TallyGenicom 6600 Series Maintenance Manual
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TallyGenicom 6600 Series Maintenance Manual

6600 series
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Table of Contents

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See also: User Manual , Quick Reference Manual
6600 Series Printers
Maintenance Manual
Approved Final
May 19, 2011

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Summary of Contents for TallyGenicom 6600 Series

  • Page 1 6600 Series Printers Maintenance Manual Approved Final May 19, 2011...
  • Page 3 6600 Series Printers Maintenance Manual...

  • Page 4: Trademark Acknowledgements

    Trademark Acknowledgements ANSI is a registered trademark of American National Standards Institute, Inc. Belkin is a registered trademark of Belkin Corporation. Centronics is a registered trademark of Genicom Corporation. Chatillon is a trademark of John Chatillon & Sons, Inc. Code V is a trademark of Quality Micro Systems. Dataproducts is a registered trademark of Dataproducts Corporation.
  • Page 5 Warranty And Copyright Information Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not be held responsible for errors contained herein or any omissions from this material or for any damages, whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution, performance or use of this material.

  • Page 6: Communication Notices

    Communication Notices Federal Communications Commission (FCC) Statement This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Fules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.

  • Page 7: Industry Canada Compliance Statement

    Properly shielded and grounded cables and connectors must be used in order to reduce the potential for causing interference to radio and TV communications and to other electrical or electronic equipment. Such cables and connectors are available from Printronix authorized dealers. Printronix cannot accept responsibility for any interference caused by using other than recommended cables and connectors.

  • Page 8: German Conformity Statement

    Australia/New Zealand Attention: This is a Class A Product. In a domestic enviroment this product may cause radio interference in which case the user may be required to take adequate measures. China Declaration: This is a Case A Product. In a domestic environment this product may cause radio interference, in which case the user may be required to take practical actions.
  • Page 9 EN 55024: Begrenzung Werte für Gebrauch in bevölkerten Bereiche, kommerziellen und Industriegebieten sind innen Übereinstimmung mit den spezifizierten Anforderungen Hinsichtlich Störfreiheit. Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte, wie in den Handbüchern angegeben, zu installieren und zu betreiben. European Union (EC) Electromagnetic Compatibility Directives This product conforms to the protection requirements of EC Council Directive...

  • Page 11: Table Of Contents

    Table of Contents 1 Maintenance Overview ......... 17 TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series ....17 Order the Correct Spares ..............18 How to Identify a 6600 Cartridge Ribbon Printer......19 Zero Tear Pedestal (ZTP) Printers ...........19 Printer Configuration Code...............20 Forms Handling ................20 Important Maintenance Notes..............21 Notices .....................21 About this Manual ...................22...
  • Page 12 Table of Contents 3 Troubleshooting ............ 43 Introduction ..................... 43 Troubleshooting Aids ................43 Start Here....................44 Troubleshooting Display Messages............45 List of Messages ................46 Troubleshooting Other Symptoms ............111 General Symptom List..............112 Communications Failures ..............134 Diagnostic Printer Tests................ 136 Selecting And Running Diagnostic Printer Tests ......
  • Page 13 Table of Contents Tractor Belt Tension Adjustment ............181 Shuttle Electrical Short Check ..............182 Hammer Bank Power Cable Shorts Test..........183 Cable Shorts Test .................184 Main Wire Harness Test Diagnostic .............186 Power Supply Operational Check............187 5 Replacement Procedures ........191 Organization of this Chapter ..............191 Replacement Procedures ..............191 List of Removal / Installation Procedures ........191 Belt, Paper Feed Timing ..............193...
  • Page 14 Table of Contents Shuttle Frame Assembly ..............239 Spring, Extension, Hammer Bank ..........241 Switch Assembly, Paper Detector ..........242 Switch Assembly, Platen Interlock ..........243 Tractor (L/R) ................... 244 Weld Sensor................... 244 6 Illustrated Parts Breakdown ........ 245 Organization of this Chapter ..............245 Illustrations of Printer Components ..........245 7 Principles Of Operation........
  • Page 15 Table of Contents D SureStak™ Power Stacker ........ 353 Contents ....................353 Introduction ...................354 Stacker Operation.................354 Stacker Problems .................359 Stacker First Inspection..............359 Stacker Confidence Check.............360 Stacker Motor Check..............361 Removing the Power Stacker ...............364 Installing the Power Stacker ..............370 Replacing the Constant Force Spring...........382 Replacing the Timing Belts ..............384 Replacing the Roller Drive Shaft............387 Illustrated Parts Breakdown..............390...
  • Page 16 Table of Contents Replacement Procedures ..............421 List of Removal / Installation Procedures ........421 Belt, Paper Feed Timing ..............422 Control Panel Assembly ..............423 Cover Assembly, Top, Pedestal Models ........423 Paper Feed Motor ................424 Paper Guide Leaf, Center .............. 425 Paper Guide Leaf, Front..............

  • Page 17: Maintenance Overview

    Maintenance Overview ® TallyGenicom 6600 Cartridge Ribbon Printer (CRP) Series ® TallyGenicom has been the global leader in industrial printing solutions for over 30 years, earning a reputation for designing and manufacturing leading edge products and delivering them to market with unsurpassed service and support.

  • Page 18: Order The Correct Spares

    Chapter TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series Pedestal • The pedestal model has a clamshell design that allows easy access to all controls, providing faster ribbon replacements and easier paper loading. • Oversized casters are standard making movement easy. •...

  • Page 19: How To Identify A 6600 Cartridge Ribbon Printer

    How to Identify a 6600 Cartridge Ribbon Printer How to Identify a 6600 Cartridge Ribbon Printer A 6600 printer has a model number logo and ribbon cartridge logo on the printer front cover. The model number is an alphanumeric code that identifies the printer type, its housing, and its maximum rated print speed.

  • Page 20: Printer Configuration Code

    Chapter TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series Printer Configuration Code Every printer has a configuration code which specifies the printer’s cabinet type, controller board revision level, V8 ASIC revision level, and MECA ASIC revision level. The configuration code is included in the configuration printout. Figure 2 shows how to interpret the printer’s configuration code.

  • Page 21: Important Maintenance Notes

    Notices Table 1. Paper Stackers Used On Cabinet Models Passive Front Power Fixed Paper Printer Paper Access Paper Fence Stacker Stacker Stacker 6605Q Standard Option Option Option 6610Q Not Used Standard Option Option 6615Q Not Used Standard Option Option 6620Q Not Used Standard Option...

  • Page 22: About This Manual

    • 6600 Series Printers Emulations Applications Manual, Volume 1 Defines printer emulations. • 6600 Series Printers Fonts and Character Sets Applications Manual, Volume 3 Defines printer fonts and character sets. • 6600 Series Printers Graphics Languages Applications Manual, Volume 4 Defines Code V, PGL, and MT660 IG printer graphics languages.

  • Page 23: Printing Conventions In This Manual

    Printing Conventions in this Manual Printing Conventions in this Manual Control panel keys and indicators are highlighted in UPPERCASE BOLD PRINT. Example: Press the CLEAR key, then press the ONLINE key. Messages that appear on the LCD (Liquid Crystal Display) are set off by quotation marks (“...

  • Page 24: Hinweise Zur Sicherheit

    Chapter Hinweise zur Sicherheit Hinweise zur Sicherheit VORSICHT Bevor Sie anfällige Wartungsarbeiten durchführen, müssen Sie zuerst immer das Netzkabel aus der Steckdose ziehen. Wird das Netzkabel nicht herausgezogen, können Verletzungen oder Geräteschäden entstehen. Falls die Wartungsarbeit Stromzufuhr erfordert, wird im Wartungsablauf darauf hingewiesen.

  • Page 25: Controls And Indicators

    Electrical Controls Controls and Indicators Electrical Controls Switch or Active Active Function Indicator Online Offline Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker. Status Indicator On when the printer is online, off when the printer is offline. Flashes to indicate a fault or warning.
  • Page 26 Chapter Controls and Indicators Switch or Active Active Function Indicator Online Offline MENU/ENTER While in offline mode, this key allows entry into the configuration menus. When navigating the configuration menus, MENU/ENTER selects the currently displayed option value as the active value. An asterisk (*) appears next to the active value on the display.
  • Page 27 Electrical Controls Rotated 180 Degrees (Off) (On) Power Switch Message Status Circular Pad Display Indicator VIEW 184071 REV B ONLINE CONFIG ONLINE MENU/ENTER CLEAR Figure 3. Electrical Controls...

  • Page 28: Mechanical Controls

    Chapter Controls and Indicators Mechanical Controls Control or Indicator Function Paper Supports Help prevent paper jams by supporting inner sections of paper. They are positioned manually by sliding them along the tractor shafts. Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. This lever must be fully opened (raised) to load paper, unload paper, and move paper with the vertical position knob.
  • Page 29 Mechanical Controls Ribbon Ribbon Cartridge Tab (2) Ribbon Tension Knob Tractor (2) Blue Tractor Lock (2) Splined Shaft Hammer Bank Cover and Paper Ribbon Mask Support (2) Slot (2) Vertical Position Knob Platen Lever Platen Stop Ribbon Cartridge Interface 183871 REV A Air Shroud Assembly Figure 4.

  • Page 30: Tools And Test Equipment

    Chapter Tools and Test Equipment Tools and Test Equipment For field level maintenance of the printer, you will need these tools: Adapter, 1/4 in. hex to 1/4 in. square, Utica® HW-18 Alcohol, anhydrous Allen Wrench, 1/16 inch Allen Wrench, 3/32 inch Allen Wrench, 5/32 inch Allen Wrench, 7/64 inch Allen Wrench, 5/64 inch...

  • Page 31: Plugging In The Printer

    Mechanical Controls Plugging in the Printer Power Cord Requirements In compliance with international safety standards, a 6600 printer is equipped with a three-pronged electrical plug on the power cord. When this power cord is plugged into a correctly wired AC power outlet, the ground conductor ensures that the printer chassis is at ground (earth) electrical potential.

  • Page 32: Tallygenicom Customer Support Center

    Chapter TallyGenicom Customer Support Center TallyGenicom Customer Support Center The TallyGenicom Customer Support Center offers technical support with: • Installation • Configuration and setup • Loading supplies and operating the printer • Specifications of the proper ribbons, forms, and paper •...

  • Page 33: Corporate Offices

    Mechanical Controls Corporate Offices Printronix, Inc. 14600 Myford Road P.O. Box 19559 Irvine, CA 92623-9559 Phone: (714) 368-2300 Fax: (714) 368-2600 Printronix, Inc. Nederland BV P.O. Box 163, Nieuweweg 283 NL-6600 Ad Wijchen The Netherlands Phone: (31) 24 6489489 Fax: (31) 24 6489499 Printronix Schweiz GmbH 42 Changi South Street 1 Changi South Industrial Estate...
  • Page 34 Chapter Maintenance Training for TallyGenicom Products...

  • Page 35: Preventive Maintenance

    Preventive Maintenance Cleaning the Printer The printer is designed to require very little maintenance. Aside from normal replenishment of paper and ribbons, the only preventive maintenance necessary is periodic cleaning. Clean the printer every six months or after every 1000 hours of operation, whichever occurs first. If the printer is located in a dusty area or is used for heavy duty printing, clean it more often.

  • Page 36: Cleaning The Interior

    Chapter Cleaning the Printer Cleaning the Interior 1. Power off the printer and unplug the printer power cord. 2. Open the printer cover. 3. Fully raise the platen lever. 4. Unload the paper. 5. Remove the ribbon cartridge. 6. Lift the ribbon out of the ribbon path. 7.
  • Page 37 Cleaning the Interior Ribbon Ribbon Cartridge Ribbon Tension Knob Ribbon Turn Tab (2) Direction Arrow Tractor (2) Blue Tractor Lock (2) Hammer Bank Splined Shaft Cover and Paper Ribbon Mask Support (2) Slot (2) Base Casting Vertical Position Knob Platen Lever Platen Stop Ribbon Cartridge Shuttle Cover...

  • Page 38: Cleaning The Shuttle Frame Assembly

    Chapter Cleaning the Shuttle Frame Assembly Cleaning the Shuttle Frame Assembly NOTE: To help steady the shuttle, be sure to obtain a shuttle stabilizer tool, P/N 255447-001 (see Figure 37 on page 239). 1. Prepare the printer for maintenance (page 154). 2.
  • Page 39 Cleaning the Interior 15. Place the shuttle so that the base sits flat on the work surface. Use the brush provided to remove as much debris as possible from the hammer tips, brushing in a downward direction (Figure 6.). Rotate the shuttle 90° away from you and repeat the brushing this time working from the center of the shuttle outward towards both ends.
  • Page 40 Chapter Cleaning the Shuttle Frame Assembly 22. For a 6600 nonflat product, reinstall the frets in the appropriate locations using a wood or plastic tool to seat them against the locating pins. For 6600 flat shuttles use the appropriate alignment tool from Table A to align the frets in the appropriate location and torque in place using a 14 inch pound driver and #10 Torx bit.

  • Page 41: Cleaning The Card Cage Fan Assembly

    Cleaning the Interior Cleaning the Card Cage Fan Assembly 1. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint. (Figure 7.) 3.
  • Page 42 Chapter Cleaning the Card Cage Fan Assembly...

  • Page 43: Troubleshooting

    Troubleshooting Introduction This chapter lists fault messages and general symptoms, and provides procedures for troubleshooting printer malfunctions. NOTE: Because you must operate the printer to check its performance and sometimes you may have to reconfigure it, always have the User’s Manual handy when you troubleshoot.

  • Page 44: Start Here

    Chapter Start Here... Start Here... Are you here because of an Go to Troubleshooting Display error message? Messages, page 45. Power on the printer and observe the control panel for the following sequence of events (retry as required): Did the status 1.

  • Page 45: Troubleshooting Display Messages

    Troubleshooting Display Messages WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to do so could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 46: List Of Messages

    Chapter Troubleshooting Display Messages List of Messages Find the message in the Message List below and follow the suggested procedure. After correcting an error, press the CLEAR key to clear the message and place the printer in the offline state. If an error is not cleared, the printer will try to print again but will display the error message until the error is cleared.
  • Page 47 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution 15V CTL FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print job again. If the message appears, remove the hammer bank logic cable, inspect it for damage, and test it for continuity.
  • Page 48 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution 23.5V CTL FAIL* 23.5 Volt Controller Failed: a 1. Cycle Power. Run the print job voltage failure on the again. If the message appears, controller board. download the emulation software again (page 169).
  • Page 49 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution 48V CHECK* 48 Volt Power Failed: an 1. Power off the printer. Remove the internal power failure. paper path or pedestal top cover. Check that power supply connector P101 is fully seated in connector J101 on the controller board.
  • Page 50 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution 48V PWR FAIL* 48 Volt Power Failed: an 1. Power off the printer. Remove the internal power failure. paper path or pedestal top cover. Check that power supply connector P101 is fully seated in connector J101 on the controller board.
  • Page 51 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution B01 STATUS: 8245 Status message: printer No action required. SDRAM TEST 32MB boot-up routines are testing SDRAM. B02 STATUS: Status message informing No action required. SDRAM PASSED the operator that the printer finished testing SDRAM.
  • Page 52 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution B20 STATUS: 00% Status message informing No action required. DOWNLOAD MODE the operator that software is being downloaded through the printer’s parallel port using the three-key download activation (page 173).
  • Page 53 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution B35 STATUS: Status message: the DC on Cycle power. If the message appears WAITING FOR EC the controller board is again, replace the controller board. STATUS waiting for communication Record the message and return it with the EC.
  • Page 54 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution B43 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message TOO MANY BANKS* tests detect incorrect appears again, reseat the SDRAM. SDRAM DIMM. 2. Power on the printer. If the message appears, install a new SDRAM DIMM of the correct type and size.
  • Page 55 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution B46 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message HAS MIXED SIZES* tests detect incorrect appears again, reseat the SDRAM. SDRAM DIMM. 2. Power on the printer. If the message appears, install a new SDRAM DIMM of the correct type and size.
  • Page 56 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution B50 ERROR: SDRAM Printer boot initialization 1. Cycle power. If the message LOGIC COMB tests detect incorrect appears again, reseat the BANKS* SDRAM. SDRAM DIMM. 2. Power on the printer. If the message appears, install a new SDRAM DIMM of the correct type and size.
  • Page 57 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution B54 ERROR: SDA The SDRAM or a PCI card is 1. Cycle power. If the message LINE STUCK LOW shorting out the serial data appears again, reseat the bus on the controller board.
  • Page 58 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution CRTG INCOMPAT The cartridge board being 1. Press the CLEAR key, open the Use correct RBN used is not compatible with platen, or cycle power to change the software in the printer.
  • Page 59 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution CLEAR PAPER JAM Paper jam. 1. Inspect the paper path for jams. Clear jams. Load paper. 2. Press FF several times and check that forms feed without erratic motion, noise, or pin-hole damage.
  • Page 60 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution CLEAR PAPER JAM 9. Inspect the tractors and tractor (continued) door springs for damage, excessive wear, and equal door closing tension. If either tractor is worn, damaged, or exhibits uneven door closing tension, replace both tractor assemblies 10.
  • Page 61 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution CLOSE PLATEN The forms thickness lever is 1. Load paper. Close the forms open. thickness lever. 2. Power off the printer. Remove the paper path or pedestal top cover. Disconnect connector P107 from the controller board.
  • Page 62 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution CTL VOLT FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print job 15 V failure on the controller again. If the message appears, board. download the emulation software again (page 169).
  • Page 63 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution DP FIFO Busy* There is a timing problem in 1. Cycle Power. Run the print job the Engine Controller again. If the message appears, firmware. download the emulation software again (page 169).
  • Page 64 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E01B TYPE 0x60 An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 65 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E03C DSI BAT PL An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 66 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E03G DSI ECXIWX An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 67 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E04C ISI PROTEC An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program. access the exception menu and record the displayed messages (page 146).
  • Page 68 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E12 SYSTEM CALL An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 69 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E18 DSTORE MISS An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program. access the exception menu and record the displayed messages (page 146).
  • Page 70 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E31A EVENT O BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 71 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E31E EVENT 4 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 72 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E32A CND 0 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 73 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E32E CND 4 BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 74 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution E33 WRITE BP An illegal or unsupported 1. Cycle Power. Run the print job. If See User Manual instruction was attempted in the message appears again, the application program.
  • Page 75 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution ERROR: CPLD NOT The Complex Programmable Cycle power. If the message appears PROGRAMMED Logic Device (CPLD) on the again, replace the controller board. controller board is not Record the message and return it programmed.
  • Page 76 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution ERROR: EC Where XXXX is a number 1. Power off the printer. Remove the STOPPED from 0000 to 0010. The flash memory SIMM and SDRAM AT STATE XXXX Engine Controller has DIMM.
  • Page 77 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution ERROR: LOCKED Where nnnnnnnnnnnnnnnn 1. Remove the SPX from the Debug is the serial number of the Port. nnnnnnnnnnnnnnnn printer’s security key. The 2. Cycle printer power. SPX gets “locked”...
  • Page 78 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution ERROR: SECURITY The security key is not 1. Check the security key at KEY NOT DETECTED present or has failed. connector J9 on the controller board. If the key is absent, install the correct key.
  • Page 79 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution ETHERNET Status message indicating No action required. DETECTED that the PrintNet ethernet interface has established communication. Status message that No action required. ETHERNET INITIALIZING indicates that the internal Network Interface Card is processing the boot procedure.
  • Page 80 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution EXHAUST FAN FLT Exhaust Fan Fault. Sensors 1. Cycle power. If the message cannot detect current in the appears, press CLEAR. fan circuit. 2. Check that the exhaust fan is connected to exhaust fan cable NOTE: For cabinet models connector J307.
  • Page 81 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution FIRMWARE ERROR Application software tried to 1. Cycle power. Run the print job. If perform an illegal printer the message appears, download function or damaged the emulation software again memory is detected on the (page 169).
  • Page 82 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution H01: PCI J12 The controller board is not 1. Cycle power. If the message See User Manual communicating with the PCI appears, power down and reseat card in PCI slot J12.
  • Page 83 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution <Online, etc..> This is a status message, 1. Advise the user to move the Half Speed Mode not an operational state. The printer to cooler, cleaner location. controller samples the 2.
  • Page 84 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution HAMMER COIL BAD Hammer coil(s) number #, #, 1. Cycle power. If the message #, #, #, #, ... etc. etc. failed the current test at appears, replace the shuttle power-up.
  • Page 85 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution HMR BANK FAN FLT Hammer Bank Fan Fault. 1. Cycle power. If the message Sensors cannot detect appears, press CLEAR. If the current in the fan circuit. message does not clear, go to step 2.
  • Page 86 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution ILLGL OPR ACCSS* Illegal Operand Accessed. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again (page 169).
  • Page 87 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution INTERRUPT UNUSED This message is generated 1. Cycle power. If this message VECTOR 00 when the controller board occurred once and never again, gets an interrupt it does not you can ignore it.
  • Page 88 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution LOAD PAPER The printer is out of paper. 1. Load paper. Press CLEAR. If message does not clear, go to the next step. 2. Check for black or colored backing on the paper being used in printer.
  • Page 89 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution LOADING PROGRAM The printer has deleted the No action required. INTO FLASH previous program from flash memory and is loading the new program into flash memory. NEW SPX DETECTED The printer detects an SPX Press the ENTER key.
  • Page 90 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution OLD RIBBON The sensor detects a ribbon Install a new ribbon. Install New RBN that was previously declared to be at the end of its service life.
  • Page 91 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PAP FIFO OVERFL* Paper First In First Out 1. Cycle power. Run the print job Overflow. Firmware error on again. If the message appears, the controller board. download the emulation software again.
  • Page 92 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PAP FIFO UNDRFL* Paper First In First Out 1. Cycle power. Run the print job Underflow. Firmware error again. If the message appears, on the controller board. download the emulation software again.
  • Page 93 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PAP ILLGL ST* Paper Illegal State. Firmware 1. Cycle power. Run the print job error on the controller board. again. If the message appears, download the emulation software again.
  • Page 94 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PAP NOT SCHED* Paper Not Scheduled. The 1. Cycle power. Run the print job paper feed process is not again. If the message appears, scheduling on the controller download the emulation software board, and the printer cannot again.
  • Page 95 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PARITY ERROR The printed output may Verify that the printer matches contain random ? (question host serial configuration settings mark) characters. Make a for Data Protocol, Baud Rate, configuration printout.
  • Page 96 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PLEASE WAIT... Status message: the printer No action required. RESET IN finished loading the program PROGRESS into flash memory and is automatically resetting itself. POWER SAVER This is a status message.
  • Page 97 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PRINTER HOT This message indicates 1. Controller board sensors report internal temperatures over high temperatures on the board. 60° Celsius (140° Inspect printer environment for Fahrenheit). Print jobs will severity.
  • Page 98 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution PWR SUPP VOLT* Power Supply Voltage. The Replace the power supply board. power supply has failed. RIBBON AT END Integrated Print Install a new ribbon. POINT Management System Change Ribbon software has determined...
  • Page 99 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution RIBBON STALL The controller board does 1. Cycle power. If the message not detect ribbon movement. appears, power off the printer. 2. Check that the ribbon cartridge is properly set.
  • Page 100 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution SECURITY Security code of the security 1. Remove the paper path or VIOLATION key at J9 on the controller pedestal top cover. Check that board does not match the the security key is correctly code of the firmware on the installed.
  • Page 101 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution SHUTL INV CMD* Shuttle Invalid Command. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again.
  • Page 102 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution SHUTTLE JAM The shuttle is not moving or 1. Set the forms thickness lever to is moving at the wrong match the thickness of paper, but speed.
  • Page 103 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution SHUTTLE JAM 9. Run a print test. If the message (continued) appears, replace the controller board. Record the message and return it with the defective board. 10. Run a print test. If the message appears, replace the shuttle frame assembly.
  • Page 104 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution SPX FOUND, ERROR: The controller board does 1. Remove the SPX from the Debug KEY NOT DETECTED not have a security key. Port. 2. Power down the printer. 3.
  • Page 105 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution STACKER FAULT Two situations can trigger 1. Open the cabinet rear door and this message: check for obstructions preventing 1. The stacker elevator is elevator movement. Remove any obstructed while attempting obstructions.
  • Page 106 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution STACKER FULL Status message: the power 1. Unload the stacker. paper stacker is full. 2. Check the stacker limit switches. (See page 121.) If the limit switches are OK, go to the next step.
  • Page 107 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution STACKER JAM This message is triggered if 1. Open the cabinet rear door and there is paper inside the check for obstructions preventing throat of the stacker elevator movement.
  • Page 108 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution TCB CORRUPTED* Task Control Block 1. Cycle power. Run the print job Corrupted. Firmware error again. If the message appears, on the controller board. download the emulation software again.
  • Page 109 List of Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution UNDEF INTERRUPT* Undefined Interrupt. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again. 2.
  • Page 110 Chapter Troubleshooting Display Messages Table 3. 6600 Error Messages List Displayed Message Explanation Solution WAITING FOR This status message No action required. ETHERNET appears when the printer is ADAPTER first powered on if the optional ethernet NIC is installed. An ethernet adapter must be detected early in the power up sequence so the printer can...

  • Page 111: Troubleshooting Other Symptoms

    List of Messages Troubleshooting Other Symptoms WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to do so could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 112: General Symptom List

    Chapter Troubleshooting Other Symptoms General Symptom List Table 4 is a list of possible printer problems that are not indicated by messages on the LCD. Troubleshooting procedures are included for each symptom. If you encounter a problem that is not listed in Table 4, troubleshoot using the Half-Split Method described on page 111.
  • Page 113 General Symptom List Table 4. General Symptom List Symptom Solution Jams CLEAR PAPER JAM 1. Power off the printer. Remove the paper path or pedestal message instead of LOAD top cover. Remove the barrier shield (cabinet model) or PAPER when printer is out of the barrier shield and paper guide (pedestal model).
  • Page 114 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution CLEAR PAPER JAM 1. Power off the printer. Remove the paper path or pedestal message will not clear but top cover. Check that connector P106/PMD is fully seated paper moves in connector J106 on the controller board.

  • Page 115: Control Panel

    General Symptom List Table 4. General Symptom List Symptom Solution Control Panel Black squares on control 1. Power off the printer. Remove the paper path or pedestal panel top cover. Disconnect the control panel cable from the panel and from J110 on the controller board. Check continuity of the cable.
  • Page 116 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Control panel display shows 1. Remove the paper path or pedestal top cover. Check garbled, broken characters cable connections into the controller board. Make sure the control panel cable is seated in connector J110 on the controller board.

  • Page 117: Power Failures

    General Symptom List Table 4. General Symptom List Symptom Solution Power Failures No power, and control panel 1. Check that the AC power outlet has power. Restore AC blank, and card cage fan not power if necessary. running 2. Unplug the printer AC power cord from the printer (leave it plugged into the power outlet) and check for AC power at the printer end of the cord.

  • Page 118: Power Stacker

    Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Power Stacker Printer does not detect 1. Check that the power stacker is enabled under the Printer presence of power stacker Control menu. (Refer to the User’s Manual.) If the power stacker enable/disable option does not appear in the menu, go to the next step.
  • Page 119 General Symptom List Table 4. General Symptom List Symptom Solution Stacker “chatters” at upper or 1. Power off the printer. Unload paper. Open the rear cabinet lower limit door and check that stacker motion is not obstructed by the control panel cable or other obstruction. Remove obstruction or reroute the stacker control panel cable as necessary.
  • Page 120 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Stacker does not stack 1. Check for and remove obstructions preventing elevator properly movement. 2. Check for misaligned stacker rails. Adjust the stacker rails if they are not vertical and parallel. 3.
  • Page 121 General Symptom List Table 4. General Symptom List Symptom Solution Stacker limit switch check NOTE: This procedure tests the upper and lower limit switches on the right vertical rail. These magnetic switches are normally closed. You can quickly check their functionality with a small, powerful magnet. Right Vertical Rail You will usually be referred to this procedure from Upper Limit...
  • Page 122 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Stacker motor check NOTE: This procedure tests the four stacker motors and their cables. You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.

  • Page 123: Print Quality

    General Symptom List Table 4. General Symptom List Symptom Solution Print Quality Characters or dots are 1. Check the forms thickness lever: if it is set too loose or too missing, smeared, too light, tightly print quality can be affected. Set the forms or too dark.
  • Page 124 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Characters are compressed Adjust the tension of the tractor belts (page 181). on first line of a form Horizontal misalignment of 1. Take the printer offline and print a test pattern of All H’s. If characters (Dots or characters shift left or right from line to line, there might be characters move left or right...
  • Page 125 General Symptom List Table 4. General Symptom List Symptom Solution Randomly misplaced dots 1. Power off the printer. Check the platen gap. Adjust the platen gap if necessary. 2. Remove the paper guide assembly or pedestal top cover. On the left rear wall of the card cage, make sure the nut which secures the line filter ground line and the AC In Power Supply cable lead to the ground stud is tight.
  • Page 126 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Vertical misalignment of 1. Load paper. Press FF and check that paper feeds characters: smoothly. Press VIEW to verify that paper moves in both 1. Dots or characters move directions.

  • Page 127: Printer Operation

    General Symptom List Table 4. General Symptom List Symptom Solution Printer Operation Downloads consistently fail NOTE: Most download problems are detected by software during the procedure and communicated by LCD messages. If downloads fail consistently with no messages or with erratic messages, suspect a hardware failure.
  • Page 128 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Paper feeds poorly 1. Check the forms thickness lever: if it is set too tightly paper feeding can be affected. Set the forms thickness lever to match the thickness of the paper being used. 2.
  • Page 129 General Symptom List Table 4. General Symptom List Symptom Solution Paper feeds poorly 11. Load paper. Power on the printer. Press FF and VIEW (continued) several times and check that paper moves in both directions. Replace the paper feed motor if paper does not move in both directions.
  • Page 130 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Printer does not print self 1. Power off the printer. Remove the paper path or pedestal tests top cover. Disconnect the control panel cable from connector J110 on the controller board. Disconnect the control panel cable from the control panel.
  • Page 131 General Symptom List Table 4. General Symptom List Symptom Solution TOF is lost repeatedly 1. Check that the customer is setting the forms length to match the size paper used. Set the forms length to match the length of paper being used. 2.
  • Page 132 Chapter Troubleshooting Other Symptoms Table 4. General Symptom List Symptom Solution Shuttle Shuttle does not move 1. Power down the printer. Remove the shuttle cover. Check the MPU gap. Adjust the gap between the MPU assembly and the flywheel to 0.010 ± 0.001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch MPU clamp screw to 18 inch-pounds (2.03 N•m).
  • Page 133 General Symptom List Table 4. General Symptom List Symptom Solution Shuttle is noisy 1. Check the bolts securing the mechanism base to the base pan. Tighten the mechanism base mounting bolts if they are loose enough to permit movement of the mechanism base.

  • Page 134: Communications Failures

    Chapter Communications Failures Communications Failures Many host-printer communications problems are complex. With the exception of a defective interface cable, most communications problems are not a result of a hardware failure. They usually result from an incompatible configuration of the host computer system, network (LAN, print server, controller, multiplexer, etc.), or the printer.
  • Page 135 General Symptom List Table 5. Communications Problems Ethernet PCBA responds Ethernet 1. Open a telnet session using the IP address of to “ping” and “telnet” the ethernet card. utilities, and can print from 2. Enter these commands: “ftp”, but card cannot be config http on accessed by a browser.

  • Page 136: Diagnostic Printer Tests

    Chapter Diagnostic Printer Tests Diagnostic Printer Tests A set of printer tests is included in the DIAGNOSTICS configuration menu for use as diagnostic tools. Use these tests to check the print quality and basic operation of the printer. You will also use some of the tests in some adjustment procedures.

  • Page 137: Selecting And Running Diagnostic Printer Tests

    Selecting And Running Diagnostic Printer Tests • Ethernet Test — Prints the ethernet statistics stored on the ethernet interface (if present). See page 140. • Acoustics — A test used by the manufacturer to measure acoustic properties of the printer. This test has no value as a maintenance tool. •...
  • Page 138 Chapter Diagnostic Printer Tests Step Press LCD Result Notes PATTERN PRINTER TESTS PATTERN TEST WIDTH UNTIL Test Width Full Width* Test Width Cycle through choices. X = Full Width or X = 80 columns. Test Width Test width is ENTER selected.
  • Page 139 Selecting And Running Diagnostic Printer Tests Step Press LCD Result Notes ENTER SWITCH Locks the ENTER LOCKED key and control panel. ONLINE Places the printer in ONLINE CONFIG 1 online mode. Examine print quality. Characters should be fully formed and of uniform density.
  • Page 140 Chapter Diagnostic Printer Tests Printing the Ethernet Test NOTE: You must set TOF after printing the Ethernet Test. Step Press LCD Result Notes Make sure the printer is on. Raise the printer cover. Load paper. Set TOF. (Refer to the User’s Manual.) OFFLINE The printer must be ONLINE...

  • Page 141: Boot Diagnostics Menu

    Selecting And Running Diagnostic Printer Tests Step Press LCD Result Notes Printer Tests Stops printing. ENTER Ethernet Test ENTER SWITCH Locks the ENTER LOCKED key and control panel. ONLINE Places the printer in ONLINE CONFIG 1 online mode. Set TOF. (Refer to the User’s Manual.) Boot Diagnostics Menu Printer boot-up software contains a “Boot Diagnostics”...
  • Page 142 Chapter Boot Diagnostics Menu > = Down Arrow Key BOOT DIAGNOSTICS < = Next Arrow Key PRESS ENTER ENTER DIAGNOSTICS MENU < VERSION CONTROL > VERSION MENU VERSION MENU VERSION MENU VERSION MENU < < < < \SOFTWARE VERSION HARDWARE VERSION V8 ASIC VERSION BOOTCODE VERSION ENTER...
  • Page 143 Selecting And Running Diagnostic Printer Tests DIAGNOSTICS MENU DIAGNOSTICS MENU DIAGNOSTICS MENU < < MISC. TOOLS EXIT DIAGNOSTICS EXCEPTION VIEWER From previous > ENTER > page B30: STATUS > INITIALIZING... = Down Arrow Key < = Next Arrow Key MISC. TOOLS MENU MISC.

  • Page 144: Factory Menu

    Chapter Factory Menu Factory Menu Printer software contains a Factory menu that you can access by holding down the four arrow keys when the printer is in the offline state. This menu is not intended for the end user, but is used by manufacturing and maintenance personnel to set or change certain operational perameters.
  • Page 145 Selecting And Running Diagnostic Printer Tests > = Down Arrow Key < = Next Arrow Key Press ENTER to select or activate. Factory Factory Factory < < Set Coil Temp PRINTER MGMT Demo Count > ENTER > PLEASE WAIT... Demo Count (See also the procedure on page 178.) <...

  • Page 146: Exception Menu

    Chapter Exception Menu Exception Menu The exception menu is only accessible when certain faults occur. It provides additional troubleshooting information for some fault mesages. You will only use this menu when directed to by a troubleshooting procedure. When you come to this procedure, the printer will be powered on, with a specific fault message displayed which prevents further operation.

  • Page 147: Firmware Diagnostic Port

    Diagnostic Cable Firmware Diagnostic Port The firmware diagnostic port enables you to help with firmware troubleshooting when necessary. Diagnostic routines built into the software are used by TallyGenicom engineers to determine the cause of a fault or failure. In some cases the engineers will ask for specific information to be captured or provide a diagnostics test build.

  • Page 148: Capturing Information

    Chapter Firmware Diagnostic Port Capturing Information The diagnostic port is located on the rear panel of the printer at J7 on the Hurricane controller board. 1. Connect the cable from the printer's debug port to the serial port on the 2.

  • Page 149: Hex Code Printout

    How To Print A Hex Dump Hex Code Printout A hex code printout (or “hex dump”) prints every ASCII data character received from the host computer, and lists its corresponding two-character hexadecimal code. You can use hex dumps as an aid in troubleshooting data reception problems.
  • Page 150 Chapter Hex Code Printout Step Press LCD Result Notes DUMP MODE Cycle through choices. Style 1, 2 or 3 DUMP MODE Asterisk (*) indicates ENTER Style 1* choice is active. ENTER SWITCH Locks the ENTER key LOCKED and control panel. ONLINE Places the printer in ONLINE...

  • Page 151: Ascii Character Set

    How To Print A Hex Dump ASCII Character Set BITS OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character Name BITS COLUMN (XON) " 0 0 1 0 0 0 1 1 (XOFF) 0 1 0 0 0 1 0 1 &...

  • Page 152: Hard Reset (Cycle Power)

    Chapter Hard Reset (Cycle Power) Hard Reset (Cycle Power) A hard(ware) reset is a power shutdown and restart that runs all initialization and diagnostic routines. This is also called “cycling power.” 1. Set the printer power switch to O (off). 2.

  • Page 153: Adjustments And Tests

    Adjustments and Tests Introduction The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment and may need to be tested as part of a troubleshooting procedure. You usually will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.

  • Page 154: Preparing The Printer For Maintenance

    Chapter Preparing the Printer for Maintenance Preparing the Printer for Maintenance WARNING Unplug the printer power cord from the printer or power outlet before you do any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 155: Returning The Printer To Normal Operation

    Adjustments and Tests Returning the Printer to Normal Operation When you have finished servicing the printer, return it to service by doing the following steps: 1. Load paper. 2. Connect the data (signal) cable(s) to the printer interface. 3. Plug the AC power cord into the printer and the power source. 4.

  • Page 156: Belt, Paper Feed Timing, Adjustment

    Chapter Belt, Paper Feed Timing, Adjustment Belt, Paper Feed Timing, Adjustment 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Remove the timing belt cover (1) by squeezing the front and back to release the plastic tabs from the slots in the side plate.
  • Page 157 Adjustments and Tests 1/8 inch Direction of Force Legend: Timing Belt Shield Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Figure 10. Paper Feed Timing Belt Adjustment...

  • Page 158: Belt, Platen Open, Adjustment

    Chapter Belt, Platen Open, Adjustment Belt, Platen Open, Adjustment 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate.
  • Page 159 Adjustments and Tests 3/16 inch Legend: Belt Cover Motor Mount Screw (2) Platen Open Motor Shaft Figure 11. Platen Open Belt Adjustment...

  • Page 160: Paper Scale Alignment

    Chapter Paper Scale Alignment Paper Scale Alignment 1. Open the printer cover. 2. Load paper. 3. Connect the power cord to the AC power source. 4. Set the printer power switch to 1 (on). 5. Verify that the shuttle cover (1) is properly installed (page 203). 6.
  • Page 161 Adjustments and Tests Legend: Shuttle Cover Screw, Button-Head, 5/64 inch hex (3) Paper Scale Figure 12. Paper Scale Alignment...

  • Page 162: Platen Gap Adjustment

    Chapter Platen Gap Adjustment Platen Gap Adjustment IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen was replaced by a new or refurbished unit, or if you were instructed to in a troubleshooting procedure. 1. Prepare the printer for maintenance (page 154). 2.
  • Page 163 Adjustments and Tests NOTE: Right side adjustment shown. Left side is the same. Legend: Platen Stop Knob Forms Thickness Lever Feeler Gauge Hammer Bank Cover Ribbon Mask Setscrew, 3/32 inch hex (2) Figure 13. Platen Gap Adjustment...

  • Page 164: Paper Out Adjustment

    Chapter Paper Out Adjustment Paper Out Adjustment This procedure tests and sets the distance from the page perforation at which a LOAD PAPER fault message is triggered. This adjustment prevents printing on the platen when the printer runs out of paper. The measurement units are dot rows.
  • Page 165 Adjustments and Tests 7. If the printer is online, press the ONLINE key to place the printer offline. Press the MENU/ENTER key and “OFFLINE / QUICK SETUP.” displays. 8. On the control panel, press the keys to unlock the ENTER key. “ENTER SWITCH UNLOCKED”...
  • Page 166 Chapter Paper Out Adjustment 20. Press until “Paper Out Dots” displays. 21. Press . The top line of the display will show “Paper Out Dots” and the bottom line will show the current setting for the number of dots. 22. Press .

  • Page 167: Hammer Phasing Adjustment

    Adjustments and Tests Hammer Phasing Adjustment You must check and adjust hammer phasing if the controller board is replaced, the shuttle frame assembly is removed, or if the MPU is replaced. The hammer phase value is a timing parameter that permits you to adjust the vertical alignment of dots in character printing.
  • Page 168 Chapter Hammer Phasing Adjustment 10. Press : The current phase index displays. Press again: An asterisk (*) appears next to the phase value. 11. Press to increase or to decrease the phasing index value, then press ENTER to activate the value as it prints. Continue to increase or decrease the phasing index until the pattern of H’s is acceptable.

  • Page 169: Loading Flash Memory

    Adjustments and Tests Loading Flash Memory Flash memory is contained in a SIMM (single in-line memory module) located on the controller board. Printer control languages (the “emulations”) and printer operating system software are loaded into flash memory at the factory, but there are occasions when you may have to load this software: •...

  • Page 170: Loading Software With The Firmware Download Utility

    Chapter Loading Flash Memory Loading Software with the Firmware Download Utility If your computer has the Java runtime environment installed, the Firmware Download Utility (FDU) allows you to load program files into the printer with an easy to use graphical interface. FDU is a utility program included on the CD that comes with the printer and can be used on computers with Windows®, UNIX®, and Linux®...

  • Page 171: Loading Through Parallel Port Using Dos

    Adjustments and Tests 14. Double-click on the FDU.jar file you copied to your computer. It will launch its own window, then you can use it to select the emulation, the location of the file to be downloaded, the port into which to load it, and initiate the download.
  • Page 172 Chapter Loading Flash Memory 10. Open the readme.txt file on the CD-ROM. There are emulation sets with corresponding part number files from which to choose. All emulations include the program file or emulation code. They are offered in two file formats: .exe and .prg.

  • Page 173: Loading Software If Flash Contains Only Boot Code

    Adjustments and Tests Loading Software if Flash Contains Only Boot Code If the flash memory contains only boot code (for example, if it is new), or if a download was interrupted (for example, by a power outage) you must download software through the printer’s parallel port using the three-key initialization sequence covered in this section.

  • Page 174: Loading Software Through The Nic

    Chapter Loading Flash Memory 16. At the command prompt on the computer: filename.exe -pb<Enter> where filename.exe is the file name you noted in step 11. This command decompresses the file on the hard drive and copies it as a binary file into the flash memory on the printer controller board.
  • Page 175 Adjustments and Tests 12. At the command prompt type: C:<Enter> cd \download<Enter> 13. Start the FTP (file transfer protocol) program by typing: 123456 -n xxx.xxx.xxx.xxx<Enter> (where xxx.xxx.xxx.xxx is the IP Address of the printer.) IMPORTANT Do not interrupt the downloading process once it has started. Interrupting a download will leave the flash memory on the controller board and NIC incompletely loaded, and the printer may not boot up.

  • Page 176: Reprogramming The Security Key

    Chapter Reprogramming the Security Key Reprogramming the Security Key The security key on the PSA3 controller board can be reprogrammed with a Software Program Exchange (SPX) module. This allows the user or a service technician to enable features such as new emulations without having to remove covers and install a new security key on the controller board.
  • Page 177 Adjustments and Tests 4. Power on the printer. The printer will begin its boot-up sequence. 5. When the printer detects a valid SPX, the control panel displays: “NEW SPX DETECTED PRESS ENTER” NOTE: If an error message displays, find the message in the Message List in Chapter 3 and follow the troubleshooting instructions.

  • Page 178: Coil Temperature Adjustment

    Chapter Coil Temperature Adjustment Coil Temperature Adjustment IMPORTANT This procedure applies only to models 6615, 6615Q, 6620, and 6620Q. Do this procedure only when the original controller board or shuttle frame assembly have been replaced or you are instructed to do so in a maintenance or troubleshooting procedure.

  • Page 179: Dynamic Paper Tension Adjustment

    Adjustments and Tests Dynamic Paper Tension Adjustment This procedure helps you identify and eliminate conditions that contribute to paper jams, excessive tension on the paper feed motor, and vertical dot compression or expansion. 1. Open the printer cover. 2. Unload paper. 3.
  • Page 180 Chapter Dynamic Paper Tension Adjustment 8. Use the scale to pull the paper slowly straight up through the print station for about six inches and note the maximum force exerted on the scale. Do not pull any page perforations through the print station. (Figure 17.) Scale Figure 17.

  • Page 181: Tractor Belt Tension Adjustment

    Adjustments and Tests Tractor Belt Tension Adjustment First line print compression can be reduced by adjusting the tension of the tractor belts. The procedure below removes the slack that can occur in some tractors. IMPORTANT Only do this procedure when the user reports that the first print line of forms is compressed and only after adjusting the dynamic paper tension (page 179).

  • Page 182: Shuttle Electrical Short Check

    Chapter Shuttle Electrical Short Check Shuttle Electrical Short Check This procedure checks for metallic debris and checks for hammer coils shorting to the shuttle frame. The hammer driver circuit board attached to the shuttle frame assembly can attract metal objects because of the magnets in the hammer bank. Such stray metal pieces can cause electrical shorting and damage to the shuttle assembly.

  • Page 183: Hammer Bank Power Cable Shorts Test

    Adjustments and Tests 13. Install the ribbon cartridge. (Refer to the User’s Manual.) 14. Return the printer to normal operation (page 155). Hammer Bank Power Cable Shorts Test This test determines if the hammer bank power cable is shorted. 1. Prepare the printer for maintenance (page 154). 2.

  • Page 184: Cable Shorts Test

    Chapter Cable Shorts Test Cable Shorts Test This test determines if a cable has a short to ground or a pin-to-pin short (also called a wire-to-wire short). Such shorts can be caused by cables resting on or moving across sharp edges. The edges over time can wear away the non- conductive shielding of the cable, exposing the conductor.
  • Page 185 Adjustments and Tests 9. If you find a short to ground, replace the cable. If no short is detected, repeat steps 7 and 8 for the rest of the pins on the same end of the cable. If no shorts to ground are detected for any of the pins, proceed to the next section, which checks for pin-to-pin shorts.

  • Page 186: Main Wire Harness Test Diagnostic

    Chapter Main Wire Harness Test Diagnostic Main Wire Harness Test Diagnostic This is a procedure for extended testing of various printer components. 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3.

  • Page 187: Power Supply Operational Check

    Adjustments and Tests Power Supply Operational Check This procedure shows you how to use the Power Supply Tester (Field Kit, Tester, Power Supplies, Generic, P/N 178083-001), to quickly and safely monitor the output voltages of the printer power supply from outside the card cage.
  • Page 188 Chapter Power Supply Operational Check Power Supply Tester Load Block — Can become warm when used continuously Pin 1 Power Supply Board Pin 1 Pin 1 Connector P101 Stacker Power Cable (Only on cabinet models with the power stacker) Controller Board Connector J101 Figure 19.
  • Page 189 Adjustments and Tests 17. Measure the+8.5 V test point. It should be 8.1 to 9.4 volts. 18. Release the Push Button. 19. If you must measure voltages again, for each minute you held the Push Button down, wait at least two minutes with the Push Button released This allows the Load Block to cool.
  • Page 190 Chapter Power Supply Operational Check 23. Unplug power supply connector P101 from the 12-pin connector on the power supply tester Load Block. (Figure 19.) 24. Connect power supply cable connector P101 to either the power stacker power cable or connector J101 on the controller board. (Figure 19.) 25.

  • Page 191: Replacement Procedures

    Replacement Procedures Organization of this Chapter This chapter contains written procedures for removing and installing components that are replaceable at the field service level of maintenance. The replacement procedures refer you to the illustrations in Chapter 6 on page 245. Replacement Procedures WARNING Unplug the printer power cord from the printer or power outlet before...
  • Page 192 Chapter Replacement Procedures Cover Assembly, Shuttle..............page 203 Cover Assembly, Top, Pedestal Models ......... page 204 Dashpot................... page 205 Fan Assembly, Cabinet Exhaust ............. page 206 Fan Assembly, Card Cage .............. page 207 Fan Assembly, Hammer Bank ............page 208 Hammer Spring Assembly ..............

  • Page 193: Belt, Paper Feed Timing

    Belt, Paper Feed Timing Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate.

  • Page 194: Belt, Platen Open

    Chapter Replacement Procedures Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate.

  • Page 195: Cartridge Interface Board (Cib)

    Cartridge Interface Board (CIB) Cartridge Interface Board (CIB) Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the motor bracket assembly (page 219). 3. Remove the three 6-32 x 1/4 inch button head fasteners securing the cartridge interface board to the motor bracket assembly. 4.

  • Page 196: Circuit Breaker

    Chapter Replacement Procedures Circuit Breaker Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the card cage fan (page 207). 3. Disconnect the four circuit breaker electrical leads. (Cabinet Models: See page 274. Pedestal Models: See page 260.) 4.

  • Page 197: Connector Coupling Shrouds

    Connector Coupling Shrouds Connector Coupling Shrouds Some of the cable connectors in the printer are grouped inside connector coupling shrouds designated P106 and P107. This procedure explains how to remove and install cable assemblies from these coupling shrouds. NOTE: There is also a diagram of the P106 / P107 connector coupling shrouds on the plastic protective barrier over the power supply.
  • Page 198 Chapter Replacement Procedures P106 Connector Configuration P107 Connector Configuration Connectors are viewed 19 17 15 13 11 9 7 5 3 1 19 17 15 13 11 9 7 5 3 1 from the top, as seen when plugged into the PLAT M controller board.

  • Page 199: Control Panel Assembly

    Control Panel Assembly Control Panel Assembly NOTE: The procedure for removing and installing the control panel is the same for cabinet and pedestal model printers. Removal 1. Prepare the printer for maintenance (page 154). 2. Open the printer cover. 3. Disconnect the RJ-11 connector P310 from J2 on the back of the control panel.

  • Page 200: Controller Board

    Chapter Replacement Procedures Controller Board Removal IMPORTANT To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) NOTE: The MAC address for the onboard ethernet interface on the V6 controller board will be printed on the printer’s configuration printout after completing this replacement procedure.
  • Page 201 Controller Board Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. If this is a replacement controller board, install the flash SIMM and security key on the new controller (page 234). 2.

  • Page 202: Cover Assembly, Hammer Bank / Ribbon Mask

    Chapter Replacement Procedures Cover Assembly, Hammer Bank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the shuttle frame assembly (page 239). 3. Lift the thick plate of the hammer bank cover assembly at one end, and peel the cover away from hammer bank magnets.

  • Page 203: Cover Assembly, Shuttle

    Cover Assembly, Shuttle Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3. Loosen the shuttle cover screws (page 256, item 2). 4. Unplug the weld sensor cable (page 304). 5.

  • Page 204: Cover Assembly, Top, Pedestal Models

    Chapter Replacement Procedures Cover Assembly, Top, Pedestal Models Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the control panel assembly (page 199). 3. Loosen (do not remove) the two #2 Phillips hold-down screws on the rear of the printer. (See page 252, item 5.) 4.

  • Page 205: Dashpot

    Dashpot Dashpot CAUTION Two persons may be required to do this procedure. Prop or hold the printer cover securely while disengaging the dashpot. NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 154). 2.

  • Page 206: Fan Assembly, Cabinet Exhaust

    Chapter Replacement Procedures Fan Assembly, Cabinet Exhaust NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 154). 2. Open the front and rear cabinet doors and the printer cover. 3. Remove the paper fence/paper tray assembly. (See page 248.) 4.

  • Page 207: Fan Assembly, Card Cage

    Fan Assembly, Card Cage Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Disconnect the card cage fan cable connector. (See page 272.) 4.

  • Page 208: Fan Assembly, Hammer Bank

    Chapter Replacement Procedures Fan Assembly, Hammer Bank Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the ribbon. (Refer to the User’s Manual.) 3. Remove the shuttle cover assembly (page 203). 4. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204).

  • Page 209: Hammer Spring Assembly, Version 1

    Hammer Spring Assembly, Version 1 Hammer Spring Assembly, Version 1 Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the shuttle frame assembly (page 239). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 202). CAUTION Hammer springs and hammer tips are fragile.
  • Page 210 Chapter Replacement Procedures Installation 1. Using a clean dry cloth, wipe the hammer spring mounting surface on the hammer bank. Make sure the cloth does not leave lint on the hammer bank. CAUTION Hammer springs and hammer tips are fragile. Do not touch the hammer springs or tips.

  • Page 211: Hammer Spring Assembly, Version 2

    Hammer Spring Assembly, Version 2 Hammer Spring Assembly, Version 2 Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the shuttle frame assembly (page 239). 3. Carefully vacuum the shuttle frame assembly. 4. Remove the hammer bank cover assembly (page 202). CAUTION Hammer springs and hammer tips are fragile.
  • Page 212 Chapter Replacement Procedures Installation Using The Short Tip Alignment Tool This procedure is for installing one hammer spring assembly at a time, using short the tip alignment tool that comes with version 2 replacement hammer spring. To install more than one hammer spring assembly at a time, you must use the long tip alignment tool (page 214).
  • Page 213 Hammer Spring Assembly, Version 2 Torque Sequence • 14 inch-pounds (1.58 N Tip Alignment Tool Mounting Screw (3 or 4) Hammer Spring Assembly Figure 27. Installing the Mounting Screws in the Hammer Spring Assembly 5. Install the mounting screws in the hammer spring assembly. There will be three or four mounting screws, depending on the printer model.
  • Page 214 Chapter Replacement Procedures Installation Using The Long Tip Alignment Tool This procedure is for installing more than one version 2 hammer spring assembly at a time, using the long tip alignment tool. To install one hammer spring assembly at a time, use the short tip alignment tool (page 212). NOTE: If the hammer spring assemblies are being removed for cleaning, note their locations on the hammer bank and return them to the same locations when you reinstall them.
  • Page 215 Hammer Spring Assembly, Version 2 CAUTION In the next step, use ONLY the guide tool that comes with the alignment tool to align the version 2 hammer spring assemblies. To avoid damaging threads, never insert any metallic tool into the hammer spring mounting holes in the hammer bank.
  • Page 216 Chapter Replacement Procedures 6. Continue to apply a slight downward pressure on the tool and install the mounting screws in the hammer spring assemblies. Depending on the printer model, there will be three or four mounting screws per assembly. Torque the inner screw(s) to 14 in-lbs (1.58 N•m), then torque the outer screws to 14 in-lbs (1.58 N•m).

  • Page 217: Magnetic Pickup (Mpu) Assembly

    Magnetic Pickup (MPU) Assembly Magnetic Pickup (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the ribbon. (Refer to the User’s Manual.) 3. Remove the shuttle cover (page 203). 4. Disconnect the magnetic pickup (MPU) cable connector (page 266, item 5).

  • Page 218: Memory (Flash, Expansion)

    Chapter Replacement Procedures Memory (Flash, Expansion) CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component. Removal 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2.

  • Page 219: Motor Bracket Assembly

    Motor Bracket Assembly Motor Bracket Assembly Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Model: Remove the paper guide assembly (page 222). Pedestal Model: Remove the top cover assembly (page 202). 3. Unplug the CIB cable from the controller board at P122CIB/J122CIB. 4.

  • Page 220: Paper Feed Motor

    Chapter Replacement Procedures Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate (page 256, item 7).

  • Page 221: Paper Ironer

    Paper Ironer Paper Ironer WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the shuttle frame assembly (page 239). 3.

  • Page 222: Paper Guide Assembly

    Chapter Replacement Procedures Paper Guide Assembly NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 154). 2. Loosen—do not remove—the three screws that secure the paper path to the card cage. (See Figure 31.) 3.

  • Page 223: Platen

    Platen Platen Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the shuttle frame assembly (page 239). 3. Remove the paper ironer (page 221). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly. (See page 270, items 4, 5, and 6.) 5.
  • Page 224 Chapter Replacement Procedures Installation IMPORTANT Install the platen with the longer shaft on the right hand side of the printer. The dowel pins protruding from the ends of the platen are the platen shafts. The platen shafts are not of equal length. 1.
  • Page 225 Platen Platen Adjust Bracket Platen Washers Wear Saddle Mechanism Base Platen Seat Figure 33. Positioning the Platen Adjust Brackets 9. Install the interlock switch bracket: a. Slide the bracket, with the interlock switch assembly attached, onto the platen shaft and up against the right side plate. b.
  • Page 226 Chapter Replacement Procedures 13. Install the paper ironer bracket. (See Figure 32.) a. With the flat part of the bracket facing the front of the printer, place the two hooks of the upper part of the paper ironer over the platen shafts.

  • Page 227: Platen Open Motor

    Platen Open Motor Platen Open Motor Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Cabinet Models: Remove the card cage fan (page 207). 4.
  • Page 228 Chapter Replacement Procedures Installation 1. Position the platen open motor assembly with the wires toward the rear (page 272, item 5). 2. Install the 5/16 inch lower motor mount screw and torque it to 30 inch-pounds (3.39 N•m). 3. Install the 5/32 inch upper motor mount screw, platen spring post, and platen belt spring such that the screw is just loose enough to permit movement of the motor in the slotted side plate.

  • Page 229: Platen Stop Assembly

    Platen Stop Assembly Platen Stop Assembly NOTE: The forms thickness lever is part of the platen stop assembly. Removal 1. Prepare the printer for maintenance (page 154). 2. Loosen—do not remove—the 7/64 inch clamp screw and pull the platen stop assembly off the platen shaft. (See page 270, items 12 through 15.) Installation 1.

  • Page 230: Power Supply Board

    Chapter Replacement Procedures Power Supply Board WARNING To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply board. Do not touch components on the board during removal or installation. Lift and handle the board only by the loops provided for this purpose.

  • Page 231: Resistors, Terminating, V6 Controller Board

    Resistors, Terminating, V6 Controller Board Resistors, Terminating, V6 Controller Board For parallel interface configurations, the printer is equipped with 470 Ohm and and 1K Ohm terminating resistors on the controller board. These are suitable for most applications. (See Figure 34, page 232.) If the standard terminating resistor pack is not compatible with the particular interface driver requirements of the host computer, other RP1 and RP2 values may be required.
  • Page 232 Chapter Replacement Procedures RP1 and RP2 Default: 470/1K Ohm Alt: 220/330 Ohm Figure 34. Terminating Resistors, V6 Controller Board, Removal/Installation...

  • Page 233: Ribbon Drive Motor

    Ribbon Drive Motor Ribbon Drive Motor Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3. Remove the shuttle cover (page 203). 4. Disconnect the ribbon drive motor cable connector (page 272, item 12, cable portion).

  • Page 234: Security Key

    Chapter Replacement Procedures Security Key CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when handling circuit boards, the shuttle frame assembly, and any other electronic component. Removal 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) 2.
  • Page 235 Security Key Controller Board J9: Security Key Notched End on this side Flash Memory: J10: 72-pin Flash Memory SIMM: 4 MB = P/N 204480-901 8 MB = P/N 204480-902 16MB = P/N 204480-903 32MB = P/N 204480-904 Figure 35. Memory Modules and Security Key...

  • Page 236: Shaft, Splined

    Chapter Replacement Procedures Shaft, Splined IMPORTANT In order to preserve correct alignment of the side plates, the barrier panel must remain installed and fastened during this procedure. Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the paper supports from the splined shaft and support shaft. (See page 268, item 4.) 3.
  • Page 237 Shaft, Splined Tractor NOTE: Align the marks on both tractors before inserting the splined shaft. Tolerance Alignment Marks Ring Splined Shaft Figure 36. Splined Shaft and Tractor Installation...

  • Page 238: Shaft, Support

    Chapter Replacement Procedures Shaft, Support IMPORTANT In order to preserve correct alignment of the side plates, make sure the barrier panel remains installed and fastened during this procedure. Removal 1. Prepare the printer for maintenance (page 154). 2. Unlock the tractors and slide them to the far right. 3.

  • Page 239: Shuttle Frame Assembly

    Shuttle Frame Assembly Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3. Remove the shuttle cover assembly (page 203). 4. Disconnect the MPU cable connector P03 and shuttle motor cable connector P02 (page 266, items 5 and 6).
  • Page 240 Chapter Replacement Procedures Installation 1. Install the hammer bank / ribbon mask cover assembly if it was removed (page 202). CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when you handle the shuttle frame assembly.

  • Page 241: Spring, Extension, Hammer Bank

    Spring, Extension, Hammer Bank Spring, Extension, Hammer Bank CAUTION Do not let the hammer bank rotate toward the platen during spring replacement. Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3.

  • Page 242: Switch Assembly, Paper Detector

    Chapter Replacement Procedures Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Remove the two 1/4 inch screws securing the paper detector switch assembly.

  • Page 243: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 154). 2. Cabinet Models: Remove the paper path (page 222). Pedestal Models: Remove the top cover assembly (page 204). 3. Fully close the forms thickness lever (position ‘A’). 4.

  • Page 244: Tractor (L/R)

    Chapter Replacement Procedures Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 154). 2. Remove the support shaft (page 238). 3. Remove the splined shaft (page 236). Installation 1. Using the replacement tractors, install the support shaft (page 238). 2.

  • Page 245: Illustrated Parts Breakdown

    Illustrated Parts Breakdown Organization of this Chapter This chapter contains drawings of all electrical and mechanical assemblies in the printer. The table following each illustration lists the illustrated parts and their part numbers. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly.
  • Page 246 Chapter Organization of this Chapter Figure 38. Top Cover, Doors, and Casters...
  • Page 247 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 177505-901 Top Cover Assembly, Stealth Black Includes items 2 and 3 179781-901 Top Cover Assembly, Lt Gray Includes items 2 and 3 131803-904 Window, Cabinet 175680-001 Wireform Paper Path, Standard 177541-901 Rear Door Assembly, Stealth Black For printers without power stacker;...
  • Page 248 Chapter Organization of this Chapter Figure 39. Paper Fence, Paper Chains, and Front Access Stacker...
  • Page 249 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 158179-901 Passive Stacker Assembly Not used on printers with the power stacker; includes items 6, 7, and 8 153503-001 Grommet Kit, Cabinet 153778-001 Chain Assembly Kit AC Power Cord Grommet, Power Cord (2) Included in item 2 151910-001...
  • Page 250 Chapter Organization of this Chapter Figure 40. Control Panel and Cabinet Details...
  • Page 251 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 254284-901 Control Panel Assembly, Cab 152440-901 Cable Assembly, Control Panel 107961-905 Dashpot Kit Includes ball studs, spring clips, and mounting hardware Screw, w/Lock Washer (3) 6-32x.375 Screw, w/Lock Washer (3) 6-32x2.00 150261-901 Fan Assembly...
  • Page 252 Chapter Organization of this Chapter Figure 41. Pedestal Details...
  • Page 253 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 254284-902 Control Panel Assembly, Ped Screw, Captive (2) 179163-001 Field Kit, Lid Assembly, Ped, Blk Both kits also contain items 8, 14, and 179845-001 Field Kit, Lid Assembly, Ped, Gray Screw (2) 152440-901 Cable Assembly, Control Panel...
  • Page 254 Chapter Organization of this Chapter Figure 42. Quiet Pedestal Details...
  • Page 255 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 254284-902 Control Panel Assembly, Ped Screw, Captive (2) 179163-001 Field Kit, Lid Assembly, Ped, Blk Both kits also contain items 8, 14, and 179845-001 Field Kit, Lid Assembly, Ped, Gray Screw (2) 152440-901 Cable Assembly, Control Panel...
  • Page 256 Chapter Organization of this Chapter Underside of the shuttle frame assembly. Ribbon Weld Processor PCBA located on the underside (see Detail B). Figure 43. Inside Covers, Cabinet Models...
  • Page 257 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 179128-901 Shuttle Cover Assembly or Shroud Assembly Air Shroud Assembly Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread-forming (2) 6-32x.25 and #6 flat washer Barrier Shield 175188-901 Paper Path, V3 Screw, w/Lock Washer (3) 6-32.25 and #6 flat washer 153488-001...
  • Page 258 Chapter Organization of this Chapter Underside of the shuttle frame assembly. Ribbon Weld Processor PCBA located on the underside (see Detail B). See Figure 45, page 260. Figure 44. Inside Covers and Card Cage, Pedestal Models...
  • Page 259 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 179128-901 Shuttle Cover Assembly or Shroud Assembly Air Shroud Assembly 254991-901 Shuttle Cover (including paper scale) Air Shroud Assembly (including paper scale) Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread-forming (2) 6-32x.25 and #6 flat washer Barrier Shield...
  • Page 260 Chapter Organization of this Chapter From Figure 44, page 258. Rotated 180 degrees. To IEC 320 AC Power Input (Connector To Connector P1 J301, White (White Wire) Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) To Connector P1 (Black Wire) Figure 45.
  • Page 261 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) Nut, 6-32 (1) Upper right fan corner only 150261-901 Card Cage Fan Assembly Air flow is into card cage Fan Guard Screw, w/Lock Washer (4) 6-32x1.75 Card Cage, Pedestal 142013-901 Circuit Breaker Baffle, Power Supply, Ped, 6600...
  • Page 262 Chapter Organization of this Chapter Two places: Exploded to show assembly. Do not remove the clamps and screws. To J03 To J02 (MPU) (Shuttle Motor) To the Terminator Board on the Shuttle Frame Figure 46. Print Mechanism and Circuit Boards...
  • Page 263 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 254350-901 HB Cover Assy 6605, 6605Q 254353-901 HB Cover Assy 6610, 6610Q 254356-901 HB Cover Assy 6615, 6615Q 254138-901 Cover Assy 6620, 6620Q 254504-901 Shuttle Assembly, 05 6605, 6605Q 254504-991 Shuttle Assembly, 05, Adv Exch 6605, 6605Q...
  • Page 264 Chapter Organization of this Chapter Part No. Item (RoHS Description Notes Compliant) 177482-001 Paper Feed Motor Assembly with Pulley, (20) 6620, 6620Q 178046-001 Paper Feed Motor 6605, 6605Q, 6610, 6610Q, 6615, 6615Q 178535-001 Paper Feed Motor 6605, 6605Q, 6610, 6610Q 179526-901 PCBA, Cartridge Interface Board, w/ harness.
  • Page 265 Illustrations of Printer Components (Parts lists continue on the next page.)
  • Page 266 Chapter Organization of this Chapter Spring Lug (Do not remove grease) Spring Lug (Do not remove grease) 0.010 ± .001 inch (0.254 ± .025 mm) CAUTION: Make sure the MPU cable does not touch the extension spring after cable connection. Figure 47.
  • Page 267 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 150281-901 Magnetic Pickup (MPU) Assembly Bracket, MPU Part of item 1 Screw, Socket Cap 6-32x.38 153537-901 Spring, Hammer Bank MPU Cable Connector (P03) 176507-001 Anti-Rotation Spring Constraint 6620 and 6620Q only 152425-901 Magnetic Pickup (MPU) Cable Assembly...
  • Page 268 Chapter Organization of this Chapter IMPORTANT: In order to preserve correct alignment of the side plates, the barrier panel must remain installed and fastened if the splined or support shafts are removed or replaced. The barrier panel is shown in Figure 43 and Figure 44.
  • Page 269 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) Screw, Socket Cap, 6-32x.312 Trilob (Self- Tapping) (2) 173130-001 Plate, Tractor Shaft, Left 151944-001 Bearing, Ball, Sealed 178990-901 Paper Support (2) 204155-001 Tolerance Ring,.37X.25,.006 THK,SS 178988-901 Splined Shaft Assembly (Blue Handle) Screw, Socket Cap, 6-32x.312 Trilob (Self- Tapping) 173217-001...
  • Page 270 Chapter Organization of this Chapter NOTE: NOTE: Black tape faces paper On 6615, 6615Q, 6620 and 6620Q motion detector. models, install item 27 in front of item 3; that is, on the shuttle side. All others do not use item 27. Do NOT install Items 3 and 27 on ZTP printers.
  • Page 271 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) Setscrew (2) Part of item 25 Bracket, Platen (2) Part of item 25 150957-901 Ironer Assembly, Reverse Paper Feed All except ZTP printers Screw, Thread-forming (3) 6-32x.25 174968-001 Ironer Bracket/Plate Field Kit Plate, Ironer Part of item 5 253246-901...
  • Page 272 Chapter Organization of this Chapter Ribbon Drive Motor Cable Connector Figure 50. Motors, Fans, and Paper Detector Switch...
  • Page 273 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 150261-901 Card Cage Fan Assembly Air flow is into card cage Screw, w/Lock Washer (3) Two 6-32x1.75 on bottom, One 6-32x0.50 on top left 152415-901 Switch Assembly, Paper Detector 170172-001 Field Kit, Slotted Black Back Form Switch Optional switch used with black back...
  • Page 274 Chapter Organization of this Chapter See inside detail below. To IEC 320 AC Power Input (Connector J301, White Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) To Connector P1 (Black Wire) (Card cage fan and To Connector P1 power supply board (White Wire) removed for clarity.)
  • Page 275 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 142013-901 Circuit Breaker IEC 320 AC Power Connector Connector J301 Part of Field Kit, AC Assy 153502-001 Chassis Ground Stud Part of Field Kit, AC Assy 153502-001 Connector P1 To power supply board connector J1 Part of Field Kit, AC Assy 153502-001 Cable Assembly, AC-In, Power Supply...
  • Page 276 Chapter Organization of this Chapter Figure 52. The NIC (Network Interface Card) on the V6 Controller Board...
  • Page 277 Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 250678-901 Spare PCBA, PCI-Network On the V6 controller board the NIC is 250678-991 Spare PCBA, PCI-Network, Adv Exch part of the board. 250675-901 Spare PCBA, PCI Wireless 176257-001 Cover Plate, PCI Rear of Card Cage Screw V6 Controller Board...
  • Page 278 Chapter Organization of this Chapter...

  • Page 279: Principles Of Operation

    Principles Of Operation Line Matrix Printing A line matrix printer creates characters and graphics by printing patterns of ink dots an entire line at a time. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix.
  • Page 280 Chapter Line Matrix Printing When the shuttle reaches the end of a horizontal sweep, it reverses direction, the paper advances upward one dot row, and the hammer springs print the next row of dots as the shuttle moves in the opposite direction. When a line of text characters is completed, hammer action stops and the paper advances to the first dot row of the next print line.
  • Page 281 Succesive Hammer Strokes Per Scan Shuttle 1 3 5 1 3 5 7 1 3 5 7 9 Scan Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: = Hammer Released and Dot Printed = Hammer Not Released;...

  • Page 282: Printing Rates

    Chapter Printing Rates Printing Rates A line matrix printer prints entire lines sequentially, and measures the printing speed of text in lines per minute (lpm). This is faster than a moving-printhead printer, which prints single characters sequentially and measures its speed in characters per minute (cpm).

  • Page 283: Shuttle Frame Assembly

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

  • Page 284: Shuttle Drive Motor

    Chapter Shuttle Frame Assembly Shuttle Drive Motor The shuttle drive motor is built into the shuttle assembly casting and spins a crankshaft, to which are attached the big ends of two connecting rods. (Figure 56.) The small end of one connecting rod attaches to the hammer bank;...

  • Page 285: Paper Transport System

    Shuttle Drive Motor While the hammer is in flight the coils are de-energized and their magnetic field collapses, restoring the magnetic attraction of the permanent magnet in the hammer bank. After striking the ribbon and paper, the hammer rebounds and is recaptured by the permanent magnet. When the shuttle reaches the end of a sweep, it reverses direction, the paper is micro-stepped upwards one dot row, and the hammer springs print the next row of dots as the shuttle sweeps in the opposite direction.

  • Page 286: Ribbon Transport System

    Chapter Ribbon Transport System prevents paper jams when paper direction is reversed after viewing the print area, setting top of form, or allowing applications to overprint forms. Paper is positioned horizontally using the tractors. Each tractor is locked in position with a friction lock and engages the paper perforations with six sprocket pins.

  • Page 287: Integrated Print Management System

    Operation Integrated Print Management System The 6600 has a new feature that automatically monitors and communicates the status of the ribbon life to help the operator know when to change ribbons. Using an ink delivery system called the Cartridge Ribbon System (CRS), the printer can automatically detect when a new or used ribbon is loaded, and all ribbon properties.
  • Page 288 Chapter Integrated Print Management System Ribbon End Point Factory default is Normal. The Integrated Print Management System tracks ribbon life to the recommended end point before declaring RIBBON INK LOW or RIBBON INK OUT. Ribbon End Point is a global setting, which means it is in effect for all printer configurations and cannot be set for individual printer configurations.
  • Page 289 Operation RBN Low Warn @ This option allows the user to select the Ribbon Life value at which point the printer will declare a ribbon low condition and display the "RIBBON UNDER XX% / Change RBN Soon" warning message. The default is Under 2%. See “RBN Low Action”...

  • Page 290: Logical Control Of The Printer

    Chapter Logical Control of the Printer Logical Control of the Printer The printer consists of four subsystems: the control panel, the controller board, the power supply board, and the print mechanism, as illustrated in Figure 60. Power Supply Controller Board Print Mechanism Control Panel Figure 60.

  • Page 291: Control Panel

    Operation Control Panel The user communicates with the printer by pressing keys on the control panel. The keys are momentary contact switches. The control panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user.

  • Page 292: Controller Board

    Chapter Controller Board Controller Board The heart of a 6600 printer is the “Hurricane” V6 controller board, which controls all printer functions and supports all 6600 models. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs.
  • Page 293 Operation Control Bus JTAP Data Bus System Reset SDRAM Motorola MPC8245 PCI Bus Buffer microprocessor FLASH Buffer Core Volt Regulator Non-Vol Port Control PCI Bus Logic RS-232 RS-232/422 Diagnostic Diagnostic Host I/O Port Port V8 ASIC Drivers IEEE-1284 (Parallel) Control Control Panel Panel...

  • Page 294: Data Controller

    Chapter Controller Board Data Controller The data controller (DC) consists of the following elements: • MPC8245 microprocessor • A 72-pin flash SIMM socket that holds up to 32MB of program memory • A 32MB SDRAM DIMM for data memory • 8K x 8 Non-Volatile Battery-Backed Static RAM (NVRAM) for storage of configuration and system statistical data (optional) •...
  • Page 295 Data Controller V8 ASIC The V8 is a multi-function custom gate array ASIC containing all the logic for the DC that is not contained in the MPC8245 processor. The V8 provides the following services: • Memory Access Controller • SDRAM Controller •...

  • Page 296: Engine Controller

    Chapter Controller Board “Cajun” Bus Interface The “Cajun” bus connects the DC and the EC. The EC uses this bus to access DC resources, including the semaphore registers. (The semaphore registers are the primary communications path between the EC and DC.) Ports The V8 ASIC controls the following I/O functions: •...
  • Page 297 Engine Controller 80C167 Microcontroller The Siemens SAB 80C167 is a high-integration microcontroller with many features that suit it extremely well to real-time control applications. This controller and the MECA ASIC provide the functionality of three separate processors used in earlier controller board architectures. In this manual, the 80C167 is referred to as the EC.

  • Page 298: Power Supply Board

    Chapter Power Supply Board The paper feed, ribbon drive, and shuttle motors are driven in control loops containing power MOSFETs, voltage and current sensors, the MECA ASIC, and the EC processor. The platen motor is driven by a stepping motor controller IC and the EC processor.

  • Page 299: Printer Interface

    DC Power than 200 milliseconds and requires recycling of the circuit breaker (On/Off switch) to reset the latch. Loss of +48 V is seen by the EC and reported as a fault. Printer Interface The printer interface is the point where the data (signal) cable from the host computer plugs into the printer.
  • Page 300 Chapter Printer Interface...

  • Page 301: A Wire Data

    Wire Data NOTE: Abbreviations, acronyms, and signal mnemonics are defined in Appendix B (page 343). Interconnection Diagram ..............page 303 Cable Routing, Cabinet Model ............page 304 Cable Routing, Pedestal Model............page 305 Main Wire Harness Test Tables ............page 306 Circuit Board Pinouts V6 Controller Board ..............
  • Page 302 Appendix A Power Stacker Cables Frame Cable, Power Stacker ..........page 333 Logic Cable, Power Stacker ..........page 334 Power Cable, Power Stacker ..........page 335 Rail Cable, Power Stacker ..........page 336 Elevator I/O Cable, Power Stacker ........page 337 Fan Assembly, Hammer Bank ............

  • Page 303: Interconnection Diagram

    Interconnection Diagram P106 J310 P310 P104 P102 PSTR P103 P110 J102 J110 PSTR J117...

  • Page 304: Cable Routing, Cabinet Model

    Appendix A Cable Routing, Cabinet Model NOTE: 6620 and 6620Q model uses a unique power supply. See page 316. Weld Sensor Cable Exhaust Fan...

  • Page 305: Cable Routing, Pedestal Model

    Cable Routing, Pedestal Model Exhaust Fan Weld Sensor Cable...

  • Page 306: Main Wire Harness Test Tables

    Appendix A Main Wire Harness Test Tables P106 Connector P107 Connector Connectors are viewed from the top, as seen 19 17 15 13 11 9 7 5 3 1 when plugged into the 19 17 15 13 11 9 7 5 3 1 controller board.

  • Page 307: V6 Controller Board

    V6 Controller Board CAUTION: Do not try to remove or replace the NVRAM. The NVRAM contains a lithium battery that can explode if replaced incorrectly. NVRAM is replaced only at the factory. Power Supply J101 Motor Sensor Left N TEMP HI J106 N STDBY VCC1...
  • Page 308 Appendix A V6 Controller Board (continued) 0 Ohm 0.125W EC BOOT STRAP Hammer Bank Logic EC Diagnostics J108 J120 0.1W +10V SW C167 DB TXD HMR DAT COIL C167 DB RXD μ 50 MHz HMR DAT RET HMR CLK C167 NCS1 HMR CLK RET PPR TRIG CMD DAT...
  • Page 309 V6 Controller Board (continued) Cartridge Interface Board Sensor J122 BC DATA COVER OPEN 2-Pin Jumpers External Power 4.7 K EXT 5V 0.1 W J102 μ 1000 PF 4.7 K 0.1 W μ 1000 PF 500 Ohm LOGIC HIGH CHASSIS GND...
  • Page 310 Appendix A V6 Controller Board (continued) RJ-45 LAN (Ethernet) Host RS232 J201 Diagnostic Port SHL1 DB TXD SHL2 DB RXD Shuttle Drive J116 SHUT A SHUT B SHUT C Control Panel J110 N FP DATA AVAIL Paper Stacker J117 FP CLK STK R NW 470 PF N FP LED WR...
  • Page 311 V6 Controller Board (continued) Host RS422 2.2K 0.062W Paper Feed Motor J103 SOFT ID DIFF TXD+ DIFF TXD- PF 4 PF 3 PF 2 DIFF RXD+ PF 1 1 2 3 DIFF RXD- Software Security Key Phase Driver Port J115 UD 1 UD 2 PH REF...
  • Page 312 Appendix A V6 Controller Board (continued) PCI Connection VCC1 VCC1 NIRQ1 NINTA NINTB NINTC NINTB NINTC NINTD NINTD NPRSNT2 NPRSNT1 3.3V NPRSNT3 NPRSNT2 3.3VAUX PCI_NRST NRST CLK1 3.3V NGNT1 NGNT NREQ1 NREQ 3.3V NPME AD31 AD30 AD31 AD30 AD29 AD29 3.3V AD28 AD28...
  • Page 313 V6 Controller Board (continued) Centronics Connector J112 N STROBE N ACK BUSY PAPER EMPTY SELECT N INIT N AUTOFEED N FAULT 4.7K 0.1W NDPSEL EXT 5V N SELECT IN HOST LOGIC H NDPEN 0.1W CHASSIS GND...

  • Page 314: Power Supply: 6605, 6605Q, 6610, And 6610Q

    Appendix A Power Supply: 6605, 6605Q, 6610, and 6610Q Cable Assembly AC In P101 Power Supply AC Common N TEMP HI White Chassis Ground N STDBY Orange LOAD +5V RTN Black = FAST-ON TERMINAL +5V RTN Black +48V / +8.5V RTN Brown LOAD = RING TERMINAL...

  • Page 315: Power Supply: 6615 And 6615Q

    Power Supply: 6615 and 6615Q (Line Filter Area) AC Input AC COMMON CHASSIS GND P101 NACFAIL (Not AC Fail) Cable Assembly NSTBY (Not Standby) AC In +5 Volts Power Supply +5 Volts +5 Return / Logic GND LOAD +5 Return / Logic GND +48 / +8.5 Return = FAST-ON TERMINAL +48 / +8.5 Return...

  • Page 316: Power Supply: 6620 And 6620Q

    Appendix A Power Supply: 6620 and 6620Q (Phase Driver Control) UD 1 UD 2 +2.5V reference (Phase Driver Power) UD 3 UD 4 DIODE 1 DIODE 2 DIODE 3 DIODE 4 N COILTEST LDFB OPTO RET CABLE DET HD SENSE Chassis GND LDFB BUF Controller GND...

  • Page 317: Surestak Power Stacker Pcba

    SureStak Power Stacker PCBA...

  • Page 318: Cable Assemblies Weld Sensor

    Appendix A Cable Assembly, Weld Sensor (P/N 254475-001) Wiring Table CONN 1 CONN 2 PIN 1 PIN 1 PIN 2 PIN 2 PIN 3 PIN 3 PIN 4 PIN 4...

  • Page 319: Centronics I/O

    Cable Assembly, Centronics I/O (P/N 152439-901) IMPORTANT To comply with Electromagnetic Compatibility (EMC) regulatory requirements, all interface cables must be of a minimal quality level, be the correct length, and be properly installed. RS-232 port and parallel port cables must meet the following specifications: 1) The cable design must be double shielded with a copper braid over an aluminum mylar foil...

  • Page 320: 2-Pin Jumper, 0.1 Ctr

    Appendix A Cable Assembly, 2-Pin Jumper, 0.1 Ctr (P/N 154470-901)

  • Page 321: Ac In, Power Supply

    Cable Assembly, AC In, Power Supply (AC Kit P/N 153502-901) To Circuit Breaker To Power Supply J1...

  • Page 322: Ac Power Input

    Appendix A Cable Assembly, AC Power Input (AC Kit P/N 153502-901) To Circuit Breaker Input Power Connector...

  • Page 323: Ps I/O

    Cable Assy, PS I/O (P/N 176601-901)

  • Page 324: Card Cage Fan

    Appendix A Cable Assembly, Card Cage Fan (P/N 152422-901) PIN 1 PIN 1...

  • Page 325: Control Panel

    Cable Assembly, Control Panel (P/N 152440-901) PIN 8 (Brown) PIN 1 (Gray) PIN 8 (Brown) PIN 1 (Gray)

  • Page 326: Exhaust Fan

    Appendix A Cable Assembly, Exhaust Fan (P/N 152424-901) PIN 1 PIN 1...

  • Page 327: Hammer Bank Logic

    Cable Assembly, Hammer Bank Logic (P/N 152421-901) To Shuttle To Controller Board...

  • Page 328: Hammer Bank Power

    Appendix A Cable Assy, Hammer Bank Power (P/N 164805-901) IMPORTANT: Use this cable on any 6600 printer except the 6600 and 6620Q. On the 6600 and 6620Q use P/N 173215-901, shown on the next page. To Controller Board To Shuttle Wire Table P105...

  • Page 329: Hammer Bank Power

    Cable Assy, Dual Hammer Bank Power (P/N 173215-901) IMPORTANT: Use this cable on the 6620 and 6620Q printer. On any other 6600 printer use P/N 164805-901, shown on the previous page. To Power Supply To Shuttle Wire Table...

  • Page 330: Mpu

    Appendix A Cable Assembly, MPU (P/N 152425-901) PIN 2 PIN 3 PIN 1 PIN 1...

  • Page 331: Ribbon Motor, Extension

    Cable Assembly, Ribbon Motor, Extension (P/N 154067-001)

  • Page 332: Shuttle Motor Drive

    Appendix A Cable Assembly, Shuttle Motor Drive (P/N 152420-001)
  • Page 333 Frame Cable, Power Stacker (P/N 173824-001)
  • Page 334 Appendix A Logic Cable, Power Stacker (P/N 176029-001)
  • Page 335 Power Cable, Power Stacker (P/N 174414-001)
  • Page 336 Appendix A Rail Cable, Power Stacker (P/N 173823-001)
  • Page 337 Elevator I/O Cable, Power Stacker (P/N 174759-001)
  • Page 338 Appendix A Fan Assembly, Hammer Bank (P/N 152416-901) P107 / HBF...
  • Page 339 Magnetic Pickup (MPU) Assembly (P/N 150281-901)
  • Page 340 Appendix A Switch Assembly, Paper Detector (P/N 152415-901)
  • Page 341 Switch Assembly, Platen Interlock (P/N 152417-901)
  • Page 342 Appendix A...

  • Page 343: B Abbreviations

    Abbreviations NOTE: Signal abbreviations with first letter “N” are negative true. Abbreviation Definition KΩ 1,000 Ohms MegΩ 1,000,000 Ohms μF microfarad (10 farad) μs microsecond (10 second) μsec microsecond (10 second) A0, A1, etc. Address 0, Address 1, etc. Alternating Current Access Acknowledge Amplitude;...
  • Page 344 Appendix B Cathode Card Cage Card Cage Fan CHNG Change Circuit Clock Cover Open COLL Collector COMM Communication CONTLR Controller Command Connector, Connection Characters Per Inch CPLD Complex Programmable Logic Device Carriage Return Control Cartridge Ribbon System Clear to Send Control Unit Current D0, D1, etc.
  • Page 345 Data Set Ready Data Terminal Ready Engine Controller (a functional unit of the controller board) EEPROM Electrically Erasable/Programmable Read-Only Memory Exhaust Fan Elevator motor (power stacker) EMEA Europe, Mideast, and Africa ElectroMagnetic Interference EMIT Emitter EPROM Electrically Programmable Read-Only Memory Error Electrostatic Discharge Exhaust, Extra...
  • Page 346 Appendix B Hammer Driver HDIC Hammer Driver Integrated Circuit HDPH Hammer Driver Phase Hammer Bank Logic, Signals, and Power Hardware Integrated Circuit Identification Intelligent Graphics Printing INST Instruction Interrupt Input/Output Illustrated Parts Breakdown Inches Per Minute Interrupt Request Jack connector JEDEC Joint Electron Device Engineering Council.
  • Page 347 Motor Magnetic Pick-Up (Unit) millisecond (10 second) Motor and Sensors, Left Motor and Sensors, Right Negative True; Newton (metric unit of force) Network Interface Card (ethernet interface) Not Connected Not Connected Near Letter Quality Number NOVRAM Nonvolatile Random Access Memory nanosecond (10 second) NVRAM...
  • Page 348 Appendix B Printronix Graphics Language Phase A Phase B Paper Instruction PLAT Platen Platen Motor Platen Open Switch Paper Motion Detect Pin or Plug Part Number Paper Out Paper Out Detector Switch Paper PROM Programmable Read-Only Memory Power Supply Power Supply + 5 Volt PSA3 Printronix System Architecture, Third Generation Pointer, Printer...
  • Page 349 Request Ribbon and Shuttle Processor Reset Request to Send Receive Data SNA Character Stream SDRAM Synchronous Dynamic Random Access Memory Security (Key) Select Sense, Sensor Structured Field Signal Ground Shuttle Hall (Effect) Shuttle Motor SHUT Shuttle SHUTL Shuttle SIMM Single Inline Memory Module SLCT Select (Online) Slew...
  • Page 350 Appendix B Task Control Block TEMP Temperature; Temporary Top Of Form (first print line) Test Point Transistor-Transistor Logic Transmit Data UART Universal Asynchronous Receiver/Transmitter UDPH Upper Drive Phase UNDEF Undefined USART Universal Synchronous/Asynchronous Receiver/ Transmitter Volts Volts, Alternating Current Volts, Direct Current Voltage at Collector Voltage at Drain Code V™...

  • Page 351: C Metric Conversion Tables

    Metric Conversion Tables Length Multiply To Obtain foot 0.3048* meter (m) foot 30.48* centimeter (cm) foot 304.8* millimeter (mm) inch 0.0254* meter (m) inch 2.54* centimeter (cm) inch 25.4* millimeter (mm) meter 3.280840 foot centimeter 0.03280840 foot millimeter 0.003280840 foot meter 39.37008 inch...

  • Page 352: Mass And Density

    Appendix C Mass and Density Multiply To Obtain pound* 0.4535924 kilogram (kg) ounce* 28.34952 gram (g) kilogram 2.204622 pound* gram 0.03527393 ounce* * avoirdupois Temperature To Convert Use Formula temperature Celsius (t temperature Fahreheit (t = 1.8 t + 32 temperature Fahreheit (t temperature Celsius (t = (t...

  • Page 353: Contents

    SureStak Power Stacker ™ Contents Introduction ..................page 354 Stacker Operation ................page 354 Setting Up The Power Stacker ..........page 355 Loading And Starting The Power Stacker......... page 358 Stacker Problems ................page 359 Stacker First Inspection ............page 359 Stacker Confidence Check ............

  • Page 354: Introduction

    Appendix D Introduction Introduction The SureStak Power Stacker is a factory-installed option that augments the paper feed system of cabinet model printers. It is designed to work with forms 5 to 12 inches long (12.7 to 30.5 cm) and up to 16 inches (41 cm) wide without the paper tent installed or up to 15.5 inches (39.5 cm) wide with the paper tent installed.

  • Page 355: Setting Up The Power Stacker

    Setting up the Power Stacker 1. Set the printer power switch to | (On). 2. On the rear control panel, press the ON LINE key to take the printer offline. (Figure 64.) 3. Press the ELEVATOR UP key and wait for the elevator assembly to reach the top of its travel.
  • Page 356 Appendix D Stacker Operation 4. If the paper you will use is not wider than 15.5 inches (39.5 cm) pull out the paper tray and install the wireform paper tent. (Figure 65.) If the paper is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer. Paper Tent Paper Tray Note the positions of...
  • Page 357 5. Push or pull the paddle shaft toward the front or the rear of the printer to set the desired paper length. Align the indicator notch on the bearing bracket with the paper length indicator. The power stacker can handle paper or forms from 5 to 12 inches (12.7 to 30.5 cm) long.

  • Page 358: Loading And Starting The Power Stacker

    Appendix D Stacker Operation Loading and Starting the Power Stacker 1. Press the PAPER ADVANCE key and hand feed the paper down into the paper throat of the stacker. Continue to advance the paper until it reaches the paper tent (if installed) and feed three to five extra sheets into the stacker.

  • Page 359: Stacker Problems

    Stacker First Inspection Stacker Problems The power stacker augments the paper feed system of the printer. The most frequently occurring problems in the paper feed system are paper jams. Other problems that can occur are worn or poor electrical connections and cabling, worn or defective feed motors, worn or damaged mechanical components, or incorrect installation of the stacker assembly.

  • Page 360: Stacker Confidence Check

    Appendix D Stacker Problems c. With the elevator at its lowest position, run the Shuttle Slow test (page 136) from the front operator panel. While the test runs, interrupt both IR beams, one at a time, and verify that the elevator rises. d.

  • Page 361: Stacker Stacker Motor Check

    Stacker Motor Check 6. Using the rear operator panel, press the PAPER ADVANCE (down arrow) key until three or four pages feed through the stacker throat. a. Check the LCD on the front operator panel for faults. If there is a fault, the paper out detector is failing and needs to be checked and cleaned.
  • Page 362 Appendix D Stacker Problems 8. Check all four stacker motors for 15.2 ± 1.5 Ohms resistance per phase. All four motors are the same: Measure pin 1 to pin 2 for Phase A Measure pin 3 to pin 4 for Phase B pin 1 = red pin 2 = yellow pin 3 = orange...
  • Page 363 Stacker Motor Check Table 7. Power Stacker Problems Symptom Origin of Symptom Explanation Solution Stacker limit switch Other troubleshooting A procedure that tests the page 121 check procedures. motion limit switch at the top and bottom of the right vertical rail. You will usually be referred to this procedure from other troubleshooting procedures.

  • Page 364: Removing The Power Stacker

    Appendix D Removing the Power Stacker Removing the Power Stacker 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3. Unload paper from the stacker area. (Refer to the User’s Manual.) 4. Remove the paper tent (if present). (Figure 68.) Paper Tent Figure 68.
  • Page 365 Stacker Motor Check 6. Remove the two 10-32 x 5/32 inch buttonhead screws and washers securing the vertical rails to the upper frame cross-member at the rear of the cabinet. (Figure 70.) 7. Remove the two Torx T-10 screws securing the stacker base to the cabinet floor.
  • Page 366 Appendix D Removing the Power Stacker 10. Loosen one turn (do not remove) the M3x6 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (Figure 71.) M3x6 Buttonhead Screw (Two on each rail) Access Hole in Tray Rail Figure 71.
  • Page 367 Stacker Motor Check 11. Lower the elevator assembly to its lowest position. Tilt the vertical rails towards the front of the printer to make room for removing the control panel. 12. Remove the two 4-40 x 1/4 inch screws securing the elevator I/O cable to the elevator assembly and disconnect the stacker I/O cable.
  • Page 368 Appendix D Removing the Power Stacker 13. Remove two screws, washers, and the standoff from the stacker control panel. (Figure 73.) Standoff Washer Washer Long Screw Short Screw Figure 73. Removing the Stacker Control Panel 14. Remove four cables from the stacker control panel, and remove the stacker control panel.
  • Page 369 Stacker Motor Check NOTE: It may be easier to wear gloves for the next step. 15. Slide the stacker assembly slightly to the right to clear the air exhaust duct. Tilt the vertical rails toward the front of the printer until they clear the upper frame cross-member.

  • Page 370: Installing The Power Stacker

    Appendix D Installing the Power Stacker Installing the Power Stacker NOTE: This section shows installation of the power stacker assembly, the stacker cable assemblies, and the stacker control panel. 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3.
  • Page 371 Stacker Motor Check 5. Connect the power stacker logic cable P103 to connector J117 on the controller board. (Figure 77.) 6. Disconnect the power supply cable from connector J101 on the controller board. (Figure 77.) 7. Connect power supply cable connector P101 to the stacker power cable, then connect the stacker power cable to connector J101 on the controller board.
  • Page 372 Appendix D Installing the Power Stacker 10. Pull the paper tray out until the holes in the rails permit access to the M3 buttonhead screws. (Figure 78.) 11. Loosen one turn—do not remove—the M3 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (Figure 78.) M3x6 Buttonhead Screw (Two on each rail) Access Hole in...
  • Page 373 Stacker Motor Check 12. Position the elevator assembly at the bottom of the vertical rails. (Figure 79.) 13. Connect the elevator I/O cable to the elevator assembly and install the two 4-40 x 1/4 inch screws, as shown in Figure 79. Vertical Rail Elevator Assembly Stacker I/O...
  • Page 374 Appendix D Installing the Power Stacker NOTE: It may be easier to wear gloves for the next step. 14. Position the stacker assembly slightly to the right in order to clear the air exhaust duct, insert the vertical rails inside and under the upper frame cross-member, then slowly swing the base of the stacker assembly into the cabinet.
  • Page 375 Stacker Motor Check 17. Align the holes in the stacker base with the holes in the cabinet floor. (Figure 80c and Figure 81) 18. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer securing the left vertical rail to the upper frame cross-member. (Do not install the right hand screw yet.) (Figure 81.) 19.
  • Page 376 Appendix D Installing the Power Stacker 21. Gather the stacker rail cable, elevator I/O cable, logic cable, and power cable. Route the cables outboard of the elevator assembly. (Figure 82.) Elevator I/O Cable Elevator Assembly Rail Cable Card Cage) Control Panel) Stacker Stacker...
  • Page 377 Stacker Motor Check 22. Connect the stacker cables to the rear of the stacker control panel assembly and make sure the ejector levers close over the connectors. (Figure 83.) 23. Press rail cable connector P107 into the control panel until the ejectors close, then tie wrap the ejectors to the connector.
  • Page 378 Appendix D Installing the Power Stacker 24. Apply the double-sided tape to one end of the control panel standoff. Remove the paper backing and hold the standoff inside the cabinet while you insert the upper mounting screw and washer through the hole in the frame.
  • Page 379 Stacker Motor Check 27. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer securing the right vertical rail to the upper frame cross-member. (Figure 81.) 28. Move the elevator assembly up and down on the vertical rails until it travels smoothly with no binding.
  • Page 380 Appendix D Installing the Power Stacker Cutout Beneath Card Cage Fan Stacker Cables Wire Saddle Figure 85. Securing Stacker Cables 33. Install the paper fence. (Figure 86.) Paper Stacker Fence Base Figure 86. Paper Fence...
  • Page 381 Stacker Motor Check 34. If the paper you will use is not wider than 15.5 inches (39.5 cm), pull out the paper tray and install the paper tent. (Figure 87.) If the paper is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer Paper Tent Paper Tray Note the positions of...

  • Page 382: Constant Force Spring

    Appendix D Replacing the Constant Force Spring Replacing the Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 364.) 2. Raise the elevator assembly to within about 1/4 inch of its highest position and secure it to the vertical rails using tie wraps or string. Do not over- tighten the tie wraps or string;...
  • Page 383 Stacker Motor Check WARNING The constant force spring is powerful and under high tension. Protect your hands with gloves. To avoid pinching or cutting your fingers, grip the spring and drum firmly in the next two steps. Coil the spring slowly and carefully.

  • Page 384: Replacing The Timing Belts

    Appendix D Replacing the Timing Belts Replacing the Timing Belts 1. Remove the stacker assembly from the printer (page 364). 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. Do not over-tighten the tie wraps or string;...
  • Page 385 Stacker Motor Check 6. Remove the shoulder screw and large washer that secure the constant force spring to the vertical rail. (Figure 92.) NOTE: Left is shown. Right is the same. Constant Force Spring Large Washer Shoulder Screw Figure 92. Releasing the Constant Force Spring 7.
  • Page 386 Appendix D Replacing the Timing Belts 8. Remove the timing belt by working it around the vertical rail and constant force spring. (Figure 94.) 9. To install a timing belt, reverse the steps of this procedure. NOTE: Left timing belt is shown. Right is the same.

  • Page 387: Roller Drive Shaft

    Stacker Motor Check Replacing the Roller Drive Shaft 1. Remove the stacker assembly from the printer (page 364). 2. Unhook the right bearing pivot plate’s extension spring from the tab on the elevator. (Figure 95.) 3. Using an M-2 Allen wrench, remove the screw securing the right bearing pivot plate to the elevator.
  • Page 388 Appendix D Replacing the Roller Drive Shaft 4. Move the idler shaft enough to expose the lower mount screw of the power stacker stepper motor. (Figure 96.) 5. Cut and remove the upper tie wrap securing the stepper motor wires to the elevator.
  • Page 389 Stacker Motor Check 9. Remove the roller drive shaft, taking care to retain the bearing at the left end of the shaft and the collar at the right end of the shaft. (Figure 97.) 10. Remove the bearing and collar from the old roller drive shaft and retain these items for installation on the new roller drive shaft.

  • Page 390: List Of Illustrations

    Appendix D Illustrated Parts Breakdown Illustrated Parts Breakdown The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the power stacker assembly and subassemblies. Parts are listed next to each drawing. IMPORTANT The Phase III (newest) power stacker is illustrated in this section. If the stacker you are working on does NOT look like the one illustrated here, order the part designated Phase II if the part has both a Phase II and Phase III listing.
  • Page 391 List of Illustrations Parts not Illustrated in this Section • Extended Door Assembly, Stealth Black:177489-001 Extended Door Assembly, Lt Gray: 179792-001 • Reed Limit Switch Assembly: 204234-001 • Control Panel Assy, Pwr Stkr, Black, Americas and Asia/Pacific: 178911-901; EMEA (RoHS): :250676-901) (See Figure 84, page 378) Cont.

  • Page 392: Figure 98. Stacker Assembly

    Appendix D Illustrated Parts Breakdown See page 394. 3 4 5 Figure 98. Stacker Assembly...
  • Page 393 List of Illustrations Part No. Item (RoHS Description Notes Compliant) 178908-001 Stacker Assembly, Power, Black 179804-001 Stacker Assembly, Power, Gray 204956-001 Washer, 5/16 X .200 X .030, Stainless Steel Part of item 36 203251-001 Screw, Hex Skt Btn Hd, Zinc M3X8mm 204458-001 Washer, Shim, .125 ID X .010 inch Thick 173818-001...

  • Page 394: Figure 99. Elevator Detail: Motors, Rollers, And Paddles

    Appendix D Illustrated Parts Breakdown From page 392. See page 396. See page 400. 45 46 See page 398. See page 398. Figure 99. Elevator Detail: Motors, Rollers, and Paddles...
  • Page 395 List of Illustrations Part No. Item (RoHS Description Notes Compliant) 158313-001 Anti-Static Brush Shear Grommet Part of item 36 Cap Nut Part of item 36 158736-901 Drive Shaft Assy (Roller Drive Shaft) Includes items 14, 70, and 75 156393-001 Spacer, Drive Roller Part of item 47 202789-901 Bearing, Flanged...

  • Page 396: Figure 100. Stacker Detail: Motor Bracket

    Appendix D Illustrated Parts Breakdown From page 394. Flag Connector Figure 100. Stacker Detail: Motor Bracket...
  • Page 397 List of Illustrations Part No. Item (RoHS Description Notes Compliant) Clip-On Bearing Part of item 36 158288-001 Holder, LED, Round LED, IR, T-1, 3/4...

  • Page 398: Figure 101. Stacker Detail: Elevator Bracket

    Appendix D Illustrated Parts Breakdown From page 394. Flag Connector Figure 101. Stacker Detail: Elevator Bracket...
  • Page 399 List of Illustrations Part No. Item (RoHS Description Notes Compliant) Clip-On Bearing Part of item 36 158290-001 Holder, LED, Flat Photodarlington, NPN, Rectifier...

  • Page 400: Figure 102. Stacker Detail: Paper Motion Detector

    Appendix D Illustrated Parts Breakdown From page 394. Rotated 180 Degrees Connector Figure 102. Stacker Detail: Paper Motion Detector...
  • Page 401 List of Illustrations Part No. Item (RoHS Description Notes Compliant) 158290-001 Holder, LED, Flat Photodarlington, NPN, Rectifier Retaining Ring, External, 0.093 inch Part of item 115 Screw, Panhead, Type B, 2 x 3/16 Part of item 36 Shaft, Paper Detector Switch, Long Part of item 115 LED, IR, Rectangular 170289-001...
  • Page 402 Appendix D Illustrated Parts Breakdown...

  • Page 403: Contents

    Zero Tear Pedestal (ZTP) Printer Contents Overview ..................page 404 Operation ..................page 405 Load Paper and Set Up the Tractors ........page 405 Remove Paper................page 406 Adjust The Paper Guides............page 407 Position the Paper Out Sensor ..........page 409 Set the Tear Bar Distance ............

  • Page 404: Overview

    Appendix E Overview Tractor (L/R) ................page 432 Tractor Assembly Support Gate ..........page 433 Illustrated Parts Lists............... page 435 Figure 119. ZTP Details ..............page 436 Figure 120. ZTP Inside Covers, Barrier Shield, and Shuttle Assy .. page 438 Figure 121.

  • Page 405: Operation

    Load Paper and Set Up the Tractors Operation Load Paper and Set Up the Tractors Top Cover Paper Edge Paper Label Paper Paper Supply Box Figure 103. Aligning and Loading Paper onto the Printer 1. Align the paper supply box with the label on the bottom left side of the modesty panel.

  • Page 406: Remove Paper

    Appendix E Operation Outer Paper Guide Leaf (2) Front Paper Center Paper Guide Leaf (3) Guide Leaf Paper Tractor (2) Tractor Lock (2) Paper Out Sensor Figure 104. Adjusting the Horizontal Paper Tension 3. Unlock and open the tractor doors and slide the paper from below, through the black paper out sensor slot on the left side, and up between all front and rear paper guide leaves.

  • Page 407: Adjust The Paper Guides

    Adjust The Paper Guides Adjust The Paper Guides Outer Paper Guide Leaf (2) Center Paper Guide Leaf Front Paper Guide Leaf (3) Paper Guide Knob (3) Figure 105. Adjusting The Paper Guides NOTE: You must remove the paper before adjusting the paper guide leaves. Ensure that the paper guide leaves are not damaged.
  • Page 408 Appendix E Operation Center Paper Outer Paper Guide Leaf Guide Leaf (2) Paper Tractor (2) Outboard Mount Center Mount Block (2) Block Figure 106. Adjusting Paper Guide Leaves 4. Slide the left outboard mount block so that the left outer paper guide leaf is .5 inches from the left tractor.

  • Page 409: Position The Paper Out Sensor

    Position the Paper Out Sensor Position the Paper Out Sensor Extrusion Bar At least 2 inches Sensor Knob Paper Out Sensor Paper Figure 107. The Paper Out Sensor The paper out sensor indicates when the printer runs out of paper. (The sensor does not work with black backed forms.) Unlike the standard pedestal printer, the ZTP printer requires you to load the paper through the paper out sensor slot (Figure 104 and Figure 107).

  • Page 410: Set The Tear Bar Distance

    Appendix E Operation Set the Tear Bar Distance To set the tear bar distance, do the following steps: 1. Make sure the printer is offline. 2. Press MENU/ENTER key to enter the menu. 3. Press the right arrow until “OFFLINE/ZTP Menu” displays. 4.

  • Page 411: Set The Top Of Form

    Set the Top Of Form Set the Top Of Form Paper Tear Bar Form Advance Knob Figure 109. Setting The Tear Off Position The ZTP printer uses the tear bar as the reference point for setting the tear off position. To set the position of the forms perforation to the tear bar, use the TOF button as follows: 1.

  • Page 412: Control Panel Menus

    Appendix E Control Panel Menus Control Panel Menus The ZTP SETTINGS menu includes the ability to enable and disable features unique to the Zero Tear printer (ZTP), set the tear bar distance, set the auto present data time, and set the auto present wait time. This section defines these options.

  • Page 413: Performance Limitations

    Set the Top Of Form Performance Limitations Forms Type The paper feed tractors on the ZTP printer push the paper up through the print station instead of pulling it through, as in the standard pedestal printer. This limits the variety of forms the ZTP printer can use. If the forms do not fall within the range specified in Table 8, dot compression and line separation may occur.

  • Page 414: Paper Jams

    Appendix E Performance Limitations Paper Jams Printer jams can occur if you tear off the form incorrectly. If you experience two or more paper jams per box of forms, follow these guidelines to help reduce jams: • Position the lower paper guides properly •...

  • Page 415: Adjustments And Tests

    List of Adjustments and Tests Procedures Adjustments and Tests The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment and may need to be tested as part of a troubleshooting procedure. You usually will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.

  • Page 416: Preparing The Ztp Printer For Maintenance

    Appendix E Adjustments and Tests Preparing the ZTP Printer for Maintenance WARNING Unplug the printer power cord from the printer or power outlet before you do any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 417: Barrier Panel

    Barrier Panel Barrier Panel 1. Prepare the printer for maintenance (page 416). 2. Loosen (do not remove) the two #2 Phillips hold-down screws on the rear of the printer. (See page 436, item 4.) 3. Remove the top cover assembly. (See page 423.) 4.

  • Page 418: Belt, Paper Feed Timing, Adjustment

    Appendix E Adjustments and Tests Belt, Paper Feed Timing, Adjustment 1. Prepare the printer for maintenance (page 416). 2. Remove the top cover assembly (page 423). 3. Remove the hex screws and right cover plate. (See page 419, items 1 and 2.) 4.
  • Page 419 Belt, Paper Feed Timing, Adjustment Direction of Force 1/8 inch Legend: Screw, Hex w/Lockwasher (4) Cover Plate, Right Extension Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaf Pulley Paper Feed Timing Belt Paper Feed Motor Pulley Figure 112. Paper Feed Timing Belt Adjustment...

  • Page 420: Paper Guide Leaf, Front, Center, Outer

    Appendix E Adjustments and Tests Paper Guide Leaf, Front, Center, Outer 1. Prepare the printer for maintenance (page 416). 2. Adjust the paper guides. (See page 407.) Paper Out Sensor, Adjustment 1. Prepare the printer for maintenance (page 416). 2. Adjust the paper out sensor. (See page 409.) Paper Tension, Horizontal 1.

  • Page 421: Replacement Procedures

    List of Removal / Installation Procedures Replacement Procedures WARNING Unplug the printer power cord from the printer or power outlet before doing any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. Only apply power during maintenance if you are instructed to do so in a maintenance procedure.

  • Page 422: Belt, Paper Feed Timing

    Appendix E Replacement Procedures Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 416). 2. Remove the hex screws and right cover plate. (See page 419, items 1 and 2.) 3. Loosen (do not remove) the two 5/16 inch paper feed motor mount screws.

  • Page 423: Control Panel Assembly

    Control Panel Assembly Control Panel Assembly Removal 1. Prepare the printer for maintenance (page 416). 2. Open the printer cover. 3. Disconnect the RJ-11 connector P310 from J2 on the back of the control panel. (See page 436, item 5.) 4.

  • Page 424: Paper Feed Motor

    Appendix E Replacement Procedures Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 416). 2. Remove the top cover assembly. (See page 423.) 3. Remove the paper feed timing belt. (See page 422.) 4. Trace the paper feed motor cables back to the controller board, releasing it from tie wraps.

  • Page 425: Paper Guide Leaf, Center

    Paper Guide Leaf, Center Paper Guide Leaf, Center Removal 1. Prepare the printer for maintenance (page 416). 2. Remove the center paper guide knob and center paper guide leaf. (See page 429, Figure 116.) 3. Remove the top button head screw, bottom flat head screw, and center guide leaf.

  • Page 426: Paper Out Sensor

    Appendix E Replacement Procedures Paper Out Sensor Paper Out Screw (4) Sensor Cable Left Cover (See page 198, Figure 21 Plate for P106 connector configuration details.) Tie Wraps (5) Paper Out Sensor Sensor Wrap Knob Figure 114. Replacing the Paper Out Sensor Assembly Removal 1.
  • Page 427 Paper Out Sensor Removal 1. Install the sensor knob and paper out sensor. 2. Route the paper out sensor cable up along the left side of the printer. (See Figure 114 on page 426.) 3. Connect coupling shroud connector P106 to the controller board and install tie-wraps to secure the motor cable.

  • Page 428: Shaft, Splined

    Appendix E Replacement Procedures Shaft, Splined Back Cover Plate Screw (4) Right Cover Plate Screw (4) Motor Mount Screw (2) Paper Feed Timing Belt Figure 115. Removing the Right Cover Plate and Back Cover Plate...
  • Page 429 Shaft, Splined Removal 1. Prepare the printer for maintenance (page 416). 2. Remove the hex screws and right cover plate. (See Figure 115.) 3. Remove the screws and the back cover plate. 4. Loosen (do not remove) the two 5/16 inch paper feed motor mount screws.
  • Page 430 Appendix E Replacement Procedures Installation 1. Position the splined shaft so the alignment marks are at the bottom on both tractors. (See Figure 117.) 2. Slide the splined shaft through the right side plate, tractors, and block mounts. Make sure the same spline passes the marked groove on each tractor.

  • Page 431: Shaft, Support

    Shaft, Support Shaft, Support Removal 1. Prepare the printer for maintenance (page 416). 2. Remove the hex screws and right cover plate. (See page 440, items 24 and 25.) 3. Unlock the tractors and slide them to the far right. (See page 442, item 1.) 4.

  • Page 432: Tractor (L/R)

    Appendix E Replacement Procedures Installation 1. Slide the support shaft into the right side plate, through the top holes in the tractors, and block mounts. (See page 442, items 1, 2, 21, 22, and 26.) 2. Slide the support shaft through the left side plate until it bottoms in the left tractor shaft plate.

  • Page 433: Tractor Assembly Support Gate

    Tractor Assembly Support Gate Tractor Assembly Support Gate Removal 1. Prepare the printer for maintenance. (See page 416.) 2. Close the tractor doors. (See page 434.) 3. Unlock the left tractor and slide it to the center of the support shaft and splined shaft.
  • Page 434 Appendix E Replacement Procedures Support Shaft Splined Shaft Tractor Door (2) Tractor Lock (2) Left Side Plate Tractor Assembly Support Gate (2) Right Side Plate Figure 118. Removing and Installing the Tractor Assembly Support Gate...

  • Page 435: Illustrated Parts Lists

    Illustrations of ZTP Components Illustrated Parts Lists Only replaceable parts are given part numbers in the illustrated parts lists. Part numbers are not listed for common fasteners and attachment hardware. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly.
  • Page 436 Appendix E Illustrated Parts Lists Figure 119. ZTP Details...
  • Page 437 Illustrations of ZTP Components Part No. Item (RoHS Description Notes Compliant) 250483-002 Control Panel Assembly, Ped Screw, Captive (2) 250086-001 Top Cover Assembly, Ped, Blk 250087-001 Top Cover Assembly, Ped, Gray Screw (2) 152440-901 Cable Assembly, Control Panel 179081-001 Packaged Ped Kit, Stealth Black 179776-001 Packaged Ped Kit, Lt Gray 179162-001...
  • Page 438 Appendix E Illustrated Parts Lists To J02 (Shuttle Two places: Motor) Exploded to show assembly. Do not remove the clamps and screws. To J03 (MPU) See Figure 45, page 260. Figure 120. ZTP Inside Covers, Barrier Shield, and Shuttle Assembly...
  • Page 439 Illustrations of ZTP Components Part No. Item (RoHS Description Notes Compliant) Shuttle Cover Air Shroud Assembly Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread-forming (2) 6-32x.25 and #6 flat washer 179396-001 Barrier Shield 179276-001 Power Supply Insulator Taped to card cage along upper edge 254350-901 Cover Assy 6605, 6605Q, 6605Z...
  • Page 440 Appendix E Illustrated Parts Lists To the Terminator Board on the Shuttle Frame Figure 121. ZTP Circuit Boards and Paper Feed Assembly...
  • Page 441 Illustrations of ZTP Components Part No. Item (RoHS Description Notes Compliant) 250297-901 Power Supply, PFC, 5/10 6605, 6605Q, 6605Z, 6610, 6610Q, 6610Z 250297-991 Power Supply, PFC, 5/10, Adv Exch 6605, 6605Q, 6605Z, 6610, 6610Q, 6610Z 250251-901 Power Supply, PFC, 15 6615, 6615Q, 6615Z 250251-991 Power Supply, PFC, 15, Adv Exch...
  • Page 442 Appendix E Illustrated Parts Lists Figure 122. ZTP Tractor Shafts, Paper Guides, and Paper Feed Motor...
  • Page 443 Illustrations of ZTP Components Part No. Item (RoHS Description Notes Compliant) 179065-901 Tractor Set, Non-Roller, 05/10/15 (Blue) 177821-001 Shaft, Spacer, Tractor, ZTP Part of item 24 178132-001 Pad, Nylon, Mount Block, ZTP Part of item 24 Screw, Button Head (3) 178046-001 Field Kit, Paper Feed Motor, V3 Screw, Hex w/Lock Washer, 10-24x.50 (2)
  • Page 444 Appendix E Illustrated Parts Lists NOTE: Item 24: Platen Hardware Kit Figure 123. ZTP Platen and Integrated Print Management Sensor Assembly...
  • Page 445 Illustrations of ZTP Components Part No. Item (RoHS Description Notes Compliant) Setscrew (2) Part of item 24 Bracket, Platen (2) Part of item 24 Screw, Thread-forming (3) 6-32x.25 174968-001 Ironer Bracket/Plate Field Kit Plate, Ironer Part of item 4 112657-901 Platen Assembly Washer, Flat (2) Part of item 24...
  • Page 446 Appendix E Illustrated Parts Lists Figure 124. ZTP Hammer Bank Fan and Motors...
  • Page 447 Illustrations of ZTP Components Part No. Item (RoHS Description Notes Compliant) 152415-901 Switch Assembly, Paper Detector Optional switch used with black back 170172-001 Field Kit, Slotted Black Back Form Switch forms Screw, Thread-forming, 6-32x.375 (2) Part of item 1 179638-001 Motor Assembly, Platen Includes pulley Undefined...
  • Page 448 Appendix E Illustrated Parts Lists...
  • Page 449 Paper Specifications And Forms Design Introduction This appendix is divided into two sections. The first section lists general specifications for continuous form paper used in this printer. (Specific brands of paper are not recommended.) The second section goes into more detail, providing definitions, guidelines, and a checklist you can use to design forms that will run smoothly through the printer.

  • Page 450: General Paper Specifications

    Appendix F General Paper Specifications General Paper Specifications This section describes the minimum paper specifications that must be met to ensure the best printer performance. Always test paper and forms before buying large quantities. Make all ° ° ° ° measurements at 20 to 26 Celsius (68...

  • Page 451: Paper Guidelines

    Terms and Definitions Test the paper first if it will be used in environments with greater than 80% or less than 20% humidity. Test paper that will be used at high humidity for satisfactory feeding and handling. Test paper that will be used at low humidity to determine if static buildup must be eliminated for proper paper stacking.
  • Page 452 Appendix F Paper Guidelines The figure below illustrates the terms used in this appendix. Side Perforation Margin Area Tractor Pin Hole Page Perforation Cut Point Tie Point Print Area Form Span Side View of Form Printed Side of Form Outward Perforation Inward Perforation Figure 125.

  • Page 453: Environmental Considerations

    Environmental Considerations Environmental Considerations Before they are used, forms should be stored for at least 24 hours — preferably 48 hours — in the environment in which they will be used. This stabilizes the moisture content of the paper, resulting in better feeding and stacking.

  • Page 454: Methods Of Forms Attachment

    Appendix F Paper Guidelines Specification Inches Millimeters Hole centerline (CL) to edge of form 0.236 ± 0.028 6.0 ± 0.10 Hole Diameter (Serrations or any 0.156 ± 0.004 4.0 ± 0.10 occlusion due to incorrect registration of multipart forms cannot exceed this dimension.) Distance between centers of two 0.500 ±...

  • Page 455: Chaff Content

    Chaff Content Preferred Unacceptable Cut Point Tie Point Direction of Forms Movement Tie Point Cut Point Figure 126. Preferred vs. Unacceptable Form Staples Cut-To-Tie Ratio A common cut-to-tie ratio for bond forms is 4:1 (that is, 80% cut to 20% ties). This value is dictated chiefly by the application program that the form runs under.

  • Page 456: Form Design Checklist

    Appendix F Form Design Checklist Form Design Checklist Use this checklist to help you remember key areas of consideration when designing and ordering forms and paper stocks. Environment ________ Before they are used, forms are given at least 24 hours of condensing time in the environment in which they will be used.
  • Page 457 Chaff Content Form Evenness The evenness of the form = ________ (Not to exceed 0.003 in. / 0.00762 cm) Tenting due to buildup of perforation thickness must be minimized. A perforation thickness measured at the major perforation that exceeds 1.25 times the forms thickness measured in the print area will result in an unreliable and unpredictable form.
  • Page 458 Appendix F Form Design Checklist ________ Staples should be placed in the margins so that they coincide with areas of the form where printing will not occur Cut-To-Tie Ratio ____:____ (Typical ratio is 4:1, or 80% cut to 20% tie) Thickness Buildup = ________ in.

  • Page 459: Summary

    Storage and Handling Summary Because it is impossible to test all possible forms available for use in the printer, TallyGenicom recommends that paper conform to the specifications outlined in this appendix for the best printer performance. But the guidelines in this appendix are not a substitute for actual testing. Always test forms—including special single-part paper, multipart forms, forms with glue strips, carbonless forms, card stock, and labels—for satisfactory feeding, registration, and print quality prior to purchase.
  • Page 460 Appendix F Summary...

  • Page 461: Tallygenicom Customer Support Center

    Customer Support TallyGenicom Customer Support Center The TallyGenicom Customer Support Center offers technical support with: • Installation • Configuration and setup • Loading supplies and operating the printer • Specifications of the proper ribbons, forms, and paper • Answers to post-sale service support questions IMPORTANT Please have the following information available before you call the TallyGenicom Customer Support Center:...

  • Page 462: Tallygenicom Supplies Department

    Appendix G TallyGenicom Supplies Department TallyGenicom Supplies Department Contact the TallyGenicom Supplies Department for genuine TallyGenicom supplies. Americas (800) 733-1900 Europe, Middle East, and Africa 33 (0) 1 46 25 19 07 Asia Pacific (65) 6548 4116 or (65) 6548 4182 China (86) 400-886-5598 http://www.tallygenicom.com/supplies/default.aspx...
  • Page 463 Index Numerics Asterisk (*), meaning on messages, 45 15V POWER FAIL, 47 23.5V FAIL*, 48 B00 STATUS: SDRAM DETECTION 166MHZ, 50 48 V CIRCUIT* See User Manual, 48 B01 STATUS: 8245 SDRAM TEST 32MB, 51 48V CHECK*, 49 B02 STATUS: SDRAM PASSED, 51 48V PWR FAIL*, 50 B10 ERROR: NO DRAM DETECTED*, 51 8.5V POWER FAIL*, 46...
  • Page 464 Belt Communications failures, 134 paper feed timing Configuration, 22 replacement, 193 Configuration code, printer, 20 tension adjustment, 156 Connector coupling shrouds, replacement, 197 platen open Control panel replacement, 194 block diagram, 291 tension adjustment, 158 keys, 25 Block diagram, control panel, 291 replacement, 199 Boards Controller board...
  • Page 465 Diagrams E31E EVENT 4 BP - See User Manual, 71 cable routing, 301 E31F EVENT 5 BP - See User Manual, 71 interconnection and cables, 301 E31G EVENT 6 BP - See User Manual, 71 DIMM, location and replacement, 218 E31H EVENT 7 BP - See User Manual, 71 Display messages, printing conventions, 23 E32A CND 0 BP - See User Manual, 72...
  • Page 466 Exception menu, 146 EXCESS RIBBON WEAR - Install New RBN, 79 I/O cable requirements, 31 EXHAUST FAN FLT, 80 Identifying printer models, 19 ILL EXT BUS ACC*, 85 Factory menu, 144 ILL INST ACCSS*, 85 Fan assembly ILLGL OPR ACCSS*, 86 card cage, replacement, 207 Illustrated Parts Lists, ZTP, 435 hammer bank, replacement, 206, 208...
  • Page 467 important maintenance notes, 21 overview, 17 OLD RIBBON - Install New RBN, 90 preventive, 35 Operation, principles of, 279 training for TallyGenicom products, 33 Overview, printer models, 17 Maintenance Preparation, ZTP, 416 Manual how to use, 22 PAP BSY TOO LNG*, 90 notes and notices, 23 PAP FD DRVR CIR* See Manual, 90 printing conventions, 23...
  • Page 468 Platen Procedures gap adjustment, 162 adjustment, 153 interlock switch assembly, replacement, 243 cleaning, 35 platen open belt adjustment, 158 PROTECTED INSTR*, 97 platen open motor, replacement, 227 PWR SUPP VOLT*, 98 platen stop assembly, replacement, 229 replacement, 223 RBN DRVR CIR*, 98 PLEASE WAIT ...
  • Page 469 platen interlock switch assembly, 243 Self-tests platen open belt, 194 diagnostic, printer, 136 platen open motor, 227 printer, 136 platen stop assembly, 229 Setup, SureStak Power Paper Stacker, 355 power supply circuit board, 230 Shaft resistors, terminating, 231 splined, replacement, 236 ribbon drive motor, 233 splined, skew adjustment, 164 security key, 234...
  • Page 470 STACKER FAULT, 105 power supply operation, 187 STACKER FULL, 106 printer, 136 STACKER JAM, 107 printer, diagnostic, 136 Stacker, power, 353 TIP MISMATCH, 108 confidence check, 360 Tool, shuttle stabilizer, 239 installation, 370 Tools, test equipment, and supplies, 30 motor check, 361 Torque, conversion to or from metric, 351 operation, 354 Tractor, replacement, 244...
  • Page 471 forms type, 413 ZTP Platen Open, 412 front paper guide replacement, 425 ZTP TearDist, 412 front, center, outer paper guide leaf ZTP WaitTime, 412 adjustments, 420 horizontal paper tension adjustments, 420 illustrated parts lists, 435 load paper, 405 maintenance preparation, 416 operation, 405 outer paper guide replacement, 425 overview, 404...
  • Page 474 Approved Final May 19, 2011 *255559-001* 255559-001A...

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