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Tally T6090 Maintenace Manual

Line impact printer
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Summary of Contents for Tally T6090

  • Page 1 T6090 Maintenance Manual Line Impact Printer with T6065, T6091, T6100 & T6101 Supplements...
  • Page 2 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.
  • Page 3 able of ontents...

  • Page 5: Table Of Contents

    Table Of Contents Subject Listing Chapter 1. Electronic Hardware Architecture, Performance And Specifications Technical Overview ............................... 1–1 T6090 Electronic Hardware Architecture ........................1–1 Engine Control Module ............................1–1 Control Processor ............................1–1 Sensor Inputs ............................1–1 Shuttle Processor ............................1–1 Hammer/Motor logic and drive ........................
  • Page 6 T6090 Maintenance Manual Chapter 2. Menu Operations Introduction ..................................2–1 Technical Access Mode ..............................2–1 Entering Tech Access Mode ..........................2–1 Exiting Tech Access Mode ............................ 2–1 Testing, Troubleshooting, and Calibration ........................2–1 Printer Tests ................................2–1 Hex Dumps ................................2–2 Printer Information Printouts and Displays ......................
  • Page 7 No Paper Motion – No Paper Motion fault is reported ..................3–15 Paper Handling Problems ............................3–16 T6090 Engine Controller To Hammer Bank CBA Cables ..................3–17 Troubleshooting The Hammer Driver Transistors ...................... 3–20 Chapter 4. Removal And Reinstallation Procedures Introduction ..................................
  • Page 8 T6090 Maintenance Manual Procedure 14 – Hammer Module ..........................4–24 Procedure 15 – The Shuttle Assembly ........................4–26 Procedure 16 – The Platen ............................4–27 Procedure 17 – The Platen Open Sensor ........................4–29 Procedure 18 – The Shuttle Motor ..........................4–30 Procedure 19 –...
  • Page 9 Connector Pinouts ....................3–17 Table 3–4. J703 Connector to Hammer Bank CBA Continuity Check Points ......3–18 Table 3–5. T6090 Hammer Coil/Module Troubleshooting ............3–19 Table 3–6. J703 Hammer Driver Pinouts ................... 3–21 Table 3–7. J704 Hammer Driver Pinouts ................... 3–22...
  • Page 10 T6090 Maintenance Manual Figure Listing Chapter 4 Figure 4–1. Disconnecting the Gas Spring ..................4–2 Figure 4–2. Removing the Lid ....................... 4–3 Figure 4–3. Removing the Control Panel ..................4–4 Figure 4–4. Reinstalling the Control Panel ................... 4–5 Figure 4–5.
  • Page 11 ntroduction...

  • Page 13: Chapter 1. Electronic Hardware Architecture, Performance And Specifications

    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.
  • Page 15 hapter Electronic Hardware Architecture, Performance & Specifications...

  • Page 17: Technical Overview

    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 opera- tions, supporting a workload of 160,000 pages per month with minimal maintenance.

  • Page 18: Hammer/Motor Logic And Drive

    T6090 Maintenance Manual 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 •...

  • Page 19: Serial And Parallel Interfaces

    Chapter 1: Electronic Hardware Architecture, Performance & Specifications Serial and Parallel Interfaces Serial • 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 •...

  • Page 20: Specifications

    Characters Per Inch The T6090 offers a variety of CPI’s for use in printer output. Available CPI’s 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.

  • Page 21: Lines Per Inch

    Chapter 1: Electronic Hardware Architecture, Performance & Specifications Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations Print Modes Type Styles 10 CPI Group 12 CPI Group 15 CPI Group Constant Density Draft Base Matrix: 9 x 8 Base Matrix: 7 x 8 Base Matrix: 5 x 8 Dot Density: 60 x 48...

  • Page 22: Dot Densities And Plot Speeds

    240 x 288 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.

  • Page 23: Paper Slew Speed

    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.

  • Page 24: Acoustics

    T6090 Maintenance Manual Acoustics The noise generated by the T6090 printer varies according to its configuration as shown in the table that follows: Table 1–7. Acoustics Printer Sound Power per Sound Pressure Level Configuration ISO 7779-C (9 position average) Tabletop Unit 7.4 bels...

  • Page 25: Preventive Maintenance

    Chapter 1: Electronic Hardware Architecture, Performance & Specifications 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.

  • Page 26: Heat Load Contribution

    0.64 A/42 W (>5 min.) 100% Uppercase Rolling ASCII 2.57 A/268 W Black Page Plot 6.29 A/491 W 1677 Physical Configurations The T6090 printer is available in the following configurations: Standard Tabletop Printer Optional Printer with Stand Optional 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.

  • Page 27: Printer Dimensions

    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...

  • Page 29: Chapter 2. Menu Operations

    hapter Menu Operations...

  • Page 31: Introduction

    Chapter 2: 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.

  • Page 32: Hex Dumps

    T6090 Maintenance Manual 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.

  • Page 33: Report Parameter (Menu Level 2)

    Chapter 2: Menu Operations 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 Param- eter is located in the CONFIGuration Menu, under the Printer Category. Report selections (Menu Level 3) Configs Prints a report showing the setups of the configurations.

  • Page 34: Test Menu

    T6090 Maintenance Manual 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.
  • Page 35 Chapter 2: Menu Operations Table 2–1, Continued To access Categories Parameters Selections FORMS Depress this key Level 1 Level 2 Level 3 Rbn Spd 1–250 Ribn Thr 1–255 POut Thr 0–255 PMotThr 0–255 Use the Key to scroll to the Max T 1–255 desired selection.

  • Page 36: Pattern Category (Menu Level 1)

    T6090 Maintenance Manual 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.

  • Page 37: Plot Parameter (Menu Level 2)

    Chapter 2: Menu Operations 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.

  • Page 38: Selecting And Running A Print Test

    T6090 Maintenance Manual 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 ( Key) until the Pattern Category is displayed.

  • Page 39: Selecting And Running A Current Calibration Routine

    Chapter 2: Menu Operations Selecting And Running a Current 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 ( Key) until the Diag Category is displayed.

  • Page 40: Meter Parameter (Menu Level 2)

    T6090 Maintenance Manual 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.

  • Page 41: Sht Spd (Shuttle Speed) Parameter (Menu Level 2)

    Chapter 2: Menu Operations Sht Spd (Shuttle Speed) Parameter (Menu Level 2) Provides a means to vary the Shuttle Motor speed for a Shuttle Motor Test. Shuttle Speed selections (Menu Level 3) 23—48 Hz. Rbn Spd (Ribbon Speed) Parameter (Menu Level 2) Provides a means to vary the Ribbon Motor speed for a Ribbon Motor Test.

  • Page 42: Max T (Maximum Temperature) Parameter (Menu Level 2)

    T6090 Maintenance Manual 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.

  • Page 43: Platen Parameter (Menu Level 2)

    Chapter 2: Menu Operations Platen Parameter (Menu Level 2) This parameter provides fault override for the Platen Open Sensor. Ctrl (Control Processor) Parameter (Menu Level 2) This parameter provides fault override for the control processor fault reporting status. Link Parameter (Menu Level 2) This parameter provides fault override for control processor to main processor communica- tions.

  • Page 45: Chapter 3. Troubleshooting

    hapter Troubleshooting...

  • Page 47: Introduction

    Chapter 3: 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. Trouble- shooting tables and diagnostic flow charts have been included.

  • Page 48: Fault Override

    T6090 Maintenance Manual 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.

  • Page 49: Table 3–1. Display Messages

    Chapter 3: Troubleshooting Table 3–1. Display Messages MESSAGE Explanation and Corrective Action Bad Packet Explanation: This message indicates that a fault has occurred in the communica- tions between the I/O processor and the main processor. Corrective Action: Cycle power and try again. If the problem returns, remove and replace the Personality CBA.
  • Page 50 T6090 Maintenance Manual Table 3–1, Continued MESSAGE Explanation and Corrective Action Explanation: Fatal Fault n A fault has been detected in the software. Corrective Action: 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.
  • Page 51 Chapter 3: Troubleshooting Table 3–1, Continued MESSAGE Explanation and Corrective Action Explanation: Offline Dump On The printer is in Offline condition and Dump Mode is enabled. Corrective Action: 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.) Explanation:...
  • Page 52 T6090 Maintenance Manual Table 3–1, Continued MESSAGE Explanation and Corrective Action Explanation: Paper Out Paper is not being detected in the lower paper path below the print mechanism. Corrective Action: If this message is correct, refer to the ENTER Key Section of Chapter 2 of the Operator/Application Manual, then load paper.
  • Page 53 Chapter 3: Troubleshooting Table 3–1, Continued MESSAGE Explanation and Corrective Action Explanation : Print Fault Faulty communication between the main and control processor has occurred causing a dot row to misprint. The printer automatically recovers from this condition. Corrective Action : Under normal circumstances there is no corrective action other than to depress the CLEAR Key to remove the fault message from the display.
  • Page 54 T6090 Maintenance Manual Table 3–1, Continued MESSAGE Explanation and Corrective Action Explanation: Shuttle Fault 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.
  • Page 55 Chapter 3: Troubleshooting Table 3–1, Continued MESSAGE Explanation and Corrective Action Thermal Fault Explanation: The ambient temperature has exceeded the limit (Max T). Corrective Action: 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.

  • Page 56: Hardware Troubleshooting Guides

    T6090 Maintenance Manual 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 trouble- shooting procedures in this section will help you to repair hardware problems.

  • Page 57: The Printer Powers Up But The Control Panel Does Not Function

    Chapter 3: Troubleshooting The Printer powers up but the Control Panel does not function. There are four things that can cause this problem. 1. A bad connection. 2. A bad control panel. 3. A bad Engine Controller CBA. 4. Loss of 5 V power supply. If the red Power On Indicator is the only one that does not function, the problem is most likely a malfunctioning Control Panel.

  • Page 58: There Is No Printed Output But The Printer Appears To Be Operating Normally

    T6090 Maintenance Manual 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.

  • Page 59: Printed Output Appears Shaky Or Fuzzy

    Chapter 3: Troubleshooting 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 worn—the shuttle counterweight gears or the bearings are worn.

  • Page 60: Two Adjacent Character Columns Not Printing

    T6090 Maintenance Manual Two adjacent character columns not printing There are five things that can cause this problem. 1. Broken Hammer. 2. Defective Hammer Coil; either shorted or open. 3. Defective Hammer Bank Cable. 4. Malfunctioning Engine Controller CBA. 5. The hammer may be sticking due to contamination, such as paper and ink buildup.

  • Page 61: The Printer Is Out Of Paper - No Paper Out Fault Is Reported

    Chapter 3: Troubleshooting 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.

  • Page 62: Paper Handling Problems

    T6090 Maintenance Manual Paper Handling Problems The following table lists the few paper handling problems you may encounter along with corrective actions you may take. Table 3–2. Paper/Printing Corrective Action Problem Cause Corrective Action The paper holes are wider than Horizontal paper tension is too tight.

  • Page 63: T6090 Engine Controller To Hammer Bank Cba Cables

    Chapter 3: Troubleshooting T6090 Engine Controller To Hammer Bank CBA Cables Table 3–3. Connector Pinouts Common = 48V Power P703 P704 Function Function Function Function Hammer 33 Hammer 32 Hammer 66 Hammer 65 Hammer 31 Common Hammer 64 Common Hammer 30...
  • Page 64 T6090 Maintenance Manual Table 3–4. P703 & P704 Connector to Hammer Bank CBA Continuity Check Points 3–18...

  • Page 65: Table 3–5. T6090 Hammer Coil/Module Troubleshooting

    Chapter 3: Troubleshooting Table 3–5. T6090 Hammer Coil/Module Troubleshooting Print Hammer Hammer Print Hammer Hammer Columns Coil Module Driver Columns Coil Module Driver 1 & 2 67 & 68 3 & 4 69 & 70 5 & 6 71 & 72 7 &...

  • Page 66: Troubleshooting The Hammer Driver Transistors

    T6090 Maintenance Manual 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 compo- nents should be checked along with the other components involved in the function.

  • Page 67: Table 3–6. J703 Hammer Driver Pinouts

    Chapter 3: Troubleshooting Table 3–6. J703 Hammer Driver Pinouts Circuit Side of Engine Controller CBA Pin Numbers Top Of CBA 1 2 3 4 5 6 7 8 9 10 11 12 J703 3–21...
  • Page 68 T6090 Maintenance Manual Table 3–6. J704 Hammer Driver Pinouts Circuit Side of Engine Controller CBA Pin Numbers Top Of CBA 1 2 3 4 5 6 7 8 9 10 11 12 J704 3–22...
  • Page 69 hapter Removal & Reinstallation Procedures...

  • Page 71: Chapter 4. Removal And Reinstallation Procedures

    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 –...

  • Page 72: Procedure 1 - The Printer Lid

    T6090 Maintenance Manual 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.

  • Page 73: Figure 4–2. Removing The Lid

    Chapter 4: Removal and Reinstallation Procedures 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 Hinges Figure 4–2.

  • Page 74: Procedure 2 - The Control Panel

    T6090 Maintenance Manual Procedure 2 – The Control Panel Before beginning this procedure, turn the printer off and disconnect the power cable. 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.

  • Page 75: Figure 4–4. Reinstalling The Control Panel

    Chapter 4: Removal and Reinstallation Procedures Reinstalling STEP 1. If the Control Panel was removed from the printer, plug the new panel into the Engine Control- ler CBA (J801). Then advance to STEP 2. If the Control Panel is still connected to the Engine Controller CBA and is lying in the inside of the printer, lift it out of the opening gently.

  • Page 76: Procedure 3 - The Right End Cover

    T6090 Maintenance Manual Procedure 3 – The Right End Cover Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Printer Control Panel. (See Procedure 2) STEP 2. Remove the screws at positions 1 and 2.

  • Page 77: Figure 4–6. Reinstalling The Right End Cover

    Chapter 4: Removal and Reinstallation Procedures Place in front of printer lip Figure 4–6. Reinstalling the Right End Cover STEP 3. It may be a tight fit and require considerable downward pressure to get the cover to set down completely. Before pressing down, make sure that all cables are clear of the contact area between the cover and printer.

  • Page 78: Procedure 4 - The Engint Controller Cba

    T6090 Maintenance Manual 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.
  • Page 79 Chapter 4: Removal and Reinstallation Procedures 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.

  • Page 80: Procedure 5 - The Personality Module Cba And Enclosure

    T6090 Maintenance Manual Procedure 5 – The Personality Module CBA and Enclosure Before beginning this procedure, turn the printer off and disconnect the power cable. 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.

  • Page 81: Figure 4–9. Removing The Personality Module Enclosure

    Chapter 4: Removal and Reinstallation Procedures 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.

  • Page 82: Procedure 6 - The Fan Motor Assembly

    T6090 Maintenance Manual Procedure 6 –The Fan Assembly Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Right End Cover (see Procedure 3). STEP 2. Remove the Engine Controller CBA (see Procedure 4).

  • Page 83: Procedure 7 - Power Supply

    Chapter 4: Removal and Reinstallation Procedures Procedure 7 – Power Supply Before beginning this procedure, turn the printer off and disconnect the power cable. 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.

  • Page 84: Figure 4–12. Removing The Power Supply

    T6090 Maintenance Manual 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.

  • Page 85: Procedure 8 - The Left End Cover

    Chapter 4: Removal and Reinstallation Procedures Procedure 8 – The Left End Cover Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the printer lid (see Procedure 1). STEP 2. Remove the screws in locations 1 and 2. STEP 3.

  • Page 86: Procedure 9 - The Ribbon Platform

    T6090 Maintenance Manual Procedure 9 – The Ribbon Platform Before beginning this procedure, turn the printer off and disconnect the power cable. 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).

  • Page 87: Figure 4–15. Removing The Ribbon Platform

    Chapter 4: Removal and Reinstallation Procedures 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 4–15.

  • Page 88: Procedure 10 - The Ribbon Motor

    T6090 Maintenance Manual Procedure 10 – The Ribbon Motor Before beginning this procedure, turn the printer off and disconnect the power cable. 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.

  • Page 89: Procedure 11 - The Hammer Bank

    Chapter 4: Removal and Reinstallation Procedures Procedure 11 – The Hammer Bank Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Printer lid and the Control Panel (see Procedures 1 and 2). STEP 2.

  • Page 90: Figure 4–18. Removing The Hammer Bank

    T6090 Maintenance Manual 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...

  • Page 91: Procedure 12 - The Ribbon Shield

    Chapter 4: Removal and Reinstallation Procedures Procedure 12 – The Ribbon Shield Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Left End Cover (see Procedure 8). STEP 2. Remove the Right End Cover (see Procedure 3). STEP 3.
  • Page 92 T6090 Maintenance Manual 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.

  • Page 93: Procedure 13 - Hammer Bank Air Duct

    Chapter 4: Removal and Reinstallation Procedures Procedure 13 – Hammer Bank Air Duct Before beginning this procedure, turn the printer off and disconnect the power cable. Removal STEP 1. Remove the Hammer Bank (see Procedure 11). STEP 2 Remove the cable clamp bracket and screw. STEP 3.

  • Page 94: Procedure 14 - Hammer Module

    T6090 Maintenance Manual Procedure 14 – Hammer Module Before beginning this procedure, turn the printer off and disconnect the power cable. 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).

  • Page 95: Figure 4–22. Using The Hammer Alignment Tool

    Chapter 4: Removal and Reinstallation Procedures 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. 6-Pack Hammer AllignmentTool Hammer...

  • Page 96: Procedure 15 - The Shuttle Assembly

    T6090 Maintenance Manual Procedure 15 – The Shuttle Assembly Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Right End Cover (see Procedure 3). STEP 2. Remove the Ribbon Platform (see Procedure 9).

  • Page 97: Procedure 16 - The Platen

    Chapter 4: Removal and Reinstallation Procedures Procedure 16 – The Platen Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Hammer Bank (see Procedure 11). STEP 2. Remove the Left End Cover (see Procedure 8). STEP 3.
  • Page 98 T6090 Maintenance Manual 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.

  • Page 99: Procedure 17 - The Platen Open Sensor

    Chapter 4: Removal and Reinstallation Procedures Procedure 17 – The Platen Open Sensor Before beginning this procedure, turn the printer off and disconnect the power cable. 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.

  • Page 100: Procedure 18 - The Shuttle Motor

    T6090 Maintenance Manual Procedure 18 – The Shuttle Motor Before beginning this procedure, turn the printer off and disconnect the power cable. 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.

  • Page 101: Figure 4–28. Reinstalling Shuttle Motor Pulley

    Chapter 4: Removal and Reinstallation Procedures 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.

  • Page 102: Procedure 19 - Shuttle Motion Sensor

    T6090 Maintenance Manual 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.
  • Page 103 Chapter 4: Removal and Reinstallation Procedures 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.

  • Page 104: Procedure 20 -The Shuttle Drive Belt

    T6090 Maintenance Manual Procedure 20 —The Shuttle Drive Belt Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Printer Control Panel (see Procedure 2) and place it in the bottom of the printer.

  • Page 105: Procedure 21 - The Paper Advance Motor

    Chapter 4: Removal and Reinstallation Procedures Procedure 21 – The Paper Advance Motor Before beginning this procedure, turn the printer off and disconnect the power cable. 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 4–11).

  • Page 106: Figure 4–32. Paper Advance Motor Assembly

    T6090 Maintenance Manual 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...

  • Page 107: Procedure 22 - Tractor Belt Phasing/Paper Drive Belt Adjustment

    Chapter 4: Removal and Reinstallation Procedures 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.

  • Page 108: Figure 4–35. Paper Drive Belt Adjustment

    T6090 Maintenance Manual 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).

  • Page 109: Procedure 23 - Upper Tractor Assembly

    Chapter 4: Removal and Reinstallation Procedures Procedure 23 – Upper Tractor Assembly Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Right End Cover (see Procedure 3). STEP 2. Remove the Left End Cover (see Procedure 8). STEP 3.

  • Page 110: Figure 4–37. Upper Tractor Alignment

    T6090 Maintenance Manual 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.

  • Page 111: Procedure 24 - Lower Tractor Assembly

    Chapter 4: Removal and Reinstallation Procedures Procedure 24 – Lower Tractor Assembly Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove Right End Cover (see Procedure 3). STEP 2. Remove Left End Cover (see Procedure 8). STEP 3.

  • Page 112: Figure 4–39. Lower Tractor Alignment

    T6090 Maintenance Manual 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.

  • Page 113: Procedure 25 - Platen Gap Adjustment Procedure

    Chapter 4: Removal and Reinstallation Procedures 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, don’t force it, proceed to step 2.
  • Page 115 ppendix Schematics...

  • Page 117: Appendix A. Schematics

    Appendix A: Schematics T6090 Engine Controller CBA...
  • Page 118 T6090 Maintenance Manual...
  • Page 119 Appendix A: Schematics...
  • Page 120 T6090 Maintenance Manual...
  • Page 121 Appendix A: Schematics...

  • Page 122: Ser/Par Personality Module Cba

    T6090 Maintenance Manual T6090 Ser/Par Personality Module CBA...
  • Page 123 Appendix A: Schematics...
  • Page 124 T6090 Maintenance Manual...
  • Page 125 Appendix A: Schematics...
  • Page 126 T6090 Maintenance Manual A-10...

  • Page 127: Fourplex Personality Module Cba

    Appendix A: Schematics T6090 FourPlex Personality Module CBA A-11...
  • Page 128 T6090 Maintenance Manual A-12...
  • Page 129 Appendix A: Schematics A-13...
  • Page 130 T6090 Maintenance Manual A-14...
  • Page 131 Appendix A: Schematics A-15...
  • Page 133 ppendix Recommended Spare Parts, Illustrated Parts Breakdown and Components Lists...

  • Page 135: Recommended Spare Parts List

    Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists Recommended Spare Parts List PART NAME PART NO. Power Supply 081153 Personality CBA (Ser/Par) 080901 Personality CBA (4 Plex) 081086 Personality CBA (Lan) 080920 Engine Controller CBA 080873 Control Panel Assembly 075123 Hammer Bank Assembly 081144...

  • Page 136: Cover Set

    Maintenance Manual Cover Set – T6090...
  • Page 137 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists...

  • Page 138: Basic Assembly

    Maintenance Manual Basic Assembly – T6090...
  • Page 139 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists...
  • Page 140 Maintenance Manual Print Mechanism – T6090...
  • Page 141 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists...

  • Page 142: Paper Movement System

    Maintenance Manual Paper Movement System – T6090...
  • Page 143 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists...

  • Page 144: Hammer Bank And Electronics

    Maintenance Manual Hammer Bank and Electronics Assembly – T6090 B-10...
  • Page 145 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists B-11...

  • Page 146: Engine Controller

    Maintenance Manual Engine Controller – T6090 B-12...
  • Page 147 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists B-13...
  • Page 148 Maintenance Manual B-14...
  • Page 149 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists This page intentionally left blank B-15...

  • Page 150: Serial/Parallel Personality Modules (080900 & 080898 )

    Maintenance Manual Serial/Parallel Personality Modules (080900 & 080898 ) B-16...
  • Page 151 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists B-17...
  • Page 152 Maintenance Manual B-18...
  • Page 153 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists This page intentionally left blank B-19...

  • Page 154: Fourplex Personality Module (080750 )

    Maintenance Manual FourPlex Personality Module (080750 ) B-20...
  • Page 155 Appendix B: Recommended Spare Parts, Illustrated Parts Breakdowns, and Component Lists B-21...
  • Page 156 Maintenance Manual B-22...

  • Page 157: Appendix C. Downloading Printer Firmware

    ppendix Downloading Printer Firmware...

  • Page 159: Firmware Update Procedure

    STEP 3. Power up the printer while holding down the following four keys on the control panel: VIEW Key, LINE FEED Key, 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.

  • Page 161: Supplements

    Supplement Hammer Module Replacement & Realignment...
  • Page 163 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.
  • Page 164 Supplement Hammer Module Before beginning this procedure, turn the printer off and disconnect the power cable. Removing STEP 1. Remove the Hammer Bank from the printer (see Procedure 11, Maintenance Manual). STEP 2. Remove the Ribbon Shield from the Hammer Bank (see Procedure 12, Maintenance Manual).
  • Page 165 Supplement to Manual 080933 Shim Reinstalling Spacer(s) STEP 1. Install shim spacers underneath the spares replacement modules as Hammer Bank Carriage appropriate. Two .0015" shim spacers Hammer are included in each module kit Module Module (#081152). After the screws for the Mounting module are tightened, check the Screws (2)
  • Page 166 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).

  • Page 167: T6091 Printer

    Supplement T6091 Printer...
  • Page 169 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.
  • Page 170 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 Main- tenance 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.
  • Page 171 Supplement to Manual 080933 T6091 Assembly Diagram...
  • Page 172 T6090 Maintenance Manual Supplement Fan Assembly Diagram Figure 2. Fan Assembly Diagram...
  • Page 173 Supplement to Manual 080933 Removal and Reinstallation Procedures The procedures in this section are specific to the cabinet of the T6091. For any Proce- dure numbers listed, go to that appropriate procedure in the Maintenance Manual. Procedure 1B — Top Cover Opening for Service Access The cover assembly of the T6091 CANNOT be removed.
  • Page 174 T6090 Maintenance Manual Supplement 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. Turn the power off. Step 2. Follow Procedure 1B (on the previous page) for opening the cover an additional amount.

  • Page 175: T6065 Printer

    Supplement T6065 Printer...
  • Page 177 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.

  • Page 178: Main Power

    T6065 Maintenance Manual Supplement 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.
  • Page 179 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.

  • Page 180: Print Speeds

    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 T6090 Figure 2: Maximum Character Print Speeds...
  • Page 181 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 T6090 Figure 3: Maximum Plot Speeds...
  • Page 182 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) ................
  • Page 183 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 ............
  • Page 184 T6065 Maintenance Manual Supplement Blank Page...

  • Page 185: T6100/T6101 Printers

    Supplement T6100/T6101 Printer...
  • Page 187 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...
  • Page 188 T6100/T6101 Supplement 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.
  • Page 189 T6100/T6101 Supplement Engine Controller...
  • Page 190 T6100/T6101 Supplement Engine Controller...
  • Page 191 T6100/T6101 Supplement Engine Controller...
  • Page 192 T6100/T6101 Supplement Engine Controller...
  • Page 193 T6100/T6101 Supplement...
  • Page 194 T6100/T6101 Supplement...
  • Page 195 T6100/T6101 Supplement...
  • Page 196 T6100/T6101 Supplement...
  • Page 197 T6100/T6101 Supplement...
  • Page 198 T6100/T6101 Supplement...
  • Page 199 T6100/T6101 Supplement...
  • Page 200 T6100/T6101 Supplement Phasing Bracket Assembly Lower Idler Assembly...
  • Page 201 Information: 1-425-251-5500 Fax: 1-425-251-5520 Germany http://www.tally.com Tally GmbH Postfach 29 69 Asia D-89019 Ulm/Donau. Tally AMT Printers Pte. Ltd., Germany 63, Hillview Avenue Telephone: +49-7308-800 No. 08/22, Lam Soon Indutrial Bldg. Fax: +49-7308-85903 Singapore 669569 http://www.tally.de Tel.: (65) 760-8833...

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