variables
• Set Initialized RAM Variables
• Configure RAM (allocated based upon amount in the printer)
• Jump to MTOS (Multi-Tasking Operating System)
• Initialize the Processor (cache, vector table, etc.)
• Partition RAM for Tasks
• Allocate Peripheral Interfaces (console driver, etc.)
155
• Start Main Task (supervisor)

• Verify and Initialize NVRAM (statistics are cleared if NVRAM is not valid)
• Initialize Libraries (fault, system, emulation)
• Load Front Panel Menus from ROM
• Initialize these tasks, then start them after all have initialized:
Print Engine Driver Task
CT Driver Task (sends 8344 code to the CT expansion board)
Serial Driver Task
Parallel Driver Task
CT Emulation Task
IGP Task (PGL or VGL)
Base Emulation Task:
Initialize Fonts
Initialize Graphics Library
Complete Emulation Library Initialization
Wait for all emulation tasks to initialize
Front Panel Task
• Display “ONLINE” on control panel
156
4 Adjustments and Tests
Introduction
The printer is a durable, low-maintenance machine, but some components
and systems require occasional adjustment and may need to be tested as
part of a troubleshooting procedure.
You usually will be referred to this chapter by a troubleshooting procedure, or
as part of a removal/installation procedure.
Adjustments and Tests

Preparing the Printer for Maintenance ............................................ page 158
Returning the Printer to Normal Operation...................................... page 159
Belt, Paper Feed Timing, Adjustment ............................................. page 160
Belt, Platen Open, Adjustment ........................................................ page 162
Paper Scale Alignment.................................................................... page 164
Platen Gap Adjustment ................................................................... page 166
Ribbon Guide Alignment ................................................................. page 168
Paper Out Adjustment..................................................................... page 170
Hammer Phasing Adjustment ......................................................... page 173
Loading Flash Memory.................................................................... page 175
Reprogramming the Security Key ................................................... page 182
Coil Temperature Adjustment ......................................................... page 184
Dynamic Paper Tension Adjustment ............................................... page 185
Tractor Belt Tension Adjustment ..................................................... page 187
Shuttle Electrical Short Check......................................................... page 188
Hammer Bank Power Cable Shorts Test ........................................ page 189
Cable Shorts Test ........................................................................... page 190
Main Wire Harness Test Diagnostic ................................................ page 192
Power Supply Operational Check ................................................... page 193
157
Chapter 4 Preparing The Printer For Maintenance
Preparing The Printer For Maintenance

WARNING Unplug the printer power cord from the printer or power outlet before
you do any maintenance procedure. Failure to remove power could
result in injury to you or damage to equipment. If you must apply power
during maintenance, you will be instructed to do so in the maintenance
procedure.
IMPORTANT Do not try to repair electronic components or assemblies in the field. Do

not de-solder any circuit board components. Replace a malfunctioning
electronic assembly with an operational spare. Most electronic
problems are corrected by replacing the printed circuit board assembly,
sensor, or cable that causes the fault indication. This is also true of
failures traced to the hammer bank—it is not field repairable and you
must replace the entire shuttle frame assembly. Hammer spring
assemblies are the only replaceable components of the shuttle frame
assembly.
To prepare the printer for maintenance, do the following steps before you
make any adjustments or perform any maintenance procedure:
2. Unplug the printer power cord from the printer or AC power source.
3. Disconnect the data (signal) cable(s) from the printer interface.
4. Unload paper.
5. Read the entire adjustment or maintenance procedure before you begin
working on the printer.
6. Gather the necessary tools and parts before you begin working on the
printer.
158
Returning The Printer To Normal Operation

When you are finished servicing the printer, test its operation and return it to
service by doing the following steps:
1. Load paper.
2. Connect the data (signal) cable(s) to the printer interface.
4. Close the cabinet doors.
5. Set the printer power switch to | (on).
6. Test printer operation by selecting and running one of the operator print
tests. (See page 134.)
7. Select the emulation. (Refer to the User’s Manual.)
8. Set the top-of-form. (Refer to the User’s Manual.)
9. Close the printer cover.
159
Chapter 4 Belt, Paper Feed Timing, Adjustment
Belt, Paper Feed Timing, Adjustment

1. Prepare the printer for maintenance (page 158).
3. Remove the timing belt cover (1) by squeezing the front and back to
release the plastic tabs from the slots in the side plate.
4. Loosen (do not remove) the two 5/16 inch motor mount bolts (2).
5. Using the straight end of a force gauge, apply 15 pounds (66.7 N) of
pressure to the paper feed drive motor (3). Use the splined shaft (4) to
steady the gauge.
6. Reduce tension to 12 pounds (53.4 N) and torque the 5/16 inch paper
feed motor mount bolts (2) to 18 ± 2 inch-pounds (2.03 ± 0.23 N•m).
NOTE: Belt tension is correct if the belt deflects 1/8 inch (3.175 mm) midway
between the pulleys.
7. Snap the timing belt cover (1) into the slots in the side plate.
8. Cabinet Models: Install the paper path (page 225).
160
1/8 inch
4
Direction of Force 1
Legend:
1) Timing Belt Shield
2) Motor Mount Bolt (2)
3) Paper Feed Drive Motor
4) Splined Shaft
Figure 12. Paper Feed Timing Belt Adjustment
161
Chapter 4 Belt, Platen Open, Adjustment
Belt, Platen Open, Adjustment

3. Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.
4. Using a 5/32 inch Allen wrench, slowly loosen the motor adjustment
screw (2) just enough to permit movement of the platen open motor in the
slotted side plate.
5. Close the forms thickness lever all the way.
CAUTION Too much tension on the platen open belt can cause the platen gap to
change, which can lead to premature wear of the platen, damaged
hammer tips, and poor print quality.
6. The spring will automatically tension the belt.
7. Slowly tighten the motor adjustment screw (2).
between the pulleys. If deflection is more or less than 3/16 inch,
repeat steps 4 through 7.
8. Snap the platen open belt cover (1) into the slots in the side plate.
162
3/16 inch
2
3
1
Legend:
1) Belt Cover
2) Motor Mount Screw (2)
3) Platen Open Motor Shaft
Figure 13. Platen Open Belt Adjustment
163
Chapter 4 Paper Scale Alignment
Paper Scale Alignment

2. Load paper.
3. Connect the power cord to the AC power source.
4. Set the printer power switch to 1 (on).
5. Verify that the shuttle cover (1) is properly installed (page 209).
6. Print a full 136 column line by selecting and running one of the diagnostic
self-tests. (See page 134.)
7. Check alignment of the scale to the print at column positions 1 and 136.
8. If adjustment is necessary, loosen the three 5/64 inch button-head hex
screws (2).
9. Position the scale (3) so that column positions 1 and 136 line up with the
first and last characters on the 136 character printout.
10. Tighten the 5/64 inch button-head hex screws (2).
164
Legend:
1) Shuttle Cover
2) Screw, Button-Head, 5/64 inch hex (3)
3) Paper Scale
Figure 14. Paper Scale Alignment
165
Chapter 4 Platen Gap Adjustment
Platen Gap Adjustment

IMPORTANT Only do this procedure if the original equipment shuttle frame assembly
or platen was replaced by a new or refurbished unit, or if you were
instructed to in a troubleshooting procedure.
2. Remove the ribbon and paper. (Refer to the User’s Manual.)
4. Loosen the platen open belt (page 162, steps 2, 3, and 4).
5. Rotate the platen stop knob (1) until the white pointer is aligned with “A”
on the forms thickness label.
6. Raise the forms thickness lever (2) to the fully open position.
CAUTION Do not force the platen against the feeler gauge and do not move the
feeler gauge laterally across the hammer bank. Damage to the hammer
tips will result.
7. Insert a 0.012 inch (0.30 mm) flat feeler gauge (3) straight down between
the hammer bank cover plate (4) and ribbon mask (5), within four hammer
positions of the left end of the hammer bank.
CAUTION Adjust the platen setscrews less than 1/4 turn on one side, then check
the other side. Adjustment sensitivity is approximately 0.03 inch per
revolution of the setscrew. Also, insert the feeler gauge no more than 2
inches down from the top of the ribbon mask.
8. Gently close the forms thickness lever (2) all the way. As the platen is
closing, gently slide the feeler gauge up and down, keeping it between the
hammer tip and ribbon mask. If the feel is too tight when the platen is
being closed, adjust the 3/32 inch setscrew (6) at the end of the platen
counterclockwise. If the feel is too loose, adjust the setscrew clockwise.
With the forms thickness lever closed all the way, the feeler gauge should
contact both the hammer tips and the ribbon mask and move with light
friction. Shift the gauge slightly to verify.
9. Repeat steps 6 through 8 at the right end of the hammer bank.
10. After adjusting both sides, check the gap again at both ends. Readjust if
necessary.
11. When the platen gap is correct at both ends of the platen, adjust the
platen open belt (page 162).
NOTE: Gap widths other than 0.012 inch (0.30 mm) in the middle and inner
sections of the platen are okay, provided the gap at each end of the
platen is 0.012 inch (0.30 mm).
13. Install the ribbon. (Refer to the User’s Manual.)
14. Check the hammer phasing adjustment (page 173).
166
2 NOTE: Left side adjustment

shown. Right side is the same.
5 3
4
6
A
Legend:
1) Platen Stop Knob
2) Forms Thickness Lever
3) Feeler Gauge
4) Hammer Bank Cover
5) Ribbon Mask
6) Setscrew, 3/32 inch hex (2)
Figure 15. Platen Gap Adjustment
167
Chapter 4 Ribbon Guide Alignment
Ribbon Guide Alignment

2. Load paper.
4. Using the Shuttle Slow diagnostic printer test (page 134), wind the ribbon
fully onto the ribbon spool on the side opposite the ribbon guide you want
to adjust. For example, to align the right ribbon guide, wind the ribbon
until the left ribbon spool is full. (You can reverse ribbon tracking by
shorting across the ribbon guide skid screws (1) with a screwdriver or
Allen wrench.)
5. Check ribbon tracking by running the Shuttle Slow diagnostic printer test.
(See page 134.)
6. On the ribbon guide to be adjusted, momentarily short between the ribbon
guide skid screws (1) to verify that the ribbon reverses.
7. Observe how the ribbon (2) passes around and across the ribbon guide. It
should be centered and not folding against the top or bottom steel
washers (3).
8. If the ribbon is not centered, stop the Shuttle Slow test. Use a small
7/32 inch box-end/open-wrench to loosen the retaining screws (4) just
enough so that you can rotate the ribbon guide to new positions, but it will
remain in place once moved.
9. Rotate the ribbon guide as required to center the ribbon (2).
10. Tighten the retaining screws (4).
11. Allow most of the ribbon to wind onto the ribbon spool on the side you
adjusted, then repeat steps 5 through 10 for the other ribbon guide.
168
A Left Ribbon Guide Right Ribbon Guide B
2
2
Legend:
1) Screw, Skid (2)
2) Ribbon
3) Steel Washer
4) Screw, Retaining (2)
Figure 16. Ribbon Guide Alignment
169
Chapter 4 Paper Out Adjustment
Paper Out Adjustment

This procedure tests and sets the distance from the page perforation at which
a LOAD PAPER fault message is triggered. This adjustment prevents printing
on the platen when the printer runs out of paper.
The measurement units are dot rows.
You will use the dot row patterns printed by the Paperout Adj. test to verify
that this parameter is set correctly.
NOTE: Do this procedure only if a new paper detector switch assembly has
been installed, the controller board has been replaced, or if you are
sure the paper out adjustment is incorrect. A paper out triggering
distance of 1 or 2 dot rows above the perforation is acceptable; 5 to 7
dot rows above or any dot rows below indicates adjustment is
required. Also, although it is not required, it is advisable to test the
paper out triggering distance with 6-part paper, in order to verify
correct printing with multi-part forms.
The procedure below describes how to run the Paperout Adj. test and modify
the paper out “Dots” value.
2. On cabinet models, open the cabinet front door.
3. Load paper. Make sure the forms thickness lever is closed.
5. On the sheet of paper just below the paper entrance slot, cut or tear a four
inch square on the left side, immediately below the perforation. (See
Figure 17.) This creates a hole that will trigger a LOAD PAPER fault
message, but allows printing to the right of the hole (which would occur on
the platen in a true paper out condition).
6. Cut or tear a four inch square in the manner described above, on every
third sheet, until you have made 3 or 4 holes.
Page Perforation
4 in.
Cut out here 4 in.
Figure 17. Paper Preparation for Paper Out Adjustment Test
170
7. If the printer is online, press the ON LINE key to place the printer offline.
“OFFLINE / QUICK SETUP.” displays.
simply press =and >again. This is the default key combination. The
lock/unlock key combination can be programmed by the user. If = >
+
does not unlock ENTER, get the new key combination from the user.)
9. Press the ; key. “DIAGNOSTICS” displays.
10. Press >. “DIAGNOSTICS / Printer Tests” displays.
11. Press >. “SHIFT / RECYCLE” displays.
12. Press < until “Paperout Adj.” displays.
This test will print a vertical “comb” pattern at around column 70, each
long bar separated by three shorter bars. An enlarged example of the
comb pattern is shown below.
13. Press ENTER until the Paper Out Adjustment test starts. The comb
pattern will print until the display shows “LOAD PAPER” and the audible
alarm sounds.
14. Open the platen and move the paper up with the vertical position knob
and examine the area of the page perforation.
If a long bar just meets the perforation, the paper out adjustment distance
is correct, skip to step 27. (1 or 2 dot rows above the perforation is OK; 5
to 7 dot rows above or any dots below the perforation mean adjustment of
the Paper Out Dots value is required.)
If the comb pattern stopped short of the perforation or printed beyond the
perforation, go to step 15.
15. Measure how short or long the comb pattern printed by counting the
number of dot rows needed to reach the perforation, or the number of dot
rows that printed beyond the perforation.
NOTE: You can use the long bars to count the dot rows quickly. There are
three dot rows between each long bar, so each long bar increases the
number of dot rows by four. You can also tear off a small piece of the
comb pattern from the beginning of the pattern and use it as a ruler to
help you measure the dot rows required either to reach the
perforation or back up to it.
16. Close the platen.
17. Press CLEAR to remove the fault condition.
“OFFLINE / QUICK SETUP” displays.
18. Press the ; key. “DIAGNOSTICS” displays.
171
Chapter 4 Paper Out Adjustment
20. Press < until “Paper Out Dots” displays.

21. Press >. The top line of the display will show “Paper Out Dots” and the
bottom line will show the current setting for the number of dots.
>
22. Press . The number of dots will move up to the top line of the display
with an asterisk (*) next to it.
23. Using the < ;
or key, adjust the XX DOTS value up or down by the
number of dots you counted in step 15. (If the comb pattern stopped short
of the perforation, increase the number of dots. If the comb pattern printed
beyond the perforation, decrease the number of dots.)
24. Press ENTER to select the new number of dots as the active value. (The
asterisk that appears tells you that it is now the active value.)
25. Press CLEAR to place the printer offline.
“OFFLINE / QUICK SETUP” displays.
26. Run the Paper Out Dots and the Paper Out Adjustment tests until the
comb pattern prints at an acceptable distance from the page perforation.
(Return to step 10.)
27. When the paper out triggering distance is acceptable, reload the paper,
feed it past any remaining unused holes that you tore in it, and set the top
of form.
28. Press + = > (or the key combination set by the user). “ENTER SWITCH
LOCKED” briefly displays.
30. Press the ON LINE key to place the printer online.
172
Hammer Phasing Adjustment

You must check and adjust hammer phasing if the controller board is
replaced, the shuttle frame assembly is removed, or if the MPU is replaced.
The hammer phase value is a timing parameter that permits you to adjust the
vertical alignment of dots in character printing. The phase value numerical
units are relative; they do not represent a physical measurement or value.
Thus there is no “correct” value or range. But, if the phasing value is far
enough from the theoretical ideal value on a particular printer, errors can
occur. If, for example, you are adjusting phasing and an error such as PAP
FIFO UNDRFL* occurs, the phase value may be too high. Try a lower value.
The factory prints the initial phase value on the shuttle assembly casting, next
to the motor housing. Adjust the phasing to this value and recheck the vertical
alignment. When vertical alignment is acceptable, write the new phasing
value on the shuttle.
Phasing should be adjusted with the printer printing at full paper width.
IMPORTANT The printer must be printing the Phase pattern of “H’s” when the
Phasing Value is changed, or the New Phasing Value will not be written
into memory. If the value is changed when not printing, the printer will
return to its default phasing value when powered off then back on.
1. Load full width (136 column) paper and set the top of form.
3. If the printer is online, press the ON LINE key to place the printer offline.
“OFFLINE / QUICK SETUP.” displays.
4. On the control panel, press the += > keys to unlock the ENTER key.
simply press =and >
again. This is the default key combination. The
lock/unlock key combination can be programmed by the user. If = >
+
does not unlock ENTER, get the new key combination from the user.)
5. Press the ; key. “OFFLINE / DIAGNOSTICS” displays.
7. Press >. “Printer Tests / Shift Recycle” displays.
8. Press < until “Printer Tests / Phase Printer” displays.
9. Press ENTER. The display shows “Printer Tests / Phase Printer” and the
test begins. The current phasing value is printed on the left of the printed
pattern of all H’s. As the pattern prints, compare the H’s to the figure
below. If the phasing needs adjustment, go to step 10. If the phasing is
OK, go to step 13.
Needs Correct Needs

Adjustment Adjustment
173
Chapter 4 Hammer Phasing Adjustment
>
10. Press : The current phase index displays. Press > again: An asterisk
(*) appears next to the phase value.
11. Press <
to increase or ;
to decrease the phasing index value, then
press ENTER to activate the value as it prints. Continue to increase or
decrease the phasing index until the pattern of H’s is acceptable.
12. Press = twice: “Printer Tests / Phase Printer” displays.
13. Press ENTER to stop the test.
14. Press CLEAR. “OFFLINE / QUICK SETUP” displays.
15. Press + = > (or the key combination set by the user). “ENTER SWITCH
LOCKED” briefly displays.
17. Press the ON LINE key to place the printer online.
NOTE: If you changed the phasing value, power down the printer, remove
the ribbon and shuttle cover, and write the new phase value on the
aluminum shuttle casting.
174
Loading Flash Memory

Flash memory is contained in a SIMM (single in-line memory module) located
on the controller board. Printer control languages (the “emulations”) and
printer operating system software are loaded into flash memory at the factory,
but there are occasions when you may have to load this software:
• You have replaced the controller board
• You have replaced flash memory
• The customer needs to upgrade printer software
• The customer needs different emulation software
• The customer buys the PGL or VGL graphics language, the
CT option, the IPDS option, or the ethernet NIC (Network Interface Card)
option after the printer is installed
Emulation and operating system software are included as files on a CD-ROM
that comes with the printer. You will copy the appropriate file from the CD-
ROM to a computer’s hard disk, then download the file from the computer into
printer memory.
IMPORTANT When downloading emulation and operating system software to the

printer, all other optional fonts, customer-supplied logos, setup files,
feature files, and TIFF files will be erased. You will need to reload those
files. Before starting a download, make sure you have all the necessary
files on hand.
You can load software through the serial, parallel, or ethernet port of the
printer, and you can do it three ways:
• If your computer can run Java™ programs, you can load software through
any printer port by using the Firmware Download Utility included on the
CD that comes with the printer. (See below.)
• You can use DOS commands to load software through the parallel port or
serial port. (See page 177.)
• If the printer has the ethernet NIC (Network Interface Card) installed, you
can load software through the ethernet port. (See page 180.)
Loading Software With The Firmware Download Utility

If your computer has the Java runtime environment installed, the Firmware
Download Utility (FDU) allows you to load program files into the printer with an
easy to use graphical interface. FDU is a utility program included on the CD
that comes with the printer and can be used on computers with Windows®,
UNIX®, and Linux® operating systems. With FDU, you can choose which
printer port through which to load software (all are supported), choose the
baud rate if you opt for serial, and launch the load process. FDU is a Java-
based program, so you need Java runtime environment version J2re1.4.2 or
higher installed on your computer. (The runtime environment can be
downloaded free from http://www.java.com/en/download.)
1. Make a configuration printout of all saved configurations. (Refer to the
User’s Manual.)
175
Chapter 4 Loading Flash Memory

3. Disconnect the data (signal) cable(s) from the printer interface
connectors.
4. Connect a printer data cable to the parallel, serial, or ethernet port of the
computer you will use to download the software.
5. Connect the printer data cable to the appropriate I/O port of the printer.
6. On the printer control panel, press and hold down the ON LINE and
PAPER ADVANCE keys. Without releasing the keys, power the printer
on. When you see “B01 STATUS: 8245 SDRAM TEST 32MB” on the
LCD, release the keys.
7. Wait until you see “PROGRAM DOWNLOAD” on the LCD before doing
the next step. This can take a few seconds to appear, depending on the
emulations and interfaces installed in the printer.
8. On your computer, create a directory named download at the root level
of the hard drive. (For example, C:\download on a Windows computer.)
9. Insert the printer emulation software CD into your computer’s CD-ROM
drive.
10. Copy the FDU.jar file from the CD-ROM to your computer.
11. Open the readme.txt file on the CD-ROM. There are five emulation sets
with corresponding part number files from which to choose:
CT / IPDS / IGP
ANSI / IGP
TN / IGP
PCL2 / IGP
LG / IGP
All emulations include the LP+ emulation. They are offered in two file
formats: .exe and .prg. You can use either format with the FDU program.
12. Identify which emulation set you want to load into the printer and note the
filename that corresponds to that emulation. The filename is a six digit
number plus .exe or .prg. For example: 123456.exe or 123456.prg
This is the file you will download into the printer.
13. Copy the file to the download directory you created in step 8.
14. Double-click on the FDU.jar file you copied to your computer. It will
launch its own window, then you can use it to select the emulation, the
port into which to load it, and initiate the download.
IMPORTANT Do not interrupt the downloading process once it has started.

Interrupting a download will leave the flash memory on the controller
board incompletely loaded, and the printer may not boot up.
15. When the new software has successfully loaded into flash memory and
the printer has reset itself, set the printer power switch to O (off).
16. Remove the CD-ROM from your computer and store it with the printer.
17. If required, reconnect the data input cable(s) to the printer.
19. Using the configuration printout(s) you made in step 1, restore the printer
configurations. (Refer to the printer User’s Manual.)
176
Loading Through Parallel Or Serial Port Using DOS

User’s Manual.)
connectors.
4. Connect a parallel data printer cable to the LPT1 port or a serial data
printer cable to the COM1 port of an IBM-compatible computer running
the PC-DOS, MS-DOS, or Windows (3.1x, 95, 98, Me, NT, 2000, or XP)
operating system.
NOTE: You can connect the cable to the LPT2 port if the LPT1 port is in use.
The load command is different if you use this port, so make sure you
use the LPT2 commands in step 15.
Software loads at 9600 baud if you load through the serial port with a
DOS command. This can take a long time. Software loads much
faster through the parallel port.
5. Connect the data cable to the appropriate I/O port of the printer.
8. Using Windows Explorer, create a directory named download at the root
level of your C: hard drive. (C:\download)
9. Insert the printer emulation software CD-ROM into your computer’s CD-
ROM drive.
CT / IPDS / IGP
ANSI / IGP
TN / IGP
PCL2 / IGP
LG / IGP
formats: .exe and .prg. Use .exe files to download through the parallel
or serial port.
number plus .exe. For example: 123456.exe
13. Start a command prompt session. (The Start Menu icon is usually labeled
MS-DOS Prompt or Command Prompt.)
177
14. At the command prompt type:

C:<Enter>
cd \download<Enter>
15. To load the file through the LPT1 parallel port on the computer, type the
following at the command prompt on the computer:
filename.exe -pb<Enter>
where filename.exe is the file name you noted in step 11. This command
decompresses the file on the hard drive and copies it as a binary file into
the flash memory on the printer controller board.
To load the file through the LPT2 parallel port on the computer, enter the
following command:
filename.exe -pb2 <Enter>
To load the file through the serial port, enter the following commands:
mode COM1:9600,N,8,1,P<Enter>
filename.exe -pbc1<Enter>
NOTE: Software loads at 9600 baud if you load through the serial port with a
DOS command. This can take a long time. Software loads much
faster through the parallel port.
When you power up in download mode (step 6) the printer is ready to
accept data from all ports. When the printer receives data from one of
the ports (based on the load command you give) the other ports shut
down.

board incompletely loaded, and the printer may not boot up.
While the file is copied into memory, the display screen on the printer
control panel informs you of the load process and status.
17. Remove the CD-ROM from the host computer and store it with the printer.
20. Using the configuration printout(s) you made in step 1 on page 177,
restore the printer configurations. (Refer to the printer User’s Manual.)
Loading Software If Flash Contains Only Boot Code

If the flash memory contains only boot code (for example, if it is new), or if a
download was interrupted (for example, by a power outage) you must
download software through the printer’s parallel port using the three-key
initialization sequence covered in this section.
1. Make sure the printer’s parallel port is available. In some configurations,
you may have to re-install the Centronics® I/O cable and connector in
order to load basic software into the printer.
User’s Manual.)
178

connectors.
5. Connect a parallel data printer cable to the LPT1 port or LPT2 port of an
IBM-compatible computer running the PC-DOS, MS-DOS, or Windows
(3.1x, 95, 98, Me, NT, 2000, or XP) operating system.
6. Connect the data cable to the Centronics port of the printer.
7. On the printer control panel, press and hold down the
ON LINE + PAPER ADVANCE + VIEW / EJECT keys. Without releasing
the keys, power the printer on.When you see “B01 STATUS: 8245
SDRAM TEST 32MB” on the LCD, release the keys.
8. Wait until you see “B20: STATUS 00% / DOWNLOAD MODE” or
“PROGRAM DOWNLOAD” on the LCD before doing the next step.This
can take a few seconds to appear, depending on the emulations and
interfaces installed in the printer.
ROM drive.
CT / IPDS / IGP
ANSI / IGP
TN / IGP
PCL2 / IGP
LG / IGP
formats: .exe and .prg. Use .exe files to download through the parallel
port.
number plus .exe. For example: 123456.exe
14. Start a command prompt session. (The Start Menu icon is usually labeled
MS-DOS Prompt or Command Prompt.)
C:<Enter>
cd \download<Enter>
16. To load the file through the LPT1 parallel port on the computer, type the
following at the command prompt on the computer:
filename.exe -pb<Enter>
where filename.exe is the file name you noted in step 11. This command
decompresses the file on the hard drive and copies it as a binary file into
the flash memory on the printer controller board.
179
To load the file through the LPT2 parallel port on the computer, enter the
following command:
filename.exe -pb2 <Enter>
17. When the software has successfully loaded into flash memory and the
printer has reset itself, set the printer power switch to O (off).
18. Starting at step 6 of “Loading Through Parallel Or Serial Port Using DOS”
on page 177, load the software again through the parallel port. (In other
words, use the two-key method to load software again. This ensures that
all necessary code is loaded into printer memory.
Loading Software Through The NIC

IMPORTANT To load software through the ethernet NIC (Network Interface Card) you
need the IP Address of the printer and the flash memory must contain
basic printer code. If the flash memory was replaced, or if a download
was interrupted (for example, by a power outage), you must load
software through the parallel port. (Refer to “Loading Software If Flash
Contains Only Boot Code” on page 178.)
User’s Manual.)
3. Connect the ethernet cable to the printer interface.
ROM drive.
CT / IPDS / IGP
ANSI / IGP
TN / IGP
PCL2 / IGP
LG / IGP
formats: .exe and .prg. Use .prg files to download through the NIC.
number plus .prg. For example: 123456.prg
This is the file you will download into the NIC.
180
11. Start a command prompt session in Windows. (The Start Menu icon is
usually labeled MS-DOS Prompt or Command Prompt.)
C:<Enter>
cd \download<Enter>
13. Start the FTP (file transfer protocol) program by typing:
ftp xxx.xxx.xxx.xxx<Enter>
(where xxx.xxx.xxx.xxx is the IP Address of the printer.)
14. Log in to the printer by typing:
root<Enter>
You are given a password prompt.
NOTE: The default is no password. If the program requires a password,
contact the system administrator.
15. At the password prompt, press <Enter>.
16. Once logged in, type the following sequence at the command prompt to
download the filename.prg file to the printer:
cd dest<Enter>
cd d1prn<Enter>
bin<Enter>
put filename.prg<Enter>
(where filename.prg is the file name you noted in step 9)

board and NIC incompletely loaded, and the printer may not boot up.
17. When the download is complete, exit the FTP program by typing:
quit<Enter>
19. Remove the CD-ROM from the host computer and store it with the printer.
22. Using the configuration printout(s) you made in step 1 on page 180,
restore the printer configurations. (Refer to the printer User’s Manual.)
181
Chapter 4 Reprogramming the Security Key
Reprogramming the Security Key

The security key on the PSA3 controller board can be reprogrammed with a
Software Program Exchange (SPX) module.
The SPX is an intelligent module that plugs into the debug port on the back of
printers equipped with the PSA3 controller board. The SPX is used only once;
it automatically overwrites itself after successfully reprogramming a security
key. This allows the end user or a service technician to enable features such
as new emulations without having to remove covers and install a new security
key on the controller board.
The SPX is used at power-up only and is not left in the printer during normal
operation. Because it is a single-use disposable item the user is not required
to return it to the vendor or manufacturer.
How To Reprogram The Security Key

2. On cabinet models, open the rear door. On pedestal models, use the
illustration below to locate the debug port at the rear of the printer.
3. Insert the SPX into the debug port, as shown below.
Debug Port
SPX
4. Power on the printer. The printer will begin its boot-up sequence.
5. When the printer detects a valid SPX, the control panel displays:
“NEW SPX DETECTED
PRESS ENTER”
NOTE: If an error message displays, find the message in the Message List in
Chapter 3 and follow the troubleshooting instructions.
182
6. Press the ENTER key to activate the reprogramming sequence. The

display will read:
“DO NOT POWER OFF
Upgrading...”
7. When the security key is reprogrammed, the display will read:
“REMOVE USED SPX
THEN PRESS ENTER”
8. Remove the SPX from the debug port at the rear of the printer.
9. Press the ENTER key. The printer will reboot itself and you may resume
normal printing.
10. You may need to download the emulation if the emulation supported by
the SPX is not in the current printer firmware..
11. You may need to set additional menu parameters for any new features
that have been added or enabled. (Refer to the User’s Manual.)
183
Chapter 4 Coil Temperature Adjustment
Coil Temperature Adjustment

IMPORTANT This procedure applies only to models P7215 and P7220.
Do this procedure only when the original controller board or shuttle frame
assembly have been replaced or you are instructed to do so in a maintenance
or troubleshooting procedure. Do not do this procedure if the original
controller board or shuttle frame assembly were removed and reinstalled as
part of other maintenance tasks.
IMPORTANT The shuttle frame assembly must be at room temperature to do this

procedure. Power off the printer and let it cool for at least one hour
before doing this procedure.
3. The printer must be offline to do this procedure. If the printer is online,
press the ON LINE key. “OFFLINE / QUICK SETUP” will display.
simply press = and > again. This is the default key combination. The lock/
unlock key combination can be programmed by the user. If += > does
not unlock ENTER, get the new key combination from the user.)
5. Press = > < ;
+ + + to enter the factory menu. (Press all four keys at
the same time.) “Factory / Set Coil Temp” appears on the display.
6. Press ENTER. The display tells you to “PLEASE WAIT” while the coil
temperature is set by an automatic calibration sequence in printer
software.
7. When the display again reads “Factory / Set Coil Temp” press = + > to
lock the ENTER key.
8. Press the ON LINE key to exit the Factory menu.
9. Coil temperature is set. Return the printer to normal operation (page 159).
184
Dynamic Paper Tension Adjustment

This procedure helps you identify and eliminate conditions that contribute to
paper jams, excessive tension on the paper feed motor, and vertical dot
compression or expansion.
2. Unload paper.
3. Unlock both tractors and move them outward to the sides as far as they
will go.
4. Prepare a length of 14 inch wide paper consisting of three sheets that are
still attached at the perforations. The paper must be single part, 18 lb.
maximum weight, 0.0036 inch (0.09 mm) maximum thickness. Open the
cabinet front door and feed the paper up through the print station until the
first page clears the ribbon mask by about one inch. (Figure 18.)
5. Fold a two inch piece of plastic tape over the top sheet, midway between
the sides, as shown in Figure 18 detail A.
Plastic Tape
Three sheets of 14 inch, 18

pound paper
Figure 18. Preparing Paper for Tension Measurement
6. Close the forms thickness lever all the way (pointer at ‘A’).
7. Insert the hook of a “fish scale” force gauge through the tape you installed
in step 5. (Figure 19.)
185
Chapter 4 Dynamic Paper Tension Adjustment
8. Use the scale to pull the paper slowly straight up through the print station
for about six inches and note the maximum force exerted on the scale. Do
not pull any page perforations through the print station. (Figure 19.)
Scale
Figure 19. Measuring Paper Tension

9. Repeat steps 6 through 8 several times to get an average value of force
on the gauge.
10. The average tension should be 6 to 12 ounces for printers with one paper
ironer, and 9 to 15 ounces on printers with an additional auxiliary paper
ironer. If the average value is greater than 13 (or 16) ounces, paper
handling and print quality problems are likely.
11. If the average value is greater than 13 (or 16) ounces, check the platen
gap (page 166), adjust if necessary, and recheck the dynamic paper
tension.
12. If the platen gap is correct, remove the shuttle frame assembly (page 241)
and check the following:
a. Inspect the hammer bank cover assembly for ribbon debris, paper
debris, or other foreign matter. If the ribbon mask or hammer bank
cover is damaged or deformed, replace it.
b. Inspect the paper ironer for distortion or misalignment. Reposition or
replace it if necessary.
c. Make sure the paper guides are properly seated on the splined and
support shafts.
d. Make sure the paper entrance guide pivots freely with minimal down
force. Reposition the springs or the guide if necessary.
e. Check for correct position and function of the paper motion detector
assembly. Reposition or replace if necessary.
f. Inspect the paper path from above (below the paper ironer), and from
below (above the paper entrance guide), for debris, foreign matter, or
anything that could inhibit paper motion. Correct as necessary.
186
Tractor Belt Tension Adjustment

First line print compression can be reduced by adjusting the tension of the
tractor belts. The procedure below removes the slack that can occur in some
tractors.
IMPORTANT Only do this procedure when the user reports that the first print line of
forms is compressed and only after adjusting the dynamic paper
tension (page 185). Always adjust both tractors.
2. Adjust the dynamic paper tension (page 185).
3. Carefully note the initial position of the adjustment screws. (Figure 20.)
CAUTION Adjust tractors only ONE detent at a time. Over-tightening a tractor belt
can cause other paper feed problems and result in premature wear in
the tractors.
4. On the inner side of the left tractor, use a Torx T-10 driver to rotate the
adjustment screw one detent to increase tension. On the inner side of the
right tractor, use a Torx T-10 driver to rotate the adjustment screw one
detent to increase tension. (See Figure 20.)
5. Load paper, run a print test, and check for first line compression.
6. If compression still occurs, rotate the adjustment screws one more detent
and test again.
7. If compression is not improved after adjusting the tension by two detents,
return the adjustment screws to the initial positions you noted in step 3.
Arrow points to LH
(left) or RH (right)
tractor. Left tractor
(LH) is shown here.
Right Tractor: One Click and Test.
A
A
Left Tractor: One Click and Test.
Figure 20. Tractor Belt Tension Adjustment
187
Chapter 4 Shuttle Electrical Short Check
Shuttle Electrical Short Check

This procedure checks for metallic debris and checks for hammer coils
shorting to the shuttle frame.
The hammer driver circuit board attached to the shuttle frame assembly can
attract metal objects because of the magnets in the hammer bank. Such stray
metal pieces can cause electrical shorting and damage to the shuttle
assembly. (The hammer driver board does not have a protective cover
because of concerns about component temperatures.)
IMPORTANT Do this procedure

a) If you removed the shuttle cover during servicing and before you re-
install the shuttle cover.
b) Before you replace the controller board with a new or refurbished
board.
2. Remove the ribbon. (Refer to the User’s Manual.)
4. Check the shuttle driver circuit board area for any foreign metal parts or
objects (paper clips, staples, screws, chips of metal, broken shuttle spring
fragments, etc.).
5. If you find any foreign metal parts or objects, carefully remove them.
6. Disconnect the hammer bank logic cable (P04) and the hammer bank
power cable (P05) at the shuttle.
7. Set your Ohmmeter to the 10K Ohm scale or the scale closest to 10K
Ohms.
8. Hold the two meter leads apart from each other (not touching anything)
and note how your meter indicates an open circuit. For example, some
meters read OL (Over Load), -1, flashing display, infinite resistance, etc.
9. Attach the common meter lead (usually black) to the shuttle frame.
10. Touch the positive meter lead (usually red) to another part of the shuttle
frame and verify continuity. (Continuity is a low resistance reading of less
than 1 Ohms.)
11. Attach the common meter lead to the shuttle frame, touch the positive
lead to pins 1 through 10 of both hammer bank power plugs J05 and J06
located on the terminator board on the shuttle assembly. Pin 1 of each
plug is the right-most pin as you face the printer. Hold the positive lead for
a few seconds on each pin allowing the meter to stabilize, then read the
resistance:
a. If the resistance of any pin is less than 1000 Ohms, replace the
shuttle frame assembly (page 241).
b. If pin resistances are 1000 Ohms or greater (including an “open”
reading as in step 7), the shuttle passes the test and is probably okay.
Reconnect hammer bank logic cable (P04) and hammer bank power
cable (P05) to the shuttle
188

Hammer Bank Power Cable Shorts Test

This test determines if the hammer bank power cable is shorted.
3. Disconnect hammer bank power cable connector P105 from J105 on the
controller board. (See Figure 42, page 264, item 10.)
4. Attach or hold the common lead (usually black) of an Ohmmeter to the
shuttle frame.
5. At the hammer bank power cable plug (P05) on the shuttle terminator
board, touch each of the 10 pins with the positive (usually red) meter lead
and test for shorts to ground. If you find any shorts to ground, replace the
hammer bank power cable.
6. Disconnect the common meter lead from the shuttle frame.
7. Check the hammer bank power cable for shorts by checking pin-to-pin:
touch pin 1 with one meter lead and pin 2 with the other meter lead. If
there is continuity, it means there is a short. (Continuity is defined as a
reading of less than 1 Ohm; in other words, very low resistance.) Repeat
this process until you have tested all the pins in the cable. If you find any
shorts, replace the cable.
8. Connect hammer bank power cable connector P105 to J105 on the
controller board. (See Figure 42, page 264, item 10.)
189
Chapter 4 Cable Shorts Test
Cable Shorts Test

This test determines if a cable has a short to ground or a pin-to-pin short (also
called a wire-to-wire short). Such shorts can be caused by cables resting on
or moving across sharp edges. The edges over time can wear away the non-
conductive shielding of the cable, exposing the conductor. A short occurs
when the exposed conductor touches another metal surface or conductor.
This procedure tests only the cables listed below that can be disconnected at
both ends:
• Intermediate cables of devices in the Main Wire Harness Test Tables:
Card Cage Fan
Left Ribbon Motor
Right Ribbon Motor
Exhaust Fan (in cabinet models)
Magnetic Pick-up Unit (MPU)
• Shuttle Motor Intermediate Cable
• Hammer Bank Power and Logic Intermediate Cables
• Control Panel Assembly Intermediate Cable
• Power Stacker Logic and Power (Intermediate) Cables
The Procedure:
2. Disconnect the cable to be tested at both ends, but leave the cable
routing as it was before you started this procedure.
3. Set your Ohmmeter to the 10K Ohm scale or the scale closest to 10K
Ohms.
4. Hold the two meter leads apart from each other (not touching anything)
and note how your meter indicates an open circuit. For example, some
meters read OL (Over Load), -1, flashing display, infinite resistance, etc.
Record this indication for later reference.
Check for shorts to ground:

5. Attach the common meter lead (usually black) to a bare metal ground
point on the printer (e.g., a bolt head on the shuttle casting).
6. Touch the positive meter lead (usually red) to another bare metal ground
point and verify continuity. (Continuity is a low resistance reading of less
than 1 Ohm.)
IMPORTANT When making continuity checks, touch the meter leads to the test points
for at least 2 to 3 seconds so your meter has time to display correctly.
7. At one end of the cable, touch one of the pins with the positive (usually
red) meter lead while the common lead (usually black) is still touching a
ground point.
190
8. Check the pin for a short to ground, which is indicated by a meter reading
of continuity (that is, a low resistance reading of less than 1 Ohm).
9. If you find a short to ground, replace the cable. If no short is detected,
repeat steps 7 and 8 for the rest of the pins on the same end of the cable.
If no shorts to ground are detected for any of the pins, proceed to the next
section, which checks for pin-to-pin shorts.
Check for pin-to-pin shorts:

10. Disconnect the common (usually black) meter lead from the ground point.
11. Check for shorts within the cable by touching the common (usually black)
meter lead to pin 1 at one end of the cable and touching the positive
(usually red) meter lead to pin 2 at the same end of the cable.
12. Check for a pin-to-pin short, which is indicated by a meter reading of
continuity (that is, a low resistance of less than 1 Ohm). For a properly
functioning cable that has no pin-to-pin short, you will see the “open
circuit” meter reading you recorded in step 4.
13. If you find a short, replace the cable. If no short is detected, check for pin-
to-pin shorts on all the remaining pairs on the same end of the cable. If
you find a short in any of the remaining pairs, replace the cable. If you find
no shorts for any of the remaining pairs, the cable passes the shorts test;
return to the procedure that referred you to this diagnostic procedure.
191
Chapter 4 Main Wire Harness Test Diagnostic
Main Wire Harness Test Diagnostic

This is a procedure for extended testing of various printer components.
3. Disconnect cable connectors P106 and P107 from the controller board.
4. Refer to the Main Wire Harness Test Tables on page 318 as you do the
following substeps:
a. Measure the resistance of the device(s) specified in the procedure
you are working.
NOTE: If you have a 60-pin expansion-CT adapter that was used on the old
CMX and CFX controller boards, you can break it down into a two-
row by 10 pin (i.e., a 20-pin) connector, which you can insert into
P106 and P107 for easier electrical measurements.
b. On motors, use the table to test for winding continuity and for no
shorts between windings and motor frame. Rotate the motor by hand
and test for shorts. If you find any shorts in a motor, replace the
motor.
c. Replace any defective devices.
5. Shuttle Motor test:
a. Remove the ribbon.
b. Remove the shuttle cover assembly (page 209).
c. Disconnect cable P02
d. At P02, check for approximately 0.7 Ohms per phase. Use this value
to test for winding continuity and for no shorts between windings and
the motor frame. Rotate the motor by hand and test for shorts.
e. Replace the shuttle frame assembly if you find any shorts.
NOTE: A number of “intermediate” cables in the printer can be disconnected
at both ends and tested using the Cable Shorts Test (page 190):
• Intermediate cables of devices in the Main Wire Harness Test Tables:
Card Cage Fan
Left Ribbon Motor
Right Ribbon Motor
Exhaust Fan (in cabinet models)
Magnetic Pick-up Unit (MPU)
• Shuttle Motor Intermediate Cable
• Hammer Bank Power and Logic Intermediate Cables
• Control Panel Assembly Intermediate Cable
• Power Stacker Logic and Power (Intermediate) Cables
192
Power Supply Operational Check

This procedure shows you how to use the Power Supply Tester (Field Kit,
Tester, Power Supplies, Generic, P/N 178083-001), to quickly and safely
monitor the output voltages of the printer power supply from outside the card
cage. You will be able to turn on and off the +48 volt and +8.5 volt outputs at
the tester’s remote Monitor Block.
To check the power supply you need a DC voltmeter with an input impedance
greater than 20,000 ohms per volt and capable of measuring 55 volts DC. To
measure +5 volt output, the voltmeter must have a low voltage range (10
volts).
CAUTION This tester is for intermittent monitoring of power supply voltages. Do

not hold down the push button on the Monitor Block for more than five
minutes at a time. To prevent overheating the Load Block, for each
minute you hold down the push button on the Monitor Block, wait at
least two minutes with the push button released. (There is no time limit
to how long the Load Block can be attached to the power supply, just to
how long you should hold down the push button.)
CAUTION To prevent electrostatic damage to electronic components, wear a

grounded static wrist strap when you work around the circuit boards.
3. Put on a static wrist strap and ground the lead to an unpainted part of the
printer frame. Touch the printer frame with the hand wearing the wrist
strap before you touch the controller board or power supply board.
4. Disconnect power supply cable connector P101 from either the power
stacker power cable or connector J101 on the controller board. (Figure
21.)
5. Plug power supply connector P101 into the 12-pin connector on the
power supply tester Load Block, as shown in Figure 21. Note the position
of Pin 1 relative to the Load Block.
6. Position the tester Monitor Block outside of the printer with the rubber feet
resting on a flat surface. (If you are working on a cabinet model, you can
close the top cover and use that as the flat surface.)
193
Chapter 4 Power Supply Operational Check
Power Supply Tester Load

Block — Can become warm
when used continuously
Pin 1
Power Supply Board
Pin 1
Pin 1
Connector P101
Stacker Power Cable

(Only on cabinet
models with the
power stacker) Controller Board
Connector J101
Figure 21. Connecting the Power Supply Tester
7. Plug the printer’s power cord into the AC power outlet and the printer.
8. Insert the negative (-) lead of the voltmeter into the ground (GND) test
jack on the Monitor Block. If the negative lead does not fit into the GND
test jack, touch the negative lead to the ground (GND) pad. (Figure 22.)
9. Set the printer’s power switch to 1 (on).
10. Touch the positive (+) lead of the voltmeter to the +5 V test point on the
Monitor Block. The voltage should be 4.85 to 5.15 volts. (Figure 22.)
11. Measure the voltage at the NTEMPHI test point; it should be greater than
2.4 volts. (Figure 22.)
12. Measure the voltage at the +48 V test point; it should be less than 0.2
volts. (Figure 22.)
13. Measure the voltage at the +8.5 V test point; it should be less than 0.2
volts. (Figure 22.)
14. Press and HOLD IN the Push Button on the Monitor Block. (Figure 22.)
15. Measure the +5 V test point. It should be 4.85 to 5.15 volts.
194
16. Measure the +48 V test point. It should be 46.0 to 49.6 volts.
17. Measure the+8.5 V test point. It should be 8.1 to 9.4 volts.
18. Release the Push Button.
19. If you must measure voltages again, for each minute you held the Push
Button down, wait at least two minutes with the Push Button released This
allows the Load Block to cool.
20. If any voltage reading is outside of the ranges listed above, replace the
power supply. If all voltages are within range, return to the diagnostic
procedure that caused you to use this tool.
21. Verify that the original problem has been corrected:
a. If the problem has been corrected, go to step 22.
b. If the problem has not been corrected, consider the following:
This tester applies a small electrical load to the power supply. The
tester load on the +5 volts is about 1.3 amps, so that a printer boot-up
should be possible if the power supply tests OK. However, it is also
possible that a power supply can test OK but still have an internal
problem that prevents it from supporting a full print load. If the printer
still does not print jobs correctly after the power supply has tested
OK:
• Consider replacing the controller board. If the problem persists,
restore the original controller board, and
• Consider again replacing the power supply.
+5 V Test Point
+8.5 V Test Point NTEMPHI Test Point
+48 V Test Point
Monitor Block
Ground (GND) Pad
Push Button: Push to

activate +8.5 V and +48 V
and place an electrical
Rubber Foot load on +5 V.
GND Test Jack: Insert Negative (-) Lead Here
Figure 22. Testing the Power Supply
195
Chapter 4 Power Supply Operational Check
22. Set the printer’s power switch to O (off).

23. Unplug power supply connector P101 from the 12-pin connector on the
power supply tester Load Block. (Figure 21.)
24. Connect power supply cable connector P101 to either the power stacker
power cable or connector J101 on the controller board. (Figure 21.)
196
5 Replacement Procedures
And Illustrated Parts Lists
Organization Of This Chapter

This chapter contains two sections.
• Section I: Replacement Procedures
Written procedures for removing and installing components that are
replaceable at the field service level of maintenance. The replacement
procedures refer you to the illustrations in Section II.
Section I begins on page 198.
• Section II: Illustrated Parts Lists
Drawings of all electrical and mechanical assemblies in the printer. On
the page facing each illustration is a list of the illustrated parts and their
part numbers.
NOTE: Only field-replaceable spares are given part numbers in the illustrated
parts lists. Part numbers are not listed for common fasteners and
attachment hardware. Items marked “Ref” in the illustrations refer to
parts that are not spared or are part of another assembly.
Section II begins on page 249.
197
Chapter 5 Section I: Replacement Procedures
Section I: Replacement Procedures

WARNING Unplug the printer power cord from the printer or power outlet before
doing any maintenance procedure. Failure to remove power could result
in injury to you or damage to equipment. Only apply power during
maintenance if you are instructed to do so in a maintenance procedure.
IMPORTANT The components specified in this chapter are field replaceable units
(FRUs). FRUs must be repaired at the factory. Do not try to repair these
items in the field.
Also do not attempt field repairs of electronic components or
assemblies. Do not de-solder any circuit board components. Replace a
malfunctioning electronic assembly with an operational spare. Most
electronic problems are corrected by replacing the printed circuit board
assembly, sensor, or cable that causes the fault indication. The same is
true of failures traced to the hammer bank: it is not field repairable so
you must replace the entire shuttle frame assembly. Hammer spring
assemblies, the hammer bank cover, and the ribbon mask are the only
replaceable components of the shuttle frame assembly.
List Of Removal / Installation Procedures

Belt, Paper Feed Timing ................................................................. page 200
Belt, Platen Open ............................................................................ page 201
Circuit Breaker ................................................................................ page 202
Connector Coupling Shrouds .......................................................... page 203
Control Panel Assembly.................................................................. page 205
Controller Board .............................................................................. page 206
Cover Assembly, Hammer Bank / Ribbon Mask ............................. page 208
Cover Assembly, Shuttle................................................................. page 209
Cover Assembly, Top, Pedestal Models ......................................... page 210
CT Board......................................................................................... page 211
Dashpot........................................................................................... page 212
Fan Assembly, Cabinet Exhaust ..................................................... page 213
Fan Assembly, Card Cage .............................................................. page 214
Fan Assembly, Hammer Bank ........................................................ page 215
Hammer Spring Assembly .............................................................. page 216
Integrated Print Management Sensor ............................................. page 218
Magnetic Pickup (MPU) Assembly.................................................. page 219
Memory and Security Key ............................................................... page 220
NIC (Network Interface Card) Assembly ......................................... page 222
Paper Feed Motor ........................................................................... page 223
198
List Of Removal / Installation Procedures
Paper Ironer .................................................................................... page 224

Paper Path ...................................................................................... page 225
Platen .............................................................................................. page 226
Platen Open Motor .......................................................................... page 230
Platen Stop Assembly (and Forms Thickness Lever) ..................... page 232
Power Supply Board ....................................................................... page 233
Resistors, Terminating .................................................................... page 234
Ribbon Drive Motor ......................................................................... page 236
Ribbon Guide Assembly (L/R)......................................................... page 237
Security Key .................................................................................... page 220
Shaft, Splined.................................................................................. page 238
Shaft, Support ................................................................................. page 240
Shuttle Frame Assembly ................................................................. page 241
Spring, Extension, Hammer Bank ................................................... page 243
Static Brush, Pedestal Printer ......................................................... page 244
Switch Assembly, Paper Detector ................................................... page 246
Switch Assembly, Platen Interlock .................................................. page 247
Tractor (L/R) .................................................................................... page 248
199
Belt, Paper Feed Timing

Removal
3. Remove the timing belt cover by squeezing the front and back to release
the plastic tabs from the slots in the side plate. (See page 161, item 1.)
4. Loosen (do not remove) the two 5/16 inch paper feed motor mount
screws. (See page 161, item 2.)
5. Roll the paper feed timing belt off the paper feed motor pulley and splined
shaft pulley.
Installation
1. Roll the paper feed timing belt onto the splined shaft pulley and the motor
pulley.
pressure to the paper feed drive motor. Use the splined shaft to steady
the gauge. (See page 161, item 2.)
between the pulleys.
3. Reduce tension to 12 pounds (53.4 N) and torque the 5/16 inch paper
feed motor mount screws to 18 ± 2 inch-pounds (2.03 ± 0.23 N•m).
4. Snap the timing belt cover into the slots in the side plate. (See page 161,
item 1.)
200
Belt, Platen Open
Belt, Platen Open

Removal
3. Remove the platen open belt cover by squeezing the top and bottom to
release the plastic tabs from the slots in the side plate. (See page 163,
item 1.)
4. Using a 5/32 inch Allen wrench, slowly loosen the motor adjustment
screw just enough to permit movement of the platen open motor in the
slotted side plate. (See page 163, item 2.)
5. Push the platen open motor shaft toward the front of the printer to loosen
the platen open belt. (See page 163, item 3.)
6. Roll the platen open belt off the motor pulley and platen open pulley.
Installation
1. Push the platen motor toward the front of the printer and install the platen
open belt over the platen open pulley and the motor pulley. (See page
163, item 3.)
2. Release the platen open motor; the spring will automatically tension the
belt.
3. Slowly tighten the motor adjustment screw. (See page 163, item 2.)
between the pulleys. If deflection is more or less than 3/16 inch (4.76
mm), slowly loosen the motor adjustment screw and repeat steps 2
and 3.
4. Snap the platen open belt cover into the slots in the side plate. (See page
163, item 1.)
201
Circuit Breaker
Removal
2. Remove the card cage fan (page 214).
3. Disconnect the four circuit breaker electrical leads.
(Cabinet Models: See page 278.
Pedestal Models: See page 262.)
4. Press in on the spring clips and remove the circuit breaker from the
printer.
Installation
1. Press the circuit breaker into the cutout until the spring clips snap into
place.
(Cabinet models: See page 278.
Pedestal models: See page 262.)
CAUTION To prevent severe damage to the printer, the circuit breaker electrical
leads must be connected correctly.
2. Connect the four circuit breaker electrical leads.
(Cabinet Models: See page 278.
Pedestal Models: See page 262.)
3. Install the card cage fan (page 214).
202
Connector Coupling Shrouds
Connector Coupling Shrouds

Some of the cable connectors in the printer are grouped inside connector
coupling shrouds designated P106 and P107. The procedure below explains
how to remove and install cable assemblies from these coupling shrouds.
NOTE: There is also a diagram of the P106 / P107 connector coupling
shrouds on the plastic protective barrier over the power supply.
Removal
3. Disconnect the connector coupling shroud containing the cable assembly
that you will replace.
4. Pull the side of the coupling shroud outward and gently pull the cable
connector upward. (See Figure 23.) Notice that in a coupling shroud two-
wire connectors are grouped across from two-wire connectors and four-
wire connectors are grouped across from four-wire connectors.
5. Disengage the key tab(s) on the cable connector from the slots in the side
of the coupling shroud.
6. Remove the cable connector from the coupling shroud. (Remove only the
cable connector for the cable you are replacing; leave the other cable
connectors in the coupling shroud.)
Installation
1. Position the cable connector in the connector coupling shroud. Two-wire
connectors are always grouped across from two-wire connectors in a
coupling shroud. Four-wire connectors are always grouped across from
four-wire connectors in a coupling shroud. (See Figure 23.)
2. Pull the side of the coupling shroud outward and gently push the cable
connector down into the coupling shroud.
3. Engage the key tab(s) on the cable connector in the slots in the side of
the coupling shroud. Press the sides of the coupling shroud inward to
make sure all cable connector key tabs are engaged in the coupling slots.
4. Connect the connector coupling shroud to its printer connection.
203
P106 Connector Configuration P107 Connector Configuration
19 17 15 13 11 9 7531 Connectors are viewed 19 17 15 13 11 9 7531

from the top, as seen
POD CCF PLAT M when plugged into the MPU PLO EHF* PAPR M
controller board.
PMD LRP LRIB M CVO RRP HBF RRIB M
Pin No.
20 18 16 14 12 10 8642 20 18 16 14 12 10 8642
CCF = Card Cage Fan CVO = Cover Open Switch (not installed)
LRIB M = Left Ribbon Motor EHF* = Exhaust Fan
LRP = Left Ribbon Guide HBF = Hammer Bank Fan
PLAT M = Platen Motor JMP = Jumper Wire
PMD = Paper Motion Detector (Switch) MPU = Magnetic Pickup
POD = Paper Out Detect (Switch) PAPR M = Paper Feed Motor
PLO = Platen Open (Switch)
RRIB M = Right Ribbon Motor
RRP = Right Ribbon Guide
* JMP on pedestal models, used as a

spacer
Key Tab
Typical 2-Wire
Cable Connector Typical 4-Wire
Cable Connector
Pull the sides outward just

enough to release the connector
key tab from the slot in the
connector coupling shroud.
Key Tab Slot

Connector Coupling Shroud
P106 / P107
P/N 202362-001
Push here to
remove the
coupling shround
from the controller J106 or J107 on
board. Controller Board
Figure 23. Connector Coupling Shrouds, Disassembly/Assembly
204
Control Panel Assembly
Control Panel Assembly

NOTE: The procedure for removing and installing the control panel is the
same for cabinet and pedestal model printers.
Removal
3. Disconnect the RJ-11 connector P310 from J2 on the back of the control
panel. (See page 254, item 2.)
4. Remove the two screws securing the control panel to the panel bracket.
(See page 254, items 1 and 11.)
5. Remove the control panel assembly from the panel bracket.
Installation
1. Engage the slot on the bottom of the control panel on the bottom edge of
the panel bracket cutout. (See page 254, items 1 and 11.)
2. Align the holes on the top rear of the control panel with the holes in the
upper edge of the panel bracket, and install the two mounting screws.
3. Connect RJ-11 connector P310 to connector J2 on the rear of the control
panel.
205
Controller Board
Removal
CAUTION To prevent electrostatic damage to electronic components, always wear
a properly grounded static wrist strap when you handle circuit boards.
User’s Manual.)
4. Remove the CT board, if it is installed (page 211).
Remove the ethernet interface assembly, if it is installed (page 222).
5. Disconnect all cable connectors from the controller board. (See page
264.)
6. Loosen but do not remove the two screws securing the metal controller
shield near serial cable connector J201.
7. Loosen but do not remove the screw securing the metal shield to the
bottom of the card cage, on the left side near the card cage fan.
CAUTION Do not separate the controller board from the metal shield. The shield
serves as a stiffener and ground plane, and is an integral part of the
controller board assembly.
8. Slide the controller board assembly to the left until the keyway clears the
screw securing the controller board to the bottom of the card cage. Lift the
controller board out of the printer.
9. If you are removing the controller board for reasons other than
replacement (i.e., you will re-install the original controller board at some
point), you do not need to remove the flash memory or security key. But if
you are replacing the controller board, remove the flash SIMM and
security key (page 220), and install them on the replacement controller
board. The security key must be installed on the replacement controller
board to ensure the printer functions correctly.
206
Controller Board
Installation
1. If this is a replacement controller board, install the flash SIMM and
security key on the new controller (page 220).
2. Position the controller board in the card cage, metal shield side down,
component side uppermost. Engage the screw on the bottom of the card
cage in the keyway in the metal controller shield. Slide the board to the
right until the serial cable connector J201 on the controller board lines up
with the cutout in the card cage. (See page 264.)
3. Tighten the two screws securing the metal shield near serial cable
connector J201.
4. Tighten the screw securing the metal shield to the bottom of the card
cage.
5. Connect all cable connectors to the controller board, using the
Interconnection Diagram in Appendix A as your guide.
6. Install the CT board, if necessary (page 211).
7. Install the NIC, if necessary (page 222).
IMPORTANT If the original board was replaced, you must download the emulation
software again. Installing flash memory from the old board onto the new
board does not transfer all operating system software.
9. Load flash memory (page 175).
10. Adjust the hammer phasing (page 173).
11. Adjust the paper out distance (page 170).
12. Using the configuration printout(s) you made as step 1 of the removal
procedure, restore and save the printer configuration(s). (Refer to the
User’s Manual.)
207
Cover Assembly, Hammer Bank / Ribbon Mask

Removal
3. Lift the thick plate of the hammer bank cover assembly at one end, and
peel the cover away from hammer bank magnets. (See Figure 24.)
Installation
CAUTION The hammer bank contains a strong magnet. To prevent damage to the
hammer tips, do not let the steel hammer bank cover assembly of early
models snap into place as the hammer bank magnet attracts it. Any
impact of the cover against the hammer bank can break hammer tips.
1. With the thick plate facing the hammer bank, hold the hammer bank cover
assembly at a slight angle and engage the bottom edge on the alignment
pins. First engage the center (round) hole, then the left (oblong) hole, to
ensure that the cover lies flat on the hammer bank. (See Figure 24.)
2. Gently lower the hammer bank cover assembly until it lies flush on the
hammer bank.
3. Check that the hammer bank cover assembly is positioned over the
alignment pins and the hammer tips.
Hammer Bank
Cover Assembly
Oblong Hole
Round Hole
Alignment Pin
Figure 24. Hammer Bank Cover Assembly
208
Cover Assembly, Shuttle
Cover Assembly, Shuttle

Removal
3. Loosen the shuttle cover screws (page 258, item 2).
4. Grasping the edges of the shuttle cover assembly, tilt the rear edge up
and lift the shuttle cover assembly out of the printer.
Installation
1. Place the shuttle cover assembly in the printer. Tilt the forward edge of
the cover down slightly and work the cover into position.
NOTE: Make sure the holes in the cover are over the locating pins on the
base casting.
2. Tighten the shuttle cover screws (page 258, item 2).
209
Cover Assembly, Top, Pedestal Models

Removal
2. Remove the control panel assembly (page 205).
3. Loosen (do not remove) the two #2 Phillips hold-down screws on the rear
of the printer. (See page 256, item 5.)
4. Remove the #2 Phillips screw in the lower left front corner of the top cover
and the screw just to the right of the control panel bracket. (See page 256,
item 3.)
5. Lift the top cover assembly off the printer base.
Installation
1. Reverse steps 3 through 5 of the removal procedure.
210
CT Board
CT Board
Removal

a grounded static wrist strap when you handle circuit boards.
strap before you touch electronic components or the controller board.
4. Remove the screw securing the CT board connector plate to the rear of
the card cage. (See page 280, item 4.)
5. Angle the CT board out of the card cage cutout as you lift the CT board
out of the PCI slot on the controller board. (See page 280, item 1.)
Installation
IMPORTANT There are two expansion slots on the controller board. If the printer is a
cabinet model with a power stacker installed, you must install the CT
board in the outermost slot and leave the innermost slot empty.
211
Dashpot
CAUTION Two persons may be required to do this procedure. Prop or hold the
printer cover securely while disengaging the dashpot.
NOTE: This procedure applies only to cabinet models.
Removal
2. Open the cabinet rear door.
3. Pry back the spring retaining clips. (See Figure 37, page 254.)
4. Remove the dashpot from the ball studs.
Installation
CAUTION Install the dashpot with the narrow rod uppermost.
Two persons may be required to do this procedure. Prop or hold the
printer cover securely while installing the dashpot.
1. Position the dashpot against the ball studs on the upper and lower
brackets with the narrow rod uppermost. (See Figure 37, page 254.)
2. Using external grip ring pliers to spread the retaining clips, push the
dashpot onto the ball joints and slide the spring clips over the top (bottom)
of the ball joint into the retaining grooves.
212
Fan Assembly, Cabinet Exhaust
Fan Assembly, Cabinet Exhaust

Removal
2. Open the front and rear cabinet doors and the printer cover.
3. Remove the paper fence/paper tray assembly. (See page 252.)
4. Remove the two 1/4 inch screws securing bottom of the air exhaust duct.
(See page 254, item 4).
5. Remove the 1/4 inch screw directly below the forms thickness lever.
6. Disconnect the fan cable connector from connector P307 and remove the
air exhaust duct.
7. Disconnect the fan cable connector from the side of the air exhaust duct.
8. Remove the two 1/4 inch fan mounting screws and the cabinet exhaust
fan assembly.
Installation
CAUTION Air flow is DOWN. Install the cabinet exhaust fan so the label on the fan
faces down.
213
Fan Assembly, Card Cage

Removal
3. Disconnect the card cage fan cable connector. (See page 276.)
4. Cabinet Models: Remove the two fan mounting screws from the bottom of
the fan. (See page 276, item 2.)
Pedestal Models: Remove the four fan mounting screws and nut. (See
page 262, items 1 through 4.)
5. Remove the card cage fan assembly from the card cage.
Installation
CAUTION Air flow is INTO the card cage. Install the card cage fan so the label
faces toward the inside of the printer and the cable faces the front of the
printer.
214
Fan Assembly, Hammer Bank
Fan Assembly, Hammer Bank

Removal
5. Trace the hammer bank fan cable assembly back to the controller board
connector P107, releasing it from all cable constraints. (See the cable
routing diagrams in Appendix A.)
6. Disconnect the fan connector from connector coupling shroud P107 on
the controller board. (See page 203.)
7. Remove the two screws securing the fan to the base casting. Angle the
hammer bank fan assembly up and out of the base casting and feed the
motor wires and cable connector out from between the base casting and
the base pan. (See page 276, items 21 and 22.)
Installation
CAUTION Air flow is UP. Install the hammer bank fan so the label faces up.
1. Feed the hammer bank fan cable connector and motor wires between the
fan well of the base casting and the base pan. Reach up under the base
casting and route the fan cable to the right and angle the hammer bank
fan assembly under the shuttle motor and down into the fan well. (See
page 276.)
2. Route the fan motor wires (see cable routing diagrams, Appendix A) and
connect the fan cable connector to J107 on the controller board. (See
page 203.)
3. Install two screws in the locations shown in Figure 46 (page 276, item 21).
215
Hammer Spring Assembly

Removal
3. Carefully vacuum the shuttle frame assembly.
4. Remove the hammer bank cover assembly (page 208).
CAUTION Hammer springs and hammer tips are fragile. Do not touch the hammer
springs or tips. Handle hammer spring assemblies by the thick
mounting base only. Apply pressure only to the mounting base.
5. Remove the mounting screws from the old hammer spring assembly.
(See Figure 25.)
6. Handling the hammer spring assembly by the mounting base only, gently
push up the mounting base and pry the old hammer spring assembly off
its mounting pins. (See Figure 25.)
7. Inspect the hammer bank and the old hammer spring assembly:
a. If there is ink on the hammer bank mounting surface that was under
the hammer spring, or if there is ink on the hammer spring assembly
mounting surface that was against the hammer bank, or if there is ink
on the hammer spring neck or tines, ink migration has occured.
Reinstall the old hammer spring assembly and replace the entire
shuttle frame assembly (page 241).
b. If the old hammer spring assembly and the hammer bank are free of
ink, install the new hammer spring assembly, as shown in the next
section.
NOTE: A P7215 lpm hammer bank is

shown here. Removal, installation, and
fastener torque values are the same for
all hammer spring assemblies, even
though hammer spring assemblies vary
in appearance and number of mounting
screws.
Discard old screws.
Figure 25. Hammer Spring Assembly, Removal
216
Hammer Spring Assembly
Installation
1. Using a clean dry cloth, wipe the hammer spring mounting surface on the
hammer bank. Make sure the cloth does not leave lint on the hammer
bank.
CAUTION Hammer springs and hammer tips are fragile. Do not touch the hammer
springs or tips. Handle hammer springs by the thick mounting base
only. Apply pressure only to the mounting base.
2. Handling the hammer spring assembly by the mounting base only,
remove the new assembly and mounting screws from the box.
3. Handling the hammer spring assembly by the mounting base only,
carefully position it on the hammer bank mounting pins. then gently press
the mounting base down against the alignment pins. (See Figure 26,
page 217.)
4. Continue pressing down on the mounting base of the new hammer spring
assembly as you install the mounting screws from the replacement kit.
Using a Torx T-10 bit adapter, and starting with the inner screws, torque
each screw to 14 inch-pounds (1.58 N•m). (See Figure 26, page 217.)
5. Install the hammer bank cover assembly (page 208).
7. Install the ribbon and load paper.
CAUTION Do not attempt to adjust or “tweak” hammer springs.

8. Run a Diagnostic Printer Test and check print quality (page 134):
a. If print quality is acceptable, return the printer to normal operation
(page 159).
b. If print quality is still degraded, replace the shuttle frame assembly
(page 241).
NOTE: A P7215 lpm hammer bank is New Hammer

shown here. Removal, installation, and Spring Assembly
fastener torque values are the same for
all hammer spring assemblies, even
though hammer spring assemblies vary
in appearance and number of mounting
screws.
Gently press down on the mounting

base and hold the hammer spring in
position as you install the screws.
Use new screws from the hammer

spring replacement kit. Starting with
the inner screws, torque all screws to
14 inch-pounds (1.58 N•m).
Figure 26. Hammer Spring Assembly, Installation
217
Integrated Print Management Sensor

Removal
3. Remove the screw securing the Integrated Print Management sensor to
the base casting. (See page 272, items 28 and 29.)
4. Trace the sensor cable back to the controller board, noting the cable
routing and releasing the cable from restraints as necessary.
5. Disconnect the sensor cable connector from J122 on the controller board.
6. Lift the sensor and guide the sensor cable up and out of the base casting.
Installation
1. Reverse steps 2 through 6 of the removal procedure above.
218
Magnetic Pickup (MPU) Assembly
Magnetic Pickup (MPU) Assembly

Removal
3. Remove the shuttle cover (page 209).
4. Disconnect the magnetic pickup (MPU) cable connector (page 268, item
5).
5. Loosen the 7/64 inch hex MPU clamp screw (page 268, item 3).
6. Unscrew the MPU assembly from the MPU bracket.
Installation
1. Install the MPU assembly by screwing it into the MPU bracket. (See
Figure 43, page 268).
2. Using a feeler gauge, adjust the gap between the MPU assembly and the
flywheel to 0.010 ± .001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch
MPU clamp screw to 18 ± 1 inch-pounds (2.03 ± 0.11 N•m).
3. Check the gap between the MPU assembly and the flywheel with a feeler
gauge:
a. If the gap is 0.010 ± .001 inch (0.254 ± 0.025 mm), go to step 4.
b. If the gap is not 0.010 ± 0.001 inch (0.254 ± 0.025 mm), loosen the
MPU clamp screw and go back to step 2.
4. Route the MPU cable under the extension spring and connect the MPU
cable connector (page 268, item 5). Make sure the MPU cable does not
touch the extension spring after cable connection.
5. Install the shuttle cover (page 209).
219
Memory and Security Key

a grounded static wrist strap when you handle memory modules.
Removal
User’s Manual.)
strap before you touch memory modules or the controller board
5. To remove the flash SIMM or SDRAM DIMM, gently open the side locks,
angle the memory module upward, and remove it from the socket. (See
6. If you need to remove the security key, gently lift the locking tab on the
top side of controller board connector J9 enough to release the key, then
lift and remove the security key. (See Figure 27, page 221.)
NOTE: The security key is a 3-pin semi-programmable EEPROM that
enables the loading of microcode and emulation software. The printer
will not operate correctly without a security key. If you need to replace
the security key, contact Printronix for a replacement.
Installation
strap before you touch memory modules or the controller board.
2. If you removed the security key, position it on controller board connector
J9 so that the lock indentation is on the same side as the locking tab on
connector J9. Gently press the security key down onto the pins until the
locking tab engages the lock indentation and locks the key in place. (See
Figure 27.)
NOTE: Installing flash memory from one controller board to another does not
transfer all operating system software, so you must download the
emulation again.
3. Insert the memory module at a 45 degree angle into the correct socket
(see Figure 27) on the controller board:
a. Insert the flash SIMM in socket J11 on the controller board at a 45
degree angle. Position the flash SIMM with the notched end toward
the right side of the controller board. Press the SIMM gently into the
socket until the edge connectors are seated, then press the SIMM
downward until the side latches lock the SIMM is place. (See
220
Memory and Security Key
b. Position the SDRAM DIMM in socket J14 with the component side
upward. Press the DIMM gently into the socket until the edge
connectors are seated, then press the DIMM downward until the side
latches lock it in place. (See Figure 27 below.)
5. Download the emulation (page 175).
6. If an SPX came with the flash memory, reprogram the security key (page
182).
8. Using the configuration printout(s) you made in step 1 of the removal
procedure, reset and save the printer configuration(s). (Refer to the
User’s Manual.)
SDRAM:
32 MB DIMM = P/N 204535-901
PSA3 Controller Board
V5
J9: Security Key

Notched End
on this side
Flash Memory:
J11: 72-pin Flash Memory SIMM:
4 MB = P/N 204480-901
8 MB = P/N 204480-902
16MB = P/N 204480-903
32MB = P/N 204480-904
J10 is not used
Figure 27. Memory Modules and Security Key
221
NIC (Network Interface Card) Assembly

Removal
User’s Manual.)

grounded static wrist strap when you handle circuit boards.
5. Remove the screw securing the NIC connector plate to the rear of the
card cage. (See page 282, item 4.)
6. Angle the NIC out of the card cage cutout as you lift the NIC off the
expansion connector on the controller board. (See page 282, item 1.
Installation
3. Load printer software through the printer’s parallel port using the three-
key initialization sequence covered in “Loading Software If Flash
Contains Only Boot Code” on page 178.
4. Set the printer power switch to O (off), wait five seconds, then set the
printer power switch to 1 (on).
Testing NIC Operation

You can test the NIC by starting a telnet session (telnet IP address) and
sending
start fox prn<Return>
stop prn<Return>
This command sequence sends consecutively numbered lines of text from the
interface to the printer. The “fox” test is resident in the NIC and verifies that it
can receive commands and can transfer data successfully to the printer.
222
Paper Feed Motor
Paper Feed Motor

Removal
3. Remove the timing belt cover by squeezing the front and back to release
the plastic tabs from the slots in the side plate (page 258, item 7).
4. Loosen, but do not remove, the two 5/16 inch paper feed motor mounting
screws. (See page 276, item 6.)
5. Roll the paper feed timing belt off the paper feed motor pulley and splined
shaft pulley.
6. Trace the paper feed motor cables back to the controller board, releasing
it from tie wraps. (See the cable routing diagrams in Appendix A.)
7. Disconnect connector P107 from the controller board and remove the
paper feed motor connector from connector P107. (See page 204.)
NOTE: Some paper feed motors are mounted with nuts and bolts; other
motors have threaded flanges, eliminating the need for nuts.
8. Remove the motor mount screws (and nuts, if present).
9. Remove the paper feed motor assembly.
Installation
1. Position the paper feed motor assembly on the right side plate and install
the motor mount bolts and nuts finger tight. (See page 276, items 6 and
18.)
2. Connect the paper feed motor cable connector to connector P107, then
connect P107 to J107 on the controller board. (See page 204.)
3. Roll the paper feed timing belt onto the splined shaft pulley and the motor
pulley
pressure to the paper feed motor. Use the splined shaft to steady the
force gauge.
5. Reduce pressure to 12 pounds (53.4 N) and torque the 5/16 inch motor
mount screws to 18 ± 2 inch-pounds (2.03 ± 0.23 N•m).
NOTE: Belt tension is correct if the belt deflects 1/8 inch midway between the
pulleys.
6. Snap the timing belt cover into the slots in the side plate.
223
Paper Ironer
Removal
3. Move the forms thickness lever to the open position.
4. Push the ends of the paper ironer toward the rear of the printer,
disengage the tabs, then lift it up and out (page 272, item 3).
5. On model P7008H, P7208H, P7015, P7215, and P7220, remove the
auxiliary paper ironer, which is directly in front of the standard paper
ironer.
Installation
NOTE: The black tape on the standard paper ironer faces toward the rear of
the printer and toward the paper detector switch assembly.
1. Position the paper ironer so the black tape is on the side that faces the
rear of the printer, towards the paper detector switch assembly. (See
page 272, item 3.)
2. Push the paper ironer down into the slots until the tabs engage.
3. On model P7008H, P7208H, P7015, P7215, and P7220, install the
auxiliary paper ironer in front of the standard paper ironer. (See also the
note on page 272, next to item 27.) Make sure the tabs on both paper
ironers are firmly engaged.
224
Paper Path
Paper Path
Removal
2. Loosen—do not remove—the three screws that secure the paper path to
the card cage. (See Figure 28.)
3. Slide the paper path to the left and lift it off the card cage.
Installation
1. Position the paper path offset slightly to the left on the card cage with the
keyway cutouts over the three loosened screws. (See Figure 28.)
2. Slide the paper path to the right, engaging the three screws in the keyway
slots. Slide the paper path to the right as far as it will go.
3. Tighten the screws securing the paper path to the card cage. (See
Figure 28.)
Paper Path
Screw
Card Cage
Screw
Figure 28. The Paper Path
225
Platen
Removal
3. Remove the paper ironer (page 224).
4. Remove the three 1/4 inch screws securing the paper ironer bracket
assembly and remove the assembly. (See page 272, items 4, 5, and 6.)
5. Remove the platen open belt (page 201).
6. Remove the platen pulley (page 272, item 21), as follows:
a. Loosen the 7/64 inch collar clamp screw.
b. Pull the platen pulley off the platen shaft.
7. Pull the spring link and white plastic bushing off the platen shaft and
remove the spring link, bushing, and spring. (See page 272, items 16, 17,
and 18.)
8. Remove the platen stop assembly by loosening the 7/64 inch clamp
screw and pulling the assembly off the platen shaft. (See page 272, item
15.)
9. Remove the right side platen support spring by repeating step 7 on the
right side of the platen.
10. Remove the Phillips #1 screw and washer securing the interlock switch
bracket from the inside of the right side bracket. (See page 272, items 9
and 10.)
11. Pull the bracket, with the interlock switch assembly attached, off the
platen shaft.
12. Remove the two 7/32 inch screws and washers securing the right ribbon
guide assembly to the side plate. (See page 276, items 7, 8, and 9.)
13. Slide the ribbon guide assembly out of the side plate.
14. Pull the right side of the platen toward the front of the printer and move
the platen to the right and out of the left side plate. (Hold the black metal
washer on the left side of the shaft as you remove the platen. Make sure
the wear saddles in the platen seat of the mechanism base stay in place.)
226
Platen
Installation
IMPORTANT Install the platen with the longer shaft on the right hand side of the
printer. The dowel pins protruding from the ends of the platen are the
platen shafts. The platen shafts are not of equal length.
1. Wipe the platen shafts clean of grease and debris.
2. Install two washers on the longer (right) platen shaft. (See Figure 29
below.)
3. Apply bearing lubricant to both platen shafts.
Platen Shaft
(Right Side) Platen Adjust
Bracket
Ironer Bracket
Washer
Washer
Bushing
Figure 29. Installing the Platen Adjust Bracket

4. Make sure the two wear saddles are set flush into the corners of the
mechanism base platen seat. (See Figure 30 below.)
5. Apply a layer of bearing lubricant 1/4 inch high to the seat of each wear
saddle, making the layer as wide as the saddle and touching the rear
angled surface.
6. Install one platen adjust bracket and bushing onto the longer platen shaft,
with the screw at the top of the bracket. (See Figure 29.)
7. Place the other bracket and bushing onto the left side mechanism base
platen seat so that the mechanism base platen seat is between the
flanges of the bracket.
8. Insert the shorter platen shaft through the left platen adjust bracket and
through the opening in the left side plate. Rotate the longer shaft into the
opening in the right side plate and position the platen adjust brackets as
shown in Figure 30.
227
Platen Adjust
Bracket
Platen
Washers
Wear
Saddle
Mechanism
Base Platen
Seat
Figure 30. Positioning the Platen Adjust Brackets

9. Slide the right ribbon guide assembly into the side plate and install the
two 7/32 inch screws and washers. (See Figure 46, items 7, 8, and 9.)
10. Install the interlock switch bracket:
a. Slide the bracket, with the interlock switch assembly attached, onto
the platen shaft and up against the right side plate.
b. Install the Phillips #1 screw and washer securing the switch and
bracket.
11. Install the black metal washer onto the left side of the platen shaft. (See
page 272, item 26.)
12. Apply bearing lubricant to the nylon bearings in the two spring links, slide
the spring links onto the platen shafts, and connect the springs to the
spring hooks in the side plates. (See page 272, items 16, 17, and 18.)
13. Apply bearing lubricant to the platen shafts on both sides, between the
ends of the platen and the platen adjust brackets.
14. Install the paper ironer bracket. (See Figure 29.)
a. With the flat part of the bracket facing the front of the printer, place
the two hooks of the upper part of the paper ironer over the platen
shafts.
The left hook of the paper ironer bracket goes between the left platen
adjustment bracket and the platen.
228
Platen
On the right side of the platen, a washer goes on both sides of the
paper ironer bracket hook and the hook goes to the left of the right
platen adjustment bracket. (See Figure 29.)
b. Install and torque three screws to 20 ± 2 inch-pounds (2.26 ± 0.23
N•m).
15. Push the platen to the left.
16. Install the platen stop assembly on the right hand platen shaft, pressing
the interlock switch out of the way as the lever slides past it. Tighten the
7/64 inch clamp screw. (See page 272.) Open and close the forms
thickness lever to make sure the clamp screw does not touch the right
ribbon guide.
17. Install the platen shaft pulley with the 7/64 inch setscrew facing up and
tighten the setscrew (page 272, items 21 and 22). Open and close the
forms thickness lever and check that the platen pulley setscrew does not
hit the left ribbon guide.
18. Install, but do not adjust, the platen open belt (page 272, item 23).
19. Install the paper ironer with the black tape towards the rear of the printer
(page 272, item 3).
21. Adjust the platen gap (page 166).
22. Adjust the platen open belt (page 162).
23. Check ribbon guide alignment (page 168).
24. Check the hammer phasing (page 173).
229
Platen Open Motor

Removal
3. Cabinet Models: Remove the card cage fan (page 214).
4. Remove the platen open belt cover by squeezing the top and bottom to
release the plastic tabs from the slots in the side plate (page 272, item
24).
5. Using a 5/32 inch Allen wrench, loosen the platen motor adjustment
screw (page 276, item 10).
6. Remove the platen open belt (page 272, item 23).
7. Trace the platen open motor cables back to connector P106 on the
controller board, releasing the cables from all tie-wraps. (See cable
routing diagrams in Appendix A.)
8. Remove the platen open cable connector from connector P106. (See
page 204.)
9. Remove the 5/32 inch platen motor adjustment screw, platen spring post,
and platen belt spring (page 276, items 10, 20, and 21).
10. Remove the 5/16 inch motor lower mount screw.
11. Remove the platen open motor assembly.
230
Platen Open Motor
Installation
1. Position the platen open motor assembly with the wires toward the rear
(page 276, item 5).
2. Install the 5/16 inch lower motor mount screw and torque it to
30 inch-pounds (3.39 N•m).
3. Install the 5/32 inch upper motor mount screw, platen spring post, and
platen belt spring such that the screw is just loose enough to permit
movement of the motor in the slotted side plate. (See page 276, items 10,
20, and 21.)
4. Rotate the motor all the way forward and install the platen open belt.
5. Connect the platen motor cable connector to connector coupling shroud
P106.
6. Connect coupling shroud connector P106 to the controller board and
install tie-wraps to secure the motor cable. (See the wire routing diagrams
in Appendix A.)
7. Close the forms thickness lever all the way.
CAUTION Too much tension on the platen open belt can cause the platen gap to
change, which can lead to premature wear of the platen, damaged
hammer tips, and poor print quality.
8. The spring automatically tensions the belt.
9. Slowly tighten the motor adjustment screw.
NOTE: Belt tension is correct if the belt deflects 3/16 inch midway between
the pulleys. If deflection is more or less than 3/16 inch, repeat steps 7
through 9.
10. Snap the platen open belt cover into the slots in the side plate.
11. Cabinet Models: Install the card cage fan (page 214).
231
Platen Stop Assembly

NOTE: The forms thickness lever is part of the platen stop assembly.
Removal
2. Loosen—do not remove—the 7/64 inch clamp screw and pull the platen
stop assembly off the platen shaft. (See page 272, items 12 through 15.)
Installation
1. Install the platen stop assembly on the right hand platen shaft, pressing
the interlock switch out of the way as the lever slides past it. Tighten the
7/64 inch clamp screw. (See page 272.) Open and close the forms
thickness lever to make sure the clamp screw does not touch the right
ribbon guide.
232
Power Supply Board
Power Supply Board

WARNING To prevent injury from electric shock, wait at least one minute after
shutting off power before removing the power supply board. Do not
touch components on the board during removal or installation. Lift and
handle the board only by the loops provided for this purpose.
Removal
3. Mark then disconnect all cable assemblies going to and from the power
supply board. (See page 264, item 3.)
4. Loosen—do not remove—the two screws securing the power supply
board to top rear wall of the card cage. (See page 264, item 15.)
5. Grasp the power supply by the handling loops, tilt it forward, and lift it out
of the printer.
Installation
2. On models P7015, P7215, and P7220 adjust the coil temperature if the
original power supply was replaced by a new or refurbished power supply
(page 157).
233
Resistors, Terminating
For parallel interface configurations, the printer is equipped with 470 Ohm
pull-up terminating resistors and 1K Ohm pull-down terminating resistors on
the controller board. These are suitable for most applications. (See Figure 31,
page 235.)
If the standard terminating resistor pack is not compatible with the particular
interface driver requirements of the host computer, other values of pull-up and
pull-down resistors may be required. 220 Ohm pull-up and 330 Ohm pull-
down alternate terminating resistors are provided with the printer. If you install
the 220 Ohm pull-up resistor, you must also install the 330 Ohm pull-down
resistor. Possible terminating resistor combinations are shown below.
Configuration RP1 (Pull-Down) RP2 (Pull-Up)
Factory Default 1K Ohm 470 Ohm

Alternate 1 330 Ohm 220 Ohm
Alternate 2 None 1K Ohm
Removal
3. Locate the terminating resistor packs. (See Figure 31, page 235.)
4. Using a chip puller, remove the resistor packs.
Installation
1. Using a chip installation tool, install the resistor packs in the correct
socket. (See Figure 31, page 235.)
234
Resistors, Terminating
Controller Board
RP1 Default: 1K Ohm

Alt 1: 330 Ohm
Alt 2: None
RP2 Default: 470 Ohm

Alt 1: 220 Ohm
Alt 2: 1K Ohm
Figure 31. Terminating Resistors, Removal/Installation
235
Ribbon Drive Motor

Removal
3. Remove the screws and washers that secure the ribbon drive motor to the
base casting at the lower right and upper left corners of the motor. (See
page 276, items 13 and 14.)
4. Lift and rotate the ribbon drive motor until the motor cable is aligned with
the slot on the base casting.
5. Disconnect the ribbon drive motor cable connector.
6. Lift the motor up and out of the base casting.
Installation
NOTE: Install the the ribbon drive motor mounting screws at the right front
and left rear corners.
236
Ribbon Guide Assembly (L/R)
Ribbon Guide Assembly (L/R)

NOTE: The right ribbon guide is shown exploded in Figure 46 on page 276.
The removal procedure is the same for both ribbon guides.
Removal
2. Cut and remove the tie-wrap from the tie wrap hole to free the ribbon
guide cable. (See page 276, item 7.)
4. Trace the ribbon guide cable back to the controller board, releasing it from
the cable restraints. (See the cable routing diagrams in Appendix A.)
5. For the left ribbon guide, disconnect connector coupling shroud P106
from the controller board. For the right ribbon cable, disconnect connector
coupling shroud P107 from the controller board.
6. Trace the ribbon guide wires to the connector coupling shroud, and
remove the cable connector from the shroud (page 204).
7. Remove the two 7/32 inch screws and washers securing the ribbon guide
assembly to the side plate. To remove the screws from the right ribbon
guide when the ribbon is still in place, use a small 7/32 inch box-end/
open-end wrench. (See page 276, items 8 and 9.)
8. Slide the ribbon guide assembly out of the side plate.
Installation
2. Align the ribbon guides (page 168).
237
Shaft, Splined
IMPORTANT In order to preserve correct alignment of the side plates, the barrier
panel must remain installed and fastened during this procedure.
Removal
2. Remove the paper supports from the splined shaft and support shaft.
(See page 270, item 4.)
3. Remove the paper feed timing belt (page 200).
4. Unlock the left and right tractors and slide them to the center of the shaft.
5. Remove the screw securing the right tractor shaft plate and remove the
plate (page 270, items 7 and 8).
6. Slide the splined shaft out of the sealed ball bearing in the left tractor shaft
plate and remove the tolerance ring from the left end of the splined shaft
(page 270, items 3, 5, and 6).
7. Hold the tractors so they do not fall, grasp the vertical adjustment knob,
and slide the splined shaft to the right, out of the tractors and side plate.
238
Shaft, Splined
Installation
1. Open the doors on the left and right tractors. Position the tractor belts so
the alignment marks are at the top on both tractors. (See Figure 32.)
2. Slide the splined shaft through the right side plate and tractors. Make sure
the same spline passes the marked groove on each tractor. (See
Figure 32.)
3. Install the tolerance ring on the left end of the splined shaft (page 270,
item 5).
4. Insert the tolerance ring lead-in portion into the sealed ball bearing in the
left tractor shaft plate (page 270, items 3, 5, and 6) while sliding the ball
bearing into the right side plate. Push the splined shaft to the left until the
flange on the ball bearing is in solid contact with right side plate. The
splined shaft will protrude about 1/16 inch from the ball bearing.
5. Install the right tractor shaft plate and screw (page 270, items 7 and 8) by
first sliding the upper “fingers” up and against the flange on the ball
bearing, then sliding the rectangular cutout over the support shaft end,
then snapping the U-shaped “spring” behind the tab on the right side
plate.
6. Install the paper feed timing belt (page 200).
7. Set the paper feed timing belt tension (page 160).
8. Install the paper supports on the splined and support shafts. (See page
270, item 4.)
Tractor
NOTE: Align the marks on
both tractors before inserting
the splined shaft.
Tolerance Ring
Alignment Marks
Splined Shaft
Figure 32. Splined Shaft and Tractor Installation
239
Shaft, Support
IMPORTANT In order to preserve correct alignment of the side plates, make sure the
barrier panel remains installed and fastened during this procedure.
Removal
2. Unlock the tractors and slide them to the far right.
3. Remove the paper supports from the splined shaft and support shaft.
(See page 270, item 4.)
4. Remove the screw securing the right tractor shaft plate and remove the
plate. (See page 270, items 7 and 8.)
NOTE: Hold the tractors while removing the support shaft.
5. Slide the support shaft to the right, out of the tractors and the right side
plate. (See page 270, items 9, 10, and 11.)
Installation
1. Slide the support shaft into the right side plate and through the lower
holes in the tractors. (See page 270, items 9, 10, and 11.)
2. Slide the support shaft through the left side plate until it bottoms in the left
tractor shaft plate. (See page 270, items 2 and 9.)
3. Install the right tractor shaft plate and screw (page 270, items 7 and 8) by
first sliding the upper “fingers” up and against the flange on the ball
bearing, then sliding the rectangular cutout over the support shaft end,
then snapping the U-shaped “spring” behind the tab on the right side
plate.
4. Install the paper supports to the splined shaft and support shaft. (See
page 270, item 4.)
240
Shuttle Frame Assembly

Removal
4. Disconnect the MPU cable connector P03 and shuttle motor cable
connector P02 (page 268, items 5 and 6).

a properly grounded static wrist strap when you handle the shuttle
frame assembly.
5. Disconnect the hammer drive and hammer logic cable connectors from
the terminator board on the shuttle frame assembly. (See page 264.)
6. Loosen the side 5/32 inch socket head clamp screws on each end of the
shuttle and pull the clamps back and off the guide shaft. Do not remove
the clamps. Hand tighten the clamp screws to hold the clamps back.
7. Loosen the center 5/32 inch socket head screw enough to release the
shuttle frame assembly from the base casting.
8. Unlock and slide the tractors outward as far as they will go on the tractor
support shaft.
9. Open the forms thickness lever all the way.
10. Grasp the support legs cast on both sides of the shuttle motor and lift the
shuttle frame assembly out of the base casting. Lift it slowly and carefully:
the shuttle frame assembly is heavy.
241
Installation
1. Install the hammer bank / ribbon mask cover assembly if it was removed
(page 208).

properly grounded static wrist strap when you handle the shuttle frame
assembly.
DO NOT remove the grease from the shaft of the replacement shuttle
frame assembly. The shuttle shaft is aluminum, and the clamped ends of
the shaft must be greased to prevent galling.
2. Open the forms thickness lever and move the tractors as far left and right
as possible.
3. Holding the shuttle frame assembly by the support legs located on both
sides of the shuttle motor and set it into the base casting (page 264). Use
both hands: the shuttle frame assembly is heavy.
4. Align the center 5/32 inch socket head screw in the base casting and
hand turn the screw until only two or three threads have started.
5. Pull the shuttle frame assembly toward the front of the printer and hold it
in this position while you do step 6.
CAUTION Do not over-tighten the shuttle frame assembly clamp screws.

6. Slide each side clamp over the guide shaft and torque the 5/32 inch
socket head clamp screw to 20 ± 2 inch-pounds (2.26 ± 0.23 N•m).
7. Torque the center captive 5/32 inch socket head screw to
20 ± 2 inch-pounds (2.26 ± 0.23 N•m).
8. Connect the hammer drive and hammer logic cable connectors to the
terminator board on the shuttle frame assembly.
9. Connect the shuttle motor cable connector. (See page 268, item 6.)
10. Route the MPU cable under the extension spring and connect the MPU
cable connector. (See page 268, item 5.) After the MPU cable is
connected make sure that it does not touch the extension spring.
11. If the shuttle assembly is a new or refurbished unit, adjust the platen gap
(page 166); otherwise, skip to step 12.
242
Spring, Extension, Hammer Bank
Spring, Extension, Hammer Bank

CAUTION Do not let the hammer bank rotate toward the platen during spring
replacement.
Removal
4. Model P7220 only: Remove the anti-rotation spring constraint from the
extension spring. (See page 268, item 6.)
5. Unhook the extension spring from the spring lugs on the hammer bank
and shuttle frame. (See page 268, item 4.)
Installation
1. Apply a dab of bearing lubricant to both spring lugs.
CAUTION Do not let the hammer bank rotate toward the platen during spring
replacement. Make sure the extension spring does not touch the MPU
cable after installation.
2. Hook the extension spring over the spring lugs. (See page 268, item 4.)
3. Model P7220 only: Install the anti-rotation spring constraint over the
extension spring. (See page 268, item 6.)
243
Static Brush, Pedestal Printer

NOTE: This procedure applies only to pedestal model printers.
Removal
2. Remove the top cover assembly (page 210).
3. From the underside of the top cover, remove the tape strip covering the
static brush wire. (See Figure 33.)
4. Bend the static brush ground wire so that it points down.
5. On the top of the top cover, peel the old static brush off the rear wall of the
mounting slot and remove the static brush. (See Figure 34.)
Static Brush Ground Wire
Tape Strip
Figure 33. Static Brush Wire and Tape Strip
244
Static Brush, Pedestal Printer
Installation
1. Peel the adhesive backing off the new static brush. (See Figure 34.)
2. Insert the static brush ground wire into the hole in the top cover and
position the static brush in the slot. (See Figure 34.)
3. Hold the static brush in the bottom of the slot and press the brush against
the rear wall of the slot.
4. Run a straight edge gently along the static brush, pressing it toward the
rear, to adhere the static brush firmly to the rear wall of the mounting slot.
5. On the underside of the top cover, bend the static brush ground wire so
that it lies flush against the top cover. (See Figure 33.)
6. Install the new tape strip. (See Figure 33.)
7. Install the top cover assembly (page 210).
Adhesive Backing
Static Brush Ground Wire
Static Brush
Slot
Figure 34. Static Brush
245
Switch Assembly, Paper Detector

Removal
3. Remove the two 1/4 inch screws securing the paper detector switch
assembly. (See page 276, items 3 and 4.)
4. Trace the paper detector switch cables back to controller board connector
P106, removing all tie wraps. (See the cable routing diagrams in
Appendix A.)
5. Disconnect connector coupling shroud P106 from the controller board
(page 204).
6. Trace the paper detector switch cables to the connector coupling shroud,
and remove the PMD and POD cable connector from the shroud (page
203).
7. Remove the paper detector switch assembly.
Installation
1. Holding the slotted wheel against the PMD sensor, position the paper
detector switch assembly and install the two 1/4 inch screws securing it to
the printer base. (See page 276, items 3 and 4.)
2. Check PMD sensor arm range: make sure it travels freely and completely
back into the sensing cavity.
3. Route the switch cables back to the controller board connector P106.
(See the cable routing diagrams in Appendix A.)
4. Connect switch cables PMD and POD to the connector coupling shroud
(page 204), then connect P106 to controller board connector J106.
6. Check the paper out adjustment (page 170).
246
Switch Assembly, Platen Interlock
Switch Assembly, Platen Interlock

Removal
3. Fully close the forms thickness lever (position ‘A’).
4. Trace the platen interlock switch cable back to the controller board.
Remove tie-wraps as necessary to free the cable. (See cable routing
diagrams in Appendix A.)
5. Disconnect connector coupling shroud P107 from the controller board.
6. Remove the platen interlock cable connector from the connector coupling
shroud (page 204).
7. Remove two Phillips #1 screws securing the platen interlock switch
assembly. (See page 272, item 11.)
8. Remove the platen interlock switch assembly from the switch bracket.
9. Remove the switch cable from the cutout in the right side plate.
Installation
1. Reverse steps 2 through 9 of the removal procedure, and do the following
when you have installed the switch on its bracket:
a. Install the two Phillips #1 screws finger tight.
b. Fully close the forms thickness lever (position A).
c. Insert a 0.011 inch (0.028 cm) feeler gauge between the bottom of
the interlock switch assembly and the shaft of the forms thickness
lever, gently push down on the interlock switch, and tighten the
mounting screws. Remove the feeler gauge.
247
Tractor (L/R)
Removal
2. Remove the support shaft (page 240).
3. Remove the splined shaft (page 238).
Installation
1. Using the replacement tractors, install the support shaft (page 240).
2. Install the splined shaft (page 238).
248
Illustrations of Printer Components
Section II: Illustrated Parts Lists

NOTE: Only field-replaceable spares are given part numbers in the illustrated
parts lists. Part numbers are not listed for common fasteners and
attachment hardware. Items marked “Ref” in the illustrations refer to
parts that are not spared or are part of another assembly.

Figure 35. Top Cover, Doors, and Casters ..................................... page 250
Figure 36. Paper Fence, Paper Chains, and Front Access Stacker page 252
Figure 37. Control Panel and Cabinet Details ................................. page 254
Figure 38. Pedestal Details ............................................................. page 256
Figure 39. Inside Covers, Cabinet Models ...................................... page 258
Figure 40. Inside Covers and Card Cage, Pedestal Models ........... page 260
Figure 41. Card Cage Detail, Pedestal Models ............................... page 262
Figure 42. Print Mechanism and Circuit Boards.............................. page 264
Figure 43. Magnetic Pickup (MPU) and Extension Spring .............. page 268
Figure 44. Tractor Shafts ................................................................ page 270
Figure 45. Platen............................................................................. page 272
Figure 46. Motors, Fans, and Paper Detector Switch ..................... page 276
Figure 47. Circuit Breaker, Cabinet Models .................................... page 278
Figure 48. CT Board........................................................................ page 280
Figure 49. Network Interface Card .................................................. page 282
Figure 50. RS-422 Interface ............................................................ page 284
Figure 51. Twinax Extension Cable ................................................ page 286
Figure 52. Dipole Antenna for Wireless NIC ................................... page 288
249
Chapter 5 Section II: Illustrated Parts Lists
13
5 10 9
12
11
Figure 35. Top Cover, Doors, and Casters
250
Item
Part No. Description Notes
No.
1 177505-901 Top Cover Assembly, Stealth Black Includes items 2 and 3

179781-901 Top Cover Assembly, Lt Gray Includes items 2 and 3
2 131803-901 Window, Cabinet
3 175680-001 Wireform Paper Path, Standard
4 177541-901 Rear Door Assembly, Stealth Black For printers without power
179785-901 Rear Door Assembly, Lt Gray stacker; includes items 9,
10, 11, 12, and 13
177489-901 Extended Door Assy, Stealth Black For use with power stacker
179792-901 Extended Door Assy, Lt Gray For use with power stacker
5 177502-901 Front Door Assembly, Stealth Black Includes items 9, 10, 11, 12,
179779-901 Front Door Assembly, Lt Gray and 13
6 141278-901 Caster, with Brake Two at front
7 141278-902 Caster, without Brake Two at rear
8 Ref Logo
9 101607-003 Wire Rope, Front and Rear One on each door (rear not
shown)
10 131829-001 Door Hinge, Top
11 112367-001 Door Hinge, Bottom
12 157332-901 Door Seal Kit
13 156030-001 Top Cover Seal Kit
251
1
2
6 10
5
8 9
11
Figure 36. Paper Fence, Paper Chains, and Front Access Stacker
252
Item
No.
1 158179-901 Passive Stacker Assembly Not used on printers with the

power stacker; includes
items 6, 7, and 8
2 153503-001 Grommet Kit, Cabinet
3 153778-001 Chain Assembly Kit
4 Ref AC Power Cord
5 Ref Grommet, Power Cord (2) Included in item 2

6 151910-001 Guide Rail, Stacker Part of item 1
7 151831-001 Clip, Rail, Stacker
8 Ref Screw (4)

9 178913-001 Field Kit, Tray, Cab, Rear, Black Includes items 1, 6, 7, 8, 9,
10, and paper tent 173864-
001
179799-001 Tray, Power Stacker, Pull-Out, Gray
10 174392-901 Slide Set, Ball Bearing
11 250085-001 Field Kit, Front Access Stacker, Cab Optional on all cabinet
models
253
4 3
1
2
A
11
12
6
10
9
8
Figure 37. Control Panel and Cabinet Details
254
Item
No.
1 177529-901 Control Panel Assembly, Cab

2 152440-901 Cable Assembly, Control Panel
3 107961-905 Dashpot Kit Includes ball studs, spring

clips, and mounting
hardware
4 Ref Screw, w/Lock Washer (3) 6-32x.375
5 Ref Screw, w/Lock Washer (3) 6-32x2.00
6 150261-901 Fan Assembly Includes mounting hardware
7 Ref Duct, Air Exhaust
8 177296-001 Paper Entrance Guide, V2 P7220 only
9 173428-001 Spring, Paper Entrance Guide (2) P7220 only
10 173351-001 Bracket, Paper Entrance Guide, Right P7220 only

173352-001 Bracket, Paper Entrance Guide, Left P7220 only
11 Ref Control Panel Bracket
12 Ref Screw, Hex w/Lock Washer (2) 6-32x.375
255
18
13
8
3
1
17 4
14
12
2
9
15
11
16
10
Figure 38. Pedestal Details
256
Item
No.
1 177529-902 Control Panel Assembly, Ped

2 Ref Screw, Captive (2)
3 179163-001 Field Kit, Lid Assembly, Ped, Blk Both kits also contain items
179845-001 Field Kit, Lid Assembly, Ped, Gray 8, 14, and 17
4 Ref Screw (2)

6 179081-001 Packaged Ped Kit, Stealth Black
179776-001 Packaged Ped Kit, Lt Gray
7 179162-001 Field Kit, Caster Kit, Ped
8 178692-901 Window, Top Cover
9 Ref Housing, Pedestal, V3
10 Ref Screw (4) 10-32x.625
11 110718-001 Paper Tray
12 157070-901 Paper Fence, Rear, Ped
13 250083-001 Field Kit, Acoustic Shroud, Ped, P7000 Optional on all pedestal
models
14 178259-901 Panel, Lid, Quick Access, Black

179765-901 Panel, Lid, Quick Access, Gray
15 178241-901 Panel, Quick Access, Flip Up, Black

179766-901 Panel, Quick Access, Flip Up, Gray
16 156033-901 Paper Tray, Front, Ped
17 179971-901 Static Brush, Sized, Pedestal

18 179193-901 Top Cover, Ped, Base Assy, Stealth
Black
179770-901 Top Cover, Ped, Base Assy, Lt Gray
257
12
4 9
3
11
2 10
8
7
Figure 39. Inside Covers, Cabinet Models
258
Item
No.
1 179128-901 Shuttle Cover Air Shroud Assembly

2 Ref Screw, Captive (2) 10-24x.62 with O-ring,
.125x.250x.06
3 Ref Screw, Thread-forming (2) 6-32x.25 and #6 flat washer
4 Ref Barrier Shield
5 175188-901 Paper Path, V3

6 Ref Screw, w/Lock Washer (3) 6-32.25 and #6 flat washer
7 153488-001 Field Kit, Covers Paper Feed Belt Cover

shown
8 108664-903 Belt, Timing, .080 Pitch, 100 Teeth, Paper Feed Belt
.500 Wide
9 Ref Screw, Thread-forming (2) 6-32x.25
10 179276-001 Power Supply Insulator Taped to the upper edge of

the card cage
11 153528-901 Paper Scale
12 152284-901 Anti-static Brush Kit Mounts to top of item 4
259
See Figure 41,

8 page 262.
A
2
6
7
Figure 40. Inside Covers and Card Cage, Pedestal Models
260
Item
No.

.125x.250x.06
5 179276-001 Power Supply Insulator Taped to card cage along

upper edge
.500 Wide
7 153488-001 Platen/Paper Feed Cover Kit Paper Feed Belt Cover

shown
8 153528-901 Paper Scale
261
A
From Figure 40, page 260.
2 Rotated 180 degrees.
To IEC 320 AC
Power Input
(Connector To Connector P1
J301, White (White Wire)
Wire)
To IEC 320 AC Power

Input (Connector J301,
Black Wire)
To Connector P1
(Black Wire)
Figure 41. Card Cage Detail, Pedestal Models
262
Item
No.
1 Ref Nut, 6-32 (1) Upper right fan corner only

2 150261-901 Card Cage Fan Assembly Air flow is into card cage
3 Ref Fan Guard

5 Ref Card Cage, Pedestal
6 142013-901 Circuit Breaker
7 Ref Baffle, Power Supply, Ped, P7000
263
Two places:
Exploded to show 14
assembly. Do not
remove the 2 1
clamps and
screws.
To J02 3
(Shuttle 15
Motor) To J03
(MPU) 5
10
8
9 19
11
7 20
4 18
21
13 10
6 22 12
16
17
To the Terminator
Board on the
Shuttle Frame
Figure 42. Print Mechanism and Circuit Boards
264
Item
No.
1 178311-901 Ribbon Mask/HB Cover Assy P7005 and P7205

178310-901 Ribbon Mask/HB Cover Assy P7010 and P7210
178309-901 Ribbon Mask/HB Cover Assy P7015 and P7215
178308-901 Ribbon Mask/HB Cover Assy P7220
2 178895-901 Shuttle Assembly, 05 P7005 and P7205

178895-991 Shuttle Assembly, 05, Adv Exch P7005 and P7205
178894-901 Shuttle Assembly, 10 P7010 and P7210
178893-901 Shuttle Assembly, 15 P7015 and P7215
178892-901 Shuttle Assembly, 20 P7220
178892-991 Shuttle Assembly, 20, Adv Exch P7220
174965-901 Hammer Spring Assembly, 05 P7005 and P7205
174514-901 Hammer Spring Assembly, 20S P7220
3 179074-901 Power Supply, PFC, 5/10 P7X05, P7X10

179074-991 Power Supply, PFC, 5/10, Adv Exch P7X05, P7X10
179075-901 Power Supply, PFC, 15 P7X15
179075-991 Power Supply, PFC, 15, Adv Exch P7X15
179076-901 Power Supply, PFC, 20 P77220
179076-991 Power Supply, PFC, 20, Adv Exch P7220
4 Ref P101 Cable Connector Part of item 3
5 Ref Cable Assembly, AC-In, Power Supply Part of Field Kit, AC Assy,
153502-901
6 179077-901 Controller PCBA, (V5)

179077-991 Controller PCBA, (V5) Adv Exch
7 202362-001 Housing, Connector Kit P106, Motor Sensor, Left
8 152421-901 Hammer Bank Logic Cable Assembly
9 152420-901 Shuttle Motor Cable Assembly
10 164805-901 Hammer Bank Power Cable Assembly Use on all except P7220
173215-901 Hammer Bank Power Cable Assembly P7220 only
11 202362-001 Housing, Connector Kit P107, Motor Sensor, Right
12 152439-901 Centronics I/O Cable Assembly
13 152440-901 Control Panel Cable Assembly
14 150399-901 Clamp, Shaft, Receiving
15 Ref Screw, Captive, Power Supply (2)
265
Item
No.
16 204480-902 SIMM, Flash Memory, 8 MB Install in slot J11. J10 is not

204480-903 SIMM, Flash Memory, 16 MB used.
17 Ref Security Key
18 177482-001 Paper Feed Motor P7220

178046-001 Paper Feed Motor P7X05/10/15
178535-001 Paper Feed Motor P7X05/10/15LG
19 179526-901 Integrated Print Management System
Bar Code Sensor Assy
20 173164-901 Cable Assembly, PS I/O, 2000 Used only P7220. (See also
page 339.)
21 Ref Not Used
22 204535-901 SDRAM DIMM, MEM, 32 MB, PC100
266
(Parts lists continue on the next page.)
267
3
Spring Lug (Do not
remove grease)
Spring Lug (Do not

remove grease)
A
1
7
CAUTION:
Make sure the MPU 5
cable does not touch
the extension spring
after cable 0.010 ± .001 inch (0.254 ± .025 mm)
connection.
Figure 43. Magnetic Pickup (MPU) and Extension Spring
268
Item
No.
1 150281-901 MPU Assembly

2 Ref Bracket, MPU Part of item 1
3 Ref Screw, Socket Cap 6-32x.38
4 153537-901 Spring, Hammer Bank

5 Ref MPU Cable Connector (P03)
6 176507-001 Anti-Rotation Spring Constraint P7220 only
7 152425-901 MPU Cable Assembly
269
IMPORTANT: In order to
preserve correct alignment of
4 the side plates, the barrier
panel must remain installed
and fastened if the splined or
1 2 support shafts are removed or
3 12
replaced. The barrier panel is
shown in Figure 39 and
5 Figure 40.
6
11
8
10a 7
10b
Figure 44. Tractor Shafts
270
Item
No.
1 Ref Screw, Socket Cap, 6-32x.312 Trilob

(Self-Tapping) (2)
2 173130-001 Plate, Tractor Shaft, Left
3 151944-001 Bearing, Ball, Sealed
4 178990-901 Paper Support (2)
5 204155-001 Tolerance Ring,.37X.25,.006 THK,SS

6 178988-901 Splined Shaft Assembly (Blue Handle)

(Self-Tapping)
8 173217-001 Plate, Tractor Shaft, Right
9 173137-001 Support Shaft
10a 179061-901 Tractor Set, 20 (Blue) P7220

10b 179065-901 Tractor Set, Non-Roller, 05/10/15 Installed at the factory on
(Blue) models with power stacker;
comes standard on P7220
11 Ref Right Side Plate
12 Ref Left Side Plate
271
NOTE:
Black tape faces paper
motion detector.
NOTE:
On P7008H, P7208H, P7015, P7215,
and P7220 models, install item 27 in front
27 of item 3; that is, on the shuttle side. All
others do not use item 27.
Items 3 and 27 are not installed on ZTP
printers.
1 2
NOTE:
Item 25: Platen
Hardware Kit
6 4
5
24 7
88
23 1 2
22
20
18
16
21
17
26
9 10
11
29
28
12
13
14
19
18
17 16
15
Figure 45. Platen
272
Item
No.
1 Ref Setscrew (2) Part of item 25

2 Ref Bracket, Platen (2) Part of item 25
3 150957-901 Ironer Assembly, Reverse Paper Feed All except ZTP models

5 174968-001 Ironer Bracket/Plate Field Kit
6 Ref Plate, Ironer Part of item 5
7 112657-901 Platen Assembly
8 Ref Washer, Flat (2) Part of item 25
9 Ref Screw (2) Part of item 11
10 Ref Washer, Flat #4 (2) Part of item 11
11 179334-901 Field Kit, Switch Assy, w/Bracket Includes items 9, 10, 19
12 Ref Screw, Socket Cap, 6-32x.75 Part of item 15
13 Ref Washer Part of item 15
14 Ref Nut Part of item 15
15 178705-901 Platen Stop Lever Kit Includes items 12, 13, 14
16 Ref Spring, Extension 1.12L Part of item 25
17 Ref Link, Spring Part of item 25

18 Ref Bearing, Nylon .376 Part of item 25
19 Ref Bracket, Switch Mount Part of item 11
20 Ref Wear Saddle, Platen (2) Part of item 25

21 150703-902 Platen Pulley, Drive
23 141516-901 Belt, Timing, .080 Pitch, .312 Wide Platen Open Belt
24 153488-001 Field Kit, Covers Platen Open Belt Cover

shown
25 177558-001 Platen Hardware Kit Includes items 1, 2, 8, 16,

17, 18, 20, 26
26 Ref Platen Washer Part of item 25
273
Item
No.
27 176630-901 Paper Ironer, Auxiliary On P7008H, P7208H,

P7015, P7215, and P7220
models install item 27 in
front of item 3 (i.e., on the
shuttle side). All other
models do not use this item.
28 179526-901 Sensor Assembly, Integrated Print

Management System/Barcode
29 Ref Screw
274
275
11
2
1
Install screws here.
A
Top View
Hammer Bank Fan Route cable under

base casting
4
3 4
5 18b
13
19
14
21
10 2 18a
12
20
16 6
17
9 8
7
A See detail above
Figure 46. Motors, Fans, and Paper Detector Switch
276
Item
No.
1 150261-901 Card Cage Fan Assembly Air flow is into card cage
2 Ref Screw, w/Lock Washer (3) Two 6-32x1.75 on bottom,
One 6-32x0.50 on top left
3 152415-901 Switch Assembly, Paper Detector

170172-001 Field Kit, Slotted Black Back Form Optional switch assembly
Switch used with black back forms
4 Ref Screw, Thread-forming, 6-32x.375 (2) Part of item 3
5 179638-001 Motor Assembly, Platen Includes pulley
6 Ref Screw, Hex w/Lock Washer, 10-24x.50 Part of item 18

(2)
7 178992-902 Ribbon Guide Cable Assembly, RH

178992-901 Ribbon Guide Cable Assembly, LH
178995-001 Field Kit, Ribbon Guide, LH/RH,
P7000
8 Ref Washer, Flat #4 Part of item 7
9 Ref Screw, w/Lock Washer, 4-40x.38 Part of item 7
10 Ref Screw, w/Lock Washer, 10-32x.50 (2) Part of item 5
11 Ref Shield, Card Cage Fan

12 179073-901 Ribbon Motor Assembly, w/Hub
14 Ref Washer, Flat #6 (2)
15 Deleted Deleted
17 152416-901 Hammer Bank Fan Assembly All except P7220; air flow is
up
173427-901 Hammer Bank Fan Assembly P7220; air flow is up
18a 178046-001 Field Kit, Paper Feed Motor, V3 All except P7220
18b 177482-001 Field KIt, Paper Feed Motor w/Heat P7220—Heat sink screws:
Sink 18 inch-pounds (2.03 N•m)
20 Ref Post, Platen Belt Spring

21 Ref Spring, Platen Belt
277
See inside detail below.
To IEC 320 AC Power

Input (Connector J301,
White Wire)
A To IEC 320 AC Power
Input (Connector J301, A
Black Wire)
To Connector P1
(Black Wire)
B
To Connector P1
(Card cage fan and Black Wire (White Wire)
power supply board
removed for clarity.) 1
Black 2
Wire
White Wire
3 5
4
White Wire
Figure 47. Circuit Breaker, Cabinet Models
278
Item
No.
1 142013-901 Circuit Breaker

2 Ref IEC 320 AC Power Connector Connector J301
3 Ref Chassis Ground Stud
4 Ref Connector P1 To power supply board

connector J1 AC
5 Ref Cable Assembly, AC-In, Power Supply Part of Field Kit, AC Assy
153502-901
279
IMPORTANT:
Leave this slot empty
if the printer has a
power stacker.
Figure 48. CT Board
280
Item
No.
1 177929-901 Spare PCBA, PCI-CT, V3

177929-991 Spare PCBA, PCI-CT, V3, Adv Exch
2 176257-001 Plate, PCI Cover
3 Ref Card Cage
4 Ref Screw
5 Ref Controller Board
281
2
1
3
IMPORTANT:
Leave this slot empty
if the printer has a
power stacker.
Figure 49. The NIC (Network Interface Card)
282
Item
No.
1 179407-901 Spare PCBA, PCI-Network

179407-991 Spare PCBA, PCI-Network, Adv Exch
177308-901 Spare PCBA, PCI Wireless
2 176257-001 Cover Plate, PCI
3 Ref Rear of Card Cage
4 Ref Screw
283
4 11
11
10
See detail at
right
A 8
Pin 10
7
A
6
5
Figure 50. RS-422 Interface
284
Item
No.
1 176287-901 PCBA, RS422 ADAPTER, DB9/DB25 Part of Field Kit 176425-001

2 102922-001 Screwlock Kit, Female (2)
3 176075-901 Cable Assembly, RS-422, I/O Part of Field Kit 176425-001
4 Ref RS-422 Connector, 9-Pin Part of item 3

5 Ref Connector J15 Note that there is no Pin 10.
If Pin 10 is present, remove
it.
7 Ref Connector J201, RS-232, 9-Pin
8 Ref Cover Plate

9 Ref Nut (2) Part of item 2
10 Ref Lock Washer (2) Part of item 2
11 Ref Flat Washer (4) Part of item 2
285
2
4
Figure 51. Twinax Extension Cable for Printers with PSA3 Controller, Twinax I/O, and Power
Stacker
286
Item
No.
1 140752-002 Twinax Auto-Termination Cable

(“Smart-T”)
2 204806-901 Cable, Extension, Smart-T Required in printers with the

power stacker so the twinax
auto-termination cable will
clear the stacker elevator.
(See also page 335.)
3 Ref PCI-CT Twinax Connector
4 Ref PCI-CT Coax Connector
287
Cabinet Model
Pedestal Model
Figure 52. Dipole Antenna and Cable Used With the Optional Wireless NIC
288
Item
No.
1 179228-001 Field Kit, Antenna, Fixed Point, Dipole

2 204479-001 Cable, MMCX-BNC, 10 inch, S24
289
290
6 Principles Of Operation
Line Matrix Printing

A line matrix printer creates characters and graphics by printing patterns of
ink dots an entire line at a time.
Every text character is stored in printer memory as a pattern of dots on a
logical grid called the dot matrix. (Figure 53.) The ink dots that appear on the
paper are made by a row of hammer springs mounted on a shuttle that
sweeps rapidly back and forth. Logic circuits on the controller board divide
every line of incoming print data into horizontal dot rows. The hammers put
dots at the required positions for the entire line by driving an inked ribbon onto
the paper.
1 Column No. 12
0.10 inch
0.00835 inch
First row and column
of next character column
0.01389 inch (at 10 cpi)
Lowest descender dot line

First row and column of next
character line (at 6 LPI)
0.02 inch
Figure 53. A Dot Matrix
291
Chapter 6 Line Matrix Printing
When the shuttle reaches the end of a horizontal sweep, it reverses direction,
the paper advances upward one dot row, and the hammer springs print the
next row of dots as the shuttle moves in the opposite direction. When a line of
text characters is completed, hammer action stops and the paper advances to
the first dot row of the next print line. The number of dot rows used to
separate print lines depends on the vertical line spacing selected by the user.
The dot matrix patterns of text characters vary according to the font the user
selects. For example, in the data processing (DP) font at a line spacing of six
lines per inch (lpi), a dot matrix contains 12 dot rows from the top of one
character line to the top of the next. (Figure 53 and Figure 54.) At eight lpi
there are nine dot rows per character line, at nine lpi there are eight dot rows
per character line, and so on.
Each individual hammer spring can (and usually does) form more than one
character as the shuttle moves horizontally. This principle is illustrated in
Figure 55.
Direction of Shuttle Movement

Dot
Row
Start
1
2
3
4
5 Paper
One Feed
Text 6 Direction
Line 7
8*
9* *
10
11 Number of rows determined by line spacing
n
1
2
* This row is used only for lowercase descenders

** This row is used for underlining and lowercase descenders
Figure 54. Standard Character Formation
292
Succesive Hammer Strokes Per Scan
Shuttle Dot
1
Scan Row * *1 3
* 1 3 5
*1 3 5 7
* 1 3 5 7 9
*
1 1
1
2 2
1
2
3 3
1
2
3
4 4
1
2
3
4
5 5
1
2
3
4
5
6 6
1
2
3
4
5
6
7 7
* Even column dot centers within the printed character

area and character space hammer positions are not
illustrated in this diagram.
NOTE: = Hammer Released and Dot Printed
= Hammer Not Released; No Dot Printed
Figure 55. Typical Action of One Hammer Spring in Text Printing
293
Chapter 6 Printing Rates
Printing Rates
A line matrix printer prints entire lines sequentially, and measures the printing
speed of text in lines per minute (lpm). This is faster than a moving-printhead
printer, which prints single characters sequentially and measures its speed in
characters per minute (cpm).
Many variables affect printing speed, the main ones being the font and the
vertical dot density selected by the user. Lines containing such print attributes
as bold or emphasized print, superscripts, subscripts, or elongated characters
also reduce print speed, but the speed reduction is never less than half the
rate of the same line printed without such attributes. The actual print rate of
lines containing these attributes depends on the specific print job, but printer
software maximizes the throughput by dynamically determining which dot
rows contain adjacent dots and must be printed in two strokes.
The number of characters in a character set has no effect on printing speed.
The printing speed of graphics (“plot mode”) is expressed in inches per
minute (ipm).
The ability of the printer to feed paper both downward and upward allows the
printing of multiple dot densities on a single line. This makes it possible to
print forms and text simultaneously and to mix fonts on the same print line.
The use of multiple dot densities and reverse paper feed affect printing rates
the same way print attributes do.
Printing Mechanism
While the principles of line matrix printing are easy to state, the act of printing
dots accurately from a rapidly oscillating shuttle onto a piece of paper that is
moving vertically requires complex timing and coordination between printer
logic and the printing mechanism.
The printing mechanism consists of three integrated subassemblies:
• Shuttle Frame Assembly
• Paper Transport System
• Ribbon Transport System
294
Hammer Bank Assembly

The central element of the printing mechanism is the shuttle frame assembly,
which houses the hammer bank assembly and the shuttle drive motor.
(Figure 56.)
Counterweight
Connecting Rod
Shuttle Frame Guide Shaft

Assembly
Shuttle Drive
Motor
Figure 56. Shuttle Frame Assembly

A number of comb-like hammer spring assemblies are bolted to a solid
hammer bank, forming the hammer bank assembly. The number of individual
hammers on a hammer spring assembly and the number of hammer spring
assemblies attached to the hammer bank vary by printer model:
• Models P7005, P7005ZT, and P7205 have seven 4-hammer assemblies,
for a total of 28 individual hammer springs.
• Models P7003H, P7003ZT, P7203H, P7010, P7010ZT, and P7210 have
six 10-hammer assemblies, for a total of 60 individual hammer springs.
• Models P7006H, P7006HZT, P7206H, P7015, P7015ZT, and P7215 have
six 17-hammer assemblies, for a total of 102 individual hammer springs.
• Models P7008H, P7208H, and P7220 have seven 18-hammer
assemblies, for a total of 126 individual hammer springs.
Shuttle Drive Motor

The shuttle drive motor is built into the shuttle assembly casting and spins a
crankshaft, to which are attached the big ends of two connecting rods.
(Figure 56.) The small end of one connecting rod attaches to the hammer
bank; the small end of the other connecting rod attaches to a counterweight
frame surrounding the hammer bank. (The hammer bank and the
counterweight constitute the shuttle assembly.) The shuttle drive motor,
acting through the crankshaft and connecting rods, converts rotary motion to
linear and opposing motion of the hammer bank and counterweight, in an
295
Chapter 6 Shuttle Frame Assembly
arrangement similar to that of a horizontally-opposed gasoline engine.

Mechanically, this design achieves the same benefits as that type of engine:
perfect primary balance, low vibration, and durability.
Each hammer spring is a stiff leaf spring with a cylindrical tungsten carbide tip
attached to the free end. (Figure 57.) A powerful permanent magnet is
imbedded along the length of the hammer bank and acts on the hammer
springs through individual pole pieces. The pole pieces magnetically attract
and hold the free end of the hammer spring under tension. This is called the
retracted state.
NOTE: P7215 hammer bank shown.

Tungsten
Carbide Hammer Bank Assembly:
Hammer Tip Coils, Magnet, Pole Pieces,
Hammer Spring
Assemblies
Hammer Spring
Assembly
Alignment Pin
Figure 57. Hammer Springs and Hammer Bank (Detail)

Two electromagnetic coils are mounted behind each hammer and wound
around each pole piece. The coils are normally de-energized. When hammer
driver logic determines that a hammer must print a dot, a current pulse
energizes the coils behind the hammer. The polarity of the resulting magnetic
field opposes the field of the permanent magnet, canceling the magnetic
attraction and releasing the hammer, which springs forward, striking the
ribbon and paper and leaving an impression of its tip (a “dot”) on the paper.
While the hammer is in flight the coils are de-energized and their magnetic
field collapses, restoring the magnetic attraction of the permanent magnet in
the hammer bank. After striking the ribbon and paper, the hammer rebounds
and is recaptured by the permanent magnet. When the shuttle reaches the
end of a sweep, it reverses direction, the paper is micro-stepped upwards one
dot row, and the hammer springs print the next row of dots as the shuttle
sweeps in the opposite direction. All this happens extremely rapidly: hammer
re-firing in a 2000 lpm printer, for example, takes about 419 microseconds,
with the vertical paper movement between dot rows occurring in 2.10
milliseconds.
296
Shuttle Drive Motor
Paper Transport System
Paper Path
Tractors
Vertical
Splined Adjustment
Shaft Knob and
Tractor Splined Shaft
Support Pulley
Shaft
Shuttle Cover
Assembly
Paper Feed Timing

Belt (under the cover)
Paper Supports
Figure 58. Paper Transport System

A two-phase DC stepper paper feed motor, directed by the engine controller
(EC) on the controller board, drives two tractor sprockets by means of a
toothed belt linked to a pulley on the splined shaft. The stepper motor permits
extremely accurate vertical paper movement in 1/72 inch increments. This
drive configuration is designed for continuous, fan-folded paper from 3 to 17
inches wide and 1 to 6 sheets thick. To reverse paper movement (that is,
move it downward) a second motor opens and closes the platen by means of
a toothed belt linked to a pulley on the platen shaft. Opening the platen
prevents paper jams when paper direction is reversed after viewing the print
area, setting top of form, or allowing applications to overprint forms.
Paper is positioned horizontally using the tractors. Each tractor is locked in
position with a friction lock and engages the paper perforations with six
sprocket pins.
The vertical adjustment knob is used to position paper vertically by hand.
297
Chapter 6 Ribbon Transport System
Ribbon Transport System
Ribbon Hub
Left Ribbon Guide
Hub
Locking
Latches
Ribbon Spool
Ribbon Motor
Right Ribbon Guide
Ribbon
Figure 59. Ribbon Transport System

An inked ribbon made of a specially woven, highly durable fabric winds and
unwinds continuously on a pair of spools latched to hubs driven by the ribbon
motors. The large spools carry a longer ribbon, which contributes to greater
ribbon life. A photo-reflective sensor mounted beneath the right-hand ribbon
spool reads a bar coded label affixed to the ribbon spool and sends
specialized data to the Integrated Print Management System software in
printer memory. (Integrated Print Management is discussed in the next
section.)
The hubs and spools are offset vertically to equalize ribbon wear and prolong
ribbon life. The ribbon motors operate only when the shuttle assembly is
moving. Ribbon motion reverses when a metal strip at either end of the ribbon
crosses the left or right ribbon guide, completing a circuit that causes both
motors to reverse direction.
Constant ribbon tension is maintained by controlling each motor with a drive
and a drag circuit. While the shuttle assembly is in motion, one motor acts as
a drive motor, pulling the ribbon against the resistance exerted by the other
motor—the drag motor. This system maintains constant motor speed and
ribbon tension.
298
Operation
Integrated Print Management System

The Integrated Print Management System uses a bar coded label on special
high-capacity ribbon spools and a photo-reflective sensor mounted beneath
the right-hand ribbon spool. A bar coded label is affixed to each ribbon spool
on opposite sides, so that the underside of the right-hand spool can always be
read by the sensor. The bar code contains the following encoded information:
• Identifies the ribbon as Printronix or authorized OEM
• The thickness and length of the ribbon fabric to select the correct motor
stepper tables
• The expected yield, which is used by Integrated Print Management
software to set the ink depletion rate
• A unique identification sequence that is not duplicated on any other
ribbon
To verify the authenticity of the ribbon, the bar coded label is scanned by the
sensor as the spool rotates and the input data are decoded by the printer and
interpreted by Integrated Print Management software.
Reading the information from the bar code, the system automatically sets up
the parameters which dictate the ribbon life, based upon pre-determined
depletion rates to a set dot density. The desired ribbon end point and alert
actions can be adjusted to accomodate individual requirements.
NOTE: Each ribbon spool label has a different identification sequence
number. This permits the ribbon to be flipped over and re-used one
time, while the system recognizes and tracks it as a new ribbon
installation. In this manual, “new ribbon” means either a brand new
ribbon or one that has been flipped once.
Operation
Ribbon ink consumption continuously displays as a percentage on the control
panel display, the percentage decreasing as ink is consumed. At the default
settings, when ribbon life reaches 2% the message changes to “RIBBON INK
LOW / Install New RBN.” The control panel status lamp flashes, but the printer
continues to accept new print jobs until ribbon life reaches 0%, at which time
printing stops and the printer enters the fault state.
The default settings for the Integrated Print Management System are enabled
at the factory, and the system functions without intervention as long as
genuine Printronix ribbons are used and the Integrated Print Management
options have been set. The user can change settings, as discussed later in
this section.
Control Panel Menus

Two Integrated Print Management System options are located in the QUICK
SETUP, PRINTER CONTROL, and ADVANCED USER menus. (The User’s
Manual explains how to navigate the menu system and has complete menu
maps.) From either the QUICK SETUP or the PRINTER CONTROL menu you
can adjust the Ribbon End Point. From the ADVANCED USER menu you can
set the Ribbon Action option. These options are discussed below.
299
Chapter 6 Integrated Print Management System
Ribbon End Point

Factory default is Normal. This value corresponds to the life expectancy of an
authorized ribbon. The Integrated Print Management System tracks ribbon life
to the recommended end point before declaring RIBBON INK LOW or
RIBBON INK OUT. Ribbon End Point is a global setting, which means it is in
effect for all printer configurations and cannot be set for individual printer
configurations.
By changing this setting, you specify a point lower or higher at which the
“RIBBON INK LOW” or “RIBBON INK OUT” message will display. You can
thus set ribbon life to match the required print density for a specific
application. To change this setting, press the LEFT or RIGHT ARROW key to
select either “Darker +1” through “Darker +6” (LEFT ARROW) or “Lighter -1”
through “Lighter -10” (RIGHT ARROW). Each increment or decrement
corresponds to a predetermined density value. Pressing LEFT or RIGHT
changes the value by one increment per key press. The second line of the
display changes to show the action taken. Press ENTER to select the desired
level.
The changed setting will remain in effect until it is adjusted again. If a different
type of ribbon is installed, the density setting will remain as selected, but the
end of life value for the new ribbon type will be used.
For reference, the nominal starting density of a new black text ribbon is
approximately 1.2, with a yield down to 0.5 density of approximately 16 million
HS characters. Incrementing the Darker setting will raise the density end
point, which decreases the ribbon yield. Each Darker increment will decrease
the yield by a percentage from the expected 16 million. For example, Darker
+1 would change the expected yield to 12.67 million characters. Darker +3
would decrease the yield to 6 million characters. Conversely, decrementing
the Lighter setting decreases the print density, which increases the ribbon
yield. Each Lighter decrement increases the yield by an additional
percentage. For example, Lighter -2 would change the expected yield to 30
million characters. Lighter -5 would result in an approximate yield of 52 million
characters.
Changes to Ribbon End Point setting can be made at any time during a
ribbon’s life, and the new end point will be calculated accordingly. However,
once a depleted ribbon is removed and another ribbon installed, the depleted
ribbon is added to the used ribbon long, and may not be re-introduced into the
printer.
Ribbon Action
Factory default is Stop At RBN End. When the ribbon life reaches 0%, the
message “RIBBON INK OUT / Install New RBN” displays on the control panel.
The status lamp flashes, the alarm sounds (if enabled), printing stops, and the
printer enters the fault state. Printing cannot resume until this condition is
cleared. To complete a print job in progress, you can return the printer to
ONLINE state by pressing ONLINE / CLEAR. This allows the printer to
continue printing for approximately two minutes, at which point the printer will
go into the fault state again. You can print for another two minutes by again
pressing ONLINE / CLEAR. You can repeat this routine indefinitely, or until
power to the printer is turned off. Once power is restored and a depleted
300
Operation
ribbon is detected, “OLD RIBBON / Install New RBN” displays because the
depleted ribbon was added to the Ribbon Log. A new ribbon must be installed
to clear this condition.
When Ignore RBN End is selected, the ribbon life display remains on the
control panel, and the Integrated Print Management System continues to
monitor ink consumption to the appropriate value as set by the Ribbon End
Point . When this end point is reached, the display will continuously show
“RIBBON LIFE 0%” and the system will continue to run with no other warning
indications. The printer can be taken OFFLINE or the power cycled and the
Integrated Print Management System will permit the use of this ribbon.
However, when the ribbon reaches the calculated absolute end of life, the
printer stops printing, the status indicator flashes, the alarm sounds (if
enabled), and the display switches to the “EXCESS RBN WEAR / Install New
RBN” message. The ribbon serial number is added to the depleted ribbon log
(described below). This fault cannot be cleared by pressing ONLINE /
CLEAR. It can only be cleared by opening the platen or cycling power, at
which time the ribbon will now be detected as a depleted ribbon. A new,
recognized (authorized) ribbon must be installed to clear this fault.
Ribbon Installation And Detection

The Integrated Print Management System assumes that the full ribbon spool
will be installed on the left-hand hub and the empty spool on the right-hand
hub, but the full spool can be installed on the right ribbon hub as well. The
ribbon detection routine will simply take a few seconds longer if the full spool
is installed on the right-hand hub.
The new ribbon detection routine runs after printer power is restored, as part
of the boot cycle, or whenever the platen is opened and closed. When done
as part of the boot cycle, Shuttle Slow runs the ribbon motors to the left, the
bar code is read off the bottom of the right ribbon spool, and the ribbon is
confirmed. When the bar code is decoded, the Integrated Print Management
System is reset using the new data, and the ribbon consumption display is
updated. The ribbon motors and shuttle stop and the printer is brought to the
selected power up configuration. This routine repeats any time the platen is
closed and the printer is returned to ONLINE and no print data are in the
buffer. If no print data are present, the ribbon motors and shuttle stop and the
printer remains ONLINE. If the ribbon bar code cannot be decoded, is not
authorized, or is not detected by the sensor, an error message is reported. If a
data stream is detected during or after the ribbon detection routine, the print
cycle begins without stopping the shuttle or ribbon motors. In this case the
ribbon detection routine is done during the print cycle.
Previously used ribbons can be installed and used again to print, as long as
they were not fully depleted and declared RIBBON INK OUT.
A ribbon can also be flipped over to print on the unused half. This situation
occurs if printed images are narrow enough that only about half the ribbon is
used at one time. When a ribbon is flipped it is treated as a new (different)
ribbon, so if a ribbon is used across its full width and still flipped, it will report
as new even though it is clearly used. It is the customer’s responsibility to
determine if the printing application can support ribbon flipping.
301
Chapter 6 Integrated Print Management System
The Ribbon Log

The printer identifies each ribbon by maker (Printronix or authorized OEM),
type, and an identification code unique to that specific ribbon. The Integrated
Print Management System recognizes the currently installed ribbon and
previously used (but not depleted) ribbons, and resumes tracking the life of
the ribbon from the value it had when it was removed from the printer.
The printer keeps a log of depleted ribbons, identifying them if they are again
installed on the printer. This information is not printed in detail, but a summary
by type of all ribbons ever installed on a particular printer is listed in the log.
The log also captures any attempts to run Unknown1 or Unknown2 ribbons.
This information is recorded in the log as “Ribbon Not Recognized.” The
Ribbon Log is a permanent record; it cannot be cleared. The location and
format of the Ribbon Log is shown below.
OFFLINE
DIAGNOSTICS
DIAGNOSTICS
Printer Tests
Shift Recycle
All Es
E’s + TOF
All H’s
All Underlines
All Black
Shuttle Slow
Shuttle Fast
Shuttle Only
Phase Printer
Ribbon Log
Paperout Adj. Installed Ribbon = PTX, Ribbon Name, 55%, Normal
Burnin Test Ribbon History = PTX, Ribbon Name = 45
Print Error Log PTX, Ribbon Name2 = 33
Print Ribbon Log ENTER PTX, Undefined = 2
Clear Error Log IBM, Undefined = 66
Adapter Test Ribbon Not Recognized = 3
Ethernet Test
Acoustic
Demo
Dice Five
302
Logical Control Of The Printer
The printer consists of four subsystems: the control panel, the controller
board, the power supply board, and the print mechanism, as illustrated in
Figure 60.
Power Supply
Controller Board
Print Mechanism
Control Panel
Figure 60. Functional Elements of the Printer
303
Chapter 6 Control Panel
Control Panel
The user communicates with the printer by pressing keys on the control
panel. The keys are momentary contact switches. The control panel
processes and sends key closure information to the controller board and
displays information from the controller on the LCD. A status indicator next to
the LCD also conveys printer status information to the user.
The LCD, status indicator, and keys are mounted on a printed circuit board
assembly enclosed in a protective housing. The functions of the keys and
indicators are defined beginning on page 26.
Control Panel
• Data
• Control
• Key
(Switch)
Closures
Controller Board
Figure 61. Control Panel Functional Overview
304
Controller Board
The heart of a P7000 printer is the PSA3 controller board, which controls all
printer functions and supports all P7000 models.
The controller board receives and processes all data from the host computer,
builds the printable images, controls all motors, and drives the hammer
springs. Except for the power supply, all logic and drive circuitry for the printer
are contained on the controller board.
The controller board consists of two functional units: the DC (Data Controller)
and the EC (Engine Controller).
The DC is responsible for:
• Host Input/Output (I/O)
• Operator I/O
• Security Interface
• Print Image Generation
• Overall High Level (Logical) Control
The EC is responsible for:
• Operating the print mechanism
• Monitoring the print mechanism for faults
• Power shutdown and power saving modes
The EC and DC communicate through semaphore registers. The DC receives
input from the host and operator and returns dot images and LCD messages
to buffers in memory. Image data are passed to the EC upon request, are
processed, then sent to the hammer bank. The EC synchronizes paper,
ribbon, platen, and shuttle motion as it feeds dot data to the hammer drivers.
Figure 62 summarizes this architecture.
305
Chapter 6 Controller Board
Control Bus
JTAP
Data Bus
System
Reset
PCI Slots 0 and 1

SDRAM Motorola
MPC8245 PCI Bus
Buffer microprocessor
FLASH
Buffer
Core Volt
RTC Regulator
Non-Vol
Port
Control PCI Bus
Logic
RS-232 DC
Diagnostic RS-232/422
Diagnostic
Port Port Host I/O
V8 ASIC Drivers
IEEE-1284
(Parallel)
Control Control
Panel Panel
Interface
Data Controller
Cajun Bus
(DC)
Engine Controller
(EC)
Fault
Monitoring Fault
Circuitry Sensors
MECA ASIC
Paper
Feed
Ink
Transport
Assembly
Analog Drive
EC
Circuitry Shuttle
64K x 16
FLASH 20 MHz
Memory Siemens 80C167
Microcontroller Platen
(EC)
TTL EC
Diagnostic Diagnostic Hammer
Port Port Drive
Figure 62. Controller Board Block Diagram
306
Data Controller
Data Controller
The data controller (DC) consists of the following elements:
• MPC8245 microprocessor
• A 72-pin flash SIMM socket that holds up to 32MB of program memory
• A 32MB SDRAM DIMM for data memory
• 8K x 8 Non-Volatile Battery-Backed Static RAM (NVRAM) for storage of
configuration and system statistical data
• V8 ASIC (Application-Specific Integrated Circuit)
• Host I/O Drivers/Termination
MPC8245 Microprocessor
A Motorola MPC8245 microprocessor serves as the processor of the DC unit.
Flash Memory
The DC stores program and emulation code in flash memory. Flash memory
is erasable, non-volatile, and much faster than a disk drive.
The DC uses AMD 5.0V-only flash memory, which does not require higher
programming and erasing voltages on the board (it has an internal charge
pump to make these voltages itself). This memory supports at least 100,000
write/erase cycles. The flash memory is 8 bits wide.
A 72-pin SIMM socket designated J11 is provided for flash memory. (Socket
J10 is not used.) Up to 32MB of flash may be installed on the PSA3 controller
board.
The programs that are stored in flash memory are downloaded through the
parallel, serial, or optional ethernet port.
SDRAM
System SDRAM is used for program variables, image buffers, and input
buffers. The SDRAM supports page mode operation and is addressable by
individual byte. The SDRAM is a DIMM permanently mounted on the PSA3
controller board.
NVRAM
An 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device
provides for the storage of configuration and system statistical data.
V8 ASIC
The V8 is a multi-function custom gate array ASIC containing all the logic for
the DC that is not contained in the MPC8245 processor. The V8 provides the
following services:
• Memory Access Controller
• SDRAM Controller
• Flash Controller
307
• Two DMA Channels

• Operator Panel Interface
• “Dot Plucking” and Adjacent Dot Checking
• Interface to the “Cajun” Bus
• Host I/O and Diagnostic Port
Memory Access Controller

All MPC8245 addresses go through the V8 ASIC. The V8 handles all address
decoding, chip selects, DTACKs, and so on.
SDRAM Controller
The V8 supports up to four banks of page mode SDRAM.
Flash Controller
The V8 supports up to four banks of flash memory.
DMA Channels
The V8 provides two channels for direct memory access. These channels
move data from the host interface or expansion bus to the SDRAM and vice
versa. One address is an I/O address, the other is a memory address with
auto-increment.
Control Panel Interface

The V8 control panel interface consists of five lines: serial clock, serial data,
and three select lines. It is the V8 that handles all parallel-to-serial conversion
(and vice versa) to and from the panel, as well as any special timing needed
when toggling select lines, etc.
“Dot Plucking” And Adjacent Dot Checking

“Dot Plucking” is a specialized DMA function that removes dot data from a dot
image buffer in SDRAM in a programmable manner, serializes it, and sends it
to the hammer bank. This function is actually controlled by the EC (see page
309), which has access to the V8 through the “Cajun” Bus Interface.
“Cajun” Bus Interface

The “Cajun” bus connects the DC and the EC. The EC uses this bus to
access DC resources, including the semaphore registers. (The semaphore
registers are the primary communications path between the EC and DC.)
Ports
The V8 ASIC controls the following I/O functions:
• Interface to IEEE® 1284 Level 2 host
308
Engine Controller
• Interface to RS-232-E serial host

• Interface to RS-422-B serial host
All the circuitry required for these types of hosts is provided on the controller
board, except for the drivers themselves, ESD protection, and terminations.
Host I/O Drivers And Termination

Beyond the MPC8245 processor and V8 ASIC, additional support circuitry
completes the serial and parallel interfaces. These circuits include:
• RS-232 drivers and receivers. These circuits use internal charge pumps
to eliminate the need for ± 12V power.
• RS-422 differential drivers and receivers
• Parallel port pull-up and pull-down terminating resistors in DIP
configuration for easy removal and installation.
All interface ICs and terminations have the following characteristics:
• Provide ESD protection to 15KV for all inputs.
• Less than 0.05V common mode ripple, measured at the power and
ground of the interface ICs.
• Less than 0.02V common mode ripple, measured between chassis
ground and the ground pins of the interface ICs.
• Greater than 200V/µs slew rate for all outputs.
Engine Controller
The engine controller (EC) consists of four main elements:
• 80C167 Micro controller
• 128KB 5.0V-only FLASH program memory, organized as 64K x 16 bits.
This memory is not expandable.
• MECA (Mechanism Engine Control ASIC)
• Analog drive circuitry
80C167 Microcontroller
The Siemens SAB 80C167 is a high-integration microcontroller with many
features that suit it extremely well to real-time control applications. This
controller and the MECA ASIC provide the functionality of three separate
processors used in earlier controller board architectures. In this manual, the
80C167 is referred to as the EC.
Bus Configuration
The 80C167 bus is configured for 18-bit address, 16-bit data, non-multiplexed
and segmented operation. The flash memory runs with zero wait states. An
external PAL is used for address decoding.
309
Power Reduction
The 80C167 chip has two power reduction modes: idle and Energy Star. Idle
mode is not used. In Energy Star mode, the +48V and all motors are
de-energized, but the EC operates as normal.
EC Flash Memory
The EC stores all boot code, program code, and tables in its own local flash
memory. This flash is organized as 64Kx16 bits and uses the same
technology as the DC flash: it is +5.0V-only and is rated for a minimum of
100,000 write/erase cycles. EC memory is fixed; it is soldered to the controller
board. Its contents can be updated through the DC. At run time, the EC also
stores tables in shared SDRAM, which is accessed through the Cajun bus.
MECA ASIC
The 80C167 uses many counters, PWM generators, and FIFOs in the MECA
to control printer motor functions. The MECA is a custom gate array,
specifically designed to drive this system.
Analog Drive Circuitry

The analog drive circuits convert +48 volts and +8.5 volts into the power used
to drive the motors and hammers in the printer. Sensors monitor the operation
and status of critical components within the printer.
The printer has five electric motors: two ribbon drive, one paper feed, one
platen open, and the shuttle motor. The shuttle motor is a brushless DC motor
driven by current control. The MPU encoder is used as feedback for motor
commutations, hammer fire timing, and motor stall detection. The paper feed
motor is a DC stepping motor driven by current control. The paper feed motor
may be driven in full, half, or 1/72 inch microsteps, depending on print
requirements. The ribbon drive system uses two DC stepping motors that
alternate drive and drag roles when the ribbon fabric reaches turnaround. The
drive ribbon motor is microstepped in voltage mode, while the drag motor is
loaded and monitored to maintain correct linear speed and tension. The
platen motor is driven in current mode and can be full or half stepped. The
overall current level may be reduced for standby modes.
The paper feed, ribbon drive, and shuttle motors are driven in control loops
containing power MOSFETs, voltage and current sensors, the MECA ASIC,
and the EC processor. The platen motor is driven by a stepping motor
controller IC and the EC processor.
Control of the hammer drive is split between the controller board and the
hammer bank. Common circuits are located on the controller board, while
circuitry specific to the hammers is contained on the hammer bank. The EC
uses the MECA ASIC on the controller board to set timing and upper drive
profiles for hammer fire events. The controller also contains diagnostic
circuitry for the hammer system. The hammer bank contains HBA ASICs that
interpret fire commands and data from the MECA and V8 ASICs. The HBAs
control lower drive MOSFETs on the hammer bank. These determine which
hammers will participate in a fire event generated by the controller’s upper
drive.
310
AC Power
Power Supply Board

The printer’s power supply is on a printed circuit board mounted on the rear
wall of the card cage. The power supply automatically senses and adjusts to
any commercial electrical system that provides AC mains potential in 50 or 60
Hertz systems. This means the printer can operate anywhere in the world on
local commercial power.
The power supply converts alternating current (AC) to direct current (DC) at
three voltage levels and sends the DC voltages to the controller board. The
controller board distributes all DC power to the logic and electromechanical
circuits.
AC Power
The power supply operates on AC voltages ranging from 88 volts to 270 volts.
It can tolerate variations in frequency of 47 to 63 Hz. The power supply is
designed to withstand an AC input overvoltage of 300 VAC for one second
with no degradation of DC output voltage or damage to printer circuits.
DC Power
The power supply board contains two DC power supply systems for the
printer. The first is a +5 V bus for logic. The second consists of +48 V and
+8.5 V buses for the hammer bank and motors.
The +5 V supply has an isolated return line that connects to the +48 V return
at the printer load. Both returns are tied together in a one-point ground. The
+5 V power supply has its own inverter, separate from the +48 V and +8.5 V
outputs.
There is an opto-isolated input on the power supply that will shut down and
latch off the +48 V and +8.5 V supplies unless it is pulled up to +5V with a
1K Ω resistor. This resistor is mounted on the controller board and may be
pulled down or disconnected by software or internal cable interlocks. The
+5 V output will remain stable for reporting and latching the fault condition.
The return for this signal is the +5 V return. In addition, this shutdown circuit
discharges and latches the +48 V down to a level lower than +15 V in less
than 200 milliseconds and requires recycling of the circuit breaker (On/Off
switch) to reset the latch.
Loss of +48 V is seen by the EC and reported as a fault.
311
Chapter 6 Printer Interface
Printer Interface
The printer interface is the point where the data (signal) cable from the host
computer plugs into the printer. The printer interface processes all signals and
data to and from the host computer.
The printer supports a number of standard and optional interfaces to the host:
computer:
• Centronics parallel (standard)
• IEEE 1284 parallel (standard)
• EIA®-232-E serial (standard)
• EIA-422-B serial (standard, but requires 9-pin/25-pin interface adapter kit)
• CT (Coaxial/Twinaxial) (optional)
• 10/100Base-T Ethernet Network Interface Card (NIC) (optional)
Selection of the interface is controlled by configuration menus accessed at the
control panel. It is possible to physically connect more than one interface, but
only one interface may be electrically active at any given time.
Graphics
The VGL Advanced Graphics programming language (a QMS graphics
emulation) and the PGL Advanced Graphics programming language (a
Printronix IGP emulation) are options that install in flash memory on the
controller board.
These programming languages simplify the job of creating forms, bar codes,
logos, expanded characters, and other graphics. The languages enable the
printer to print sideways, upside down, and to make forms combining
graphics, alphanumeric data, and bar codes—all in a single pass. Documents
explaining configuration, operation, and programming are included with each
option.
312
A Wire Data
NOTE: Abbreviations, acronyms, and signal mnemonics are defined in

Appendix B.
Interconnection Diagram ................................................................. page 315
Cable Routing, Cabinet Model ........................................................ page 316
Cable Routing, Pedestal Model....................................................... page 317
Main Wire Harness Test Tables ...................................................... page 318
Circuit Board Pinouts
PSA3 Controller Board ............................................................. page 319
Power Supply: P7005, P7205, P7010, and P7210 ................... page 327
Power Supply: P7015 and P7215............................................. page 328
Power Supply: P7220 ............................................................... page 329
CT Board .................................................................................. page 330
SureStak Power Stacker PCBA................................................ page 331
Cable Assemblies
Centronics I/O........................................................................... page 332
Dataproducts® Adapter ............................................................ page 333
Twinax Auto-Termination.......................................................... page 334
Cable Extension, Smart-T......................................................... page 335
2-Pin Jumper, 0.1 Ctr................................................................ page 336
AC In, Power Supply................................................................. page 337
AC Power Input......................................................................... page 338
PS I/O ....................................................................................... page 339
Card Cage Fan ......................................................................... page 340
Control Panel ............................................................................ page 341
Exhaust Fan.............................................................................. page 342
Hammer Bank Logic ................................................................. page 343
Hammer Bank Power................................................................ page 344
Hammer Bank Power................................................................ page 345
MPU.......................................................................................... page 346
Ribbon Guide............................................................................ page 347
Ribbon Motor, Extension .......................................................... page 348
313
Appendix A
Shuttle Motor Drive ................................................................... page 349

Power Stacker Cables
Frame Cable, Power Stacker ............................................. page 350
Logic Cable, Power Stacker ............................................... page 351
Power Cable, Power Stacker ............................................. page 352
Rail Cable, Power Stacker ................................................. page 353
Elevator I/O Cable, Power Stacker .................................... page 354
Fan Assembly, Hammer Bank ........................................................ page 355
Magnetic Pickup (MPU) Assembly.................................................. page 356
Switch Assemblies
Switch Assembly, Paper Detector ............................................ page 357
Switch Assembly, Platen Interlock............................................ page 358
314
Interconnection Diagram
P06
J06
HBL =
315
Appendix A
Cable Routing, Cabinet Model
NOTE: P7220 model uses a

unique power supply. See
page 329.
Cabinet Exhaust Fan
316
Cable Routing, Pedestal Model
317
Appendix A

P106 Connector Connectors are viewed P107 Connector
from the top, as seen
19 17 15 13 11 9 7531 when plugged into the 19 17 15 13 11 9 7531
controller board. For
POD CCF PLAT M connector assembly and MPU PLO EHF* PAPR M
disassembly, see page
PMD LRP LRIB M 203. CVO RRP HBF RRIB M
20 18 16 14 12 10 8642 20 18 16 14 12 10 8642
Resistance Pin No. Resistance
Device P106 Pins Normal Device P107 Pins Normal
LRIB M 2, 4 and 6,8 7.2 - 8.8 Ω RRIB M 2, 4 and 6,8 7.2 - 8.8 Ω
PLAT M 1, 3 and 5, 7 1.35 - 1.65 Ω PAPR M 1, 3 and 5, 7 0.417 - 0.681 Ω
LRP 10, 12 Open across pins HBF 10, 12 2.7 KΩ

Short across post
EHF 9, 11 4.6 KΩ
CCF 9, 11 4.6 KΩ
RRP 14, 16 Open across pins
PMD 14, 16 8 Meg Ω Short across post
18, 20 Open
PLO 13, 15 Continuity: switch closed
POD 13, 15 8 Meg Ω Open: switch open
17, 19 Open
CVO 18, 20 Continuity: switch closed
CCF = Card Cage Fan Open: switch open
LRIB M = Left Ribbon Motor
LRP = Left Ribbon Guide MPU 17, 19 670 Ω
PLAT M = Platen Open Motor
PMD = Paper Motion Detector (Switch) CVO = Cover Open Switch (not installed)
POD = Paper Out Detect (Switch) EHF* = Exhaust Fan
HBF = Hammer Bank Fan
MPU = Magnetic Pickup
PAPR M = Paper Feed Motor
PLO = Platen Open (Switch)
RRIB M = Right Ribbon Motor
RRP = Right Ribbon Guide
* JMP on pedestal models, used as a spacer
J106 J107
MOTOR NOTES:
All Motors: Use the table values to test for winding continuity and for no shorts between winding and the
motor frame. Rotate the motor by hand and test for shorts; replace the motor if you find any shorts.
Shuttle Motor = approx. 0.7 - 0.8 Ω per phase, except for the P20Q printer, which shows 0.42 Ω per phase.
Use this value to test for winding continuity and for no shorts between windings and the motor frame. Rotate
the motor by hand and test for shorts; replace the shuttle frame assembly if you find any shorts.
All fans have brushless DC motors powered by solid-state circuits and controlled by feedback from a fan
rotor position Hall Effect sensor. Fans driven by +48V measure 4 - 5 KΩ. Fans driven by +24V measure 2 - 3
KΩ. A very low reading can mean one of the winding drive transistors is shorted. An open circuit could
indicate defective fan electronics or an open cable. Fans will run whenever +48V is present; failure to run
can mean a defective cable, connector, or current sense resistor on the controller board. An open circuit
current sense resistor (on the controller board) will prevent the fan from running but will not allow software to
detect the fault.
318
PSA3 Controller Board
CAUTION: Do not try to remove or replace

the NVRAM. The NVRAM contains a
lithium battery that can explode if replaced
incorrectly. NVRAM is replaced only at the
factory.
Power Supply
J101
Motor Sensor Left 1 N TEMP HI
J106 2 N STDBY
1 PLAT 1 3 VCC1
2 RIB L1 4
3 PLAT 2 5 100 PF .01 µ F 10 µ F
4 RIB L2 6 10% 10% 10%
7 50V 100V 16V TANT
5 PLAT 3
6 RIB L3 +48V 8
7 PLAT 4 9
8 RIB L4 10
CC FAN + +8.5V +48V
9 11
10 L RBN POST + .01 µ F 12
CC FAN - 10% 470 PF
11 470 PF
L RBN POST - 100V 10%
12 10%
POD A 50V
13 50V
14 PMD A
15 POD K Motor Sensor Right
PMD K
16 J107
17 POD C
1 PF 1
18 PMD C RIB R1
2
19 POD E
3 PF 2
20 PMD E
4 RIB R2
5 PF 3
6 RIB R3 +48V
7 PF 4
8 RIB R4
EXH FAN +
9
10
11 EXH FAN - .01 µ F
12 BANK FAN 10%
13 PLAT OPEN SW 100V
14 R RBN POST +
15 PLAT OPEN RET
R RBN POST -
16
17 MPU -
18 COVER OPEN SW
19 MPU +
COVER OPEN RET
20
319
Appendix A
PSA3 Controller Board (continued)
VCC
0 Ohm
0.125W
10K EC BOOT STRAP
Hammer Bank Logic EC Diagnostics 1%
J108 J120 0.1W
+10V SW
1 1 C167 DB TXD
2 HMR DAT COIL 2 C167 DB RXD
50 MHz .01 µ F
3 HMR DAT RET
10% 3
4 HMR CLK 50V 4 NC
5 HMR CLK RET 5 PPR TRIG
6 CMD DAT 6 PPR MOVING
7 CMD DAT RET 7 FT EVENT
8 CMD CLK 8 MPU OUT
9 DMD CLK RET 9 SHUT DIR
10 10
COIL
50 MHz
Hammer Bank Power

J105
1 PH1
2 PH2
3 PH3
PH4
4 LDFB
5
6
7 3300 PF 3300 PF 3300 PF 3300 PF
8 5% 5% 5% 5%
9 100V 100V 100V 100V
10
320
J1
J16
J23 J8
J4
J28 J20
Integrated Print J25
Management System
J1 Sensor
J122
J4
1 2 1
2 BC DATA
J8 3 LED CTRL
4 VCC
J16
J20
J23
J25
J28
2-Pin Jumpers
VCC1
4.7 K External Power
0.1 W EXT 5V
J102
4.7 K 1 10 µ F 1000 PF
0.1 W 2 10% 10%
16V 50V
U58
1 8 0.1 µ F
2 7 20% 1000 PF
3 6
16V 10% 500 Ohm
4 5 NC
PER 50V
LOGIC
HIGH
CHASSIS GND
321
Appendix A
Host RS232
Diagnostic Port
J7
J201
1 NC
2 1 DCD
3 DB TXD 10 2 RXD
4 3 TXD
5 DB RXD 4 DTR
6 NC 5
11 6 DSR
7 NC 470PF
8 NC 10% 7 RTS
50V 8 CTS
9 NC
Shuttle Drive On-Line Verifier

J116 J109
1 EXT 5V
1 SHUT A 2 V TXC C
2 SHUT B 3 V RXD C
3 SHUT C 4 NC
5 NC Control Panel
6 J110
1 N FP DATA AVAIL
Paper Stacker 2
VCC 3 FP CLK
J117 4
STK R NW 470 PF
1 5 N FP LED WR
10%
2 6 FP DATA
50V
3 STK DATA 7
4 8 N FP LCD WR
5 STK LOAD
6
7 STK CLK
8
9 470 PF 470 PF 470 PF 470 PF 470 PF
10 10% 10% 10% 10% 10%
11 NC 50V 50V 50V 50V 50V
12 NC
13 NC
14 NC
322
VDD
Host RS422
J15
2.7K 1
0.1W 2 NC
Paper Feed Motor
3 NC
J103 SOFT ID 4 DIFF TXD+
1 PF 4 5 DIFF TXD-
6 NC
2 PF 3
7 NC
3 PF 2
8 DIFF RXD+
4 PF 1
J9 1 2 3 9 DIFF RXD-
10 NC
Software Security Key
Not
Used VCC +48V
J6
1
Phase Driver Port 2 SDA
J115 3
1 UD 1 4 SCL
2 5
UD 2
3 6 NC
PH REF
4 7 VCC
5 UD 3 8
6 UD 4 9
7 10
11 RN7 RN7 RN7 RN7
8 DIODE 1 1K 1K 1K
12 CPLD Program Port 1K
9 DIODE 2
10 13 NC J2
11 14 NC 1 LC TCK
12 DIODE 3 15 2
13 DIODE 4 16 3 LC TDI
14 N COILTEST 4
15 5 LC TMS
16 CABLE DET 6 NC
17 HD SENSE 7 NC
18 LDFB 8 NC
19 9 LC TDO
20 10
323
Appendix A
J12
VDD PCI Connection VDD
VCC1 VCC1
B1 RSV RSV A1
B2 RSV RSV A2
B3 GND RSV A3
B4 RSV RSV A4
B5 5V 5V A5
B6 5V NINTA A6 NIRQ1
NINTB B7 NINTB NINTC A7 NINTC
NINTD B8 NINTD 5V A8
NPRSNT2 B9 NPRSNT1 RSV A9
B10 RSV 3.3V A10
B12 KEY KEY A12
B13 KEY KEY A13
B14 RSV 3.3VAUX A14
B15 GND NRST A15 PCI_NRST
CLK1 B16 CLK 3.3V A16
B17 GND NGNT A17 NGNT1
NREQ1 B18 NREQ GND A18
B19 3.3V NPME A19
AD31 B20 AD31 AD30 A20 AD30
AD29 B21 AD29 3.3V A21
B22 GND AD28 A22 AD28
AD27 B23 AD27 AD26 A23 AD26
AD25 B24 AD25 GND A24
B25 3.3V AD24 A25 AD24
NC_BE3 B26 NC/BE3 IDSEL A26 IDSEL1
AD23 B27 AD23 3.3V A27
AD21 B29 AD21 AD20 A29 AD20
B31 3.3V AD18 A31 AD18
AD17 B32 AD17 AD16 A32 AD16
NC_BE2 B33 NC/BE2 3.3V A33
B34 GND NFRAME A34 NFRAME
NIRDY B35 NIRDY GND A35
B36 3.3V NTRDY A36 NTRDY
NDEVSEL B37 NDEVSEL GND A37
B38 GND NSTOP A38 NSTOP
B39 NLOCK 3.3V A39
NPERR B40 NPERR RSV A40
B41 3.3V RSV A41
NSERR B42 NSERR GND A42
B43 3.3V PAR A43 PAR
NC_BE1 B44 NC/BE1 AD15 A44 AD15
AD14 B45 AD14 3.3V A45
AD12 B47 AD12 AD11 A47 AD11
B49 M66EN AD9 A49 AD9
B50 GND GND A50
B51 GND GND A51
AD8 B52 AD8 NC/BE0 A52 NC_BE0
AD7 B53 AD7 3.3V A53
B54 3.3V AD6 A54 AD6
AD5 B55 AD5 AD4 A55 AD4
AD3 B56 AD3 GND A56
B57 GND AD2 A57 AD2
B59 3.3V 3.3V A59
B60 I2CDATA I2CCLK A60
B61 5V 5V A61
B62 5V 5V A62
0 Ohm 0 Ohm
0W 0W
0% 0%
Slot 1
SDA SCL
324
J13
VDD PCI Connection VDD
VCC1 VCC1
B1 RSV RSV A1
B2 RSV RSV A2
B3 GND RSV A3
B4 RSV RSV A4
B5 5V 5V A5
B6 5V NINTA A6 NIRQ2
NINTB B7 NINTB NINTC A7 NINTC
NINTD B8 NINTD 5V A8
B10 RSV 3.3V A10
B12 KEY KEY A12
B13 KEY KEY A13
B14 RSV 3.3VAUX A14
B15 GND NRST A15 PCI_NRST
CLK2 B16 CLK 3.3V A16
B17 GND NGNT A17 NGNT2
NREQ2 B18 NREQ GND A18
B19 3.3V NPME A19
AD31 B20 AD31 AD30 A20 AD30
AD29 B21 AD29 3.3V A21
AD27 B23 AD27 AD26 A23 AD26
B25 3.3V AD24 A25 AD24
NC_BE3 B26 NC/BE3 IDSEL A26 IDSEL2
AD23 B27 AD23 3.3V A27
AD21 B29 AD21 AD20 A29 AD20
B31 3.3V AD18 A31 AD18
AD17 B32 AD17 AD16 A32 AD16
NC_BE2 B33 NC/BE2 3.3V A33
B34 GND NFRAME A34 NFRAME
NIRDY B35 NIRDY GND A35
B36 3.3V NTRDY A36 NTRDY
NDEVSEL B37 NDEVSEL GND A37
B38 GND NSTOP A38 NSTOP
B39 NLOCK 3.3V A39
NPERR B40 NPERR RSV A40
B41 3.3V RSV A41
NSERR B42 NSERR GND A42
B43 3.3V PAR A43 PAR
NC_BE1 B44 NC/BE1 AD15 A44 AD15
AD14 B45 AD14 3.3V A45
AD12 B47 AD12 AD11 A47 AD11
B49 M66EN AD9 A49 AD9
B50 GND GND A50
B51 GND GND A51
AD8 B52 AD8 NC/BE0 A52 NC_BE0
AD7 B53 AD7 3.3V A53
B54 3.3V AD6 A54 AD6
AD3 B56 AD3 GND A56
B57 GND AD2 A57 AD2
B59 3.3V 3.3V A59
B60 I2CDATA I2CCLK A60
B61 5V 5V A61
B62 5V 5V A62
0 Ohm 0 Ohm
0W 0W
0% 0%
Slot 2
SDA SCL
325
Appendix A
Centronics Connector
J112
1 N STROBE
2
3 P1
4
5 P2
6
7 P3
8
9 P4
10
11 P5
12
13 P6
14
15 P7
16
17 P8
18
19 N ACK
20
21 BUSY
22
23 PAPER EMPTY
24
25 SELECT
26 N INIT
27 N AUTOFEED
28 N FAULT
29 PI
30 VCC1
31
32 4.7K
33 0.1W
34 NDPSEL
35 EXT 5V
36 N SELECT IN
37 HOST LOGIC H
38 NDPEN
10K
39 1%
40 0.1W
CHASSIS GND
326
Power Supply: P7005, P7205, P7010, and P7210
J1 Cable Assembly
AC 1 1 AC In
Power Supply P101
AC Common 2 P1 2
Chassis Ground 3 3 White 1 N TEMP HI
Orange 2 N STDBY
LOAD
Red 3 +5V
Red 4 +5V
Black 5 +5V RTN
= FAST-ON TERMINAL
Black 6 +5V RTN
Brown 7 +48V / +8.5V RTN
LOAD = RING TERMINAL Brown 8 +48V / +8.5V RTN
Yellow 9 +8.5V
Yellow 10 +8.5V
Blue 11 +48V
Blue 12 +48V
GND
327
Appendix A
Power Supply: P7015 and P7215
(Line Filter Area)
1 AC Input
AC
AC COMMON
CHASSIS GND
J1
P101
1 NACFAIL (Not AC Fail)

Cable Assembly
AC In 1 2 NSTBY (Not Standby)
Power Supply P1 2 3 +5 Volts
3 4 +5 Volts
5 +5 Return / Logic GND
LOAD 6 +5 Return / Logic GND
7 +48 / +8.5 Return
= FAST-ON TERMINAL 8 +48 / +8.5 Return
9 +8.5 Volts
= RING TERMINAL 10 +8.5 Volts
LOAD 11 +48 Volts
12 +48 Volts
GND
328
Power Supply: P7220
(Phase Driver Control)
1 UD 1
2 UD 2
3 +2.5V reference
4
(Phase Driver Power) 5 UD 3
6 UD 4
1 PH1
7
2 8 DIODE 1
3 PH2
9 DIODE 2
4 10
5 PH3
11
6 12 DIODE 3
7 PH4
13 DIODE 4
8 14 N COILTEST
9 LDFB OPTO RET
15
10 16 CABLE DET
Chassis GND 17 HD SENSE
18 LDFB BUF
19
20
Controller GND
(Line Filter Area)
J2
AC Input
J1
AC
AC Common
Chassis Ground
1
2 P1 1 NACFAIL (Not AC Fail)
3 2 NSTBY (Not Standby)
LOAD 3 +5 Volts
4 +5 Volts
= FAST-ON TERMINAL
7 +48 / +8.5 Return
= RING TERMINAL
LOAD 8 +48 / +8.5 Return
9 +8.5 Volts
10 +8.5 Volts
11 +48 Volts
12 +48 Volts
GND
329
Appendix A
CT Board
Twinax Connection
J2
1 NC
2 NC
3 NC
4 NC
16
5
6 NC
7 TWINAX PHASE A
8 NC
17 9 NC
10 NC
11 NC
12 NC
13 NC
14 TWINAX PHASE B
15 NC
Coax Connection
J3
1
COAX DATA 2
9400 pF, 1500 V Built-in

COAX SHIELD capacitor coax shield to
frame ground
.01 µ F
10%
500V
330
J1 J2 VCC J3
Test Test Limit Switches and
Elevator Motor
1 1 SKP DB TXD 1
2 N RESET 2 SKP DB RXD 2 STK FULL SWT
3 N 42V FAIL 3 3 FULL SWT RET
4 PMD SIG 4 LIMIT SIG 4 STK LIMIT SWT
5 PAP IN SIG 5 FULL SIG 5 LIMIT SWT RET
6 SW1 6 BEAM SIG 6 EL PHA 1
7 SW2 7 N PD FLT 7 EL PHA 2 Elevator
ELEVATOR Motor:
MOTOR:
8 SW3 8 N EL FLT 8 EL PHB 1 Resistance
RESISTANCE==15.2 1.5W
15.2 ± 1.5
/ PHASE
Ohm / Phase
9 SW4 9 N PI FLT 9 EL PHB 2
10 HW1 HW3 HW5
10 10
HW2 HW4
+48V
J6
J6
Power
Power +5 V
Supply
Supply
11 J4
P102
2 FRAME Motors
3 + + + + CABLE
and Sensors
4 10 mF 10 mF 10 mF 10 mF
10% 10% 10% 10% 1
10V 10V 10V 10V M1 A1 2 PD PHA 1 M1
M1 =
= REAR PADDLE
REARPADDLE
MOTOR
MOTOR
M1 A2 3 RESISTANCE = 15.2
M1 B1 4 PD PHB 1 Resistance = 15.2 ± 1.5
1.5 W / PHASE
J3 M1 B2 5 Ohm / Phase

J5 M2 A1 6 M2 FRONT
M2==FRONT PADDLE
PADDLE
M2 A2 7 PD PHA 2 MOTOR
MOTOR
J4 M2 B1 8 PD PHB 2 RESISTANCE = 15.2
J7 J6
Resistance =
1.5 W / PHASE15.2 ± 1.5
M2 B2 9 Ohm / Phase

10
PI PHA 1 11 PI PHA 1 PINCH ROLLER
PINCH ROLLER
PI PHA 2 12 PI PHA 2 MOTOR
SureStak Power Stacker PCBA
MOTOR
VCC PI PHB 1 13 PI PHB 1 RESISTANCE = 15.2
PI PHB 2 PI PHB 2
Resistance = 15.2 ± 1.5
1.5 W / PHASE
14
Ohm / Phase

15
LD1 A 16 IR LED A
LD1 K 17
DT1 C 18 IR DET C
DT1 E 19
J7 10K 10K 10K 10K LD2 A 20 0.1 mF
0.1W 0.1W 0.1W 0.1W 20%
LD2 K 21 IR LED K 50V
Stacker DT2 C 22
R/NW IR DET E
Logic 33 DT2 E 23
PID A
0.1W 24
1 DATA PID K
25 PID C
2 33 26
0.1W 0.1 mF
3 LOAD 27 20%
4 33 28 50V
5 0.1W 29 PID E
CLK
6 30 PMD C
33
7 0.1W 31
LOGIC CON 0.1 mF
8 32 PMD A 20%
9 100 PF 100 PF 100 PF 100 PF 100 PF PMD K 50V
10% 10% 10% 10% 10%
33
10 1K 50V 50V 50V 50V 50V 34
0.1W 35 PMD E
SW EL DEN
36
37 NC
38 NC
331
39 NC
40 NC
Appendix A
Cable Assembly, Centronics I/O (P/N 152439-901)
PIN 1
NOTE:
If you replace the I/O cable
assembly, you must install
the ferrite clamp.
See Appendix E.
PIN 1
332
Cable Assembly, Centronics-to-Dataproducts Adapter
(P/N 154695-001)
333
Appendix A
Cable Assembly, Twinax Auto-Termination (P/N 140752-002)
Jack
1 2
White
14
Gray
7
Shield
5
Resistance Chart
Pin Pin Ohms

1 2 110
3 4 110
1, 2, 3, 4 Shield 55
5 Shield 0
14 1, 4 0
3 4 7 2, 3 0
Jack
334
Cable Extension, Smart-T (P/N 204806-901)
Pin 1 Pin 1
335
Appendix A
Cable Assembly, 2-Pin Jumper, 0.1 Ctr (P/N 154470-901)
336
Cable Assembly, AC In, Power Supply
(AC Kit P/N 153502-901)
To Circuit Breaker
To Power Supply J1
337
Appendix A
Cable Assembly, AC Power Input (AC Kit P/N 153502-901)
To Circuit Breaker
Input Power Connector
338
NOTE:
Cable Assy, PS I/O (P/N 176601-901)
This cable is used on

the P7220 printer.
339
Appendix A
Cable Assembly, Card Cage Fan (P/N 152422-901)
PIN 1
PIN 1
340
Cable Assembly, Control Panel (P/N 152440-901)
PIN 8
(Brown)
PIN 1
(Gray)
PIN 8
(Brown)
PIN 1
(Gray)
341
Appendix A
Cable Assembly, Exhaust Fan (P/N 152424-901)
PIN 1
PIN 1
342
Cable Assembly, Hammer Bank Logic (P/N 152421-901)
To Shuttle To Controller Board
343
Appendix A
Cable Assy, Hammer Bank Power (P/N 164805-901)
IMPORTANT:
Use this cable on all P7000 printers
except the P7220. On the P7220
use P/N 173215-901, shown on the
next page.
To Controller Board
To Shuttle
Wire Table
P05 P105
2 1
1 2
4 3
3 4
6 5
5 6
8 7
7 8
10 9
9 10
344
Cable Assy, Dual Hammer Bank Power (P/N 173215-901)
IMPORTANT:
Use this cable on the P7220. On all
other P7000 printers use P/N
164805-901, shown on the
previous page.
To Shuttle To Power Supply
P06 P3
Wire Table
P06 P3
2 1
1 2
4 3
3 4
6 5
5 6
8 7
7 8
10 9
9 10
345
Appendix A
Cable Assembly, MPU (P/N 152425-901)
PIN 2 PIN 3
PIN 1
PIN 1
346
Cable Assembly, Ribbon Guide, P7000
Left: 178992-001
Right: 178992-002
Pin Connection
P106 (LRP) / P107 (RRP) Wire Color
Pin 1 Black
Pin 2 Black
Left Guide = P106 / LRP

Right Guide = P107 / RRP
Pin 2 Pin 1
347
Appendix A
Cable Assembly, Ribbon Motor, Extension (P/N 154067-901)
348
Cable Assembly, Shuttle Motor Drive (P/N 152420-001)
349
Appendix A
Frame Cable, Power Stacker (P/N 173824-001)
350
Logic Cable, Power Stacker (P/N 176029-001)
351
Appendix A
Power Cable, Power Stacker (P/N 174414-001)
P1101
P1101
352
Rail Cable, Power Stacker (P/N 173823-001)
353
Appendix A
Elevator I/O Cable, Power Stacker (P/N 174759-001)
354
Fan Assembly, Hammer Bank (P/N 152416-901)
P107 / HBF
P107/HBF
355
Appendix A
Magnetic Pickup (MPU) Assembly (P/N 150281-901)
356
Switch Assembly, Paper Detector (P/N 152415-901)
357
Appendix A
Switch Assembly, Platen Interlock (P/N 152417-901)
P107/PLO
358
B Abbreviations
NOTE: Signal abbreviations with first letter “N” are negative true.
Abbreviation Definition
KΩ 1,000 Ohms
MegΩ 1,000,000 Ohms
µF microfarad (10-6 farad)
µs microsecond (10-6 second)
µsec microsecond (10-6 second)
A0, A1, etc. Address 0, Address 1, etc.

AC Alternating Current
ACC Access
ACK Acknowledge
AMP Amplitude; Ampere
AMPL Amplitude
AN Anode
ASIC Application-Specific Integrated Circuit
ATTN Attention
B Buffered
BANK FAN Hammer Bank Fan
BCOM Buffered Communication
BCP Bi-phase Communications Processor
BHSC Buffered Hammer Shift Clock
BN Buffered, Low True
BNLD Buffered, Low True, Lower Driver
BPS Bits Per Second
BSY Busy
BTU British Thermal Unit
BUD Buffered Upper Driver
359
Appendix B
CA Cathode
CC Card Cage
CCF Card Cage Fan
CHNG Change
CIR Circuit
CLK Clock
CO Cover Open
COLL Collector
COMM Communication
CONTLR Controller
CMD Command
CNC Connector, Connection
CPI Characters Per Inch
CR Carriage Return
CT Coaxial/Twinaxial (“Coax/Twinax”)
CTL Control
CTS Clear to Send
CU Control Unit
CUR Current
D0, D1, etc. Data Bit 0, Data Bit 1, etc.

DAT Data
DBCS Double Byte Character Set
DC Direct Current, Data Controller (a functional unit of
the controller board)
DCD Data Carrier Detect
DIAG Diagnostic
DIFF Differential
DIMM Dual Inline Memory Module
DMA Direct Memory Access
DP Data Processing, Dataproducts
DPEN Dataproducts Enable
DPMC Dot Plucker Memory Controller
DPU Data Processing Unit
DRAM Dynamic Random Access Memory
DRV Drive or Driver
DRVR Driver
360
DSR Data Set Ready
DTR Data Terminal Ready
EC Engine Controller (a functional unit of the

controller board)
EEPROM Electrically Erasable/Programmable Read-Only
Memory
EHF Exhaust Fan
EL Elevator motor (power stacker)
EMI ElectroMagnetic Interference
EMIT Emitter
EPROM Electrically Programmable Read-Only Memory
ERR Error
ESD Electrostatic Discharge
EX Exhaust, Extra
EXH Exhaust
EXF Exhaust Fan
EXP Expansion
EXPND Expand
FD Feed
FF Form Feed
FIFO First In, First Out
FLT Fault
FLTR Filter
FP Front Panel (Control Panel)
FTIC Fire Timer Integrated Circuit
GND Ground
HB Hammer Bank
HBA Hammer Bank ASIC
HBF Hammer Bank Fan
HBL Hammer Bank, Left
HBP Hammer Bank Power
HBR Hammer Bank, Right
HD Hammer Driver
HDIC Hammer Driver Integrated Circuit
361
Appendix B
HDPH Hammer Driver Phase

HLP Hammer Bank Logic, Signals, and Power
HW Hardware
IC Integrated Circuit
ID Identification
IGP Intelligent Graphics Printing
INST Instruction
INT Interrupt
I/O Input/Output
IPB Illustrated Parts Breakdown
IRQ Interrupt Request
(J) Jack connector

JEDEC Joint Electron Device Engineering Council. An organization
that sets standards for electronic devices and components.
L Left
LAN Local Area Network
LCD Liquid Crystal Display
LED Light-Emitting Diode
LF Line Feed
LO Low
LPI Lines Per Inch
LPM Lines Per Minute
LRIB Left Ribbon
LRP Left Ribbon Guide
M Motor
MAIN Maintenance Jack, RS-232 (Optional)
MECA Mechanism Engine Control ASIC
MECH Mechanism
MF microfarad (10-6 farad)
MH Mounting Hole, Main Harness
MOSFET Metal Oxide Semiconductor Field Effect
Transistor
MOT Motor
MPU Magnetic Pick-Up (Unit)
362
ms millisecond (10-3 second)
MSL Motor and Sensors, Left
MSR Motor and Sensors, Right
N Negative True
NIC Network Interface Card (ethernet interface)
N/C Not Connected
NC Not Connected
NLQ Near Letter Quality
No. Number
NOVRAM Nonvolatile Random Access Memory
ns nanosecond (10-9 second)
NT Not
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer

OLV On Line Verify
OP Operand
P5 + 5 VDC
(P) Pin connector
P(1), P(2), etc. Parallel data 1, data 2, etc.
PAL Programmable Array Logic
PAP Paper
PAPR Paper
PARM Parameter
PCBA Printed Circuit Board Assembly
PCB Printed Circuit Board
PCI Peripheral Component Interconnect
PD Paper Detect(or)
PE Printer Error, Paper Empty
PER Peripheral Device
PF Paper Feed, picofarad (10-12 farad)
PFC Paper Feed Controller, Power Factor Corrected (a power
supply used on 500 lpm and 1000 lpm printers)
PFM Paper Feed Motor
PGL Printronix Graphics Language
PHA Phase A
363
Appendix B
PHB Phase B
PI Paper Instruction
PLAT Platen
PLM Platen Motor
PLO Platen Open Switch
PMD Paper Motion Detect
PN Pin or Plug
P/N Part Number
PO Paper Out
POD Paper Out Detector Switch
PPR Paper
PROM Programmable Read-Only Memory
PS Power Supply
PS5 Power Supply + 5 Volt
PSA3 Printronix System Architecture, Third Generation
PTR Pointer, Printer
PWM Pulse Width Modulation
PWR Power
R Right
RBN Ribbon
RD Read
RDY Ready
RET Return
RIB Ribbon
RG Ribbon Guide
RGL Ribbon Guide, Left
RGR Ribbon Guide, Right
RM Ribbon Motor
RML Ribbon Motor, Left
RMR Ribbon Motor, Right
RQ Request
RRIB Right Ribbon
RRP Right Ribbon Guide
RSP Ribbon and Shuttle Processor
RST Reset
RTS Request to Send
364
RXD Receive Data
SCS SNA Character Stream

SDRAM Synchronous Dynamic Random Access Memory
SEC Security (Key)
SEL Select
SEN Sense, Sensor
SF Structured Field
SG Signal Ground
SHH Shuttle Hall (Effect)
SHM Shuttle Motor
SHUT Shuttle
SHUTL Shuttle
SIMM Single Inline Memory Module
SLCT Select (Online)
Slew Rapid vertical paper movement
SMD Shuttle Motor Drive
SNA Systems Network Architecture
SOFT Software
SPU Shuttle Processor Unit
SPX Software Program Exchange module
SRAM Static Random Access Memory
STAT Status or State
STBY Standby
STK Stacker
SW Switch, Software
SYNC Synchronize
TCB Task Control Block

TEMP Temperature; Temporary
TOF Top Of Form (first print line)
TP Test Point
TTL Transistor-Transistor Logic
TXD Transmit Data
UART Universal Asynchronous Receiver/Transmitter

UDPH Upper Drive Phase
365
Appendix B
UNDEF Undefined
USART Universal Synchronous/Asynchronous Receiver/
Transmitter
V Volts
VAC Volts, Alternating Current
VDC Volts, Direct Current
VCC Voltage at Collector
VDD Voltage at Drain
VGL Code V™ Graphics Language
VSS Voltage at Source
V8 A special ASIC on the controller board
containing circuits that help the data controller (DC)
operate.
WR Write
w/ With
w/o Without
XMT Transmit
ZTP Zero Tear Pedestal
366
C Metric Conversion Tables
Length
Multiply By To Obtain
foot 0.3048* meter (m)

foot 30.48* centimeter (cm)
foot 304.8* millimeter (mm)
inch 0.0254* meter (m)

inch 2.54* centimeter (cm)
inch 25.4* millimeter (mm)
meter 3.280840 foot
centimeter 0.03280840 foot
millimeter 0.003280840 foot
meter 39.37008 inch
centimeter 0.3937008 inch
millimeter 0.03937008 inch
* Figure is exact.
Torque and Force
pound-inch 0.11298 Newton-meter (N•M)
pound-foot 1.3558 Newton-meter (N•M)
Newton-meter (N•M) 8.8511 pound-inch

Newton-meter (N•M) 0.7376 pound-foot
pound 4.4482 Newton (N)
Newton (N) 0.22481 pound
367
Appendix C
Mass and Density
pound* 0.4535924 kilogram (kg)

ounce* 28.34952 gram (g)
kilogram 2.204622 pound*
gram 0.03527393 ounce*

* avoirdupois
Temperature
To Convert To Use Formula
temperature Celsius (tc) temperature Fahreheit (tf) tf = 1.8 tc + 32
temperature Fahreheit (tf) temperature Celsius (tc) tc = (tf - 32) / 1.8
Power
Btu (International Table)/ 0.2930711 watt (W)

hour
watt (W) 3.412141 Btu (International Table)/

hour
watt (W) 0.001359621 horsepower (metric)
horsepower (metric) 735.499 watt (W)
368
D SureStak™ Power Stacker
Contents
Introduction ..................................................................................... page 370
Stacker Operation ........................................................................... page 370
Setting Up The Power Stacker ................................................. page 371
Loading And Starting The Power Stacker................................. page 374
Stacker Operation ........................................................................... page 375
Removing The Power Stacker ........................................................ page 380
Installing The Power Stacker .......................................................... page 386
Replacement Procedures
Constant Force Spring.............................................................. page 397
Timing Belts .............................................................................. page 399
Roller Drive Shaft...................................................................... page 402
Illustrated Parts Breakdown ............................................................ page 405
369
Appendix D Introduction
Introduction
The SureStak Power Stacker is a factory-installed option that augments the
paper feed system of cabinet model printers. It is designed to work with forms
5 to 12 inches long (12.7 to 30.5 cm) and up to 16 inches (41 cm) wide without
the paper tent installed or up to 15.5 inches (39.5 cm) wide with the paper tent
installed. (See Figure 63.) Using longer or shorter paper can cause error
messages and unpredictable operation of the stacker.
Because most of the stacker assembly is inside the cabinet, you must remove
the stacker from the printer to service it or replace most of its components.
This appendix has three parts:
• An overview of stacker operation.
• Removal/installation instructions for the entire power stacker assembly
and for components that require the most frequent replacement.
• An illustrated parts breakdown (IPB) showing how the power stacker is
assembled and listing the part numbers for replaceable parts.
NOTE: Only replaceable parts have part numbers in the IPB. If you need to
replace a part for which no part number is shown, replace the entire
stacker assembly.
Stacker Operation
The power stacker mechanically directs the paper from the printer to the
paper stack. It is mounted in the rear of the cabinet and has its own control
panel. Its main components are shown in Figure 63.
Paper Throat
Rear Control
Panel
Elevator
Disable Switch Pinch Rollers
Elevator Lift
Handle
Paper Length
Indicator
Bearing Bracket Paper Tent
Paddle Shaft
Figure 63. Power Stacker Component Locations
370
Setting Up The Power Stacker
1. Set the printer power switch to | (On).
2. On the rear control panel, press the ON LINE key to take the printer
offline. (Figure 64.)
3. Press the ELEVATOR UP key and wait for the elevator assembly to
reach the top of its travel. (Figure 64.)
ON LINE
PAPER ADVANCE
ELEVATOR UP
ELEVATOR DOWN
Figure 64. The Rear Control Panel
371
Appendix D Stacker Operation
4. If the paper you will use is not wider than 15.5 inches (39.5 cm) pull out
the paper tray and install the wireform paper tent. (Figure 65.) If the paper
is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer.
Paper Tent
Paper Tray
Note the positions of

alignment tab and the
paper fence.
Figure 65. The Paper Tent
372
5. Push or pull the paddle shaft toward the front or the rear of the printer to
set the desired paper length. Align the indicator notch on the bearing
bracket with the paper length indicator. The power stacker can handle
paper or forms from 5 to 12 inches (12.7 to 30.5 cm) long. (Figure 66.)
Paddle Shaft
Paper Length Indicator
Bearing Bracket
Figure 66. The Paper Length Indicator
373
Appendix D Stacker Operation
Loading And Starting The Power Stacker

1. Press the PAPER ADVANCE key and hand feed the paper down into the
paper throat of the stacker. Continue to advance the paper until it reaches
the paper tent (if installed) and feed three to five extra sheets into the
stacker. Make sure the paper passes through the paper throat of the
stacker. (Figure 67.)
2. Stack the extra pages on top of the wire paper tent (if installed), making
sure the paper bends with the natural fold. (Figure 67.)
3. Press the ON LINE key to put the printer in the online state. The stacker
elevator will return to the correct position for printing.
4. Check that the paper is still centered between the sides of the paper tent
(if installed).
5. Close the cabinet rear door.
6. If necessary, set Top Of Form. (Refer to the User’s Manual.)
A
ON LINE
PAPER
ADVANCE
A
Figure 67. Stacking Paper on the Wire Paper Tent
374
Stacker First Inspection
Stacker Problems
The power stacker augments the paper feed system of the printer. The most
frequently occurring problems in the paper feed system are paper jams.
Because of the electromechanical nature of the system, other problems that
can occur are worn or poor electrical connections and cabling, worn or
defective feed motors, worn or damaged mechanical components, or
incorrect installation of the stacker assembly. Table 7 shows some of the
problems that can occur with the power stacker and the page where you can
find the troubleshooting procedure.
Stacker First Inspection

NOTE: Do this inspection before doing any other troubleshooting or repair
work on the power stacker.
1. Verify that the elevator seats all the way down on its left and right hand
stops without having to force it down or hold it in position.
a. If necessary, correct improper seating by moving the elevator all the
way down to the bottom of its travel and loosen the drive belt pulley
on the side(s) that does not seat properly.
b. While holding the elevator in the fully down position, tighten the pulley
setscrews.
c. Verify that the elevator seats against both stops.
ATTENTION While doing the next step, make sure the idler rollers do not interfere
with the drive rollers as they move along the drive shaft.
2. Verify that the friction washers do not bind on the driver shaft.
a. Manually retract and hold the idler roller shaft so the paper throat is
open. While the throat is open, slide the drive roller on one end
toward the center of the shaft.
b. Wipe a finger across the shaft and check for lubricant.
c. Release the drive roller and allow it to spring back into position along
the drive shaft.
d. Repeat substeps a, b, and c on the other end of the driver shaft.
e. Verify that there was no oil on the shafts.
f. If the drive rollers returned to position without hanging up on the
shaft, they are not binding and are OK.
g. If there was oil on the shafts or the drive rollers hung up on the shaft,
replace the roller drive shaft (page 402).
3. Power on the printer and move the stacker elevator up and down using
the ELEVATOR UP and ELEVATOR DOWN keys on the rear operator
panel.
a. Check the stacker limit switches (page 118).
b. Move the elevator up and down using the ELEVATOR UP and
ELEVATOR DOWN keys on the rear operator panel. While the
375
Appendix D Stacker Problems
elevator is moving, press the ELEVATOR UP or ELEVATOR DOWN

key. Elevator motion should stop.
c. With the elevator at its lowest position, run the Shuttle Slow test ()
from the front operator panel. While the test runs, interrupt both IR
beams, one at a time, and verify that the elevator rises.
d. With the Shuttle Slow test running, verify that:
- Both paddle shafts rotate downwards towards the paper stack;
- While holding each of the idler rollers one at a time, the rest of the
idler assembly continues to rotate freely;
- That the pinch rollers are rotating downwards at the pinch point;
- With the elevator at its lowest position, create a stack of four
continuous forms. Press the FORM FEED key on rear operator panel.
All of the forms should pass through the pinch rollers and stack
normally.
Stacker Confidence Check

1. Verify that all cables are properly connected at the back of the rear control
panel.
2. From the rear control panel, do and observe the following:
a. Power on the printer and make sure it goes the READY state.
b. The green LED should be on.
c. Press the ON LINE key and observe the yellow LED. The yellow LED
should come on when the printer is online.
d. The yellow LED should be off when the printer is offline.
e. Press the PAPER ADVANCE (down arrow) key. The printer should
do a form feed every time you press this key.
f. Press and release the ELEVATOR UP key. The elevator should go
up.
g. Press and release the ELEVATOR DOWN key. The elevator should
go down.
3. Disable the power stacker from the configuration menu using the front
operator panel. With the printer in the offline state, press the ELEVATOR
UP key on the rear control panel. The elevator should move upward and
automatically stop when it reaches its highest position. (Do NOT force it
up.)
4. Using the heaviest form available, slide the form over the paper path and
into the stacker throat. It should be able to go through the stacker throat
without having to force it. If the form cannot go through the stacker throat,
do the STACKER JAM troubleshooting procedure on page 103.
5. With the power stacker still at its highest position, enable the power
stacker using the configuration menu atthe front operator panel. Put the
printer in READY state. The stacker elevator should automatically go to
the lowest position possible, depending on how much paper is in the
stacker tray.
376
Stacker Motor Check
6. Using the rear operator panel, press the PAPER ADVANCE (down arrow)
key until three or four pages feed through the stacker throat.
a. Check the LCD on the front operator panel for faults. If there is a fault,
the paper out detector is failing and needs to be checked and
cleaned.
b. If there are no faults on the LCD, load the forms in the printer and
through the stacker throat. Feed enough forms into the stacker so
that they fold properly in the tray or stacker base.
7. Run a Ripple Print or All H’s print test (page 134), and make sure that
both rows of rubber paddles are rotating inward and the pinch rollers are
rotating downward.
8. Run the All E’s + FF test (page 134) for ten pages. The stacker should
stack and fold the paper without errors.
9. Move the elevator up approximately one inch and cover the emitter with
opaque or black tape. From your laptop or the host computer, run a
multiple page print job. The elevator should start to move upward about
1/2 inch every three seconds until it reaches its topmost position. The
LCD should display STACKER FULL when the elevator reaches the top
of its travel.
10. Lower the elebator by pressing ELEVATOR DOWN key. The elevator
should stop at its bottom position without motor noise. If you hear motor
noise, do the “Stacker ‘chatters’ at upper or lower limit” procedure on
page 116.
11. Set the elevator at the lowest position permitted by the amount of paper
stacked in the tray. Run an operator print test and induce a paper jam
before the paper throat of the power stacker. STACKER JAM should
display on the front operator panel.
12. If the stacker has not failed any test up to this point, the stacker checks
out OK. If errors occurred during these checks refer to Table 4 on page
39 and troubleshoot the appropriate symptom. When the stacker is
operational, clear the error log and place the printer online.
Stacker Motor Check

2. Open the rear cabinet door.
3. Unfasten the cable clamp holding the stacker control panel cables.
4. Disconnect stacker rail cable connector P107 from J3 on the back of the
stacker operator panel.
5. Disconnect stacker frame cable connector P102 from connector J4 on the
back of the stacker operator panel.
6. Find pin 1 of connectors P107 and P102.
7. Check both cables for damaged pins, continuity, and shorts.
8. Check all four stacker motors for 15.2 ± 1.5 Ohms resistance per phase.
All four motors are the same:
Measure pin 1 to pin 2 for Phase A
377
Appendix D Stacker Problems
Measure pin 3 to pin 4 for Phase B

pin 1 = red
pin 2 = yellow
pin 3 = orange
pin 4 = brown
a. Elevator motor assembly connector J3, pins 6, 7, 8, and 9
b. Rear paddle motor assembly (M1) connector J4 pins 2, 3, 4, and 5
c. Front paddle motor assembly (M2) connector J4 pins 6, 7, 8, and 9
d. Pinch roller motor assembly connector J4 pins 11, 12, 13, and 14
9. Replace any cable that is damaged or fails continuity/shorts check.
10. Replace any motor that fails the resistance check.
Table 7. Power Stacker Problems
Symptom Origin of Symptom Explanation Solution
Printer does not detect Reported by user. Various causes possible. page 115
presence of power
stacker
STACKER FAULT Message on control This message is triggered page 101

panel LCD. when the elevator cannot
reach the top or bottom limit
switch before timing out.
STACKER FULL Message on control Status message: the power page 102
panel LCD. paper stacker is full.
STACKER JAM Message on control Paper is bunching above the page 103
panel LCD. elevator or the paper motion
detector is not working
properly.
Stacker “chatters” at Reported by user. Various causes possible. page 116

upper or lower limit
Stacker does not stack Reported by user. Various causes possible. page 117
properly
Stacker elevator does Reported by user. Various causes possible. page 117
not move
Stacker elevator moves Reported by user. Various causes possible. page 117
by itself
378
Stacker Motor Check
Table 7. Power Stacker Problems
Symptom Origin of Symptom Explanation Solution
Stacker limit switch Other troubleshooting A procedure that tests the page 118
check procedures. motion limit switch at the top
and bottom of the right
vertical rail. You will usually
be referred to this procedure
from other troubleshooting
procedures. When you have
completed this procedure,
return to the procedure that
sent you there.
Stacker motor check Other troubleshooting A procedure that tests the page 119
procedures. four stacker motors and their
cables. You will usually be
referred to this procedure
from other troubleshooting
procedures. When you have
completed the procedure,
return to the procedure that
sent you there.
Stacker not operating Reported by user. Same symptom as “Printer page 115
does not detect presence of
power stacker”
379
Appendix D Removing The Power Stacker
Removing The Power Stacker

2. Unplug the power cord.
3. Unload paper from the stacker area. (Refer to the User’s Manual.)
4. Remove the paper tent (if present). (Figure 68.)
Paper Tent
Figure 68. Removing the Paper Tent

5. Cut the tie wrap (if present) and remove the paper fence. (Figure 69.)
Paper
Fence Stacker
Base
Figure 69. Removing the Paper Fence
380
Stacker Motor Check
6. Remove the two 10-32 x 5/32 inch buttonhead screws and washers
securing the vertical rails to the upper frame cross-member at the rear of
the cabinet. (Figure 70.)
7. Remove the two Torx T-10 screws securing the stacker base to the
cabinet floor. (Figure 70.)
8. Remove the two Torx T-10 screws that secure the rail bracket to the
cabinet floor. (Figure 70.)
Right Screw, 10-32 x 5/32 inch

Right Vertical Rail
Washer
Upper Frame
Cross-Member
Left Vertical Rail
Washer
Left Screw, 10-32

x 5/32 inch
Screw,
Torx T-10
(2 places)
Screw,
Torx T-10
Stacker Base
Rail Bracket
Screw,
Torx T-10
Figure 70. Preparing the Stacker for Removal
381
9. Pull the paper tray out until the holes in the rails permit access to the M3
buttonhead screws. (Figure 71.)
10. Loosen one turn (do not remove) the M3x6 screws securing the vertical
rails to the stacker base. Each rail is secured by two screws. (Figure 71.)
M3x6 Buttonhead Screw

(Two on each rail)
Access Hole in
Tray Rail
Figure 71. The Lower Screws in the Vertical Rails
382
Stacker Motor Check
11. Lower the elevator assembly to its lowest position. Tilt the vertical rails
towards the front of the printer to make room for removing the control
panel.
12. Remove the two 4-40 x 1/4 inch screws securing the elevator I/O cable to
the elevator assembly and disconnect the stacker I/O cable. (Figure 72.)
Do not grasp the

stacker in this area to
lift it.
Lift the
stacker by
grasping
the vertical Vertical Rail
rails.
Elevator Assembly
Stacker I/O
Cable
Screw, 4-40x1/4,
Pan Head (2)
Figure 72. Disconnecting the Stacker I/O Cable
383
13. Remove two screws, washers, and the standoff from the stacker control
panel. (Figure 73.)
Standoff
Washer
Washer
Long Screw
Short Screw
Figure 73. Removing the Stacker Control Panel

14. Remove four cables from the stacker control panel, and remove the
stacker control panel. (Figure 74.)
Ejection Lever
Logic Cable (P104)
Power Cable
Remove the
Tie Wrap
Elevator I/O Cable
(P102)
A
Rail Cable (P107)
A
Figure 74. Removing Cables from the Stacker Control Panel
384
Stacker Motor Check
NOTE: It may be easier to wear gloves for the next step.

15. Slide the stacker assembly slightly to the right to clear the air exhaust
duct. Tilt the vertical rails toward the front of the printer until they clear the
upper frame cross-member. Grasping the stacker assembly by the
vertical rails, lift and slide it to the rear and angle it out of the cabinet, as
shown in Figure 75.
Upper Frame
Cross-Member
Elevator
Assembly
Vertical Rail
Figure 75. Removing the Stacker Assembly
385
Appendix D Installing The Power Stacker
Installing The Power Stacker

NOTE: This section shows installation of the power stacker assembly, the
stacker cable assemblies, and the stacker control panel.
2. Unplug the power cord.
3. Remove paper.
4. Loosen—do not remove—the three paper path hold-down screws. Slide
the paper path to the left and lift it off the card cage. (Figure 76.)
Paper Path
Screw
Card Cage
Screw
Figure 76. Remove the Paper Path
386
Stacker Motor Check
5. Connect the power stacker logic cable P103 to connector J117 on the
controller board. (Figure 77.)
6. Disconnect the power supply cable from connector J101 on the controller
board. (Figure 77.)
7. Connect power supply cable connector P101 to the stacker power cable,
then connect the stacker power cable to connector J101 on the controller
board. (Figure 77.)
8. Route the stacker power cable in front of the controller board and down
through the cutout under the card cage fan. (Figure 77.)
9. Route the stacker logic cable in front of the controller board and down
through the cutout under the card cage fan. (Figure 77.)
Stacker Power Cable
Power Supply Connector P101
Connector P103
Cutout Beneath
Card Cage Fan
Stacker Logic
Cable
Connector J117
Connector J101
Figure 77. Power Stacker Connections on the PSA3 Controller Board
387
10. Pull the paper tray out until the holes in the rails permit access to the M3
buttonhead screws. (Figure 78.)
11. Loosen one turn—do not remove—the M3 screws securing the vertical
rails to the stacker base. Each rail is secured by two screws. (Figure 78.)
M3x6 Buttonhead Screw

(Two on each rail)
Access Hole in
Tray Rail
Figure 78. The Lower Screws in the Vertical Rails

12. Position the elevator assembly at the bottom of the vertical rails.
(Figure 79.)
13. Connect the elevator I/O cable to the elevator assembly and install the
two 4-40 x 1/4 inch screws, as shown in Figure 79.
Vertical Rail
Elevator Assembly
Stacker I/O
Cable
Screw, 4-40x1/4,
Pan Head (2)
Figure 79. The Elevator I/O Cable
388
Stacker Motor Check
CAUTION The paper stacker assembly mounts to the rear upper frame cross-
member and the cabinet floor. It is a snug fit. During installation, grasp
the stacker by the vertical rails and take care to avoid scratching painted
surfaces or damaging the stacker.
NOTE: It may be easier to wear gloves for the next step.
14. Position the stacker assembly slightly to the right in order to clear the air
exhaust duct, insert the vertical rails inside and under the upper frame
cross-member, then slowly swing the base of the stacker assembly into
the cabinet. (Figure 80a.)
15. Work the stacker base rearward and engage the upper brackets of the
vertical rails under the upper frame cross-member. (Figure 80b.)
16. Align the holes in the vertical rail brackets with the holes in the upper
frame cross-member. (Figure 80c and Figure 81.)
Upper Frame
a b
Cross-Member
Elevator
Assembly
Vertical Rail
Stacker Base
Figure 80. Stacker Installation
389
17. Align the holes in the stacker base with the holes in the cabinet floor.
(Figure 80c and Figure 81)
18. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer
securing the left vertical rail to the upper frame cross-member. (Do not
install the right hand screw yet.) (Figure 81.)
19. Install and tighten the two Torx T-10 screws securing the stacker base to
the cabinet floor. (Figure 81.)
20. Install and tighten the two Torx T-10 screws that secure the rail bracket to
the cabinet floor. (Figure 81.)
Right Screw, 10-32 x 5/32 inch

Right Vertical Rail
Washer
Upper Frame
Cross-Member
Left Vertical Rail
Washer
Left Screw, 10-32

x 5/32 inch
Screw,
Torx T-10
(2 places)
Screw,
Torx T-10
Stacker Base
Rail Bracket
Screw,
Torx T-10
Figure 81. Stacker Fasteners
390
Stacker Motor Check
21. Gather the stacker rail cable, elevator I/O cable, logic cable, and power
cable. Route the cables outboard of the elevator assembly. (Figure 82.)
Elevator I/O
Cable
Elevator
Assembly
Rail Cable
(To
Card
(To Cage)
Control
Panel)
Stacker
Stacker Logic
Power Cable Cable
Figure 82. Stacker Cable Routing
391
22. Connect the stacker cables to the rear of the stacker control panel
assembly and make sure the ejector levers close over the connectors.
(Figure 83.)
23. Press rail cable connector P107 into the control panel until the ejectors
close, then tie wrap the ejectors to the connector. (Figure 83, detail A.)
Ejection Lever
Logic Cable (P104)
Power Cable
Elevator I/O Cable

(P102)
Rail Cable (P107)
Tie Wrap
A
Figure 83. Stacker Control Panel Cables
392
Stacker Motor Check
24. Apply the double-sided tape to one end of the control panel standoff.
Remove the paper backing and hold the standoff inside the cabinet while
you insert the upper mounting screw and washer through the hole in the
frame. Use the screw as a guide to align the standoff with the hole, then
press the standoff against the inside wall and push the upper screw in as
far as it will go. Now maneuver the control panel into position and install
the upper mounting screw finger tight in the control panel. (Figure 84.)
25. Inspect the distance between the control panel lower bracket and the
inner panel of the cabinet.
a. If the control panel lower bracket is flush with the cabinet inner panel,
proceed to step 26.
b. If there is a gap between the control panel lower bracket and the
cabinet inner panel, do the following:
1) Peel the backing off the spacer adhesive. (Figure 84.)
2) Align the spacer with the holes in the lower bracket and inner
panel. (Figure 84.)
3) Press the spacer adhesive against the inner panel. (Figure 84.)
26. Install the lower mounting screw and washer. Tighten the upper mounting
screw. (Figure 84.)
Double-Sided Tape
Standoff
Stacker
Control
Panel
Washer
Spacer
Adhesive
Control Backing
Panel Lower
Bracket
Washer Upper Mounting

Screw
Lower Mounting Screw
Cabinet Inner Panel
Figure 84. Installing the Stacker Control Panel
393
27. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer
securing the right vertical rail to the upper frame cross-member.
(Figure 81.)
28. Move the elevator assembly up and down on the vertical rails until it
travels smoothly with no binding.
29. Tighten the two 10-32 x 5/32 inch buttonhead screws securing the vertical
rails to the upper frame cross-member.
30. Pull the paper tray out until the holes in the rails permit access to the
M3x6 screws. Tighten the M3 screws securing the vertical rails to the
stacker base. Each rail is secured by two screws. (Figure 78.)
31. Move the elevator assembly up and down and make sure it travels
smoothly with no binding. If the elevator binds or catches anywhere along
its path of travel, slightly loosen the upper rail screws and repeat steps 28
and 29 until the elevator moves smoothly.
32. Bundle the stacker control panel cables in the wire saddles located under
the card cage. Tie wrap the cables so they do not catch in the stacker
mechanism as it moves up and down. Route the stacker rail and frame
cables so they move without snagging as the elevator assembly moves
up and down. (Figure 85.)
Cutout Beneath
Card Cage Fan
Stacker Cables
Wire Saddle
Figure 85. Securing Stacker Cables
394
Stacker Motor Check
33. Install the paper fence. (Figure 86.)
Stacker
Base
Paper
Fence
Figure 86. Paper Fence
395
34. If the paper you will use is not wider than 15.5 inches (39.5 cm), pull out
the paper tray and install the paper tent. (Figure 87.) If the paper is wider
than 15.5 inches (39.5 cm) leave the paper tent out of the printer
Paper Tent
Paper Tray
Note the positions of

the alignment tab and
the paper fence.
Figure 87. Paper Tent

35. Install the paper path that you removed in step 4.
36. Install paper and test stacker operation. (Refer to the User’s Manual.)
396
Stacker Motor Check
Replacing The Constant Force Spring

1. Remove the stacker assembly from the printer. (See page 380.)
2. Raise the elevator assembly to within about 1/4 inch of its highest position
and secure it to the vertical rails using tie wraps or string. Do not over-
tighten the tie wraps or string; tighten them just enough to hold the
elevator up. (Figure 88.)
Elevator Tie Wrap

Assembly
Tie Wrap
Figure 88. Securing the Elevator Assembly
397
Appendix D Replacing The Constant Force Spring
WARNING The constant force spring is powerful and under high tension. Protect
your hands with gloves. To avoid pinching or cutting your fingers, grip
the spring and drum firmly in the next two steps. Coil the spring slowly
and carefully. Do not let the spring twist or crimp.
3. Remove the shoulder screw, large washer, spacer, and small washer
from the constant force spring and drum. Let the spring coil itself up until it
reaches the top of its travel on the vertical rail. (Figure 89.)
4. Firmly gripping the spring and drum, remove the rail screw and washer
securing the spring to the vertical rail. (Figure 89.)
5. Position a new constant force spring on the vertical rail and install the rail
screw and washer. (Figure 89.)
6. Install the shoulder screw, large washer, spacer, and small washer as
shown in Figure 89.
Rail Screw
Washer
Constant Force Spring
Large Washer
Small
Shoulder Screw Washer
Spacer
Drum
Figure 89. Removing and Installing the Constant Force Spring
398
Stacker Motor Check
Replacing The Timing Belts

1. Remove the stacker assembly from the printer (page 380).
2. Raise the elevator assembly to its highest position and secure it to the
vertical rails using tie wraps or string. Do not over-tighten the tie wraps or
string; tighten them just enough to hold the elevator up. (Figure 88, page
397.)
3. If you are removing the left timing belt, remove the screw and washer
from the pulley at the bottom of the left vertical rail, and remove the pulley.
(Figure 90.) Go to step 6.
4. If you are removing the right timing belt, remove the two metric Allen
screws that secure the timing belt motor to the right vertical rail.
(Figure 90.) Go to step 5.
Metric Allen Screw Timing Belt

Right Vertical Rail Motor
and Washer (2)
Left Vertical
Rail
Washer
Screw
Pulley
Figure 90. Removing the Timing Belt Pulley and Motor

5. Loosen the two setscrews on the motor pulley and remove the pulley.
Unplug the motor cable, if necessary. (Figure 91.) Go to step 6.
Timing Belt Motor
Setscrew
Pulley
Setscrew
Figure 91. Removing the Timing Belt Motor Pulley
399
Appendix D Replacing The Timing Belts
6. Remove the shoulder screw and large washer that secure the constant
force spring to the vertical rail. (Figure 92.)
NOTE: Left is shown.

Right is the same.
Constant Force Spring
Large Washer
Shoulder Screw
Figure 92. Releasing the Constant Force Spring

7. Remove two Allen screws from the belt clamp that secures the timing belt
to the stacker frame. (Figure 93.)
Allen Screw
Belt Clamp
Allen
Screw
Belt Clamp
Figure 93. Removing the Belt Clamps
400
Stacker Motor Check
8. Remove the timing belt by working it around the vertical rail and constant
force spring. (Figure 94.)
9. To install a timing belt, reverse the steps of this procedure.
NOTE: Left timing

belt is shown. Right is
the same.
Timing Belt
Figure 94. Removing the Timing Belt
401
Appendix D Replacing The Roller Drive Shaft
Replacing The Roller Drive Shaft

1. Remove the stacker assembly from the printer (page 380).
2. Unhook the right bearing pivot plate’s extension spring from the tab on the
elevator. (Figure 95.)
3. Using an M-2 Allen wrench, remove the screw securing the right bearing
pivot plate to the elevator. (Figure 95.)
A
Right Bearing
Pivot Plate
Extension
Spring
Tab
Screw
Figure 95. Right Bearing Pivot Plate and Extension Spring
402
Stacker Motor Check
4. Move the idler shaft enough to expose the lower mount screw of the
power stacker stepper motor. (Figure 96.)
5. Cut and remove the upper tie wrap securing the stepper motor wires to
the elevator. (Be careful not to cut a motor wire.)
6. Using an M-2 Allen wrench, remove the two screws securing the power
stacker stepper motor to the elevator. (Figure 96.)
7. Using a 9/64 inch Allen wrench, loosen (do not remove) the collar screw
securing the collar to the roller drive shaft. (Figure 96.)
8. Support the roller drive shaft with one hand and pull the stepper motor
shaft out of the roller drive shaft. Let the stepper motor hang from its
cables.
Collar Screw
Power Stacker
Stepper Motor
Stepper Motor
Mount Screws
Roller
Drive Shaft
Idler Shaft
Figure 96. Power Stacker Stepper Motor
403
Appendix D Replacing The Roller Drive Shaft
9. Remove the roller drive shaft, taking care to retain the bearing at the left
end of the shaft and the collar at the right end of the shaft. (Figure 97.)
10. Remove the bearing and collar from the old roller drive shaft and retain
these items for installation on the new roller drive shaft. (Figure 97.)
11. Using an M-2 Allen wrench, remove the screw securing the grounding clip
to the left side of the elevator. Discard the old grounding clip, but retain
the screw so you can install a new grounding clip when you install the
new roller driver shaft. (Figure 97.)
12. Remove the new roller drive shaft, grounding clip, and bearing lubricant
from the packaging.
13. Inspect the new roller drive shaft for oil and grease; wipe off any oil or
grease from the roller drive shaft and rollers. The roller drive shaft must
be dry and clean.
14. Apply a small dab of bearing lubricant to the dimple in the new grounding
clip. Make sure this is the only area containing lubricant. (Figure 97.)
15. Reverse the steps of the removal procedure, making sure to to install the
new grounding clip to the side of the elevator and the bearing and collar
onto the new roller drive shaft.
Collar
Roller Drive Shaft
Bearing
Small dab of
lube in the
dimple.
New Grounding
Clip
Screw
Figure 97. Roller Drive Shaft
404
List of Illustrations
Illustrated Parts Breakdown

The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the
power stacker assembly and subassemblies. Parts are listed next to each
drawing.
IMPORTANT The Phase III (newest) power stacker is illustrated in this section. If the
stacker you are working on does NOT look like the one illustrated here,
order the part designated Phase II if the part has both a Phase II and
Phase III listing. If a part is not listed as both Phase II and Phase III, you
can use that part on any stacker.
Only replaceable parts are assigned part numbers. If a part or assembly is
damaged but does not have a part number, replace the entire power stacker
assembly.
The IPB starts on the next page.
Figure 98. Stacker Assembly .......................................................... page 406
Figure 99. Elevator Detail: Motors, Rollers, and Paddles ............... page 408
Figure 100. Stacker Detail: Motor Bracket ...................................... page 410
Figure 101. Stacker Detail: Elevator Bracket .................................. page 412
Figure 102. Stacker Detail: Paper Motion Detector......................... page 414
Parts Not Illustrated In This Section:

• Extended Door Assembly, Stealth Black:177489-001
Extended Door Assembly, Lt Gray: 179792-001
• Reed Limit Switch Assembly: 204234-001
• Control Panel Assy, Pwr Stkr, Black: 178911-001 (Figure 84, page 393)
Control Panel Assy, Pwr Stkr, Gray: 179798-001
• Stacker Hardware Kit: 173830-001
• Rail Cable, Power Stacker: 173823-001 (See page 353)
• Power Cable, Power Stacker: 174414-001 (See page 352)
• Logic Cable, Power Stacker: 176029-001 (See page 351)
• Frame Cable, Power Stacker: 173824-001 (See page 350)
• Elevator I/O Cable, Power Stacker: 174759-001 (See page 354)
405
Appendix D Illustrated Parts Breakdown
See page 408. A

10
14 12
7
35
30 9
11
20 2
20
9 2
15
12 3 4 5 25 13
8
8
10
37
12 22
21
23
Figure 98. Stacker Assembly
406
Item
No.
1 178908-001 Stacker Assembly, Power, Black

179804-001 Stacker Assembly, Power, Gray
2 204956-001 Washer, 5/16 X .200 X .030, Stainless Part of item 36

Steel
3 203251-001 Screw, Hex Skt Btn Hd, Zinc M3X8mm
4 204458-001 Washer, Shim, .125 ID X .010 inch

Thick
5 173818-001 Timing Belt Tensioner Assy, Pwr Stkr
6 178899-001 Deflector, Power Stacker, Black

179802-001 Deflector, Power Stacker, Gray
7 202721-901 Clip-On Bearing Part of item 36
8 Ref Screw, Torx, 6-32 x .25 Part of item 36

9 Ref Screw, Shoulder, 10-32 Part of item 36
10 202716-001 Timing Belt
11 173726-001 Shaft, Lift, Phase III
12 178058-001 Pulley, Timing, Fairloc,12T
13 159398-001 Pulley, Motor
14 175726-901 Clip, Ground, Dimpled, Pwr Stkr Part of item 47
15 158446-001 Motor Assembly, Power Stacker Elevator motor and paddle

motor
16 173530-001 Motor, Stepper, Power Stacker Paper puller motor
20 178918-001 Spring, Conforce, with Spool Assy
21 178913-001 Field Kit, Tray, Cab, Rear, Black
22 174392-001 Slide, Ball Bearing, Rear Tray
23 173864-001 Tent, Paper, Power Stacker
25 151527-905 Chain Mount outboard of shafts

30 202705-901 Nylon Plug
35 202720-901 Cable
36 173830-001 Stacker Hardware Kit Kit not illustrated

37 Ref Screw, Shoulder, 8-32 Part of item 36
407
16 From page 406.

A
51
15
47
See page 410.
75 B 15
70
53
66
40 46
45
50 50
D
See page
46 414.
45
50
45 46 60
55
45
46
52
65 55
54
5snipb2
52
49
53
C
See page 412.
65
C See page 412.
Figure 99. Elevator Detail: Motors, Rollers, and Paddles
408
Item
No.
40 158313-001 Anti-Static Brush

45 Ref Shear Grommet Part of item 36
46 Ref Cap Nut Part of item 36
47 158736-901 Drive Shaft Assy (Roller Drive Shaft) Includes items 14, 70, and
75
48 156393-001 Spacer, Drive Roller Part of item 47

49 202789-901 Bearing, Flanged Part of item 36
50 202824-901 Bearing Part of item 36
51 202708-901 Collar Clamp

52 Ref Collar, Setscrew Part of item 36
53 156390-001 Support Shaft
54 174570-001 Fence, Wireform, Phase III

55 203032-001 Extension Spring
60 157275-001 Idler Roller
65 157054-001 Paddle, Power Stacker
66 204235-001 Switch, Assy, Rocker Elevator Disable Switch
70 157960-001 Drive Roller Part of item 47
75 176781-001 Compression Spring Part of item 47

76 204234-001 Switch Assy, Reed Limit (2) Not illustrated; attach to
item 77
77 250235-001 Reed Switch Mounting Plate (2) Not illustrated; attach to

top and bottom of right
vertical rail
409
From page 408.
95
95
96 E
100
Flag
Connector
E 96
Key
Figure 100. Stacker Detail: Motor Bracket
410
Item
No.
95 Ref Clip-On Bearing Part of item 36

96 158288-001 Holder, LED, Round
100 Ref LED, IR, T-1, 3/4
411
C
From page 408.
105
Connector
Flag F
95
Nib
Key
95 F
5snelvbk
97
Figure 101. Stacker Detail: Elevator Bracket
412
Item
No.
95 Ref Clip-On Bearing Part of item 36

97 158290-001 Holder, LED, Flat
105 Ref Photodarlington, NPN, Rectifier
413
From page 408.
D
Rotated 180 Degrees
108
107 106
5sndtect
Connector
Key
97
Nib 107
105
115
116
97
110
Figure 102. Stacker Detail: Paper Motion Detector
414
Item
No.
97 158290-001 Holder, LED, Flat

105 Ref Photodarlington, NPN, Rectifier
106 Ref Retaining Ring, External, 0.093 inch Part of item 115
107 Ref Screw, Panhead, Type B, 2 x 3/16 Part of item 36

108 Ref Shaft, Paper Detector Switch, Long Part of item 115
110 Ref LED, IR, Rectangular
115 170289-001 Field Kit, Power Stacker, PMD Paper Motion Detector
116 Ref Spring, Torsion Part of item 115
415
416
E Zero Tear Pedestal (ZTP)
Contents
Overview ......................................................................................... page 417
Performance Limitations ................................................................. page 417
Control Panel Menus....................................................................... page 419
Operation ........................................................................................ page 420
Adjust The Paper Guides.......................................................... page 420
Load Paper ............................................................................... page 421
Set The Tear Bar Distance ....................................................... page 422
Position The Paper Out Sensor ................................................ page 424
Illustrated Parts Lists ....................................................................... page 425
Figure 108. ZTP Details .................................................................. page 426
Figure 109. ZTP Inside Covers, Barrier Shield, and Shuttle Assy .. page 428
Figure 110. ZTP Circuit Boards and Paper Feed Assembly ........... page 430
Figure 111. ZTP Tractor Shafts, Pap Gds, and Pap Feed Motor .... page 432
Figure 112. ZTP Platen and Integrated Print Mgmt Sensor Assy ... page 436
Figure 113. ZTP Hammer Bank Fan, Motors, and Ribbon Guides . page 438
Overview
The Zero Tear Pedestal (ZTP) printer can print a form and present it for tear
off without losing a form between print jobs. The printer automatically
presents the current print line to the tear bar when it finishes printing and no
data are being sent to the printer. When it receives more data from the host
computer, the printer pulls the form down to the print station and resumes
printing.
The ZTP is available as a 500 lpm, 1000 lpm, 1500 lpm ASCII printer and as a
300 lpm or 600 lpm H-Series (DBCS) printer.
Performance Limitations
Forms Type
The paper feed tractors on the ZTP push the paper up through the print
station instead of pulling paper through, as in the standard pedestal printer.
This limits the kinds of forms the ZTP can use. If the forms do not fall within
417
Appendix E Performance Limitations
the limits specified in Table 8, the printer may lose top-of-form, the frequency
of paper jams may increase, dot compression and line separation could
occur, or printing may not even be possible. The user should match the media
to the application to ensure acceptable print quality. Also, because the paper
is pushed from below the print station, the last form in the paper supply may
not print fully or may not be presented to the printer exit for retrieval.
All paper used in the ZTP must have the standard tractor feed holes, spaced
one half inch apart. The ZTP does not support cut sheet and continuous
friction fed paper. Also, the forms specified in Table 8 can have no more than
one form per page horizontally.
Table 8. Forms Type
Width
Description Length
(edge to edge)
One to three part, continuous, with

carbon, fan-folded, edge-perforated 3 to 12 inches 7 to 16½ inches
paper forms
One to four part, continuous, with
carbon, fan-folded, edge-perforated 3 to 12 inches 7 to 12 inches
paper forms
One to four part, continuous,
carbonless, 3 to 12 inches 7 to 16.5 inches
fan-folded, edge-perforated paper forms
One to six part, continuous, carbonless, 3 to 12 inches 7 to 12 inches
fan-folded, edge-perforated paper forms
Forms with a paper weight of 20 to 100
pounds and a maximum thickness of 3 to 12 inches 7 to 16½ inches
0.025 inches
Forms with a paper weight of 18 to 100
pounds and a maximum thickness of 3 to 12 inches 7 to 12 inches
0.025 inches
Forms with all approved types of
interleaf edge attachment except those
using metallic or other hard devices
Paper Jams
Paper jams can occur if you tear off a form incorrectly. If you experience two
or more paper jams per box of forms, follow these guidelines to help reduce
jams:
• Position the lower paper guides properly
• Adjust the paper web tightness properly
• Position the form perforation against the tear bar
• Do not tear off a form while the paper is moving
• Direct the tear force toward the user and across the tear bar, not upward
418
User Environment
Printed forms exit the printer from the top of the pedestal lid. This makes the
ZTP a little noiser than a standard pedestal printer.
Control Panel Menus

The ZTP SETTINGS menu includes the ability to enable or disable the
features unique to the ZTP, set the tear bar distance, set the auto present
data time, and set the auto present wait time. This section defines these
options. (For more information about configuration menus, refer to the User’s
Manual.)
ZTP Function
This option enables or disables all the functions unique to the ZTP. The
default is Enable.
ZTP Tear Bar Dist

This option sets the tear off distance from the current print position to the tear
bar. Adjustable values in increments of 1/144th inch range from 200 to 2880.
The up and down arrows adjust the display value. When you press the Enter
key, the selected value is stored and a scale is printed to indicate the current
tear off position. The default value is 1060.
ZTP Data Time

This option sets the pause time in the data stream that the ZTP requires
before moving the form to the tear bar once a print job is completed. The
values range from .5 to 5 seconds. The default is .5 seconds.
ZTP Wait Time

This option sets the minimum amount of time that the form stays at the tear
bar. This allows you time to remove the form before the form is retracted to
print the next form. The adjustable values range from 1 to 10 seconds in
increments of 1 second. The default value is 2 seconds.
ZTP Platen Open

This option allows the user to have the platen open whenever forms are
reversed. Enabled is the default, used for most papers and labels. The feature
can be disabled as required by some multi-part forms.
419
Appendix E Operation
Operation
Adjust The Paper Guides
A Rear Paper Guide (3)
Front Paper Guide (3)
Knob (3)
Figure 103. Adjusting The Paper Guides
1. Turn the knob on the front left paper guide counterclockwise to loosen the
guide.
2. Slide both the front and rear left paper guides as close to the left tractor
as possible.
3. Turn the knob on the front left paper guide clockwise to tighten the guide.
4. Similarly, position the right paper guides as close to the right tractor as
possible.
5. Position the middle paper guides in the center.
420
Load Paper
Load Paper
Rear Paper Guide
Tractor Door
Front Paper Guide
Paper Out Sensor
Paper
Figure 104. Loading Paper
1. Open both tractor doors.

2. Slide the paper up through the paper out sensor slot on the left side, and
up between the front and rear paper guides.
3. Unlock the left tractor and load the paper on the left tractor sprockets.
4. Close the left tractor door.
5. Unlock the right tractor and load the paper onto the right tractor sprockets.
6. Close the right tractor door.
7. Adjust the paper web tightness by sliding the right tractor to remove slack
or to adjust for various paper widths.
8. Lock both tractors in position by pressing down on the tractor locks.
421
Set The Tear Bar Distance

To set the tear bar distance, do the following steps:
1. Power the printer on.
2. Make sure the printer is offline.
3. Press the right arrow until “OFFLINE/ZTP SETTINGS” displays.
4. Press the down arrow . “ZTP DataTime” displays.
5. Press the right arrow until “ZTP TearDist” displays.
6. Press the down arrow . “ZTP TearDist/xx/144 Inch” displays.
7. Press the Enter key. A scale prints to indicate the tear bar distance in
relation to the tear bar.
8. Press the left arrow or right arrow to decrease or increase the tear
bar distance in increments of 1/144th inch.
9. Press Enter to select the desired value. An asterisk appears next the
selected value.
10. Press Enter again to print a new scale. For correct tear bar distance, the
zero should align with the tear bar. (See Figure 105.)
+50
Physical TearBar
0 Position
-50
Correct
TearBar
Distance
Print Station
Figure 105. Correct Tear Bar Distance
11. Reset the top of form, using the procedure on page 423.
422
Set The Top Of Form
Set The Top Of Form
Tear Bar
Paper
Form Advance
Knob
Figure 106. Setting The Tear Off Position

The ZTP uses the tear bar as the reference point for setting the tear off
position. To set the position of the forms perforation to the tear off bar, use the
SET TOF key as follows:
1. Make sure the paper guides are adjusted correctly and the paper is
properly loaded.
2. Press the SET TOF key on the control panel. The printer display will read
“Align at TearBar/Then Press TOF”.
3. Use the form advance knob to move the top of the form to the tear off bar.
4. Position the perforation so it aligns with the tear off bar. This is easily
done by advancing one complete sheet above the tear off bar and folding
it over at the perforation.
5. Position the fold exactly at the tear off bar.
6. Tear the sheet off to ensure proper positioning and a clean tear off.
NOTE: If you do not want to lose a form, position the top of the form at the
tear off bar. Run a finger along the back of the form along the tear off
bar to ensure the perforation is presented at the tear off point.
7. Press the SET TOF key again. The printer display will read “Top Of Form
Set/Press ONLINE”. The printer will then be brought OFFLINE and the
top of form will be set.
8. Press the ONLINE/CLEAR key to bring the printer online.
423
Position The Paper Out Sensor
Perforation
At least 2 inches
Sensor Knob
Paper Out Sensor
Paper
Figure 107. The Paper Out Sensor

The paper out sensor indicates when the printer runs out of paper. (The
sensor does not work with black-backed forms.) Unlike the standard pedestal
printer, on the ZTP you must load the paper through the paper out sensor slot
(Figure 104 and Figure 107). Correct positioning of the paper out sensor
ensures that the last form the printer prints will be properly presented to the
tear bar. To position the paper out sensor, do the following:
1. Position the paper properly at the tear bar (page 423).
2. Loosen the paper out sensor by turning the sensor knob
counterclockwise.
3. Position the paper out sensor so that there are at least two inches
between a perforation and the top of the paper out sensor. (Figure 107.)
4. Tighten the paper out sensor by turning the sensor knob clockwise.
5. Press ONLINE/CLEAR. When the first print job is sent to the printer, the
paper is drawn into the printer, the top of form aligns with the print station,
and the print job begins.
424
Illustrations of ZTP Printer Components
Illustrated Parts Lists

Only replaceable spares are given part numbers in the illustrated parts lists.
Part numbers are not listed for common fasteners and attachment hardware.
Items marked “Ref” in the illustrations refer to parts that either are not spared
or are part of another assembly.

Figure 108. ZTP Details .................................................................. page 426
Figure 109. ZTP Inside Covers, Barrier Shield, and Shuttle Assy .. page 428
Figure 110. ZTP Circuit Boards and Paper Feed Assembly ........... page 430
Figure 111. ZTP Tractor Shafts and Paper Feed Motor.................. page 432
Figure 112. ZTP Platen and Integrated Print Mgmt Sensor Assy ... page 436
Figure 113. ZTP Hammer Bank Fan, Motors, and Ribbon Guides . page 438
425
Appendix E Illustrated Parts Lists
17
8
13
1 3 18
14
4
15
12
16
11
10
Figure 108. ZTP Details
426
Item
No.
1 177530-902 Control Panel Assembly, Ped

2 Ref Screw, Captive (2)
3 179163-001 Field Kit, Lid Assembly, Ped, Blk

179845-001 Field Kit, Lid Assembly, Ped, Gray
4 Ref Screw (2)

6 179081-001 Packaged Ped Kit, Stealth Black
179776-001 Packaged Ped Kit, Lt Gray
7 179162-001 Field Kit, Caster Kit, Ped
8 178692-901 Window, Top Cover
9 Ref Housing, Pedestal, V3
10 Ref Screw (4) 10-32x.625
11 110718-001 Paper Tray
12 157070-901 Paper Fence, Rear, Ped
13 250081-001 Field Kit, Short Stack, Ped, P7000 Contains items 18
14 179395-001 Wireform, Upper, ZTP, Ped, P7000

15 178241-901 Panel, Quick Access, Flip Up, Black
179766-901 Panel, Quick Access, Flip Up, Gray
16 156033-901 Paper Tray, Front, Ped
17 250086-001 Top Cover Assembly, P7000, ZTP, Does not include control
Black panel (item 1)
250087-001 Top Cover Assembly, P7000, ZTP, Does not include control
Gray panel (item 1)
18 250014-001 Slide, Output Basket, Pedestal Part of item 13
427
Two places:
Exploded to show 8
assembly. Do not 7
remove the 6
clamps and
screws.
To J02
(Shuttle
Motor)
To J03
(MPU)
3 4
See Figure 41,

page 262. A
5
Figure 109. ZTP Inside Covers, Barrier Shield, and Shuttle Assembly
428
Item
No.

.125x.250x.06
5 179276-001 Power Supply Insulator Taped to card cage along

upper edge
6 178311-901 Ribbon Mask/HB Cover Assy P7005
7 178895-901 Shuttle Assembly, 05 P7005

174965-901 Hammer Spring Assembly, 05 P7005
8 150399-901 Clamp, Shaft, Receiving
429
3
15
10 5
8
9 19
11
7 20
4 18
21
13 10
6 12
16
17
To the Terminator
Board on the
Shuttle Frame
25
22
24
23
Figure 110. ZTP Circuit Boards and Paper Feed Assembly
430
Item
No.
3 179074-901 Power Supply, PFC, 5/10 P7X05, P7X10

179074-991 Power Supply, PFC, 5/10, Adv Exch P7X05, P7X10
179075-901 Power Supply, PFC, 15 P7X15
179075-991 Power Supply, PFC, 15, Adv Exch P7X15
4 Ref P101 Cable Connector Part of item 3
5 Ref Cable Assembly, AC-In, Power Supply Part of Field Kit, AC Assy,
153502-901
6 179077-901 Controller PCBA, (V5)

179077-991 Controller PCBA, (V5) Adv Exch
7 202362-001 Housing, Connector Kit P106, Motor Sensor, Left
8 152421-901 Hammer Bank Logic Cable Assembly
9 152420-901 Shuttle Motor Cable Assembly
10 164805-901 Hammer Bank Power Cable Assembly Used on all except P7220
11 202362-001 Housing, Connector Kit P107, Motor Sensor, Right
12 152439-901 Centronics I/O Cable Assembly
15 Ref Screw, Captive, Power Supply (2)
16 204480-902 SIMM, Flash Memory, 8 MB Install in slot J11. J10 is not

204480-903 SIMM, Flash Memory, 16 MB used.
17 Ref Security Key
18 Ref Paper Feed Motor 178046-001 Cable P7X05/10/15

Ref Paper Feed Motor 178535-001 Cable P7X05/10/15LG
19 Ref Integrated Print Management System
Bar Code Sensor (179526-901) Cable
20 Ref Not Used
21 Ref Not Used
22 179990-001 Paper Feed Assembly, ZTP Not spared as an assembly
23 Ref Screw w/Lociwasher and Flat Washer
24 Ref Screw, Hex w/Lockwasher, 8X.38
25 Ref Cover Plate, Right Extension
431
4
3
2
19
18
16 17 20
21
22
5
15
7
11
13
12
14
9 8
10
25
23
Figure 111. ZTP Tractor Shafts, Paper Guides, and Paper Feed Motor
432
Item
No.
1 179065-901 Tractor Set, Non-Roller, 05/10/15

(Blue)
2 Ref Shaft, Spacer, Tractor, ZTP Part of item 24
3 Ref Pad, Nylon, Mount Block, ZTP Part of item 24
4 Ref Screw, Button Head (3)
5 178046-001 Field Kit, Paper Feed Motor, V3

6 Ref Screw, Hex w/Lock Washer, 10-24x.50 Part of item 5
(2)
7 173217-001 Plate, Tractor Shaft, Right
8 Ref Screw, Socket Cap, 6-32x.312 Trilob,

Self-Tapping
9 178988-901 Splined Shaft Assembly (Blue Handle)
10 204155-001 Tolerance Ring,.37X.25,.006 THK,SS
11 250088-001 Field Kit, Leaf, Paper Guide, P7000, Contains three front leaf
ZTP guide assemblies
12 177812-001 Plate, Clamping, Paper Guide, ZTP (3) Part of item 11
13 Ref Screw, 6-32x.25, ¼ Hex Hd, Washer Part of item 11

(6)
14 Ref Screw, M5X16X.8, SHCS-Thumb, SS, Part of item 24

ASTM F837M
15 Ref Bearing, Ball, Sealed

(Self-Tapping) (2)
17 173130-001 Plate, Tractor Shaft, Left
18 Ref Screw, Flat HD, Metric, M3x6mm (3)
19 Ref Leaf, Guide, Paper, Outer, ZTP (2)
20 Ref Leaf, Guide, Paper, Center, ZTP

21 Ref Block, Mount, Ctr Paper Guide, ZTP
22 Ref Block, Mounting, Outboard, Paper

Guide, ZTP (2)
23 177814-001 Extrusion, Paper Guide, ZTP (3) Part of item 11

24 178717-001 Field Kit, Hardware, ZTP
433
Item
No.
.500 Wide
434
435
1 2
NOTE:
Item 24: Platen
Hardware Kit 3
5 4
6
7
23 1 2
22
21 19
17
15
20 8
16
25
9
27
26 10
11
12
13
18
16
15 17
14
Figure 112. ZTP Platen and Integrated Print Management Sensor Assembly
436
Item
No.
1 Ref Setscrew (2) Part of item 24

2 Ref Bracket, Platen (2) Part of item 24
4 174968-001 Ironer Bracket/Plate Field Kit

5 Ref Plate, Ironer Part of item 4
6 112657-901 Platen Assembly
7 Ref Washer, Flat (2) Part of item 24
8 Ref Screw (2) Part of item 10

9 Ref Washer, Flat #4 (2) Part of item 10
10 179334-901 Field Kit, Switch Assy, w/Bracket Includes items 8, 9, 18

12 Ref Washer Part of item 14
13 Ref Nut Part of item 14
14 178705-901 Platen Stop Lever Kit Includes items 11, 12, 13
15 Ref Spring, Extension 1.12L Part of item 24
16 Ref Link, Spring Part of item 24
17 Ref Bearing, Nylon .376 Part of item 24
18 Ref Bracket, Switch Mount Part of item 10
19 Ref Wear Saddle, Platen (2) Part of item 24
20 150703-902 Platen Pulley, Drive

22 141516-901 Belt, Timing, .080 Pitch, .312 Wide Platen Open Belt
23 153488-001 Field Kit, Covers Platen Open Belt Cover

shown
24 177558-001 Platen Hardware Kit Includes items 1, 2, 7, 15,
16, 17, 19, 25
25 Ref Platen Washer Part of item 24
26 179526-901 Sensor Assembly, Integrated Print

Management System/Barcode
27 Ref Screw
437
Install screws here.

A
Top View
Hammer Bank Fan Route cable under

base casting
2
1
3
9 13
10 15
7
14
11
12
6 5 4
A See detail above
Figure 113. ZTP Hammer Bank Fan, Motors, and Ribbon Guides
438
Item
No.
1 152415-901 Switch Assembly, Paper Detector

170172-001 Field Kit, Slotted Black Back Form Optional switch assembly
Switch used with black back forms
2 Ref Screw, Thread-forming, 6-32x.375 (2) Part of item 1
3 179638-001 Motor Assembly, Platen Includes pulley
4 178992-902 Ribbon Guide Cable Assembly, RH

178992-901 Ribbon Guide Cable Assembly, LH
178995-001 Field Kit, Ribbon Guide, LH/RH,
P7000
5 Ref Washer, Flat #4 Part of item4
6 Ref Screw, w/Lock Washer, 4-40x.38 Part of item 4
7 Ref Screw, w/Lock Washer, 10-32x.50 (2) Part of item 3
8 179073-901 Ribbon Motor Assembly, w/Hub
10 Ref Washer, Flat #6 (2)
12 152416-901 Hammer Bank Fan Assembly All except P7220; air flow is
up
173427-901 Hammer Bank Fan Assembly P7220; air flow is up
14 Ref Post, Platen Belt Spring
15 Ref Spring, Platen Belt
439
440
F Paper Specifications And
Forms Design
Introduction
This appendix is divided into two sections.
The first section lists general specifications for continuous form paper used in
this printer. (Specific brands of paper are not recommended.)
The second section goes into more detail, providing definitions, guidelines,
and a checklist you can use to design forms that will run smoothly through the
printer.
Adherence to these specifications will ensure the best print quality and
reliable operation of the printer.
441
Appendix F General Paper Specifications
General Paper Specifications

This section describes the minimum paper specifications that must be met to
ensure the best printer performance.
Always test paper and forms before buying large quantities. Make all
measurements at 20° to 26° Celsius (68° to 78° Fahrenheit) and 45% to 55%
relative humidity. Printronix printers perform well with forms that meet the
specifications listed in Table 9 and Table 10 below.
NOTE: Printronix conforms to ANSI® Standard X3.96-1983, “American
National Forms Information Systems for Continuous Business
Forms,” and ISO Recommendation No. 2784, which cover common
form widths and depths, standards for sprocket feed holes and
margins, and other basic tolerances.
Table 9. Paper Sizes
Maximum Form Width 17.0 inches (43.18 cm) edge to edge
Minimum Form Width 3.0 inches (7.62 cm) edge to edge
Maximum Printing Width 13.6 inches (34.54 cm)

Maximum Right Margin 1 to 13.6 inches (2.54 to 34.54 cm)
Maximum Left Margin 0 to 13.5 inches (0 to 34.29 cm)
Maximum Form Length 16 inches (40.64 cm)
Minimum Form Length 2 inches (5.08 cm)
Table 10. Paper Weights
Single-Part Forms
Standard 15 to 100 pound (57 to 380 gm/meter2)
Best Print Quality 18 to 60 pound (68 to 227 gm/meter2)

Multipart Forms
Carbon Paper 12 pounds (46 gm/meter2) up to 6 total pages
Carbons 8 pounds (30 gm/meter2) up to 6 total pages
Pack Thickness Maximum 0.025 inch (0.635 mm) total
Carbonless Up to 4-part forms
Test the paper first if it will be used in environments with greater than 80% or
less than 20% humidity. Test paper that will be used at high humidity for
442
Terms And Definitions
satisfactory feeding and handling. Test paper that will be used at low humidity
to determine if static buildup must be eliminated for proper paper stacking.
Paper Guidelines
The terms below are used to describe and discuss continuous form paper.
Terms And Definitions

Chaff Bits of paper not completely removed after the punch
process that creates tractor pin holes, major and minor
perforations, etc.
Cut Point The area along a perforation where a cut has been made
that extends through the entire form. (Compare Tie Point.)
Cut-to-Tie Ratio The ratio of cut points to tie points occurring along a
perforation.
Evenness The amount of variation between the thickest and thinnest
points measured across the print area (i.e., between the
side perforations).
Form Thickness Thickness measured at the thickest point of the entire
form. This includes glue lines, compressed staples,
perforations, etc., and is not limited to the printed region of
the form.
Margin The region outside the print area of the form. The margin is
typically bounded by the outermost vertical perforations
(i.e., where the tractor holes are located) and the edge of
the form.
Print Area The region where printing occurs, and which is always
between the side perforations.
Print Station The area in the printer where occur the actual impacts that
constitute printing.
Staple A punch-cut fastening stitch located along the vertical edge
and within the side perforation region of a multipart form.
(Note that this is not a metal staple.)
Tenting The measured thickness between the print area of the form
and the peak thickness of a major perforation. Tenting is
typically caused by overly stiff perforations or incorrect
registration of the inner parts of multipart forms.
Tie Point The area along a perforation between the cut points.
(Compare Cut Point.)
443
Appendix F Paper Guidelines
The figure below illustrates the terms used in this appendix.
Side Perforation
Margin Area
Tractor Pin Hole
Page Perforation
Cut Point Tie Point

Print Area
Form Span
Side View of Form
Printed Side of Form
Outward Perforation
Inward Perforation
Figure 114. Forms Terminology
444
Environmental Considerations
Environmental Considerations
Before they are used, forms should be stored for at least 24 hours —
preferably 48 hours — in the environment in which they will be used. This
stabilizes the moisture content of the paper, resulting in better feeding and
stacking. But forms should never be stored in environments that result in
damage such as delamination of glues, creasing, folding, etc.
Form Types
Three kinds of continuous form paper are specified for use with the printer:
• Edge-perforated, fanfolded, single-part forms
• 2- to 6-part multipart carbon forms
• 2- to 4-part multipart carbonless forms
For all forms, the width range is 3 to 17 inches, the length range is 2 to 12
inches.
Form Weight
Use 15 to 100 pound (6.80 to 45.36 kg) stock. Light weight and recycled
forms must be strong enough to assure that tractor holes and perforations do
not tear or detach during form feed, skipping, and ejecting operations.
Form Thickness
Forms must be no thicker than 0.025 inches (0.0635 cm) at the thickest part
of the form — including glue lines, staples, perforations, etc. — and is not
restricted to just the print area.
Form Evenness
The evenness of forms must not exceed 0.003 inches (0.00762 cm) across
the print area (between the side perforations).
Tenting caused by buildup of perforation thickness must be minimized. A
perforation thickness measured at the major perforation that exceeds 1.25
times the forms thickness measured in the print area will result in an
unpredictable and unreliable form. The perforation thickness must never
exceed the maximum forms thickness of 0.025 inches (0.0635 cm).
Tractor Pin Engagement

The printer uses tractors with 6-pin engagement. Detailed engagement
specifications are given in ISO-2784, but are summarized in the table below.
445
Appendix F Paper Guidelines
Specification Inches Millimeters
Hole centerline (CL) to edge of form 0.236 ± 0.028 6.0 ± 0.10
Hole Diameter (Serrations or any 0.156 ± 0.004 4.0 ± 0.10

occlusion due to incorrect registration
of multipart forms cannot exceed this
dimension.)
Distance between centers of two 0.500 ± 0.002 12.7 ± 0.05

consecutive holes
Maximum deviation of holes from their 0.004 0.10

centerline
Maximum deviation of lefthand hole to 0.006 0.15

adjacent righthand hole (CL to CL)
Maximum parallel deviation of lefthand 0.006 0.15

hole CL to righthand hole CL
Methods Of Forms Attachment

Any method of attachment (staples, crimps, gluing, etc.) must be designed in
a way that does not permit air to be trapped between copies of a form. Hard or
wire brads and staples must not be used.
Any attachment must not coincide with the major perforation or any horizontal
perforation.
Gluing
Gluing must be controlled and uniform, since it is a major contributor to the
maximum form thickness. A form that meets the maximum forms thickness
requirement in the print area but which exceeds the maximum thickness at a
glue line is considered an unreliable and unpredictable form.
Staples
Staples must be used only in the margin area of the form and must not be in
line with the path of the tractor holes. Ideally, staples are placed in the
margins so that they coincide with areas of the form where printing does not
occur.
Figure 115 below shows preferred and unacceptable ways of fabricating
staples.
446
Chaff Content
Preferred Unacceptable
Tie Point Cut Point
Direction of
Forms
Movement
Cut Point Tie Point
Figure 115. Preferred vs. Unacceptable Form Staples
Cut-To-Tie Ratio
A common cut-to-tie ratio for bond forms is 4:1 (that is, 80% cut to 20% ties).
This value is dictated chiefly by the application program that the form runs
under. Lower cut-to-tie ratios will yield better form handling, but stacking may
suffer due to increased stiffness of the perforations. Some level of
experimentation is required to determine the best cut-to-tie ratio. But
remember that a cut-to-tie ratio that causes a thickness buildup greater than
0.025 inch (0.635 mm) or that creates an evenness variation greater than
0.003 inch (0.0762 mm) will result in an unreliable and unpredictable form.
Perforation Intersections
Whenever a horizontal line of perforations intersects with a vertical line of
perforations, the point of intersection must be a tie point. Cut points at such
intersections make the form unacceptable.
Chaff Content
Tractors holes should be clear of chaff. As much as possible, there should not
be loose chaff in the box in which the paper is packed.
447
Appendix F Form Design Checklist
Form Design Checklist

Use this checklist to help you remember key areas of consideration when
designing and ordering forms and paper stocks.
Environment
________ Before they are used, forms are given at least 24 hours of
condensing time in the environment in which they will be
used.
________ Forms are not stored in environments that result in such
damage as delamination of glue lines, creasing, folding, etc.
Type Of Form
Form Type (Check One)
1 Part 2 Part 3 Part 4 Part 5 Part 6 Part
<--------- Carbonless Range --------->
<---------------------------- Carbon Range ------------------------------>
Recycled Paper? Yes _______ No _______ If yes, assure adequate form

strength to prevent tractor holes and perforations from tearing or detaching
during form feeds and page ejects.
Security Form? Yes _______ No _______ If yes, the last page of the form
should have a minimum 50% reflectance and, if possible, the stippled page
faces inward to the form.
Form Weight
Form weight = ________
(Minimum = 15 lb. / 6.8 kg ; Maximum = 100 lb / 45.36 kg)
Form Thickness
Form thickness = ________
(0.025 inches / 0.0635 cm maximum measured at the thickest point of the
form, which includes perforations, compressed staples, glue lines, etc.)
Form Evenness
The evenness of the form = ________
(Not to exceed 0.003 in. / 0.00762 cm)
Tenting due to buildup of perforation thickness must be minimized. A
perforation thickness measured at the major perforation that exceeds 1.25
times the forms thickness measured in the print area will result in an
448
Chaff Content
unreliable and unpredictable form. Perforation thickness must not exceed the
maximum form thickness of 0.025 in. / 0.0635 cm.
Tractor Pin Holes

The holes which engage the tractor pins must conform to the following
specifications:
Specification Inches Millimeters
Hole centerline (CL) to edge of form 0.236 ± 0.028 6.0 ± 0.1
Hole Diameter (Serrations or any 0.156 ± 0.004 4.0 ± 0.1

occlusion due to incorrect registration
of multipart forms cannot exceed this
dimension.)
Distance between centers of two 0.500 ± 0.002 12.7 ± 0.05

consecutive holes
Maximum deviation of holes from their 0.004 0.1

centerline
Maximum deviation of lefthand hole to 0.006 0.15

adjacent righthand hole (CL to CL)
Maximum parallel deviation of lefthand 0.006 0.15

hole CL to righthand hole CL
Methods Of Forms Attachment

________ Must not allow air entrapment between copies of the form
________ Must not use hard brads or staples
________ Must not coincide with major perforation or any horizontal
perforation
________ Gluing lines must not result in a form that exceeds 0.025 in. /
0.0635 cm thickness
________ Staples must be used only in margin area of form
________ Staple cuts must not be in the direction of form movement
through the tractors
________ Staples must not occur in-line with the path of the tractor
holes
________ Staples should be placed in the margins so that they coincide
with areas of the form where printing will not occur
Cut-To-Tie Ratio
____:____ (Typical ratio is 4:1, or 80% cut to 20% tie)
449
Appendix F Form Design Checklist
Thickness Buildup = ________ in. / cm

NOTE: A cut-to-tie ratio that causes a thickness buildup greater than 0.025
in. / 0.0635 cm, or that creates an evenness variation greater than
0.003 in. / 0.00762 cm, will result in an unreliable and unpredictable
form.
Perforation Intersections
________ Horizontal-vertical perforations are tie points. Cut points at
such intersections are unacceptable.
Chaff Content
________ Tractor holes are clear of chaff.
________ There is no loose chaff in the box the paper is packed in.
450
Storage And Handling
Summary
Because it is impossible to test all possible forms available for use in the
printer, Printronix recommends that paper conform to the specifications
outlined in this appendix for the best printer performance.
But the guidelines in this appendix are not a substitute for actual testing.
Always test forms—including special single-part paper, multipart forms, forms
with glue strips, carbonless forms, card stock, and labels—for satisfactory
feeding, registration, and print quality prior to purchase. For best results in
selecting standard or specialty forms, consult a forms vendor who can ensure
conformance to the guidelines in this appendix and who can recommend cost-
effective purchases.
Storage And Handling

The performance of the printer depends to a large degree on the condition of
the paper used; therefore, the following principles for packaging, handling,
and storage are highly recommended.
Packaging
To avoid damage during handling, use top and bottom fillers in continuous
form cartons to hold the paper stack firmly in place. Proper packaging
ensures that the paper remains flat and is not damaged along the edges.
Storage
Do not store cartons directly on the floor, and do not stack them more than six
high. Set each carton upright and squarely on the one underneath. Do not
place anything else on the stack of paper, as this can damage the paper.
Preconditioning Forms
Protect paper from temperature and humidity extremes. Store paper in the
same environment as the printer for 24 to 48 hours before using the paper.
This allows the moisture content of the paper to stabilize.
P7000 printers are used at temperatures from 5° to 40° C (41° to 104° F) up
to 1524 meters (5000 feet), from 5° to 32° C (41° to 90° F) up to 2438 meters
(8000 feet), with a non-condensing relative humidity of 10% to 90%. This is
the full operating range; for the best results store the printer paper at 18° to
24° C (65° to 75° F), with a relative humidity of 40% to 50%.
If the printer is in an environment subject to extremes of temperature or
humidity, store the printer paper in a better environment and move it to the
printer as needed.
451
Appendix F Summary
452
G Maintenance Manuals For
P5000 Printers
This manual covers only P7000 printers. Information about Printronix P5000
line matrix printers is contained in the maintenance manuals summarized
below.
Type of Controller Type of

Printer Model Maintenance Manual
Board Hammer Bank
P5000 - Early CMX, CFX Single 164253-001 (See Table 11)
P5B / 10 / 15 CMX, CFX Single 175455-001 (See Table 12)

P5000 - Recent PSA3 Single 176475-001 (See Table 13)
P5220D, CFX, PSA3 Dual 173843-001 (See Table 14)

P5224D
Table 11. Early P5000 Single Hammer Bank Printers: Maintenance Manual 164253-001
Max Controller
Single Hammer
Model Print Enclosure
Speed
Bank Board1
P50KA™ 585 lpm Pedestal 91 Hammers 25 MHz CMX

Kanji / Hanzi
P500™ 900 lpm Pedestal 49 Hammers 25 MHz CMX
P5003H™ N/A Pedestal 60 Hammers 40 MHz CFX

Pedestal w/
P5005-QA™ 475 lpm Quick-Access 28 Hammers 25 MHz CMX
Cover
P5005-12™ 475 lpm Pedestal 28 Hammers, 25 MHz CMX

12 MIL tips
453
Appendix G
Max Controller
Single Hammer
Speed
Bank Board1
Pedestal w/ 28 Hammers,
P5005-12-QA™ 475 lpm Quick-Access 12 MIL tips 25 MHz CMX
Cover
P5005A™ 500 lpm Pedestal 28 Hammers 25 MHz CMX
Pedestal w/
P5005A-QA™ 500 lpm Quick-Access 28 Hammers 25 MHz CMX
Cover
P5005A-12™ 500 lpm Pedestal 28 Hammers, 25 MHz CMX

12 MIL tips
P5005A-12-QA™ 500 lpm Quick-Access 12 MIL tips 25 MHz CMX
Cover
P5005B™ 500 lpm Pedestal 28 Hammers 40 MHz CMX
Pedestal w/
P5005B-QA™ 500 lpm Quick-Access 28 Hammers 40 MHz CMX
Cover
P5005B-12™ 500 lpm Pedestal 28 Hammers, 40 MHz CMX

12 MIL tips
P5005B-12-QA™ 500 lpm Quick-Access 12 MIL tips 40 MHz CMX
Cover
P5006H™ N/A Pedestal 102 Hammers 40 MH CFX
Pedestal w/
Cover
Pedestal w/
Cover
Pedestal w/
Cover
454
Max Controller
Single Hammer
Speed
Bank Board1
Pedestal w/
Cover
P51KA™ 585 lpm Table Top 91 Hammers 25 MHz CMX
Kanji / Hanzi
P52KA™ 585 lpm Cabinet 91 Hammers 40 MHz CMX

Kanji / Hanzi
P5203H™ N/A Cabinet 60 Hammers 40 MHz CFX
P5205™ 475 lpm Cabinet 28 Hammers 25 MHz CMX
P5205-12™ 475 lpm Cabinet 28 Hammers, 25 MHz CMX

12 MIL tips
P5205A™ 500 lpm Cabinet 28 Hammers 25 MHz CMX
P5205A-12™ 500 lpm Cabinet 28 Hammers, 25 MHz CMX

12 MIL tips
P5205B™ 500 lpm Cabinet 28 Hammers 40 MHz CMX
P5205B-12™ 500 lpm Cabinet 49 Hammers, 40 MHz CMX

12 MIL tips
Cabinet
P5214-SS™ 1400 lpm w/SureStak 91 Hammers 40 MHz CMX
Paper Stacker
Cabinet
Paper Stacker
1
The 40 MHz CMX controller board is also compatible with earlier models that used the 25
MHz CMX board and should be used if the CMX board is replaced in one of these older models.
The CFX, V1, controller board was used only in early models P5003H, P5203H, P5006H, and
P5206H.
455
Appendix G
Table 12. Later P5000 Single Hammer Bank Printers (The “P5B/10/15” Line):
Maintenance Manual 175455-001
Maximum Controller
Model Print Enclosure Hammer Bank
Speed 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- 28 Hammers 40 MHz CMX

Access Cover
P5005B-12™ 500 lpm Pedestal 28 Hammers, 40 MHz CMX

12 MIL tips
P5005B-12-QA™ 500 lpm Pedestal w/Quick- 28 Hammers, 40 MHz CMX

Access Cover 12 MIL tips
P5006H™ N/A Pedestal 102 Hammers 40 MH CFX
P5010-QA™ 1000 lpm Pedestal w/Quick- 60 Hammers 40 MHz CMX

Access Cover
P5015-QA™ 1500 lpm Pedestal w/Quick- 102 Hammers 40 MHz CMX

Access Cover
P5205B™ 500 lpm Cabinet 28 Hammers 40 MHz CMX
P5205B-12™ 500 lpm Cabinet 49 Hammers, 40 MHz CMX

12 MIL tips
Cabinet
Paper Stacker
1The 40 MHz CMX controller board is compatible with all PSA P5XXX printers except the
P5220S and H-Series (which use the CFX controller board) and printers that use the PSA3
controller board. The 40 MHz CFX, V3, controller board was used in PSA models P5003H,
P5203H, P5006H, and P5206H until the H-Series line expanded and upgraded to the PSA3
controller board.
456
Table 13. P5000 PSA3 Single Hammer Bank Printers: Maintenance Manual 176475-001
Maximum Printer Controller

Model Hammer Bank
Print Speed Enclosure Board1
P5003H™ 340 lpm Pedestal 60 Hammers PSA3
P5203H™ 340 lpm Cabinet 60 Hammers PSA3


P5220S™ 2000 lpm Cabinet 126 Hammers PSA3
Cabinet
P5220S-SS™ 2000 lpm w/SureStak 126 Hammers PSA3
Paper Stacker
1The PSA3 controller board is the only controller board that can be used in these printers.
Printers that use the PSA3 board cannot use the CMX or CFX controller boards.
Table 14. P5220D and P5224D Dual Hammer Bank Printers:

Maintenance Manual 173843-001
Maximum Print Printer Controller

Model Hammer Bank
Speed Enclosure Board1
P5220D™ 2000 lpm Cabinet 156 Hammers CFX
Cabinet
P5220D-SS™ 2000 lpm w/SureStak 156 Hammers CFX
Paper Stacker
P5224D™ 2400 lpm Cabinet 156 Hammers PSA3
Cabinet
P5224D-SS™ 2400 lpm w/SureStak 156 Hammers PSA3
Paper Stacker
1
The controller boards are not interchangeable in these printers. The PSA3 and CFX controller
boards and their respective card cages differ in physical dimensions and design.
457
Appendix G
458
Index
Numerics splined shaft skew adjustment, 170

tractor belt tension, 187
06 HOST REQUEST, 39 ASCII character set, 149
08 HOLD PRINT TIMEOUT, 39 Asterisk (*), meaning on messages, 39
15 COMM CHECK, 40
B
15V POWER FAIL, 41
22 INVALID ADDR, 41 B00 STATUS: SDRAM DETECTION 166MHZ, 48
23.5V FAIL*, 42 B01 STATUS: 8245 SDRAM TEST 32MB, 48
31 PAPER OUT TIMEOUT, 42 B10 ERROR: NO DRAM DETECTED*, 48
32 PAPER JAM TIMEOUT, 43 B11 ERROR: RAM TEST FAILED*, 48
33 PLATEN OPEN TIMEOUT, 44 B12 ERROR: PROGRAM MISSING*, 48
34 RIBBON STALL TIMEOUT, 45 B13 ERROR: NOT COMPATIBLE*, 48
48 V CIRCUIT* See User Manual, 46 B19 ERROR: DC RETURNED*, 49
48V PWR FAIL*, 46 B20 STATUS: 00% DOWNLOAD MODE, 49
733 DP FIFO Busy*, 47 B21 STATUS: PRINTER RESET, 49
8.5V POWER FAIL*, 40 B22 ERROR: DECOMPRESS SIZE*, 49
A B23 ERROR: DECOMPRESS CKSUM*, 49
B30 STATUS: INITIALIZING..., 49
A TO D OVERRUN*, 48 B35 STATUS: WAITING FOR EC STATUS, 50
Abbreviations, 359 B40 ERROR: SDRAM EEPROM CKSUM BAD*, 50
About This Manual, 23 B41 ERROR: DIMM MEMORY NOT SDRAM*, 50
ACCESS NULL PTR*, 47 B42 ERROR: SDRAM ROWS NOT ALLOWED*, 50
Acronyms, 359 B43 ERROR: SDRAM TOO MANY BANKS*, 51
ACTIVATE LOST, 47 B44 ERROR: SDRAM NOT 64 BITS WIDE*, 51
Adjustments, 157 B45 ERROR: SDRAM IS WRONG VOLTAGE*, 51
coil temperature, 184 B46 ERROR: SDRAM HAS MIXED SIZES*, 52
dynamic paper tension, 185 B47 ERROR: SDRAM LARGER THAN 256M*, 52
hammer phasing, 173 B49 ERROR: SDRAM # LOGICAL BANKS*, 52
loading flash memory, 175 B50 ERROR: SDRAM LOGIC COMB BANKS*, 53
paper feed timing belt tension, 160 B51 STATUS: XX% LOADING, 53
paper out, 170 B54 ERROR: SDA LINE STUCK LOW, 53
paper scale, 164 B55 SEND PROGRAM TO EC, 53
platen gap, 166 BARCODE DAMAGED - Reverse Ribbon, 54
platen open belt, 162 BARCODE MISSING - Install New RBN, 54
ribbon guide, 168 Belt
459
paper feed timing CLOSE PLATEN, 57
replacement, 200 Code, configuration, printer, 20
tension adjustment, 160 Coil temperature adjustment, 184
platen open Communications failures, 132
replacement, 201 Configuration, 23
tension adjustment, 162 Configuration code, printer, 20
Block diagram Connector coupling shrouds, replacement, 203
control panel, 304 Control panel
Boards block diagram, 304
controller, 206 keys
layouts, connections, and pinouts, 313 cabinet models, 26
power supply, 233 replacement, 205
Boot diagnostics menu, 140 Controller board
Brush, static, pedestal printer, replacement, 244 principles of operation, 305
BUFFER OVERRUN, 54 replacement, 206
C status LEDs, 151
Controls and indicators
Cable assembly cabinet models, 26
coupling shroud and cable replacement, 203 mechanical, 28
interconnections, 313 printing conventions, 24
part numbers, 313 Conventions, printing, used in this manual, 24
routing diagrams, 313 Conversion, metric measurement, 367
Cable shorts test, 190 Coupling shrouds, connector, replacement, 203
Card cage Cover assembly
fan assembly, replacement, 214 hammer bank/ribbon mask, replacement, 208
CD-ROM, loading software from, 175 shuttle, replacement, 209
Checks top, pedestal models, 210
cable shorts, 190 CT board, replacement, 211
hammer bank power cable shorts, 189 CTL VOLT FAIL*, 58
shuttle electrical shorts, 188 Customer Support Center, 31
Circuit board Cycle power, 150
replacement
D
controller, 206
power supply, 233 Dashpot, replacement, 212
Circuit breaker Data controller (DC), 307
replacement, 202 DC (Data Controller, PSA3 controller board), 307
Cleaning DIAGNOSTIC PASSED, 58
card cage fan assembly, 36 Diagnostic printer tests, 134
printer, 33 Diagrams
shuttle frame assembly, 35 cable routing, 313
CLEAR PAPER JAM, 55 interconnection and cables, 313
Clearing LCD messages, 39 DIMM, location and replacement, 220
CLEARING PROGRAM FROM FLASH, 56 Display messages, printing conventions, 24
460
Documents related to this manual, 23 E32C CND 2 BP - See User Manual, 68
Downloading software, 175 E32D CND 3 BP - See User Manual, 68
DP FIFO Busy*, 58 E32E CND 4 BP - See User Manual, 68
DRVR CIR BAD*, 59 E32F CND 5 BP - See User Manual, 69
E E32G CND 6 BP - See User Manual, 69
E32H CND 7 BP - See User Manual, 69
E Net Test Unavailable, 70 E33 WRITE BP - See User Manual, 69
E00 EXE @ ADDR0 - See User Manual, 59 E34 TRACE CMPLT - See User Manual, 70
E01A TYPE 0x40 - See User Manual, 59 E99 UNKNOWN INT - See User Manual, 70
E01B TYPE 0x60 - See User Manual, 59 EC (Engine Controller, CMX board), 309
E02 MACHINE CHK - See User Manual, 60 Emulation software, loading, 175
E03A DSI HASH L - See User Manual, 60 Engine controller (EC), 309
E03B DSI HASH S - See User Manual, 60 Error messages, 39
E03C DSI BAT PL - See User Manual, 60 clearing, 39
E03D DSI BAT PS - See User Manual, 61 ERROR OCCURRED FLUSHING QUEUES*, 70
E03E DSI CXIWX - See User Manual, 61 ERROR: DC PROGRAM NOT VALID, 70
E03F DSI CXOWX - See User Manual, 61 ERROR: DRAM AT ADDRESS XXXXXXXX, 70
E03G DSI ECXIWX - See User Manual, 61 ERROR: EC PROGRAM NOT VALID, 71
E03H DSI ECXOWX - See User Manual, 62 ERROR: EC STOPPED AT STATE XXXX, 71
E04A ISI NO TRA - See User Manual, 62 ERROR: FLASH DID NOT PROGRAM, 71
E04B ISI DIRECT - See User Manual, 62 ERROR: FLASH NOT DETECTED, 71
E04C ISI PROTEC - See User Manual, 62 ERROR: LOCKED SN=nnnnnnnnnnnnnnnn, 72
E06 NOT ALIGNED - See User Manual, 63 ERROR: NO DRAM DETECTED, 72
E07 ILLEGAL INS - See User Manual, 63 ERROR: NVRAM FAILURE, 72
E08 FLOATINGPNT - See User Manual, 63 ERROR: PROGRAM NEEDS MORE FLASH, 72
E12 SYSTEM CALL - See User Manual, 63 ERROR: PROGRAM NEES MORE DRAM, 72
E13 TRACE INT - See User Manual, 64 ERROR: PROGRAM NOT COMPATIBLE, 72
E16 ITRANS MISS - See User Manual, 64 ERROR: PROGRAM NOT VALID, 72
E17 DLOAD MISS - See User Manual, 64 ERROR: SECURITY KEY NOT DETECTED, 73
E18 DSTORE MISS - See User Manual, 64 ERROR: SHORT AT ADDRESS XXXX, 73
E19 BREAKPOINT - See User Manual, 65 ERROR: WRITING TO FLASH, 73
E20 SYS MANAGE - See User Manual, 65 ERROR: WRONG CHECKSUM, 73
E30 DEBUGGER - See User Manual, 65 ERROR: WRONG OEM OR PRINTER TYPE, 73
E31A EVENT 0 BP - See User Manual, 65 ETHERNET DETECTED, 73
E31B EVENT 1 BP - See User Manual, 66 ETHERNET INITIALIZING, 74
E31C EVENT 2 BP - See User Manual, 66 Ethernet interface, replacement, 222
E31D EVENT 3 BP - See User Manual, 66 EXCESS RIBBON WEAR - Install New RBN, 74
E31E EVENT 4 BP - See User Manual, 66 EXHAUST FAN FLT, 75
E31F EVENT 5 BP - See User Manual, 67
F
E31G EVENT 6 BP - See User Manual, 67
E31H EVENT 7 BP - See User Manual, 67 Factory menu, 143
E32A CND 0 BP - See User Manual, 67 Fan assembly
E32B CND 1 BP - See User Manual, 68 card cage, replacement, 214
461
hammer bank, replacement, 213, 215 Illustrations, replacement procedures, 249
Fault messages, 39 Important Maintenance Notes, 22
FIRMWARE ERROR, 76 Incompat E-NET - Remove NIC, 81
FM HEADER ERROR, 76 Incompat WLAN - Remove NIC, 81
FRAMING ERROR, 76 Installation, 23
G INTAKE FAN FAULT, 81
Integrated Print Management System, 299
Gap, adjustment control panel menus, 299
magnetic pick-up (MPU), 219 operation, 299
platen, 166 ribbon action, 300
GRF CHK ERROR PRESS STOP, 76 ribbon end point, 300
Grounding requirements, 31 ribbon installation and detection, 301
H ribbon log, 302
INTERRUPT UNUSED VECTOR 00, 82
H00: PCI SLOT ? - See User Manual, 77
INVALID ACTIVATE, 82
H01: PCI J12 - See User Manual, 77
INVALID COMMAND, 83
H02: PCI J13 - See User Manual, 77
Half Speed Mode, 78 K
HAM. COIL OPEN*, 78 Kanji printers, 20
Hammer Key, security, location, 221
phasing adjustment, 173 Keys, locations and operation
spring assembly, replacement, 216 cabinet models, 26
Hammer bank
L
cover assembly, replacement, 208
fan assembly, replacement, 213, 215 LAN interface, replacement, 222
power cable shorts test, 189 LEDs, controller board status, 151
wiring diagram, 313 Levers and knobs, 28
HAMMER COIL BAD #, #, #, #, ... etc., 79 Line matrix printing explained, 291
Hammer phasing adjustment, 173 LO DRV. SHORT*, 83
Hangul printers, 20 LOAD PAPER, 84
Hanzi printers, 20 LOADING PROGRAM FROM PORT XX%, 84
Hard reset, 150 LOADING PROGRAM INTO FLASH, 85
HB NOT INSTALLED*, 79 M
Hex code printout, 146
HMR BANK FAN FLT, 80 Magnetic pick-up assembly
How to Identify the Printer, 18 gap adjustment, 219
How to Use This Manual, 24 replacement, 219
H-Series printers, 20 Main wire harness test diagnostic, 192
Maintenance
I
adjustments, 157
Identifying printer models, 18 cleaning the printer, 33
ILL EXT BUS ACC*, 80 important maintenance notes, 22
ILL INST ACCSS*, 80 overview, 17, 453
ILLGL OPR ACCSS*, 81 preventive, 33
462
training for Printronix products, 32 PAP FIFO UNDRFL*, 88
Manual PAP ILLGL ST*, 89
how to use, 24 PAP INCMPL ENER*, 89
notes and notices, 24 PAP INVLD CMD*, 89
printing conventions, 24 PAP INVLD PARM*, 89
related documents, 23 PAP NOT SCHED*, 90
Mechanical controls and indicators, 28 PAP NT AT SPEED*, 90
Memory PAP UNEXP INT*, 90
loading, 175 Paper
location and replacement, 220 detector switch assembly, replacement, 246
Menus dynamic paper tension adjustment, 185
printer test, 134 feed drive motor, replacement, 223
Message List (troubleshooting), 39 feed timing belt replacement, 200
Messages feed timing belt tension adjustment, 160
asterisk (*), what it means, 39 ironer, replacement, 224
clearing, 39 path, removal, 225
Metric measurement, conversion tables, 367 scale adjustment, 164
Mnemonics, 359 specifications, 441
Models, printer, how to identify, 18 stacker, power, 369
Motor tractor (L/R), replacement, 248
paper feed drive, replacement, 223 Paper out adjustment procedure, 170
platen open, replacement, 230 PARAMETER ERROR, 91
ribbon drive, replacement, 236 PARITY ERROR, 91
MPU See Magnetic pick-up assembly, 219 Parts
N illustrations, 249
Phasing adjustment, 173
NEW SPX DETECTED PRESS ENTER, 85 Pinouts, 313
NIC (Network Interface Card) assembly, PLAT INV CMD*, 92
replacement, 222 PLAT INV PARM*, 92
Notes and notices PLAT INV STATE*, 92
safety and information, 24 Platen
O gap adjustment, 166
interlock switch assembly, replacement, 247
OLD RIBBON - Install New RBN, 85
platen open belt adjustment, 162
ONLINE 28 CU NOT ENAB, 85
platen open motor, replacement, 230
ONLINE 8344 FAILED, 86
platen stop assembly, replacement, 232
ONLINE CU TIMED OUT, 86
replacement, 226
Operation, principles of, 291
PLEASE WAIT ... RESET IN PROGRESS, 92
P Power
PAP BAD TABLE*, 86 cycle, how to, 150
PAP BSY TOO LNG*, 86 start up sequence, 151
PAP FD DRVR CIR* See Manual, 87 Power on sequence, 151
PAP FIFO OVERFL*, 87 POWER SAVER MODE, 92
463
Power supply board circuit breaker, 202
operational check, 193 connector coupling shrouds, 203
principles of operation, 311 control panel assembly, 205
replacement, 233 controller circuit board, 206
POWER SUPPLY HOT, 93 cover assembly, top, pedestal models, 210
Principles of operation, 291 CT board, 211
Printer dashpot, 212
adjustments, 157 Ethernet interface, 222
cleaning, 33 extension spring, hammer bank, 243
configuration, 23 hammer bank / ribbon mask cover assembly,
diagnostic self-tests, 134 208
diagnostic tests, 134 hammer bank fan assembly, 213, 215
grounding requirements, 31 hammer spring, 216
identification, 18 LAN interface, 222
installation, 23 magnetic pick-up assembly, 219
logical control of, 303 memory and security key, 220
maintenance overview, 17, 453 NIC (Network Interface Card) assembly, 222
models, 17 paper detector switch assembly, 246
how to identify, 18 paper feed drive motor, 223
Kanji/Hanzi, 20 paper feed timing belt, 200
power paper stacker, 369 paper ironer, 224
principles of operation, 291 paper path, 225
reset, 150 platen, 226
troubleshooting, 37 platen interlock switch assembly, 247
PRINTER HOT, 94 platen open belt, 201
Printing platen open motor, 230
conventions is this manual, 24 platen stop assembly, 232
line matrix printing explained, 291 power supply circuit board, 233
problems, 37 resistors, terminating, 234
Printouts ribbon drive motor, 236
hex code, 146 ribbon guide assembly (L/R), 237
Procedures shuttle cover assembly, 209
adjustment, 157 shuttle frame assembly, 241
cleaning, 33 splined shaft, 238
PROTECTED INSTR*, 94 static brush, pedestal printer, 244
PWR SUPP VOLT*, 94 support shaft, 240
Q tractor (L/R), 248
Reset, soft vs. hard, 150
QUEUE OVERRUN, 95 Resistors, terminating
R location of, 235
RESTORING BOOT CODES, 95
REMOVE USED SPX THEN PRESS ENTER, 95
Ribbon
Replacement
drive motor, replacement, 236
card cage fan assembly, 214
464
guide assembly (L/R), replacement, 237 SIMM, location and replacement, 220
guide assembly, alignment, 168 Soft reset, 150
mask, replacement, 208 SOFTWARE ERROR* CYCLE POWER, 99
RIBBON AT END POINT - Change Ribbon, 95 Software Program Exchange (SPX) module, 182
Ribbon Log, 302 Software, loading, 175
RIBBON UNDER 2% - Change RBN Soon, 95 Specifications
S paper, 441
Splined shaft
Safety, 25 replacement, 238
notices, 25 skew adjustment, 170
notices, defined, 24 Spring
Safety Notices, 25 extension, hammer bank, replacement, 243
SCS COMMAND ERROR, 96 hammer, replacement, 216
Security key SPX, 182
location and replacement, 220, 221 SPX FOUND, ERROR: KEY NOT DETECTED, 99
reprogramming with the SPX module, 182 SPX NOT NEEDED OPTIONS ENABLED, 100
SECURITY PAL NOT DETECTED, 96 STACK OVERFLOW*, 100
SECURITY VIOLATION, 96 STACK UNDERFLOW*, 100
Self-tests STACKER FAULT, 101
diagnostic, printer, 134 STACKER FULL, 102
printer, 134 STACKER JAM, 103
Setup, SureStak Power Paper Stacker, 371 Stacker, power, 369
SF ERROR, 96 confidence check, 376
Shaft installation, 386
splined, replacement, 238 motor check, 377
splined, skew adjustment, 170 operation, 370
support, replacement, 240 operational inspection, 375
Shorts problems, 375
cable, checking for, 190 removal, 380
hammer bank power cable, checking for, 189 replacing
Shorts, electrical, shuttle, checking for, 188 constant force spring, 397
SHUT DRVR CIR* See User Manual, 97 timing belts, 399
SHUTL INV CMD*, 97 Start up sequence, 151
SHUTL INV PARM*, 97 Static brush, pedestal printer, replacement, 244
SHUTL OVR SPEED*, 97 Status LEDs on the controller board, 151
Shuttle Supplies Department, 32
cover assembly, replacement, 209 Support shaft
frame assembly, replacement, 241 replacement, 240
Shuttle Electrical Short Check, 188 Support, technical, 31
SHUTTLE JAM, 98 SureStak Power Paper Stacker
SHUTTLE STALL, 99 loading, 374
SHUTTLE TYPE NOT SUPPORTED*, 99 setup, 371
Signal mnemonics, 359 starting, 374
465
Switch Troubleshooting, 37
paper detector switch assembly, replacement, aids, 37
246 communications failures, 132
platen interlock switch assembly, replacement, fault messages, 39
247 message list, 39
power, replacement, 202 power paper stacker, 375
T procedures, 132
start here..., 38
TCB CORRUPTED*, 104 symptoms not indicated by messages, 107
TCP Port Busy, 104 Troubleshooting Procedures, 132
Technical support, 31
U
Temperature, coil, adjustment, 184
Tension adjustment UNDEF INTERRUPT*, 105
dynamic paper tension, 185 UNDFNED OPCODE*, 105
paper feed timing belt, 160 UNKNOWN RBN1, 105
platen open belt, 162 UNKNOWN RBN2, 105
Terminating resistors UP DRV. SHORT*, 105
location of, 235 W
replacement, 234
Test WAITING FOR ETHERNET ADAPTER, 106
equipment, tools, and supplies, 30 Wiring diagrams, 313
Tests Z
cable shorts, 190
Zero Tear Pedestal (ZTP), 417
hammer bank cable shorts, 189
adjust paper guides, 420
main wire harness diagnostic, 192
control panel menus, 419
power supply operation, 193
forms type, 417
printer, 134
load paper, 421
printer, diagnostic, 134
operation, 420
Tools, test equipment, and supplies, 30
overview, 417
Torque
position paper out sensor, 424
conversion to or from metric, 367
set top of form, 423
Tractor
ZTP, 417
replacement, 248
parts lists, 425
Training, maintenance, for Printronix products, 32
TRNSPT INVL CMD* See User Manual, 95
466
Printronix, Inc. Printronix Schweiz Gmbh Printronix, Inc.
14600 Myford Road 42 Changi South Street 1 Nederland BV
P.O. Box 19559 Changi South Industrial P.O. Box 163 Nieuweweg 283
Irvine, CA92623-9559 Estate Singapore 486763 NI-6600 Ad Wijchen
Phone: (714) 368-2300 Phone: (65) 6542 0110 The Netherlands
Fax: (714) 368-2600 Fax: (65) 6543 0220 Phone: (31) 24 6489 489
Fax: (31) 24 6489 499
Or visit the Printronix web site at www.printronix.com
*177705-001*
177705-001B

Printronix p7000 Maintenance Manual

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Maintenance Manual

Printronix P7000 Series of Line Matrix Printers

Warranty And Copyright Information

Copyright © 2005, Printronix, Inc.

The Environmental Protection Agency ENERGY STAR® Computers program is

European Union (EU) Conformity Statement

This is a Class A product. In a domestic environment this product may

Industry Canada Compliance Statement

Cet appareil numérique de la classe A conform á la norme NMB-003 du

Statement of CISPR 22 Edition 2 Compliance

Japanese VCCI Class A

Warning: This is a Class A product. In a domestic environment this product

German Conformity Statement

Das Gerät erfüllt die Schutzanforderungen nach EN 55022 und

EN 55022 Klasse A Geräte bedürfen folgender Hinweise:

Paragraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung

European Union (EC) Electromagnetic Compatibility

1 Maintenance Overview ....................................... 17

2 Preventive Maintenance ..................................... 33

General Symptom List................................................................. 108

4 Adjustments and Tests ..................................... 157

Tractor (L/R) ................................................................................ 248

6 Principles Of Operation..................................... 291

A Wire Data ......................................................... 313

C Metric Conversion Tables ................................ 367

D SureStak™ Power Stacker .............................. 369

Replacing The Constant Force Spring............................................... 397

E Zero Tear Pedestal (ZTP) ................................ 417

F Paper Specifications And Forms Design.......... 441

G Maintenance Manuals For P5000 Printers ...... 453

Printronix P7000 Printers

Optional Features Enhance Graphics

Order The Correct Spares

How To Identify A P7000 Printer

Figure 1. How to Interpret a Model Number

Table 1. P7000 Printers

P7003H 300 lpm Pedestal 60 Hammers

P7003HZT 300 lpm Zero Tear 60 Hammers

P7005 500 lpm Pedestal 28 Hammers

P7005ZT 500 lpm Zero Tear 28 Hammers

P7205 500 lpm Cabinet 28 Hammers

P7006H 600 lpm Pedestal 102 Hammers

P7006HZT 600 lpm Zero Tear 102 Hammers

P7206H 600 lpm Cabinet 102 Hammers

P7008H 800 lpm Pedestal 126 Hammers

P7208H 800 lpm Cabinet 126 Hammers

P7010 1000 lpm Pedestal 60 Hammers

P7210 1000 lpm Cabinet 60 Hammers

P7015 1500 lpm Pedestal 102 Hammers

P7015ZT 1500 lpm Zero Tear 102 Hammers

P7215 1500 lpm Cabinet 102 Hammers

P7220 2000 lpm Cabinet 126 Hammers

Table 2. H-Series Character Sets

Character Set Where Used

BIG-5, with an additional 3000 Cantonese characters Hong Kong

Zero Tear Pedestal (ZTP) Printers

Printer Configuration Code

V8 ASIC Revision Level

Figure 2. How to Interpret the Printer’s Configuration Code