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T6090 Maintenance Manual Line Impact Printer with T6065, T6091, T6100 & T6101 Supplements
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Page 1: 083533TX - 6090 Updated Maintenance Manual

T6090Maintenance Manual

Line Impact Printer

with T6065, T6091,T6100 & T6101 Supplements

Page 2: 083533TX - 6090 Updated Maintenance Manual

This Manual is published by Tally Printer Corporation for use withthe computer printer described herein. Translations, reprinting orcopying by any means of this manual, complete or in part, in anydifferent form requires our explicit approval. Tally PrinterCorporation reserves the right to revise this manual without notice,for any reason. This includes, but is not limited to, utilization ofadvances in the state-of-the-art and changes in the equipment orconfiguration thereof. Liability for difficulties arising fromunknown or unforeseen technical limitations is disclaimed.

FCC StatementThis equipment has been tested and found to comply with the limitsfor a Class A digital device, pursuant to Part 15, Subpart B of theFCC Rules. These limits are designed to provide reasonableprotection against harmful interference when the equipment isoperated in a commercial environment. This equipment generates,uses, and can radiate radio frequency energy and, if not installed andused in accordance with the instruction manual, may cause harmfulinterference to radio communications. Operation of this equipmentin a residential area is likely to cause harmful interference, in whichcase the user will be required to correct the interference at his ownexpense.

PRINT

ED

O

NRECYCLE

DP

APER

© Jan. 1997Tally Printer CorporationAll rights reservedPrinted in the United States

Ref. Manual Number 080933Tally Printer Corporation8301 South 180th Street

Kent, Washington 98032

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Table of Contents

Table of Contents

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Table Of Contents

1

Subject Listing

Chapter 1. Electronic Hardware Architecture, Performance And SpecificationsTechnical Overview ....................................................................................................................................................... 1–1T6090 Electronic Hardware Architecture ..................................................................................................................... 1–1

Engine Control Module ......................................................................................................................................... 1–1Control Processor ........................................................................................................................................... 1–1

Sensor Inputs .......................................................................................................................................... 1–1Shuttle Processor ............................................................................................................................................ 1–1Hammer/Motor logic and drive ..................................................................................................................... 1–2EEPROM ........................................................................................................................................................ 1–2

T6090 Personality Module .................................................................................................................................... 1–2Serial and Parallel Interfaces ................................................................................................................................. 1–3

Serial ............................................................................................................................................................... 1–3Parallel ............................................................................................................................................................ 1–3

Motorola MC68340 ............................................................................................................................................... 1–3Flash Memory ........................................................................................................................................................ 1–3DRAM .................................................................................................................................................................... 1–3Altera EPM7064 .................................................................................................................................................... 1–3

Specifications ................................................................................................................................................................. 1–4Serial/Parallel Emulations ..................................................................................................................................... 1–4Font Styles .............................................................................................................................................................. 1–4

Courier and Gothic ......................................................................................................................................... 1–4Data Processing and Draft ............................................................................................................................. 1–4OCR–A and OCR–B ...................................................................................................................................... 1–4

Characters Per Inch ................................................................................................................................................ 1–4Lines Per Inch ........................................................................................................................................................ 1–5Dot Densities and Plot Speeds ............................................................................................................................... 1–6Graphic Benchmarks .............................................................................................................................................. 1–6Paper Slew Speed ................................................................................................................................................... 1–7Ribbons................................................................................................................................................................... 1–7Forms/Paper Description ....................................................................................................................................... 1–7Acoustics ................................................................................................................................................................ 1–8Power Supply ......................................................................................................................................................... 1–8Cooling System ...................................................................................................................................................... 1–8Safety ...................................................................................................................................................................... 1–8Preventive Maintenance ......................................................................................................................................... 1–9Environment ........................................................................................................................................................... 1–9

Operating ........................................................................................................................................................ 1–9Nonoperating .................................................................................................................................................. 1–9

Heat Load Contribution ....................................................................................................................................... 1–10Physical Configurations ....................................................................................................................................... 1–10

Weight .......................................................................................................................................................... 1–10Printer Dimensions............................................................................................................................................... 1–11Industry and Agency Standards ........................................................................................................................... 1–11Electromagnetic Emissions .................................................................................................................................. 1–11Agency Approvals ................................................................................................................................................ 1–11

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Chapter 2. Menu OperationsIntroduction .................................................................................................................................................................... 2–1Technical Access Mode ................................................................................................................................................. 2–1

Entering Tech Access Mode .................................................................................................................................. 2–1Exiting Tech Access Mode .................................................................................................................................... 2–1

Testing, Troubleshooting, and Calibration .................................................................................................................... 2–1Printer Tests ............................................................................................................................................................ 2–1Hex Dumps ............................................................................................................................................................. 2–2Printer Information Printouts and Displays ........................................................................................................... 2–2

HELP Menu ................................................................................................................................................... 2–2Printing a HELP Menu ........................................................................................................................... 2–2

Report Parameter (Menu Level 2) ................................................................................................................. 2–2Report selections (Menu Level 3) .......................................................................................................... 2–3Selecting a Printer Report ....................................................................................................................... 2–3

TEST Menu .................................................................................................................................................................... 2–3Pattern Category (Menu Level 1) .......................................................................................................................... 2–5

Print Parameter (Menu Level 2) .................................................................................................................... 2–6Print selections (Menu Level 3) .............................................................................................................. 2–6

Print2 Parameter (Menu Level 2) .................................................................................................................. 2–6Print2 selections (Menu Level 3) ............................................................................................................ 2–6

Plot Parameter (Menu Level 2) ...................................................................................................................... 2–6Plot selections (Menu Level 3) ............................................................................................................... 2–7Selecting And Running a Print Test ........................................................................................................ 2–7

Diagnostic Category (Menu Level 1) .................................................................................................................... 2–8PrntCal (Print Calibration) Parameter (Menu Level 2) ................................................................................. 2–8

Selecting And Running a Hammer Calibration Routine ........................................................................ 2–8Selecting And Running a Current Calibration Routine .......................................................................... 2–9Selecting And Running a Paper Out Calibration Routine ...................................................................... 2–9

Meter Parameter (Menu Level 2) .................................................................................................................. 2–9Meter selections (Menu Level 3) .......................................................................................................... 2–10

Motors Parameter (Menu Level 2) .............................................................................................................. 2–10Motors selections (Menu Level 3) ........................................................................................................ 2–10

Sht Spd (Shuttle Speed) Parameter (Menu Level 2) ................................................................................... 2–10Shuttle Speed selections (Menu Level 3) ............................................................................................. 2–11

Rbn Spd (Ribbon Speed) Parameter (Menu Level 2) ................................................................................. 2–11 Speed selections (Menu Level 3) ......................................................................................................... 2–11

RibnThr (Ribbon Threshold) Parameter (Menu Level 2) ........................................................................... 2–11Threshold selections (Menu Level 3) ................................................................................................... 2–11

POutThr (Paper Out Threshold) Parameter (Menu Level 2) ...................................................................... 2–11Threshold selections (Menu Level 3) ................................................................................................... 2–11

PMoThr (Paper Motion Threshold) Parameter (Menu Level 2) ................................................................. 2–11Threshold selections (Menu Level 3) ................................................................................................... 2–11

Heavy (Heavy Forms) Parameter (Menu Level 2) ...................................................................................... 2–11Heavy Forms selections (Menu Level 3) .............................................................................................. 2–11

Max T (Maximum Temperature) Parameter (Menu Level 2) ..................................................................... 2–11EnStar (Energy Star) Parameter (Menu Level 2) ........................................................................................ 2–12

Energy Star selections (Menu Level 3) ................................................................................................ 2–12Clear Parameter (Menu Level 2) ................................................................................................................. 2–12

Clear selections (Menu Level 3) .......................................................................................................... 2–12Fault Override (FltOvrd) Category (Menu Level 1) ........................................................................................... 2–12

Pap Mot (Paper Motion) Parameter (Menu Level 2) .................................................................................. 2–12

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Pap Out (Paper Out) Parameter (Menu Level 2) ......................................................................................... 2–12Rib Mot (Ribbon Motion) Parameter (Menu Level 2) ................................................................................ 2–12Shuttle Parameter (Menu Level 2) ............................................................................................................... 2–12Temp (Temperature) Parameter (Menu Level 2) ......................................................................................... 2–12Platen Parameter (Menu Level 2) ................................................................................................................ 2–13Ctrl (Control Processor) Parameter (Menu Level 2) ................................................................................... 2–13Link Parameter (Menu Level 2) ................................................................................................................... 2–13Hvy Frm (Heavy Forms) Parameter (Menu Level 2) .................................................................................. 2–13Panel Parameter (Menu Level 2) ................................................................................................................. 2–13

Control Panel Key Operations For Controlling Fault Reporting ........................................................................ 2–13ALL Fault Reporting .................................................................................................................................... 2–13Four Faults Only .......................................................................................................................................... 2–13Paper Out Only ............................................................................................................................................. 2–13

Chapter 3. TroubleshootingIntroduction .................................................................................................................................................................... 3–1Messages ........................................................................................................................................................................ 3–1

Faults ...................................................................................................................................................................... 3–1Fault Correction Procedure ............................................................................................................................ 3–1Fault Override ................................................................................................................................................ 3–2Dump Mode ................................................................................................................................................... 3–2

Hardware Troubleshooting Guides .............................................................................................................................. 3–10The printer does not power up when switched on............................................................................................... 3–10When the printer is powered up, nothing works except the fan. ........................................................................ 3–10The printer powers up but the Control Panel does not function. ........................................................................ 3–11The Control Panel Display functions partially, nonsensically, or not at all. ...................................................... 3–11There is no printed output but the printer appears to be operating normally. .................................................... 3–12Printed output appears light ................................................................................................................................. 3–12Printed output appears shaky or fuzzy ................................................................................................................ 3–13Two adjacent character columns not printing ..................................................................................................... 3–14The Printer is out of paper – No Paper Out fault is reported .............................................................................. 3–15No Paper Motion – No Paper Motion fault is reported ....................................................................................... 3–15

Paper Handling Problems ............................................................................................................................................ 3–16T6090 Engine Controller To Hammer Bank CBA Cables .......................................................................................... 3–17Troubleshooting The Hammer Driver Transistors ...................................................................................................... 3–20

Chapter 4. Removal And Reinstallation ProceduresIntroduction .................................................................................................................................................................... 4–1Required Tools ............................................................................................................................................................... 4–1Procedure 1 – The Printer Lid ....................................................................................................................................... 4–2Procedure 2 – The Control Panel ................................................................................................................................... 4–4Procedure 3 – The Right End Cover .............................................................................................................................. 4–6Procedure 4 – The Engint Controller CBA ................................................................................................................... 4–8Procedure 5 – The Personality Module CBA and Enclosure ...................................................................................... 4–10Procedure 6 – The Fan Motor Assembly ..................................................................................................................... 4–12Procedure 7 – Power Supply ........................................................................................................................................ 4–13Procedure 8 – The Left End Cover .............................................................................................................................. 4–15Procedure 9 – The Ribbon Platform ............................................................................................................................ 4–16Procedure 10 – The Ribbon Motor .............................................................................................................................. 4–18Procedure 11 – The Hammer Bank ............................................................................................................................. 4–19Procedure 12 – The Ribbon Shield .............................................................................................................................. 4–21Procedure 13 – Hammer Bank Air Duct ..................................................................................................................... 4–23

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Procedure 14 – Hammer Module ................................................................................................................................. 4–24Procedure 15 – The Shuttle Assembly ........................................................................................................................ 4–26Procedure 16 – The Platen ........................................................................................................................................... 4–27Procedure 17 – The Platen Open Sensor ..................................................................................................................... 4–29Procedure 18 – The Shuttle Motor .............................................................................................................................. 4–30Procedure 19 – Shuttle Motion Sensor ........................................................................................................................ 4–32Procedure 20 – The Shuttle Drive Belt ........................................................................................................................ 4–34Procedure 21 – The Paper Advance Motor .................................................................................................................. 4–35Procedure 22 – Tractor Belt Phasing/Paper Drive Belt Adjustment ........................................................................... 4–37Procedure 23 – Upper Tractor Assembly .................................................................................................................... 4–39Procedure 24 – Lower Tractor Assembly .................................................................................................................... 4–41Procedure 25 – Platen Gap Adjustment Procedure ..................................................................................................... 4–43

Appendix A. SchematicsEngine Controller CBA................................................................................................................................................. A–1Ser/Par Personality Module CBA ................................................................................................................................. A–6FourPlex Personality Module CBA ............................................................................................................................ A–11

Appendix B. Recommended Spare Parts List, Illustrated Parts Breakdowns,and Component Lists

Recommended Spare Parts List .................................................................................................................................... B–1Cover Set ....................................................................................................................................................................... B–2Basic Assembly ............................................................................................................................................................. B–4Print Mechanism/Shuttle .............................................................................................................................................. B–6Paper Movement System .............................................................................................................................................. B–8Hammer Bank and Electronics ................................................................................................................................... B–10Engine Controller ........................................................................................................................................................ B–12Serial/Parallel Personality Modules (080900 & 080898 ) ......................................................................................... B–16FourPlex Personality Module (080750 ) .................................................................................................................... B–20

Appendix C. Downloading Printer FirmwareFirmware Update Procedure ......................................................................................................................................... C–1

Christine
Hammer Module Replacement & Realignment T6091 Printer T6065 Printer T6100/T6101 Printers
Christine
Supplements
Christine
Tally Worldwide Locations
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Table Listing

Chapter 1Table 1–1. Personality Module Configurations ........................................................................... 1–2Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations ......................... 1–5Table 1–3. Plot Data Output Speed .............................................................................................. 1–6Table 1–4. Graphics Benchmarks ................................................................................................ 1–7Table 1–5. POSTNET Label Speeds ............................................................................................ 1–7Table 1–6. Slew Speed ................................................................................................................. 1–7Table 1–7. Acoustics .................................................................................................................... 1–8Table 1–8. Power Requirements .................................................................................................. 1–8Table 1–9. Heat Load Contributions .......................................................................................... 1–10Table 1–10. Actual Weight: Main Components .......................................................................... 1–10Table 1–11. Actual Weight: By Configuration ........................................................................... 1–10Table 1–12. Shipping Weight: By Configuration........................................................................ 1–10Table 1–13. Printer Dimensions ................................................................................................... 1–11

Chapter 2Table 2–1 Test Menu ................................................................................................................... 2–4

Chapter 3Table 3–1. Display Messages ....................................................................................................... 3–3Table 3–2. Paper/Printing Corrective Action ............................................................................. 3–16Table 3–3. Connector Pinouts ....................................................................................................3–17Table 3–4. J703 Connector to Hammer Bank CBA Continuity Check Points .......................... 3–18Table 3–5. T6090 Hammer Coil/Module Troubleshooting ....................................................... 3–19Table 3–6. J703 Hammer Driver Pinouts ................................................................................... 3–21Table 3–7. J704 Hammer Driver Pinouts ................................................................................... 3–22

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Figure Listing

Chapter 4Figure 4–1. Disconnecting the Gas Spring .................................................................................... 4–2Figure 4–2. Removing the Lid ....................................................................................................... 4–3Figure 4–3. Removing the Control Panel ...................................................................................... 4–4Figure 4–4. Reinstalling the Control Panel ................................................................................... 4–5Figure 4–5. Removing the Right End Cover ................................................................................. 4–6Figure 4–6. Reinstalling the Right End Cover .............................................................................. 4–7Figure 4–7. Removing the Engine Controller CBA ...................................................................... 4–8Figure 4–8. Removing the Personality Module CBA ................................................................. 4–10Figure 4–9. Removing the Personality Module Enclosure ......................................................... 4–11Figure 4–10. Removing the Fan Assembly. ................................................................................... 4–12Figure 4–11. Disconnecting the Static Ground. and Removing the Sound Deadening Hood ...... 4–13Figure 4–12. Removing the Power Supply .................................................................................... 4–14Figure 4–13. Removing the Left End Cover ................................................................................. 4–15Figure 4–14. Disconnecting the Ribbon Platform Components ................................................... 4–16Figure 4–15. Removing the Ribbon Platform ............................................................................... 4–17Figure 4–16. Removing the Ribbon Motor ................................................................................... 4–18Figure 4–17. Disconnecting the Hammer Bank ............................................................................ 4–19Figure 4–18. Removing the Hammer Bank ................................................................................... 4–20Figure 4–19. Removing the Ribbon Shield ................................................................................... 4–21Figure 4–20. Removing Hammer Bank Air Duct .......................................................................... 4–23Figure 4–21. Removing and Replacing the Hammer Module. ..................................................... 4–24Figure 4–22. Using the Hammer Alignment Tool ......................................................................... 4–25Figure 4–23. Shuttle Assembly Removal ...................................................................................... 4–26Figure 4–24. Removing the Platen ................................................................................................4–27Figure 4–25. Platen End Assembies .............................................................................................. 4–28Figure 4–26. Removing the Platen Open Sensor .......................................................................... 4–29Figure 4–27. Removing the Shuttle Motor .................................................................................... 4–30Figure 4–28. Reinstalling Shuttle Motor Pulley ............................................................................ 4–31Figure 4–29. Removing the Shuttle Motion/Capture Sensor ........................................................ 4–32Figure 4–30. The Shuttle Drive Belt .............................................................................................. 4–34Figure 4–31. Removing the Paper Drive Motor ............................................................................ 4–35Figure 4–32. Paper Advance Motor Assembly .............................................................................. 4–36Figure 4–33. Phasing/Belt Adjustments ........................................................................................ 4–37Figure 4–34. Phasing Gauge Installation ...................................................................................... 4–37Figure 4–35. Paper Drive Belt Adjustment ................................................................................... 4–38Figure 4–36. Removing Upper Tractor Assembly......................................................................... 4–39Figure 4–37. Upper Tractor Alignment ......................................................................................... 4–40Figure 4–38. Removing Lower Tractor Assembly ........................................................................ 4–41Figure 4–39. Lower Tractor Alignment ......................................................................................... 4–42Figure 4–40. Platen Gap Adjustment ............................................................................................. 4–43

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Introduction Introduction

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Introduction

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IntroductionThis manual presents operational theory, specifications, troubleshooting, and Removal andReplacement procedures for the T6090 Printer.

The following chapter explanations will give you an overview of the contents of this manual.

Chapter 1: Electronic Hardware Architecture, Performance, and SpecificationsThis chapter presents basic operational theory of the T6090 Printer. In addition, design andoperational specifications for the printer are given.

Chapter 2: Menu OperationsChapter 2 presents the Menu Operations concerned with troubleshooting and maintaining theprinter.

Chapter 3: TroubleshootingThis chapter lists the display messages you may encounter, their cause, and possible correctiveactions.

Chapter 4: Removal and Reinstallation ProceduresThis chapter presents instructions for removing and reinstalling/replacing various componentsof the printer.

Appendix A: SchematicsThe schematics in this appendix will assist you in troubleshooting problems and locatingcomponents that control printer operations.

Appendix B: Recommended Spare Parts List, Illustrated Parts Breakdowns,and Components ListsThese IPBs present exploded views of all printer components along with parts listings.

Appendix C: Downloading Printer FirmwareThis appendix explains how to download firmware to the printer.

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Chapter 1Electronic Hardware Architecture,

Performance & Specifications

Electronic Hardw

areA

rchitecture, Performance

& Specifications

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1–1

Technical OverviewThe T6090 is a medium speed, line impact dot matrix printer. It has a maximum speed of 900lines per minute in uppercase draft text mode. The T6090 is designed for long term opera-tions, supporting a workload of 160,000 pages per month with minimal maintenance.

T6090 Electronic Hardware ArchitectureThe electronic design of the T6090 is implemented in two basic modules. These are the EngineControl and the Personality Module.

Engine Control ModuleThe primary components of the Engine Control Module are:

• Control Processor – Intel 87C196KB• Shuttle Processor– Philips/Signetics 87C750• Sensor Inputs• Hammer/Motor logic and drive• EEPROM – X24C08

Control Processor• 12.288 MHz clock• High speed outputs for driving the paper motor and hammer firing• High speed inputs for synchronizing timing of the shuule position• 8 channel 10 bit Analog to Digital Converter for sensor readings (paper out, paper

motion, shuttle motion, ribbon motion, platen gap, hammer current, power supplyvoltage, ambient temperature)

• Serial channel for communication (19.2K bps) with Main CPU• Port control of Shuttle/Ribbon microcontroller• Port control of control panel, ribbon clock, and hammer loading

Sensor Inputs• Paper motion sensor – optical• Paper out sensor – optical• Platen gap sensor – optical• Shuttle motion/capture sensor – optical• Ambient temperature – thermistor• Power supply voltage – resistor divider

Shuttle Processor• 12.288 MHz clock• Drives stepping phases to the Shuttle and Ribbon motors

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Hammer/Motor logic and drive• 2 hammer driver ASICs – each of the 66 outputs drives a transistor• 17 quad Hammer drive transistor arrayss – SMA4032• 17 Zener Diodes for absorbing coil drive energy– 1N5347B• 6 H-bridge Motor drive chips (2 for ribbon, 2 for shuttle and 2 for paper) – Allegro

3952EEPROM

The EEPROM stores engine calibration and printer configuration settings.

T6090 Personality ModuleInterface control is provided by the Personality Module. There are four Personality Modulesavailable, two of which have optional configurations. The configurations vary in terms of hostinterface, memory configuration, and installed software.

The primary components of the Personality Module are:

• Main processor – Motorola MC68340• Flash EPROM – comprised of 4M-bit and/or 2M-bit parts (determined by the type of

interface)• DRAM – .5 Meg, 1 Meg, or 2 Meg (determined by the type of interface)• EPLD – Altera EPM7064• Parts specific to the type of interface (Serial/Parallel, Lan, Twinax/Coax and

Dataproducts). (See Table 1-1.)

The following table shows the modules and optional configurations:

Table 1–1. Personality Module Configurations

Personality Module Standard Ser/Par Extended Ser/Par LANPlex FourPlexHost I/Os IEEE 1284 IEEE 1284 IEEE 1284 IEEE 1284

RS-232-C RS-232-C RS-232-C RS-232-CDataproducts1 Ethernet Twinax

CoaxStandard Graphics IG, Code V, PGL, IG, Code V, PGL, IG, Code V, PGL, Code V, PGL,Languages & MTPL & MTPL & MTPLOptional Configurations Dataproducts Standard IPDS2 Graphics

or LonglinesFlash ROM 768 K 768 K 1.5 meg 1 MegRAM 512 K 512 K 2 Meg 512 K 3

1 Dataproducts may be set up for Standard or Longlines operation.2 With IPDS Option, Code V and PGL are not included.3 With IPDS Option, 512 K RAM is upgraded to 1 Meg.

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Serial and Parallel InterfacesSerial

• MC145406 (+/- 12V) chip is used for the RS-232 drivers and receivers• Internal programmable bps generator (300 bps to 38.4K bps)• Both DTR/Busy and XON/XOFF is supported• Standard secondary RTS on pins 11 and 19. Primary RTS is capable of being

jumpered to pin 4

Parallel• Altera EPM7064 and 74LS374/74LS244 – supports IEEE-1284 compatibility and

nibble modes

Motorola MC68340• 25MHz clock• 16-bit CPU bus• Two direct Memory Access (DMA) channels – One for hammer loading, and one for

the IEEE-1284 parallel Interface• Two serial channels – One for the control CPU communication, and one for the

external serial interface

Flash MemoryThe amount of Flash Memory depends on the configuration of the personality module.

DRAMThe amount of DRAM depends on the configuration of the personality module.

Altera EPM7064• Dynamic random access memory (DRAM) control• Logic for IEEE-1284 Parallel interface• Glue logic (chip selects, hammer data and clock, row and column selection for

DRAM)

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Specifications

Serial/Parallel EmulationsNine emulations are available on the T6090: MT660, Genicom ANSI, HP2564C, PrintronixP600, Printronix P6000, IBM Proprinter III XL, Epson FX-100+, DEC LG01, and MTPL.

Font StylesThere are 6 resident type styles available on your printer. They include: Courier, Data Process-ing, Draft, Gothic, OCR-A, and OCR-B. All font styles and the two output modes (Enhancedand Constant Density Fonts for Draft and DP) are selected through the printer control panel.

Courier and GothicThese two font styles provide near letter quality (NLQ) printing on your printer. They print athigher dot densities and use denser character matrixes. NLQ type styles provide greaterreadability for reports and other text output.

Data Processing and DraftData Processing and Draft styles appear in two modes: Constant Density (CDF) and En-hanced. Constant Density Fonts print at the same dot density regardless of the CPI. Thisproduces consistent print speed even when changing from one CPI to another.

Enhanced Mode provides higher resolution and a greater range of CPI’s than CDF Mode.Because Enhanced Mode uses a variety of dot densities, you should expect a change in printspeed of text when switching from one CPI to another.

OCR-A and OCR-BThese font styles print at 10 CPI only. They are used mainly for Optical Character Recogni-tion.

Characters Per InchThe T6090 offers a variety of CPI’s for use in printer output. Available CPI’s are dictated bythe font style selected. Each CPI is based on one of twelve character matrixes and twelve dotdensities. Each matrix uses a specific number of dot columns for character composition andintercharacter gap. CPI’s are grouped in any given type style by the base CPI matrix used forthe group. These base CPI’s are 10, 12, and 15.

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Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations

Print Modes Type Styles 10 CPI Group 12 CPI Group 15 CPI Group

Constant Density Draft Base Matrix: 9 x 8 Base Matrix: 7 x 8 Base Matrix: 5 x 8Dot Density: 60 x 48 Dot Density: 60 x 48 Dot Density: 60 x 48CPIs: 5 and 10 CPIs: 6, 6.67, 12, CPIs: 15 & 17.14

& 13.33

Data Processing Base Matrix: 9 x 12 Base Matrix: 7 x 12 Base Matrix: 5 x 12Dot Density: 60 x 72 Dot Density: 60 x 72 Dot Density: 60 x 72CPIs: 5 & 10 CPIs: 12 & 13.33 CPIs: 15 & 17.14

Enhanced Draft Base Matrix: 9 x 8 Base Matrix: 13 x 8 Base Matrix: 9 x 8Dot Density: 60 x 48 Dot Density: 80 x 48 Dot Density: 120 x 48CPIs: 5 &10 CPIs: 6, 6.67, 12, CPIs: 7.5, 8.33, 8.57,

& 13.33 15, 16.67, 17.14, & 20

Data Processing Base Matrix: 9 x 12 Base Matrix: 13 x 12 Base Matrix: 9 x 12Dot Density: 60 x 72 Dot Density: 80 x 72 Dot Density: 120 x 72CPIs: 5 & 10 CPIs: 6, 6.67, 12 CPIs: 7.5, 8.33, 8.57, 15,

and 13.33 16.67, 17.14, & 20Near Letter Quality Gothic Base Matrix: 19 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

Dot Density: 80 x 96 Dot Density: 80 x 96 Dot Density: 120 x 96CPIs: 5 &10 CPIs: 6, 6.67, 12, CPIs: 7.5, 8.33, 8.57,

& 13.33 15, 16.67, 17.14, & 20

Courier Base Matrix: 19 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16Dot Density: 80 x 96 Dot Density: 80 x 96 Dot Density: 120 x 96CPIs: 5 & 10 CPIs: 6, 6.67, 12, CPIs: 7.5, 8.33, 8.57,

& 13.33 15, 16.67, 17.14, & 20Optical Character OCR-A Base Matrix: 9 x 16Recognition Dot Density: 60 x 96

CPIs: 10

OCR-B Base Matrix: 19 x 24Dot Density: 80 x 144CPIs: 10

Lines Per InchNine lines per inch (LPI) settings are available through the control panel. They include 1.5, 2,3, 4, 5, 6, 8, 9, and 10 LPI. In some emulations the availability of certain LPI’s are restricted.

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Dot Densities and Plot SpeedsThe T6090 printer supports Horizontal row plots (single and multiple row), Vertical columnplots, and specialized Graphic plots. Your printer supports the following horizontal DPI’s: 40,48, 50, 60, 72, 80, 90, 96, 100, 120, 144, 150, 160, 180, 200, and 240. Your printer supportsthe following vertical DPI’s: 48, 72, 96,144, and 288. All other selections are emulatedthrough the use of scaling techniques.

Table 1–3. Plot Data Output Speed

Dot Plot Print SpeedHor./Vert. Inches Per Min.60 x 48 10060 x 72 67120 x 72 33120 x 144 16240 x 288 4

Graphics BenchmarksTwo benchmark tests were used to rate graphics output on the T6090 printer. The first was anAIAG label containing bar codes and block characters inside a box. The second was aPOSTNET label with one line of POSTNET bar code and four lines of text.

The AIAG test consisted of a series of labels printed two across repeated vertically with a 0.1"vertical space. The test was performed in two variations: Normal AIAG printed with 60 DPIbar codes and Dark AIAG printed with 120 DPI bar codes.

The POSTNET test consisted of rows of labels printed four across with one blank line betweeneach row. In addition, the POSTNET test was run with 4 variations: Draft and Data Process-ing (DP) type styles for text/bar codes printed at 6 and 8 LPI.

Tests were timed, then results were converted into labels per hour.

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Table 1–4. Graphics Benchmarks

AIAG Label Benchmark ResultsGraphics Dots Per In.Language 60 120

Code V 1950 LPH 1300 LPH

PGL 1950 LPH 1300 LPH

Table 1–5. POSTNET Label Speeds

POSTNET Label Benchmark ResultsLines Type Style

Per Inch Draft Data Processing

6 LPI 32000 LPH 29000 LPH

8 LPI 33000 LPH 30500 LPH

Paper Slew SpeedTable 1–6. Slew Speed

Print Mode Maximum Slew Speed

Normal 16 Inches Per SecondHeavy Forms 12 Inches Per Second

RibbonsThe T6090 is designed to operate optimally with Tally ribbon cartridges. These cartridges aredesigned for easy access and loading.

Forms/Paper DescriptionThe T6090 is designed to use continuous, sprocket feed type paper, 3 to 16.53 inches in width,and 3 to 12 inches in length. One to six part paper may be used with a maximum thickness of.025 inches. (Reference specifications: ISO 2784, DIN 9771, and DIN 6721.)

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AcousticsThe noise generated by the T6090 printer varies according to its configuration as shown in thetable that follows:

Table 1–7. Acoustics

Printer Sound Power per Sound Pressure LevelConfiguration ISO 7779-C (9 position average)

Tabletop Unit 7.4 bels 57 dBA

Printer with Pedestal 6.9 bels 52 dBAQuick Access Configuration 7.9 bels 62 dBA

Power SupplyThe printer requires single phase, 47 to 63 Hz. 90 to 264 VAC input power. The printer’suniversal power supply automatically adjusts to the correct values. A fuse is provided tointerrupt power to the power supply. The following table gives typical current values.

Table 1–8. Power Requirements

External Power Current/Wattage RequirementsSupply @ Nominal Voltage

AC Volts Frequency Average Peak Average Average(RMS) (Hz) Operating Operating Idle (<5 min.) Idle (>5 min.)

110 50 2.56 A/166 W 6.30 A/506 W 0.88 A/41 W 0.64 A/25 W

110 60 2.57 A/171 W 6.29 A/508 W 0.85 A/42 W 0.62 A/25 W

220 50 1.39 A/168 W 3.91 A/496 W 0.41 A/42 W 0.31 A/26 W

Cooling SystemCooling system malfunctions are detected and a failure will result in shuttle motion, papermotion, and printing functions being inhibited. The malfunction will be reported on thecontrol panel display.

SafetyPersonnel hazard areas have restricted access with appropriate warning labels. Catastrophicequipment failures are inhibited with protective functions in major areas of overload potential.

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Preventive MaintenanceThe T6090 is designed to eliminate the requirement of scheduled maintenance procedures,such as alignment, adjustment, or lubrication. Preventive maintenance is limited to periodiccleaning. Dust and paper fibers should be removed periodically with a soft cloth and brush ora vacuum cleaner. Clean the printer case with a damp cloth and soapy water. DO NOT useany abrasive cleaners or solvents, as they will damage the case.

EnvironmentOperating

TemperatureDry Bulb: 50°F to 104°F (10°C to 40°C)

Humidity: 10 to 90% noncondensing with a maximum wet bulbtemperature of 82°F (28°C) and a minimum dew point of36°F (2°C )

Altitude: To 8,000 ft. (2438 meters)Mechanical Shock: Half sine wave shock pulse of 10 g peak and 10 +/- 3 ms

duration, three times in the vertical direction.Vibration: Applied to each of the three axes:

• 5 – 22 Hz 0.010 in. double amp.• 22 – 500 Hz 0.25 g peak• 500 – 22 Hz 0.25 g peak• 22 – 500 Hz 0.010 in. peak

Sweep rate of 1 octave/min.

NonoperatingTemperature:

Boxed: - 40°F to 151°F (-40°C to 66°C)Unboxed: 14°F to 122°F (-10°C to 50°C)

Humidity: 5 to 95% noncondensingAltitude: To 10,000 ft. (3048 meters)Thermal Shock: 29°F (16°C) per minuteVibration: Units meet NSTA (National Safe Transit Association)

requirements.

The printer must be allowed to reach room temperature before operating. Three hours out ofthe shipping container is usually enough time for stabilization. Complies with NSTA Program1 & 2.

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Heat Load ContributionThe average heat load contribution to the environment is approximately 580 BTUs per hour(170 Watts) with a maximum potential of 1677 BTUs per hour (491 Watts) under continuousfull-load printing conditions.

Table 1–9. Heat Load Contributions

Printing Conditions (110 VAC/60 Hz) Current/Wattage BTU/HrPower On, not printing 0.64 A/42 W (>5 min.) 143100% Uppercase Rolling ASCII 2.57 A/268 W 915Black Page Plot 6.29 A/491 W 1677

Physical ConfigurationsThe T6090 printer is available in the following configurations:

Standard Tabletop PrinterOptional Printer with StandOptional Printer with Quietized Pedestal

Before installing a Tabletop model, make sure that an opening has been provided in thetable that allows access to the paper path opening on the bottom of the printer.

WeightTable 1–10. Actual Weight: Main Components

Component Weight

Tabletop Printer 90 lbsStand 30 lbs

Pedestal 52 lbs

Table 1–11. Actual Weight: By Configuration

Option Weight

Tabletop Printer 90 lbsPrinter plus Stand 120 lbs

Printer plus Pedestal 142 lbs

Table 1–12. Shipping Weight: By Configuration

Option Weight

Tabletop Printer 110 lbsPrinter with Stand 150 lbs

Printer plus Pedestal 185 lbs

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Printer DimensionsTable 1–13. Printer Dimensions

Dimension Printer ConfigurationParameter Tabletop Unit On the Open Stand On the Quietized Pedestal

Height 15.8" 41.4" 40.6"Height/Lid Open 28.4" 54.3" 53.2"

Width 31.5" 31.5" 31.5"Depth with Exit Hood 23.5" 23.7" 23.2"

Depth with Paper Tray N/A 28.7" 29.5"

Industry and Agency StandardsThe T6090 is designed to meet the requirements of several industry and Government agencystandards.

Electromagnetic EmissionsEMI: FCC part 15, subpart J, Class A and CISPR 22 Class BESD: IEC 801-2 (ref Q1012)RF Susceptability: IEC 801-3Line Transients: IEC 801-4Power FActor Correction: IEC 555-2

Agency ApprovalsUnited StatesThe T6090 complies with UL 1950, C22.2 No. 950-M89, and IEC 950(TUV) via EN 60950(cb scheme) safety requirements.

The T6090 printer is Energy Star compliant.

EuropeIEC 950 (1986) plus Amendment 1 (1988) and 2 (1990) and National Deviations CA, DE, FI,GB, NL, NO, SE, US(CAN/CSA-C22.2 No. 950-M89 and CSA TIL F-18 (May 19, 1992)(UL Std no. 1950-1989)

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Paper Path

Chapter 2Menu Operations

Menu O

perations

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Chapter 2: Menu Operations

IntroductionAll testing, troubleshooting, and calibration procedures are located in the multilevel menusystem of the T6090 printer. They are located in the CONFIGuration and TEST menus andcan be accessed through the Printer Control Panel.

Technical Access ModeTechnical (Tech) Access Mode is provided for the repair technician. It provides him access totests, calibration, and diagnostic procedures for use in troubleshooting and correcting problemswith the printer.

Entering Tech Access ModePlace the printer Offline. Depress the LINE FEED Key and ENTER Key simultaneously.When the printer enteers Tech AccessMode the printer alarm sounds and the display flashes,"Tech Access On." Release the keys immediately when the alarm sounds..

Exiting Tech Access ModeThere are two methods for leaving Tech Access.

1. Place the printer Offline. Depress the LINE FEED Key and ENTER Key simulta-neously. Release the keys immediately when the alarm sounds.

2. Cycle power on the printer.

Testing, Troubleshooting, and CalibrationThe printer is equipped with the following types of Print Tests, Hex Dumps, and PrinterInformation Printouts.

Printer TestsPrint tests appear in both normal menu operations and in the Technical Access Mode of theprinter. These tests consist of the following patterns and types.

• ASCII print patterns• Plot Mode patterns• Calibration routines• Electronic hardware tests

In-depth explanations of all of the print tests follow in the TEST Menu Section of this chap-ter.

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Hex DumpsThese dumps are located in the Configuration Menu, in the Printer Category, under theDmp Mod (Dump Mode) Parameter in normal menu operations. Hex Dumps can be usedto check printer functions and data processing operations and are also used to help solveproblems that can affect printer performance. There are three styles of Dump Modes on theprinter.

Style 1 Text, spaces, and control codes are printed out in hexadecimal format.

Make sure that wide paper (132 columns — 13+ inches of printable width) is loaded onthe printer before running a Style 1 Hex Dump.

Style 2 Control codes are printed out in hexadecimal format while text and spaces areprinted out in their original form.

Style 3 Control codes and spaces are printed out in hexadecimal format, while text isprinted out in its original form.

Printer Information Printouts and DisplaysThere are five printouts and displays that you can access through the printer control panel.One is listed as one of the menus (HELP) and four others can be found in the ConfigurationMenu, under the Printer Category.

HELP MenuThe HELP Menu is a printout that lists selections that are available for each parameter in themultilevel menus on the printer and indicates with an asterisk (*) which ones are currentlyactive.

Before printing out the HELP Menu, make sure that there is at least 13 inches of print-able width on the installed paper.

Printing a HELP Menu In Tech Access ModeSTEP 1. Take the printer Offline.

STEP 2. Depress the LINE FEED Key and ENTER Key simultaneously until the printeralarm sounds, then release them immediately to place the printer in Tech AccessMode.

STEP 3. Depress the MODE Key to enter the multilevel menu system, then scroll ( Key) tothe HELP selection.

STEP 4. Depress the ENTER Key to begin printing the HELP Menu.

This printout will end when the entire HELP Menu is printed out.

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Chapter 2: Menu Operations

Report Parameter (Menu Level 2)This parameter has four selections. Two of the selections, Configs and CalData, generateprintouts. The second pair of reports (LastFlt and Version) are displays. The Report Param-eter is located in the CONFIGuration Menu , under the Printer Category.

Report selections (Menu Level 3)Configs Prints a report showing the setups of the configurations.CalData Prints a report showing timing signals and voltage levels that govern certain basic

printer functions.LastFlt The Control Panel Display shows the Last Fault that occurredVersion The Control Panel Display shows the version number of the currently installed

firmware.

To clear the displays, depress any key on the printer control panel.

Selecting a Printer ReportSTEP 1. Take the printer Offline.

STEP 2. Depress the MODE Key to enter the multilevel menu system, then scroll ( Key) tothe CONFIG selection.

STEP 3. Depress the FORMS/1 Key to access the CONFIG Menu categories, then scroll( Key) until the Printer Category is displayed.

STEP 4. Depress the CPI/2 Key to access the Printer Category parameters, then scroll( Key) until the Report Parameter is displayed.

STEP 5. Depress the LPI/3 Key to access the Report selections, then scroll ( Key) to thedesired selection.

STEP 6. Depress the ENTER Key to begin the Report printout or display.

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TEST MenuThe TEST Menu contains the parameters for testing printer operation, adjusting print quality,and controlling fault reporting. There are three categories in this menu: Pattern, Diagnostics,and Fault Override .

The table that follows presents the categories, parameters, and parameter selections that willappear in the TEST Menu while the printer is in Tech Access Mode.

Table 2–1 Test Menu

To access Categories Parameters Selections

Depress this key

FORMS

1 Level 1

CPI

2 Level 2

LPI

3 Level 3

Pattern Print UpperAll Chrs63/69ECMAColumns

Print2 PaperSvThermCyLower1 LineAll H'sAll E'sAll #'sAll +'sParensRuboutRibbon

Plot GridCrossGrayBlackBlock

Diag PrntCal HammerCurrentPap Out

Meter Pap OutPap MotSht SenRib MotTmp SenPowerPlatenCurrentKeypad

Motors RibbonShuttle

Sht Spd 23–48

Use the Key to scroll to thedesired selection.

Use the ENTER Key to selecta value or option.

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Table 2–1, Continued

To access Categories Parameters Selections

Depress this key

FORMS

1 Level 1

CPI

2 Level 2

LPI

3 Level 3

Rbn Spd 1–250

Ribn Thr 1–255

POut Thr 0–255

PMotThr 0–255

Max T 1–255

Heavy OFFON

EnStar On

Off

Clear CalDataCountsNVRAM

FltOvrd Pap Mot OFFON

Pap Out OFFON

Rib Mot OFFON

Shuttle OFFON

Temp OFFON

Platen OFFON

Ctrl OFFON

Link OFFON

Hvy Frm OFFON

Use the Key to scroll to thedesired selection.

Use the ENTER Key to selecta value or option.

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Pattern Category (Menu Level 1)The Pattern Category contains several predefined print patterns used to test basic printerfunctionality. There are three parameters in this category: Print , Print2 , and Plot.

Print Parameter (Menu Level 2)This parameter is also available in normal menu operations. It has five selections.

Print selections (Menu Level 3)Upper Prints a rolling pattern of 63 UPPERCASE ASCII characters.All Chrs Prints all Character Sets available on your printer.63/69 Prints rolling ASCII with spaces.ECMA Prints pattern designed to produce a specific audible noise pattern specified by

European Computer Manufacturers Association used for acoustics testing.Columns This test labels each column in the current print line. The line length used is

based on the current margin settings.

To stop any of the above tests, depress the ENTER Key or the CLEAR Key.

Print2 Parameter (Menu Level 2)This parameter is available in Tech Access only. It has 11 print test selections.

Print2 selections (Menu Level 3)Except for the 1 Line test all of the tests below run continuously. They will continue to rununtil you depress either the ENTER Key or the CLEAR Key.

PaperSv This option provides a means of completing long-term testing of the printerwithout wasting large amounts of paper. It prints a pattern of all uppercasecharacters that is advanced by one character on each line. Each pass is four lineslong. The printer then backs up three lines and prints another four line pass. Theprinter then continues printing in this fashion until it makes 30 passes. On the30th pass the printer does not back up.

ThermCy This option prints the PaperSv pattern for 15 minutes, stops printing for fiveminutes, then starts the cycle over. It is used to test the temperature cyclingabilities of the printer.

Lower This option prints a rolling pattern of all 95 lowercase ASCII characters.1 Line This option prints one line only of upper-and lowercase characters.All H's This option prints lines composed of the uppercase letter H.All E's This option prints lines composed of the uppercase letter E.All #'s This option prints lines composed of the # symbol.All +'s This option prints lines composed of the + sign.Parens This option prints lines composed of the left paren followed by a vertical bar

followed by the right paren.Rubout This option prints lines composed of the currently selected fill character.Ribbon This option prints lines composed of rolling ASCII uppercase characters.

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Plot Parameter (Menu Level 2)This parameter is available in Tech Access only and it contains selections of plot patterns usedto test such things as hammer ball alignment and dot placement. There are five selections forthis parameter.

Plot selections (Menu Level 3)After you have started one of the tests below, it will run continuously until you depress eitherthe ENTER Key or the CLEAR Key.

Grid This option prints a grid pattern that can be used to check hammer ball alignment.

Cross This option prints a crosshatch pattern of diagonal lines that can be used to checklinearity of dot placement.

Gray This option prints a grayscale pattern at 60 by 72 DPI. This test fires all 66hammers (printing every other dot vertically and horizontally), which should laydown an even gray tone across the page. Any changes in the gray tone indicates avariation in the gap between the hammer module and the platen, most commonlyindicating either a worn hammer module or a replacement module in need ofalignment.

Black This option prints a solid black page at 60 by 72 DPI matrix. The Black PagePrint Mode is the most dense print test that can be run for verifying the properoperation of the printer’s power supply. This test places the greatest electricalcurrent load on the power supply as well as increasing the thermal load on theelectronics.

Block This option prints alternating bars at 60 by 72 DPI matrix. Each bar is offset fromthe previous bar in order to check on dot placement. This pattern is used to testthe printer at its maximum sustainable graphics rate without exceeding the bound-aries of thermal change or electrical current overload. This test is useful inexamining the capabilities of the print mechanism, for checking proper hammeralignment/spacing, and print quality. The output in the printed areas should haveuniform shading. If not, parameters such as individual hammer module heightsand alignments should be checked.

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Selecting And Running a Print TestSTEP 1. Take the printer Offline and place it in Tech Access Mode.

STEP 2. Access the TEST Menu.

STEP 3. Depress the FORMS/1 Key to access the TEST Menu categories, then scroll ( Key) until the Pattern Category is displayed.

STEP 4. Depress the CPI/2 Key to access the Pattern Category parameters, then scroll( Key) until the desired Print Test parameter (Print , Print2 , or Plot) is displayed.

STEP 5. Depress the LPI/3 Key to access the parameter selections, then scroll ( Key) to thedesired test pattern.

STEP 6. Depress the ENTER Key to begin the Print Test.

With the exception of the 1 Line print test, the print tests are continuous and willcontinue to print until you depress the CLEAR Key or ENTER Key.

Diagnostic Category (Menu Level 1)This category contains parameters for testing various printer components, for setting opera-tional thresholds, and for calibrating certain sensors. You are guided through these diagnosticprocedures by instructions on the Control Panel Display. There are 12 diagnostic parameters.

PrntCal (Print Calibration) Parameter (Menu Level 2)This parameter provides a means to calibrate the hammer timing pulses to obtain the best printquality. There are three selections for PrntCal: Hammer, Current , and Pap Out.

Selecting And Running a Hammer Calibration RoutineSTEP 1. Take the printer Offline and place it in Tech Access Mode.

STEP 2. Access the TEST Menu.

STEP 3. Depress the FORMS/1 Key to access the TEST Menu categories, then scroll( Key) until the Diag Category is displayed.

STEP 4. Depress the CPI/2 Key to access the Diag Category parameters, then scroll ( Key)until the PrntCal Parameter is displayed.

STEP 5. Depress the LPI/3 Key to access the PrntCal selections, then scroll ( Key) untilthe Hammer selection is displayed.

STEP 6. Depress the ENTER Key to begin the Hammer Calibration Routine.

The printer generates coarse test patterns using hammer lead times from 23Hz(prints twice), 30Hz, 34Hz, 40Hz, and 45Hz.

STEP 7. Examine each line of the printed output for each lead time and select the one thathas the best dot placement, then scroll to that setting on the Control Panel anddepress the ENTER Key to select it.

After you make the last selection (for 45Hz) the printer prints out the settings for the variouslead times and the calibration routine is over.

Repeat the Print calibration routine with "Heavy Forms" turned on and with heavyforms installed on the printer.

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Selecting And Running a Current Calibration RoutineStep 1. Take the printer offline and place it in Tech Access Mode.

Step 2. Access the TEST Menu.

Step 3. Depress the Forms/1 key to access the TEST Menu categories, then scroll ( Key)until the Diag Category is displayed.

Step 4. Depress the CPI/2 key to access the Diag Category parameters, then scroll ( Key)until the Prntcal Parameter is displayed.

Step 5. Depress the LPI/3 key to access the Prntcal selections, then scroll ( Key) untilCurrent is displayed.

Step 6. Looking at the Control Panel display, depress the ENTER key. The printer firm-ware performs a calibration routine and the new value will be displayed. (Valueswill vary from printer to printer). Once the value is displayed you have completedthe routine.

Selecting And Running a Paper Out Calibration RoutineStep 1. Take the printer offline and place it in Tech Access Mode.

Step 2. Access the TEST Menu.

Step 3. Depress the Forms/1 key to access the TEST Menu categories, then scroll ( Key)until the Diag Category is displayed.

Step 4. Depress the CPI/2 key to access the Diag Category parameters, then scroll ( Key)until the Printcal Parameter is displayed.

Step 5. Depress the LPI/3 key to access the Printcal selections, then scroll ( Key) untilPapOut is displayed.

Step 6. Depress the ENTER key to begin the first part of the Paper Out CalibrationRoutine. Follow steps on display.

When removing paper, the tractor door must be closed to ensure proper reading.

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Meter Parameter (Menu Level 2)This parameter has nine selections. The sensor tests that are available under this parametercan be used to adjust the sensor for optimum performance or to test sensors to ensure that theyare operating properly.

Meter selections (Menu Level 3)Sht Sen (see explanation below)Pap Out (see explanation below)Pap Mot (see explanation below)Rib Mot (see explanation below)Tmp Sen (reads current voltage drop across the thermistor)Power (used on printer Production Line only)Platen (used on printer Production Line only)Current (used on printer Production Line only)Keypad (displays each key name when it is depressed)

Each Meter Test is initiated by depressing the ENTER Key when the desired selection isdisplayed.

The first 4 tests are used to check positioning of the sensor itself. Each sensor is checked in a"covered" and "uncovered" mode.

For the Paper Out and Paper Motion sensors, depress the ENTER Key then check them withpaper installed (covered) and paper removed (uncovered). The Paper Out Sensor should readless than .2 volts with paper removed and greater than 4 volts with paper installed. The PaperMotion Sensor only needs to have a differential of greater than 2 volts between the high andlow reading to function properly.

The Shuttle Motion Sensor should read less than 0.5 volts with the open portion of the uppergear over it (uncovered), and greater than 4.5 volts with the solid portion of the gear over it(covered).

The Ribbon Motion Sensor is read with the silver portion of the wheel inside the RibbonCartridge over it (uncovered), then with the black portion over it (covered). The readingsshould be greater than 4V uncovered and less than .2V covered.

Motors Parameter (Menu Level 2)This parameter allows you to test the Shuttle Motor and Ribbon Motor. They can be tested atthe current selection (Default) or you can select a variety of speeds at which to test them. (SeeSht Spd Parameter and Rib Spd Parameter.)

Motors selections (Menu Level 3)RibbonShuttle

The selected test is initiated by depressing the ENTER Key. After the motor reaches itsassigned speed the test can be stopped by depressing the ENTER Key again. This sequencemay be repeated until you are satisfied with the operation of the motor.

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Sht Spd (Shuttle Speed) Parameter (Menu Level 2)Provides a means to vary the Shuttle Motor speed for a Shuttle Motor Test.

Shuttle Speed selections (Menu Level 3)23—48 Hz.

Rbn Spd (Ribbon Speed) Parameter (Menu Level 2)Provides a means to vary the Ribbon Motor speed for a Ribbon Motor Test.

Speed selections (Menu Level 3)1—250Default

RibnThr (Ribbon Threshold) Parameter (Menu Level 2)This parameter allows you to set the Ribbon Sensor Threshold value for the Ribbon MotionSensor .

Threshold selections (Menu Level 3)1—255

POutThr (Paper Out Threshold) Parameter (Menu Level 2)This parameter allows you to set the Paper Out Threshold value for the Paper Out Sensor tocompensate for reflectivity variances for different types of paper.

Threshold selections (Menu Level 3)0—255

PMoThr (Paper Motion Threshold) Parameter (Menu Level 2)This parameter allows you to set the Paper Motion Threshold value for the Paper MotionSensor to compensate for reflectivity variances for different types of paper.

Threshold selections (Menu Level 3)0—255

Heavy (Heavy Forms) Parameter (Menu Level 2)This Parameter allows you to slow the slew speed and increase the hammer fire for heavyforms.

Heavy Forms selections (Menu Level 3)OFFON

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Max T (Maximum Temperature) Parameter (Menu Level 2)Max T is the thermal limit for the printer. If the thermistor on the Engine Controller PCBexceeds this limit, the Thermal Fault message will appear on the Control Panel Display.

DO NOT change the factory setting.

EnStar (Energy Star) Parameter (Menu Level 2)This parameter allows you to control Energy Star Operation on the printer.

Energy Star selections (Menu Level 3)OFFON

Clear Parameter (Menu Level 2)This parameter provides you with a means of clearing part or all of NVRAM.

Clear selections (Menu Level 3)CalData Clears the calibration data from NVRAM. When CalData is selected you will

have to perform a Hammer Calibration Routine before using the printer.Counts Clears the count information from NVRAM.NVRAM Clears ALL NVRAM.

Fault Override (FltOvrd) Category (Menu Level 1)This category provides you a means of controlling fault reporting from the Engine Manager tothe Control Processor. Each of the following parameters has two selections: OFF and ON.

When the parameter is set to OFF, faults are reported as they happen (Fault Override is dis-abled). When the parameter is set to ON, faults are not reported on the display (Fault Overrideis Enabled).

Pap Mot (Paper Motion) Parameter (Menu Level 2)This parameter provides fault override for Paper Motion Faults.

Pap Out (Paper Out) Parameter (Menu Level 2)This parameter provides fault override for Paper Out Faults.

Rib Mot (Ribbon Motion) Parameter (Menu Level 2)This parameter provides fault override for Ribbon Motion Faults.

Shuttle Parameter (Menu Level 2)This parameter provides fault override for Shuttle Fault reporting.

Temp (Temperature) Parameter (Menu Level 2)The Temp Parameter provides fault override for Temperature Threshold fault reporting.

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Platen Parameter (Menu Level 2)This parameter provides fault override for the Platen Open Sensor.

Ctrl (Control Processor) Parameter (Menu Level 2)This parameter provides fault override for the control processor fault reporting status.

Link Parameter (Menu Level 2)This parameter provides fault override for control processor to main processor communica-tions.

Hvy Frm (Heavy Forms) Parameter (Menu Level 2)This parameter overrides automatic platen gap sensing.

Panel Parameter (Menu Level 2)This parameter provides fault override for Panel Fault reporting.

Control Panel Key Operations For Controlling Fault ReportingIn addition to being able to use the above parameters to set up individual fault overrides, youmay also use three different key sequences to set up fault overrides. You may set up all faultoverrides, four specific overrides, or just Paper Out Fault override.

To use the following options the printer must be in Tech Access Mode.

ALL Fault ReportingTo turn ALL fault reporting OFF, place the printer Offline and depress the FORM FEED Keyand ENTER Key simultaneously until the printer alarm sounds. To turn ALL fault reportingback ON, hold down the same two keys when the printer is Offline until the printer alarmsounds.

Four Faults OnlyTo turn fault reporting OFF for Paper Motion, Paper Out, Ribbon Fault, and Platen Opensensors, hold down the ENTER Key and TOF Key simultaneously until the printer alarmsounds. To toggle them back ON, hold down the same two keys until the printer alarm sounds.

Paper Out OnlyTo turn OFF fault reporting for the Paper Out sensor, depress the FORMS/1 Key and EN-TER Key simultaneously until the printer alarm sounds. To turn it back ON, depress the samekeys until the printer alarm sounds.

The displays that appear when you are enabling the options above can be somewhatconfusing. Just remember, when you turn on fault overrides you are losing faultprotection.

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Paper Path

Paper Path

Chapter 3Troubleshooting

Troubleshooting

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IntroductionThis chapter deals with troubleshooting problems on the T6090 printer. Messages thatindicate printer faults and errors are explained and corrective action given. The fewpaper handling and print quality problems that may occur are also explained. Trouble-shooting tables and diagnostic flow charts have been included.

MessagesMessages on the Control Panel Display report both normal operation and fault situa-tions. In Table 3–1 we present a listing of the Display Messages that need explanationor action on the part of the operator or repair person. Each message listing includescauses and corrective actions where necessary.

FaultsWhen a fault occurs, it will cause the printer to cease operation and go Offline. Theprinter alarm will sound, the FAULT Indicator will illuminate, and the display willreport a fault message.

In some cases it is possible to clear an error message and continue using the printer bydepressing the CLEAR Key. However, the quality of the print may be questionable andcollateral damage to other parts may result. If the fault message returns, perform therequired corrective action.

If a nondestructive fault occurs in the middle of printing a document, one line of textmay be lost after the error condition is corrected and the printer put back Online.

If the fault is in the control panel or interprocessor link, the fault message may notbe displayed, and the beeper and FAULT LED may not operate.

Fault Correction ProcedureSTEP 1. First check the fault message on the Control Panel Display and look it up in the Fault

Message tables provided later in this chapter.

STEP 2. Perform the required corrective action. Some Fault and Error messages will automati-cally clear as soon as the problem is corrected (for example, the Platen Open messagewill clear when the Form Thickness lever is lowered to the proper thickness).

STEP 3. If a faulty piece of hardware is found, turn to Chapter 4: Removal/Replacement Proce-dures, for instructions on removal and replacement of faulty parts.

STEP 4. If any other faults appear on the display after you have corrected the original problem,go back to Step 1 and perform required corrective actions for the new problem. Other-wise place the printer back Online and test it during normal print operations.

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Fault OverrideTo allow continued printer operation during serious faults, which usually shut downprinter operation, you may use the Fault Override Category in the printer menus system.This allows you to troubleshoot serious faults in order to repair them.

One Fault Override Parameter (Paper Motion) is available in the Standard MultilevelMenus. Once it is enabled it remains enabled until it is disabled through the ControlPanel, a printer reset escape sequence is received by the printer, or printer power iscycled.

Eight more are available in the Tech Access Mode, under the TEST Menu. They can onlybe enabled while the printer is in Tech Access Mode. However, they will remain inwhichever setting (On or Off) you select when you leave Tech Access Mode.

All of the Fault Override Parameters are explained in Chapter 2, under TEST Menu.

This feature must be used with extreme caution. Any time you disable one of the FaultSensing Systems on your printer you lose protection from situations that may result indamage to the printer.

Dump ModeDump Mode is used to troubleshoot problems that may arise when processing data. Youcan print out only control codes, control codes and spaces, or control codes, spaces andtext in hexadecimal format for use as a debugging tool. The Dump Mode Parameter isexplained in Chapter 2: Menu Operations.

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Table 3–1. Display Messages

MESSAGE Explanation and Corrective ActionBad Packet Explanation: This message indicates that a fault has occurred in the communica-

tions between the I/O processor and the main processor.Corrective Action: Cycle power and try again. If the problem returns, remove and

replace the Personality CBA. If the problem returns, download newprinter firmware.

Bad TWICO Int. Explanation: The Personality Module CBA is damaged or corrupted.Corrective Action: Cycle power and try again. If this does not clear the problem, remove

and replace the Personality Module CBA.

Bad VFU Channel Explanation: A VFU channel command has been received from the host request-ing an illegal channel.

Corrective Action: Correct data from host and retransmit.

Bad VFU Count Explanation: An incorrect number of bytes has been detected in a VFUdownload.

Corrective Action: Correct data from host and retransmit.

Buffer Overflow Explanation: A buffer overflow has been detected on the currently active hostinterface. It is most likely caused by a host failure to respond to abusy signal.

Corrective Action: 1. Ensure correct protocol has been selected.2. Check wiring of I/O cable between host and printer. (See Appen-

dix C in the Operator/Application Manual for a detailed explana-tion.)

3. Ensure correct protocol has been selected.

Chnl Not Found Explanation: VFU Channel requested by the host computer cannot be found.Corrective Action: Correct data from host and retransmit.

Ctrl Fault (n) Explanation: This message indicates that a fault has occurred in the controlprocessor.If n = :

(4) Control CPU Reset(7) Control CPU RAM Fault(8) Control CPU Checksum Failure

Corrective Action: Cycle printer power. If this does not clear the problem, remove andreplace the Engine Controller CBA If the problem still exists, replacethe Personality Module CBA.

Ctrl Link Flt Explanation: The Control Processor has detected a fault in the Main Processor toControl Processor link.

Corrective Action: Cycle power and try again. If it fails again, remove and replace thePersonality CBA. If this does not clear the problem, remove andreplace the Engine CBA.

Data Overrun Explanation: A data overrun has been detected on the currently active host inter-face. This is most likely caused by an incorrectly configured serialprotocol bit rate, data bits, parity or host failure to respond to a busysignal.

Corrective Action: Check setting on Serial Protocol bit rate, Data Bits, and Parityparameters through the printer control panel.

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Table 3–1, Continued

MESSAGE Explanation and Corrective ActionFatal Fault n Explanation: A fault has been detected in the software.

Corrective Action: Cycle power and try again. If this does not clear the problem, removeand replace the Personality CBA. If it fails again, remove and replacethe Engine Controller CBA.

Flt Clr Timeout Explanation: The Main CPU cannot clear a fault in the Control CPU.Corrective Action: Remove and Replace the Engine Controller CBA.

Font Dnld Error Explanation: An error has been detected during a font download.Corrective Action: Correct data and retransmit from host.

Heap Overflow Explanation: Graphics memory space is full and the printer cannot accept orprocess data. Printer will reset and data will be lost.

Corrective Action: Insert line terminators in data stream so the printer will process thedata, then retransmit the data.

Link Fault (n) Explanation: This message indicates that data flow has been interrupted betweenthe main processor and the control processor.If n = :(0) Maximum Packet Length Exceeded(1) Inter processor Link Transmit Timeout(2) Illegal Packet Length(3) Illegal Packet Type(5) Inter processor Link Receive Timeout(6) Sweep Done Timeout(9) Inter processor Link Receive Overrun(10) Status Request Timeout(11) Temperature Request Timeout

Corrective Action: Cycle printer power. If that does not clear the problem, download newprinter firmware.

Main CPU Fault Explanation: A fault has been detected in the main processor during powerupdiagnostics.

Corrective Action: Remove and replace the Personality Module CBA.

No VFU Loaded Explanation: A VFU command was received from the host before a VFU wasDownloaded.

Corrective Action: Download the required VFU information, then retransmit the data.

NVRAM Fault Explanation: The nonvolatile data checksum has failed because the variable valueshave been altered in a destructive manner.

Corrective Action: Depress the CLEAR Key. If the message does not clear, cycle printerpower. If the message still does not clear, remove and replace theEngine Controller CBA.

Offline Data In Explanation: The printer is in Offline condition and nonprinted data is in the buffer.Corrective Action: There is no corrective action required. Under normal conditions the

printer will continue to print when it is placed back Online. If you donot want the buffered data to print, enter the Clear Menu by depress-ing the CLEAR Key before going back Online and select the ClearBuffers entry to clear the buffered data.

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Table 3–1, Continued

MESSAGE Explanation and Corrective ActionOffline Dump On Explanation: The printer is in Offline condition and Dump Mode is enabled.

Corrective Action: No corrective action is necessary. Place the printer back Online whenyou are ready to print. (See the explanation at the beginning of thischapter and in Chapter 2 , under Hex Dumps for explanations abouthow the data from the host is printed.)

Online Dump On Explanation: The printer is ready to accept and print data from the host throughDump Mode. (See the explanation at the beginning of this chapterand in Chapter 2 , under Hex Dumps for explanations about how thedata from the host is printed.)

Corrective Action: No corrective action is required.

Overflow VFU Explanation: An excessive number of bytes has been sent by the host in a VFUdownload.

Corrective Action: Correct data and retransmit from host.

Panel Fault Explanation: The control processor has detected a fault in the circuitry for thecontrol panel. Depending on the location of the fault, this messagemay not display.

Corrective Action: Remove and replace the Control Panel. If this does not clear the fault,remove and replace the Engine Controller CBA.

Paper Motion Flt Explanation: The control processor has detected that the paper has failed to movethe required distance after sending a command to the Paper DriveMotor.

Corrective Action: Check for paper feed problems. If there are any paper feed problems,correct them, then depress the CLEAR key to clear the fault andcontinue operation.If this does not clear the problem, check for paper debris blocking thesensor.If problem still exists, check cable connection at the Engine CBA. If itfails again, check the sensor’s voltage output (in the meter parameterof the Control Panel). The reading should be approx. +5.0 Voltswithout paper and ≤ + 3.0 Volts with paper. Ideally the voltage readingshould differ at least 2V between paper in and paper out. If thedifferential is less than 2V, or the voltage does not change or is zero,the Upper Tractor set (Includes Paper Motion Sensor) needs to bereplaced.If all the above does not clear the problem, remove and replace theEngine Controller CBA.

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Table 3–1, Continued

MESSAGE Explanation and Corrective ActionPaper Out Explanation: Paper is not being detected in the lower paper path below the print

mechanism.Corrective Action: If this message is correct, refer to the ENTER Key Section of

Chapter 2 of the Operator/Application Manual, then load paper. (SeeLoading Paper Section of Chapter 1 of the Operator/ApplicationManual.)If this message is in error, check the sensor connection on the EngineController CBA and sensor position on its mounting bracket. If theconnection is OK and the sensor is properly installed, then recalibratethe Paper Out Sensor. (See TEST Menu in Chapter 2 for the proce-dure.) If the problem still exists, the Lower Tractor Set (includesPaper Motion Sensor) needs to be replaced.If all of the above checks and fixes do not clear the problem, removeand replace the Engine Controller CBA.

Parity Error Explanation: Parity is enabled and a mismatch on Bit 8 has been detected on thecurrently active host interface.

Corrective Action: If there is a mismatch between the setting of the printer and thesetting of the host, you can change printer parity by referring to theConfiguration Menu section of Chapter 2 of the Operator's Manual .If there is no mismatch between the printer and host settings, then thedata sent from the host has been corrupted. Retransmit the data fromthe host. If the condition repeats, set up the printer for Dump Mode(see Configuration Menu Section in Chapter 2 of the Operator'sManual ) and retransmit the data again. If you find no errors in theDump Mode data, remove and replace the Personality Module CBA.If this still does not correct the problem, the likely cause is in the I/Ocable or the host.

Platen Open Explanation: The Form Thickness Lever is set beyond the maximum settingfor paper thickness. This message may display when you are loadingpaper or a Ribbon Cartridge into the printer. This condition disablesthe printer and the only keys that will function on the control panel arethe form movement keys.

Corrective Action: When you are loading paper or a Ribbon Cartridge, this message willclear when you lower the Form Thickness Lever and close the PlatenGap. If this message appears at any other time or will not clear, checkthe sensor connection on the Engine Controller CBA and perform ameter test on the sensor. (See TEST Menu in Chapter 2 for theprocedure.) The sensor should read less than .2 volts with the FormThickness Lever closed and greater than 4 volts with the form Thick-ness Lever fully opened. If the readings do not differ, download newprinter firmware.

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Table 3–1, Continued

MESSAGE Explanation and Corrective ActionPrint Fault Explanation: Faulty communication between the main and control processor has

occurred causing a dot row to misprint. The printer automaticallyrecovers from this condition.

Corrective Action: Under normal circumstances there is no corrective action other than todepress the CLEAR Key to remove the fault message from thedisplay. If this does not clear the problem, remove and replace thePersonality CBA. If, however, this problem persists, remove andreplace the Engine Controller CBA.

RAM Test Fail Explanation: A fault has been detected in the Main Processor primary RAM or afault exists in the RAM address lines.

Corrective Action: Remove and replace the Personality Module CBA.

Self Testing Explanation: The printer is performing internal diagnostic tests.Corrective Action: If this message does not clear automatically after a few seconds,

remove and replace the Personality Module CBA.

Setup Address Explanation: The printer address has not been set up or a configuration withaddress set to UNDEFIN has been loaded.

Corrective Action: Set up the printer address using the multilevel menus on the printer.The procedure is located in Chapter 4 of the Operator Manual , underthe Configuration Menu .

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Table 3–1, Continued

MESSAGE Explanation and Corrective ActionShuttle Fault Explanation: If the control processor detects the shuttle operating either above or

below the proper frequency, it shuts down the shuttle and attempts torestart it. If the shuttle still operates incorrectly after three consecutiveattempts, the Control Processor goes Offline, and the Shuttle Faultmessage is displayed.

Corrective Action: Depress the CLEAR Key, then put the printer back Online. Send aprint job to the printer or perform a print test.If the error condition returns, cycle printer power, then try to print againIt the fault condition returns after performing the above actions,perform the following checks:Check and verify that the shuttle drive belt is not broken or loose.Replace it if it is.Check sensor position, cable, and CBA connection. If the connectionand cable are OK and the sensor is properly installed, perform ameter check of the Shuttle Motion Sensor (see TEST Menu Section ofChapter 2 in this manual). The sensor should read less than .5 voltswith the closed segment of the shuttle gear over the sensor andgreater than 4.5 volts with the open segment of the gear over thesensor. If the readings are not within the range listed above, removeand replace the sensor.If the sensor is OK, turn the shuttle drive gears by hand. If they do notturn freely, remove the shuttle mechanism and check it again. If itturns freely while removed, check the Hammer Bank for free side toside movement.If the Hammer Bank is binding and does not slide freely, replace theshaft bearing blocks on the Hammer Bank.If the shuttle mechanism still does not turn freely or you find broken orexcessively worn gears, replace the Shuttle Drive Mechanism.If they turn freely, the Hammer Bank is not binding, and no excessivewear is present, perform a motor check using the Shuttle Selectionunder the Motor Parameter in the TEST Menu . If the motor does notfunction properly, check the drive motor connection on the EngineController CBA and check the motor cable. Correct any problems youencounter with these items.If the connection and cable are OK, check and ensure that the propervoltage is provided at the motor connector plug on the Engine Control-ler CBA. If the voltage is incorrect, check voltage at the PowerSupply. If power supply voltage is OK, replace the Engine ControllerCBA. If Power Supply voltage is not correct, check the input voltage.If the input voltage is OK, then replace the Power Supply. If the inputvoltage is not correct, there is a problem with the site power supply.

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Table 3–1, Continued

MESSAGE Explanation and Corrective ActionThermal Fault Explanation: The ambient temperature has exceeded the limit (Max T).

Corrective Action: Check to see if the Cirscuit Cooling and Hammer Bank fans areworking. If both fans are working, you have a faulty Engine ControllerCBA.

If only one of the two fans is not working, check power at the EngineController CBA for the fan that is not operating. If power is OK,remove and replace the fan. If power is not OK remove and replacethe Engine Controller CBA.

If neither fan is working, either the Engine Controller CBA or thePower Supply is malfunctioning. Check voltage output of the PowerSupply. If it is OK remove and replace the Engine Controller CBA. Ifit is not OK, check the power source voltage. If the power sourcevoltage is OK, remove and replace the Power Supply. If the powersource voltage is incorrect, call an electrician.

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Hardware Troubleshooting GuidesNot all printer problems are reported by an error message. Malfunctioning hardwarecan cause a wide variety of problems without triggering a fault indication. The trouble-shooting procedures in this section will help you to repair hardware problems.

The printer does not power up when switched onThere are four things that can cause this problem.

1. A bad connection.2. A malfunctioning On/Off switch.3. Incorrect input power.4. A malfunctioning power supply.

Troubleshooting ProcedureSTEP 1. Check all power connections.

Is the printer plugged in?Are the connections on the On/Off switch secure?Are the input power connections on the Power Supply secure?Is the Power Supply connection to the Engine Controller CBA secure?

STEP 2. Check the input power supply voltage. Input power should be 90—130 VAC or180—264 VAC, single phase, 50 ± 3—60 ± 3 Hz. Check input power at the plug-in, onthe Power Supply side of the On/Off switch, and on the input side of the Power Supply.

If input power at the plug-in is incorrect, either the printer power cord isdefective or the power supply is defective. Check power at the outlet to makesure the power source voltage is correct. If the power source voltage is OK, theproblem is in the cord.

If input power at the plug-in is OK, check power from the On/Off switch tothe Power Supply. If there is no power at the back of the On/Off switch whenit is switched On, the On/Off switch is defective. Remove and replace thePower Supply.

If input power is OK on the back of the On/Off switch, check input power onthe Power Supply. If there is no input power at the Power Supply, the cablingfrom the On/Off switch to the Power Supply is defective.

STEP 3. If input power to the printer Power Supply is OK, check output voltage of the PowerSupply. Power Supply output voltage should be approximately 48 VDC. If the outputvoltage is incorrect, remove and replace the Power Supply.

When the printer is powered up, nothing works except the fan.The only thing that can cause this problem is a malfunctioning Engine Controller CBA.Remove and replace the Engine Controller CBA.

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The Printer powers up but the Control Panel does not function.There are four things that can cause this problem.

1. A bad connection.2. A bad control panel.3. A bad Engine Controller CBA.4. Loss of 5 V power supply.

If the red Power On Indicator is the only one that does not function, the problem ismost likely a malfunctioning Control Panel.

Troubleshooting ProcedureSTEP 1. Check the form movement keys to see if they function.

If the form movement keys function properly, the problem is either in the Control Panelor in the Engine Controller CBA.

Try another Control Panel first. If that does not correct the problem, then remove andreplace the Engine Controller CBA.

STEP 2. If the form movement keys do not function properly, check the Control Panel connec-tion to the Engine Controller CBA.

If the connection is OK, the problem is in either the Control Panel or in the EngineController CBA. Try another Control Panel first. If that does not correct the problem,then remove and replace the Engine Controller CBA.

The Control Panel Display functions partially, nonsensically, or not at all.There are three things that can cause this problem.

1. A bad connection.2. A malfunctioning Control Panel.3. A malfunctioning Engine Controller CBA.

Troubleshooting ProcedureSTEP 1. Check the Control Panel connection to the Engine Controller CBA.

STEP 2. If the connection is OK, the problem is in either the Control Panel or in the EngineController CBA.

Try another Control Panel first. If that does not correct the problem, then remove andreplace the Engine Controller CBA.

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There is no printed output but the printer appears to be operating normally.There are three things that can cause this problem.

1. The Form Thickness Lever may be open too far but not far enough to cause aPlaten Open message.

2. The Ribbon Cartridge may not be functioning properly or is not installed.3. Platen alignment may be incorrect.

Troubleshooting ProcedureSTEP 1. Check the Form Thickness Lever and make sure it is closed properly.

STEP 2. Make sure the Ribbon Cartridge is installed and functioning properly. If the RibbonCartridge is not functioning properly, replace it.

STEP 3. If STEPs 1–2 do not correct the problem, check and adjust the platen alignment guides.The Platen Gap should be approximately .013 " with the Form Thickness Lever fullyclosed. (See Procedure 24 in Chapter 4.)

Printed output appears lightThere are three things that can cause this problem.

1. The Form Thickness Lever may be open too far but not far enough to cause aPlaten Open message.

2. The Ribbon Cartridge may be worn out or is not moving.3. Platen alignment may be incorrect.

Troubleshooting Procedure.STEP 1. Check the Form Thickness Lever and make sure it is closed properly.

STEP 2. If the Ribbon Cartridge is functioning properly, it is probably out of ink. Remove andreplace the Ribbon Cartridge.

STEP 3. If the Ribbon Cartridge is not moving, remove the ribbon and check it by turning theribbon knob to see if it will turn.

If the ribbon knob does not turn, replace the Ribbon Cartridge.

If the ribbon knob does turn, check the ribbon motor to make sure it is operat-ing properly. (See Ribbon Motion Fault Message, earlier in this chapter fortroubleshooting procedure.)

STEP 4. If STEPs 1–3 do not correct the problem, check and adjust the platen alignment guides.The Platen Gap should be approximately .013 " with the Form Thickness Lever fullyclosed. (See Procedure 24 in Chapter 4.)

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Printed output appears shaky or fuzzyThere are six things that can cause this problem.

1. The Form Thickness Lever may be open too far but not far enough to cause aPlaten Open message.

2. The shuttle mechanism is worn—the shuttle counterweight gears or the bearingsare worn.

3. The hammers are not firing properly.4. Platen alignment may be incorrect.5. Damaged platen.6. The Shuttle Sensor is misaligned.

Troubleshooting ProcedureSTEP 1. Check the Form Thickness Lever and make sure it is closed properly.

STEP 2. Check the Shuttle Mechanism for wear in the gears or play in the bearings.

If the Shuttle Mechanism is defective, replace the Shuttle Mechanism, then perform aHammer Calibration procedure for optimum print quality.

STEP 3. Perform a Hammer Calibration procedure. This procedure is explained in Chapter 2, inthe TEST Menu Section, under the Diagnostic Category (PrntCal Parameter).

If the hammers can not be calibrated, the problem is in the Engine Controller CBA.Replace the Engine Controller CBA following the procedure explained in Chapter 4.

STEP 4. Check and adjust the platen alignment guides. The Platen Gap should be .012 " – .014"with the Form Thickness Lever fully closed.

STEP 5. Check the impact area of the platen and replace the platen if this area is damaged.

STEP 6. Make sure the Shuttle Sensor is properly aligned. (See Procedure 18 in Chapter 4.)

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Two adjacent character columns not printingThere are five things that can cause this problem.

1. Broken Hammer.2. Defective Hammer Coil; either shorted or open.3. Defective Hammer Bank Cable.4. Malfunctioning Engine Controller CBA.5. The hammer may be sticking due to contamination, such as paper and ink

buildup.

Troubleshooting ProcedureSTEP 1. Remove the right end cover of the printer.

STEP 2. Inspect the Hammer Bank cables for rub spots, cracked insulation, burn spots, etc.

If any physical defects are found in the cables, remove and replace the Ham-mer Bank Assembly and correct the cause of the problem with the cable.

Test the printer to see if the problem is still present. If it isn’t, reinstall theright end cover and place the printer back in service.

If the problem is still present, proceed to STEP 3.

If no physical defects are found proceed to the next step.

STEP 3. Remove the Ribbon Cartridge and Ribbon Platform.

STEP 4. Check continuity from the Hammer Bank Cable Connector (J703) to the affected coils.

To assist you in checking continuity, connector pinouts (Table 3–3) and illustrationsshowing the pin arrangements of the connector and the soldered connections on theHammer Bank (Table 3–4) are included at the end of this chapter.

STEP 5. Check continuity of the Hammer Coil. Resistance of the coil should be 12 Ω (Ohms) ±.3 Ω at 70° F. If the coil resistance is outside of this range, remove and replace theHammer Module.

If the Hammer Coil is defective, check the Hammer Driver on the Engine ControllerCBA also. Defective Hammer Drivers can cause problems with Hammer Coils. Instruc-tions for checking Hammer Drivers are located at the end of this chapter.

STEP 6. Is the hammer broken or defective? If so, remove and replace the Hammer Module.

STEP 7. Check between the Hammer Plate and the Hammer Module Return Plate and betweenthe Hammer Head and Hammer Coil for ink and paper buildup. Clean the HammerBank by prying out gently on the hammer with your finger and running a piece ofpaper behind the hammer to remove the contamination. For stubborn buildup you mayuse a little isopropyl alcohol on the paper to loosen the contamination.

STEP 8. If there are no physical defects, shorts, or opens, the likely cause of the problem is amalfunctioning Engine Controller CBA. Remove and replace the Engine ControllerCBA.

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The Printer is out of paper — No Paper Out fault is reportedThere are three things that can cause this problem.

1. Fault override for paper out sensor is on, disabling the paper out sensor.2. Calibration values have been lost for the paper out sensor.3. Malfunctioning Engine CBA.

STEP 1. Check to see if the fault override is enabled for Paper Out sensing.

STEP 2. If Fault Overrides are not enabled, check the sensor connections and recalibrate thePaper Out sensor. (See Chapter 2, under Diag Category.)

STEP 3. If none of the above checks eliminates the problem, the most likely cause is a malfunc-tioning Engine Controller CBA. Remove and replace the Engine Controller CBA.

If you have no idea how long the printer has been banging away with no paperinstalled, check the platen for damage. If necessary, remove and replace the platenand any damaged hammers.

No Paper Motion — No Paper Motion fault is reportedThere are three things that can cause this problem

1. Fault override for paper motion sensor is on, disabling the paper motion sensor.2. Defective Paper Motion Sensor.3. Malfunctioning Engine Controller CBA.

STEP 1. Check to see if the fault override is enabled for Paper Motion sensing.

STEP 2. Use the PapMot Meteer Test to check the sensor If it does not check correctly, removeand replace the upper tractor set.

STEP 3. If none of the above checks eliminates the problem, the most likely cause is a malfunc-tioning Engine Controller CBA. Remove and replace the Engine Controller CBA.

If you have no idea how long the printer has been banging away with no papermotion, check the platen for damage. If necessary, remove and replace the platenand any damaged hammers.

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Paper Handling ProblemsThe following table lists the few paper handling problems you may encounter alongwith corrective actions you may take.

Table 3–2. Paper/Printing Corrective Action

Problem Cause Corrective ActionThe paper holes are wider thannormal after passing through thetractors.

Horizontal paper tension is too tight. Unlock and readjust the tractors.

(2) The tractors are too far apart. Unlock and realign the tractors.

Printed characters on heavy-weight or multi-part paper aresmeared.

The Form Thickness Lever is not setcorrectly.

Raise the Form Thickness Lever.

The printed characters are toolight.

The Form Thickness Lever is out ofadjustment or the ribbon is worn out.

Readjust the Form Thickness Lever.If this does not correct the problem,replace the ribbon cartridge with anew one.

The printed characters are shaky. The Form Thickness Lever is not setcorrectly.

Adjust the Form Thickness Lever.

The printed characters in oneline are shorter than normal.

Vertical paper tension is too loose. Move the Paper Tension Lever untilthe paper is taut but not too tight.

The paper holes are elongatedafter passing through the tractors.

Vertical paper tension is too tight. Move the Paper Tension Leveruntil the paper is taut but not tootight.

The paper comes out of thetractors or the paper tears at theright or left holes along the edges.

(1) The vertical or horizontalpaper tension is incorrect.

To change the vertical tension,raise the Paper Tension Lever toincrease tension, and lower it todecrease tension.

To change the horizontal tension,unlock the upper right and/orlower right tractor and move it leftor right to make the necessaryadjustment.

(3) Upper tractors not alignedwith the lower tractors.

Unlock and realign the tractorsso that the lower set is directlyunder the upper set.

(4) The Form Thickness Lever isnot set correctly.

Raise the Form Thickness Lever.

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T6090 Engine Controller To Hammer Bank CBA Cables

Table 3–3. Connector Pinouts

Common = 48V Power

P703 P704

PIN Function PIN Function PIN Function PIN Function

1 Hammer 33 2 Hammer 32 1 Hammer 66 2 Hammer 653 Hammer 31 4 Common 3 Hammer 64 4 Common5 Hammer 30 6 Hammer 29 5 Hammer 63 6 Hammer 627 Hammer 28 8 Common 7 Hammer 61 8 Common9 Hammer 27 10 Hammer 26 9 Hammer 60 10 Hammer 5911 Hammer 25 12 Common 11 Hammer 58 12 Common13 Hammer 24 14 Hammer 23 13 Hammer 57 14 Hammer 5615 Hammer 22 16 Common 15 Hammer 55 16 Common17 Hammer 21 18 Hammer 20 17 Hammer 54 18 Hammer 5319 Hammer 19 20 Common 19 Hammer 52 20 Common21 Hammer 18 22 Hammer 17 21 Hammer 51 22 Hammer 5023 Hammer 16 24 Common 23 Hammer 49 24 Common25 Hammer 15 26 Hammer 14 25 Hammer 48 26 Hammer 4727 Hammer 13 28 Common 27 Hammer 46 28 Common29 Hammer 12 30 Hammer 11 29 Hammer 45 30 Hammer 4431 Hammer 10 32 Common 31 Hammer 43 32 Common33 Hammer 9 34 Hammer 8 33 Hammer 42 34 Hammer 4135 Hammer 7 36 Common 35 Hammer 40 36 Common37 Hammer 6 38 Hammer 5 37 Hammer 39 38 Hammer 3839 Hammer 4 40 Common 39 Hammer 37 40 Common41 Hammer 3 42 Hammer 2 41 Hammer 36 42 Hammer 3543 Hammer 1 44 Common 43 Hammer 34 44 Common

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Table 3–4. P703 & P704 Connector to Hammer Bank CBA Continuity Check Points

12

34

56

78

910

11

36

912

1518

2124

2730

33

Ham

mer

bank

Firi

ng L

ine

— T

op V

iew

— L

eft t

o R

ight

Pow

erS

uppl

y P

ins

Ham

mer

s

Ham

mer

Mod

ules

Ham

mer

bank

CB

A S

olde

red

Con

nect

ions

J6J5

P70

3 P

in N

umbe

rsC

onne

ctor

Alig

nmen

tP

704

Pin

Num

bers

P70

3 H

amm

erba

nk R

ibbo

n C

able

P70

4 H

amm

erba

nk R

ibbo

n C

able

431

35

79

1113

1517

1921

2325

2729

3133

3537

3941

442

46

810

1214

1618

2022

2426

2830

3234

3638

4042

431

35

79

1113

1517

1921

2325

2729

3133

3537

3941

442

46

810

1214

1618

2022

2426

2830

3234

3638

4042

25

811

1417

2023

2629

32

14

710

1316

1922

2528

31

48V

48V

48V

48V

48V

48V

48V

48V

48V

48V

48V

3538

4144

4750

5356

6063

66

3639

4345

4851

5457

5962

65

3437

4043

4649

5255

5861

64

48V

48V

48V

48V

48V

48V

48V

48V

48V

48V

48V

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Table 3–5. T6090 Hammer Coil/Module Troubleshooting

Print Hammer Hammer CBA Print Hammer Hammer CBAColumns Coil Module Driver Columns Coil Module Driver

1 & 2 1 1 U20 67 & 68 34 12 U123 & 4 2 1 U20 69 & 70 35 12 U115 & 6 3 1 U20 71 & 72 36 12 U117 & 8 4 2 U19 73 & 74 37 13 U119 & 10 5 2 U19 75 & 76 38 13 U1111 & 12 6 2 U19 77 & 78 39 13 U1013 & 14 7 3 U19 79 & 80 40 14 U1015 & 16 8 3 U18 81 & 82 41 14 U1017 & 18 9 3 U18 83 & 84 42 14 U1019 & 20 10 4 U18 85 & 86 43 15 U921 & 22 11 4 U18 87 & 88 44 15 U923 & 24 12 4 U17 89 & 90 45 15 U925 & 26 13 5 U17 91 & 92 46 16 U927 & 82 14 5 U17 93 & 94 47` 16 U829 & 30 15 5 U17 95 & 96 48 16 U831 &3 2 16 6 U16 97 & 98 49 17 U833 & 34 17 6 U16 99 & 100 50 17 U835 &36 18 6 U16 101 & 102 51 17 U737 & 38 19 7 U16 103 & 104 52 18 U739 & 40 20 7 U15 105 & 106 53 18 U741 &4 2 21 7 U15 107 & 108 54 18 U743 & 44 22 8 U15 109 & 110 55 19 U645 & 46 23 8 U15 111 & 112 56 19 U647 & 48 24 8 U14 113 & 114 57 19 U649 & 50 25 9 U14 115 & 116 58 20 U651 & 52 26 9 U14 117 & 118 59 20 U553 & 54 27 9 U14 119 & 120 60 20 U555 & 56 28 10 U13 121 & 122 61 21 U557 & 58 29 10 U13 123 & 124 62 21 U559 & 60 30 10 U13 125 & 126 63 21 U461 & 62 31 11 U13 127 & 128 64 22 U463 & 64 32 11 U12 129 & 130 65 22 U465 & 66 33 11 U12 131 & 132 66 22 U4

Driver Information is intended for Service Center only.

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Troubleshooting The Hammer Driver TransistorsThe Hammer Driver Transistors are located on the Engine Controller CBA. When youare having problems like Hammer Coil shorting or Hammers not firing, these compo-nents should be checked along with the other components involved in the function.

To check the Hammer Driver for the malfunctioning hammer, use an Ohmmeter on itslowest scale. Test the collector (C) to base (B) by placing the Positive (+) lead on thecollector terminal and the Negative ( – or Common) lead on the base terminal. If thereading is either a short (0 Ohms) or an open (∞, infinity), the driver is bad and youshould replace the Engine Controller CBA. If this check is OK, then test the base (B) toemitter (E) by placing the positive (+) lead on the base terminal and the negative (– orCommon) lead on the emitter terminal. If the reading is either a short (0 Ohms) or anopen (∞, infinity), the driver is bad and you should replace the Engine Controller CBA.Use the following table to locate the correct driver terminals to check for the hammer(s)you are having trouble with.

The Base of each segment of the driver goes to the LSI Chip, which turns On/Offeach segment. The Collector of each driver segment is connected to the corre-sponding Hammer Coil.

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Table 3–6. J703 Hammer Driver Pinouts

U121 2 3 4 5 6 7 8 9 10 11 12

Pin Numbers

B C C BH32 H33

Circuit Side of Engine Controller CBA

Top Of CBA

J703

U14

U15

U16

U18

U17

U19

U20

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

H24 H25 H26 H27

H20 H21 H22 H23

H16 H17 H18 H19

H12 H13 H14 H15

H8 H9 H10 H11

H4 H5 H6 H7

H1 H2 H3

U13

B C C B B C C BH28 H29 H30 H31

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Table 3–6. J704 Hammer Driver Pinouts

J704U4

U5

U6

U7

U9

U8

U10

U11

U12

1 2 3 4 5 6 7 8 9 10 11 12Pin Numbers

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

B C C B B C C B

H59 H60 H61 H62

H55 H56 H57 H58

H51 H52 H33 H54

H47 H48 H49 H50

H43 H44 H45 H46

H39 H40 H41 H42

H35 H36 H37 H38

H34

H63 H64 H66

Circuit Side of Engine Controller CBA

Top Of CBA

H65

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Paper Path

Paper Path

Chapter 4Removal & Reinstallation Procedures

Rem

oval & R

einstallationProcedures

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IntroductionThis chapter covers removal and reinstallation of selected field replaceable components andassemblies of your printer.

WARNING!HIGH VOLTAGE POTENTIAL

High levels of AC voltage are present in the power supply. Always ensure that the power cord

is unplugged before performing maintenanceon the printer.

Any time you remove a component that is involved in some aspect of the print-ing process, perform a print test to ensure that print quality has not been af-fected. If necessary, perform the required calibration or set up to ensure bestpossible print quality.

Required ToolsThe following list presents the tools you will need to perform the procedures in this chapter.All of the tools (except where noted) are included in the T6090 Tool Kit that is availablethrough our Spares Department.

Volt/Ohm Meter – not included in the tool kit

Platen Gap Shim Gauges – .012", .014"

Hammer Alignment Tool

Snap Ring Pliers

6" Phillips Screwdriver #1 Tip – not included in tool kit

6" Phillips Screwdriver #2 Tip – not included in tool kit

3" Phillips Screwdriver #1 Tip – not included in tool kit

8" Longnose Pliers – not include in tool kit

5/64 Hex Key Allen Wrench

1/16 Hex Key Allen Wrench – not included in tool kit

.050 Hex Key Allen Wrench

Phasing strip/gauge

5/32 Hex Allen T-Handle

Paper Belt Tension Gauge

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Procedure 1 – The Printer LidBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Raise the printer lid. Grasp the gas spring near where it connects to the printer cabinet. Insert

a narrow screwdriver under the spring clip on the gas spring where it attaches to the printer.Lift the clip straight up until it unlocks and the gas spring can be easily taken off its post.

Spring Clip

Pivot Post Small Flat Blade Screwdriver

Figure 4–1. Disconnecting the Gas Spring

The printer lid is heavy and will immediately try to come crashing down ontowhichever part of your anatomy is within reach when you remove the end of thegas spring from its post. So be careful when you disconnect the gas spring!

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STEP 2. Grasp the printer lid by the front edge with one hand while you use a Phillips screwdriver toremove the hinge-stop to the immediate left of the right hinge.

Step 3. Slide Lid to Leftand Off

Hinges

Step 2.RemoveHinge Stop

Figure 4–2. Removing the Lid

STEP 3. After you remove the hinge-stop, slide the lid assembly to the left to remove it from theprinter. If the lid does not slide off easily, loosen the hinge screws , then try to slide the lid offagain.

ReinstallingTo reinstall the printer lid, reverse the removal steps.

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Procedure 2 – The Control PanelBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Raise the printer lid.

STEP 2. Insert a small, flat screwdriver straight into the slot located to the left of the Control Panel.

STEP 3. Push the screwdriver straight in until the Control Panel’s latch releases and the left edge of thepanel can be lifted up.

STEP 4. Lift Panel out gently, minimize any stress to the Control Panel cable.

If you are installing a new Control Panel, reach inside and unplug the Control Panel cable fromthe Engine Controller CBA (J801).

If you are removing the Right End Cover, carefully insert Control Panel back through itsopening and rest it in the inside of the printer.

Panel Latch

Latch Release Access Slot

Figure 4–3. Removing the Control Panel

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ReinstallingSTEP 1. If the Control Panel was removed from the printer, plug the new panel into the Engine Control-

ler CBA (J801). Then advance to STEP 2.

If the Control Panel is still connected to the Engine Controller CBA and is lying in the insideof the printer, lift it out of the opening gently.

Make sure the Control Panel cable is clear of the Shuttle gears. If the cable getsentangled in the shuttle gears it may be damaged and it may also damage theshuttle.

STEP 2. Insert the right edge of the Control Panel into the opening and push it all the way to the right.

STEP 3. Lower the left edge down until it rests on the edge of the opening. Push in on the latch until thepanel slides easily into the opening.

STEP 4. Push down on the left edge of the Control Panel until it is securely latched into place.

Figure 4–4. Reinstalling the Control Panel

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Procedure 3 – The Right End CoverBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Printer Control Panel. (See Procedure 2)

STEP 2. Remove the screws at positions 1 and 2.

STEP 3. Loosen the screws at positions 3, 4, and 5.

STEP 4. Pull up on the front edge of the cover until it comes free of the channel it sits in. When thefront edge comes free you can lift straight up on the cover and remove it from the printer.

Step 2. Remove 2 Screws

Step 4.

Step 3. Loosen Screws

1.

2.

3.5.

4.

Figure 4–5. Removing the Right End Cover

ReinstallingSTEP 1. Make sure that all connections are secure and all cables are kept away from the areas where

the cover contacts the printer.

STEP 2. Set the end cover over the Engine Controller CBA and Shuttle. Align the short lip on the frontinside edge of the cover over the lip (1) on the printer and the channel in front (2) and side (3)of the printer.

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Place infront of printer lip

1.

2.

3.

Place inchannelPlace inchannel

Figure 4–6. Reinstalling the Right End Cover

STEP 3. It may be a tight fit and require considerable downward pressure to get the cover to set downcompletely. Before pressing down, make sure that all cables are clear of the contact areabetween the cover and printer.

STEP 4. Reinstall the screws in position 1 and 2, then tighten the screws at positions 3, 4, and 5 (seeFigure 4–5).

STEP 5. Reinstall the Printer Control Panel.

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Procedure 4 –The Engine Controller CBABefore beginning this procedure, turn the printer off and disconnect the power cable.

If you are going to replace the Engine Controller CBA, print out a Configuration reportand a Calibration Data report before you remove the old CBA. This will give you theinformation you need to make sure the printer is properly set up after you finish.

RemovingSTEP 1. Remove the Right End Cover (see Procedure 3).

STEP 2. Remove the Personality Module (see Procedure 5).

STEP 3. Disconnect all cables and connectors attached to the Engine Controller CBA.

Fan J2

Power Supply J302

Shuttle Drive Motor J501Ribbon Drive Motor J502

Paper Drive Motor J503

Shuttle Sensor J604 J603 Paper Motion Sensor

J602 Paper Out SensorJ601 Platen Open Sensor

J801 Control Panel

J901 Ribbon Fault Detect

J704 Hammer Bank

J703 Hammer Bank

J3 RibbonPlatform Blower

Figure 4–7. Removing the Engine Controller CBA

STEP 4. The Engine Controller CBA is secured in the printer by two Phillips screws and four counter-sunk screws along the bottom outside edge of the CBA. Remove these screws. The EngineController CBA can now be separated from the Personality Module CBA.

The Engine Controller CBA can now be removed from the printer.

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ReinstallingTo reinstall the original Engine Controller CBA or install a new one, reverse the sequence andactions of the removal steps.

After installing a new Engine Controller CBA, run the meter tests (as explained in the PaperOut, Paper Motion Flt, Shuttle Fault, Platen Open, and Ribbon Fault messages in Chapter 3and the Hammer Calibration routines provided in the TEST Menu of the printer. Use theprintouts you made earlier to set up communications and other printer operations.

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Procedure 5 – The Personality Module CBA and EnclosureBefore beginning this procedure, turn the printer off and disconnect the power cable.

Removing The Personality ModuleSTEP 1. Loosen the knurled screws securing the Personality Module CBA into its enclosure, then slide

it out and set it aside.

Figure 4–8. Removing the Personality Module CBA

STEP 2. Remove the Right End Cover (see Procedure 3).

STEP 3. Remove the Engine Controller CBA (see Procedure 4).

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STEP 4. Remove the cables from the cable support located on top of the enclosure.

STEP 5. Remove the five screws securing the enclosure to the back of the printer. Once the screws areremoved you can remove the enclosure from the printer.

Cable Support

Figure 4–9. Removing the Personality Module Enclosure

ReinstallingTo reinstall the Personality Module and its Enclosure, reverse the sequence and actions of theabove steps.

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Procedure 6 –The Fan AssemblyBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Right End Cover (see Procedure 3).

STEP 2. Remove the Engine Controller CBA (see Procedure 4).

STEP 3. Remove the Personality Module CBA and its Enclosure (see Procedure 5).

STEP 4. Remove the three screws securing the Fan Assembly to the base of the printer. You can nowlift the fan out of the printer.

Figure 4–10. Removing Fan Assembly.

ReinstallingTo reinstall the Fan Assembly, reverse the sequence of the above steps.

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Procedure 7 – Power SupplyBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove any printed forms along with the Paper Stacking Tray, if they are present. Disconnect

the Static Ground from the printer and remove the hood from the back of the printer.

Paper Rack

Sound Deadening Hood

StaticGroundWire

Figure 4–11. Disconnecting the Static Ground and Removing the Sound Deadening Hood

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STEP 2. Remove Right End Cover (see Procedure 3) and disconnect the Power Supply from the EngineController CBA (J302 ) and remove the cable from the cable supports (2 ea) that route thecable to the Engine Controller CBA.

STEP 3. Remove the five screws securing the Power Supply to the printer. You can now remove thePower Supply from the Printer.

Figure 4–12. Removing the Power Supply

ReinstallingTo install the Power Supply, reverse the sequence of the above steps.

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Procedure 8 – The Left End CoverBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the printer lid (see Procedure 1).

STEP 2. Remove the screws in locations 1 and 2.

STEP 3. Loosen the screws in locations 3, 4, and 5 . On pedestal models, the screw in position 5 canonly be accessed if the pedestal door is partially open.

4.

5.

3.

2.1.

Figure 4–13. Removing the Left End Cover

STEP 4. Lift up on the end cover until it clears the printer and can be removed.

ReinstallingSTEP 1. Align the lip of the cover with the lip on the printer just above screw location 5, then insert the

lip around the base of the cover into the mounting channel on the printer.

STEP 2. Press down on the cover until it seats in the channel.

STEP 3. Reinstall the screws at locations 1 and 2.

STEP 4. Tighten the screws at locations 3, 4, and 5.

STEP 5. Reinstall the printer lid.

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Procedure 9 – The Ribbon PlatformBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Open the Printer lid, raise the Form Thickness Lever, and remove the Ribbon cartridge.

STEP 2. Remove the Control Panel and lay it in the bottom of the printer (see Procedure 2).

STEP 3. Remove the Right End Cover (see Procedure 3).

STEP 4. Disconnect the Ribbon Motor cable from the Engine Controller CBA (J502). Disconnect theRibbon Platform Fan Assembly cable from the Engine Controller CBA (J3). You will need toremove both cables from a cable clamp and remove a ferrite bead encircling the group ofcables that contains the Ribbon Motor cable.

STEP 4a. To remove the ferrite bead, use a pair of needlenose pliers (or equivalent) to press inon the two tabs on the bead. Pry the two halves apart and remove the bead.

Ferrite Bead Locking Tabs

J502J3

Figure 4–14. Disconnecting the Ribbon Platform Components

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STEP 5. Remove the three mounting screws that secure the Ribbon Platform to the printer. Now youcan lift the Ribbon Platform out of the printer.

Raise Form Thickness Lever

Ribbon Platform

Remove the three mounting screws

Figure 4–15. Removing the Ribbon Platform

ReinstallingTo reinstall the Ribbon Platform, reverse the sequence of removal steps.

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Procedure 10 – The Ribbon MotorBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Ribbon Platform (see Procedure 9).

STEP 2. Remove the panduit that secures the Ribbon Motor cable to the platform. The motor can nowbe removed.

STEP 3. Remove the four screws that secure the motor to the Ribbon Platform.

Ribbon Motor

J502

Figure 4–16. Removing the Ribbon Motor

ReinstallingSTEP 1. Insert the motor shaft through the hole in the Ribbon Platform, then align the screw holes

(make sure that the motor cable is on the side toward the Control Panel) and reinstall the motormounting screws. Secure the Ribbon Motor cable to the platform with a panduit.

STEP 2. Reinstall the Ribbon Platform.

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Procedure 11 – The Hammer BankBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Printer lid and the Control Panel (see Procedures 1 and 2).

STEP 2. Remove the Right End Cover (see Procedure 3).

STEP 3. Remove the Ribbon Platform (see Procedure 9).

STEP 4. Disconnect the Hammer Bank cables from the Engine Controller CBA (J703 & J704). Re-move the two screws from the flex loop bracket and remove the Hammer Bank cables from thecable clamp near the flex loop bracket.

FlexloopBracket

Cable Clamp

Ferrite Bead

Figure 4–17. Disconnecting the Hammer Bank

If you are replacing the Hammer Bank, remove the ferrite bead from the cable andinstall it on the new Hammer Bank cable.

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STEP 5. Remove the three screws from the Right Bearing Block.

STEP 6. Remove the two screws from the Left Bearing Block. Slide the loosened Bearing block to theleft off of the Hammer Bank shaft.

Hammer Bank

Shuttle Assembly

Left Hand Bearing Block Screws

Right Hand Bearing Block Screws

Figure 4–18. Removing the Hammer Bank

STEP 7. Remove the shuttle Motor Belt. Grasp the Shuttle Assembly firmly and carefully pull theHammer Bank towards you until the bearing underneath the shuttle pulls free from the stabi-lizer block. The Hammer Bank can now be separated from the printer.

If you are installing a new Hammer Bank, you will need to remove the Shuttle Assemblyand install it on your new Hammer Bank. To remove the Shuttle see Procedure 15.

ReinstallingWhen you are ready to reinstall the Hammer Bank, reverse the above sequence of removalsteps.

Before you install the Ribbon Platform, you must reset the Platen gap described later in thischapter (see Procedure 25).

Perform a Hammer Calibration to adjust for optimum print quality. (Hammer calibration isexplained in Chapter 2, under PrntCal Parameter.)

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Procedure 12 – The Ribbon ShieldBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Left End Cover (see Procedure 8).

STEP 2. Remove the Right End Cover (see Procedure 3).

STEP 3. Remove the Ribbon Platform (see Procedure 9).

STEP 4. Remove the Hammer Bank (see Procedure 11).

STEP 5. Using a .050" Allen wrench, (in tool kit 081147) remove the four screws that secure theRibbon Shield to the Hammer Bank.

Be careful when handling the Ribbon Shield. It can be bent easily, which canaffect operation of the printer. It also has very sharp edges that can put a realhurt on you if you aren’t careful how you handle it.

Hammer BankAssembly

Ribbon ShieldScrews, 4x

Ribbon Shield

Figure 4–19. Removing the Ribbon Shield

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ReinstallingTo reinstall the Ribbon Shield, reverse the sequence and actions of the removal steps. Makesure the shield is flush against the Hammer Bank, and the tips of the hammers themselves arecentered in the holes of the Ribbon Shield.

After installing a new Ribbon Shield, check for proper platen gap alignment (see Proce-dure 25) and perform a Hammer Calibration. (Hammer calibration is explained inChapter 2, under PrntCal Parameter.)

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Procedure 13 – Hammer Bank Air DuctBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovalSTEP 1. Remove the Hammer Bank (see Procedure 11).

STEP 2 Remove the cable clamp bracket and screw.

STEP 3. Remove the six screws that attach the airduct to the Hammer Bank. You now can remove theairduct from the Hammer Bank.

Hammer BankAir Duct

Air Duct Mounting Screws, 6x

Cable Clamp

Cable Clamp Screw

Figure 4–20. Removing Hammer Bank Air Duct

ReinstallationTo reinstall, reverse the sequence of removal.

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Procedure 14 – Hammer ModuleBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Hammer Bank from the printer (see Procedure 11).

STEP 2. Remove the Ribbon Shield from the Hammer Bank (see Procedure 12).

Be careful when handling the Ribbon Shield. It can be bent easily, which canaffect operation of the printer. It also has very sharp edges that can put a realhurt on you if you aren’t careful how you handle it.

STEP 3. Remove the Air Duct and Cable Clamp from the Hammer Bank (see Procedure 13).

STEP 4. Each module has six hammers and is held in place on the carriage by two screws on thebackside of the Hammer Bank. Remove these screws and the individual module can beremoved.

Before removing a defective module, insert strips of tape between it and themodules immediately adjacent to it. This will protect the coils on adjacentmodules during removal and reinstallation.

Hammer InterconnectCBA

Ribbon ShieldAlignment Plate

6-Pack HammerModule

Hammer Bank Carriage

Module Mounting Screws (2)

Hammer Interconnect CBA

Fold Back Tape

Figure 4–21. Removing and Replacing the Hammer Module.

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ReinstallingSTEP 1. Install the new Module on the Hammer Bank. Use the Hammer Alignment Tool (#080614

available in tool kit, #081147) to realign the Hammers. Tighten the two mounting screws, thenreinstall the Ribbon Shield.

6-PackHammerModules

Hammer AllignmentToolP/N 080614

Figure 4–22. Using the Hammer Alignment Tool

STEP 2. Reinstall the Hammer Bank.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust asnecessary (see Procedure 25).

After completing the installation, perform a Hammer Calibration to maintain optimum printquality (see PrntCal Parameter in Chapter 2).

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Procedure 15 – The Shuttle AssemblyBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Right End Cover (see Procedure 3).

STEP 2. Remove the Ribbon Platform (see Procedure 9).

STEP 3. Remove the Hammer Bank (see Procedure 11).

STEP 5. Using a 5/32" T-handled allen driver, (in tool kit 081147) remove the two hex screws connect-ing the Hammer Bank to the right bearing block. The shuttle assembly can now be separatedfrom the Hammer Bank.

ShuttleAssembly

TieBlocks

RightBearing Block

Shuttle ScrewsTie Block Screws

Figure 4–23. Shuttle Assembly Removal

ReinstallingTo reinstall the shuttle assembly, reverse the sequence and actions of the removal procedure.

Loosen the two tie block screws for easier installation. Remember to tighten up any loosescrews before reinstalling the Hammer Bank into printer.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust asnecessary (see Procedure 25).

After completing the installation, perform a Hammer Lead Time Calibration Routine (seeChapter 2, under the PrntCal Parameter) to adjust for optimum printed output.

You will need to rotatethe shuttle gears to getappropriate access toremove the screwssecuring the shuttleassembly to theHammer Bank shafts.

Extreme care mustbe taken not to stripthe screws whenreinstalling the hexscrews that connectthe Hammer Bank tothe shuttle assem-bly.

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Procedure 16 – The PlatenBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Hammer Bank (see Procedure 11).

STEP 2. Remove the Left End Cover (see Procedure 8).

STEP 3. Remove the two springs (one on each end of the platen) that hold the platen in place.Disconnect the Platen Open Sensor from the left end of the platen, then lift the Platen out ofthe printer.

It may help to disconnect it if you first disconnect the sensor cable (J601) from the MainController CBA to allow some slack in the cable.

The Platen Open Sensor is held in place on the Platen by two small plastic tabs.Be careful not to damage them when you disconnect the sensor from thePlaten.

Remove Springs-Right and Left ends of the Platen

Platen OpenSensor

Figure 4–24. Removing the Platen

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ReinstallingSTEP 1. Reconnect the Platen Open Sensor to the Platen.

It is possible that the end assemblies of the platen may come off of the platen when youremove it. When you reassemble the platen make sure ALL parts are included. Someparts are small (for example, the spring washers on the right end of the platen) and areeasily lost. Refer to the figure below to identify the parts and the installation sequence.

Platen

Platen OpenSensor

FormThicknessLever

Platen Adjust Plate

Curved Spring Washers

Platen Adjust Plate

Platen - Right EndPlaten - Left End

Figure 4–25. Platen End Assemblies

STEP 2. Place the springs back on the ends of the platen and secure it in place.

STEP 3. Reinstall the Hammer Bank.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust asnecessary (see Procedure 25).

After completing the installation, perform a Hammer Calibration to maintain optimum printquality (see PrntCal Parameter in Chapter 2).

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Procedure 17 – The Platen Open SensorBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Platen from the printer (see Procedure 16).

STEP 2. Disconnect the Platen Sensor cable (J601) from the Engine Controller CBA, remove the cablefrom any cable supports and remove the ferrite bead encircling the cables.

STEP 4. The Platen Open Sensor is secured to the end of the platen detent plate by two plastic tabs,release the tabs and the sensor will come free.

J601

PlatenAlignment Plate

DetentPlate

PlatenOpen Sensor

PlatenAssembly

Figure 4–26. Removing the Platen Open Sensor

ReinstallingSTEP 1. Snap the new sensor into place on the Platen detent plate. Plug the Platen Open Sensor cable

(J601) into the Engine Controller CBA and reinstall the platen.

STEP 3. Turn power on and open the platen all the way. The control panel display should readPLATEN OPEN if new sensor is functioning properly.

STEP 4. Finish the installation by reinstalling all other components you have removed.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust asnecessary (see Procedure 25).

After completing the installation, perform a Hammer Calibration Routine (as explained inChapter 2, under the PrntCal Parameter) to adjust for optimum printed output.

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Procedure 18 – The Shuttle MotorBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovalSTEP 1. Remove the Right End Cover (see Procedure 3).

STEP 2. Unplug the Shuttle Stepper Motor (J501) from the Engine Controller CBA. Remove theshuttle motor cable from any cable supports and remove the ferrite bead encircling the cable.

STEP 3. Remove the Shuttle Drive Belt (see Procedure 20 ).

STEP 4. Remove all but one of the four mounting screws from the Shuttle Motor, then while supportingthe motor with one hand remove the last screw. The Shuttle Motor can now be removed fromthe printer.

ShuttleMotor

J501

Shuttle MotorPulley

MountingBracket

Figure 4–27. Removing the Shuttle Motor

STEP 5. Loosen the set screw that secures the Shuttle Motor Drive Pulley to the motor output shaft,then remove the pulley from the old motor for installation onto the new motor.

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ReinstallingSTEP 1. Reinstall the Shuttle Motor Pulley onto the output shaft of the new motor. There should be

approximately 1/2" of motor output shaft protruding from the top of the pulley to the end ofthe output shaft.

J501

Shuttle MotorPulley

ShuttleMotor

OutputShaft

OutputShaft

Shuttle MotorPulley Set Screw

Figure 4–28. Reinstalling Shuttle Motor Pulley

STEP 2. Insert the new motor into the mounting bracket on the printer, making sure that the motorcable is on the side nearest the Engine Controller CBA, then reinstall the mounting screws.

STEP 3. Reinstall the cable back through the cable support, reinstall the ferrite bead, and reconnectJ501 into the Engine Controller CBA.

STEP 4. Reinstall the Shuttle Drive Belt, the Right End Cover, and the Printer Control Panel.

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Procedure 19 — Shuttle Motion SensorThe Shuttle Motion Sensor is mounted on the bracket behind the lower Shuttle Gear.

RemovingSTEP 1. Remove Right End Cover (see Procedure 3).

STEP 2. Using a #1 Phillips stubby screwdriver, loosen the screw securing the sensor.

STEP 3. Lift sensor over loosened screw, disconnect sensor cable from Engine Controller CBA (J604),and remove the ferrite bead encircling the group of cables atop the Engine Controller CBA.

J604

ShuttleSensor

Figure 4-29. Removing the Shuttle Motion/Capture Sensor

ReinstallingSTEP 1. Mount the sensor on the bracket behind the lower Shuttle gear. Do not tighten screw yet;

you’ll need the sensor loose to adjust it.

The sensor position should not interfere with rotation of Shuttle.

STEP 2. Connect the sensor cable into Engine Controller CBA (J604), reinstall the ferrite bead aroundthe cables, then perform the adjustment procedure that follows to set up correct sensing levels.

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AdjustingSTEP 1. Install paper, turn printer on a d enable Tech Access. In the Meter Parameter of the control

panel, select Shuttle Sensor.

STEP 2. Turn the shuttle by hand until the solid side of shuttle gear is directly over the sensor. Movethe sensor by hand until the control panel reading is less than 0.5V, then tighten screw.

If the sensor cannot be adjusted when the solid portion of the shuttle gear is over it sothat the low reading is less than 0.5 volts, remove and replace the sensor.

STEP 3. Turn shuttle by hand until open side of shuttle gear is directly over the sensor. Check thevoltage reading on the display. The reading should be greater than 4.5V.

If the sensor does not read greater than 4.5V when the open portion of the shuttle gear isover it and the low reading is less than 0.5 volts, remove and replace the sensor.

Both readings have to match specifications at the same sensor adjustment inorder to obtain optimum print quality.

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Procedure 20 —The Shuttle Drive BeltBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Printer Control Panel (see Procedure 2) and place it in the bottom of the printer.

STEP 2. Reach inside the Control Panel opening, grasp the belt and pull it up off of the Shuttle pulleythen remove it from the Shuttle Motor Pulley.

Shuttle Motor Pulley

ShuttlePulley

Shuttle Drive Belt

Figure 4-30. The Shuttle Drive Belt

ReinstallingSTEP 1. Place the belt around the Shuttle Motor Pulley, then place it around the Shuttle pulley.

STEP 2. Turn the Shuttle a few turns by hand to make sure the belt is centered on the pulleys.

STEP 3. Reinstall the Control Panel.

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Procedure 21 – The Paper Advance MotorBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Disconnect the Static Ground, then remove the Sound Deadening Hood from the back of the

printer and any printed forms along with the paper stacking tray (see Figure 4–11).

STEP 2. Remove the printer Control Panel (see Procedure 2).

STEP 3. Remove the Right End Cover (see Procedure 3).

STEP 4. Remove the Left End Cover (see Procedure 8).

STEP 5. Remove the Power Supply (see Procedure 7). Do not let the Power Supply hang by its wireharness. Disconnect the harness from the Engine Controller CBA (J302) and set the PowerSupply aside.

STEP 6. Disconnect the Paper Motor Cable from the extension cable coupling just inside the PowerSupply opening.

STEP 7. Loosen the three mounting screws securing the Paper Advance Motor to the left side frame.

STEP 8. Once the motor is loose, remove the Paper Drive Belts from the Paper Motor Pulley. Withyour left hand, reach inside the Power Supply opening and grasp the case of the motor, thenremove the screws loosened in STEP 7. You can now remove the Paper Advance Motor.

LowerBelt

Upper Belt

Paper Advance MotorMounting Screws

J503

Power SupplyOpening

Extension Cable Coupling

Paper Advance Motor

Figure 4–31. Removing the Paper Drive Motor

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STEP 9. After you have taken the Motor out of the printer, remove the pulley using a 1/16" hex keywrench, and motor flywheel using a 5/64 hex key wrench.

Paper Drive Pulley

Flywheel

FlywheelSet Screws, 2x

Paper AdvanceMotor

Figure 4–32. Paper Advance Motor Assembly

ReinstallingSTEP 1. Install the pulley and flywheel onto the new motor. The flywheel should be installed approxi-

mately .10" from the Motor body, and the pulley should be flush against the flywheel.

STEP 2. Insert the motor through the Power Supply opening and reinstall the mounting screws loosely.

STEP 3. Reinstall the drive belts onto the pulley.

STEP 4. Apply slight downward pressure on the motor to remove slack in the drive belts, then tightenthe mounting screws.

STEP 5. Reconnect the paper motor cable to the extension cable coupling just inside the Power Supplyopening.

STEP 6. Reinstall the Power Supply and plug it in to the Engine Controller CBA.

STEP 7. Phase the Upper and Lower tractors using Phasing Gauge (#075467) from tool kit (#081147).(Refer to Procedure 21)

STEP 8. Adjust the Paper Motor Belts for proper tension using Paper Belt tension gauge (#081148) intool kit (#081147). (Refer to Procedure 21.)

Optional: Before continuing with motor installation, you may want to plug in the controlpanel and perform a motor test with the FORM FEED Key, LINE FEED Key, and the Key. Make sure you enable the fault overrides before attempting these tests.

STEP 9. Reinstall the Left End Cover.

STEP 10. Reinstall the Right End Cover and Control Panel.

STEP. 11. Reinstall the Sound Deadening Hood and Paper Tray.

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Procedure 22 – Tractor Belt Phasing/Paper Drive Belt AdjustmentBefore beginning this procedure, turn the printer off and disconnect the power cable.

Any time a tractor pulley or drive belt is removed, the paper system needs to be checked forproper phasing and belt tensioning.

STEP 1. Loosen the screw holding the lower idler bracket and slide it away from the belt, then retightenit to hold the bracket in place temporarily.

1

1

3

3

2

2 P.A. MotorMounting Screws

Paper DrivePulley

Lower Belt Lower IdlerBracket Screw

Lower IdlerBracket

Lower ShaftPulley

Lower Shaft

Paper DriveMotor

Figure 4–33 Phasing/Belt Adjustments

STEP 2. Loosen the three screws holding the paper drive motor to the side frame plate.

STEP 3. With the lower drive belt installed, slidethe motor up as far as possible. Re-tighten one screw to hold the motor inplace.

STEP 4. Place the Form Thickness Lever atabout its midpoint position, then installthe phasing gauge (#075467) from toolkit (#081147) or a single sheet of paperin the tractors.

Figure 4–34. Phasing GaugeInstallation

Upper Tractor

LowerTractor

PhasingGauge

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STEP 5. Gently turn the upper drive shaft pulley (without belt) manually until the gauge or paper issnug.

STEP 6. Install the upper drive belt. (The phasing gauge or paper must be kept snug during this step).

STEP 7. Loosen the one screw holding the paper drive motor snug. Adjust the tension on the upper beltby pushing the motor down towards the floor and tighten the screws. At this point, check thetension by using tension gauge (#081148) in tool kit (#081147). Lay the angled end of tensiongauge on the inside half of the paper drive motor pulley until the gauge comes in contact withthe idler phase pulley. The spring loaded pin on the gauge should be flush with the plasticcasing of the gauge for proper tensioning. If the pin is extended out to the second shoulder,tension is too tight. If the pin is not flush with casing, tension is too low. Adjust paper drivemotor positioning until proper tension is achieved.

Lower Belt

Paper Drive Pulley

Paper Drive Pulley

Paper Drive Pulley

Lower IdlerBracket

Lower ShaftPulley

Tension Gauge

Upper Belt

Inside Pulley

Outside Pulley

Idler PhasePulley

Tension Gauge

Tension GaugeIndicator

Tension GaugeIndicator

Figure 4–35. Paper Drive Belt Adjustment

STEP 8. Loosen the screw securing the lower idler bracket and slide it down to adjust the lower belttension. Lay the angled end of the belt tension gauge on the outside half of the paper drivemotor pulley until it touches the lower shaft pulley. Adjust the position of the lower idlerbracket until proper tension is achieved.

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Procedure 23 – Upper Tractor AssemblyBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Right End Cover (see Procedure 3).

STEP 2. Remove the Left End Cover (see Procedure 8).

STEP 3. Remove the snap rings from both ends of the square shaft using the ssnap ring removal tool intool kit (#081147). Leave the snap rings sitting loosely on the shaft.

STEP 4. Slide the square drive shaft to the left through upper tractor pulley. Do not remove the pulleyor drive belt from the shaft.

If the pulley or drive belt are removed from the printer, you will need to rephase theupper and lower tractor sets.

Drive Shaft

Support Shaft

Drive BeltPulley

Snap Ring

Support Shaft Nuts, 2x

Tractor Drive Shaft Pulley

Paper Tension Lever

Snap Ring

Figure 4–36. Removing Upper Tractor Assembly

When removing the uppertractors, you must unplug thepaper motion sensor cable (J603)from the Engine Controller CBA, twocable supports, and a ferrite bead encir-cling the cables. (The Paper Motion Sensoris attached to the upper left tractor).

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STEP 5. Lower the Paper Tension Lever all the way, then remove the nut on right end of support shaft.Slide the support shaft to the left far enough to take off the second nut on the support shaft.You now have enough room to slide off both tractors by sliding them to the right. Keep trackof springs and washers on the support shaft when removing.

ReinstallingReinstallation of the upper tractors is the reverse sequence of removal.

When installing the upper tractors, be sure that the alignment mark on the inner face ofthe tractors are aligned with each other.

Left Tractor Right Tractor

Snap Ring

AlignmentMark

AlignmentMark

Support Shaft Nut

Figure 4–37. Upper Tractor Alignment

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Procedure 24 – Lower Tractor AssemblyBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove Right End Cover (see Procedure 3).

STEP 2. Remove Left End Cover (see Procedure 8).

STEP 3. Remove the snap rings from both ends of the square shaft using the snap ring removal tool intool kit (#081147). Leave the snap rings so they are sitting loosely on the shaft.

STEP 4. Slide the square drive shaft to the left through upper tractor pulley. Do not remove the pulleyor drive belt from the shaft.

If the pulley or drive belt are removed from the printer, you will need to rephase theupper and lower tractor sets.

SupportShaft Nuts, 2x

Drive Shaft

Support Shaft

Drive BeltPulley

Tractor Drive Shaft Pulley

Snap Ring

Snap Ring

Figure 4–38. Removing Lower Tractor Assembly

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STEP 5. Remove the nut on right end of support shaft. Slide the support shaft to the left far enough totake off the second nut on the support shaft. You now have enough room to slide off bothtractors by sliding them to the right. Keep track of springs and washers on thesupport shaftwhen removing.

When removing the lower tractors, you must unplug the paper out sensor cable (J602)from the Engine Controller CBA, two cable support, and a ferrite bead encircling thecables. (The Paper Out Sensor is attached to the lower right tractor).

ReinstallingReinstallation of the lower tractors is the reverse sequence of removal.

When installing the lower tractors, be sure that the alignment mark on the inner face ofeach tractor is positioned the same as the opposite tractor.

Left Tractor

"C" Clip

AlignmentMark

Right Tractor

AlignmentMark

Support Shaft Nut

Figure 4–39. Lower Tractor Alignment

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Procedure 25 – Platen Gap Adjustment ProcedureBefore beginning this procedure, turn the printer off and disconnect the power cable.

STEP 1. Insert your .012" or .014" shim gauge (in tool kit #081147) between ribbon shield and platen.If your gauge will not fit, don’t force it, proceed to step 2.

STEP 2. Using a 5/64" Allen wrench, (in tool kit 081147) insert it into the left hand tensioning setscrew. Turn wrench clockwise to tighten the existing gap. Turn wrench counterclockwise toloosen the existing gap.

Platen Gap Adjust Plates

Platen

RibbonShield

ShimGauge

Right Side View

Figure 4–40. Platen Gap Adjustment

STEP 3: Using a 5/64" Allen wrench, insert it into the right hand tensioning set screw. Turn screwclockwise to tighten the existing gap. Turn the screw counterclockwise to loosen the existinggap.

Tool kit 081147 includes both .012" and .014" shim gauge. You can use either, governedby print quality.

Repeat STEPs 2 & 3 until gap is equal across Hammer Bank. After adjusting the platen gapperform a Hammer Calibration Procedure (see PrntCal Parameter in Chapter 2).

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Paper Path

Paper Path

Appendix ASchematics A

ppendix A

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Appendix A: SchematicsT6090 Engine Controller CBA

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T6090 Maintenance Manual

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Appendix A: Schematics

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T6090 Maintenance Manual

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Appendix A: Schematics

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T6090 Maintenance ManualT6090 Ser/Par Personality Module CBA

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Appendix A: Schematics

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T6090 Maintenance Manual

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Appendix A: Schematics

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T6090 Maintenance Manual

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Appendix A: SchematicsT6090 FourPlex Personality Module CBA

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T6090 Maintenance Manual

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Appendix A: Schematics

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Appendix A: Schematics

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Paper Path

Paper Path

Appendix BRecommended Spare Parts,

Illustrated Parts Breakdown and Components Lists

Appendix B

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Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists

Recommended Spare Parts ListPART NAME PART NO.Power Supply 081153Personality CBA (Ser/Par) 080901Personality CBA (4 Plex) 081086Personality CBA (Lan) 080920Engine Controller CBA 080873Control Panel Assembly 075123Hammer Bank Assembly 081144Hammer Module Kit 081152Control Panel Cable 079873Paper/Shuttle Drive Motor 078259Ribbon Drive Motor 075138Fan 079644Blower (Under Platform) 081095Power Cord 730078Shuttle Sensor 081123Platen Sensor 080185Tractor Kit, Upper (set w/sensors) 080878Tractor Kit, Lower (set w/sensors) 081128Gas Spring, (Lid) 731060Paper Drive Belts 075127Paper Advance Motor Pulley 080711Paper Tractor Pulley, (Top) 080635Paper Tractor Pulley, (Bottom) 080647Duct (H.B.) 080727Duct Seal 080751Tie Block, Lower 080658Tie Block, Upper (H.B. Shaft) 080657Bearing Block, Right 081326Bearing Block, Left 081327Shuttle Drive Belt 731685Shuttle Assembly 081149Ribbon Shield Assembly 081298Platen Assembly 080953Tool Kit 081147Sound Deadening Hood 079622

ManualsSerial/Parallel Ops/Aps 080932LAN Supplement 081057FourPlex Ops/Aps 080978Maintenance Manual 080933

RibbonsFabric Ribbon, 25 Million Char, Box of 4 081267Fabric Ribbon, 50 Million Char, Box of 4 081269Fabric Ribbon, 150 Million Char, Box of 2 081271

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Maintenance Manual

Rea

r V

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Cover Set – T6090

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Maintenance ManualBasic Assembly – T6090

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Paper Movement System – T6090

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ywhe

el08

0733

538–

32 x

0.5

0 Se

t Scr

ew (2

ea)

4006

90 –

67

548–

32 x

0.3

8 SE

MS

Scre

w (1

ea)

4025

24 –

42

568–

32 x

0.5

0 SE

MS

Scre

w (7

ea)

4025

24 –

43

58Lo

wer

Tra

ctor

Dri

ve P

ulle

y08

0647

70Ph

asin

g Le

ver

Gua

rd08

1339

71Ph

asin

g B

rack

et A

ssem

bly

0806

3672

Spri

ng P

lung

er40

3738

– 1

73Le

ft Li

near

Bea

ring

Mou

nt A

ssem

bly

0806

5374

Bea

ring

Mou

nt S

uppo

rt08

1344

755/

16"

Cur

ved

Spri

ng W

ashe

r (2

ea)

7301

8678

Low

er Id

ler

Ass

embl

y08

0944

798–

32 x

0.8

75 S

EMS

Scre

w (1

ea)

4025

24 –

48

80Lo

wer

Pap

er D

rive

Tra

ctor

/Sen

sor

Set

0811

28

Page 144: 083533TX - 6090 Updated Maintenance Manual

B-10

Maintenance ManualHammer Bank and Electronics Assembly – T6090

Page 145: 083533TX - 6090 Updated Maintenance Manual

B-11

Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component ListsR

efer

ence

#D

escr

ipti

onPa

rt N

umbe

r1

Shut

tle A

ssem

bly

0811

492

Rib

bon

Shie

ld08

1298

3B

eari

ng B

lock

, Rig

ht08

1236

4Fa

n07

9644

5Po

wer

Sup

ply

0811

5311

Bea

ring

Blo

ck, L

eft

0812

3714

Ham

mer

t Ban

k D

uct

0807

2715

Ham

mer

Ban

k08

1144

16Pr

int M

echa

nism

0806

9922

832

x 0.

437

SEM

S Sc

rew

(4 e

a)40

2524

– 4

934

8–32

X 2

.00

SEM

S Sc

rew

(1 e

a)73

1723

374–

40 x

0.2

5 82

°40

0258

– 0

139

8–32

x 0

.875

SEM

S Sc

rew

4 e

a40

2524

– 4

840

Pers

onal

ity C

BA

(Ser

/Par

)08

0901

Pers

onal

ity C

BA

(4 P

lex)

0810

86Pe

rson

ality

CB

A (L

an)

0809

2046

Nyl

on T

wis

t-lo

ck C

able

Sup

port

(3ea

)73

0755

502.

5" E

lect

rica

l Tap

e73

0597

51H

ardw

are

Rem

oval

Fla

g79

400

52En

gine

Con

trol

ler

CB

A08

0873

544–

40 x

1/4

" SE

MS

Scre

w (6

ea)

4025

24 –

01

60D

uct C

able

Cla

mp

Bra

cket

0807

6861

Cab

le P

rote

ctor

Pad

0810

9762

6–32

x 0

.50

SEM

S Sc

rew

4025

24 –

23

63I/O

Per

sona

lity

Mod

ule

Hou

sing

0808

6864

4–40

x 0

.375

82°

Fla

t Hea

d Sc

rew

4002

58 –

02

65I/O

Mod

ule

Inse

rtio

n G

uide

s (2

ea)

7321

65

Page 146: 083533TX - 6090 Updated Maintenance Manual

B-12

Maintenance Manual

Engine Controller – T6090

Page 147: 083533TX - 6090 Updated Maintenance Manual

B-13

Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component ListsC

ompo

nent

#D

escr

ipti

onPa

rt N

umbe

rU

1Fi

rmw

are

– C

tl Pr

oces

sor

87C

196

4030

54-0

1So

cket

–PLC

C 6

8-pi

n73

1012

U4–

U20

Arr

ay–T

rans

/Dio

de S

MA

4032

7309

80U

21I.C

. 74

HC

T14

4037

40-0

1U

22I.C

. X

24C

0873

1069

U23

I.C.

74H

CT7

440

3782

-01

U24

Firm

war

e –

87C

750

0811

94So

cket

I.C

. 24

-pin

Slim

line

4030

54-0

1U

26I.C

. LM

324

4023

28-0

1U

27–U

32I.C

. 395

273

1071

Hea

tsin

k I.C

. Dip

4038

83-0

3R

P1–R

P17

Res

isto

r Si

p 51

0 8-

pin

Isol

4030

06-0

9R

1 R

8R

esis

tor

120Ω

1/4

W ±

5%40

0072

-75

R2

R67

R74

Res

isto

r 12

1/4

W ±

5%40

0073

-27

R3

Res

isto

r 4.

99K

Ω 1

/4W

±1%

4022

85-1

68R

4 R

6R

esis

tor

121Ω

1/4

W ±

1%40

2285

-09

R5

R24

R53

Res

isto

r 2.

10K

Ω 1

/4W

±1%

4022

85-1

32R

7 R

13 R

60 R

65R

esis

tor

10K

Ω 1

/4W

±1%

4022

85-2

01R

9 R

10 R

11 R

14 R

16 R

42R

esis

tor

1KΩ

1/4

W ±

5%73

0105

R12

Res

isto

r 5.

1KΩ

1/4

W ±

5%40

0073

-18

R15

Res

isto

r 10

0KΩ

1/4

W ±

1%40

2285

-301

R17

R19

R22

R54

Res

isto

r 3.

3KΩ

1/4

W ±

5%73

0106

R20

Res

isto

r 51

1/4

K ±

5%40

0073

-42

R25

R30

Res

isto

r 10

0KΩ

1/4

W ±

5%40

0073

-49

R23

Res

isto

r 23

7Ω 1

/4W

±1%

4022

85-3

7R

26 R

27 R

31 R

35 R

75 R

76 R

77R

esis

tor

10K

Ω 1

/4W

±5%

7301

08R

28R

esis

tor

22Ω

1/4

W ±

5%73

0259

R29

Res

isto

r 16

1/4

W ±

5%40

0073

-30

R32

Res

isto

r 10

0Ω 1

/4W

±5%

7301

03R

33R

esis

tor

510Ω

1/4

W ±

5%40

0072

-90

R34

Res

isto

r 2.

49K

Ω 1

/4W

±1%

4022

85-1

39R

36 R

48R

esis

tor

1meg

Ω 1

/4W

±1%

4022

85-4

01R

37R

esis

tor

0.5Ω

1/4

W73

2161

R38

R51

R52

R55

R57

R62

R66

Res

isto

r 24

1/4

W ±

5%40

0073

-34

R39

Res

isto

r 24

330

W ±

5%40

0073

-61

R40

Res

isto

r 20

1/4

W ±

5%40

0073

-32

Com

pone

nt #

Des

crip

tion

Part

Num

ber

R41

R43

R44

R44

AR

esis

tor

24K

Ω 2

0W ±

1%40

2285

-230

R45

R46

Res

isto

r 8.

25K

Ω 1

/4W

±1%

4022

85-1

89R

46A

Res

isto

r 1.

8KΩ

1/4

W ±

5%40

0073

-07

R47

Res

isto

r 1.

0Ω 5

W73

2163

R49

R50

Res

isto

r 30

.1K

Ω 1

/4W

±1%

4022

85-2

47R

56R

esis

tor

750K

Ω 1

/4W

±5%

4000

73-7

0R

58 R

63R

esis

tor

13K

Ω 1

/4W

±1%

4022

85-2

12R

59 R

64R

esis

tor

15K

Ω 1

/4W

±1%

4022

85-2

18R

68 R

69R

esis

tor

.3Ω

1W

4030

26-0

2R

70 R

71R

esis

tor

1.0Ω

1W

4030

26-0

3R

72 R

73R

esis

tor

.5Ω

1W40

3026

-06

R18

NO

T IN

STA

LLED

C26

C35

C36

NO

T IN

STA

LLED

U3

717

J901

NO

T IN

STA

LLED

U2

U25

I.C. H

amV

LSI 5

2-pi

n08

0336

C9

C12

Cap

.01M

FD 5

0V 1

0% S

MD

7315

45C

1 C

2 C

4-C

7C

13 C

14C

apac

itor

4700

PFD

50V

±10

%40

2910

-133

C3

C15

C18

-C20

C23

C25

C27

C28

C30

C31

C34

C37

C46

C51

C53

C55

C57

C59

C61

Cap

acito

r .1

MFD

50V

7301

42C

8 C

21C

apac

itor

22M

FD 2

5V T

AN

T73

0120

C10

C11

Cap

acito

r 10

00PF

D 5

0V ±

10%

7310

17C

15A

Cap

acito

r 12

00PF

D 1

00V

±10

%40

2910

-126

C16

C17

Cap

acito

r 33

PFD

50V

±10

%73

0617

C22

C24

C29

Cap

acito

r 12

0PFD

50V

±10

%73

0168

C28

AC

apac

itor

1MFD

50V

4021

72-0

7C

32C

apac

itor

10M

FD 2

5V A

LUM

7304

42C

33C

apac

itor

100M

FD 2

5V A

LUM

4021

72-5

8C

38 C

40 C

41 C

45 C

47 C

48 C

63C

apac

itor

1200

PFD

100

V ±

10%

4029

10-1

26C

39 C

42 C

43 C

44 C

52 C

54 C

56 C

58 C

60 C

62C

apac

itor

.1M

FD 1

00V

±10

%40

2910

-149

C64

C65

Cap

acito

r 18

00M

FD 6

3V73

1750

C66

Cap

acito

r 10

0MFD

63V

7310

83C

67C

apac

itor

10M

FD 6

3V73

1708

CR

1 C

R21

Dio

de 1

N91

4B40

0836

-04

CR

2-C

R18

Dio

de Z

ener

1N

5347

B 1

0V40

0049

-45

CR

19D

iode

Zen

er 1

N59

0873

1072

Page 148: 083533TX - 6090 Updated Maintenance Manual

B-14

Maintenance ManualC

ompo

nent

#D

escr

ipti

onPa

rt N

umbe

rC

R22

Rec

tifie

r 2N

6505

7321

60C

R23

CR

24D

iode

UF4

002

4038

80-0

2C

R25

Dio

de Z

ener

1N

5359

A 2

4V40

0049

-80

CR

26D

iode

1N

4003

4006

98-0

3C

R27

Dio

de M

UR

820

7310

75C

R28

Dio

de Z

ener

1N

5255

B 2

8V73

1747

CR

29D

iode

1N

4751

A 3

0V40

0664

-61

Y1

Cry

stal

12.

288M

HZ

par

a fu

nd.

7312

43Q

1Tr

ansi

stor

2N

3904

4013

40-0

1Q

2Tr

ansi

stor

MJE

800

4009

51-0

1Q

3Tr

ansi

stor

2N

5550

4022

78-0

1Q

4Tr

ansi

stor

2N

4403

7316

90V

R1

Reg

ulat

or–V

olta

ge L

M31

740

2668

-01

VR

2R

egul

ator

–Vol

tage

LM

2576

HV

T-5

7310

80V

R3

Reg

ulat

or–V

olta

ge 7

912

4014

44-0

1RT

1Th

erm

isto

r73

0099

L1Fi

lter-

EMI S

uppr

esso

r73

0097

L2 L

3In

duct

or 1

50U

H73

1522

L4-L

15B

ead–

Ferr

ite, l

eade

d73

0098

L16

Indu

ctor

22U

H73

1098

J2C

onne

ctor

3-p

in73

0163

J3C

onne

ctor

2-p

in73

2164

J17

Con

nect

or M

ale

32-p

in D

in73

1733

J302

Con

nect

or P

ower

4-p

in73

1119

J501

-J50

3C

onne

ctor

5-p

in73

1731

J601

-J60

4C

onne

ctor

Pho

ne 4

-pin

4037

60-0

1J7

03 J7

04C

onne

ctor

44-

pin

4023

30-0

2J8

01C

onne

ctor

6-p

in73

0012

Page 149: 083533TX - 6090 Updated Maintenance Manual

B-15

Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists

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B-16

Maintenance ManualSerial/Parallel Personality Modules (080900 & 080898 )

Page 151: 083533TX - 6090 Updated Maintenance Manual

B-17

Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists08

0900

Com

pone

nt L

ist

Com

pone

nt #

Des

crip

tion

Part

Num

ber

U3

I.C. 7

4F25

140

4024

– 7

3111

5U

4I.C

. 145

406

4037

50 –

730

004

U5

I.C. E

PM70

6470

0680

– 0

8119

0U

8I.C

. 74F

1440

4006

– 7

3108

3U

9I.C

. 74L

S244

4019

56 –

730

130

U10

I.C. 7

4LS3

74 7

3012

9R

P1R

esis

tor

SIP

10K

Ω 1

0 Pi

n40

2078

– 0

2R

P8 R

P13

Res

isto

r SI

P 10

8 P

in73

0494

RP2

–RP7

RP9

–RP1

1RP1

8 R

P18

Res

isto

r SI

P 47

Ω 8

Pin

ISO

L73

0174

RP1

2R

esis

tor

SIP

47Ω

10

Pin

ISO

L73

0170

RP1

4R

esis

tor

SIP

33Ω

10

Pin

ISO

L73

1032

RP1

5 R

P16

Res

isto

r SI

P 1.

2KΩ

8 P

in73

1031

R12

R19

R25

Res

isto

r 10

1/4

W ±

5%73

0108

R13

Res

isto

r 47

9Ω 1

/4W

±5%

7301

04R

14R

esis

tor

10M

Ω 1

/4W

±5%

7311

89R

15 R

16R

esis

tor

SIP

1.2K

Ω 8

Pin

7310

31R

17R

esis

tor

330K

Ω 1

/4W

±5%

4000

73 –

61

R18

Res

isto

r 20

1/4

W ±

5%73

1189

R20

R0A

Res

isto

r 47

Ω 1

/4W

±5%

7303

39R

21 R

28 R

29R

esis

tor

3.4K

Ω 1

/4W

±5%

7301

06R

22 R

23 R

24R

esis

tor

120Ω

1/4

W ±

5%73

0746

R26

Res

isto

r 10

1/4

W ±

5%73

1189

R27

Res

isto

r 75

0Ω 1

/4W

±5%

4000

72 –

94

C12

C23

C35

Cap

acito

r 12

0Pfd

50V

±10

%73

0168

C13

C15

C20

C33

C34

C36

C41

C43

C44

AC

44 C

46 C

47 C

49 C

52 C

53 C

58 C

59C

apac

itor

.1M

fd 5

0V 7

3014

2C

24 C

26 C

31C

apac

itor

10Pf

d 50

V ±

10%

7303

34C

28N

ot In

stal

led

C30

Cap

acito

r 22

Pfd

50V

±10

%73

0195

C32

Cap

acito

r .0

1Mfd

50V

±10

%73

0196

C37

C38

C39

Cap

acito

r 12

00Pf

d 10

0V ±

10%

4029

10 –

126

C40

C47

Cap

acito

r 47

0Pfd

50V

±10

%73

0194

C45

C51

C54

Cap

acito

r 10

00Pf

d 50

V ±

10%

7310

17C

48 C

56 C

57C

apac

itor

120P

fd 5

0V ±

10%

7301

68C

50 C

15A

C15

BC

apac

itor

10M

fd 2

5V73

0442

Com

pone

nt #

Des

crip

tion

Part

Num

ber

C55

Cap

acito

r .3

3Mfd

50V

7301

19C

R2

Dio

de 1

N91

4B40

0836

– 0

4Y

2C

ryst

al 2

0MH

z Pa

r. Fu

nd73

1707

Y3

Cry

stal

32.

768K

Hz

7310

96Q

1Tr

ansi

stor

2N

3904

4013

40 –

01

Q2

Tran

sist

or 2

N44

0373

1690

L3 L

4Le

aded

Fer

rite

Bea

d73

0098

J14

39 P

in C

onne

ctor

–730

385

J15

25 P

in C

onne

ctor

730

147

J17

32 P

in F

emal

e D

IN C

onne

ctor

404-

94 –

731

734

U7

I.C. X

2432

5P73

1700

U8

I.C. 7

4F14

7310

83U

9I.C

. 74L

S244

7301

30U

10I.C

. 74L

S374

7301

29R

P1R

esis

tor

SIP

10K

Ω 1

0 Pi

n40

2078

– 0

2R

P8 R

P13

Res

isto

r SI

P 10

8 P

in73

0494

RP2

–RP7

RP9

–RP1

1RP1

8 R

P18

Res

isto

r SI

P 47

Ω 8

Pin

ISO

L 7

3017

4R

P12

Res

isto

r SI

P 47

Ω 1

0 Pi

n IS

OL

7301

70R

P14

Res

isto

r SI

P 33

Ω 1

0 Pi

n IS

OL

7310

32R

P15

RP1

6R

esis

tor

SIP

1.2K

Ω 8

Pin

7310

31R

1R

esis

tor

1KΩ

1/4

W ±

1%40

2285

– 1

01R

2R

esis

tor

470Ω

1/4

W ±

5% 7

3010

4R

5R

esis

tor

270Ω

1/4

W ±

5% 7

3046

7R

8 –

R11

Res

isto

r 1.

5KΩ

1/4

W ±

5%40

2285

– 1

01R

12 R

19 R

25R

esis

tor

10K

Ω 1

/4W

±5%

730

108

R13

Res

isto

r 47

9Ω 1

/4W

±5%

730

104

R14

Res

isto

r 10

1/4

W ±

5% 7

3118

9R

15 R

16R

esis

tor

SIP

1.2K

Ω 8

Pin

–731

031

R17

Res

isto

r 33

0KΩ

1/4

W ±

5%40

0073

– 6

1R

18R

esis

tor

20M

Ω 1

/4W

±5%

731

189

R20

R0A

Res

isto

r 47

Ω 1

/4W

±5%

730

339

R21

R28

R29

Res

isto

r 3.

4KΩ

1/4

W ±

5% 7

3010

6R

22 R

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r .0

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7315

45

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B-18

Maintenance ManualC

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B-19

Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists

This page intentionally left blank

Page 154: 083533TX - 6090 Updated Maintenance Manual

B-20

Maintenance Manual

FourPlex Personality Module (080750 )

Page 155: 083533TX - 6090 Updated Maintenance Manual

B-21

Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component ListsC

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C1

C2

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C21

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C32

C35

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C47

C49

C52

C53

C56

C58

C60

C62

C66

C72

C74

C75

Cap

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2942

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r 22

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518

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B-22

Maintenance ManualC

ompo

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#D

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769

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4039

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J15

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onne

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4030

81 –

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4039

41 –

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166

Page 157: 083533TX - 6090 Updated Maintenance Manual

Paper Path

Paper Path

Appendix CDownloading Printer Firmware

Appendix C

Page 158: 083533TX - 6090 Updated Maintenance Manual
Page 159: 083533TX - 6090 Updated Maintenance Manual

Appendix C: Downloading Printer Firmware

C–1

Firmware Update ProcedureThe following instructions explain how to download updated printer firmware.

STEP 1. Power up your printer normally and print out a Configuration Report. This will give you ahard copy of the printer setup. You will need this to restore any parameters that you have setin the printer. Power the T6090 down.

STEP 2. Connect your printer to your computer using the parallel interface.

STEP 3. Power up the printer while holding down the following four keys on the control panel: VIEWKey, LINE FEED Key, Key, and MODE Key. Hold them down until the followingmessage scrolls on the control panel display: “Mannesmann Tally Flash Loader.” The displaythen stops scrolling and says: “Flash Dnld Ready.”

STEP 4. Change the directory to the floppy drive. From the DOS Command Prompt enter:

<filename> -P

This will cause the compressed file to expand directly to the PRN device.

The time required to update the firmware depends upon the speed of the computer you areusing. Typically the times will vary from 3—10 minutes.

STEP 5. After the download is complete, check the hard copy of the configuration and set up theappropriate parameters.

The firmware download is now complete.

You will get an NVRAM fault at the end of the download. It does not indicate a problemwith the printer, simply depress the CLEAR Key on the printer control panel and themessage will clear. You will need to perform a print calibration, paper motion sensorcalibration , and a paper out sensor calibration. (These calibraiton routines are ex-plained in Chapter 2, under PrntCal, Pap Mot, and Pap Out parameters, respectively.)The printer is now ready for use.

Page 160: 083533TX - 6090 Updated Maintenance Manual
Page 161: 083533TX - 6090 Updated Maintenance Manual

SupplementHammer Module Replacement & Realignment

Ham

mer M

oduleR

eplacement &

Realignm

ent

Page 162: 083533TX - 6090 Updated Maintenance Manual
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1

Supplement to Manual 080933

Supplement to Manual 080933

T6090 Line Impact Printer

Maintenance Manual

This Supplement presents descriptions and explanations about additions/changes to the operation of your printer. Please read through this document

before operating your printer. In addition, you may want to make references tothis document in applicable areas of your Maintenance Manual.

Ref. 081725

Page 164: 083533TX - 6090 Updated Maintenance Manual

Supplement

2

Hammer ModuleBefore beginning this procedure, turn the printer off and disconnect the power cable.

RemovingSTEP 1. Remove the Hammer Bank from the printer (see Procedure 11, Maintenance Manual).

STEP 2. Remove the Ribbon Shield from the Hammer Bank (see Procedure 12, MaintenanceManual).

Be careful when handling the Ribbon Shield. It can be bent easily, which can affectoperation of the printer. It also has very sharp edges that can injure you if you aren’tcareful how you handle it.

STEP 3. Remove the Air Duct and Cable Clamp from the Hammer Bank (see Procedure 13,Maintenance Manual).

STEP 4. Each module has six hammers and is held in place on the carriage by two screws on thebackside of the Hammer Bank. Remove these screws and the individual module can beremoved.

Before removing a defective module, insert strips of tape between it and the modulesimmediately adjacent to it. This will protect the coils on adjacent modules duringremoval and reinstallation.

Hammer InterconnectCBA

Ribbon ShieldAlignment Plate

6-Pack HammerModule

Hammer Bank Carriage

Module Mounting Screws (2)

Hammer Interconnect CBA

Fold Back Tape

Figure S–1. Removing and Replacing the Hammer Module.

Page 165: 083533TX - 6090 Updated Maintenance Manual

3

Supplement to Manual 080933

ReinstallingSTEP 1. Install shim spacers underneath the

spares replacement modules asappropriate. Two .0015" shim spacersare included in each module kit(#081152). After the screws for themodule are tightened, check theheight of the module for accuracy.

STEP 2. Install the new Module on theHammer Bank. Be very carefulwhen installing the new module. The male prongs can be bent easily and may notalign properly when they are plugged in.

Depending on module height,you may or may not need to addshims.

Figure S–3. Checking Module Height

STEP 3. Use the Hammer Alignment Tool (#080614 available in tool kit, #081147) to realign theHammers. Tighten the two mounting screws, then reinstall the Ribbon Shield.

6-PackHammerModules

Hammer AllignmentToolP/N 080614

Figure S–4. Using the Hammer Alignment Tool

Hammer Bank Carriage

ModuleMounting

Screws (2)

ShimSpacer(s)

HammerModule

Figure S–2. Installing Shim Spacer

Add Shims

Remove Shims

Correct

Page 166: 083533TX - 6090 Updated Maintenance Manual

Supplement

4

STEP 4. Reinstall the Hammer Bank by reversing the sequence of steps required to remove it.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust asnecessary (see Procedure 25, Maintenance Manual).

After completing the installation, perform a Hammer Calibration to maintain optimumprint quality (see PrntCal Parameter in Chapter 2 of the Maintenance Manual).

Page 167: 083533TX - 6090 Updated Maintenance Manual

SupplementT6091 Printer

T6091 Printer

Page 168: 083533TX - 6090 Updated Maintenance Manual
Page 169: 083533TX - 6090 Updated Maintenance Manual

T6091 Supplement toManual 080933: T6090

Line Impact PrinterMaintenance Manual

This Supplement presents descriptions and explanations about additions/changes to the functionality of your printer. Please read through this documentbefore performing any repairs. In addition, you may want to make references to

this document in applicable areas of your Operator Manual.

Ref. 082454

Page 170: 083533TX - 6090 Updated Maintenance Manual

T6090 Maintenance Manual Supplement

2

T6091 PrinterThis supplement gives detailed information, on the T6091, that cannot be found in theT6090 Maintenance Manual. Place this supplement in the section of the T6090 Main-tenance Manual entitled, "Supplements."

SpecificationsAcoustics

The sound power generated by the printer is 6.6 bels per ISO 7779-C with a soundpressure level of 50 dBA.

Physical ConfigurationThe T6091 printer is available enclosed in a quietized cabinet with an actual weight of254 lbs and a shipping weight of 304 lbs.

Printer DimensionsParameter Dimensions

Height 42.2"

Height/Lid Open 61.0"

Width 32.0"

Depth 29.0"

Unique Spare Parts Listing-T6091 Printer

Item Part Description Support Qty.Number Level

17 082224 Label, Connector locations \B 119 402524-42 Screw, #8-32 x 0.375 SEMS B,C 220 081670 Foam, Door B 230 082217 Fan Assembly A 131 400627-201 Screw, #8-32 x 1.50, pan head, B,C 4

stainless steel32 400215-10 Washer, #8, split lock B,C 433 400216-10 Washer, #8, flat B,C 434 402524-63 Washer, #8, flat B,C 337 402524-45 Screw, #10-32 x 0.50 SEMS B,C 438 079400 Flag, hardware removal B 440 400341-03 Cable Tie B,C 142 732228 Gasket Clips B 1644 730755 Support Cable, nylon, twist lock B 245 732165 Guide, printed circuit board B,C 346 732550 Guide, printed circuit board B,C 2

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3

Supplement to Manual 080933

T6091 Assembly Diagram

Page 172: 083533TX - 6090 Updated Maintenance Manual

T6090 Maintenance Manual Supplement

4

Fan Assembly Diagram

Figure 2. Fan Assembly Diagram

Page 173: 083533TX - 6090 Updated Maintenance Manual

5

Supplement to Manual 080933

Removal and Reinstallation ProceduresThe procedures in this section are specific to the cabinet of the T6091. For any Proce-dure numbers listed, go to that appropriate procedure in the Maintenance Manual.

Procedure 1B — Top Cover Opening for Service AccessThe cover assembly of the T6091 CANNOT be removed. It can be openedan additional amount to allow increased access to the inside of the printerin the following manner:

Step 1. Partially open the back door of the printer.

Step 2. Use the Control Panel removal tool to release the Control Panel. Lift it outcarefully then set it back down inside the printer under the shuttle assembly.

Step 3. Lift the cover assembly to the full open position.

Step 4. Release the two gas springs at the top connection point. (Each of the connectionpoints has a wire retaining clip which must be removed before the gas spring canbe removed.)

a. Unclip the part of the wire mechanism that is around the shaft just beneaththe connection then pull the wire assembly down toward the shaft of the gasspring to remove it. Save this wire clip.

Release the Gas Springs.

Partially open backdoor of printer. RestPrinter lid on door.

Spring Clip

Small Flat Blade Screwdriver

Pivot Post

Figure 3. Opening the Cover

b. Push the top of the gas spring toward the inside of the printer to release itfrom the mounting stud. Be careful to support the cover by hand whenreleasing the last gas spring and then lower the cover gently onto thepartially opened back door.

Page 174: 083533TX - 6090 Updated Maintenance Manual

T6090 Maintenance Manual Supplement

6

Procedure 2B. Paper Guide Access (T6091)

This procedure must be performed to allow access to the print mechanismand electronics in the T6091 printer series.

Step 1. Turn the power off.

Step 2. Follow Procedure 1B (on the previous page) for opening the cover an additionalamount.

Step 3. Follow Procedure 2 in the Maintenance Manual for removing the ControlPanel.

Step 4. Loosen the two screws that secure the back of the paper guide/cover in place. Reach behind the paper guide and grasp the paper stacking chainsand lift them up as you pull up on the back of the paper guide cover to pivot ittoward the front of the printer.

Step 5. If you need to completely remove the paper guide assembly (for example, to gainaccess to the hammerbank area), remove the four front screws then lift the paperguide assembly off the printer.

Remove the fourfront screws to completelyremove the paper guide.

Loosen the two rearscrews to pivot thepaper guide forward.

Figure 4. Removing the Paper Guide

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SupplementT6065 Printer T6065 Printer

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T6065 Supplement to Manual 080933: T6090 Line

Impact Printer Maintenance Manual

This supplement presents descriptions and explanations about additions/changes to the functionality of your printer. Please read through this document

before performing any repairs. In addition, you may want to make referencesto this document in applicable areas of your Operator Manual.

Ref. 1100 - 083072

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The T6065 is nearly identical to the T6090 in constuction and operation. The only exception isthat the T6065 is slightly lower in print speeds. From a maintenance viewpoint, there are twoareas of difference:

The T6065 Power SupplyThe primary factor that distinguishes the T6065 electronics from the T6090 electronics is thepower supply. Although the power supplies are functionally identical, the T6065 power supplysupplies only enough power to satisfy the needs of the limited performance of the T6065.

It is not possible to upgrade a T6065 to a T6090 without upgrading the power supply.

Main Power

The T6065 adjusts automatically to the various worldwide power requirements, 110 ± 20V or 220± 40V at either 60 ± 3Hz or 50 ± 3Hz. All voltages in the following table are single phase; alllisted currents are at nominal voltage and frequency.

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011 05 W531/A0.2 W704/A0.5 W93/A27.0 W92/A65.0

011 06 W931/A1.2 W014/A0.5 W93/A57.0 W92/A75.0

022 05 W831/A3.1 W414/A2.3 W04/A63.0 W92/A03.0

Figure 1: Main Power Requirements

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Controller

Hardware Architecture

The T6065 implements a highly integrated multi-processor electronic design. This design isimplemented in two basic modules. These are:

Engine Control Module

Personality Module

The purpose of separating the controller into these two modules is to allow for the easy replace-ment, retrofit, or conversion of Personality Modules which define the host interface, emulations,and memory capacity.

The Personality Module is easily accessed from the rear of the printer and can be removed orinstalled without tools. All host interface connectors are contained on the Personality Module.

An Engine Control Module is unique to a particular printer model, typically defined by print speedor other mechanically dependent characteristics. Future printer models will incorporate thismodular scheme with Personality Module software capable of run-time adaption to all models ofEngine Control Modules.

Engine Control Module

The primary components of the Engine Control Module are the Control Processor (an Intel8xC196KB microcontroller), the Shuttle Processor (a Phillips/Signetics 8xC750 microcontroller),Hammer Driver ASICs, hammer drive transistors, motor drive chips, and EEPROM, and variousdiscrete components.

The Engine Control Module contains all of the circuitry and intelligence needed to:

Communicate with the Personality Module

Control the firing of the print elements

Control and monitor the speed of the shuttle mechanism

Control and monitor paper motion

Control and monitor ribbon motion

Monitor the paper out sensor

Monitor the temperature sensor

Interface to the control panel

Save engine calibrations and printer configuration settings in an EEPROM

The Engine Control Modules differ between the T6090 and the T6065 in that they each haveunique Control Processors and Shuttle Processors.

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Performance

Print Speeds

The table below lists maximum attainable print speeds, in LPM (lines per minute), for each fontmatrix. It assumes unmixed text (using a single matrix), printed at 6 LPI. Note that print speedmay be reduced when printing at vertical densities other than 6 LPI. Also, mixed text will print atthe speed of the slowest font matrix used.

T6065

elytStnoFtfarD

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IPC01 056 056 884 884 062 093 261

IPC21 056 884 884 463 292 - -

IPC51 056 523 884 542 591 - -

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IPC01 755 755 093 093 591 292 711

IPC21 755 714 093 382 812 - -

IPC51 755 872 093 091 541 - -

T6090

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IPC21 177 875 525 293 303 - -

IPC51 177 683 525 462 202 - -

Figure 2: Maximum Character Print Speeds

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Plot Speeds

The table below lists maximum attainable plot speeds, in inches per minute, for continuousunmixed full-spaced plot data. Half-spaced plot data may plot faster. Note that plot densitieswhich are approximated plot at the speed of the next higher exact density.

T6065

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T6090

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Figure 3: Maximum Plot Speeds

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Recommended Spare Parts List

PART NAME PART NO.

Power Supply (T6090/T6091) .......................................................................... 081849Power Supply (T6065) ...................................................................................... 082090Personality CBA (Ser/Par) ................................................................................ 081980Personality CBA (4 Plex) ................................................................................. 081086Personality CBA (LANPlex I) .......................................................................... 080920Personality CBA PSIO Ready .......................................................................... 082373Personality CBA (Data Prod.) .......................................................................... 081003Engine Controller CBA (T6065) ...................................................................... 082086Engine Controller CBA (T6090) ...................................................................... 080873Engine Controller CBA (T6091) ...................................................................... 082229Control Panel Assy. ........................................................................................... 078538Hammerbank Assy. ........................................................................................... 081144Hammer Module Kit ......................................................................................... 081152Cable, Control Panel ......................................................................................... 079873Paper/Shuttle Drive Motor ................................................................................ 078259Ribbon Drive Motor ......................................................................................... 075138Fan Assy (T6065 & T6090) .............................................................................. 079644Fan Assy (T6091) ............................................................................................. 082217Blower (Under Platform) .................................................................................. 081095Power Cord ....................................................................................................... 730078Shuttle Sensor ................................................................................................... 081123Platen Sensor .................................................................................................... 080185Tractor Kit, Upper (set w/sensors) ................................................................... 080878Tractor Kit, Lower (set w/sensors) ................................................................... 081854Spring, Gas (Lid) (T6065 & T6090) ................................................................ 731060Spring, Gas (Lid) (T6091) ................................................................................ 731524Belts, Paper Drive ............................................................................................. 075127Pulley, P.A. Motor ............................................................................................. 080711Pulley, Paper Tractor (Top) ............................................................................... 080635Pulley, Paper Tractor (Bottom) ......................................................................... 080647Duct Seal ........................................................................................................... 080751Bearing Block, Right ........................................................................................ 081236Bearing Block, Left .......................................................................................... 081237Shuttle Drive Belt ............................................................................................. 731685Shuttle Assy ...................................................................................................... 081149Ribbon Shield Assy. .......................................................................................... 081129Platen Assy. ....................................................................................................... 081694Tool Kit ............................................................................................................. 081147Grounding Clip, Tractor Shaft .......................................................................... 081470

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T6065 Maintenance Manual Supplement

Recommended Spare Parts List (continued)

PART NAME PART NO.

Manuals

Ops/Aps (T6065) (Ser/Par) ............................................................................... 082179Ops/Aps (T6090) (Ser/Par) ............................................................................... 081608Ops/Aps (T6091) (Ser/Par) ............................................................................... 082179Ops/Aps (T6065/T6090/T6091) (4 Plex) ......................................................... 082180Maintenance Manual ........................................................................................ 082529Graphics Applications ....................................................................................... 079697

Ribbons

Fabric Ribbon, 25 Million Char, Box of 4 ....................................................... 080255Fabric Ribbon, 50 Million Char, Box of 4 ....................................................... 080259Fabric Ribbon, 150 Million Char, Box of 2 ..................................................... 080264

FOR CURRENT PRICE INFORMATION, CALL THE SPARE PARTS DEPARTMENT AT (425) 251-5680,OR (800) 338-3010.

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SupplementT6100/T6101 Printer

T6100/T6101 Printer

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T6100/T6101 Supplement

T6100/T6101 Supplement to the

T6090 Maintenance Manual

This supplement contains schematics and parts lists for theT6100/T6101 upgrade to the T6090 printer.

Ref. 1112-083532

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T6100/T6101 Supplement

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T6100/T6101This printer is an upgrade to the T6090. Parts differences are listed in this supplement.All of the components, and instructions for removing and replacing them (see Chapter 4of the T6090 Maintenance Manual) remain the same.

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T6100/T6101 Supplement

EngineController

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EngineController

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EngineController

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EngineController

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T6100/T6101 Supplement

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Lower Idler Assembly

Phasing BracketAssembly

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Tally Worldwide Locations

U.S.A.Tally Printer CorporationP.O. Box 97018Kent, Washington 98064-9718Tech Support: 425-251-5532Product Service: 1-800-426-4813 (U.S.A. only)Spares: 1-800-338-3010 (U.S.A. only)Information: 1-425-251-5500Fax: 1-425-251-5520http://www.tally.com

AsiaTally AMT Printers Pte. Ltd.,63, Hillview AvenueNo. 08/22, Lam Soon Indutrial Bldg.Singapore 669569Tel.: (65) 760-8833Fax: (65) 760-1066http://www.tally.com

AustriaTally Ges. m.b.H.Eduard Kittenberger Gasse 95BA-1232 ViennaAustriaTel.: +43-1-86340-0Fax: +43-1-86340-240http://www.tally.co.at

CanadaTally Corp.125 Traders Blvd., Unit #9Mississauga, OntarioCanada L4Z 2E5Telephone: +905-890-4646Fax: +905-890-4567http://www.tally.com

EnglandTally Ltd.Molly Millars Lane, WokinghamBerkshire RG11 2QTEnglandTelephone: +44-118-978-8711Fax: +44-118-979-1491http://www.tally.co.uk

FranceTally19 avenue de L’lle Saint-MartinF-92237 Nanterre CedexFranceTéléphone: +33-1-413011-00Fax: +33-1-413011-10http://www.tally.com

GermanyTally GmbHPostfach 29 69D-89019 Ulm/Donau.GermanyTelephone: +49-7308-800Fax: +49-7308-85903http://www.tally.de

ItalyTally S.R.L.Via Borsini 6I-20094 Corsico (Milan)ItalyTelephone: +39-02-48608-1Fax: +39-02-48601-141http://www.tally.it

SpainTally S.R.L.Aleixandre 82 A 28033MadridTelephone: (91) 7219181Fax: (91) 7219936http://www.tally.com

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