083533TX - 6090 Updated Maintenance Manual

Maintenance Manual Line Impact Printer
with T6065, T6091, T6100 & T6101 Supplements
T6090
This Manual is published by Tally Printer Corporation for use with the computer printer described herein. Translations, reprinting or copying by any means of this manual, complete or in part, in any different form requires our explicit approval. Tally Printer Corporation reserves the right to revise this manual without notice, for any reason. This includes, but is not limited to, utilization of advances in the state-of-the-art and changes in the equipment or configuration thereof. Liability for difficulties arising from unknown or unforeseen technical limitations is disclaimed.
FCC Statement This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15, Subpart B of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.
TED O
RECYC
LE
D PAP
IN
Ref. Manual Number 080933 Tally Printer Corporation 8301 South 180th Street Kent, Washington 98032
ER
PR
Jan. 1997 Tally Printer Corporation All rights reserved Printed in the United States
Table of Contents
Table of Contents
2=FAH 2=JD
Table Of Contents
Subject Listing
Chapter 1. Electronic Hardware Architecture, Performance And Specifications
Technical Overview ....................................................................................................................................................... 11 T6090 Electronic Hardware Architecture ..................................................................................................................... 11 Engine Control Module ......................................................................................................................................... 11 Control Processor ........................................................................................................................................... 11 Sensor Inputs .......................................................................................................................................... 11 Shuttle Processor ............................................................................................................................................ 11 Hammer/Motor logic and drive ..................................................................................................................... 12 EEPROM ........................................................................................................................................................ 12 T6090 Personality Module .................................................................................................................................... 12 Serial and Parallel Interfaces ................................................................................................................................. 13 Serial ............................................................................................................................................................... 13 Parallel ............................................................................................................................................................ 13 Motorola MC68340 ............................................................................................................................................... 13 Flash Memory ........................................................................................................................................................ 13 DRAM .................................................................................................................................................................... 13 Altera EPM7064 .................................................................................................................................................... 13 Specifications ................................................................................................................................................................. 14 Serial/Parallel Emulations ..................................................................................................................................... 14 Font Styles .............................................................................................................................................................. 14 Courier and Gothic ......................................................................................................................................... 14 Data Processing and Draft ............................................................................................................................. 14 OCRA and OCRB ...................................................................................................................................... 14 Characters Per Inch ................................................................................................................................................ 14 Lines Per Inch ........................................................................................................................................................ 15 Dot Densities and Plot Speeds ............................................................................................................................... 16 Graphic Benchmarks .............................................................................................................................................. 16 Paper Slew Speed ................................................................................................................................................... 17 Ribbons................................................................................................................................................................... 17 Forms/Paper Description ....................................................................................................................................... 17 Acoustics ................................................................................................................................................................ 18 Power Supply ......................................................................................................................................................... 18 Cooling System ...................................................................................................................................................... 18 Safety ...................................................................................................................................................................... 18 Preventive Maintenance ......................................................................................................................................... 19 Environment ........................................................................................................................................................... 19 Operating ........................................................................................................................................................ 19 Nonoperating .................................................................................................................................................. 19 Heat Load Contribution ....................................................................................................................................... 110 Physical Configurations ....................................................................................................................................... 110 Weight .......................................................................................................................................................... 110 Printer Dimensions ............................................................................................................................................... 111 Industry and Agency Standards ........................................................................................................................... 111 Electromagnetic Emissions .................................................................................................................................. 111 Agency Approvals ................................................................................................................................................ 111
T6090 Maintenance Manual

Chapter 2. Menu Operations
Introduction .................................................................................................................................................................... 21 Technical Access Mode ................................................................................................................................................. 21 Entering Tech Access Mode .................................................................................................................................. 21 Exiting Tech Access Mode .................................................................................................................................... 21 Testing, Troubleshooting, and Calibration .................................................................................................................... 21 Printer Tests ............................................................................................................................................................ 21 Hex Dumps ............................................................................................................................................................. 22 Printer Information Printouts and Displays ........................................................................................................... 22 HELP Menu ................................................................................................................................................... 22 Printing a HELP Menu ........................................................................................................................... 22 Report Parameter (Menu Level 2) ................................................................................................................. 22 Report selections (Menu Level 3) .......................................................................................................... 23 Selecting a Printer Report ....................................................................................................................... 23 TEST Menu .................................................................................................................................................................... 23 Pattern Category (Menu Level 1) .......................................................................................................................... 25 Print Parameter (Menu Level 2) .................................................................................................................... 26 Print selections (Menu Level 3) .............................................................................................................. 26 Print2 Parameter (Menu Level 2) .................................................................................................................. 26 Print2 selections (Menu Level 3) ............................................................................................................ 26 Plot Parameter (Menu Level 2) ...................................................................................................................... 26 Plot selections (Menu Level 3) ............................................................................................................... 27 Selecting And Running a Print Test ........................................................................................................ 27 Diagnostic Category (Menu Level 1) .................................................................................................................... 28 PrntCal (Print Calibration) Parameter (Menu Level 2) ................................................................................. 28 Selecting And Running a Hammer Calibration Routine ........................................................................ 28 Selecting And Running a Current Calibration Routine .......................................................................... 29 Selecting And Running a Paper Out Calibration Routine ...................................................................... 29 Meter Parameter (Menu Level 2) .................................................................................................................. 29 Meter selections (Menu Level 3) .......................................................................................................... 210 Motors Parameter (Menu Level 2) .............................................................................................................. 210 Motors selections (Menu Level 3) ........................................................................................................ 210 Sht Spd (Shuttle Speed) Parameter (Menu Level 2) ................................................................................... 210 Shuttle Speed selections (Menu Level 3) ............................................................................................. 211 Rbn Spd (Ribbon Speed) Parameter (Menu Level 2) ................................................................................. 211 Speed selections (Menu Level 3) ......................................................................................................... 211 RibnThr (Ribbon Threshold) Parameter (Menu Level 2) ........................................................................... 211 Threshold selections (Menu Level 3) ................................................................................................... 211 POutThr (Paper Out Threshold) Parameter (Menu Level 2) ...................................................................... 211 Threshold selections (Menu Level 3) ................................................................................................... 211 PMoThr (Paper Motion Threshold) Parameter (Menu Level 2) ................................................................. 211 Threshold selections (Menu Level 3) ................................................................................................... 211 Heavy (Heavy Forms) Parameter (Menu Level 2) ...................................................................................... 211 Heavy Forms selections (Menu Level 3) .............................................................................................. 211 Max T (Maximum Temperature) Parameter (Menu Level 2) ..................................................................... 211 EnStar (Energy Star) Parameter (Menu Level 2) ........................................................................................ 212 Energy Star selections (Menu Level 3) ................................................................................................ 212 Clear Parameter (Menu Level 2) ................................................................................................................. 212 Clear selections (Menu Level 3) .......................................................................................................... 212 Fault Override (FltOvrd) Category (Menu Level 1) ........................................................................................... 212 Pap Mot (Paper Motion) Parameter (Menu Level 2) .................................................................................. 212
Table Of Contents
Pap Out (Paper Out) Parameter (Menu Level 2) ......................................................................................... 212 Rib Mot (Ribbon Motion) Parameter (Menu Level 2) ................................................................................ 212 Shuttle Parameter (Menu Level 2) ............................................................................................................... 212 Temp (Temperature) Parameter (Menu Level 2) ......................................................................................... 212 Platen Parameter (Menu Level 2) ................................................................................................................ 213 Ctrl (Control Processor) Parameter (Menu Level 2) ................................................................................... 213 Link Parameter (Menu Level 2) ................................................................................................................... 213 Hvy Frm (Heavy Forms) Parameter (Menu Level 2) .................................................................................. 213 Panel Parameter (Menu Level 2) ................................................................................................................. 213 Control Panel Key Operations For Controlling Fault Reporting ........................................................................ 213 ALL Fault Reporting .................................................................................................................................... 213 Four Faults Only .......................................................................................................................................... 213 Paper Out Only ............................................................................................................................................. 213
Chapter 3. Troubleshooting
Introduction .................................................................................................................................................................... 31 Messages ........................................................................................................................................................................ 31 Faults ...................................................................................................................................................................... 31 Fault Correction Procedure ............................................................................................................................ 31 Fault Override ................................................................................................................................................ 32 Dump Mode ................................................................................................................................................... 32 Hardware Troubleshooting Guides .............................................................................................................................. 310 The printer does not power up when switched on ............................................................................................... 310 When the printer is powered up, nothing works except the fan. ........................................................................ 310 The printer powers up but the Control Panel does not function. ........................................................................ 311 The Control Panel Display functions partially, nonsensically, or not at all. ...................................................... 311 There is no printed output but the printer appears to be operating normally. .................................................... 312 Printed output appears light ................................................................................................................................. 312 Printed output appears shaky or fuzzy ................................................................................................................ 313 Two adjacent character columns not printing ..................................................................................................... 314 The Printer is out of paper No Paper Out fault is reported .............................................................................. 315 No Paper Motion No Paper Motion fault is reported ....................................................................................... 315 Paper Handling Problems ............................................................................................................................................ 316 T6090 Engine Controller To Hammer Bank CBA Cables .......................................................................................... 317 Troubleshooting The Hammer Driver Transistors ...................................................................................................... 320
Chapter 4. Removal And Reinstallation Procedures

Introduction .................................................................................................................................................................... 41 Required Tools ............................................................................................................................................................... 41 Procedure 1 The Printer Lid ....................................................................................................................................... 42 Procedure 2 The Control Panel ................................................................................................................................... 44 Procedure 3 The Right End Cover .............................................................................................................................. 46 Procedure 4 The Engint Controller CBA ................................................................................................................... 48 Procedure 5 The Personality Module CBA and Enclosure ...................................................................................... 410 Procedure 6 The Fan Motor Assembly ..................................................................................................................... 412 Procedure 7 Power Supply ........................................................................................................................................ 413 Procedure 8 The Left End Cover .............................................................................................................................. 415 Procedure 9 The Ribbon Platform ............................................................................................................................ 416 Procedure 10 The Ribbon Motor .............................................................................................................................. 418 Procedure 11 The Hammer Bank ............................................................................................................................. 419 Procedure 12 The Ribbon Shield .............................................................................................................................. 421 Procedure 13 Hammer Bank Air Duct ..................................................................................................................... 423

Procedure 14 Hammer Module ................................................................................................................................. 424 Procedure 15 The Shuttle Assembly ........................................................................................................................ 426 Procedure 16 The Platen ........................................................................................................................................... 427 Procedure 17 The Platen Open Sensor ..................................................................................................................... 429 Procedure 18 The Shuttle Motor .............................................................................................................................. 430 Procedure 19 Shuttle Motion Sensor ........................................................................................................................ 432 Procedure 20 The Shuttle Drive Belt ........................................................................................................................ 434 Procedure 21 The Paper Advance Motor .................................................................................................................. 435 Procedure 22 Tractor Belt Phasing/Paper Drive Belt Adjustment ........................................................................... 437 Procedure 23 Upper Tractor Assembly .................................................................................................................... 439 Procedure 24 Lower Tractor Assembly .................................................................................................................... 441 Procedure 25 Platen Gap Adjustment Procedure ..................................................................................................... 443
Appendix A. Schematics
Engine Controller CBA ................................................................................................................................................. A1 Ser/Par Personality Module CBA ................................................................................................................................. A6 FourPlex Personality Module CBA ............................................................................................................................ A11
Appendix B. Recommended Spare Parts List, Illustrated Parts Breakdowns, and Component Lists
Recommended Spare Parts List .................................................................................................................................... B1 Cover Set ....................................................................................................................................................................... B2 Basic Assembly ............................................................................................................................................................. B4 Print Mechanism/Shuttle .............................................................................................................................................. B6 Paper Movement System .............................................................................................................................................. B8 Hammer Bank and Electronics ................................................................................................................................... B10 Engine Controller ........................................................................................................................................................ B12 Serial/Parallel Personality Modules (080900 & 080898 ) ......................................................................................... B16 FourPlex Personality Module (080750 ) .................................................................................................................... B20
Appendix C. Downloading Printer Firmware

Firmware Update Procedure ......................................................................................................................................... C1
Supplements Hammer Module Replacement & Realignment T6091 Printer T6065 Printer T6100/T6101 Printers
Tally Worldwide Locations
Table Of Contents
Table Listing
Chapter 1
Table 11. Table 12. Table 13. Table 14. Table 15. Table 16. Table 17. Table 18. Table 19. Table 110. Table 111. Table 112. Table 113. Personality Module Configurations ........................................................................... 12 Type Style, Character Matrix, Dot Density, and CPI Combinations ......................... 15 Plot Data Output Speed .............................................................................................. 16 Graphics Benchmarks ................................................................................................ 17 POSTNET Label Speeds ............................................................................................ 17 Slew Speed ................................................................................................................. 17 Acoustics .................................................................................................................... 18 Power Requirements .................................................................................................. 18 Heat Load Contributions .......................................................................................... 110 Actual Weight: Main Components .......................................................................... 110 Actual Weight: By Configuration ........................................................................... 110 Shipping Weight: By Configuration........................................................................ 110 Printer Dimensions ................................................................................................... 111
Chapter 2
Table 21 Test Menu ................................................................................................................... 24
Chapter 3
Table 31. Table 32. Table 33. Table 34. Table 35. Table 36. Table 37. Display Messages ....................................................................................................... 33 Paper/Printing Corrective Action ............................................................................. 316 Connector Pinouts .................................................................................................... 317 J703 Connector to Hammer Bank CBA Continuity Check Points .......................... 318 T6090 Hammer Coil/Module Troubleshooting ....................................................... 319 J703 Hammer Driver Pinouts ................................................................................... 321 J704 Hammer Driver Pinouts ................................................................................... 322
Figure Listing
Chapter 4
Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 410. Figure 411. Figure 412. Figure 413. Figure 414. Figure 415. Figure 416. Figure 417. Figure 418. Figure 419. Figure 420. Figure 421. Figure 422. Figure 423. Figure 424. Figure 425. Figure 426. Figure 427. Figure 428. Figure 429. Figure 430. Figure 431. Figure 432. Figure 433. Figure 434. Figure 435. Figure 436. Figure 437. Figure 438. Figure 439. Figure 440. Disconnecting the Gas Spring .................................................................................... 42 Removing the Lid ....................................................................................................... 43 Removing the Control Panel ...................................................................................... 44 Reinstalling the Control Panel ................................................................................... 45 Removing the Right End Cover ................................................................................. 46 Reinstalling the Right End Cover .............................................................................. 47 Removing the Engine Controller CBA ...................................................................... 48 Removing the Personality Module CBA ................................................................. 410 Removing the Personality Module Enclosure ......................................................... 411 Removing the Fan Assembly. ................................................................................... 412 Disconnecting the Static Ground. and Removing the Sound Deadening Hood ...... 413 Removing the Power Supply .................................................................................... 414 Removing the Left End Cover ................................................................................. 415 Disconnecting the Ribbon Platform Components ................................................... 416 Removing the Ribbon Platform ............................................................................... 417 Removing the Ribbon Motor ................................................................................... 418 Disconnecting the Hammer Bank ............................................................................ 419 Removing the Hammer Bank ................................................................................... 420 Removing the Ribbon Shield ................................................................................... 421 Removing Hammer Bank Air Duct .......................................................................... 423 Removing and Replacing the Hammer Module. ..................................................... 424 Using the Hammer Alignment Tool ......................................................................... 425 Shuttle Assembly Removal ...................................................................................... 426 Removing the Platen ................................................................................................ 427 Platen End Assembies .............................................................................................. 428 Removing the Platen Open Sensor .......................................................................... 429 Removing the Shuttle Motor .................................................................................... 430 Reinstalling Shuttle Motor Pulley ............................................................................ 431 Removing the Shuttle Motion/Capture Sensor ........................................................ 432 The Shuttle Drive Belt .............................................................................................. 434 Removing the Paper Drive Motor ............................................................................ 435 Paper Advance Motor Assembly .............................................................................. 436 Phasing/Belt Adjustments ........................................................................................ 437 Phasing Gauge Installation ...................................................................................... 437 Paper Drive Belt Adjustment ................................................................................... 438 Removing Upper Tractor Assembly ......................................................................... 439 Upper Tractor Alignment ......................................................................................... 440 Removing Lower Tractor Assembly ........................................................................ 441 Lower Tractor Alignment ......................................................................................... 442 Platen Gap Adjustment ............................................................................................. 443
Introduction
Introduction
2=FAH 2=JD
Introduction
Introduction
This manual presents operational theory, specifications, troubleshooting, and Removal and Replacement 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 Specifications

This chapter presents basic operational theory of the T6090 Printer. In addition, design and operational specifications for the printer are given.
Chapter 2: Menu Operations

Chapter 2 presents the Menu Operations concerned with troubleshooting and maintaining the printer.
Chapter 3: Troubleshooting
This chapter lists the display messages you may encounter, their cause, and possible corrective actions.
Chapter 4: Removal and Reinstallation Procedures

This chapter presents instructions for removing and reinstalling/replacing various components of the printer.
Appendix A: Schematics
The schematics in this appendix will assist you in troubleshooting problems and locating components that control printer operations.
Appendix B: Recommended Spare Parts List, Illustrated Parts Breakdowns, and Components Lists
These IPBs present exploded views of all printer components along with parts listings.
Appendix C: Downloading Printer Firmware

This appendix explains how to download firmware to the printer.
Chapter 1
Electronic Hardware Architecture, Performance & Specifications
Electronic Hardware Architecture, Performance & Specifications
2=FAH 2=JD
Chapter 1: Electronic Hardware Architecture, Performance & Specifications
Technical Overview
The T6090 is a medium speed, line impact dot matrix printer. It has a maximum speed of 900 lines per minute in uppercase draft text mode. The T6090 is designed for long term operations, supporting a workload of 160,000 pages per month with minimal maintenance.
T6090 Electronic Hardware Architecture

The electronic design of the T6090 is implemented in two basic modules. These are the Engine Control and the Personality Module.
Engine Control Module

The 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 supply voltage, 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 3952 EEPROM The EEPROM stores engine calibration and printer configuration settings.
T6090 Personality Module

Interface control is provided by the Personality Module. There are four Personality Modules available, two of which have optional configurations. The configurations vary in terms of host interface, 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 11. Personality Module Configurations Personality Module
Host I/Os
Standard Ser/Par
IEEE 1284 RS-232-C
Extended Ser/Par
IEEE 1284 RS-232-C Dataproducts1 IG, Code V, PGL, & MTPL Dataproducts Standard or Longlines 768 K 512 K
LANPlex
IEEE 1284 RS-232-C Ethernet IG, Code V, PGL, & MTPL
FourPlex
IEEE 1284 RS-232-C Twinax Coax Code V, PGL, IPDS2 Graphics
Standard Graphics Languages Optional Configurations Flash ROM RAM
IG, Code V, PGL, & MTPL
768 K 512 K
1 2 3
1.5 meg 2 Meg
1 Meg 512 K 3
Dataproducts may be set up for Standard or Longlines operation. With IPDS Option, Code V and PGL are not included. With IPDS Option, 512 K RAM is upgraded to 1 Meg.
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Serial and Parallel Interfaces
Serial Parallel Altera EPM7064 and 74LS374/74LS244 supports IEEE-1284 compatibility and nibble modes 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
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 Memory
The amount of Flash Memory depends on the configuration of the personality module.
DRAM
The 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 Emulations
Nine emulations are available on the T6090: MT660, Genicom ANSI, HP2564C, Printronix P600, Printronix P6000, IBM Proprinter III XL, Epson FX-100+, DEC LG01, and MTPL.
Font Styles
There are 6 resident type styles available on your printer. They include: Courier, Data Processing, Draft, Gothic, OCR-A, and OCR-B. All font styles and the two output modes (Enhanced and Constant Density Fonts for Draft and DP) are selected through the printer control panel. Courier and Gothic These two font styles provide near letter quality (NLQ) printing on your printer. They print at higher dot densities and use denser character matrixes. NLQ type styles provide greater readability for reports and other text output. Data Processing and Draft Data Processing and Draft styles appear in two modes: Constant Density (CDF) and Enhanced. Constant Density Fonts print at the same dot density regardless of the CPI. This produces consistent print speed even when changing from one CPI to another. Enhanced Mode provides higher resolution and a greater range of CPIs than CDF Mode. Because Enhanced Mode uses a variety of dot densities, you should expect a change in print speed of text when switching from one CPI to another. OCR-A and OCR-B These font styles print at 10 CPI only. They are used mainly for Optical Character Recognition.
Characters Per Inch

The T6090 offers a variety of CPIs for use in printer output. Available CPIs are dictated by the font style selected. Each CPI is based on one of twelve character matrixes and twelve dot densities. Each matrix uses a specific number of dot columns for character composition and intercharacter gap. CPIs are grouped in any given type style by the base CPI matrix used for the group. These base CPIs are 10, 12, and 15.
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Table 12. Type Style, Character Matrix, Dot Density, and CPI Combinations
Print Modes Constant Density Type Styles Draft 10 CPI Group Base Matrix: 9 x 8 Dot Density: 60 x 48 CPIs: 5 and 10 Base Matrix: 9 x 12 Dot Density: 60 x 72 CPIs: 5 & 10 Base Matrix: 9 x 8 Dot Density: 60 x 48 CPIs: 5 &10 Base Matrix: 9 x 12 Dot Density: 60 x 72 CPIs: 5 & 10 Base Matrix: 19 x 16 Dot Density: 80 x 96 CPIs: 5 &10 Courier Base Matrix: 19 x 16 Dot Density: 80 x 96 CPIs: 5 & 10 Base Matrix: 9 x 16 Dot Density: 60 x 96 CPIs: 10 Base Matrix: 19 x 24 Dot Density: 80 x 144 CPIs: 10 12 CPI Group Base Matrix: 7 x 8 Dot Density: 60 x 48 CPIs: 6, 6.67, 12, & 13.33 Base Matrix: 7 x 12 Dot Density: 60 x 72 CPIs: 12 & 13.33 Base Matrix: 13 x 8 Dot Density: 80 x 48 CPIs: 6, 6.67, 12, & 13.33 Base Matrix: 13 x 12 Dot Density: 80 x 72 CPIs: 6, 6.67, 12 and 13.33 Base Matrix: 13 x 16 Dot Density: 80 x 96 CPIs: 6, 6.67, 12, & 13.33 Base Matrix: 13 x 16 Dot Density: 80 x 96 CPIs: 6, 6.67, 12, & 13.33 15 CPI Group Base Matrix: 5 x 8 Dot Density: 60 x 48 CPIs: 15 & 17.14 Base Matrix: 5 x 12 Dot Density: 60 x 72 CPIs: 15 & 17.14 Base Matrix: 9 x 8 Dot Density: 120 x 48 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20 Base Matrix: 9 x 12 Dot Density: 120 x 72 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20 Base Matrix: 9 x 16 Dot Density: 120 x 96 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20 Base Matrix: 9 x 16 Dot Density: 120 x 96 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20
Data Processing
Enhanced
Draft
Data Processing
Near Letter Quality
Gothic
Optical Character Recognition
OCR-A
OCR-B
Lines Per Inch

Nine 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 LPIs are restricted.
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Dot Densities and Plot Speeds
The T6090 printer supports Horizontal row plots (single and multiple row), Vertical column plots, and specialized Graphic plots. Your printer supports the following horizontal DPIs: 40, 48, 50, 60, 72, 80, 90, 96, 100, 120, 144, 150, 160, 180, 200, and 240. Your printer supports the following vertical DPIs: 48, 72, 96,144, and 288. All other selections are emulated through the use of scaling techniques. Table 13. Plot Data Output Speed Dot Plot Hor./Vert. 60 x 48 60 x 72 120 x 72 120 x 144 240 x 288 Print Speed Inches Per Min. 100 67 33 16 4
Graphics Benchmarks
Two benchmark tests were used to rate graphics output on the T6090 printer. The first was an AIAG label containing bar codes and block characters inside a box. The second was a POSTNET 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 DPI bar 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 between each row. In addition, the POSTNET test was run with 4 variations: Draft and Data Processing (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 14. Graphics Benchmarks AIAG Label Benchmark Results Graphics Dots Per In. Language 60 120
Code V PGL 1950 LPH 1950 LPH 1300 LPH 1300 LPH
Table 15. POSTNET Label Speeds

POSTNET Label Benchmark Results Lines Type Style Per Inch Draft Data Processing 6 LPI 32000 LPH 29000 LPH 8 LPI 33000 LPH 30500 LPH
Paper Slew Speed

Table 16. Slew Speed
Print Mode Normal Heavy Forms Maximum Slew Speed 16 Inches Per Second 12 Inches Per Second
Ribbons
The T6090 is designed to operate optimally with Tally ribbon cartridges. These cartridges are designed for easy access and loading.
Forms/Paper Description
The 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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Acoustics
The noise generated by the T6090 printer varies according to its configuration as shown in the table that follows: Table 17. Acoustics
Printer Configuration Tabletop Unit Printer with Pedestal Quick Access Configuration Sound Power per ISO 7779-C 7.4 bels 6.9 bels 7.9 bels Sound Pressure Level (9 position average) 57 dBA 52 dBA 62 dBA
Power Supply
The printer requires single phase, 47 to 63 Hz. 90 to 264 VAC input power. The printers universal power supply automatically adjusts to the correct values. A fuse is provided to interrupt power to the power supply. The following table gives typical current values. Table 18. Power Requirements
External Power Supply AC Volts (RMS) 110 110 220 Frequency (Hz) 50 60 50 Average Operating 2.56 A/166 W 2.57 A/171 W 1.39 A/168 W Current/Wattage Requirements @ Nominal Voltage Peak Operating 6.30 A/506 W 6.29 A/508 W 3.91 A/496 W Average Idle (<5 min.) 0.88 A/41 W 0.85 A/42 W 0.41 A/42 W Average Idle (>5 min.) 0.64 A/25 W 0.62 A/25 W 0.31 A/26 W
Cooling System
Cooling system malfunctions are detected and a failure will result in shuttle motion, paper motion, and printing functions being inhibited. The malfunction will be reported on the control panel display.
Safety
Personnel hazard areas have restricted access with appropriate warning labels. Catastrophic equipment failures are inhibited with protective functions in major areas of overload potential.
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Preventive Maintenance
The T6090 is designed to eliminate the requirement of scheduled maintenance procedures, such as alignment, adjustment, or lubrication. Preventive maintenance is limited to periodic cleaning. Dust and paper fibers should be removed periodically with a soft cloth and brush or a vacuum cleaner. Clean the printer case with a damp cloth and soapy water. DO NOT use any abrasive cleaners or solvents, as they will damage the case.
Environment
Operating Temperature Dry Bulb: Humidity: Altitude: Mechanical Shock: Vibration: 50F to 104F (10C to 40C) 10 to 90% noncondensing with a maximum wet bulb temperature of 82F (28C) and a minimum dew point of 36F (2C ) To 8,000 ft. (2438 meters) Half sine wave shock pulse of 10 g peak and 10 +/- 3 ms duration, three times in the vertical direction. 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. Nonoperating Temperature: Boxed: Unboxed: Humidity: Altitude: Thermal Shock: Vibration: - 40F to 151F (-40C to 66C) 14F to 122F (-10C to 50C) 5 to 95% noncondensing To 10,000 ft. (3048 meters) 29F (16C) per minute Units meet NSTA (National Safe Transit Association) requirements.
The printer must be allowed to reach room temperature before operating. Three hours out of the shipping container is usually enough time for stabilization. Complies with NSTA Program 1 & 2.
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Heat Load Contribution
The 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 continuous full-load printing conditions. Table 19. Heat Load Contributions Printing Conditions (110 VAC/60 Hz)
Power On, not printing 100% Uppercase Rolling ASCII Black Page Plot
Current/Wattage
0.64 A/42 W (>5 min.) 2.57 A/268 W 6.29 A/491 W
BTU/Hr
143 915 1677
Physical Configurations
The T6090 printer is available in the following configurations: Standard Optional Optional Tabletop Printer Printer with Stand Printer with Quietized Pedestal
Before installing a Tabletop model, make sure that an opening has been provided in the table that allows access to the paper path opening on the bottom of the printer. Weight Table 110. Actual Weight: Main Components
Component Tabletop Printer Stand Pedestal Weight 90 lbs 30 lbs 52 lbs
Table 111. Actual Weight: By Configuration

Option Tabletop Printer Printer plus Stand Printer plus Pedestal Weight 90 lbs 120 lbs 142 lbs
Table 112. Shipping Weight: By Configuration

Option Tabletop Printer Printer with Stand Printer plus Pedestal Weight 110 lbs 150 lbs 185 lbs
110

Printer Dimensions
Table 113. Printer Dimensions
Dimension Parameter Height Height/Lid Open Width Depth with Exit Hood Depth with Paper Tray Printer Configuration On the Open Stand On the Quietized Pedestal 41.4" 40.6" 54.3" 53.2" 31.5" 31.5" 23.7" 23.2" 28.7" 29.5"
Tabletop Unit 15.8" 28.4" 31.5" 23.5" N/A
Industry and Agency Standards

The T6090 is designed to meet the requirements of several industry and Government agency standards.
Electromagnetic Emissions
EMI: FCC part 15, subpart J, Class A and CISPR 22 Class B ESD: IEC 801-2 (ref Q1012) RF Susceptability: IEC 801-3 Line Transients: IEC 801-4 Power FActor Correction: IEC 555-2
Agency Approvals
United States The 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. Europe IEC 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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Chapter 2
Menu Operations
2=FAH 2=JD
Menu Operations
Introduction
All testing, troubleshooting, and calibration procedures are located in the multilevel menu system of the T6090 printer. They are located in the CONFIGuration and TEST menus and can be accessed through the Printer Control Panel.
Technical Access Mode

Technical (Tech) Access Mode is provided for the repair technician. It provides him access to tests, calibration, and diagnostic procedures for use in troubleshooting and correcting problems with the printer.
Entering Tech Access Mode

Place 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 Mode

There are two methods for leaving Tech Access. 1. Place the printer Offline. Depress the LINE FEED Key and ENTER Key simultaneously. Release the keys immediately when the alarm sounds. 2. Cycle power on the printer.
Testing, Troubleshooting, and Calibration

The printer is equipped with the following types of Print Tests, Hex Dumps, and Printer Information Printouts.
Printer Tests
Print tests appear in both normal menu operations and in the Technical Access Mode of the printer. 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 chapter.
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Hex Dumps
These dumps are located in the Configuration Menu, in the Printer Category, under the Dmp Mod (Dump Mode) Parameter in normal menu operations. Hex Dumps can be used to check printer functions and data processing operations and are also used to help solve problems that can affect printer performance. There are three styles of Dump Modes on the printer. 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 on the printer before running a Style 1 Hex Dump. Style 2 Style 3 Control codes are printed out in hexadecimal format while text and spaces are printed out in their original form. Control codes and spaces are printed out in hexadecimal format, while text is printed out in its original form.
Printer Information Printouts and Displays

There 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 Configuration Menu, under the Printer Category. HELP Menu The HELP Menu is a printout that lists selections that are available for each parameter in the multilevel menus on the printer and indicates with an asterisk (*) which ones are currently active. Before printing out the HELP Menu, make sure that there is at least 13 inches of printable width on the installed paper. Printing a HELP Menu In Tech Access Mode STEP 1. Take the printer Offline. STEP 2. Depress the LINE FEED Key and ENTER Key simultaneously until the printer alarm sounds, then release them immediately to place the printer in Tech Access Mode. STEP 3. Depress the MODE Key to enter the multilevel menu system, then scroll (v Key) to the 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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Report Parameter (Menu Level 2) This parameter has four selections. Two of the selections, Configs and CalData, generate printouts. The second pair of reports (LastFlt and Version) are displays. The Report Parameter 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 occurred Version 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 Report STEP 1. Take the printer Offline. STEP 2. Depress the MODE Key to enter the multilevel menu system, then scroll (v Key) to the CONFIG selection. STEP 3. Depress the FORMS/1 Key to access the CONFIG Menu categories, then scroll (v Key) until the Printer Category is displayed. STEP 4. Depress the CPI/2 Key to access the Printer Category parameters, then scroll (v Key) until the Report Parameter is displayed. STEP 5. Depress the LPI/3 Key to access the Report selections, then scroll (v Key) to the desired selection. STEP 6. Depress the ENTER Key to begin the Report printout or display.
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TEST Menu
The 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 will appear in the TEST Menu while the printer is in Tech Access Mode. Table 21 Test Menu To access Depress this key
Use the v Key to scroll to the desired selection. Print2
Categories
FORMS 1
Parameters
CPI
Selections
LPI
Level 1
Level 2
Level 3
Pattern
Print
Upper All Chrs 63/69 ECMA Columns PaperSv ThermCy Lower 1 Line All H's All E's All #'s All +'s Parens Rubout Ribbon Grid Cross Gray Black Block Hammer Current Pap Out Pap Out Pap Mot Sht Sen Rib Mot Tmp Sen Power Platen Current Keypad Ribbon Shuttle 2348
Use the ENTER Key to select a value or option. Plot
Diag
PrntCal
Meter
Motors Sht Spd
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Table 21, Continued To access Depress this key Categories
FORMS 1
Parameters
CPI
Selections
LPI
Level 1
Level 2
Level 3
Rbn Spd Ribn Thr POut Thr Use the v Key to scroll to the desired selection. PMotThr Max T Heavy EnStar Clear Use the ENTER Key to select a value or option.
1250 1255 0255 0255 1255 OFF ON On Off CalData Counts NVRAM OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON
FltOvrd
Pap Mot Pap Out Rib Mot Shuttle Temp Platen Ctrl Link Hvy Frm
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Pattern Category (Menu Level 1)
The Pattern Category contains several predefined print patterns used to test basic printer functionality. 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 run until you depress either the ENTER Key or the CLEAR Key. This option provides a means of completing long-term testing of the printer without wasting large amounts of paper. It prints a pattern of all uppercase characters that is advanced by one character on each line. Each pass is four lines long. The printer then backs up three lines and prints another four line pass. The printer then continues printing in this fashion until it makes 30 passes. On the 30th pass the printer does not back up. ThermCy This option prints the PaperSv pattern for 15 minutes, stops printing for five minutes, then starts the cycle over. It is used to test the temperature cycling abilities 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. PaperSv
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Plot Parameter (Menu Level 2) This parameter is available in Tech Access only and it contains selections of plot patterns used to test such things as hammer ball alignment and dot placement. There are five selections for this parameter. Plot selections (Menu Level 3) After you have started one of the tests below, it will run continuously until you depress either the ENTER Key or the CLEAR Key. Grid Cross Gray This option prints a grid pattern that can be used to check hammer ball alignment. This option prints a crosshatch pattern of diagonal lines that can be used to check linearity of dot placement. This option prints a grayscale pattern at 60 by 72 DPI. This test fires all 66 hammers (printing every other dot vertically and horizontally), which should lay down an even gray tone across the page. Any changes in the gray tone indicates a variation in the gap between the hammer module and the platen, most commonly indicating either a worn hammer module or a replacement module in need of alignment. This option prints a solid black page at 60 by 72 DPI matrix. The Black Page Print Mode is the most dense print test that can be run for verifying the proper operation of the printers power supply. This test places the greatest electrical current load on the power supply as well as increasing the thermal load on the electronics. This option prints alternating bars at 60 by 72 DPI matrix. Each bar is offset from the previous bar in order to check on dot placement. This pattern is used to test the printer at its maximum sustainable graphics rate without exceeding the boundaries of thermal change or electrical current overload. This test is useful in examining the capabilities of the print mechanism, for checking proper hammer alignment/spacing, and print quality. The output in the printed areas should have uniform shading. If not, parameters such as individual hammer module heights and alignments should be checked.
Black
Block
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Selecting And Running a Print Test STEP 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 (v Key) until the Pattern Category is displayed. STEP 4. Depress the CPI/2 Key to access the Pattern Category parameters, then scroll (v 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 (v Key) to the desired 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 will continue 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 operational thresholds, and for calibrating certain sensors. You are guided through these diagnostic procedures 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 print quality. There are three selections for PrntCal: Hammer, Current, and Pap Out. Selecting And Running a Hammer Calibration Routine STEP 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 (v Key) until the Diag Category is displayed. STEP 4. Depress the CPI/2 Key to access the Diag Category parameters, then scroll (v Key) until the PrntCal Parameter is displayed. STEP 5. Depress the LPI/3 Key to access the PrntCal selections, then scroll (v Key) until the 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 that has the best dot placement, then scroll to that setting on the Control Panel and depress the ENTER Key to select it. After you make the last selection (for 45Hz) the printer prints out the settings for the various lead times and the calibration routine is over. Repeat the Print calibration routine with "Heavy Forms" turned on and with heavy forms installed on the printer. 28

Selecting And Running a Current Calibration Routine Step 1. Take the printer offline and place it in Tech Access Mode. Step 2. Step 3. Step 4. Step 5. Step 6. Access the TEST Menu. Depress the Forms/1 key to access the TEST Menu categories, then scroll (v Key) until the Diag Category is displayed. Depress the CPI/2 key to access the Diag Category parameters, then scroll (v Key) until the Prntcal Parameter is displayed. Depress the LPI/3 key to access the Prntcal selections, then scroll (v Key) until Current is displayed. Looking at the Control Panel display, depress the ENTER key. The printer firmware performs a calibration routine and the new value will be displayed. (Values will vary from printer to printer). Once the value is displayed you have completed the routine.
Selecting And Running a Paper Out Calibration Routine Step 1. Take the printer offline and place it in Tech Access Mode. Step 2. Step 3. Step 4. Step 5. Step 6. Access the TEST Menu. Depress the Forms/1 key to access the TEST Menu categories, then scroll (v Key) until the Diag Category is displayed. Depress the CPI/2 key to access the Diag Category parameters, then scroll ( v Key) until the Printcal Parameter is displayed. Depress the LPI/3 key to access the Printcal selections, then scroll (v Key) until PapOut is displayed. Depress the ENTER key to begin the first part of the Paper Out Calibration Routine. 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 parameter can be used to adjust the sensor for optimum performance or to test sensors to ensure that they are 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 is displayed. 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 with paper installed (covered) and paper removed (uncovered). The Paper Out Sensor should read less than .2 volts with paper removed and greater than 4 volts with paper installed. The Paper Motion Sensor only needs to have a differential of greater than 2 volts between the high and low reading to function properly. The Shuttle Motion Sensor should read less than 0.5 volts with the open portion of the upper gear 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 Ribbon Cartridge over it (uncovered), then with the black portion over it (covered). The readings should 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 at the current selection (Default) or you can select a variety of speeds at which to test them. (See Sht Spd Parameter and Rib Spd Parameter.) Motors selections (Menu Level 3) Ribbon Shuttle The selected test is initiated by depressing the ENTER Key. After the motor reaches its assigned speed the test can be stopped by depressing the ENTER Key again. This sequence may 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) 2348 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) 1250 Default RibnThr (Ribbon Threshold) Parameter (Menu Level 2) This parameter allows you to set the Ribbon Sensor Threshold value for the Ribbon Motion Sensor . Threshold selections (Menu Level 3) 1255 POutThr (Paper Out Threshold) Parameter (Menu Level 2) This parameter allows you to set the Paper Out Threshold value for the Paper Out Sensor to compensate for reflectivity variances for different types of paper. Threshold selections (Menu Level 3) 0255 PMoThr (Paper Motion Threshold) Parameter (Menu Level 2) This parameter allows you to set the Paper Motion Threshold value for the Paper Motion Sensor to compensate for reflectivity variances for different types of paper. Threshold selections (Menu Level 3) 0255 Heavy (Heavy Forms) Parameter (Menu Level 2) This Parameter allows you to slow the slew speed and increase the hammer fire for heavy forms. Heavy Forms selections (Menu Level 3) OFF ON
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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 PCB exceeds 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) OFF ON 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 to the 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 disabled). When the parameter is set to ON, faults are not reported on the display (Fault Override is 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 communications. 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 Reporting

In addition to being able to use the above parameters to set up individual fault overrides, you may also use three different key sequences to set up fault overrides. You may set up all fault overrides, four specific overrides, or just Paper Out Fault override. To use the following options the printer must be in Tech Access Mode. ALL Fault Reporting To turn ALL fault reporting OFF, place the printer Offline and depress the FORM FEED Key and ENTER Key simultaneously until the printer alarm sounds. To turn ALL fault reporting back ON, hold down the same two keys when the printer is Offline until the printer alarm sounds. Four Faults Only To turn fault reporting OFF for Paper Motion, Paper Out, Ribbon Fault, and Platen Open sensors, hold down the ENTER Key and TOF Key simultaneously until the printer alarm sounds. To toggle them back ON, hold down the same two keys until the printer alarm sounds. Paper Out Only To turn OFF fault reporting for the Paper Out sensor, depress the FORMS/1 Key and ENTER Key simultaneously until the printer alarm sounds. To turn it back ON, depress the same keys until the printer alarm sounds. The displays that appear when you are enabling the options above can be somewhat confusing. Just remember, when you turn on fault overrides you are losing fault protection.
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Chapter 3
Troubleshooting
2=FAH 2=JD
Troubleshooting
Introduction
This chapter deals with troubleshooting problems on the T6090 printer. Messages that indicate printer faults and errors are explained and corrective action given. The few paper handling and print quality problems that may occur are also explained. Troubleshooting tables and diagnostic flow charts have been included.
Messages
Messages on the Control Panel Display report both normal operation and fault situations. In Table 31 we present a listing of the Display Messages that need explanation or action on the part of the operator or repair person. Each message listing includes causes and corrective actions where necessary.
Faults
When a fault occurs, it will cause the printer to cease operation and go Offline. The printer alarm will sound, the FAULT Indicator will illuminate, and the display will report a fault message. In some cases it is possible to clear an error message and continue using the printer by depressing the CLEAR Key. However, the quality of the print may be questionable and collateral damage to other parts may result. If the fault message returns, perform the required corrective action. If a nondestructive fault occurs in the middle of printing a document, one line of text may 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 not be displayed, and the beeper and FAULT LED may not operate.
Fault Correction Procedure

STEP 1. STEP 2. First check the fault message on the Control Panel Display and look it up in the Fault Message tables provided later in this chapter. Perform the required corrective action. Some Fault and Error messages will automatically clear as soon as the problem is corrected (for example, the Platen Open message will clear when the Form Thickness lever is lowered to the proper thickness). If a faulty piece of hardware is found, turn to Chapter 4: Removal/Replacement Procedures, for instructions on removal and replacement of faulty parts. 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. Otherwise place the printer back Online and test it during normal print operations.
STEP 3. STEP 4.
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Fault Override
To allow continued printer operation during serious faults, which usually shut down printer 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 Multilevel Menus. Once it is enabled it remains enabled until it is disabled through the Control Panel, a printer reset escape sequence is received by the printer, or printer power is cycled. Eight more are available in the Tech Access Mode, under the TEST Menu. They can only be enabled while the printer is in Tech Access Mode. However, they will remain in whichever 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 Fault Sensing Systems on your printer you lose protection from situations that may result in damage to the printer. Dump Mode
Dump Mode is used to troubleshoot problems that may arise when processing data. You can print out only control codes, control codes and spaces, or control codes, spaces and text in hexadecimal format for use as a debugging tool. The Dump Mode Parameter is explained in Chapter 2: Menu Operations.
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Table 31. Display Messages
MESSAGE
Bad Packet
Explanation and Corrective Action

Explanation: Corrective Action:
This message indicates that a fault has occurred in the communications between the I/O processor and the main processor. Cycle power and try again. If the problem returns, remove and replace the Personality CBA. If the problem returns, download new printer 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. Explanation: Corrective Action:
A VFU channel command has been received from the host requesting an illegal channel. Correct data from host and retransmit. An incorrect number of bytes has been detected in a VFU download. Correct data from host and retransmit. A buffer overflow has been detected on the currently active host interface. It is most likely caused by a host failure to respond to a busy signal. 1. Ensure correct protocol has been selected. 2. Check wiring of I/O cable between host and printer. (See Appendix C in the Operator/Application Manual for a detailed explanation.) 3. Ensure correct protocol has been selected. VFU Channel requested by the host computer cannot be found. Correct data from host and retransmit. This message indicates that a fault has occurred in the control processor. If n = : (4) Control CPU Reset (7) Control CPU RAM Fault (8) Control CPU Checksum Failure Cycle printer power. If this does not clear the problem, remove and replace the Engine Controller CBA If the problem still exists, replace the Personality Module CBA. The Control Processor has detected a fault in the Main Processor to Control Processor link. Cycle power and try again. If it fails again, remove and replace the Personality CBA. If this does not clear the problem, remove and replace the Engine CBA. A data overrun has been detected on the currently active host interface. This is most likely caused by an incorrectly configured serial protocol bit rate, data bits, parity or host failure to respond to a busy signal. Check setting on Serial Protocol bit rate, Data Bits, and Parity parameters through the printer control panel.
Bad VFU Channel
Bad VFU Count
Buffer Overflow
Explanation:
Corrective Action:
Chnl Not Found Ctrl Fault (n)
Explanation: Corrective Action: Explanation:
Corrective Action:
Ctrl Link Flt
Data Overrun
Explanation:
Corrective Action:
33

Table 31, Continued
MESSAGE
Fatal Fault n

A fault has been detected in the software. Cycle power and try again. If this does not clear the problem, remove and replace the Personality CBA. If it fails again, remove and replace the Engine Controller CBA. The Main CPU cannot clear a fault in the Control CPU. Remove and Replace the Engine Controller CBA. An error has been detected during a font download. Correct data and retransmit from host. Graphics memory space is full and the printer cannot accept or process data. Printer will reset and data will be lost. Insert line terminators in data stream so the printer will process the data, then retransmit the data. This message indicates that data flow has been interrupted between the 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 Cycle printer power. If that does not clear the problem, download new printer firmware. A fault has been detected in the main processor during powerup diagnostics. Remove and replace the Personality Module CBA. A VFU command was received from the host before a VFU was Downloaded. Download the required VFU information, then retransmit the data. The nonvolatile data checksum has failed because the variable values have been altered in a destructive manner. Depress the CLEAR Key. If the message does not clear, cycle printer power. If the message still does not clear, remove and replace the Engine Controller CBA. The printer is in Offline condition and nonprinted data is in the buffer. There is no corrective action required. Under normal conditions the printer will continue to print when it is placed back Online. If you do not want the buffered data to print, enter the Clear Menu by depressing the CLEAR Key before going back Online and select the Clear Buffers entry to clear the buffered data.
Flt Clr Timeout Font Dnld Error Heap Overflow
Explanation: Corrective Action: Explanation: Corrective Action: Explanation: Corrective Action:
Link Fault (n)
Explanation:
Corrective Action:
Main CPU Fault
No VFU Loaded
NVRAM Fault
Offline Data In
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Table 31, Continued
MESSAGE
Offline Dump On

The printer is in Offline condition and Dump Mode is enabled. No corrective action is necessary. Place the printer back Online when you are ready to print. (See the explanation at the beginning of this chapter and in Chapter 2, under Hex Dumps for explanations about how the data from the host is printed.) The printer is ready to accept and print data from the host through Dump Mode. (See the explanation at the beginning of this chapter and in Chapter 2, under Hex Dumps for explanations about how the data from the host is printed.) No corrective action is required. An excessive number of bytes has been sent by the host in a VFU download. Correct data and retransmit from host. The control processor has detected a fault in the circuitry for the control panel. Depending on the location of the fault, this message may not display. Remove and replace the Control Panel. If this does not clear the fault, remove and replace the Engine Controller CBA. The control processor has detected that the paper has failed to move the required distance after sending a command to the Paper Drive Motor. Check for paper feed problems. If there are any paper feed problems, correct them, then depress the CLEAR key to clear the fault and continue operation. If this does not clear the problem, check for paper debris blocking the sensor. If problem still exists, check cable connection at the Engine CBA. If it fails again, check the sensors voltage output (in the meter parameter of the Control Panel). The reading should be approx. +5.0 Volts without paper and + 3.0 Volts with paper. Ideally the voltage reading should differ at least 2V between paper in and paper out. If the differential is less than 2V, or the voltage does not change or is zero, the Upper Tractor set (Includes Paper Motion Sensor) needs to be replaced. If all the above does not clear the problem, remove and replace the Engine Controller CBA.
Online Dump On
Explanation:
Corrective Action:
Overflow VFU
Panel Fault
Explanation:
Corrective Action:
Paper Motion Flt
Explanation:
Corrective Action:
35

Table 31, Continued
MESSAGE
Paper Out

Paper is not being detected in the lower paper path below the print mechanism. If this message is correct, refer to the ENTER Key Section of Chapter 2 of the Operator/Application Manual, then load paper. (See Loading Paper Section of Chapter 1 of the Operator/Application Manual.) If this message is in error, check the sensor connection on the Engine Controller CBA and sensor position on its mounting bracket. If the connection is OK and the sensor is properly installed, then recalibrate the Paper Out Sensor. (See TEST Menu in Chapter 2 for the procedure.) If the problem still exists, the Lower Tractor Set (includes Paper Motion Sensor) needs to be replaced. If all of the above checks and fixes do not clear the problem, remove and replace the Engine Controller CBA. Parity is enabled and a mismatch on Bit 8 has been detected on the currently active host interface. If there is a mismatch between the setting of the printer and the setting of the host, you can change printer parity by referring to the Configuration Menu section of Chapter 2 of the Operator's Manual. If there is no mismatch between the printer and host settings, then the data sent from the host has been corrupted. Retransmit the data from the host. If the condition repeats, set up the printer for Dump Mode (see Configuration Menu Section in Chapter 2 of the Operator's Manual) and retransmit the data again. If you find no errors in the Dump Mode data, remove and replace the Personality Module CBA. If this still does not correct the problem, the likely cause is in the I/O cable or the host. The Form Thickness Lever is set beyond the maximum setting for paper thickness. This message may display when you are loading paper or a Ribbon Cartridge into the printer. This condition disables the printer and the only keys that will function on the control panel are the form movement keys. When you are loading paper or a Ribbon Cartridge, this message will clear when you lower the Form Thickness Lever and close the Platen Gap. If this message appears at any other time or will not clear, check the sensor connection on the Engine Controller CBA and perform a meter test on the sensor. (See TEST Menu in Chapter 2 for the procedure.) The sensor should read less than .2 volts with the Form Thickness Lever closed and greater than 4 volts with the form Thickness Lever fully opened. If the readings do not differ, download new printer firmware.
Parity Error
Platen Open
Explanation:
Corrective Action:
36
Table 31, Continued
MESSAGE
Print Fault

Explanation:
Faulty communication between the main and control processor has occurred causing a dot row to misprint. The printer automatically recovers from this condition. Under normal circumstances there is no corrective action other than to depress the CLEAR Key to remove the fault message from the display. If this does not clear the problem, remove and replace the Personality CBA. If, however, this problem persists, remove and replace the Engine Controller CBA. A fault has been detected in the Main Processor primary RAM or a fault exists in the RAM address lines. Remove and replace the Personality Module CBA. The printer is performing internal diagnostic tests. If this message does not clear automatically after a few seconds, remove and replace the Personality Module CBA. The printer address has not been set up or a configuration with address set to UNDEFIN has been loaded. Set up the printer address using the multilevel menus on the printer. The procedure is located in Chapter 4 of the Operator Manual, under the Configuration Menu.
Corrective Action:
RAM Test Fail
Self Testing
Explanation: Corrective Action: Explanation: Corrective Action:
Setup Address
37

Table 31, Continued
MESSAGE
Shuttle Fault

Explanation:
If the control processor detects the shuttle operating either above or below the proper frequency, it shuts down the shuttle and attempts to restart it. If the shuttle still operates incorrectly after three consecutive attempts, the Control Processor goes Offline, and the Shuttle Fault message is displayed. Depress the CLEAR Key, then put the printer back Online. Send a print job to the printer or perform a print test. If the error condition returns, cycle printer power, then try to print again It 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 connection and cable are OK and the sensor is properly installed, perform a meter check of the Shuttle Motion Sensor (see TEST Menu Section of Chapter 2 in this manual). The sensor should read less than .5 volts with the closed segment of the shuttle gear over the sensor and greater than 4.5 volts with the open segment of the gear over the sensor. If the readings are not within the range listed above, remove and replace the sensor. If the sensor is OK, turn the shuttle drive gears by hand. If they do not turn freely, remove the shuttle mechanism and check it again. If it turns freely while removed, check the Hammer Bank for free side to side movement. If the Hammer Bank is binding and does not slide freely, replace the shaft bearing blocks on the Hammer Bank. If the shuttle mechanism still does not turn freely or you find broken or excessively worn gears, replace the Shuttle Drive Mechanism. If they turn freely, the Hammer Bank is not binding, and no excessive wear is present, perform a motor check using the Shuttle Selection under the Motor Parameter in the TEST Menu. If the motor does not function properly, check the drive motor connection on the Engine Controller CBA and check the motor cable. Correct any problems you encounter with these items. If the connection and cable are OK, check and ensure that the proper voltage is provided at the motor connector plug on the Engine Controller CBA. If the voltage is incorrect, check voltage at the Power Supply. If power supply voltage is OK, replace the Engine Controller CBA. If Power Supply voltage is not correct, check the input voltage. If the input voltage is OK, then replace the Power Supply. If the input voltage is not correct, there is a problem with the site power supply.
Corrective Action:
38
Table 31, Continued
MESSAGE
Thermal Fault

The ambient temperature has exceeded the limit (Max T). Check to see if the Cirscuit Cooling and Hammer Bank fans are working. If both fans are working, you have a faulty Engine Controller CBA. If only one of the two fans is not working, check power at the Engine Controller CBA for the fan that is not operating. If power is OK, remove and replace the fan. If power is not OK remove and replace the Engine Controller CBA. If neither fan is working, either the Engine Controller CBA or the Power Supply is malfunctioning. Check voltage output of the Power Supply. If it is OK remove and replace the Engine Controller CBA. If it is not OK, check the power source voltage. If the power source voltage is OK, remove and replace the Power Supply. If the power source voltage is incorrect, call an electrician.
39
Hardware Troubleshooting Guides

Not all printer problems are reported by an error message. Malfunctioning hardware can cause a wide variety of problems without triggering a fault indication. The troubleshooting procedures in this section will help you to repair hardware problems.
The printer does not power up when switched on

There are four things that can cause this problem. 1. 2. 3. 4. A bad connection. A malfunctioning On/Off switch. Incorrect input power. A malfunctioning power supply.
Troubleshooting Procedure
STEP 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 90130 VAC or 180264 VAC, single phase, 50 360 3 Hz. Check input power at the plug-in, on the 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 is defective or the power supply is defective. Check power at the outlet to make sure the power source voltage is correct. If the power source voltage is OK, the problem is in the cord. If input power at the plug-in is OK, check power from the On/Off switch to the Power Supply. If there is no power at the back of the On/Off switch when it is switched On, the On/Off switch is defective. Remove and replace the Power Supply. If input power is OK on the back of the On/Off switch, check input power on the Power Supply. If there is no input power at the Power Supply, the cabling from 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 Power Supply. Power Supply output voltage should be approximately 48 VDC. If the output voltage 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.
310
The Printer powers up but the Control Panel does not function.
There are four things that can cause this problem. 1. 2. 3. 4. A bad connection. A bad control panel. A bad Engine Controller CBA. Loss of 5 V power supply.
If the red Power On Indicator is the only one that does not function, the problem is most likely a malfunctioning Control Panel.
STEP 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 Panel or in the Engine Controller CBA. Try another Control Panel first. If that does not correct the problem, then remove and replace the Engine Controller CBA. STEP 2. If the form movement keys do not function properly, check the Control Panel connection to the Engine Controller CBA. If the connection is OK, the problem is in either the Control Panel or in the Engine Controller 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.
STEP 1. STEP 2. Check the Control Panel connection to the Engine Controller CBA. If the connection is OK, the problem is in either the Control Panel or in the Engine Controller CBA. Try another Control Panel first. If that does not correct the problem, then remove and replace the Engine Controller CBA.
311

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 a Platen Open message. 2. The Ribbon Cartridge may not be functioning properly or is not installed. 3. Platen alignment may be incorrect.
STEP 1. STEP 2. STEP 3. Check the Form Thickness Lever and make sure it is closed properly. Make sure the Ribbon Cartridge is installed and functioning properly. If the Ribbon Cartridge is not functioning properly, replace it. If STEPs 12 do not correct the problem, check and adjust the platen alignment guides. The Platen Gap should be approximately .013 " with the Form Thickness Lever fully closed. (See Procedure 24 in Chapter 4.)
Printed output appears light

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 a Platen Open message. 2. The Ribbon Cartridge may be worn out or is not moving. 3. Platen alignment may be incorrect.
Troubleshooting Procedure.
STEP 1. STEP 2. STEP 3. Check the Form Thickness Lever and make sure it is closed properly. If the Ribbon Cartridge is functioning properly, it is probably out of ink. Remove and replace the Ribbon Cartridge. If the Ribbon Cartridge is not moving, remove the ribbon and check it by turning the ribbon 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 operating properly. (See Ribbon Motion Fault Message, earlier in this chapter for troubleshooting procedure.) STEP 4. If STEPs 13 do not correct the problem, check and adjust the platen alignment guides. The Platen Gap should be approximately .013 " with the Form Thickness Lever fully closed. (See Procedure 24 in Chapter 4.)
312
Printed output appears shaky or fuzzy
There are six things that can cause this problem. 1. The Form Thickness Lever may be open too far but not far enough to cause a Platen Open message. 2. The shuttle mechanism is wornthe shuttle counterweight gears or the bearings are worn. 3. The hammers are not firing properly. 4. Platen alignment may be incorrect. 5. Damaged platen. 6. The Shuttle Sensor is misaligned.
STEP 1. STEP 2. Check the Form Thickness Lever and make sure it is closed properly. 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 a Hammer Calibration procedure for optimum print quality. STEP 3. Perform a Hammer Calibration procedure. This procedure is explained in Chapter 2, in the 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. STEP 5. STEP 6. Check and adjust the platen alignment guides. The Platen Gap should be .012 " .014" with the Form Thickness Lever fully closed. Check the impact area of the platen and replace the platen if this area is damaged. Make sure the Shuttle Sensor is properly aligned. (See Procedure 18 in Chapter 4.)
313

Two adjacent character columns not printing
There are five things that can cause this problem. 1. 2. 3. 4. 5. Broken Hammer. Defective Hammer Coil; either shorted or open. Defective Hammer Bank Cable. Malfunctioning Engine Controller CBA. The hammer may be sticking due to contamination, such as paper and ink buildup.
STEP 1. STEP 2. Remove the right end cover of the printer. 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 Hammer 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 isnt, reinstall the right 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. STEP 4. Remove the Ribbon Cartridge and Ribbon Platform. Check continuity from the Hammer Bank Cable Connector (J703) to the affected coils. To assist you in checking continuity, connector pinouts (Table 33) and illustrations showing the pin arrangements of the connector and the soldered connections on the Hammer Bank (Table 34) are included at the end of this chapter. STEP 5. Check continuity of the Hammer Coil. Resistance of the coil should be 12 (Ohms) .3 at 70 F. If the coil resistance is outside of this range, remove and replace the Hammer Module. If the Hammer Coil is defective, check the Hammer Driver on the Engine Controller CBA also. Defective Hammer Drivers can cause problems with Hammer Coils. Instructions for checking Hammer Drivers are located at the end of this chapter. STEP 6. STEP 7. Is the hammer broken or defective? If so, remove and replace the Hammer Module. Check between the Hammer Plate and the Hammer Module Return Plate and between the Hammer Head and Hammer Coil for ink and paper buildup. Clean the Hammer Bank by prying out gently on the hammer with your finger and running a piece of paper behind the hammer to remove the contamination. For stubborn buildup you may use a little isopropyl alcohol on the paper to loosen the contamination. If there are no physical defects, shorts, or opens, the likely cause of the problem is a malfunctioning Engine Controller CBA. Remove and replace the Engine Controller CBA.
STEP 8.
314
The Printer is out of paper No Paper Out fault is reported
There 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. STEP 2. STEP 3. Check to see if the fault override is enabled for Paper Out sensing. If Fault Overrides are not enabled, check the sensor connections and recalibrate the Paper Out sensor. (See Chapter 2, under Diag Category.) If none of the above checks eliminates the problem, the most likely cause is a malfunctioning 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 paper installed, check the platen for damage. If necessary, remove and replace the platen and any damaged hammers.
No Paper Motion No Paper Motion fault is reported

There 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. STEP 2. STEP 3. Check to see if the fault override is enabled for Paper Motion sensing. Use the PapMot Meteer Test to check the sensor If it does not check correctly, remove and replace the upper tractor set. If none of the above checks eliminates the problem, the most likely cause is a malfunctioning 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 paper motion, check the platen for damage. If necessary, remove and replace the platen and any damaged hammers.
315
Paper Handling Problems

The following table lists the few paper handling problems you may encounter along with corrective actions you may take. Table 32. Paper/Printing Corrective Action
Problem
The paper holes are wider than normal after passing through the tractors. Printed characters on heavyweight or multi-part paper are smeared. The printed characters are too light.
Cause
Horizontal paper tension is too tight.
Corrective Action
Unlock and readjust the tractors.
The Form Thickness Lever is not set correctly. The Form Thickness Lever is out of adjustment or the ribbon is worn out.
Raise the Form Thickness Lever.
Readjust the Form Thickness Lever. If this does not correct the problem, replace the ribbon cartridge with a new one. Adjust the Form Thickness Lever. Move the Paper Tension Lever until the paper is taut but not too tight. Move the Paper Tension Lever until the paper is taut but not too tight. To change the vertical tension, raise the Paper Tension Lever to increase tension, and lower it to decrease tension. To change the horizontal tension, unlock the upper right and/or lower right tractor and move it left or right to make the necessary adjustment. Unlock and realign the tractors.
The printed characters are shaky. The printed characters in one line are shorter than normal. The paper holes are elongated after passing through the tractors. The paper comes out of the tractors or the paper tears at the right or left holes along the edges.
The Form Thickness Lever is not set correctly. Vertical paper tension is too loose. Vertical paper tension is too tight.
(1) The vertical or horizontal paper tension is incorrect.
(2) The tractors are too far apart.
(3) Upper tractors not aligned with the lower tractors. (4) The Form Thickness Lever is not set correctly.
Unlock and realign the tractors so that the lower set is directly under the upper set. Raise the Form Thickness Lever.
316
T6090 Engine Controller To Hammer Bank CBA Cables

Table 33. Connector Pinouts Common = 48V Power
P703 PIN
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43
P704 Function
Hammer 32 Common Hammer 29 Common Hammer 26 Common Hammer 23 Common Hammer 20 Common Hammer 17 Common Hammer 14 Common Hammer 11 Common Hammer 8 Common Hammer 5 Common Hammer 2 Common
Function
Hammer 33 Hammer 31 Hammer 30 Hammer 28 Hammer 27 Hammer 25 Hammer 24 Hammer 22 Hammer 21 Hammer 19 Hammer 18 Hammer 16 Hammer 15 Hammer 13 Hammer 12 Hammer 10 Hammer 9 Hammer 7 Hammer 6 Hammer 4 Hammer 3 Hammer 1
PIN
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
PIN
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43
Function
Hammer 66 Hammer 64 Hammer 63 Hammer 61 Hammer 60 Hammer 58 Hammer 57 Hammer 55 Hammer 54 Hammer 52 Hammer 51 Hammer 49 Hammer 48 Hammer 46 Hammer 45 Hammer 43 Hammer 42 Hammer 40 Hammer 39 Hammer 37 Hammer 36 Hammer 34
PIN
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
Function
Hammer 65 Common Hammer 62 Common Hammer 59 Common Hammer 56 Common Hammer 53 Common Hammer 50 Common Hammer 47 Common Hammer 44 Common Hammer 41 Common Hammer 38 Common Hammer 35 Common
317
318
Hammerbank Firing Line Top View Left to Right 2 Hammerbank CBA Soldered Connections
6 5 4 7 10 13 16 19 22 25 28 31 34 37 40 43 8 11 14 17 20 23 26 29 32 36 39 43 45 46 9 12 15 18 21 24 27 30 33 35 38 41 44 47 48 50 51 49 53 54 52 56 57 55 60 59 58 63 62 61
Hammer Modules
{
3 4 5 6 7 8 9
10
11
J6
J5
66 65 64
Hammers
{
4 3 1 2 7 5
Power Supply Pins
48V 48V 48V 48V 48V 48V 48V 48V 48V 48V 48V
48V 48V 48V 48V 48V 48V 48V 48V 48V 48V 48V
P703 Hammerbank Ribbon Cable
P704 Hammerbank Ribbon Cable

44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11 9 7 5 4 3 2 1
44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6
43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11 9
Table 34. P703 & P704 Connector to Hammer Bank CBA Continuity Check Points
P704 Pin Numbers
P703 Pin Numbers
Connector Alignment
Table 35. T6090 Hammer Coil/Module Troubleshooting
Print Columns
1&2 3&4 5&6 7&8 9 & 10 11 & 12 13 & 14 15 & 16 17 & 18 19 & 20 21 & 22 23 & 24 25 & 26 27 & 82 29 & 30 31 &3 2 33 & 34 35 &36 37 & 38 39 & 40 41 &4 2 43 & 44 45 & 46 47 & 48 49 & 50 51 & 52 53 & 54 55 & 56 57 & 58 59 & 60 61 & 62 63 & 64 65 & 66
Hammer Coil
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Hammer Module
1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 10 10 10 11 11 11
CBA Driver
U20 U20 U20 U19 U19 U19 U19 U18 U18 U18 U18 U17 U17 U17 U17 U16 U16 U16 U16 U15 U15 U15 U15 U14 U14 U14 U14 U13 U13 U13 U13 U12 U12
Print Columns
67 & 68 69 & 70 71 & 72 73 & 74 75 & 76 77 & 78 79 & 80 81 & 82 83 & 84 85 & 86 87 & 88 89 & 90 91 & 92 93 & 94 95 & 96 97 & 98 99 & 100 101 & 102 103 & 104 105 & 106 107 & 108 109 & 110 111 & 112 113 & 114 115 & 116 117 & 118 119 & 120 121 & 122 123 & 124 125 & 126 127 & 128 129 & 130 131 & 132
Hammer Coil
34 35 36 37 38 39 40 41 42 43 44 45 46 47` 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
Hammer Module
12 12 12 13 13 13 14 14 14 15 15 15 16 16 16 17 17 17 18 18 18 19 19 19 20 20 20 21 21 21 22 22 22
CBA Driver
U12 U11 U11 U11 U11 U10 U10 U10 U10 U9 U9 U9 U9 U8 U8 U8 U8 U7 U7 U7 U7 U6 U6 U6 U6 U5 U5 U5 U5 U4 U4 U4 U4
Driver Information is intended for Service Center only.
319
Troubleshooting The Hammer Driver Transistors

The Hammer Driver Transistors are located on the Engine Controller CBA. When you are having problems like Hammer Coil shorting or Hammers not firing, these components 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 its lowest scale. Test the collector (C) to base (B) by placing the Positive (+) lead on the collector terminal and the Negative ( or Common) lead on the base terminal. If the reading is either a short (0 Ohms) or an open (, infinity), the driver is bad and you should replace the Engine Controller CBA. If this check is OK, then test the base (B) to emitter (E) by placing the positive (+) lead on the base terminal and the negative ( or Common) lead on the emitter terminal. If the reading is either a short (0 Ohms) or an open (, 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/Off each segment. The Collector of each driver segment is connected to the corresponding Hammer Coil.
320
Table 36. J703 Hammer Driver Pinouts
Circuit Side of Engine Controller CBA Top Of CBA U12

B C H32 C B H33 C B H29 C B H25 C B H21 C B H17 C B H13 C B H9 C B H5 C B H1
Pin Numbers 1 2 3 4 5 6 7 8 9 10 11 12
U13 J703 U14

B C H24 B C H28
} }
B C H30 B C H26 B C H22 B C H18 B C H14 B C H10 B C H6 B C H2
C B H31 C B H27 C B H23 C B H19 C B H15 C B H11 C B H7 C B H3
U15
B C H20
U16
B C H16
U17
B C H12
U18
B C H8
U19
B C H4
U20
B C
321

Table 36. J704 Hammer Driver Pinouts
Circuit Side of Engine Controller CBA Top Of CBA U4 J704 U5

B C H59 C B H60 C B H56 C B H52 C B H48 C B H44 C B H40 C B H36 C B
Pin Numbers 1 2 3 4 5 6 7 8 9 10 11 12
B C H63
C B H64
B C H65 B C H61 B C H57 B C H33 B C H49 B C H45 B C H41 B C H37 B C
C B H66 C B H62 C B H58 C B H54 C B H50 C B H46 C B H42 C B H38 C B H34
U6
B C H55
U7
B C H51
U8
B C H47
U9
B C H43
U10
B C H39
U11
B C H35
U12
B C
322
Removal & Reinstallation Procedures
Chapter 4
Removal & Reinstallation Procedures
2=FAH 2=JD
Introduction
This chapter covers removal and reinstallation of selected field replaceable components and assemblies of your printer.
HIGH VOLTAGE POTENTIAL

High levels of AC voltage are present in the power supply. Always ensure that the power cord is unplugged before performing maintenance on the printer.
WARNING!
Any time you remove a component that is involved in some aspect of the printing process, perform a print test to ensure that print quality has not been affected. If necessary, perform the required calibration or set up to ensure best possible print quality.
Required Tools
The 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 available through 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 4 1
Procedure 1 The Printer Lid

Before beginning this procedure, turn the printer off and disconnect the power cable.
Removing
STEP 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.
Pivot Post
Small Flat Blade Screwdriver
Spring Clip
Figure 41. Disconnecting the Gas Spring The printer lid is heavy and will immediately try to come crashing down onto whichever part of your anatomy is within reach when you remove the end of the gas spring from its post. So be careful when you disconnect the gas spring!
42

STEP 2. Grasp the printer lid by the front edge with one hand while you use a Phillips screwdriver to remove the hinge-stop to the immediate left of the right hinge.
Step 2. Remove Hinge Stop
Step 3. Slide Lid to Left and Off

Hinges
Figure 42. Removing the Lid STEP 3. After you remove the hinge-stop, slide the lid assembly to the left to remove it from the printer. If the lid does not slide off easily, loosen the hinge screws , then try to slide the lid off again.
Reinstalling
To reinstall the printer lid, reverse the removal steps.
4 3
Procedure 2 The Control Panel

Removing
STEP 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 Panels latch releases and the left edge of the panel 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 from the Engine Controller CBA (J801). If you are removing the Right End Cover, carefully insert Control Panel back through its opening and rest it in the inside of the printer.
Panel Latch
Latch Release Access Slot
Figure 43. Removing the Control Panel
44

Reinstalling
STEP 1. If the Control Panel was removed from the printer, plug the new panel into the Engine Controller CBA (J801). Then advance to STEP 2. If the Control Panel is still connected to the Engine Controller CBA and is lying in the inside of the printer, lift it out of the opening gently. Make sure the Control Panel cable is clear of the Shuttle gears. If the cable gets entangled in the shuttle gears it may be damaged and it may also damage the shuttle. 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 the panel 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 44. Reinstalling the Control Panel
4 5
Procedure 3 The Right End Cover

Removing
STEP 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 the front edge comes free you can lift straight up on the cover and remove it from the printer.
Step 2. Remove 2 Screws 2. 1.
3. 4. Step 4. Step 3. Loosen Screws
5.
Figure 45. Removing the Right End Cover
Reinstalling
STEP 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 front inside edge of the cover over the lip (1) on the printer and the channel in front (2) and side (3) of the printer.
46
Place in front of printer lip
1.
Place channin el
2.
Place in channel
3.
Figure 46. Reinstalling the Right End Cover STEP 3. It may be a tight fit and require considerable downward pressure to get the cover to set down completely. Before pressing down, make sure that all cables are clear of the contact area between the cover and printer. STEP 4. Reinstall the screws in position 1 and 2, then tighten the screws at positions 3, 4, and 5 (see Figure 45). STEP 5. Reinstall the Printer Control Panel.
4 7
Procedure 4 The Engine Controller CBA

Before 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 report and a Calibration Data report before you remove the old CBA. This will give you the information you need to make sure the printer is properly set up after you finish.
Removing
STEP 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.
Shuttle Sensor J604
J603 Paper Motion Sensor J602 Paper Out Sensor J601 Platen Open Sensor J801 Control Panel J901 Ribbon Fault Detect J704 Hammer Bank J703 Hammer Bank
Paper Drive Motor J503 Ribbon Drive Motor J502 Shuttle Drive Motor J501 Fan J2 Power Supply J302 J3 Ribbon Platform Blower
Figure 47. Removing the Engine Controller CBA STEP 4. The Engine Controller CBA is secured in the printer by two Phillips screws and four countersunk screws along the bottom outside edge of the CBA. Remove these screws. The Engine Controller CBA can now be separated from the Personality Module CBA. The Engine Controller CBA can now be removed from the printer.
48

Reinstalling
To reinstall the original Engine Controller CBA or install a new one, reverse the sequence and actions of the removal steps. After installing a new Engine Controller CBA, run the meter tests (as explained in the Paper Out, Paper Motion Flt, Shuttle Fault, Platen Open, and Ribbon Fault messages in Chapter 3 and the Hammer Calibration routines provided in the TEST Menu of the printer. Use the printouts you made earlier to set up communications and other printer operations.
4 9
Procedure 5 The Personality Module CBA and Enclosure

Removing The Personality Module

STEP 1. Loosen the knurled screws securing the Personality Module CBA into its enclosure, then slide it out and set it aside.
Figure 48. 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).
410

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 are removed you can remove the enclosure from the printer.
Cable Support
Figure 49. Removing the Personality Module Enclosure
Reinstalling
To reinstall the Personality Module and its Enclosure, reverse the sequence and actions of the above steps.
4 11
Procedure 6 The Fan Assembly

Removing
STEP 1. Remove the Right End Cover (see Procedure 3). STEP 2. STEP 3. Remove the Engine Controller CBA (see Procedure 4). 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 now lift the fan out of the printer.
Figure 410. Removing Fan Assembly.
Reinstalling
To reinstall the Fan Assembly, reverse the sequence of the above steps.
412
Procedure 7 Power Supply

Removing
STEP 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.
Sound Deadening Hood
Static Ground Wire
Paper Rack
Figure 411. Disconnecting the Static Ground and Removing the Sound Deadening Hood
4 13

STEP 2. Remove Right End Cover (see Procedure 3) and disconnect the Power Supply from the Engine Controller CBA (J302 ) and remove the cable from the cable supports (2 ea) that route the cable to the Engine Controller CBA. STEP 3. Remove the five screws securing the Power Supply to the printer. You can now remove the Power Supply from the Printer.
Figure 412. Removing the Power Supply
Reinstalling
To install the Power Supply, reverse the sequence of the above steps.
414
Procedure 8 The Left End Cover

Removing
STEP 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 can only be accessed if the pedestal door is partially open.
2. 3. 1.
4.
5.
Figure 413. Removing the Left End Cover STEP 4. Lift up on the end cover until it clears the printer and can be removed.
Reinstalling
STEP 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.
4 15
Procedure 9 The Ribbon Platform

Removing
STEP 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 the Ribbon Platform Fan Assembly cable from the Engine Controller CBA (J3). You will need to remove both cables from a cable clamp and remove a ferrite bead encircling the group of cables that contains the Ribbon Motor cable. STEP 4a. To remove the ferrite bead, use a pair of needlenose pliers (or equivalent) to press in on the two tabs on the bead. Pry the two halves apart and remove the bead.
Ferrite Bead Locking Tabs
J502 J3
Figure 414. Disconnecting the Ribbon Platform Components
416

STEP 5. Remove the three mounting screws that secure the Ribbon Platform to the printer. Now you can lift the Ribbon Platform out of the printer.
Remove the three mounting screws
Ribbon Platform Raise Form Thickness Lever
Figure 415. Removing the Ribbon Platform
Reinstalling
To reinstall the Ribbon Platform, reverse the sequence of removal steps.
4 17
Procedure 10 The Ribbon Motor

Removing
STEP 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 now be removed. STEP 3. Remove the four screws that secure the motor to the Ribbon Platform.
Ribbon Motor J502
Figure 416. Removing the Ribbon Motor
Reinstalling
STEP 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 motor mounting screws. Secure the Ribbon Motor cable to the platform with a panduit. STEP 2. Reinstall the Ribbon Platform.
418
Procedure 11 The Hammer Bank

Removing
STEP 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). Remove the two screws from the flex loop bracket and remove the Hammer Bank cables from the cable clamp near the flex loop bracket.
Flexloop Bracket
Cable Clamp
Ferrite Bead
Figure 417. Disconnecting the Hammer Bank If you are replacing the Hammer Bank, remove the ferrite bead from the cable and install it on the new Hammer Bank cable.
4 19

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 the left off of the Hammer Bank shaft.
Left Hand Bearing Block Screws
Hammer Bank
Right Hand Bearing Block Screws
Shuttle Assembly
Figure 418. Removing the Hammer Bank STEP 7. Remove the shuttle Motor Belt. Grasp the Shuttle Assembly firmly and carefully pull the Hammer Bank towards you until the bearing underneath the shuttle pulls free from the stabilizer 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 Assembly and install it on your new Hammer Bank. To remove the Shuttle see Procedure 15.
Reinstalling
When you are ready to reinstall the Hammer Bank, reverse the above sequence of removal steps. Before you install the Ribbon Platform, you must reset the Platen gap described later in this chapter (see Procedure 25). Perform a Hammer Calibration to adjust for optimum print quality. (Hammer calibration is explained in Chapter 2, under PrntCal Parameter.)
420
Procedure 12 The Ribbon Shield

Removing
STEP 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 the Ribbon Shield to the Hammer Bank. Be careful when handling the Ribbon Shield. It can be bent easily, which can affect operation of the printer. It also has very sharp edges that can put a real hurt on you if you arent careful how you handle it.
Hammer Bank Assembly
Ribbon Shield Screws, 4x Ribbon Shield
Figure 419. Removing the Ribbon Shield
4 21

Reinstalling
To reinstall the Ribbon Shield, reverse the sequence and actions of the removal steps. Make sure the shield is flush against the Hammer Bank, and the tips of the hammers themselves are centered in the holes of the Ribbon Shield. After installing a new Ribbon Shield, check for proper platen gap alignment (see Procedure 25) and perform a Hammer Calibration. (Hammer calibration is explained in Chapter 2, under PrntCal Parameter.)
422
Procedure 13 Hammer Bank Air Duct

Removal
STEP 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 the airduct from the Hammer Bank.
Hammer Bank Air Duct Cable Clamp
Air Duct Mounting Screws, 6x
Cable Clamp Screw
Figure 420. Removing Hammer Bank Air Duct
Reinstallation
To reinstall, reverse the sequence of removal.
4 23
Procedure 14 Hammer Module

Removing
STEP 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 can affect operation of the printer. It also has very sharp edges that can put a real hurt on you if you arent 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 the backside of the Hammer Bank. Remove these screws and the individual module can be removed. Before removing a defective module, insert strips of tape between it and the modules immediately adjacent to it. This will protect the coils on adjacent modules during removal and reinstallation.
Hammer Interconnect CBA
Hammer Bank Carriage
Ribbon Shield Alignment Plate
Module Mounting Screws (2)
6-Pack Hammer Module
Fold Back Tape
Figure 421. Removing and Replacing the Hammer Module.
424

Reinstalling
STEP 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, then reinstall the Ribbon Shield.
Hammer AllignmentTool P/N 080614 6-Pack Hammer Modules
Figure 422. 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 as necessary (see Procedure 25). After completing the installation, perform a Hammer Calibration to maintain optimum print quality (see PrntCal Parameter in Chapter 2).
4 25
Procedure 15 The Shuttle Assembly

Removing
STEP 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 connecting the Hammer Bank to the right bearing block. The shuttle assembly can now be separated from the Hammer Bank.
Tie Blocks Shuttle Assembly
You will need to rotate the shuttle gears to get appropriate access to remove the screws securing the shuttle assembly to the Hammer Bank shafts.
Tie Block Screws
Shuttle Screws
Extreme care must be taken not to strip the screws when reinstalling the hex screws that connect the Hammer Bank to the shuttle assembly.
Right Bearing Block
Figure 423. Shuttle Assembly Removal
Reinstalling
To 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 loose screws before reinstalling the Hammer Bank into printer. Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust as necessary (see Procedure 25). After completing the installation, perform a Hammer Lead Time Calibration Routine (see Chapter 2, under the PrntCal Parameter) to adjust for optimum printed output.
426
Procedure 16 The Platen

Removing
STEP 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 of the printer. It may help to disconnect it if you first disconnect the sensor cable (J601) from the Main Controller 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 the Platen.
Platen Open Sensor
Remove SpringsRight and Left ends of the Platen
Figure 424. Removing the Platen
4 27

Reinstalling
STEP 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 you remove it. When you reassemble the platen make sure ALL parts are included. Some parts are small (for example, the spring washers on the right end of the platen) and are easily lost. Refer to the figure below to identify the parts and the installation sequence.
Platen Open Sensor Platen Adjust Plate Platen - Left End Form Thickness Lever Pla ten
Curved Spring Washers
Platen Adjust Plate
Platen - Right End
Figure 425. 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 as necessary (see Procedure 25). After completing the installation, perform a Hammer Calibration to maintain optimum print quality (see PrntCal Parameter in Chapter 2).
428
Procedure 17 The Platen Open Sensor

Removing
STEP 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 cable from 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.
Platen Alignment Plate
J601 Platen Open Sensor Detent Plate
Platen Assembly
Figure 426. Removing the Platen Open Sensor
Reinstalling
STEP 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 read PLATEN 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 as necessary (see Procedure 25). After completing the installation, perform a Hammer Calibration Routine (as explained in Chapter 2, under the PrntCal Parameter) to adjust for optimum printed output. 4 29
Procedure 18 The Shuttle Motor

Removal
STEP 1. Remove the Right End Cover (see Procedure 3). STEP 2. Unplug the Shuttle Stepper Motor (J501) from the Engine Controller CBA. Remove the shuttle 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 supporting the motor with one hand remove the last screw. The Shuttle Motor can now be removed from the printer.
Mounting Bracket
Shuttle Motor Pulley
J501 Shuttle Motor
Figure 427. 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.
430

Reinstalling
STEP 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 of the output shaft.
Output Shaft
Shuttle Motor
Shuttle Motor Pulley Set Screw Output Shaft
J501
Figure 428. Reinstalling Shuttle Motor Pulley STEP 2. Insert the new motor into the mounting bracket on the printer, making sure that the motor cable 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 reconnect J501 into the Engine Controller CBA. STEP 4. Reinstall the Shuttle Drive Belt, the Right End Cover, and the Printer Control Panel.
4 31
Procedure 19 Shuttle Motion Sensor

The Shuttle Motion Sensor is mounted on the bracket behind the lower Shuttle Gear.
Removing
STEP 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
Shuttle Sensor
Figure 4-29. Removing the Shuttle Motion/Capture Sensor
Reinstalling
STEP 1. Mount the sensor on the bracket behind the lower Shuttle gear. Do not tighten screw yet; youll 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 around the cables, then perform the adjustment procedure that follows to set up correct sensing levels.
432

Adjusting
STEP 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. Move the 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 so that 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 the voltage 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 is over 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 in order to obtain optimum print quality.
4 33
Procedure 20 The Shuttle Drive Belt

Removing
STEP 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 pulley then remove it from the Shuttle Motor Pulley.
Shuttle Drive Belt
Shuttle Pulley
Figure 4-30. The Shuttle Drive Belt
Reinstalling
STEP 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.
434
Procedure 21 The Paper Advance Motor

Removing
STEP 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 411). 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 wire harness. Disconnect the harness from the Engine Controller CBA (J302) and set the Power Supply aside. STEP 6. Disconnect the Paper Motor Cable from the extension cable coupling just inside the Power Supply 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. With your left hand, reach inside the Power Supply opening and grasp the case of the motor, then remove the screws loosened in STEP 7. You can now remove the Paper Advance Motor.
Upper Belt
Power Supply Opening Extension Cable Coupling J503
Paper Advance Motor
Paper Advance Motor Mounting Screws
Lower Belt
Figure 431. Removing the Paper Drive Motor 4 35

STEP 9. After you have taken the Motor out of the printer, remove the pulley using a 1/16" hex key wrench, and motor flywheel using a 5/64 hex key wrench.
Flywheel Paper Drive Pulley
Paper Advance Motor Flywheel Set Screws, 2x
Figure 432. Paper Advance Motor Assembly
Reinstalling
STEP 1. Install the pulley and flywheel onto the new motor. The flywheel should be installed approximately .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 tighten the mounting screws. STEP 5. Reconnect the paper motor cable to the extension cable coupling just inside the Power Supply opening. 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) in tool kit (#081147). (Refer to Procedure 21.) Optional: Before continuing with motor installation, you may want to plug in the control panel and perform a motor test with the FORM FEED Key, LINE FEED Key, and the v 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. 436
Procedure 22 Tractor Belt Phasing/Paper Drive Belt Adjustment

Before 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 for proper phasing and belt tensioning. STEP 1. Loosen the screw holding the lower idler bracket and slide it away from the belt, then retighten it to hold the bracket in place temporarily.
1 2 3 P.A. Motor Mounting Screws 2 Lower Belt Lower Idler Bracket Screw
Paper Drive Motor 1 Paper Drive Pulley
Lower Shaft Pulley Lower Shaft
Lower Idler Bracket
Figure 433 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, slide the motor up as far as possible. Retighten one screw to hold the motor in place. STEP 4. Place the Form Thickness Lever at about its midpoint position, then install the phasing gauge (#075467) from tool kit (#081147) or a single sheet of paper in the tractors.
Upper Tractor
Phasing Gauge
Figure 434. Phasing Gauge Installation

Lower Tractor
4 37

STEP 5. Gently turn the upper drive shaft pulley (without belt) manually until the gauge or paper is snug. 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 belt by pushing the motor down towards the floor and tighten the screws. At this point, check the tension by using tension gauge (#081148) in tool kit (#081147). Lay the angled end of tension gauge on the inside half of the paper drive motor pulley until the gauge comes in contact with the idler phase pulley. The spring loaded pin on the gauge should be flush with the plastic casing 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 drive motor positioning until proper tension is achieved.
Inside Pulley Idler Phase Pulley Tension Gauge Paper Drive Pulley
Upper Belt
Tension Gauge Indicator
Outside Pulley
Paper Drive Pulley
Tension Gauge Indicator
Tension Gauge
Paper Drive Pulley
Lower Idler Bracket Lower Belt
Lower Shaft Pulley
Figure 435. Paper Drive Belt Adjustment STEP 8. Loosen the screw securing the lower idler bracket and slide it down to adjust the lower belt tension. Lay the angled end of the belt tension gauge on the outside half of the paper drive motor pulley until it touches the lower shaft pulley. Adjust the position of the lower idler bracket until proper tension is achieved. 438
Procedure 23 Upper Tractor Assembly

Removing
STEP 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 in tool 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 pulley or drive belt from the shaft. If the pulley or drive belt are removed from the printer, you will need to rephase the upper and lower tractor sets.
Snap Ring Drive Belt Pulley
Snap Ring
Support Shaft Nuts, 2x Support Shaft
Drive Shaft
Paper Tension Lever
Tractor Drive Shaft Pulley
When removing the upper tractors, you must unplug the paper motion sensor cable (J603) from the Engine Controller CBA, two cable supports, and a ferrite bead encircling the cables. (The Paper Motion Sensor is attached to the upper left tractor). Figure 436. Removing Upper Tractor Assembly 4 39

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 track of springs and washers on the support shaft when removing.
Reinstalling
Reinstallation 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 of the tractors are aligned with each other.
Snap Ring Alignment Mark Alignment Mark
Support Shaft Nut Left Tractor Right Tractor
Figure 437. Upper Tractor Alignment
440
Procedure 24 Lower Tractor Assembly

Removing
STEP 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 in tool 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 pulley or drive belt from the shaft. If the pulley or drive belt are removed from the printer, you will need to rephase the upper and lower tractor sets.
Snap Ring
Tractor Drive Shaft Pulley
Drive Belt Pulley
Snap Ring Support Shaft Nuts, 2x
Support Shaft Drive Shaft
Figure 438. Removing Lower Tractor Assembly
4 41

STEP 5. 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 track of springs and washers on thesupport shaft when 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 the cables. (The Paper Out Sensor is attached to the lower right tractor).
Reinstalling
Reinstallation 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 of each tractor is positioned the same as the opposite tractor.
"C" Clip Alignment Mark
Alignment Mark
Support Shaft Nut Left Tractor Right Tractor
Figure 439. Lower Tractor Alignment
442
Procedure 25 Platen Gap Adjustment Procedure

Before 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, dont 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 set screw. Turn wrench clockwise to tighten the existing gap. Turn wrench counterclockwise to loosen the existing gap.
Platen Gap Adjust Plates
Ribbon Shield
Shim Gauge
Platen
Right Side View
Figure 440. Platen Gap Adjustment STEP 3: Using a 5/64" Allen wrench, insert it into the right hand tensioning set screw. Turn screw clockwise to tighten the existing gap. Turn the screw counterclockwise to loosen the existing gap. Tool kit 081147 includes both .012" and .014" shim gauge. You can use either, governed by print quality. Repeat STEPs 2 & 3 until gap is equal across Hammer Bank. After adjusting the platen gap perform a Hammer Calibration Procedure (see PrntCal Parameter in Chapter 2).
4 43
Appendix A
Schematics
Appendix A
2=FAH 2=JD
T6090 Engine Controller CBA
A-1
A-2
A-3
A-4
A-5

T6090 Ser/Par Personality Module CBA
A-6
A-7
A-8
A-9
A-10
T6090 FourPlex Personality Module CBA
A-11
A-12
A-13
A-14
A-15
Appendix B
Recommended Spare Parts, Illustrated Parts Breakdown and Components Lists
Appendix B
2=FAH 2=JD
Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists
Recommended Spare Parts List PART NAME Power Supply Personality CBA (Ser/Par) Personality CBA (4 Plex) Personality CBA (Lan) Engine Controller CBA Control Panel Assembly Hammer Bank Assembly Hammer Module Kit Control Panel Cable Paper/Shuttle Drive Motor Ribbon Drive Motor Fan Blower (Under Platform) Power Cord Shuttle Sensor Platen Sensor Tractor Kit, Upper (set w/sensors) Tractor Kit, Lower (set w/sensors) Gas Spring, (Lid) Paper Drive Belts Paper Advance Motor Pulley Paper Tractor Pulley, (Top) Paper Tractor Pulley, (Bottom) Duct (H.B.) Duct Seal Tie Block, Lower Tie Block, Upper (H.B. Shaft) Bearing Block, Right Bearing Block, Left Shuttle Drive Belt Shuttle Assembly Ribbon Shield Assembly Platen Assembly Tool Kit Sound Deadening Hood Manuals Serial/Parallel Ops/Aps LAN Supplement FourPlex Ops/Aps Maintenance Manual Ribbons Fabric Ribbon, 25 Million Char, Box of 4 Fabric Ribbon, 50 Million Char, Box of 4 Fabric Ribbon, 150 Million Char, Box of 2 PART NO. 081153 080901 081086 080920 080873 075123 081144 081152 079873 078259 075138 079644 081095 730078 081123 080185 080878 081128 731060 075127 080711 080635 080647 080727 080751 080658 080657 081326 081327 731685 081149 081298 080953 081147 079622
080932 081057 080978 080933
081267 081269 081271
B-1
Maintenance Manual
Cover Set T6090
B-2
Rear View
Reference# 2 3 5 6 7 8 10 11 14 19 20 21
Description Part Number Lid Cover Assembly 079616 Sound Deadening Hood 079622 Gas Spring 731060 Hinge Stop 079684 832 x 3/8" SEMS Screw 402524 42 Bracket Paper Guide, closing 081098 Cabinet RH End Assembly 090706 Cabinet LH End Assembly 079875 Control Panel Assembly 075123 832 x 5/8" SEMS Screw 402524 51 832 x 3/8" SEMS Screw 402524 42 832 x 3/8" Countersunk Flathead, crosspoint 402524 42
B-3
Maintenance Manual
Basic Assembly T6090
(O PT IO N)
B-4
Reference# 4 6 15 22 23 27 29 35 36 38 46 47
Description Ribbon Drive Motor Duct Seal Blower 832 x 0.437 SEMS Screws (20ea) Belt Flat (Shuttle) Front Cabinet Assembly Ribbon Platform 632 x 0.375 SEMS Screws 832 x 0.625 SEMS Screws 832 x 0.375 SEMS Flathead Screws Nylon Twistlock Cable Support Clamp-on Ferrite Bead (3 ea)
Part Number 075138 080751 081095 402524 49 731685 080702 612591 730381 402524 51 402454 45 730755 730910
B-5
Maintenance Manual
Print Mechanism T6090
B-6
Reference # 17 21 23 24 080185 081008 080618 730213 400236 107 731114 731694 078259 081231 081232 402524 41 402524 21 402524 43 402524 03 400512 254 400512 252 080626 078549 080656 081123 081230 075490 402898 01 080632
Part Number 080953 080931 400995 20
25 27 28 29 30 44 45 48 51 54 55 56 57 59
60
61 62 63 64 65 67 68 69 76 400844 04 402524 49 400215 10 400216 10
80 81 82
Description Platen Assembly Platen Lever Detent Plate 3/8" Spring Washer Platen Open Sensor Cable Assembly Platen Position Label Platen Gap Adjust Plate 242 Thread Locking Adhesive 832 x 0.625 Set Screw (2 ea) Platen Adjust Spring Extension Spring Shuttle Drive Motor LH Pivot Bracket Assembly RH Pivot Bracket Assembly 832 x 0.38 SEMS Screws (4 ea) 632 x 0.25 SEMS Screws (3 ea) 832 x 0.50 SEMS Scrrews (10 ea) 440 x 0,50 SEMS Screw (1 ea) 832 x 1.25 Socket Head Screw (2 ea) 832 x 1.0 Socket Head Screw (2 ea) Lower Paper Guide Assembly Stabilizer Block Assembly Stabilizer Support Bracket Shuttle Sensor Cable Assembly Upper Paper Guide Flat Belt Pulley Assembly Nylon Linear Bearing Paper Guide Wire Form Bronze Flanged Bushing, Oil Impregnated 832 x 0.437 SEMS Screw (4 ea) #8 Split Lock Washer (4) #8 Flat Washer
B-7
Maintenance Manual
Paper Movement System T6090
B-8
Reference # 9 31 32 33 34 35 36 37 38 39 40 42 43 45 46 47 49 50 52 53 54 56 58 70 71 72 73 74 75 78 79 80
Description Frame End-plate Assembly Adhesive Activator Double-sealed Bearing with Ring Paper Drive Shaft Tractor Support Shaft Upper Paper Drive Tractor/Sensor Set 1/8" Flush Hole Plug 832 x 5/8" SEMS Screw (3ea) Retaining Ring Square Shaft Bushing 5/16" x 18 thread KEPS Hex Nut Paper Spring Idler Paper Movement Motor Paper Motor Extension Cable Paper Drive Timing Belt Upper Tractor Drive Pulley Paper Motor Drive Pulley Paper Motor flywheel 832 x 0.50 Set Screw (2 ea) 832 x 0.38 SEMS Screw (1 ea) 832 x 0.50 SEMS Screw (7 ea) Lower Tractor Drive Pulley Phasing Lever Guard Phasing Bracket Assembly Spring Plunger Left Linear Bearing Mount Assembly Bearing Mount Support 5/16" Curved Spring Washer (2 ea) Lower Idler Assembly 832 x 0.875 SEMS Screw (1 ea) Lower Paper Drive Tractor/Sensor Set
Part Number 080698 732239 731090 081186 080649 080877 732182 402524 51 400641 18 075480 400783 15 602631 1 075477 078259 079677 075127 080635 080711 080733 400690 67 402524 42 402524 43 080647 081339 080636 403738 1 080653 081344 730186 080944 402524 48 081128
B-9
Maintenance Manual
Hammer Bank and Electronics Assembly T6090
B-10
Reference # 1 2 3 4 5 11 14 15 16 22 34 37 39 40
46 50 51 52 54 60 61 62 63 64 65
Description Shuttle Assembly Ribbon Shield Bearing Block, Right Fan Power Supply Bearing Block, Left Hammert Bank Duct Hammer Bank Print Mechanism 832 x 0.437 SEMS Screw (4 ea) 832X 2.00 SEMS Screw (1 ea) 440 x 0.25 82 832 x 0.875 SEMS Screw 4 ea Personality CBA (Ser/Par) Personality CBA (4 Plex) Personality CBA (Lan) Nylon Twist-lock Cable Support (3ea) 2.5" Electrical Tape Hardware Removal Flag Engine Controller CBA 440 x 1/4" SEMS Screw (6 ea) Duct Cable Clamp Bracket Cable Protector Pad 632 x 0.50 SEMS Screw I/O Personality Module Housing 440 x 0.375 82 Flat Head Screw I/O Module Insertion Guides (2 ea)
Part Number 081149 081298 081236 079644 081153 081237 080727 081144 080699 402524 49 731723 400258 01 402524 48 080901 081086 080920 730755 730597 79400 080873 402524 01 080768 081097 402524 23 080868 400258 02 732165
B-11
Maintenance Manual
Engine Controller T6090
B-12
Component # U1
Part Number 402285-230 402285-189 400073-07 732163 402285-247 400073-70 402285-212 402285-218 403026-02 403026-03 1W403026-06
Part Number 403054-01 731012 730980 403740-01 731069 403782-01 081194 403054-01 402328-01 731071 403883-03 403006-09 400072-75 400073-27 402285-168 402285-09 402285-132 402285-201 080336 731545 402910-133 730105 400073-18 402285-301 730106R20 400073-42 400073-49 402285-37
730142 730120 731017 402910-126 730617 730168 402172-07 730442 402172-58 402910-126
730108 730259 400073-30 730103 400072-90 402285-139 402285-401 732161 400073-34 400073-61 400073-32
Description Firmware Ctl Processor 87C196 SocketPLCC 68-pin U4U20 ArrayTrans/Diode SMA4032 U21 I.C. 74HCT14 U22 I.C. X24C08 U23 I.C. 74HCT74 U24 Firmware 87C750 Socket I.C. 24-pin Slimline U26 I.C. LM324 U27U32 I.C. 3952 Heatsink I.C. Dip RP1RP17 Resistor Sip 510 8-pin Isol R1 R8 Resistor 120 1/4W 5% R2 R67 R74 Resistor 12K 1/4W 5% R3 Resistor 4.99K 1/4W 1% R4 R6 Resistor 121 1/4W 1% R5 R24 R53 Resistor 2.10K 1/4W 1% R7 R13 R60 R65 Resistor 10K 1/4W 1% R9 R10 R11 R14 R16 R42 Resistor 1K 1/4W 5% R12 Resistor 5.1K 1/4W 5% R15 Resistor 100K 1/4W 1% R17 R19 R22 R54 Resistor 3.3K 1/4W 5% Resistor 51K 1/4K 5% R25 R30 Resistor 100K 1/4W 5% R23 Resistor 237 1/4W 1% R26 R27 R31 R35 R75 R76 R77 Resistor 10K 1/4W 5% R28 Resistor 22 1/4W 5% R29 Resistor 16K 1/4W 5% R32 Resistor 100 1/4W 5% R33 Resistor 510 1/4W 5% R34 Resistor 2.49K 1/4W 1% R36 R48 Resistor 1meg 1/4W 1% R37 Resistor 0.5 1/4W R38 R51 R52 R55 R57 R62 R66 Resistor 24K 1/4W 5% R39 Resistor 24K 330W 5% R40 Resistor 20K 1/4W 5%
Component # Description R41 R43 R44 R44A Resistor 24K 20W 1% R45 R46 Resistor 8.25K 1/4W 1% R46A Resistor 1.8K 1/4W 5% R47 Resistor 1.0 5W R49 R50 Resistor 30.1K 1/4W 1% R56 Resistor 750K 1/4W 5% R58 R63 Resistor 13K 1/4W 1% R59 R64 Resistor 15K 1/4W 1% R68 R69 Resistor .3 1W R70 R71 Resistor 1.0 1W R72 R73 Resistor .5 R18 NOT INSTALLED C26 C35 C36 NOT INSTALLED U3 717 J901 NOT INSTALLED U2 U25 I.C. HamVLSI 52-pin C9 C12 Cap .01MFD 50V 10% SMD C1 C2 C4-C7 C13 C14 Capacitor 4700PFD 50V 10% C3 C15 C18-C20 C23 C25 C27 C28 C30 C31 C34 C37 C46 C51C53 C55 C57 C59 C61 Capacitor .1MFD 50V C8 C21 Capacitor 22MFD 25V TANT C10 C11 Capacitor 1000PFD 50V 10% C15A Capacitor 1200PFD 100V 10% C16 C17 Capacitor 33PFD 50V 10% C22 C24 C29 Capacitor 120PFD 50V 10% C28A Capacitor 1MFD 50V C32 Capacitor 10MFD 25V ALUM C33 Capacitor 100MFD 25V ALUM C38 C40 C41 C45 C47 C48 C63 Capacitor 1200PFD 100V 10% C39 C42 C43 C44 C52 C54 C56 C58 C60 C62 Capacitor .1MFD 100V 10% C64 C65 Capacitor 1800MFD 63V C66 Capacitor 100MFD 63V C67 Capacitor 10MFD 63V CR1 CR21 Diode 1N914B CR2-CR18 Diode Zener 1N5347B 10V CR19 Diode Zener 1N5908
402910-149 731750 731083 731708 400836-04 400049-45 731072
B-13
B-14
Part Number 732160 403880-02 400049-80 400698-03 731075 731747 400664-61 731243 401340-01 400951-01 402278-01 731690 402668-01 731080 401444-01 730099 730097 731522 730098 731098 730163 732164 731733 731119 731731 403760-01 402330-02 730012
Maintenance Manual
Component # CR22 CR23 CR24 CR25 CR26 CR27 CR28 CR29 Y1 Q1 Q2 Q3 Q4 VR1 VR2 VR3 RT1 L1 L2 L3 L4-L15 L16 J2 J3 J17 J302 J501-J503 J601-J604 J703 J704 J801
Description Rectifier 2N6505 Diode UF4002 Diode Zener 1N5359A 24V Diode 1N4003 Diode MUR820 Diode Zener 1N5255B 28V Diode 1N4751A 30V Crystal 12.288MHZ para fund. Transistor 2N3904 Transistor MJE800 Transistor 2N5550 Transistor 2N4403 RegulatorVoltage LM317 RegulatorVoltage LM2576HVT-5 RegulatorVoltage 7912 Thermistor Filter-EMI Suppressor Inductor 150UH BeadFerrite, leaded Inductor 22UH Connector 3-pin Connector 2-pin Connector Male 32-pin Din Connector Power 4-pin Connector 5-pin Connector Phone 4-pin Connector 44-pin Connector 6-pin
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B-15
Maintenance Manual
Serial/Parallel Personality Modules (080900 & 080898 )
B-16
080900 Component List

Part Number 404024 731115 403750 730004 700680 081190 404006 731083 401956 730130 730129 402078 02 730494 730174 730170 731032 731031 730108 730104 731189 731031 400073 61 731189 730339 730106 730746 731189 400072 94 730168
Part Number 730119 400836 04 731707 731096 401340 01 731690 730098 730385 730147 404-94 731734 731700 731083 730130 730129 402078 02 730494
730142 730334
730174 730170 731032 731031 402285 101 730104 730467 402285 101 730108 730104 731189 731031 400073 61 731189 730339 730106 730746 731189 400072 94 730195 730196 402910 126 730194 731017 730168 730442 731545
Component # Description U3 I.C. 74F251 U4 I.C. 145406 U5 I.C. EPM7064 U8 I.C. 74F14 U9 I.C. 74LS244 U10 I.C. 74LS374 RP1 Resistor SIP 10K 10 Pin RP8 RP13 Resistor SIP 10K 8 Pin RP2RP7 RP9RP11RP18 RP18 Resistor SIP 47 8 Pin ISOL RP12 Resistor SIP 47 10 Pin ISOL RP14 Resistor SIP 33 10 Pin ISOL RP15 RP16 Resistor SIP 1.2K 8 Pin R12 R19 R25 Resistor 10K 1/4W 5% R13 Resistor 479 1/4W 5% R14 Resistor 10M 1/4W 5% R15 R16 Resistor SIP 1.2K 8 Pin R17 Resistor 330K 1/4W 5% R18 Resistor 20M 1/4W 5% R20 R0A Resistor 47 1/4W 5% R21 R28 R29 Resistor 3.4K 1/4W 5% R22 R23 R24 Resistor 120 1/4W 5% R26 Resistor 10M 1/4W 5% R27 Resistor 750 1/4W 5% C12 C23 C35 Capacitor 120Pfd 50V 10% C13 C15 C20 C33 C34 C36 C41 C43 C44A C44 C46 C47 C49 C52 C53 C58 C59 Capacitor .1Mfd 50V C24 C26 C31 Capacitor 10Pfd 50V 10% C28 Not Installed C30 Capacitor 22Pfd 50V 10% C32 Capacitor .01Mfd 50V 10% C37 C38 C39 Capacitor 1200Pfd 100V 10% C40 C47 Capacitor 470Pfd 50V 10% C45 C51 C54 Capacitor 1000Pfd 50V 10% C48 C56 C57 Capacitor 120Pfd 50V 10% C50 C15A C15B Capacitor 10Mfd 25V
Component # Description C55 Capacitor .33Mfd 50V CR2 Diode 1N914B Y2 Crystal 20MHz Par. Fund Y3 Crystal 32.768KHz Q1 Transistor 2N3904 Q2 Transistor 2N4403 L3 L4 Leaded Ferrite Bead J14 39 Pin Connector J15 25 Pin Connector J17 32 Pin Female DIN Connector U7 I.C. X24325P U8 I.C. 74F14 U9 I.C. 74LS244 U10 I.C. 74LS374 RP1 Resistor SIP 10K 10 Pin RP8 RP13 Resistor SIP 10K 8 Pin RP2RP7 RP9RP11RP18 RP18 Resistor SIP 47 8 Pin ISOL RP12 Resistor SIP 47 10 Pin ISOL RP14 Resistor SIP 33 10 Pin ISOL RP15 RP16 Resistor SIP 1.2K 8 Pin R1 Resistor 1K 1/4W 1% R2 Resistor 470 1/4W 5% R5 Resistor 270 1/4W 5% R8 R11 Resistor 1.5K 1/4W 5% R12 R19 R25 Resistor 10K 1/4W 5% R13 Resistor 479 1/4W 5% R14 Resistor 10M 1/4W 5% R15 R16 Resistor SIP 1.2K 8 Pin R17 Resistor 330K 1/4W 5% R18 Resistor 20M 1/4W 5% R20 R0A Resistor 47 1/4W 5% R21 R28 R29 Resistor 3.4K 1/4W 5% R22 R23 R24 Resistor 120 1/4W 5% R26 Resistor 10M 1/4W 5% R27 Resistor 750 1/4W 5% C7 Capacitor 22Mfd 25V TANT C8 Capacitor .01Mfd1KV
B-17
B-18
Part Number 731706 730168 730142 730334 730195 730196 402910 126 402910 730194 731017 730168 4730442 730119 400836 04 731707 731242 731096 401340 01 731690 730098 730098 731735 7312705 403760 03 731701 730385 730147 404-94 731734 731698 731699 731064 081191 731121 731519 Component # U15 U16 C21 C25 C27 C29 R14A R208 T1 T2 VR1 Description I.C. 74F158 Capacitor .01Mfd 10% SMD Resistor 47 1/4W 1% SMD Filter Module SF1020 Pulse Transformer ST7033 Voltage Regulator PM6535 Part Number 731513 731545 731546 731704 731703 731702
Maintenance Manual
Component # Description C9 Capacitor 47Mfd 25V ALUM C12 C23 C35 Capacitor 120Pfd 50V 10% C13 C15 C20 C33 C34 C36 C41 C43 C44A C44 C46 C47 C49 C52 C53 C58 C59 Capacitor .1Mfd 50V C24 C26 C31 Capacitor 10Pfd 50V 10% C28 Not Installed C4 C5 C30 Capacitor 22Pfd 50V 10% C10 C32 Capacitor .01Mfd 50V 10% C37 C38 C39 Capacitor 1200Pfd 100V 10% C40 C47 Capacitor 470Pfd 50V 10% C6 C14 C45 C51 C54 Capacitor 1000Pfd 50V 10% C3 C11 C48 C56 C57 Capacitor 120Pfd 50V 10% C50 C15A C15B Capacitor 10Mfd 25V C55 Capacitor .33Mfd 50V CR1 CR2 Diode 1N914B Y1 Crystal 20MHz Par. Fund Y2 Crystal 3.6864MHz Par. Fund Y3 Crystal 32.768KHz Q1 Transistor 2N3904 Q2 Transistor 2N4403 L1 L2 Leaded Ferrite Bead L3 L4 Leaded Ferrite Bead LED3 LED DS1 Sparkgap J3 8 Pin Phone Connector J4 BNC Connector J14 39 Pin Connector J15 25 Pin Connector J17 32 Pin Female DIN Connector U1 I.C. DP8392CV U2 I.C. DP83934CVUL 25 U6 I.C. MC68340 U12 Firmware I.C. 28F400 U11 U13 I.C. 28F200 U14 DRAM I.C. 514256
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B-19
Maintenance Manual
FourPlex Personality Module (080750 )
B-20
Part Number 611744 076967 611744 076968 401953 01 404061 731531 4036-8 732148 403750 730004 403837 01 401818 01 700680 081188 700680 081187 403694 731064 403986 731513 404054 731519 404057 731525 401956 731150 700680 081189 404002 731078 401936 732149 404006 732151 403006 730174 401925 730128 401925 730494 401925 731031 407813 730170 403813 731032 402285 69 400073 39 400073 03 400073 730847 402285 730848 402285 156 402285 01 402285 61 400073 06 400073 783108 402285 730849
Component # Description U1 TESTED I.C. 75112 U2 TESTED I.C. 75110A U3 I.C. 74LS373 U4 U5 U9 I.C.62256 U6 I.C. LM361 U7 I.C. 145406 U8 I.C. DS8344 U10 I.C. DS3487 U11 I.C. EPM7064 12 U12 I.C. EPM7032 12 U13 I.C. MC68340 U14 U15 I.C. 74F158 U16 DRAM I.C. 514256 U17 42 Pin SOJ Socket U18 I.C. 74LS244 U19 Firmware I.C. 28F400 U20 I.C. 28F400 U22 I.C. 74LS374 U23 I.C. 74F14 RP1 RP3 RP8 RP12 RP13 RP15 RP16 SIP Resistor 47 8 Pin ISOL RP2 SIP Resistor 3.3K 8 Pin RP9 RP10 SIP Resistor 10K 8 Pin RP11 RP14 SIP Resistor 1.2K 8 Pin RP17 RP18 SIP Resistor 47 8 Pin ISOL R31 (RP19) SIP Resistor 33 10 Pin ISOL R1 R3 Resistor 511 1/4W 1% R2 Resistor 39K 1/4W 5% R4 Resistor 1.2K 1/4W 5% R5 R10 Resistor 240K 1/4W 5% R6 R12 Resistor 45.3 1/4W 1% R7 R16 Resistor 3.74K 1/4W 1% R8 R18 Resistor 100 1/4W 1% R9 R17 Resistor 760 1/4W 1% R11 Resistor 1.6K 1/4W 5% R13 R19 R21 R27 R35 Resistor 10K 1/4W 5% R14 R15 Resistor 51.1 1/4W 1%
Component # Description Part Number R22 Resistor 51 1/4W 5% 400072 730102 R23 R24 Resistor 5.1K 1/4W 5% 400073 18 R25 Resistor 20M 1 /4W 5% 400076 731190 R26 Resistor 330K 1/4W 5% 400073 61 R28 Resistor 470 1/4W 5% 400072 730104 R29 Resistor 10M 1/4W 5% 400076 731189 R30 R34 R36 Resistor 3.3K 1/4W 5% 400073 730106 R32 Resistor 1K 1/4W 5% 400073 730105 R33 Resistor 750 1/4W 5% 400072 94 R37 R38 R39 Resistor 120 1/4W 5% 400072 75 R27A R29A Resistor 47 1/4W 1% 404070 731546 C1 C2 C4 C6 C13 C18 C19 C21 C24 C32 C35 C39 C47 C49 C52 C53 C56 C58 C60 C62 C66 C72 C74 C75 Capacitor .1Mfd 50V 402868 730142 C3 C5 Capacitor 470Pfd 50V 10% 402910 730194 C7 C54 C69 Capacitor .33Mfd 50V 400955 730119 C8 C9 C15 Capacitor .1Mfd 100V 10% 402910 149 C10 Capacitor 4.7Mfd 25V 402172 52 C11 C12 Capacitor 33Pfd 50V 5% 402910 730617 C14 C33 C34 C59 Capacitor 10Mfd 25V 402172 730442 C16 Capacitor 47Pfd 50V 10% 402910 730178 C17 Capacitor 6.8Pfd 50V 10% 402910 730687 C20 Capacitor .001Mfd 50V 402868 730265 C22 C23 C48 Capacitor .01Mfd 50V 10% 402910 730196 C25 Capacitor 33Pfd 50V 5% 403648 730851 C26 C31 C68 C70 C71 C76 Capacitor 1000Pfd 50V 10% 403941 731017 C27 C30 Capacitor 1Mfd 35V TANT 401389 730122 C28 C29 C55 C57 C67 C73 Capacitor 120Pfd 50V 10% 402942 731016 C40 C42 C45 Capacitor 10Pfd 50V 10% 402910 730334 C41 C43 C44 C50 Capacitor .01Mfd 50V 10% SMD 404069 731545 C46 Capacitor 22Pfd 50V 10% 402910 730195 C51 Not Installed C63 C64 C65 Capacitor 1200Pfd 100V 10% 402910 126 CR1 CR4 I.C. EPM7064 12 700680 081188 OSC 1 Oscillator 8MHz 404058 731526 Y1 Crystal 18.86MHz P.F. 404050 731518
B-21
B-22
Part Number 404050 731242 404012 731096 401444 02 400709 730098 401340 01 403747 730098 403845 730850 403967 730385 403081 730147 404094 731734 403941 730166
Maintenance Manual
Component # Y2 Y3 VR1 Q1 Q2 L1 L2 T1 J14 J15 J17 J204
Description Crystal 3.686MHz PAR FUND Crystal 32.768MHz Voltage Regulator 7905 Transistor 2N4403 Transistor 2N3904 Leaded Ferrite Bead Transformer PF5769 36 Pin Connector 25 Pin Connector 32 Pin Female DIN Connector 15 Pin Connector
Appendix C
Downloading Printer Firmware
2=FAH 2=JD
Appendix C
Appendix C: Downloading Printer Firmware
Firmware Update Procedure

The 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 a hard copy of the printer setup. You will need this to restore any parameters that you have set in 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: VIEW Key, LINE FEED Key, w Key, and MODE Key. Hold them down until the following message scrolls on the control panel display: Mannesmann Tally Flash Loader. The display then 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 are using. Typically the times will vary from 310 minutes. STEP 5. After the download is complete, check the hard copy of the configuration and set up the appropriate parameters. The firmware download is now complete. You will get an NVRAM fault at the end of the download. It does not indicate a problem with the printer, simply depress the CLEAR Key on the printer control panel and the message will clear. You will need to perform a print calibration, paper motion sensor calibration , and a paper out sensor calibration. (These calibraiton routines are explained in Chapter 2, under PrntCal, Pap Mot, and Pap Out parameters, respectively.) The printer is now ready for use.
C1
Supplement
Hammer Module Replacement & Realignment
Hammer Module Replacement & Realignment
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 to this document in applicable areas of your Maintenance Manual.
Ref. 081725 1
Supplement
Hammer Module
Removing
STEP 1. STEP 2. Remove the Hammer Bank from the printer (see Procedure 11, Maintenance Manual). Remove the Ribbon Shield from the Hammer Bank (see Procedure 12, Maintenance Manual). Be careful when handling the Ribbon Shield. It can be bent easily, which can affect operation of the printer. It also has very sharp edges that can injure you if you arent careful how you handle it. STEP 3. STEP 4. Remove the Air Duct and Cable Clamp from the Hammer Bank (see Procedure 13, Maintenance Manual). Each module has six hammers and is held in place on the carriage by two screws on the backside of the Hammer Bank. Remove these screws and the individual module can be removed. Before removing a defective module, insert strips of tape between it and the modules immediately adjacent to it. This will protect the coils on adjacent modules during removal and reinstallation.
Hammer Bank Carriage
Ribbon Shield Alignment Plate
Module Mounting Screws (2)
6-Pack Hammer Module
Fold Back Tape
Figure S1. Removing and Replacing the Hammer Module.

Reinstalling
STEP 1. Install shim spacers underneath the spares replacement modules as Hammer Bank Carriage appropriate. Two .0015" shim spacers are included in each module kit Module (#081152). After the screws for the Mounting module are tightened, check the Screws (2) height of the module for accuracy.
Shim Spacer(s)
Hammer Module
STEP 2.
Install the new Module on the Figure S2. Installing Shim Spacer Hammer Bank. Be very careful when installing the new module. The male prongs can be bent easily and may not align properly when they are plugged in.
Add Shims Remove Shims

Depending on module height, you may or may not need to add shims.
Correct
Figure S3. Checking Module Height STEP 3. Use the Hammer Alignment Tool (#080614 available in tool kit, #081147) to realign the Hammers. Tighten the two mounting screws, then reinstall the Ribbon Shield.
Hammer AllignmentTool P/N 080614 6-Pack Hammer Modules
Figure S4. Using the Hammer Alignment Tool
Supplement
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 as necessary (see Procedure 25, Maintenance Manual). After completing the installation, perform a Hammer Calibration to maintain optimum print quality (see PrntCal Parameter in Chapter 2 of the Maintenance Manual).
T6091 Printer
Supplement
T6091 Printer
T6091 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 references to this document in applicable areas of your Operator Manual.
Ref. 082454
T6090 Maintenance Manual Supplement
T6091 Printer
This supplement gives detailed information, on the T6091, that cannot be found in the T6090 Maintenance Manual. Place this supplement in the section of the T6090 Maintenance Manual entitled, "Supplements."
Specifications
Acoustics
The sound power generated by the printer is 6.6 bels per ISO 7779-C with a sound pressure level of 50 dBA.
Physical Configuration
The T6091 printer is available enclosed in a quietized cabinet with an actual weight of 254 lbs and a shipping weight of 304 lbs.
Printer Dimensions Parameter

Height Height/Lid Open Width Depth
Dimensions
42.2" 61.0" 32.0" 29.0"
Unique Spare Parts Listing-T6091 Printer

Item 17 19 20 30 31 32 33 34 37 38 40 42 44 45 46 Part Number 082224 402524-42 081670 082217 400627-201 400215-10 400216-10 402524-63 402524-45 079400 400341-03 732228 730755 732165 732550 Description Label, Connector locations Screw, #8-32 x 0.375 SEMS Foam, Door Fan Assembly Screw, #8-32 x 1.50, pan head, stainless steel Washer, #8, split lock Washer, #8, flat Washer, #8, flat Screw, #10-32 x 0.50 SEMS Flag, hardware removal Cable Tie Gasket Clips Support Cable, nylon, twist lock Guide, printed circuit board Guide, printed circuit board Support Level \B B,C B A B,C B,C B,C B,C B,C B B,C B B B,C B,C Qty. 1 2 2 1 4 4 4 3 4 4 1 16 2 3 2
T6091 Assembly Diagram
Fan Assembly Diagram
Figure 2. Fan Assembly Diagram
Removal and Reinstallation Procedures

The procedures in this section are specific to the cabinet of the T6091. For any Procedure numbers listed, go to that appropriate procedure in the Maintenance Manual.
Procedure 1B Top Cover Opening for Service Access

The cover assembly of the T6091 CANNOT be removed. It can be opened an additional amount to allow increased access to the inside of the printer in the following manner: Step 1. Step 2. Step 3. Step 4. Partially open the back door of the printer. Use the Control Panel removal tool to release the Control Panel. Lift it out carefully then set it back down inside the printer under the shuttle assembly. Lift the cover assembly to the full open position. Release the two gas springs at the top connection point. (Each of the connection points has a wire retaining clip which must be removed before the gas spring can be removed.) a. Unclip the part of the wire mechanism that is around the shaft just beneath the connection then pull the wire assembly down toward the shaft of the gas spring to remove it. Save this wire clip.
Partially open back door of printer. Rest Printer lid on door.
Small Flat Blade Screwdriver
Release the Gas Springs.
Pivot Post Spring Clip
Figure 3. Opening the Cover b. Push the top of the gas spring toward the inside of the printer to release it from the mounting stud. Be careful to support the cover by hand when releasing the last gas spring and then lower the cover gently onto the partially opened back door.

Procedure 2B. Paper Guide Access (T6091)
This procedure must be performed to allow access to the print mechanism and electronics in the T6091 printer series. Step 1. Step 2. Step 3. Step 4. Turn the power off. Follow Procedure 1B (on the previous page) for opening the cover an additional amount. Follow Procedure 2 in the Maintenance Manual for removing the Control Panel. 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 chains and lift them up as you pull up on the back of the paper guide cover to pivot it toward the front of the printer. If you need to completely remove the paper guide assembly (for example, to gain access to the hammerbank area), remove the four front screws then lift the paper guide assembly off the printer.
Step 5.
Loosen the two rear screws to pivot the paper guide forward.
Remove the four front screws to completely remove the paper guide.
Figure 4. Removing the Paper Guide
Supplement
T6065 Printer
T6065 Printer
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 references to this document in applicable areas of your Operator Manual.
Ref. 1100 - 083072

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

The primary factor that distinguishes the T6065 electronics from the T6090 electronics is the power supply. Although the power supplies are functionally identical, the T6065 power supply supplies 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; all listed currents are at nominal voltage and frequency.
AC Volts (RMS)
Frequency (Hz)
Average Operating Current and Wattage 2.0A/135W 2.1A/139W 1.3A/138W
Peak Operating Current and Wattage 5.0A/407W 5.0A/410W 3.2A/414W
Average Idle Current and Wattage (<5min) 0.72A/39W 0.75A/39W 0.36A/40W
Average Idle Current and Wattage (>5min) 0.56A/29W 0.57A/29W 0.30A/29W
110 110 220
50 60 50
Figure 1: Main Power Requirements

Controller
Hardware Architecture The T6065 implements a highly integrated multi-processor electronic design. This design is implemented 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 replacement, 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 or installed 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 speed or other mechanically dependent characteristics. Future printer models will incorporate this modular scheme with Personality Module software capable of run-time adaption to all models of Engine Control Modules. Engine Control Module The primary components of the Engine Control Module are the Control Processor (an Intel 8xC196KB microcontroller), the Shuttle Processor (a Phillips/Signetics 8xC750 microcontroller), Hammer Driver ASICs, hammer drive transistors, motor drive chips, and EEPROM, and various discrete 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 have unique Control Processors and Shuttle Processors.

Performance
Print Speeds The table below lists maximum attainable print speeds, in LPM (lines per minute), for each font matrix. It assumes unmixed text (using a single matrix), printed at 6 LPI. Note that print speed may be reduced when printing at vertical densities other than 6 LPI. Also, mixed text will print at the speed of the slowest font matrix used. T6065
Draft CDF 650 650 650 557 557 557 Draft Enhanced 650 488 325 557 417 278 DP CDF 488 488 488 390 390 390 DP Enhanced 488 364 245 390 283 190
Font Style 10 CPI Uppercase 12 CPI 15 CPI 10 CPI Lowercase 12 CPI 15 CPI
NLQ 260 292 195 195 218 145
OCR-A 390 292 -
OCR-B 162 117 -
T6090
Draft CDF 900 900 900 771 771 771 Draft Enhanced 900 675 450 771 578 386 DP CDF 675 675 675 525 525 525 DP Enhanced 675 505 340 525 392 264
Font Style 10 CPI Uppercase 12 CPI 15 CPI 10 CPI Lowercase 12 CPI 15 CPI
NLQ 360 405 270 270 303 202
OCR-A 540 405 -
OCR-B 225 405 -
Figure 2: Maximum Character Print Speeds

Plot Speeds The table below lists maximum attainable plot speeds, in inches per minute, for continuous unmixed full-spaced plot data. Half-spaced plot data may plot faster. Note that plot densities which are approximated plot at the speed of the next higher exact density. T6065
Density 60 x 48 60 x 72 120 x 72 120 x 144 240 x 288 Speed (IPM) 73 48 24 12 3
T6090
Density 60 x 48 60 x 72 120 x 72 120 x 144 240 x 288 Speed (IPM) 100 67 33 16 4
Figure 3: Maximum Plot Speeds

Recommended Spare Parts List
PART NAME PART NO.
Power Supply (T6090/T6091) .......................................................................... 081849 Power Supply (T6065)...................................................................................... 082090 Personality CBA (Ser/Par) ................................................................................ 081980 Personality CBA (4 Plex) ................................................................................. 081086 Personality CBA (LANPlex I) .......................................................................... 080920 Personality CBA PSIO Ready .......................................................................... 082373 Personality CBA (Data Prod.) .......................................................................... 081003 Engine Controller CBA (T6065) ...................................................................... 082086 Engine Controller CBA (T6090) ...................................................................... 080873 Engine Controller CBA (T6091) ...................................................................... 082229 Control Panel Assy. ........................................................................................... 078538 Hammerbank Assy. ........................................................................................... 081144 Hammer Module Kit ......................................................................................... 081152 Cable, Control Panel ......................................................................................... 079873 Paper/Shuttle Drive Motor................................................................................ 078259 Ribbon Drive Motor ......................................................................................... 075138 Fan Assy (T6065 & T6090) .............................................................................. 079644 Fan Assy (T6091) ............................................................................................. 082217 Blower (Under Platform) .................................................................................. 081095 Power Cord ....................................................................................................... 730078 Shuttle Sensor ................................................................................................... 081123 Platen Sensor .................................................................................................... 080185 Tractor Kit, Upper (set w/sensors) ................................................................... 080878 Tractor Kit, Lower (set w/sensors) ................................................................... 081854 Spring, Gas (Lid) (T6065 & T6090) ................................................................ 731060 Spring, Gas (Lid) (T6091) ................................................................................ 731524 Belts, Paper Drive ............................................................................................. 075127 Pulley, P.A. Motor ............................................................................................. 080711 Pulley, Paper Tractor (Top) ............................................................................... 080635 Pulley, Paper Tractor (Bottom) ......................................................................... 080647 Duct Seal ........................................................................................................... 080751 Bearing Block, Right ........................................................................................ 081236 Bearing Block, Left .......................................................................................... 081237 Shuttle Drive Belt ............................................................................................. 731685 Shuttle Assy ...................................................................................................... 081149 Ribbon Shield Assy. .......................................................................................... 081129 Platen Assy. ....................................................................................................... 081694 Tool Kit ............................................................................................................. 081147 Grounding Clip, Tractor Shaft .......................................................................... 081470

Recommended Spare Parts List (continued)
PART NAME PART NO.
Manuals Ops/Aps (T6065) (Ser/Par) ............................................................................... 082179 Ops/Aps (T6090) (Ser/Par) ............................................................................... 081608 Ops/Aps (T6091) (Ser/Par) ............................................................................... 082179 Ops/Aps (T6065/T6090/T6091) (4 Plex) ......................................................... 082180 Maintenance Manual ........................................................................................ 082529 Graphics Applications ....................................................................................... 079697 Ribbons Fabric Ribbon, 25 Million Char, Box of 4 ....................................................... 080255 Fabric Ribbon, 50 Million Char, Box of 4 ....................................................... 080259 Fabric 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.
Blank Page
Supplement
T6100/T6101 Printer
T6100/T6101 Printer
T6100/T6101 Supplement
T6100/T6101 Supplement to the T6090 Maintenance Manual
This supplement contains schematics and parts lists for the T6100/T6101 upgrade to the T6090 printer.
Ref. 1112-083532 1
T6100/T6101
This 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 4 of the T6090 Maintenance Manual) remain the same.
Engine Controller
Engine Controller
Engine Controller
Engine Controller
Circuit Board Assembly Engine Controller

Sheet 1 of 5
Engine Controller
Sheet 2 of 5
Engine Controller
Sheet 3 of 5
10
Engine Controller
Sheet 4 of 5
Engine Controller
Sheet 5 of 5
11
12
13
Phasing Bracket Assembly
Lower Idler Assembly
14
Tally Worldwide Locations
U.S.A. Tally Printer Corporation P.O. Box 97018 Kent, Washington 98064-9718 Tech Support: 425-251-5532 Product Service: 1-800-426-4813 (U.S.A. only) Spares: 1-800-338-3010 (U.S.A. only) Information: 1-425-251-5500 Fax: 1-425-251-5520 http://www.tally.com Asia Tally AMT Printers Pte. Ltd., 63, Hillview Avenue No. 08/22, Lam Soon Indutrial Bldg. Singapore 669569 Tel.: (65) 760-8833 Fax: (65) 760-1066 http://www.tally.com Austria Tally Ges. m.b.H. Eduard Kittenberger Gasse 95B A-1232 Vienna Austria Tel.: +43-1-86340-0 Fax: +43-1-86340-240 http://www.tally.co.at Canada Tally Corp. 125 Traders Blvd., Unit #9 Mississauga, Ontario Canada L4Z 2E5 Telephone: +905-890-4646 Fax: +905-890-4567 http://www.tally.com England Tally Ltd. Molly Millars Lane, Wokingham Berkshire RG11 2QT England Telephone: +44-118-978-8711 Fax: +44-118-979-1491 http://www.tally.co.uk
France Tally 19 avenue de Llle Saint-Martin F-92237 Nanterre Cedex France Tlphone: +33-1-413011-00 Fax: +33-1-413011-10 http://www.tally.com Germany Tally GmbH Postfach 29 69 D-89019 Ulm/Donau. Germany Telephone: +49-7308-800 Fax: +49-7308-85903 http://www.tally.de Italy Tally S.R.L. Via Borsini 6 I-20094 Corsico (Milan) Italy Telephone: +39-02-48608-1 Fax: +39-02-48601-141 http://www.tally.it Spain Tally S.R.L. Aleixandre 8 2 A 28033 Madrid Telephone: (91) 7219181 Fax: (91) 7219936 http://www.tally.com

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Maintenance Manual Line Impact Printer

with T6065, T6091, T6100 & T6101 Supplements

T6090 Maintenance Manual

Chapter 4. Removal And Reinstallation Procedures

T6090 Maintenance Manual

Appendix C. Downloading Printer Firmware

Tally Worldwide Locations

T6090 Maintenance Manual

Chapter 1: Electronic Hardware Architecture, Performance, and Specifications

Chapter 2: Menu Operations

Chapter 4: Removal and Reinstallation Procedures

Appendix C: Downloading Printer Firmware

Electronic Hardware Architecture, Performance & Specifications

Chapter 1: Electronic Hardware Architecture, Performance & Specifications

T6090 Electronic Hardware Architecture

Engine Control Module

T6090 Maintenance Manual

T6090 Personality Module

Standard Graphics Languages Optional Configurations Flash ROM RAM

IG, Code V, PGL, & MTPL

1.5 meg 2 Meg

Chapter 1: Electronic Hardware Architecture, Performance & Specifications

T6090 Maintenance Manual

Characters Per Inch

Chapter 1: Electronic Hardware Architecture, Performance & Specifications

Near Letter Quality

Optical Character Recognition

Lines Per Inch

T6090 Maintenance Manual

Chapter 1: Electronic Hardware Architecture, Performance & Specifications

Table 15. POSTNET Label Speeds

Paper Slew Speed

T6090 Maintenance Manual

Chapter 1: Electronic Hardware Architecture, Performance & Specifications

T6090 Maintenance Manual

Table 111. Actual Weight: By Configuration

Table 112. Shipping Weight: By Configuration

Chapter 1: Electronic Hardware Architecture, Performance & Specifications

Tabletop Unit 15.8" 28.4" 31.5" 23.5" N/A

Industry and Agency Standards

Chapter 2: Menu Operations

Technical Access Mode

Entering Tech Access Mode

Exiting Tech Access Mode

Testing, Troubleshooting, and Calibration

T6090 Maintenance Manual

Printer Information Printouts and Displays

Chapter 2: Menu Operations

T6090 Maintenance Manual

Use the ENTER Key to select a value or option. Plot

Motors Sht Spd

Chapter 2: Menu Operations

T6090 Maintenance Manual

Chapter 2: Menu Operations

T6090 Maintenance Manual

Diagnostic Category (Menu Level 1)

Chapter 2: Menu Operations

T6090 Maintenance Manual

Chapter 2: Menu Operations

T6090 Maintenance Manual

Fault Override (FltOvrd) Category (Menu Level 1)

Chapter 2: Menu Operations

Control Panel Key Operations For Controlling Fault Reporting