Tally T6215 Maintenance Manual
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Tally T6215 Maintenance Manual

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  • Page 1 T6215 Maintenance Manual...
  • Page 2 This Manual is published by Tally Printer Corporation for use with the computer printer described herein. Translations, reprinting or copying by any means of this manual, complete or in part, in any different form requires our explicit approval. Tally Printer Corporation reserves the right to revise this manual without notice, for any reason.
  • Page 3 Table of Contents...

  • Page 5: Table Of Contents

    Appendix B. Downloading Printer Firmware ..................Pref–1 Conventions ............................Pref–1 Chapter 1: Technical Overview Technical Overview ............................ 1–1 T6215 Electronic Hardware Architecture..................... 1–1 Engine Control Module ......................... 1–1 Control Processor ..........................1–1 Sensor Inputs ........................... 1–1 Motor logic and drive ........................1–2 EEPROM ............................
  • Page 6 T6215 Maintenance Manual Table 1–6. Slew Speed........................1–6 Ribbons ..............................1–6 Forms/Paper Description ........................1–6 Acoustics .............................. 1–6 Power Supply ............................1–6 Table 1–7. Power Requirements ..................... 1–6 Cooling System ............................. 1–6 Safety ..............................1–7 Preventive Maintenance ........................1–7 Environment ............................1–7 Operating ............................
  • Page 7 Table Of Contents Hammer ............................2–8 Fault Override Category ........................2–8 Paper Motion ..........................2–8 Paper Out ............................2–8 Ribbon Motion ..........................2–9 Shuttle ............................. 2–9 Temp ............................... 2–9 Platen .............................. 2–9 Control ............................2–9 Link ..............................2–9 Sync ..............................2–9 Diagnostic Category ..........................
  • Page 8 T6215 Maintenance Manual Chapter 3: Faults and Troubleshooting Faults ..............................3–1 Table 3–1. Display Messages ......................3–3 The printer does not power up when switched on ................3–10 The Printer powers up but the Control Panel does not function............3–11 The Control Panel Display functions partially, nonsensically, or not at all.
  • Page 9 Table Of Contents Procedure 7. 13-pack Hammer Replacement ................... 4–12 Figure 15. Measuring old hammer for replacement size ............... 4–12 Figure 16. Aligning the new hammer pack................... 4–13 Procedure 8: Coil Board Replacement ...................... 4–14 Figure 17. Coil board replacement....................4–14 Procedure 9: Shuttle Removal ........................
  • Page 10 T6215 Maintenance Manual Appendix A: Illustrated Parts Breakdowns and Schematics Illustrated Parts Breakdowns and Schematics ....................A–1 Appendix B: Firmware Update Procedure ........................B–1...
  • Page 11 Preface...

  • Page 13: Preface

    About This Manual This manual presents maintenance, alignment, and troubleshooting procedures for the T6215 printer. Also included are all schematics and diagrams necessary for repair and maintenance. The following chapter and appendix summaries will provide you with a survey of the manual contents.
  • Page 14 T6215 Maintenance Manual Blank Page Pref–2...

  • Page 15: Technical Overview

    Chapter 1: Technical Overview...

  • Page 17: T6215 Electronic Hardware Architecture

    Chapter 1. Technical Overview Technical Overview The T6215 is a high speed, low cost, line impact dot matrix printer. It's maximum print speed is 1500 lines per minute in uppercase draft text mode. It prints many fonts in a number of languages, and plots raster graphics and images at a wide variety of dot densities.

  • Page 18: Motor Logic And Drive

    T6215 Maintenance Manual Motor logic and drive • 8 Hz bridge Motor drive chips (2 for ribbon, 2 for shuttle, 2 for paper, and 2 for ribbon ink pump) – Allegro 3952 EEPROM The EEPROM stores engine calibration and printer configuration settings.

  • Page 19: Hammer Drive Module

    Recognition. Characters Per Inch The T6215 offers a variety of CPIs for use in printer output, which are dictated by the font style selected. Each CPI is based on one of twelve character matrixes and twelve dot densities. Each matrix uses a specific number of dot columns for character composition and intercharacter gap.

  • Page 20: Table 1–2. Type Style, Character Matrix, Dot Density, And Cpi Combinations

    T6215 Maintenance Manual Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations Print Modes Type Styles 10 CPI Group 12 CPI Group 15 CPI Group Constant Density Draft Base Matrix: 9 x 8 Base Matrix: 7 x 8...

  • Page 21: Dot Densities And Plot Speeds

    240 x 288 Graphics Benchmarks Two benchmark tests were used to rate graphics output on the T6215 printer. The first was an AIAG label containing bar codes and block characters inside a box. The second was a POSTNET label with one line of POSTNET bar code and four lines of text.

  • Page 22: Paper Slew Speed

    .025 inches. (Reference specifications: ISO 2784, DIN 9771, and DIN 6721.) Acoustics The noise generated by the T6215 printer is 6.7 Bel (sound power level) and 52 dB(A) (sound pressure level) per ISO 7779:1999E. Power Supply The printer requires single phase, 47 to 63 Hz.

  • Page 23: Safety

    Chapter 1. Technical Overview Safety Personnel hazard areas have restricted access with appropriate warning labels. Catastrophic equipment failures are inhibited with protective functions in major areas of overload potential. Preventive Maintenance The T61215 is designed to eliminate the requirement of scheduled maintenance procedures, such as alignment, adjustment, or lubrication.

  • Page 24: Physical Configuration

    28.3" Door Opening (paper loading) 22.7" Industry and Agency Standards The T6215 is designed to meet the requirements of several industry and Govern- ment agency standards. Electromagnetic Emissions EMI: FCC part 15, subpart J, Class A and EN5022 Class B ESD: EN 61000-4-2 (REF.

  • Page 25: Chapter 2: Menu Operations

    Chapter 2: Menu Operations...

  • Page 27: Introduction

    Chapter 2. Menu Operations Introduction The Test menu contains procedures for calibrating sensors, turning motors on and off, changing hammer lead time, running various printer tests, etc. These procedures are located in the Config and Test menus and can be accessed through the Control Panel. Technical Access Mode Technical (Tech) Access Mode is provided for the repair technician.

  • Page 28: Hex Dumps

    T6215 Maintenance Manual Hex Dumps Use Hex Dumps to check printer functions and data processing operations. They may also be helpful in resolving printer performance. These dumps are located in the Configuration menu, Printer category, under the Dump Mode parameter in normal menu operations. There are three...

  • Page 29: Report

    Chapter 2. Menu Operations Report This parameter has fifteen selections. The selections Current Config, All Configs, Configs 1-10 and Calibrations generate printouts. The second pair of reports (LastFault and Version) are displays. The Report Parameter is located in the Config Menu, under the Printer Category. Report selections Configs Prints a report showing the setups of the configurations.

  • Page 30: Test Menu

    T6215 Maintenance Manual TEST Menu The Test menu contains the parameters for testing printer operation, adjusting print quality, and controlling fault reporting. There are three categories in this menu: Pattern, Diagnostics, and Fault Override. The table that follows presents the categories, parameters, and parameter selections that will appear in the Test menu while the printer is in Tech Access Mode.
  • Page 31 Chapter 2. Menu Operations Categories Parameters Selections Control Link Sync Diag Calibrations Hammer Paper Out Platen Gap Cal Meter Paper Out Paper Motion Ribbon Weld Hammer Bus Temp Sensor Power Platen Keypad Motors Ribbon Shuttle Ribbon Pump Blower Shuttle Speed 37-80 Ribbon Speed 1–250...

  • Page 32: Pattern Category

    T6215 Maintenance Manual Pattern Category The Pattern Category contains several predefined print patterns used to test basic printer func- tionality. There are three parameters in this category: Print, Print2, and Plot. Print This parameter is also available in normal menu operations. It has five selections:...

  • Page 33: Plot

    Chapter 2. Menu Operations All E's This option prints lines composed of the uppercase letter E. All #'s This option prints lines composed of the # symbol. All +'s This option prints lines composed of the + sign. Parens This option prints lines composed of the left paren followed by a vertical bar followed by the right paren.

  • Page 34: Selecting And Running A Print Test

    T6215 Maintenance Manual shading. If not, parameters such as individual hammer module heights and align- ments should be checked. Selecting And Running a Print Test Step 1. Take the printer Offline and place it in Tech Access Mode. Step 2.

  • Page 35: Ribbon Motion

    Chapter 2. Menu Operations Ribbon Motion This parameter provides fault override for Ribbon Motion Faults. Shuttle This parameter provides fault override for Shuttle Fault reporting. Temp The Temp Parameter provides fault override for Temperature Threshold fault reporting. Platen This parameter provides fault override for the Platen Open Sensor. Control This parameter provides fault override for the control processor fault reporting status.

  • Page 36: Selecting And Running A Hammer Calibration Routine

    T6215 Maintenance Manual Selecting And Running a Hammer Calibration Routine This procedure generates a test pattern consisting of an assortment of characters and character shapes while stepping through a range of lead times during this hammer timing calibration. The lead times are measured in clock cycles and are printed along the left side of the paper (see Figure 2–1).

  • Page 37: Figure 2–1. Hammer Leadtime Calibration Printout Sample (Partial)

    Chapter 2. Menu Operations Figure 2–1. Hammer Leadtime Calibration Printout Sample (partial) Selecting And Running a Platen Gap Calibration Routine Step 1. Take the printer offline and place it in Tech Access Mode. Step 2. Access the TEST Menu. Step 3. Scroll (L Key) until the Diag Category is displayed.

  • Page 38: Meter

    T6215 Maintenance Manual Meter The Meter Parameter provides real-time dynamic measurements of various sensor readings within the printer. They can be used to adjust the sensor for optimum performance or to test sensors to ensure that they are operating properly. These test measurements are displayed directly on the Control Panel Display.

  • Page 39: Motors

    Chapter 2. Menu Operations Motors This parameter provides a means for testing individual motor circuits by turning them on or off. They can be tested at the current selection (Default) or you can select a variety of speeds at which to test them. (See Shuttle Speed parameter and Ribbon Weld parameter.) Accessing the Motor Tests: Step 1.

  • Page 40: Ribbon Threshld

    T6215 Maintenance Manual Ribbon Threshld This parameter allows you to set the Ribbon Sensor Threshold value for the Ribbon Motion Sensor. Threshold selections: 1–255 Paper Out Thold This parameter allows you to set the Paper Out Threshold value for the Paper Out Sensor. By using this, you can compensate for the reflectivity of different types of paper.

  • Page 41: Control Panel Key Operations For Controlling Fault Reporting

    Chapter 2. Menu Operations Control Panel Key Operations For Controlling Fault Reporting In addition to being able to use the above parameters to set up individual fault overrides, you may also use three different key sequences to set up fault overrides. You may set up all fault overrides, four specific overrides, or just Paper Out Fault override.
  • Page 42 T6215 Maintenance Manual Blank Page 2–16...

  • Page 43: Chapter 3: Faults And Troubleshooting

    Chapter 3: Faults and Troubleshooting...

  • Page 45: Faults

    Chapter 3. Faults and Troubleshooting Introduction This chapter deals with troubleshooting problems on the T6215 printer. Messages that indicate printer faults and errors are explained and corrective action given. The few paper handling and print quality problems that may occur are also explained. Troubleshooting tables and diagnostic flow charts have been included.
  • Page 46 T6215 Maintenance Manual Fault Override To allow continued printer operation during serious faults, which usually shut down printer operation, you may use the Fault Override Category in the printer menus system. This allows you to troubleshoot serious faults in order to repair them.

  • Page 47: Table 3–1. Display Messages

    Corrective Action: Check setting on Serial Protocol baud rate, Data Bits, and Parity parameters through the printer control panel. Dead CPU Explanation: The Main CPU has quit talking to the Control CPU. Corrective Action: Cycle power to the printer. If the error recurrs, call Tally. 3–3...
  • Page 48 T6215 Maintenance Manual Table 3–1, Continued MESSAGE Explanation and Corrective Action Fake Mode Explanation: The shuttle motor is disabled, but the printer is “faking” shuttle timing. Corrective Action: Plug in the platen sensor if it is not already. If it’s plugged in already, the platen sensor may be damaged.
  • Page 49 Chapter 3. Faults and Troubleshooting Table 3–1, Continued MESSAGE Explanation and Corrective Action Offline Data In Explanation: The printer is in Offline condition and nonprinted data is in the buffer. Corrective Action: There is no corrective action required. Under normal conditions the printer will continue to print when it is placed back Online.
  • Page 50 T6215 Maintenance Manual Table 3–1, Continued MESSAGE Explanation and Corrective Action Paper Out Explanation: Paper is not being detected in the lower paper path below the print mechanism. Corrective Action: If this message is correct, refer to the ENTER Key Section of Chapter 2 of the Operator Manual, then load paper.
  • Page 51 Chapter 3. Faults and Troubleshooting Table 3–1, Continued MESSAGE Explanation and Corrective Action Print Fault Explanation : Faulty communication between the main and control processor has occurred causing a dot row to misprint. The printer automati- cally recovers from this condition. Corrective Action : Under normal circumstances there is no corrective action other than to depress the CLEAR Key to remove the fault message from...
  • Page 52 T6215 Maintenance Manual Table 3–1, Continued MESSAGE Explanation and Corrective Action Shuttle Fault Explanation: If the control processor detects the shuttle operating either above or below the proper frequency, it shuts down the shuttle and attempts to restart it. If the shuttle still operates incorrectly after three consecutive attempts, the Control Processor goes Offline, and the Shuttle Fault message is displayed.
  • Page 53 Chapter 3. Faults and Troubleshooting Table 3–1, Continued MESSAGE Explanation and Corrective Action Explanation: Thermal Fault The ambient temperature has exceeded the limit (Max T). Corrective Action: Check to see if the Circuit Cooling and Hammer Bank fans are working. If both fans are working, you have a faulty Engine Controller Board.

  • Page 54: The Printer Does Not Power Up When Switched On

    T6215 Maintenance Manual Hardware Troubleshooting Guides Not all printer problems are reported by an error message. Malfunctioning hardware can cause a wide variety of problems without triggering a fault indication. The troubleshooting procedures in this section will help you to repair hardware problems.

  • Page 55: The Printer Powers Up But The Control Panel Does Not Function

    Chapter 3. Faults and Troubleshooting The Printer powers up but the Control Panel does not function. There are four things that can cause this problem. 1. A bad connection. 2. A bad control panel. 3. A bad Engine Controller Board. 4.

  • Page 56: There Is No Printed Output But The Printer Appears To Be Operating Normally

    T6215 Maintenance Manual There is no printed output but the printer appears to be operating nor- mally. There are three things that can cause this problem. 1. The platen may be open too far but not far enough to cause a Platen Open message.

  • Page 57: Printed Output Appears Shaky Or Fuzzy

    Chapter 3. Faults and Troubleshooting Printed output appears shaky or fuzzy There are six things that can cause this problem. The platen may be open too far but not far enough to cause a Platen Open message. The shuttle mechanism is worn—the shuttle counterweight gears or the bearings are worn.
  • Page 58 T6215 Maintenance Manual Troubleshooting Procedure Step 1. Open the cover and paper guide areas. Step 2. Inspect the Hammer Bank cables for rub spots, cracked insulation, burn spots, etc. If any physical defects are found in the cables, remove and replace the Cable Assembly and correct the cause of the problem with the cable.

  • Page 59: The Printer Is Out Of Paper - No Paper Out Fault Is Reported

    Chapter 3. Faults and Troubleshooting The Printer is out of paper — No Paper Out fault is reported There are four things that can cause this problem. Fault override for paper out sensor is on, disabling the paper out sensor. Calibration values have been lost for the paper out sensor.

  • Page 60: Table 3–2. Paper/Printing Corrective Action

    T6215 Maintenance Manual Paper Handling Problems The following table lists the few paper handling problems you may encounter along with corrective actions you may take. Table 3–2. Paper/Printing Corrective Action Problem Cause Corrective Action The paper holes are wider Horizontal paper tension is too Unlock and readjust the tractors.
  • Page 61 Chapter 3. Faults and Troubleshooting Troubleshooting The Hammer Driver Transistors The Hammer Driver Transistors are located on the Engine Controller Board. When you are having problems like Hammer Coil shorting or Hammers not firing, these components should be checked along with the other components involved in the function. To check the Hammer Driver for the malfunctioning hammer, use an Ohmmeter on its lowest scale.

  • Page 62: Figure 3–1. Power On Troubleshooting Sequence

    T6215 Maintenance Manual Power On Troubleshooting Sequence START POWER ON RESEAT OR CHECK RUNS REPLACE CONN. CONNECTIONS 120V MOTOR PRESENT WORKING @ P103? REPLACE CONTROLLER BOARD REPLACE FAN ASSEMBLY 120V Present @ P103? Power REPLACE DISPLAY LED On POWER SUPPLY PCB...

  • Page 63: Figure 3–1A. Power On Troubleshooting Sequence, Continued

    Chapter 3. Faults and Troubleshooting Power On Troubleshooting Sequence Cont. From Page 3-18 Reseat or Check Display Data Replace Conn. Connections Correct? Replace Front Panel Still Replace Incorrect Logic PCB Displays Note: Assumes Paper Is Installed Paper Out ? Recalibrate See Chapter 2, Paper Out "Menu Operations"...

  • Page 64: Figure 3–2. Print Data Troubleshooting Sequence

    T6215 Maintenance Manual START Print Data Troubleshooting Sequence DOES SHUTTLE ENERGIZE AND COME TO CORRECT SPEED? DOES SHUTTLE PLATEN BELT BROKEN CONTROL PROCESSOR OPERATING IN "FAKE" MODE (SEE CHAPTER 3) MAY BE NO SHUTTLE PROBLEM. CONNECT PLATEN SENSOR BEFORE ATTEMPTING SHUTTLE DIANOSTICS.

  • Page 65: Figure 3–2A. Print Data Troubleshooting Sequence, Continued

    Chapter 3. Faults and Troubleshooting MOST PROBABLE CAUSE IS A MECHANICAL DIFFICULTY- CHECK FOR BINDING, ETC. IS SHUTTLE MOTION ERRATIC? IS SHUTTLE BELT INTACT/ IN PLACE? RESEAT OR REPLACE BELT AT MOTOR AND COUNTERWEIGHT PULLEYS REPLACE BAD PULLEY ASSEMBLY SENSOR THEN ADJUST SHUTTLE SENSOR RETEST...

  • Page 66: Figure 3–2B. Print Data Troubleshooting Sequence, Continued

    T6215 Maintenance Manual Figure 3–2b. Print Data Troubleshooting Sequence, Continued 3–22...

  • Page 67: Figure 3–2C. Print Data Troubleshooting Sequence, Continued

    Chapter 3. Faults and Troubleshooting Figure 3–2c. Print Data Troubleshooting Sequence, Continued 3–23...

  • Page 68: Figure 3–2D. Print Data Troubleshooting Sequence, Continued

    T6215 Maintenance Manual PRINT DENSITY LIGHT PAPER THICKNESS WHEEL SET ADJUST PAPER THICKNESS WHEEL. PRINT QUALITY RIBBON MOTOR MOVING RIBBON? CHECK CONNECTION P502 RESEAT OR REPLACE CONN. THERE @P502 PLUG RIBBON MOTOR INTO PAPER MOTOR CONNECTOR AND PRESS LF KEY.

  • Page 69: Chapter 4: Removing And Replacing Components

    Chapter 4: Removing and Replacing Components...

  • Page 71: Introduction

    Required Tools This is a list of tools you will need to perform the procedures in this chapter. The tools are available through the Tally Spares Department (see Appendix A for part numbers). • Paper belt tension gauge •...

  • Page 72: Service Procedures

    T6215 Maintenance Manual Service Procedures Ribbon Platform removal ................4–3 Ribbon Motor removal.................. 4–4 Ribbon Motion Sensor PCA (Printed Circuit Assembly) removal ....4–5 Control Panel removal .................. 4–6 Hammer Bank removal ................. 4–8 Ribbon Shield removal ................. 4-11 13-pack Hammer replacement ..............4-12 Coil Board replacement ................

  • Page 73: Procedure 1: Ribbon Platform Removal

    Chapter 4: Removing and Replacing Components Procedure 1: Ribbon Platform Removal Step 1. Open the top cover of the printer. Step 2. Open the Platen Gap lever. Step 3. Loosen the screws on the left and right top of the ribbon platform and lift the platform.

  • Page 74: Procedure 2: Ribbon Motor Removal

    T6215 Maintenance Manual Procedure 2: Ribbon Motor Removal In printers set up to use the 250-million character ribbon, there are two mo- tors in the ribbon platform: one is used as the ribbon drive motor and the other drives the re-inking mechanism.

  • Page 75: Procedure 3: Ribbon Motion Sensor Pca Removal

    Chapter 4: Removing and Replacing Components Procedure 3: Ribbon Motion Sensor PCA Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Turn the platform over and unplug the orange motor cable(s) and the gray sensor cable. Step 3. Remove the two screws that hold the PCA to the platform. Figure 5.

  • Page 76: Procedure 4: Control Panel Removal

    T6215 Maintenance Manual Procedure 4: Control Panel Removal Step 1. Remove the Ribbon Platform. Step 2. Reach underneath the Control Panel assembly and unplug the gray Control Panel cable. Unplug Control Panel Cable Figure 6. Unplugging Control Panel cable. Step 3. Loosen the four screws underneath the Control Panel at the bottom edge of the frame.

  • Page 77: Procedure 4A: Control Panel Circuit Board Removal

    Chapter 4: Removing and Replacing Components Procedure 4a: Control Panel Circuit Board removal Step 1. Remove all six screws holding the circuit board to the Control Panel. Step 2. Lift the circuit board from the panel. Figure 7. Removing circuit board screws. To reinstall, seat the keypad, then mount the circuit board.

  • Page 78: Procedure 5: Hammer Bank Removal

    T6215 Maintenance Manual Procedure 5: Hammer Bank Removal The Hammer Driver CBA has components which are static sensitive! Use the appropriate ESD grounding procedures when handling the Hammer Bank Assembly. Step 1. Remove the Ribbon Platform (See Procedure 1), and open the Platen Gap lever.

  • Page 79: Figure 10. Removing Screws On Retainer Clips

    Chapter 4: Removing and Replacing Components Step 5. Slide the Shuttle Drive Belt from the pulley on the right side of the Hammer Bank. Step 6. Remove two screws securing the retainer clips at the front (toward you) of the Hammer Bank.

  • Page 80: Figure 12. Lifting Hammer Bank From Printer

    T6215 Maintenance Manual Step 6. Slide the upper left tractor as far to the left as it will go. Lift the Hammer Bank and shuttle out of the printer, being careful not to damage the ribbon shield. Hammer Bank and attached Shuttle Figure 12.

  • Page 81: Procedure 6: Ribbon Shield Removal

    Chapter 4: Removing and Replacing Components Procedure 6: Ribbon Shield Removal Step 1. Remove the Hammer Bank (see Procedure 5). Step 2. Remove the three screws and lift the Ribbon Shield from the Hammer Bank. Guide Pin Spring Plate, 2 places Screw, 3 places Ribbon Guide Pin...

  • Page 82: Procedure 7. 13-Pack Hammer Replacement

    T6215 Maintenance Manual Procedure 7. 13-pack Hammer Replacement Step 1. Remove the Hammer Bank assembly from the printer (see Procedure 5). Step 2. Remove the Ribbon Shield (see Procedure 6). Step 3. Using your Torx tool, remove the hammer mounting screws.

  • Page 83: Figure 16. Aligning The New Hammer Pack

    Chapter 4: Removing and Replacing Components Step 6. Place the new hammer pack in position on the bank and replace screws, but do not tighten. Step 7. Use the Hammer Alignment tool to align the impact elements of the new hammer (holes 2 and 3) with the impact elements of the neighboring ham- mers (holes 1, 4, and 5).

  • Page 84: Procedure 8: Coil Board Replacement

    T6215 Maintenance Manual Procedure 8: Coil Board Replacement Step 1. Follow steps 1-4 of the 13-pack Hammer replacement procedure (see Proce- dure 7). Step 2. Remove the coil board mounting screw. Step 3. Lift the coil board from the carriage. To do this, you may need to gently pry it with a tool.

  • Page 85: Procedure 9: Shuttle Removal

    Chapter 4: Removing and Replacing Components Procedure 9: Shuttle Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Remove the Hammer Bank (see Procedure 5). Step 3. Remove the two screws which hold the shuttle frame to the Hammer Bank. Figure 18.

  • Page 86: Procedure 10: Platen Removal

    T6215 Maintenance Manual Procedure 10: Platen Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Remove the Control Panel assembly (see Procedure 4). Step 3. Remove the Hammer Bank (see Procedure 5). Step 4. Remove the two screws (#6 Phillips) that attach the circuit board from under- neath the left side of the printer.

  • Page 87: Figure 21. Removing The Platen Springs

    Chapter 4: Removing and Replacing Components Platen Spring Platen Spring, Platen Spring, left side right side Figure 21. Removing the Platen Springs. Step 7. Rotate the Platen Gap Adjustment Wheel until it is all the way open (on "H"). Step8. Remove the three screws that attach the platen stop to the side plate. There are two washers under each screw.

  • Page 88: Platen Gap Adjustment

    T6215 Maintenance Manual Platen Gap Adjustment Wheel Platen Stop #6 Phillips screws Platen Platen Stop Figure 22. Removing screws from the platen stop. Step 9. Pull the platen stop away from the side plate enough for the platen pin to clear Step 10.

  • Page 89: Figure 23. Transferring Components From Old To New Platen

    Chapter 4: Removing and Replacing Components #6 Screws, 2 places Platen Gap Adjust Plate, 2 places Platen Spring Curved Spring Washer Lever Platen Figure 23. Transferring components from old to new platen. Step 12. Remove the spring lever from the left side. It is attached with two #6 Phillips screws.

  • Page 90: Figure 24. Adding Grease

    T6215 Maintenance Manual Grease inside of Grease Grease both frame end plates Grease Grease Figure 24. Adding grease. Step 14. Grease the sideplates of the print mechanism where they will come in contact with the Platen Gap Adjustment plates. Step 15. Place the new platen into the print mechanism. The platen pins slide into the slots on the sideframes.
  • Page 91 Chapter 4: Removing and Replacing Components Step 18. Lower the print mechanism into the cabinet (see Procedure 10). Step 19. Reattach the circuit board to the left Platen Gap Adjustment Plate. Step 20. Reinstall the Hammer Bank (see Procedure 5). Step 21.

  • Page 92: Procedure 11: Platen Gap Adjustment

    T6215 Maintenance Manual Procedure 11: Platen Gap Adjustment You must perform this procedure whenever you have removed and replaced the Hammer Bank and Shuttle. Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Remove paper, if loaded. Step 3. Set the Platen Gap Wheel to the green indicator.

  • Page 93: Figure 25. Platen Adjustment Screws And Use Of Shim

    Chapter 4: Removing and Replacing Components Platen Gap Adjustment Wheel Green Indicator Allen Wrench Platen Adjustment Screw 0.011" Shim Ribbon shield and plastic finger guard Platen Adjustment Screw Figure 25. Platen Adjustment screws and use of shim. 4–23...

  • Page 94: Procedure 12: Print Mechanism Access (Tilting)

    T6215 Maintenance Manual Procedure 12: Print Mechanism Access (Tilting) Access to the Print Mechanism is more easily attained by tilting the Print Mechanism (useful for tractor removal, access to paper drive belts and motor, etc.). Follow these steps to tilt the Print Mechanism.

  • Page 95: Figure 27. Print Mechanism Tilted And Held By Strut

    Chapter 4: Removing and Replacing Components Step 4. Lift the Print Mechanism. Place the strut in the top and bottom detents, with the shoulder on the strut in the bottom detent. Strut Figure 27. Print Mechanism tilted and held by strut. 4–25...

  • Page 96: Procedure 13: Distribution Pca Removal

    T6215 Maintenance Manual Procedure 13: Distribution PCA Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Tilt the Print Mechanism (see Procedure 10). Step 3. Disconnect all cables at the Distribution PCA. Step 4. Remove the two screws that hold the mounting bracket to the frame and lift the assembly out of the printer.

  • Page 97: Procedure 14: Lower Tractor Removal

    Chapter 4: Removing and Replacing Components Procedure 14: Lower Tractor Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Tilt the Print Mechanism (see Procedure 10). Step 3. Unplug the Paper Out sensor cable from J1 of the Platen/Paper Sensor PCA. (The Paper Out Sensor is part of the Lower Left Tractor Assembly).

  • Page 98: Figure 31. Ground Spring

    T6215 Maintenance Manual Do not remove the pulley or drive belt from the shaft. If the pulley and/or the drive belt is removed, you will need to rephase the upper and lower tractor sets. (See Procedure 14). Step 5. Remove the ground spring from the right side of the square shaft.
  • Page 99 Chapter 4: Removing and Replacing Components Step 8. You should now have enough space to be able to slide both tractors to the left and off the shafts. Keep track of the position of the springs and washers on the support shaft as you remove them. Each tractor has a raised bump which corresponds to a corner of the square shaft.

  • Page 100: Procedure 15: Upper Tractor Removal

    T6215 Maintenance Manual Procedure 15: Upper T ractor Removal This is very similar to Procedure 12 on the previous pages. Step 1. Open the printer cover and remove the paper. Remove the snap rings from both ends of the square tractor shaft (located inside the frame at each end).

  • Page 101: Procedure 16: Tractor Phasing/Paper Drive Belt Tension Adjustment

    Chapter 4: Removing and Replacing Components Procedure 16: Tractor Phasing/Paper Drive Belt T ension Adjustment Any time that a tractor paper drive pulley or drive belt is removed or if the paper drive motor is replaced, the paper system must be checked for proper phasing and belt tension.

  • Page 102: Figure 34. Paper Tension Lever In Middle Position

    T6215 Maintenance Manual Step 6. Place the Paper Tension lever at about the midpoint position, then install the Phasing Gauge onto the upper and lower tractors. (If the Phasing Gauge is not available, a single sheet of computer paper can be used as a temporary tool.)

  • Page 103: Figure 36. Placing Tension Gauge

    Chapter 4: Removing and Replacing Components Step 7. Gently turn the upper drive shaft pulley (without the belt) manually until the gauge or paper is snug. Step 8. Install the upper drive belt, keeping the phasing gauge or paper snug. Step 9.

  • Page 104: Figure 37. Placing Paper Tension Gauge

    T6215 Maintenance Manual Step 11. Loosen the screw securing the Lower Idler Bracket and slide it down to adjust the lower belt tension. Lay the angled end of the belt tension gauge on the paper drive pulley and press it against the belt. Adjust the position of the lower idler bracket until proper tension is achieved (see Figure 37).

  • Page 105: Procedure 17: Paper Drive Motor Removal

    Chapter 4: Removing and Replacing Components Procedure 17: Paper Drive Motor Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Tilt the Print Mechanism (see Procedure 10). Step 3. Loosen the screw holding the lower idler bracket and slide it away from the belt, then retighten the screw to hold the bracket in place temporarily.

  • Page 106: Procedure 18: Shuttle Motor Removal

    T6215 Maintenance Manual Procedure 18: Shuttle Motor Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Tilt the Print Mechanism (see Procedure 10). Step 3. Lift the Shuttle Drive Belt from the upper pulley. Step 4. Remove the four screws at the Shuttle Motor.

  • Page 107: Procedure 19: Control Pca Assembly Removal

    Chapter 4: Removing and Replacing Components Procedure 19: Control PCA Assembly Removal The Control PCA assembly has components which are static sensitive! Use the appropriate ESD grounding procedures when handling the Control PCA assembly. Step 1. Working through the front door area, loosen the 11/32" nut securing the connector cover and remove the cover.

  • Page 108: Procedure 20: Power Supply Assembly Removal

    T6215 Maintenance Manual Procedure 20: Power Supply Assembly Removal Step 1. Remove the Ribbon Platform (see Procedure 1). Step 2. Disconnect the DC power cable at the Distribution PCA. Step 3. Working through the back door of the printer, loosen the four mounting nuts (11/32"), lift the enclosure slightly and lift it from the mounting studs.
  • Page 109 Appendix A: Schematics and Parts lists...
  • Page 111 Appendix A: Schematics and Parts Lists T6215 Illustrated Parts Breakdown and Schematics Recommended Spare Parts Part Number Belt, Paper Drive 075127 Belt, Shuttle Drive 732753 Blower Assembly (Electronics Assy) 083145 Blower Assembly (Hammer Bank) 083589 Capacitor, Surge 732752 Control Panel Assembly - Std. English...
  • Page 112 T6215 Maintenance Manual Notes: A–2...
  • Page 113 Appendix A: Schematics and Parts Lists 083674 083673 27.0" 083672 27.0" Cabinet Assembly I A–3...
  • Page 114 T6215 Maintenance Manual 083466 CABINET ASSY- PRINTER 613278-082992 CABINET ASSY 613187-082706 COVER ASSY- LID 613294-083001 DOOR ASSY 403692-732659 GAS SPRING 403692-731092 BALL STUD 613343-083601 GASKET- MAGNETIC, LID 404036-731449 CASTER 613373-083378 SHAFT- SUPPORT 404307-732796 CLIP- PLASTIC, SELF- ADHESIVE 403666-730956 GROUND STRAP- INSULATED, 18" X 1"...
  • Page 115 Appendix A: Schematics and Parts Lists Basic Printer Assembly BASIC PRINTER ASSY- W/RIBBON PLATFORM 083095 W/RFD & SKOW BASIC PRINTER ASSY- W/RIBBON PLATFORM 083464 W/RFD, W/SKOW & RE-INKING DRIVE 613333-083607 PRINT MECHANISM ASSY PLATFORM ASSY- RIBBON SUPPORT 613315-083081 W/O RE-INKING DRIVE PLATFORM ASSY- RIBBON SUPPORT 613315-083463 W/RE-INKING DRIVE...
  • Page 116 T6215 Maintenance Manual To "PAPER OUT To "PAPER MOTION TO "CBA POWER SENSOR" SENSOR" DISTRIBUTION" (LOWER TRACTOR) (UPPER TRACTOR) NOTES: APPLY A LIGHT COAT OF GREASE (ITEM 67) BETWEEN ITEM 54 AND SIDE PLATE, AROUND STANDOFF, OR INDICATED AREA. INSTALL ITEMS 51, 52, AND 61 WITH ZERO CLEARANCE TO ITEM 60, AND LOCK IN PLACE WITH ITEM 74.
  • Page 117 Appendix A: Schematics and Parts Lists Print Mechanism Assembly II (3333E P2) A–7...
  • Page 118 T6215 Maintenance Manual Print Mechanism Assembly III (3333E P3) A–8...
  • Page 119 Appendix A: Schematics and Parts Lists Print Mechanism Assembly IV (3333E P4) A–9...
  • Page 120 T6215 Maintenance Manual PRINT MECHANISM PRINT MECHANISM PRINT MECHANISM ASSEMBLY ASSEMBLY ASSEMBLY 083607 PRINT MECHANISM ASSY 400658-731239 ACTIVATOR- ADHESIVE 400726-06 NUT- #5/16-18 PLAIN HEX CENTERING GUIDE- LOWER LINEAR BEARING 613271-082951 400627-221 SCREW- #8-32 X 1.125, PAN HEAD 404114-732806 SCREW- #8-32 X 1 5/8, PAN HEAD...
  • Page 121 Appendix A: Schematics and Parts Lists 400215-10 WASHER - #8 SPLIT LOCK 402524-732692 SCREW - #8-32 X 1.625 SEMS 400512-249 SCREW - #8-32 X 5/8, SOCKET HEAD 613286-082982 SHUTTLE ASSY 613332-083567 HAMMER BANK ASSY – 083094 HAMMER BANK AND SHUTTLE ASSY 083130 ITEM PART NO.
  • Page 122 T6215 Maintenance Manual 083567 ASSEMBLY Hammer Bank Assy Basic Printer Assembly III (3332D P1) A–12...
  • Page 123 Appendix A: Schematics and Parts Lists NOTES: TORQUE TO 35 IN-LBS. 083567 HAMMER BANK ASSY TORQUE TO 14 IN-LBS. TORQUE TO 8.5-9.3 IN-LBS. TORQUE TO 25 IN-LBS. WHENCONNECTORS OF ITEM 18 AND 10 ARE MATED TOGETHER THEY SHOULD BE PUSHED TOGETHER UNTIL THE O-RING OF ITEM 18, IS CONTACTING BOTH THE PCB, ITEM 10, AND THE PLASTIC SUPPORT OF ITEM 18 CONNECTOR.
  • Page 124 T6215 Maintenance Manual PLATFORM ASSY- RIBBON SUPPORT 083081 W/O RE-INKING DRIVE ASSY PLATFORM ASSY- RIBBON SUPPORT 083463 W/ RE-INKING DRIVE ASSY 613277-082969 PLATFORM ASSY- RIBBON 613190-082691 CBA- RIBBON SENSOR 611010-075138 MOTOR 611138-083144 CABLE ASSY- SENSOR 404316-732832 CAPTIVE SCREW- PANEL, #6-32...
  • Page 125 Appendix A: Schematics and Parts Lists – 083488 CONTROL PANEL ASSSY– ENGLISH, TESTED 403077-732805 CONTAINER–ESD SENSITIVE DEVICE 613020-082766 CBA– CONTROL PANEL, TESTED 404239 - 732637 RETAINER– SHAFT, INTERNAL TOOTH 404240 - 732638 SCREW– #6 - 19 x 3/8 "PLASTITE" PAN HEAD 613164 - 082644 OVERLAY–...
  • Page 126 T6215 Maintenance Manual Control Panel Circuit Board Assembly Control Panel Circuit Board Assembly Page 1 of 2 (3020- P1 PL2&3) A–16...
  • Page 127 Appendix A: Schematics and Parts Lists Control Panel Circuit Board Assembly Page 2 of 2 (3020- P2) A–17...
  • Page 128 T6215 Maintenance Manual 403637-731042 SUPPORT- CABLE, NYLON, TWIST LOCK 613353-083577 CABLE ASSY- DC 403660-730910 BEAD- FERRITE, CLAMP-ON 403637-730755 SUPPORT- CABLE, NYLON, TWIST LOCK 613353-083129 CABLE ASSEMBLY- DC 613353-083128 CABLE ASSEMBLY- GROUND 613353-083127 CABLE ASSEMBLY-SWITCH TO POWER SUPPLY 613353-083126 CABLE ASSEMBLY- POWER INLET TO SWITCH 402524-730381 SCREW- #6-32 X 0.375 SEMS...
  • Page 129 Appendix A: Schematics and Parts Lists 082029 ASSY 082029 ASSY 082052 ASSY Controller Circuit Board Assembly Page 1 of 10 (3000D P1) A–19...
  • Page 130 T6215 Maintenance Manual 083102 ASSY 083102 ASSY 083104 ASSY (3000D P2) Controller Circuit Board Assembly Page 2 of 10 A–20...
  • Page 131 Appendix A: Schematics and Parts Lists 083537 ASSY 083537 ASSY 083539 ASSY (3000D P3) Controller Circuit Board Assembly Page 3 of 10 A–21...
  • Page 132 T6215 Maintenance Manual Controller Circuit Board Assembly Page 4 of 10 (3000D P4) A–22...
  • Page 133 Appendix A: Schematics and Parts Lists Controller Circuit Board Assembly Page 5 of 10 (3000D P5) A–23...
  • Page 134 T6215 Maintenance Manual Controller Circuit Board Assembly Page 6 of 10 (3000D P6) A–24...
  • Page 135 Appendix A: Schematics and Parts Lists Controller Circuit Board Assembly Page 7 of 10 (3000D P7) A–25...
  • Page 136 T6215 Maintenance Manual Controller Circuit Board Assembly Page 8 of 10 (3000D P8) A–26...
  • Page 137 Appendix A: Schematics and Parts Lists Controller Circuit Board Assembly Page 9 of 10 (3000D P9) A–27...
  • Page 138 T6215 Maintenance Manual Controller Circuit Board Assembly Page 10 of 10 (3000D P5) A–28...
  • Page 139 Appendix A: Schematics and Parts Lists Controller Controller Controller Circuit Board Assembly Circuit Board Assembly Circuit Board Assembly (3000D PL2-7) A–29...
  • Page 140 T6215 Maintenance Manual D21 – D66 Hammer Driver Circuit Board Assembly Page 1 of 5 (3040C P1) A–30...
  • Page 141 Appendix A: Schematics and Parts Lists Hammer Driver Circuit Board Assembly Page 2 of 5 (3040C P2) A–31...
  • Page 142 T6215 Maintenance Manual Hammer Driver Circuit Board Assembly Page 3 of 5 (3040C P3) A–32...
  • Page 143 Appendix A: Schematics and Parts Lists Hammer Driver Circuit Board Assembly Page 4 of 5 (3040C P4) A–33...
  • Page 144 T6215 Maintenance Manual Hammer Driver Hammer Driver Hammer Driver Circuit Board Assembly Circuit Board Assembly Circuit Board Assembly 404318-732843 A–34...
  • Page 145 Appendix A: Schematics and Parts Lists Power Distribution Circuit Board Assembly Page 1 of 2 (3110A P1-3) A–35...
  • Page 146 T6215 Maintenance Manual Power Distribution Circuit Board Assembly Page 2 of 2 (3110A P4 PL2) A–36...
  • Page 147 Appendix A: Schematics and Parts Lists Platen/Paper Sensor Circuit Board Assembly A–37...
  • Page 148 T6215 Maintenance Manual Ribbon Sensor Circuit Board Assembly (3190B P1&2) A–38...
  • Page 149 Appendix B: Downloading Firmware...

  • Page 151: Firmware Update Procedure

    Power up the printer while holding down the following three keys on the control panel: FF, the up arrow, and Config. Hold them down until the following message scrolls on the control panel display: “Tally Flash Loader.” The display then stops scrolling and says: “Flash Dnld Ready.”...
  • Page 152 T6215 Maintenance Manual Blank Page B–2...
  • Page 153 Supplements...
  • Page 155 Supplements Supplements Please file here any supplements you receive. Supp–1...
  • Page 156 T6215 Maintenance Manual Notes: Supp–2...
  • Page 157 Index...
  • Page 159 Index Index EEPROM 1–2 Electromagnetic Emissions 1–8 Electronic Hardware Architecture 1–1 Engine Control Module 1–1 Symbols Environment 1–7 Nonoperating 1–7 13-pack Hammer replacement 4–12 Operating 1–7 About This Manual Pref–1 Fake Mode 3–4 Acoustics 1–6 Fatal Fault n 3–4 Agency Approvals 1–8 Fault Correction Procedure 3–1 AIAG Label Benchmark Results Table 1–5 Fault Override 3–2...
  • Page 160 T6215 Maintenance Manual Self Testing 3–7 Sensor Inputs 1–1 Motorola Cold Fire 5307 1–2 Serial and Parallel Interfaces 1–2 Serial/Parallel Emulations 1–3 Service Procedures 4–2 Control Panel Removal 4–6 No VFU Loaded 3–4 Control PCA Assembly Removal 4–37 NVRAM Fault 3–4 Distribution PCA Removal 4–26...
  • Page 161 Index Serial Dump 2–14 Shuttle Change 2–14 Shuttle Off 2–14 Shuttle Speed 2–13 Fault Override Category 2–8 Control 2–9 Link 2–9 Paper Motion 2–8 Paper Out 2–8 Platen 2–9 Ribbon Motion 2–9 Shuttle 2–9 Sync 2–9 Temp 2–9 Pattern Category 2–6 Plot 2–7 Print 2–6 Print2 2–6...
  • Page 162 T6215 Maintenance Manual Blank Page Index–4...
  • Page 163 Information: 1-425-251-5500 http://www.Tally.com Fax: 1-425-251-5520 http://www.Tally.com Germany Tally Computerdrucker GmbH (TGE) Asia Postfach 29 69 Tally AMT Printers Pte. Ltd., Singapore (TAS) D-89019 Ulm/Donau. 63, Hillview Avenue Germany No. 08/22, Lam Soon Indutrial Bldg. Telephone: +49-7308-800 Singapore 669569 Fax: +49-7308-85903 Tel.: (65) 760-8833...

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