Tally Dot Matrix Printer T6045 and 6050 Supplement Parts and Service Manual

T6045
Maintenance Manual
with T6050 Supplement

Table of Contents
Table of Contents
Table Of Contents
Subject Listing
Preface
Introduction .............................................................................................................................................. 1
Chapter 1: Theory Of Operation And Specifications ....................................................................... 1
Chapter 2: Menu Operations ............................................................................................................ 1
Chapter 3: Troubleshooting .............................................................................................................. 1
Chapter 4: Remove and Reinstall ..................................................................................................... 1
Appendix A: Schematics ................................................................................................................... 1
Appendix B: Illustrated Parts Breakdowns (IPBs) ............................................................................. 1
Appendix C: Downloading Printer Firmware .................................................................................. 1
Chapter 1: Theory Of Operation and Specifications

T6045 Controller Board Theory of Operation ...................................................................................... 1–1
Main CPU .......................................................................................................................................1–1
Control CPU ....................................................................................................................................1–2
Shuttle/Ribbon Microcontroller .....................................................................................................1–2
Hammer/Motor Logic and Drivers .................................................................................................1–2
Parallel and Serial Interfaces ...........................................................................................................1–3
General Operation ..................................................................................................................................1–3
Startup .............................................................................................................................................1–3
Printing ............................................................................................................................................1–3
Specifications ..........................................................................................................................................1–4
Emulations .......................................................................................................................................1–4
Type Styles .......................................................................................................................................1–4
Characters Per Inch .........................................................................................................................1–4
Lines Per Inch ..................................................................................................................................1–6
Dot Densities and Plot Speeds ........................................................................................................1–6
Graphics Benchmarks ..................................................................................................................... 1–7
Ink-Ribbon Cartridge ......................................................................................................................1–8
Paper Movement Speed ...................................................................................................................1–8
Language Character Sets .................................................................................................................1–8
Physical Configurations ..................................................................................................................1–8
Weight .............................................................................................................................................1–8
Paper Description ............................................................................................................................1–9
Acoustics ..........................................................................................................................................1–9
Nonvolatile Memory ....................................................................................................................... 1–9
Power Supply ...................................................................................................................................1–9
Preventive Maintenance ...............................................................................................................1–10
Safety .............................................................................................................................................1–10
Cooling System .............................................................................................................................1–10
Environment .................................................................................................................................1–10
Heat Load Contribution ................................................................................................................1–11
Printer Dimensions .......................................................................................................................1–11
Industry and Agency Standards. ...................................................................................................1–11
TOC–1
T6045 Maintenance Manual
Chapter 2: Menu Operations

Introduction ...........................................................................................................................................2–1
Technical Access Mode ...........................................................................................................................2–1
Entering Tech Access Mode ............................................................................................................2–1
Exiting Tech Access Mode ...............................................................................................................2–1
Testing, Troubleshooting, and Calibration ...........................................................................................2–1
Print Tests ........................................................................................................................................2–2
Hex Dumps ......................................................................................................................................2–2
Printer Information Printouts and Displays ..................................................................................2–2
HELP Menu ...............................................................................................................................2–2
Report Parameter (Menu Level 2) ............................................................................................ 2–3
TEST Menu .............................................................................................................................................2–4
Pattern Category (Menu Level 1) .................................................................................................... 2–6
Print Parameter (Menu Level 2) ...............................................................................................2–6
Print2 Parameter (Menu Level 2) .............................................................................................2–6
Plot Parameter (Menu Level 2) ................................................................................................ 2–7
Selecting And Running a Print Test ................................................................................................ 2–8
Diagnostic Category ........................................................................................................................2–8
PrntCal (Print Calibration) Parameter (Menu Level 2) ........................................................... 2–8
Selecting And Running a Hammer Calibration Routine ............................................................... 2–8
Meter Parameter (Menu Level 2) .............................................................................................2–9
Motors Parameter (Menu Level 2) .........................................................................................2–10
Max T (Maximum Temperature) Parameter (Menu Level 2) ................................................ 2–10
Sht Spd (Shuttle Speed) Parameter (Menu Level 2)............................................................... 2–10
Rbn Spd (Ribbon Speed) Parameter (Menu Level 2) ............................................................. 2–10
Heavy (Heavy Forms) Parameter (Menu Level 2) .................................................................. 2–10
Hm Puls (Hammer Pulse) Parameter (Menu Level 2) ............................................................ 2–10
Max DSH (Maximum/Dots/Second per Hammer) Parameter (Menu Level 2) ..................... 2–11
Clear Parameter (Menu Level 2) ............................................................................................ 2–11
POutThr (Paper Out Threshold) Parameter (Menu Level 2) ................................................. 2–11
Fault Override (FltOvrd) Category ................................................................................................ 2–11
Pap Mot (Paper Motion) Parameter (Menu Level 2) ............................................................. 2–11
Pap Out (Paper Out) Parameter (Menu Level 2) ....................................................................2–11
Shuttle Parameter (Menu Level 2) .........................................................................................2–11
Temp (Temperature) Parameter (Menu Level 2) ....................................................................2–11
Platen Parameter (Menu Level 2) ...........................................................................................2–11
Ctrl (Control Processor) Parameter (Menu Level 2) .............................................................. 2–12
Link Parameter (Menu Level 2) .............................................................................................2–12
Panel Parameter (Menu Level 2) ............................................................................................ 2–12
Control Panel Key Operations For Controlling Fault Reporting ................................................. 2–12
ALL Fault Reporting ...............................................................................................................2–12
Four Faults Only ..................................................................................................................... 2–12
Paper Out Only .......................................................................................................................2–12
Chapter 3: Troubleshooting
Introduction ...........................................................................................................................................3–1
Messages .................................................................................................................................................3–1
Faults ................................................................................................................................................3–1
Fault Correction Procedure ......................................................................................................3–1
Fault Override ...........................................................................................................................3–2
Dump Mode .............................................................................................................................3–2
TOC–2
Table Of Contents
Hardware Troubleshooting Guides ........................................................................................................3–8

The printer does not power up when switched on ........................................................................3–8
When the printer is powered up, nothing works except the fan. .................................................3–9
The Control Panel LEDs and Display do not function. ................................................................. 3–9
The Control Panel Display functions partially, nonsensically, or not at all. ................................ 3–9
There is no printed output but the printer appears to be operating normally. .......................... 3–10
Printed output appears light .........................................................................................................3–10
Printed output appears shaky or fuzzy .........................................................................................3–11
Four adjacent character columns not printing ............................................................................ 3–12
Missing dots–intermittent ............................................................................................................3–13
The Printer is out of paper - No Paper Out fault is reported ....................................................... 3–14
Shuttle Motion Erratic ..................................................................................................................3–14
Paper Handling Problems ....................................................................................................................3–15
T6045 Main Controller To Hammer Bank CBA Cable ........................................................................3–15
Troubleshooting The Hammer Driver Transistors ..............................................................................3–18
Chapter 4: Remove and Reinstall

Introduction ...........................................................................................................................................4–1
Required Tools ........................................................................................................................................4–1
Procedure 1–The Printer Lid ..................................................................................................................4–2
Procedure 2–The Control Panel ............................................................................................................. 4–4
Procedure 3–The Right End Cover .........................................................................................................4–6
Procedure 4–The Main Controller CBA .................................................................................................4–8
Procedure 5–The Fan Assembly ........................................................................................................... 4–10
Procedure 6–The Printer Power Supply ...............................................................................................4–11
Procedure 7–The Power Switch ............................................................................................................4–13
Procedure 8–The Left End Cover .........................................................................................................4–14
Procedure 9–The Ribbon Platform .......................................................................................................4–16
Procedure 10–The Ribbon Motor .........................................................................................................4–18
Procedure 11–The Ribbon Fault Sensor (Printer Option, will not be on all models) ........................ 4–19
Procedure 12–The Paper Out Sensor ...................................................................................................4–20
Procedure 13–The Hammer Bank ........................................................................................................4–21
Procedure 14–The Ribbon Shield .........................................................................................................4–22
Procedure 15–The Hammer Module/Hammer Coil ............................................................................ 4–24
Procedure 16–The Shuttle Mechanism ................................................................................................ 4–27
Procedure 17–The Paper Guide ............................................................................................................4–28
Procedure 18–The Platen ..................................................................................................................... 4–29
Procedure 19–The Platen Open Sensor................................................................................................ 4–30
Procedure 20–The Form Thickness Lever ............................................................................................ 4–32
Procedure 21–The Shuttle Stepper Motor ...........................................................................................4–33
Procedure 22–The Shuttle Drive Belt ...................................................................................................4–35
Procedure 23–The Shuttle Motion/Capture Sensor ............................................................................ 4–36
Procedure 24–The Paper Advance Motor ............................................................................................ 4–37
Procedure 25–The Paper Drive Pulleys and Belt ................................................................................. 4–39
Procedure 26–The Tractors ................................................................................................................... 4–40
Procedure 27–The Paper Motion Sensor.............................................................................................. 4–42
Procedure 28–Adjusting the Platen Gap.............................................................................................. 4–44
Appendix A: Schematics
Appendix B: Illustrated Part Breakdowns
Appendix C: Downloading Printer Firmware
T6045 Firmware Update Procedure ...................................................................................................... C–1
TOC–3
Figure Listing
Chapter 1
Figure 1–1. Physical Dimensions ................................................................................................. 1–11
Chapter 4
Figure 4–1. Disconnecting the Gas Spring .................................................................................... 4–2
Figure 4–2. Removing the Lid ....................................................................................................... 4–3
Figure 4–3. Removing the Control Panel ...................................................................................... 4–4
Figure 4–4. Reinstalling the Control Panel ................................................................................... 4–5
Figure 4–5. Removing the Right End Cover .................................................................................. 4–6
Figure 4–6. Reinstalling the Right End Cover ............................................................................... 4–7
Figure 4–7. Removing the Main Controller CBA .......................................................................... 4–8
Figure 4–8. Removing the Fan Assembly .................................................................................... 4–10
Figure 4–9. Removing the Sound Deadening Hood .................................................................... 4–11
Figure 4–10. Removing the Power Supply Panel ........................................................................... 4–12
Figure 4–11. Removing the Printer Power Switch ......................................................................... 4–13
Figure 4–12. Removing the Left End Cover .................................................................................. 4–14
Figure 4–13. Disconnecting the Ribbon Motor Cable .................................................................. 4–16
Figure 4–14. Removing the Ribbon Platform ................................................................................ 4–17
Figure 4–15. Removing the Ribbon Motor .................................................................................... 4–18
Figure 4–16. Removing the Ribbon Fault Sensor (Printer Option) ............................................... 4–19
Figure 4–17. Removing And Reinstalling the Paper Out Sensor ................................................... 4–20
Figure 4–18. Removing the Hammer Bank ................................................................................... 4–21
Figure 4–19. Removing the Ribbon Shield .................................................................................... 4–22
Figure 4–20. Changing a Hammer Coil ........................................................................................ 4–24
Figure 4–21. Removing a Hammer Module .................................................................................. 4–25
Figure 4–22. Aligning the Hammers ............................................................................................. 4–26
Figure 4–23. Removing the Shuttle Mechanism ........................................................................... 4–27
Figure 4–24. Removing the Paper Guide ....................................................................................... 4–28
Figure 4–25. Removing the Platen ................................................................................................ 4–29
Figure 4–26. Removing the Platen Open Sensor ........................................................................... 4–31
Figure 4–27. Removing the Form Thickness Lever ....................................................................... 4–32
Figure 4–28. Removing the Shuttle Stepper Motor ....................................................................... 4–33
Figure 4–29. Installing the Shuttle Drive Pulley ........................................................................... 4–34
Figure 4–30. The Shuttle Drive Belt ............................................................................................... 4–35
Figure 4–31. Removing the Shuttle Motion/Capture Sensor ........................................................ 4–36
Figure 4–32. Removing the Paper Advance Motor ........................................................................ 4–37
Figure 4–33. Removing the Paper Advance Motor Flywheel and Pulley ...................................... 4–38
Figure 4–34. Replacing the Motor Drive Pulley ............................................................................ 4–39
Figure 4–35. Removing the Tractor Drive Shaft Pulley ................................................................. 4–40
Figure 4–36. Removing the Tractors .............................................................................................. 4–41
Figure 4–37. Tractor Drive Components ....................................................................................... 4–41
Figure 4–38. Removing the Paper Motion Sensor ......................................................................... 4–43
Figure 4–39. Adjusting the Platen Gap.......................................................................................... 4–44
TOC–4
Table Of Contents
Table Listing
Chapter 1
Table 1–1. Type Style, Character Matrix, Dot Density, and CPI Combinations .......................... 1–5
Table 1–2. T6045 Line Printer Performance—Rolling ASCII ....................................................... 1–6
Table 1–3. Plot Data Output Speed .............................................................................................. 1–7
Table 1–4. AIAG Graphics Benchmarks ....................................................................................... 1–7
Table 1–5. POSTNET Label Speeds ............................................................................................... 1–7
Table 1–6. Slew Speed ................................................................................................................... 1–8
Table 1–7. Actual Weight: Main Components ............................................................................ 1–8
Table 1–8. Actual Weight: By Component ................................................................................. 1–8
Table 1–9. Shipping Weight: By Configuration .......................................................................... 1–9
Table 1–10. Acoustics ..................................................................................................................... 1–9
Table 1–11. Power Requirements ................................................................................................... 1–9
Chapter 2
Table 2–1. TEST Menu .................................................................................................................. 2–4
Chapter 3
Table 3–1. Display Messages ........................................................................................................ 3–3
Table 3–2. Paper/Printing Corrective Action ............................................................................. 3–15
Table 3–3. J703 Connector Pinouts ........................................................................................... 3–15
Table 3–4. J703 Connector to Hammer Bank CBA Continuity Check Points ........................... 3–16
Table 3–5. T6045 Hammer Coil/Module Troubleshooting ........................................................ 3–17
Table 3–6. Hammer Driver Pinouts ............................................................................................ 3–19
Supplements
Removing and Replacing the Hammer Module/Hammer Coil
Chapter 4 – Removing and Reinstalling the Platen
T6050 Information
Index
Tally Worldwide Locations
TOC–5
Preface
Preface
Preface
Introduction
This manual presents operational theory, specifications, troubleshooting, and R & R
procedures for the T6045 Printer.
The following chapter explanations will give you an overview of the contents of this
manual.
Chapter 1: Theory Of Operation And Specifications

This chapter presents basic operational theory of the T6045 Printer. In addition, design
and operational specifications for the printer are given.

Chapter 2 presents the Menu Operations concerned with troubleshooting and maintain-
ing the printer.
This chapter lists the display messages you may encounter, their cause, and possible
corrective actions.

This chapter presents instructions for removing and reinstalling/replacing various
components of the printer.
Appendix A: Schematics
The schematics in this appendix will assist you in troubleshooting problems and locat-
ing components that control printer operations.
Appendix B: Illustrated Parts Breakdowns (IPBs)

These IPBs present exploded views of all printer components along with parts listings.

This appendix explains how to download firmware to the printer.
1
Chapter 1:
Theory Of Operation And Specifications
Chapter 1
Chapter 1: Theory of Operation And Specifications
T6045 Controller Board Theory of Operation

There are 5 major operational blocks to the T6045 controller board. They are:
1. Main CPU - Motorola MC68340

2. Control CPU - Intel 8797BH
3. Shuttle/Ribbon Microcontroller - 87C750
4. Hammer/Motor Logic and Drivers
5. Parallel and Serial I/O
These blocks function integrally to control printer operation. They will be described
here individually and then how they operate collectively.
Main CPU
Subcomponents
Motorola MC68340 Microprocessor
✒ 25 MHZ main clock.
✒ 16-Bit CPU bus.
✒ Two Direct Memory Access (DMA) channels - One DMA channel for hammer
loading, and one for the IEEE-1284 Parallel Interface DMA.
✒ Two Serial channels - One for the Control CPU communication and one for the
external Serial Interface.
✒ Two Programmable Timers - One for Ribbon motor speed and one for internal
use.
One 4 M-bit (512 Kbytes) Flash Memory

✒ Contains Boot Block firmware (16 Kbytes), which is not programmable (factory
installed), and the Main firmware (up to 496 Kbytes).
One 2 M-bit (256 Kbytes) Flash Memory
✒ Contains Font data and Control Panel Message data.
Two 128 K x 8-bit Pseudo-Static RAM IC’s

✒ 256 Kbytes System RAM total.
✒ Refreshed when accessing the Flash program memory.
One 8 K-bit (1 Kbytes) Serial EEPROM memory

✒ Contains nonvolatile program parameters.
✒ Some control panel and configuration parameters are saved here.
One Altera EPM7032 EPLD

✒ Glue logic for board (chip selects, hammer data loading, interrupt logic, etc.).
✒ Contains logic for the IEEE-1284 parallel interface.
1–1
Control CPU
Subcomponents
Intel 8797BH Microcontroller
✒ 12.288 MHZ clock.
✒ High-Speed Outputs for driving the Paper Motor, and Hammer firing.
✒ 8-channel 10-bit Analog to Digital (A to D) Converter for sensor readings (paper
out, paper motion, shuttle motion, ambient temperature, power supply voltage,
ribbon motion, control panel key hits, dot density).
✒ Serial channel for communication (19.2Kbaud) with Main CPU (MC68340).
✒ Port control of Shuttle/Ribbon microcontroller.
✒ Port control of control panel, hammer loading, hammer fire timing, and print
cycle timing.
Sensor Inputs
✒ Paper Motion sensor - optical
✒ Paper Out sensor - optical
✒ Platen Open sensor - optical
✒ Shuttle Motion/Capture sensor - optical
✒ Ribbon Fault sensor - optical
✒ Ambient Temperature - thermistor
✒ Power Supply Voltage - resistor divider
All optical sensors are off-board.
Shuttle/Ribbon Microcontroller
Subcomponents
Phillips 87C750 microcontroller
✒ 1 Kbyte One-Time Programmable (OTP) ROM.
✒ Drives stepping phases to the Shuttle and Ribbon motors.
✒ 12.288 MHZ clock.
Hammer/Motor Logic and Drivers

Subcomponents
Paper Motor Drive
✒ 48 Volt drivers (Allegro 3952) are controlled by the Control CPU.
Shuttle Motor Drive

✒ 48 Volt drivers (Allegro 3952) are controlled by the Shuttle/Ribbon CPU.
Ribbon Motor Drive

✒ 48 Volt drivers (Allegro 3952) are controlled by the Shuttle/Ribbon CPU
1–2
Hammer drive ASIC

✒ Data is loaded serially using one of the MC68340 DMA channels.
✒ 33 drive outputs
✒ 32 of the outputs drive 8 SMA4032 transistor arrays. The other output drives a
SJE2895 transistor. Each transistor activates one hammer. There are nine
1N5339B diodes for absorbing back EMF.
Parallel and Serial Interfaces

Subcomponents
One of the MC68340 Serial channels is used for the external serial interface.
✒ MC145407 (5V) chip is used for the RS-232 drivers and receivers.
✒ Internal programmable baud rate generator (300 baud to 38.4 Kbaud).
✒ Both DTR/Busy and XON/XOFF is supported.
✒ Standard secondary RTS on pins 11 and 19. Primary RTS is jumper capable on
pin 4.
Parallel Interface - Altera EPM7032 PLD and 74LS374/74LS244

✒ Supports IEEE-1284 compatibility and nibble modes.
General Operation
Startup
The Main CPU (MC68340) starts by accessing the boot block firmware from the 4Mbit
Flash ROM. It initializes internal peripherals first, such as Clocking, DMA, Chip Selects,
Timers, Serial UARTs, Parallel Interface, Serial Interface, and Interrupt control. The boot
block firmware then establishes communication with the Control CPU via one of the
Serial UARTs in the MC68340. Once the interprocessor communication is set up, the
boot block will then check for valid checksums on the Main firmware (4 M-bit Flash
memory) and on the Font/Message (2 M-bit Flash) memory. If the checksums are valid it
will give control to the main firmware, which further initializes the system (RAM test-
ing, control panel, emulations, realtime operating system, printing, I/O & etc.). If either
checksum is invalid, some of the boot block firmware moves itself to RAM, and then
scrolls the display “Mannesmann Tally Flash Loader,” after which it enters the Flash
program/font loader and displays “Flash Dnld Ready.” It is now ready to accept from
the parallel port, program or font data to program into the Flash memories (Main and
Font/Message).
Printing
When one of the emulations has received data through the parallel or serial I/O and has
processed that data into a form for printing, it sends a print mode and a print command
to the Control CPU. The Control CPU starts or verifies that the shuttle is running at the
print mode’s specified speed. It then sends the STROBE_A signal to the hammer logic to
load the hammer data into the Hammer ASIC via the DMA channel in the MC68340 (33
DMA cycles - one for each hammer). The Control CPU then fires the hammers via the
ENABLE_A signal. There can be up to 96 (highest resolution print mode) hammer fires
per shuttle sweep. Note: each hammer prints 4 one-tenth inch columns of text/plot
data. (0.4 inches/hammer X 240 dot positions/inch = 96 print dot positions/hammer).
1–3
Specifications
Emulations
Six emulations are available on your printer: MT660, MTKANSI, LG01, Printronix,
Epson FX100, and IBM Proprinter III XL.
Type Styles
There are six resident type styles available on your printer. They include Gothic, Cou-
rier, Data Processing, Draft, OCR-A, and OCR-B.
All type styles and the two output modes (Enhanced and Constant Density Fonts for
Draft and DP) are selectable through the printer control panel.
Gothic and Courier

These two type styles provide Near Letter Quality (NLQ) printing on your line printer.
They print at higher dot densities and use denser character matrixes. Near Letter Qual-
ity type styles provide greater readability for reports and other text intensive output.
Draft and Data Processing

Draft and Data Processing type styles print in two modes: Constant Density Fonts (CDF)
and Enhanced.
Constant Density Fonts print at the same dot density regardless of the CPI. This pro-
duces consistent print speed even when changing from one CPI to another.
Enhanced Mode provides higher resolution and a greater range of CPIs than CDF Mode.
Because Enhanced Mode uses a variety of dot densities you should expect a change in
print speed of text when switching from one CPI to another.
OCR–A and OCR–B

These type styles print at 10 CPI only. They are used mainly for Optical Character
Recognition applications.
Characters Per Inch

The T6045 printer offers a variety of CPIs for use in printer output. Available CPIs are
dictated by the Type Style selected. Each CPI is based on one of 12 character matrixes
and 12 Dot Densities. Each matrix uses a specific number of dot columns for character
composition and intercharacter gap. CPIs are grouped in any given type style by the
base CPI matrix used for the group. Tese base CPIs are 10, 12, and 15.
1–4
Table 1–1. Type Style, Character Matrix, Dot Density, and CPI Combinations
Print Modes Type Styles 10 CPI Group 12 CPI Group 15 CPI Group
Constant Density Draft Base Matrix: 9 x 8 Base Matrix: 7 x 8 Base Matrix: 5 x 8
Dot Density: 60 x 48 Dot Density: 60 x 48 Dot Density: 60 x 48
CPIs: 5 and 10 CPIs: 6, 6.67, 12, CPIs: 15 & 17.14
& 13.33
Data Processing Base Matrix: 9 x 12 Base Matrix: 7 x 12 Base Matrix: 5 x 12

CPIs: 5 & 10 CPIs: 12 & 13.33 CPIs: 15 & 17.14
Enhanced Draft Base Matrix: 9 x 8 Base Matrix: 13 x 8 Base Matrix: 9 x 8

CPIs: 5 &10 CPIs: 6, 6.67, 12, CPIs: 7.5, 8.33, 8.57, 15,
& 13.33 16.67, 17.14, & 20
Data Processing Base Matrix: 9 x 12 Base Matrix: 13 x 12 Base Matrix: 9 x 12

CPIs: 5 & 10 CPIs: 6, 6.67, 12 CPIs: 7.5, 8.33, 8.57, 15,
and 13.33 16.67, 17.14, & 20
Near Letter Gothic Base Matrix: 19 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

Quality Dot Density: 80 x 96 Dot Density: 80 x 96 Dot Density: 120 x 96
CPIs: 5 &10 CPIs: 6, 6.67, 12, CPIs: 7.5, 8.33, 8.57,
& 13.33 15, 16.67, 17.14, & 20
Courier Base Matrix: 19 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

CPIs: 5 & 10 CPIs: 6, 6.67, 12, CPIs: 7.5, 8.33, 8.57,
& 13.33 15, 16.67, 17.14, & 20
Optical Character OCR-A Base Matrix: 9 x 16

Recognition Dot Density: 60 x 96
CPIs: 10
OCR-B Base Matrix: 19 x 24

Dot Density: 80 x 144
CPIs: 10
1–5
Table 1–2 T6045 Line Printer Performance – Rolling ASCII
Print Type Test Uppercase Lowercase

Mode Style CPI Matrix LPM Matrix LPM
Constant Density Draft 10 9x5 450 9x6 385
12 7x5 450 7x6 385
15 5x5 450 5x6 385
Data Processing 10 9x7 335 9x9 270
12 7x7 335 7x9 270
15 5x7 335 5x9 270
Enhanced Draft 10 9x5 450 9x6 385
12 13 x 5 340 13 x 6 290
15 9x5 185 9x6 155
Data Processing 10 9x7 335 9x9 270
12 13 x 7 255 13 x 9 205
15 9x7 135 9x9 105
Near Letter Gothic 10 19 x 9 180 19 x 12 150
Quality 12 13 x 9 205 13 x 12 170
15 9x9 105 9 x 11 85
Courier 10 19 x 9 180 19 x 12 150
12 13 x 9 205 13 x 12 170
15 9x9 105 9 x 11 85
Optical Character OCR-A 10 9x9 270 9 x 12 205
Recognition OCR-B 10 19 x 15 110 19 x 20 85
* All print speeds are subject to individual testing variances.
Lines Per Inch

Ten Lines Per Inch (LPI) settings are available through the Control Panel. They include
1.5, 2, 3, 4, 5, 6, 8, 9, and 10 LPI. In some emulations the availability of certain LPIs is
restricted.
Dot Densities and Plot Speeds

The T6045 printer supports horizontal row plots (single and multiple row), vertical
column plots, and specialized graphic plots.
The T6045 printer supports the following horizontal DPIs: 40, 48, 60, 80, 120, and 240.
Scaled densities available are 72, 90, 96, 100, 144, 160, 180, and 200. All other selec-
tions will be converted to the next higher density.
The T6045 printer supports the following vertical DPIs: 48, 72, 96, 144, and 288. All
other selections are emulated through the use of scaling techniques.
1–6
Table 1–3. Plot Data Output Speed
Dot Plot Print Speed

Hor./Vert. Inches Per Min.
60 x 48 50
60 x 72 33
120 x 72 16
120 x 144 8
240 x 288 2
Graphics Benchmarks
Two benchmark tests were used to rate graphics output on the T6045 printer. The first
was an AIAG label containing bar codes and block characters inside a box. The second
was a POSTNET label with one line of POSTNET bar code and four lines of text.
The AIAG test consisted of a series of labels printed two across repeated vertically with a
0.1" vertical space. The test was performed in two variations: Normal AIAG printed
with 60 DPI bar codes and Dark AIAG printed with 120 DPI bar codes.
The POSTNET Test consisted of rows of labels printed four across with one blank line
between each row. In addition, the POSTNET test was run with 4 variations: Draft and
Data Processing (DP) type styles for text/bar codes printed at 6 and 8 LPI.
Tests were timed, then results were converted into labels per hour ratings.
Table 1–4. AIAG Label Graphics Benchmarks

AIAG Label Benchmark Results
Graphics Dots Per In.
Language 60 120
Code V 900 LPH 600 LPH
Printronix 900 LPH 600 LPH
Table 1–5. POSTNET Label Speeds
POSTNET Label Benchmark Results

Lines Type Style
Per Inch Draft Data Processing
6 LPI 18500 LPH 15000 LPH
8 LPI 19000 LPH 15400 LPH
1–7
Ink-Ribbon
The T6045 ink-ribbon is rated at 25 million (25,000,000) characters in Draft type style at
10 CPI.
Paper Movement Speed

Table 1–6. Slew Speed
Print Mode Maximum Slew Speed

Normal 16 Inches Per Second
Heavy Forms 12 Inches Per Second
Language Character Sets

Up to 34 Language Character Sets with up to 192 characters (some emulations have
fewer character sets with 256 characters) each are available on the T6045 printer. In
addition, the ANSI and DIN character sets are available for use with the OCR-A and
OCR-B type styles.
With the exception of ANSI and DIN, the language character sets can be printed in four
different type styles: Gothic, Courier, Data Processing, and Draft. The ANSI and DIN
characters can only be used with the OCR-A and OCR-B type styles and are selectable in
four combinations through the Printer Control Panel.
Physical Configurations
The T6045 printer is available in the following configurations:
Standard Tabletop Printer

Optional Printer with Stand
Optional Printer with Quietized Pedestal
Before installing a Tabletop model, make sure that an opening has been provided in
the table that allows access to the paper path opening on the bottom of the printer.
Weight
Table 1–7. Actual Weight: Main Components
Component Weight
Tabletop Printer 79 lbs
Stand 20 lbs
Pedestal 44 lbs
Table 1–8. Actual Weight: By Configuration
Option Weight
Printer plus Stand 99 lbs
Printer plus Pedestal 123 lbs
1–8
Table 1–9. Shipping Weight: By Configuration
Option Weight
Printer with Stand Not available
Printer with Pedestal 177 lbs
Paper Description
The printer uses continuous, sprocket-fed type paper, 4 to 16 inches outside width and
variable (according to user needs) in length. One- to six-part paper may be used with a
maximum thickness of .025 inches. (Reference specifications: ISO 2784, DIN 9771 and
DIN 6721.)
Acoustics
The noise generated by the T6045 printer varies according to its configuration as shown
in the table below.
Table 1–10. Acoustics
Printer Sound Power per Sound Pressure Level

Configuration ISO 7779-C (9 position average)
Tabletop Unit 7.0 bels 55 dBA
Printer with Pedestal 7.0 bels 55 dBA
Nonvolatile Memory
The T6045 printer stores printer configuration information in nonvolatile EEPROM.
Power Supply
The T6045 printer requires single phase, 50 ± 3 — 60 ± 3 Hz., 90—130 VAC or 180—264
VAC input power. The T6045 printer’s universal power supply automatically adjusts to
the correct values. A fuse is provided to interrupt power to the power supply. The
following table gives typical current values.
Table 1–11. Power Requirements
External Power Current Requirements

Supply @ Nominal Voltage
AC Volts Frequency Average Peak Average
(RMS) (Hz) Operating Operating Idle
110 50 1.2 A 3.0 A 0.3 A
110 60 1.2 A 3.0 A 0.3 A
220 50 0.7 A 1.8 A 0.2 A
1–9
Preventive Maintenance
These printers are designed to eliminate the requirement of scheduled maintenance
procedures, such as alignment, adjustment, or lubrication. Preventive maintenance is
limited to periodic cleaning. Dust and paper fibers should be removed periodically with
a soft cloth and brush or a vacuum cleaner. Clean the printer case with a damp cloth
and soapy water. DO NOT use any abrasive cleaners or solvents, as they will damage the
case.
Safety
Personnel hazard areas have restricted access with appropriate warning labels. Cata-
strophic equipment failures are inhibited with protective functions in major areas of
overload potential.
Cooling System
Cooling system malfunctions are detected and a failure will result in shuttle motion,
paper motion, and printing functions being inhibited. The malfunction will be reported
on the control panel display.
Environment
Operating
Temperature
Dry Bulb: 50°F to 104°F (10°C to 40°C)
Humidity: 10 to 90% noncondensing with a maximum wet bulb
temperature of 82°F (28°) and a minimum dew point
of 36°F (2°C )
Altitude: To 8,000 ft. (2438 meters)
Mechanical Shock: Half sine wave shock pulse of 10 g peak and 10 +/- 3
ms duration, three times in the vertical direction
Vibration: Applied to each of the three axes
• 5 – 22 Hz 0.010 in, double amp.

• 22 – 500 Hz 0.25 g peak
• 500 – 22 Hz 0.25.g peak
• 22 – 5 Hz 0.010 in. peak
Sweep rate of 1 octave/min.
Nonoperating
Temperature:
Boxed: -40°F to 151°F (-40°C to 66°C)
Unboxed: 14°F to 122°F (-10°C to 50°C)
Humidity: 5 to 95% noncondensing
Altitude: To 10,000 ft. (3048 meters)
Thermal Shock: 29°F (16°C) per minute
Vibration: Units meet NSTA (National Safe Transit Association)
requirements
1–10
Heat Load Contribution

The average heat load contribution to the environment is approximately 280 BTUs per
hour (82 Watts) with a maximum potential of 615 BTUs per hour (180 Watts), under
continuous full-load printing conditions.
Printer Dimensions
23"
(58.4 cm)
50 1/2" 16 1/8"
(128.3 cm) (40.9 cm)
12 5/8"
(32.1 cm)
37 5/8"
(95.6 cm)
31 1/2"
(80 cm)
Figure 1–1. Physical Dimensions
Industry and Agency Standards.

The T6045 is designed to meet the requirements of several industry and government
agency standards.
Electro-Magnetic Emissions
EMI: FCC part 15, subpart J, Class A and CISPR Class B
ESD: IEC 801-2
RF: IEC 801-3
Power Line: IEC 801-4
Safety
IEC 950 (1986) plus Amendment 1 (1988) and 2 (1990) and National Deviations
CA, DE, FI, GB, NL, NO, SE, US
(CAN/CSA-C22.2 No. 950-M89 and CSA TIL F-18 (May 19, 1992)
(UL Std no. 1950-1989)
1–11
Chapter 2:
Menu Operations
Chapter 2
Introduction
All testing, troubleshooting, and calibration procedures are located in the multilevel
menu system of the T6045 printer. They are located in two different menus and can be
accessed through the Printer Control Panel.
Technical Access Mode

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

Place the printer Offline. Depress the LINE FEED Key and ENTER Key simultaneously
until the printer alarm sounds, then immediately release the keys.
Exiting Tech Access Mode

There are two methods for leaving Tech Access.
1. Place the printer Offline. Depress the LINE FEED Key and ENTER Key simulta-
neously until the printer alarm sounds, then immediately release the keys.
2. Cycle power on the printer.
Testing, Troubleshooting, and Calibration

The printer is equipped with the following types of Print Tests, Hex Dumps, and Printer
Information Printouts.
Print Tests
Print tests appear in both normal menu operations and in the Technical Access Mode of
the printer. These tests consist of the following patterns and types.
✒ ASCII print patterns

✒ Plot Mode patterns
✒ Calibration routines
✒ Electronic hardware tests
In-depth explanations of all of the print tests follow in the TEST Menu Section of this
chapter.
2–1
Hex Dumps
These dumps are located in the Configuration Menu, in the Printer Category, under
the Dmp Mod (Dump Mode) Parameter in normal menu operations. Hex Dumps can
be used to check printer functions and data processing operations and are also used to
help solve problems that can affect printer performance. There are three styles of Dump
Modes on the printer.
Style 1 Text, spaces, and control codes are printed out in hexadecimal format.
Make sure that wide paper (132 columns—13+ inches of printable width) is loaded
on the printer before running a Style 1 Hex Dump.
Style 2 Control codes are printed out in hexadecimal format while text and spaces
are printed out in their original form.
Style 3 Control codes and spaces are printed out in hexadecimal format, while text
is printed out in its original form.
Printer Information Printouts and Displays

There are five printouts and displays that you can access through the printer control
panel. One is listed as one of the menus (HELP) and four can be found in the Configu-
ration Menu, under the Printer Category.
HELP Menu
The HELP Menu is a printout that lists selections that are available for each parameter in
the multilevel menus on the printer and indicates with an asterisk (*) which ones are
currently active.
Before printing out the HELP Menu, make sure that there is at least 13 inches of
printable width on the installed paper.
To print out a HELP Menu, perform the following procedure.
STEP 1. Take the printer Offline.

STEP 2. Depress the LINE FEED Key and ENTER Key simultaneously until the printer alarm
sounds, then release them immediately to place the printer in Tech Access Mode.
STEP 3. Depress the MODE Key to enter the multilevel menu system, then scroll (▲ Key) to the
HELP selection.
STEP 4. Depress the ENTER Key to begin printing the HELP Menu.
This printout will end when the entire HELP Menu is printed out.
2–2
Report Parameter (Menu Level 2)

This parameter has four selections. Two of the selections, Configs and CalData, gener-
ate printouts. The second pair of reports (LastFlt and Version) are displays. The Report
Parameter is located in the CONFIGuration Menu, under the Printer Category.
Report selections (Menu Level 3)

Configs Prints a report showing the setups of the configurations.
CalData Prints a report showing timing signals and voltage levels that govern certain
basic printer functions.
LastFlt Displays the Last Fault that caused the printer to shut down.
Version Displays the version number of the currently installed firmware.
To clear the displays, depress any key on the printer control panel.
To access or print out a Report, perform the following procedure.
STEP 1. Take the printer Offline.

STEP 2. Depress the LINE FEED Key and ENTER Key simultaneously until the printer alarm
sounds, then release them immediately to place the printer in Tech Access Mode.
STEP 3. Depress the MODE Key to enter the multilevel menu system, then scroll (▲ Key) to the
CONFIG selection.
STEP 4. Depress the FORMS/1 Key to access the CONFIG Menu categories, then scroll (▲ Key)
until the Printer Category is displayed.
STEP 5. Depress the CPI/2 Key to access the Printer Category parameters, then scroll (▲ Key)
until the Report Parameter is displayed.
STEP 6. Depress the LPI/3 Key to access the Report selections, then scroll (▲ Key) to the desired
selection.
STEP 7. Depress the ENTER Key to begin the Report printout or display.
2–3
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: Pat-
tern, Diagnostics, and Fault Override.
The table that follows presents the categories, parameters, and parameter selections that
will appear in the TEST Menu while the printer is in Tech Access Mode.
Table 2–1 Test Menu

To access ➛ Categories Parameters Selections
FORMS CPI LPI
Depress this key ➛ 1 Level 1 2 Level 2 3 Level 3

Pattern Print Upper
All Chrs
REMEMBER! 63/69
Use the ▲ Key to scroll to the ECMA
desired selection. Columns
Print2 PaperSv
ThermCy
Lower
1 Line
All H's
All E's
All #'s
All +'s
REMEMBER! Parens
Use the ENTER Key to select Rubout
a value or option. Ribbon
Plot Grid
Cross
Gray
Black
Block
Diag PrntCal Hammer
Meter Sht Sen
Pap Out
Pap Mot
Rib Mot
Tmp Sen
Keypad
Motors Ribbon
Shuttle
Max-T 1–255
Sht Spd 10–29
Default
2–4
Table 2–1, Continued

To access ➛ Categories Parameters Selections
FORMS CPI LPI
Depress this key ➛ 1 Level 1 2 Level 2 3 Level 3
Diag, Rbn Spd 1–250

Continued Default
Heavy OFF
ON
REMEMBER!
Hm Puls 30–100
Use the ▲ Key to scroll to the
desired selection. Max DSH 300–700
Clear CalData
Counts
NVRAM
POutThr 0–255
FltOvrd Pap Mot OFF
REMEMBER! ON
Use the ENTER Key to select Pap Out OFF
a value or option. ON
Shuttle OFF
ON
Temp OFF
ON
Platen OFF
ON
Ctrl OFF
ON
Link OFF
ON
Panel OFF
ON
2–5
Pattern Category (Menu Level 1)

The Pattern Category contains several predefined print patterns used to test basic printer
functionality. There are three parameters in this category: Print, Print2, and Plot.
Print Parameter (Menu Level 2)

This parameter is also available in normal menu operations. It has five selections.
Print selections (Menu Level 3)

Upper Prints UPPER-CASE letters only.
All Chrs Prints all ASCII characters.
63/69 Prints rolling ASCII with spaces.
ECMA A print pattern designed to produce a specific audible noise pattern specified
by European Computer Manufacturers Association that is used with acous-
tics testing equipment.
Columns This test labels each column in the current print line. The line length used is
based on the current margin settings.
To stop any of the above tests, depress the ENTER Key or the CLEAR Key.
Print2 Parameter (Menu Level 2)

This parameter is available in Tech Access only. It has 11 print test selections.
Print2 selections (Menu Level 3)

Except for the 1 Line test all of the tests below run continuously. They will continue to
run until you depress either the ENTER Key or the CLEAR Key.
PaperSv This option provides a means of completing long-term testing of the printer
without wasting large amounts of paper. It prints a pattern of all upper-case
characters that is advanced by one character on each line. The first pass is
four lines long. The printer then backs up three lines and prints another
four line pass. The printer then continues printing in this fashion until it
makes 30 passes. On the 30th pass the printer does not back up.
ThermCy This option prints the PapSv pattern for 15 minutes, stops printing for five
minutes, then starts the cycle over. It is used to test the temperature cycling
abilities of the printer.
Lower This option prints a pattern of all lower-case characters that is advanced by
one character on each line.
1 Line This option prints one line only of upper-and lower-case characters.
All H's This option prints lines composed of the upper-case letter H.
All E's This option prints lines composed of the upper-case 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.
2–6
Rubout This option prints lines composed of the currently selected fill character.
Ribbon This option prints lines composed of rolling ASCII upper-case characters.
Plot Parameter (Menu Level 2)

This parameter is available in Tech Access only and it contains selections of plot patterns
used to test such things as hammer ball alignment and dot placement. There are five
selections for this parameter.
Plot selections (Menu Level 3)

After you have started one of the tests below, it will run continuously until you depress
either the ENTER Key or the CLEAR Key.
Grid This option prints a grid pattern that can be used to check hammer ball
alignment.
Cross This option prints a cross-hatch pattern of diagonal lines that can be used to
check linearity of dot placement.
Gray This option prints a grayscale pattern at 60 by 72 DPI. This test fires all 33
hammers (printing every other dot vertically and horizontally), which
should lay down an even gray tone across the page. Any changes in the gray
tone indicates a variation in the gap between the hammer module and the
platen, most commonly indicating either a worn hammer module or a
replacement module in need of alignment.
Black This option prints a solid black page at 60 by 72 DPI matrix. The Black Page
Print Mode is the most dense print test that can be run for verifying the
proper operation of the printer’s power supply. This test places the greatest
electrical current load on the power supply as well as increasing the thermal
load on the electronics.
When running this test the print rate will slow as the electrical current and
thermal limits are reached. If the power supply shuts down, rather than
simply slowing down, the power supply probably needs replacement.
Block This option prints alternating bars at 60 by 72 DPI matrix. Each bar is offset
from the previous bar in order to check on dot placement. This pattern is
used to test the printer at its maximum sustainable graphics rate without
exceeding the boundaries of thermal change or electrical current overload.
This test is useful in examining the capabilities of the print mechanism, for
checking proper hammer alignment/spacing, and print quality. The output
in the printed areas should have uniform shading. If not, parameters such as
individual hammer module heights and alignments should be checked.
2–7
Selecting And Running a Print Test

STEP 1. Take the printer Offline and place it in Tech Access Mode.
STEP 2. Access the TEST Menu.
STEP 3. Depress the FORMS/1 Key to access the TEST Menu categories, then scroll (▲ Key) until
the Pattern Category is displayed.
STEP 4. Depress the CPI/2 Key to access the Pattern Category parameters, then scroll (▲ Key)
until the desired Print Test parameter (Print, Print2, or Plot) is displayed.
STEP 5. Depress the LPI/3 Key to access the parameter selections, then scroll (▲ Key) to the
desired test pattern.
STEP 6. Depress the ENTER Key to begin the Print Test.
With the exception of the 1 Line print test the majority of the print tests are continuous
and will continue to print until you depress the CLEAR Key or ENTER Key.
Diagnostic Category (Menu Level 1)
This category contains parameters for testing various printer components, for setting
operational thresholds, and for calibrating certain sensors. You are guided through
these diagnostic procedures by instructions on the Control Panel Display. There are 14
parameters in this category.
PrntCal (Print Calibration) Parameter (Menu Level 2)

This parameter provides a means to calibrate the hammer timing pulses to obtain the
best print quality. There is only one selection for PrntCal: Hammer. To perform a
Hammer Calibration Routine, perform the following steps.
Selecting And Running a Hammer Calibration Routine

STEP 1. Take the printer Offline and place it in Tech Access Mode.
STEP 2. Access the TEST Menu.
STEP 3. Depress the FORMS/1 Key to access the TEST Menu categories, then scroll (▲ Key) until
the Diag Category is displayed.
STEP 4. Depress the CPI/2 Key to access the Diag Category parameters, then scroll (▲ Key) until
the PrntCal Parameter is displayed.
STEP 5. Depress the LPI/3 Key to access the PrntCal selections. Since there is only one selection,
Hammer, it is pretty hard to select the wrong one.
STEP 6. Depress the ENTER Key to begin the first part of the Hammer Calibration Routine.
The printer prints out the current Hammer Lead Times, then prints 11 lines of characters
at different lead-time settings for 15 Hz. Each line is 20 increments greater than the
previous line.
STEP 7. Examine each line of the printed output and select the one that has the best dot place-
ment, then scroll to that setting and depress the ENTER Key to select it. The second
part of the Hammer Calibration Routine begins. The printer prints out 21 lines of
characters at different lead-time settings centered around the selection you made in the
previous STEP. Each line is 3 increments greater than the previous line.
2–8
STEP 8. Examine each line of the printed output and select the best line. Scroll (▲ Key) to that
setting, then depress the ENTER Key to select it. This setting is now the 15 Hz. Hammer
Lead Time and the third part of the Hammer Lead Calibration Routine now begins. The
printer prints out 9 lines of characters at different lead-time settings at 23 Hz. centered
around the selection you made in the previous STEP. Each line is 10 increments greater
than the last.
STEP 9. Examine each line of the printed output and select the one that has the best dot place-
ment, then scroll (▲ Key) to that setting and depress the ENTER Key to select it. The
fourth and last part of the Hammer Calibration Routine begins. The printer prints 11
lines of characters at different lead time settings for 23 Hz. centered around the selection
you made in the previous STEP. Each line is 2 increments greater than the previous line.
STEP 10 Examine each line of the printed output and select the one that has the best dot place-
ment, then scroll (▲ Key) to that setting and depress the ENTER Key to select it. This
selection now becomes the 23 Hz. Hammer Lead and the printer now prints out the new
settings for 15 and 23 Hz.
Meter Parameter (Menu Level 2)
This parameter has six selections. Five are for testing the printer’s sensors and one is a
keypad test. The sensor tests can be used when adjusting the sensor position for opti-
mum performance or to test the sensor to ensure that it is operating properly.
Meter selections (Menu Level 3)

Sht Sen (see explanation below)
Pap Out (see explanation below)
Pap Mot (see explanation below)
Rib Mot (see explanation below)
Tmp Sen (reads current voltage drop across the thermistor)
Keypad (displays each key name when it is depressed)
The first 4 tests are used to check positioning of the sensor itself. Each sensor is checked
in a "covered" and "uncovered" mode.
Each Meter Test is initiated by depressing the ENTER Key when the desired selection is
displayed.
For the Paper Out and Paper Motion sensors, depress the ENTER Key then check them
with paper installed (covered) and paper removed (uncovered). The Paper Out Sensor
should read less than .2 volts with paper removed and greater than 4 volts with paper
installed. The Paper Motion Sensor only needs to have a differential of greater than 2
volts between the high and low reading to function properly.
The Shuttle Motion sensor is read with the open portion of the upper gear over it
(uncovered), then with the solid portion of the gear over it (covered). The readings
should be the same as the Paper Out Sensor.
The Ribbon Motion sensor is read with the silver portion of the wheel inside the Ribbon
Cartridge over it (uncovered), then with the black portion over it (covered). The read-
ings should be the same as the Paper Out Sensor.
2–9
Motors Parameter (Menu Level 2)

This parameter allows you to test the Shuttle Motor and Ribbon Motor. They can be
tested at the current selection (Default) or you can select a variety of speeds at which to
test them. (See Sht Spd Parameter and Rib Spd Parameter.)
Motors selections (Menu Level 3)

Ribbon
Shuttle
The selected test in initiated by depressing the ENTER Key. After the motor reaches its
assigned speed the test can be stopped by depressing the ENTER Key again. This se-
quence may be repeated until you are satisfied with the operation of the motor.
Max T (Maximum Temperature) Parameter (Menu Level 2)

Max T is the thermal limit for the printer. If the thermistor on the logic board exceeds
this limit, the Thermal Fault message will appear on the Control Panel Display.
DO NOT change the factory setting.
Sht Spd (Shuttle Speed) Parameter (Menu Level 2)

Provides a means to vary the Shuttle Motor speed for a Shuttle Motor Test.
Shuttle Speed selections (Menu Level 3)

10—28 Hz.
Default
Rbn Spd (Ribbon Speed) Parameter (Menu Level 2)

Provides a means to vary the Ribbon Motor speed for a Ribbon Motor Test.
Speed selections (Menu Level 3)

1—255
Default
Heavy (Heavy Forms) Parameter (Menu Level 2)

This Parameter allows you to slow the slew speed of the printer for heavy forms.
Heavy Forms selections (Menu Level 3)

OFF
ON
Hm Puls (Hammer Pulse) Parameter (Menu Level 2)

This parameter allows you to adjust the width of the firing pulse of the hammers.
Hammer Pulse selections (Menu Level 3)

30—100
2–10
Max DSH (Maximum Dots/Second per Hammer) Parameter (Menu Level 2)

This parameter provides a means of adjusting the number of dots per second each
hammer will print.
Dots Per Second selections (Menu Level 3)

300—700
Clear Parameter (Menu Level 2)

This parameter provides you with a means of clearing part or all of NVRAM.
Clear selections (Menu Level 3)

CalData Clears the calibration data from NVRAM. When CalData is selected you will
have to perform a Hammer Calibration Routine before using the printer.
Counts Clears the count information from NVRAM.
NVRAM Clears ALL NVRAM.
POutThr (Paper Out Threshold) Parameter (Menu Level 2)

This parameter allows you to set the Paper Out Threshold value for the Paper Out Sensor
to compensate for reflectivity variances for different types of paper.
Threshold selections (Menu Level 3)

0—255
Fault Override (FltOvrd) Category (Menu Level 1)

This category provides you a means of controlling fault reporting from the Engine
Manager to the Control Processor. Each of the following parameters has two selections:
OFF and ON.
When the parameter is set to OFF, faults are reported as they happen (Fault Override is
disabled). When the parameter is set to ON, faults are not reported on the display (Fault
Override is Enabled).
Pap Mot (Paper Motion) Parameter (Menu Level 2)

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

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

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

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

This parameter provides fault reporting override for the Platen Open Sensor.
2–11
Ctrl (Control Processor) Parameter (Menu Level 2)

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

This parameter provides fault override for control processor to main processor commu-
nications.
Panel Parameter (Menu Level 2)

This parameter provides fault override for Panel Fault reporting.
Control Panel Key Operations For Controlling Fault Reporting

In addition to being able to use the above parameters to set up individual fault over-
rides, 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.
ALL Fault Reporting

To turn ALL fault reporting OFF, place the printer Offline and depress the FORM FEED
Key and ENTER Key simultaneously until the printer alarm sounds. To turn ALL fault
reporting back ON, hold down the same two keys when the printer is Offline until the
printer alarm sounds.
Four Faults Only

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

To turn OFF fault reporting for the Paper Out sensor, depress the FORMS/1 Key and
ENTER Key simultaneously until the printer alarm sounds. To turn it back ON, depress
the same keys until the printer alarm sounds.
The displays that appear when you are enabling the options above can be some-
what confusing. Just remember, when you turn on fault overrides you are turning
fault reporting off.
2–12
Chapter 3:
Troubleshooting
Chapter 3
Introduction
This chapter deals with troubleshooting problems on the T6045 printer. Messages that
indicate printer faults and errors are explained and corrective action given. The few
paper handling and print quality problems that may occur are also explained. Trouble-
shooting tables and diagnostic flow charts have been included.
Messages
Messages on the Control Panel Display report both normal operation and fault situa-
tions. In Table 3–1 we present a listing of the Display Messages that need explanation
or action on the part of the operator or repair person. Each message listing includes
causes and corrective actions where necessary.
Faults
When a fault occurs, it will cause the printer to cease operation and go Offline. The
printer alarm will sound, the FAULT Indicator will illuminate, and the display will
report a fault message.
In some cases it is possible to clear an error message and continue using the printer by
depressing the CLEAR Key. However, the quality of the print may be questionable and
collateral damage to other parts may result. If the fault message returns, perform the
required corrective action.
If a nondestructive fault occurs in the middle of printing a document, one line of text
may be lost after the error condition is corrected and the printer put back Online.
If the fault is in the control panel or interprocessor link, the fault message may not
be displayed, and the beeper and FAULT LED may not operate.
Fault Correction Procedure

STEP 1. First check the fault message on the Control Panel Display and look it up in the Fault
Message tables provided later in this chapter.
STEP 2. Perform the required corrective action. Some Fault and Error messages will automati-
cally clear as soon as the problem is corrected (for example, the Platen Open message
will clear when the Form Thickness lever is lowered to the proper thickness).
STEP 3. If a faulty piece of hardware is found, turn to Chapter 5: Removal/Replacement Proce-

dures, for instructions on removal and replacement of faulty parts.
STEP 4. If any other faults appear on the display after you have corrected the original problem,
go back to Step 1 and perform required corrective actions for the new problem. Other-
wise place the printer back Online and test it during normal print operations.
3–1
Fault Override
To allow continued printer operation during serious faults, which usually shut down
printer operation, you may use the Fault Override Category in the printer menus system.
This allows you to troubleshoot serious faults in order to repair them.
One Fault Override Parameter (Paper Motion) is available in the Standard Multilevel
Menus. Once it is enabled it remains enabled until it is disabled through the Control
Panel, a printer reset escape sequence is received by the printer, or printer power is
cycled.
Seven more are available in the Tech Access Mode, under the TEST Menu. They can
only be enabled while the printer is in Tech Access Mode. However, they will remain in
whichever setting (On or Off) you select when you leave Tech Access Mode.
All of the Fault Override Parameters are explained in Chapter 2, under TEST Menu.
This feature must be used with extreme caution. Any time you disable one of the Fault
Sensing Systems on your printer you lose protection from situations that may result in
damage to the printer.
Dump Mode
Dump Mode is used to troubleshoot problems that may arise when processing data. You
can print out only control codes, control codes and spaces, or control codes, spaces and
text in hexadecimal format for use as a debugging tool. The Dump Mode Parameter is
explained in Chapter 2: Menu Operations.
3–2
Table 3–1. Display Messages
MESSAGE Explanation and Corrective Action

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

Flt Clr Timeout Explanation: The Main CPU cannot clear a fault in the Control CPU.
Font Dnld Error Explanation: An error has been detected during a font download.
Corrective Action: Correct data and retransmit from host.
Heap Overflow Explanation: Graphics memory space is full and the printer cannot accept or
process data. Printer will reset and data will be lost.
Corrective Action: Insert line terminators in data stream so the printer will process the
data, then retransmit the data.
Link Fault (n) Explanation: This message indicates that data flow has been interrupted between
the main processor and the control processor.
If n = :
(0) Maximum Packet Length Exceeded
(1) Inter processor Link Transmit Timeout
(2) Illegal Packet Length
(3) Illegal Packet Type
(5) Inter processor Link Receive Timeout
(6) Sweep Done Timeout
(9) Inter processor Link Receive Overrun
(10) Status Request Timeout
(11) Temperature Request Timeout
Corrective Action: Cycle printer power. If that does not clear the problem, remove and
Main CPU Fault Explanation: A fault has been detected in the main processor during powerup
diagnostics.
Corrective Action: Remove and replace the Main Controller CBA.
No VFU Loaded Explanation: A VFU command was received from the host before a VFU was
Downloaded.
Corrective Action: Download the required VFU information, then retransmit the data.
NVRAM Fault Explanation: The nonvolatile data checksum has failed because the variable values
have been altered in a destructive manner.
Corrective Action: Depress the CLEAR Key. If the message does not clear, cycle printer
power. If the message still does not clear, remove and replace the
Main Controller CBA.
Offline Data In Explanation: The printer is in Offline condition and nonprinted data is in the buffer.
Corrective Action: There is no corrective action required. Under normal conditions the
printer will continue to print when it is placed back Online. If you do
not want the buffered data to print, enter the Clear Menu by depress-
ing the CLEAR Key before going back Online and select the Clear
Buffers entry to clear the buffered data.
Offline Dump On Explanation: The printer is in Offline condition and Dump Mode is enabled.
Corrective Action: No corrective action is necessary. Place the printer back Online when
you are ready to print. (See the explanation at the beginning of this
chapter and in Chapter 2, under Hex Dumps for explanations about
how the data from the host is printed.)
3–4

Online Dump On Explanation: The printer is ready to accept and print data from the host through
Dump Mode. All data received from the host will be printed in hexa-
decimal format. (See the explanation at the beginning of this chapter
and in Chapter 2, under Hex Dumps for explanations about how the
data from the host is printed.)
Corrective Action: No corrective action is required.
Overflow VFU Explanation: An excessive number of bytes has been sent by the host in a VFU
download.
Corrective Action: Correct data and retransmit from host.
Panel Fault Explanation: The control processor has detected a fault in the circuitry for the
control panel. Depending on the location of the fault, this message
may not display.
Corrective Action: Remove and replace the Control Panel. If this does not clear the
fault, remove and replace the Main Controller CBA.
Paper Motion Flt Explanation: The control processor has detected that the paper has failed to move
the required distance after sending a command to the Paper Drive
Motor.
Corrective Action: Check for paper feed problems. If there are any paper feed prob-
lems, correct them, then depress the CLEAR Key to clear the fault
and continue operation.
If there are no paper feed problems, check the sensor connection on
the Main Controller CBA and sensor position on the tractor. The
sensor should be installed all the way back against the mount screw.
If the connection is OK and the sensor is properly installed, then
meter the Paper Motion Sensor in the upper-left tractor. (See TEST
Menu in Chapter 2 for the procedure.) The sensor should have a
differential of greater than 2 volts between the high and low readings
If the differential is less than 2 volts, remove and replace the sensor.
If all of the above checks do not clear the problem, remove and
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/Application Manual, then load paper.
(See Loading Paper Section of Chapter 1 of the Operator/Applica-
tion Manual.)
If this message is in error, check the sensor connection on the Main
Controller CBA and sensor position on its mounting bracket. If the
connection is OK and the sensor is properly installed, then meter the
Paper Out Sensor. (See TEST Menu in Chapter 2 for the proce-
dure.) The sensor should read less than .2 volts with no paper in the
printer and greater than 4 volts with paper installed. If the readings
are not within the range listed above, remove and replace the sensor.
If all of the above checks do not clear the problem, remove and
3–5

Parity Error Explanation: Parity is enabled and a mismatch on Bit 8, between the computer and
the printer, has been detected on the currently active host interface.
Corrective Action: If there is a mismatch between the setting of the printer and the
setting of the host, you can change printer parity by referring to the
Configuration Menu section of Chapter 2.
If there is no mismatch between the printer and host settings, then
the data sent from the host has been corrupted. Retransmit the data
from the host. If the condition repeats, set up the printer for Dump
Mode (see Configuration Menu Section in Chapter 2) and retrans-
mit the data again. If you find no errors in the Dump Mode data,
remove and replace the Main Controller CBA.
If this still does not correct the problem, the likely cause is in the I/O
cable or the host.
Platen Open Explanation: The Form Thickness Lever is set beyond the maximum setting
for paper thickness. This message will display when you are loading
paper or a Ribbon Cartridge into the printer. This condition disables
the printer and the only keys that will function on the control panel are
the form movement keys.
Corrective Action: When you are loading paper or a Ribbon Cartridge, this message will
clear when you lower the Form Thickness Lever and close the Platen
Gap. If this message appears at any other time or will not clear,
check the sensor connection on the Main Controller CBA and per-
form a meter test on the sensor. (See TEST Menu in Chapter 2 for
the procedure.) The sensor should read less than .2 volts with the
Form Thickness Lever closed and greater than 4 volts with the form
Thickness Lever fully opened.
If the connection is OK and the sensor is properly installed, remove
and replace the sensor.
If the condition still does not clear, remove and replace the Main
Controller CBA.
RAM Test Fail Explanation: A fault has been detected in the Main Processor primary RAM or a
fault exists in the RAM address lines.
Corrective Action: Remove and replace the Main Controller CBA.
3–6

Ribbon Fault Explanation: The Ribbon Motion Sensor is not reading movement in the Ribbon
Cartridge.
Corrective Action: If the ribbon is moving as it should and the message is in error:
Check sensor connections on the Main Controller CBA, then de-
press the CLEAR Key and put the printer back Online. Send a print
job to the printer or perform a print test. If the fault returns, turn the
power switch off, then back on again. If these actions do not clear
the fault, perform the meter check on the Ribbon Fault Sensor (See
TEST Menu in Chapter 2 for the procedure.) The sensor should
read from less than .2 volts to greater than 4 volts as you rotate the
Ribbon Knob. If the meter test is OK, remove and replace the Main
Controller CBA. If the sensor does not test OK, replace the sensor.
If the ribbon is not moving:
Remove the Ribbon Cartridge and check ribbon movement by
turning the Ribbon Knob in a clockwise direction.
Check the ribbon motor connection on the Main Controller CBA. If
the connection is OK, perform the Ribbon Motor test in the TEST
Menu. If the Ribbon Motor does not check out, remove and replace
the motor. If the motor checks out OK, remove and replace the
Main Controller CBA.
Self Testing Explanation: The printer is performing internal diagnostic tests.
Corrective Action: If this message does not clear automatically after a few seconds,
then either the Main CPU or the Main EPROM is dead. Remove and
Replace the Main Controller CBA.
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.
Corrective Action: Depress the CLEAR Key, then put the printer back Online. Send a
print job to the printer or perform a print test.
If the error condition returns, cycle printer power, then send another
print job or perform a print test.
It the fault condition returns after performing the above actions, check
the sensor connection on the Main Controller CBA and sensor
position on its mounting bracket. If the connection is OK and the
sensor is properly installed, perform a meter check of the Shuttle
Motion Sensor (see TEST Menu Section of Chapter 2 in this
manual). The sensor should read less than .2 volts with the open
segment of the shuttle fear over the sensor and greater than 4 volts
with the closed segment of the gear over the sensor. If the readings
are not within the range listed above, remove and replace the sensor.
If the sensor checks out OK, then troubleshoot the Shuttle Motor.
Thermal Fault Explanation: The ambient temperature has exceeded the limit (Max T).
Corrective Action: Turn the printer off and allow the unit to cool. After a few minutes,
turn the power back on and retry the printer. If it fails again, replace
the Main Controller CBA.
3–7
Hardware Troubleshooting Guides

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

There are four things that can cause this problem.
1. A bad connection.
2. A malfunctioning On/Off switch.
3. Incorrect input power.
4. A malfunctioning power supply.
Troubleshooting Procedure
STEP 1. Check all power connections.
Is the printer plugged in?

Are the connections on the On/Off switch secure?
Are the input power connections on the Power Supply secure?
Is the Power Supply connection to the Main Controller CBA secure?
STEP 2. Check the input power supply voltage. Input power should be 90—130 VAC or
180—264 VAC, single phase, 50 ± 3—60 ± 3 Hz. Check input power at the plug-in, on
the Power Supply side of the On/Off switch, and on the input side of the Power Supply.
If input power at the plug-in is incorrect, either the printer power cord is
defective or the power supply is defective. Check power at the outlet to make
sure the Power Supply is correct. If the Power Supply is OK, the problem is in
the cord.
If input power at the plug-in is OK, check power from the On/Off switch to
the Power Supply. If there is no power at the back of the On/Off switch when
it is switched On, the On/Off switch is defective. Remove and replace the On/
Off switch module.
If input power is OK on the back of the On/Off switch, check input power on
the Power Supply. If there is no input power at the Power Supply, the cabling
from the On/Off switch to the Power Supply is defective.
STEP 3. If input power to the Printer Power Supply is OK, check output voltage of the Power
Supply. Power Supply output voltage should be approximately 48 VDC. If the output
voltage is incorrect, remove and replace the Power Supply.
3–8
When the printer is powered up, nothing works except the fan.
The only thing that can cause this problem is a malfunctioning Main Controller CBA.
Remove and replace the Main Controller CBA.
The Control Panel LEDs and Display do not function.

There are three things that can cause this problem.
2. A bad control panel.
3. A bad Main Controller CBA.
If the red Power On Indicator is the only one that does not function, the problem is
most likely a malfunctioning Control Panel.
STEP 1. Check the form movement keys to see if they function.
If the form movement keys function properly, the problem is either in the Control Panel
or in the Main Controller CBA.
Try another Control Panel first. If that does not correct the problem, then remove and
STEP 2. If the form movement keys do not function properly, check the Control Panel connec-
tion to the Main Controller CBA.
If the connection is OK, the problem is in either the Control Panel or in the Main
Controller CBA. Try another Control Panel first. If that does not correct the problem,
then remove and replace the Main Controller CBA.
The Control Panel Display functions partially, nonsensically, or not at all.

2. A malfunctioning Control Panel.
3. A malfunctioning Main Controller CBA.
STEP 1. Check the Control Panel connection to the Main Controller CBA.
STEP 2. If the connection is OK, the problem is in either the Control Panel or in the Main
Controller CBA.
Try another Control Panel first. If that does not correct the problem, then remove and
3–9
There is no printed output but the printer appears to be operating normally.

1. The Form Thickness Lever may be open too far but not far enough to cause a
Platen Open message.
2. The Ribbon Cartridge may not be functioning properly but no fault is being
reported because the Ribbon Fault Detection is Disabled, is not functioning
properly, or is not installed.
3. Platen alignment may be incorrect.
STEP 1. Check the Form Thickness Lever and make sure it is closed properly.
STEP 2. Check the Ribbon Cartridge and make sure it is functioning properly.
If the Ribbon Cartridge is not functioning properly, replace it.
STEP 3. If the Ribbon Fault Sensor Option is installed, troubleshoot the Ribbon Cartridge Fault
Sensor to see why it did not report a ribbon fault. (See Ribbon Fault Sensor Inopera-
tive troubleshooting procedure, later in this section.)
STEP 4. If STEPs 1–3 do not correct the problem, check and adjust the platen alignment guides.
The Platen Gap should be .013 " with the Form Thickness Lever fully closed.
Printed output appears light

2. The Ribbon Cartridge may be worn out or is not moving.
Troubleshooting Procedure.
STEP 2. If the Ribbon Cartridge is functioning properly, it is probably out of ink. Remove and
replace the Ribbon Cartridge.
STEP 3. If the Ribbon Cartridge is not moving, remove the ribbon and check it by turning the
ribbon knob to see if it will turn.
If the ribbon knob does not turn, replace the Ribbon Cartridge.
If the ribbon knob does turn, check the ribbon motor to make sure it is operat-
ing properly. (See Ribbon Motion Fault Message, earlier in this chapter for
troubleshooting procedure.)
STEP 4. If STEPs 1–3 do not correct the problem, check and adjust the platen alignment guides.
The Platen Gap should be .013 " with the Form Thickness Lever fully closed.
3–10
Printed output appears shaky or fuzzy

There are five things that can cause this problem.
2. The shuttle mechanism is worn—the shuttle counterweight gears or the bearings
are worn.
3. The hammers are not firing properly.
5. Damaged platen.
STEP 2. Check the Shuttle Mechanism for wear in the gears or play in the bearings.
If the Shuttle Mechanism is defective, replace the Shuttle Mechanism, then perform a
Hammer Calibration procedure for optimum print quality.
STEP 3. Perform a Hammer Calibration procedure. This procedure is explained in Chapter 2, in

the TEST Menu Section, under the Diagnostic Category (PrntCal Parameter).
If the hammers can not be calibrated, the problem is in the Main Controller CBA.
Replace the Main Controller CBA following the procedure explained in Chapter 4.
STEP 4. Check and adjust the platen alignment guides. The Platen Gap should be .013 " with
the Form Thickness Lever fully closed.
STEP 5. Check the impact area of the platen and replace the platen if this area is damaged.
3–11
Four adjacent character columns not printing

There are five things that can cause this problem.
1. Broken Hammer.
2. Defective Hammer Coil; either shorted or open.
3. Defective Hammer Bank Cable.
4. Malfunctioning Main Controller CBA.
5. The hammer may be sticking due to contamination, such as paper and ink
buildup.
STEP 1. Remove the right end cover of the printer.
STEP 2. Inspect the Hammer Bank cable for rub spots, cracked insulation, burn spots, etc.
If any physical defects in the cable are found, remove and replace the Hammer
bank Assembly. In addition, correct the cause of the problem with the cable.
Test the printer to see if the problem is still present. If it isn’t, reinstall the
right end cover and place the printer back in service.
If the problem is still present, proceed to STEP 3.
If no physical defects are found proceed to the next step.
STEP 3. Remove the Ribbon Cartridge and Ribbon Platform.
STEP 4. Check continuity from the Ribbon Cable Connector (J703) to the affected coils.
To assist you in checking continuity, connector pinouts (Table 3–3) and illustrations
showing the pin arrangements of the connector and the soldered connections on the
Hammer Bank (Table 3–4) are included at the end of this chapter.
STEP 5. Check continuity of the Hammer Coil. Resistance of the coil should be 4.9 Ω (Ohms) ±
.3 Ω at 70° F. If the coil resistance is outside of this range, remove and replace the Coil
Assembly.
If the Hammer Coil is burned out, check the Hammer Driver on the main controller
CBA. Instructions for checking Hammer Drivers are located at the end of this chapter.
STEP 6. Is the Hammer broken or defective? If so, remove and replace the Hammer Module.
STEP 7. Check between the Hammer Plate and the Hammer Module Return Plate and between
the Hammer Head and Hammer Coil for ink and paper buildup. Clean the Hammer
Bank by prying out gently on the hammer with your finger and running a piece of
paper behind the hammer to remove the contamination. For stubborn buildup you may
use a little isopropyl alcohol on the paper to loosen the contamination.
STEP 8. If there are no physical defects, shorts or opens, the likely cause of the problem is a
malfunctioning Main Controller CBA. Remove and replace the Main Controller CBA.
3–12
Missing dots—intermittent
There are four things that can cause this problem.
1. Defective Hammer Coil; either shorted or open.

2. Defective Hammer Bank Cable.
3. Malfunctioning Main Controller CBA.
4. Sticking hammer.
STEP 1. Remove the right end cover of the printer.
STEP 2. Remove the Ribbon Cartridge and Ribbon Platform.
STEP 3. Inspect the Hammer Bank cable for rub spots, cracked insulation, burn spots, etc.
If any physical defects in the cable are found, remove and replace the Hammer bank
Assembly. In addition, correct the cause of the problem with the cable.
Test the printer to see if the problem is still present. If it isn’t, reinstall the
right end cover and place the printer back in service.
If the problem is still present, the problem is most likely in the Main Control-
ler CBA. Remove and replace the Main Controller CBA.
If no physical defects are found proceed to the next step.
STEP 4. Check continuity from the Ribbon Cable Connector (J703) to the affected coils.
To assist you in checking continuity, connector pinouts (Table 3–3) and illustrations
showing the pin arrangements of the connector and the soldered connections on the
Hammer Bank (Table 3–4) are included at the end of this chapter.
STEP 5. Check continuity of the Hammer Coil. Resistance of the coil should be 4.9 Ω (Ohms) ±
.3 Ω at 70° F. If the coil resistance is outside of this range, remove and replace the Coil
Assembly.
. If the coil was burned out, test the driver transistor to see if it is shorted. If it is, remove
and replace the Main Controller CBA (Instructions for troubleshooting the driver
transistors are located at the end of this chapter.)
If the coil checks out OK, test the driver transistor for an open. If the driver transistor is
open, remove and replace the Main Controller CBA.
STEP 7. Remove the Hammer Bank and clean it as necessary. (See previous explanation for
cleaning procedure.)
STEP 8. If there are no physical defects, shorts or opens, the likely cause of the problem is a
malfunctioning Main Controller CBA. Remove and replace the Main Controller CBA.
3–13
The Printer is out of paper - No Paper Out fault is reported

STEP 1. Check to see if the printer is in Tech Access Mode and the fault override is enabled for
Paper Out sensing.
STEP 2. If Fault Overrides are not enabled, check the sensor connections, then meter the sensor
to make sure it is functioning properly.
If neither of the above checks eliminates the problem, the most likely cause is a mal-
functioning Main Controller CBA. Remove and replace the Main Controller CBA.
If you have no idea how long the printer has been banging away with no paper
installed, check the platen for damage. If necessary, remove and replace the platen.
Shuttle Motion Erratic

The Shuttle Motor may be trying to ramp up to speed but is unable to.
Shuttle Motor and Shuttle Mechanism Troubleshooting Procedure.

STEP 1. Check the Shuttle Drive Belt to make sure it is not slipping.
STEP 2. Check the Shuttle Mechanism and Shuttle Motor Pulleys to make sure they are not
slipping.
STEP 3. Check the Shuttle Drive Gears to make sure they are moving freely and they are properly
aligned and not damaged in any way.
STEP 4. Perform a Shuttle Motor Test at a variety of speeds to ensure it is operating properly.
STEP 5. If none of the above items are causing problems and you have just finished removing
and reinstalling the Hammer Bank, you may have the Ribbon Shield hung up on the
printer frame below the Hammer Bank. Check below the Hammer Bank to see if the
Ribbon Shield is jammed against the printer frame.
3–14
Paper Handling Problems

The following table lists the few paper handling problems you may encounter along
with corrective actions you may take.
Table 3–2. Paper/Printing Corrective Action
Problem Cause Corrective Action

The paper holes are wider than Horizontal paper tension is too tight. Unlock and readjust the tractors.
normal after passing through the
tractors.
The paper comes out of the (1) The tractors are too far apart. Unlock and realign the tractors.
tractors or the paper tears at the (2) The Form Thickness Lever is not Raise the Form Thickness Lever.
right or left holes along the edges. set correctly.
Printed characters on heavy- The Form Thickness Lever is not set Raise the Form Thickness Lever.
weight or multi-part paper are correctly.
smeared.
T6045 Main Controller To Hammer Bank CBA Cable

Table 3–3. J703 Connector Pinouts
PIN # Signal Description PIN# Signal Description
1 Hammer 33 2 Hammer 32
3 Hammer 31 4 48V
7 Hammer 28 8 48V
11 Hammer 25 12 48V
15 Hammer 22 16 48V
19 Hammer 19 20 48V
23 Hammer 16 24 48V
27 Hammer 13 28 48V
31 Hammer 10 32 48V
35 Hammer 7 36 48V
39 Hammer 4 40 48V
43 Hammer 1 44 48V
3–15
Table 3–4. J703 Connector to Hammer Bank CBA Continuity Check Points
Hammer
Modules { 1 2 3 4 5 6 7 8 9 10 11
Hammer Bank Firing Line

Top View—Left to Right
3 6 9 12 15 18 21 24 27 30 33
Hammers
{ 1
2
4
5
7
8 11
10
14
13
17
16
20
19
23
22
26
25 28
29
31
32
Power Supply Pins 48 V

48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V
Hammer Bank CBA Ribbon

Cable Soldered Connections
44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2
43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11 9 7 5 3 1
J703 Hammer Bank Connector Alignment Key

Ribbon Cable Connector Pin
Numbers
3–16
Table 3–5. T6045 Hammer Coil/Module Troubleshooting

Print Hammer Hammer Main CBA
Columns Coil Module Driver
1, 2, 3, 4 1 1 U17
5, 6, 7, 8 2 1 U17
9, 10, 11, 12 3 1 U17
13, 14, 15, 16 4 2 U17
17, 18, 19, 20 5 2 U16
21, 22, 23, 24 6 2 U16
25, 26, 27, 28, 7 3 U16
29, 30, 31, 32 8 3 U16
33, 34, 35, 36 9 3 U15
37, 38, 39, 40 10 4 U15
41, 42, 43, 44 11 4 U15
45, 46, 47, 48 12 4 U15
49, 50, 51, 52 13 5 U14
53, 54, 55, 56 14 5 U14
57, 58, 59, 60 15 5 U14
61, 62, 63, 64 16 6 U14
65, 66, 67, 68 17 6 U13
69, 70, 71, 72 18 6 U13
73, 74, 75, 76 19 7 U13
77, 78, 79, 80 20 7 U13
81, 82, 83, 84 21 7 U12
85, 86, 87, 88 22 8 U12
89, 90, 91, 92 23 8 U12
93, 94, 95, 96 24 8 U12
97, 98, 99, 100 25 9 U11
101, 102, 103, 104 26 9 U11
105, 106, 107, 108 27 9 U11
109, 110, 111, 112 28 10 U11
113, 114, 115, 116 29 10 U10
117, 118, 119, 120 30 10 U10
121, 122, 123, 124 31 11 U10
125, 126, 127, 128 32 11 U10
129, 130, 131, 132 33 11 Q2
Driver Information is intended for Service Center only.
3–17
Troubleshooting The Hammer Driver Transistors

The Hammer Driver Transistors are located on the Main Controller CBA. When you are
having problems like Hammer Coil shorting or Hammers not firing, these components
should be checked along with the other components involved in the function.
To check the Hammer Driver for the malfunctioning hammer, use an Ohmmeter on its
lowest scale. Test the collector (C) to base (B) by placing the Positive (+) lead on the
collector terminal and the Negative ( – or Common) lead on the base terminal. If the
reading is either a short (0 Ohms) or an open (∞, infinity), the driver is bad and you
should replace the Main Controller CBA. If this check is OK, then test the base (B) to
emitter (E) by placing the positive (+) lead on the base terminal and the negative (– or
Common) lead on the emitter terminal. If the reading is either a short (0 Ohms) or an
open (∞, infinity), the driver is bad and you should replace the Main Controller CBA.
Use the following table to locate the correct driver terminals to check for the hammer(s)
you are having trouble with.
The Base of each segment of the driver goes to the LSI Chip, which turns On/Off
each segment. The Collector of each driver segment is connected to the corre-
sponding Hammer Coil.
3–18
Table 3–6. Hammer Driver Pinouts
Circuit Side Of Main Controller CBA

H33 Top of
E C B Q2 CBA
J703
2 1 Pin Number
4 3 1 2 3 4 5 6 7 8 9 10 11 12
6 5
8 7 U10
10 9 C B B C E B C C B
12 11 H29 H30 H31 H32
14 13
U11
16 15
C B B C E B C C B
18 17
H25 H26 H27 H28
20 19
22 21 U12
24 23 C B B C E B C C B
26 25 H21 H22 H23 H24
28 27
29
U13
30
C B B C E B C C B
32 31
H17 H18 H19 H20
34 33
36 35 U14
38 37 C B B C E B C C B
40 39 H13 H14 H15 H16
42 41
44 43
U15
C B B C E B C C B
H9 H10 H11 H12
U16
C B B C E B C C B
H5 H6 H7 H8
U17
C B B C E B C C B
H1 H2 H3 H4
3–19
Chapter 4
Chapter 4:
Remove and Reinstall
Introduction
This section covers removal and installation of the various components of your printer.
WARNING!
HIGH VOLTAGE POTENTIAL
High levels of AC voltage are present in the
power supply. Always ensure that the power cord
is unplugged before performing maintenance
on the printer.
Any time you remove a component that is involved in some aspect of the printing
process, perform a print test to ensure that print quality has not been affected. If
necessary, perform the required calibration or set up to ensure best possible print
quality.
Required Tools
The following list presents the tools you will need to perform the procedures presented
in this chapter. All of the tools (except where noted) are included in a kit that is avail-
able for purchase through our Spares Department.
Volt/Ohm Meter — not included in the tool kit

Platen Gap Shim Gages — .013" thick — 2 ea.
Hammer Alignment Tool
Snap Ring Pliers
Paper Out Sensor Shim Gage — .010" thick
12" x 18" Plastic Bag
1/2" Nut Driver
6" Phillips Screwdriver — #2 Tip
3" Phillips Screwdriver — #1 Tip
8" Longnose Pliers
5/64" Allen Wrench
1/16" Allen Wrench
Loctite 262 Adhesive
4–1
Procedure 1—The Printer Lid

Before beginning this procedure, turn the printer off and disconnect the power cable.
Removing
STEP 1. Raise the printer lid. Grasp the gas spring near where it connects to the printer cabinet.
Insert a narrow cabinet screwdriver under the spring clip on the gas spring where it
attaches to the printer. Lift the clip straight up until it unlocks and the gas spring can
be easily taken off its post.
Pivot Post Small Flat Blade Screwdriver
Spring Clip
Figure 4–1. Disconnecting the Gas Spring
The printer lid is heavy and will immediately try to come crashing down onto whatever
part of your anatomy is within reach when you remove the end of the gas spring from
its post. So be careful when you disconnect the gas spring!
STEP 2. Grasp the printer lid by the front edge with one hand while you use a Phillips screw-
driver to remove the blocking plate to the immediate left of the right hinge.
4–2
Step 2.
Remove
Blocking Plate
Step 3. Slide
Lid to Left
and Off
Hinges
Figure 4–2. Removing the Lid
STEP 3. After you remove the blocking plate, slide the lid to the left until it clears the hinge
posts. You may now set it aside out of the way.
Reinstalling
To reinstall the printer lid, reverse the removal steps.
4–3
Procedure 2—The Control Panel

Removing
STEP 1. Raise the printer lid.
STEP 2. Insert a small blade-tip screwdriver straight into the slot located to the left of the Con-
trol Panel just inside the opening to the printing area.
Panel Latch
Latch Release
Access Slot
Figure 4–3. Removing the Control Panel
STEP 3. Push straight in until the Control Panel Latch releases and the left edge of the panel can
be lifted up.
STEP 4. Lift the panel out GENTLY.
The cable that attaches the Control Panel to the printed circuit board is very short and
can be damaged if you are not careful.
If you are going to remove the Right End Cover, (see Procedure 3) turn the panel until
the narrow end can be inserted back through its opening and set it in the bottom of the
opening.
If you are changing the control panel, reach inside and unplug the control panel from
the Main Controller CBA (J801).
4–4
Reinstalling
STEP 1. If the control panel was removed from the printer, plug the control panel in (J801) then
advance to STEP 2.
If the control panel is still connected to the Main Controller CBA and is lying in the
bottom of the opening, lift the panel out of the bottom of the opening GENTLY.
STEP 2. Turn it until it is properly aligned. Insert the right edge of the panel into the opening
and slide it all the way to the right of the opening.
Figure 4–4. Reinstalling the Control Panel
STEP 3. Lower the left edge down until it rests on the edge of the opening. Push in on the latch
until the panel slides easily into the opening.
STEP 4. Push down on the left edge of the panel until it is securely latched into place.
4–5
Procedure 3—The Right End Cover

Removing
STEP 1. Remove the Printer Control Panel (see Procedure 2).
STEP 2. Remove the screws at positions 1 and 2.
STEP 3. Loosen the screws at positions 3, 4, and 5.
STEP 4. Pull up on the front edge of the cover until it comes free of the channel it sits in. When
the front edge comes free you can then lift straight up on the cover and remove it from
the printer.
Step 2.
Remove 2 Screws
2.
1.
5.
3. 4.
Step 4.
Step 3.
Loosen Screws
Figure 4–5. Removing the Right End Cover
4–6
Reinstalling
STEP 1. Make sure that all connections are secure and all cables are kept away from the areas
where the cover contacts the printer.
STEP 2. Set the cover over the Main Controller CBA and Shuttle. Align the short lip on the front
inside edge of the cover over the lip (1) on the printer just above and outside the pedes-
tal door or silencer and the channel in the front (2) and side (3) of the printer.
Place in Place Place in

front of 1.
channin channel
printer lip el
3.
2.
Figure 4–6. Reinstalling the Right End Cover
STEP 3. It may be a somewhat tight fit and require considerable downward pressure to get the
cover to set down completely. Before pressing down, make sure that all cables are clear
of the contact area between the cover and printer.
STEP 4. Reinstall the screws in positions 1 and 2, then tighten the screws at positions 3, 4, and 5
(see Figure 4–5).
STEP 5. Reinstall the printer control panel.
4–7
Procedure 4—The Main Controller CBA

If you are going to replace the Main Controller CBA, print out a Configuration
Report and a Calibration Data Report before you turn off power and remove the old
CBA. This will give you the information you need to make sure the printer is
properly set up after you finish.
Removing
STEP 1. Remove the Right End Cover (see Procedure 3).
STEP 2. Disconnect all cables (see illustration that follows) attached to the Main Controller CBA.
J90 4.
1
5.
3.
J8 J6J60 J
0 1 6 02 3 604
J
J5 J502 J 01
Disconnect Cables 01 5 03
6.
ntro ller
n C o
Mai BA
C 7.
J302
J2 2.
und
Gro 1.
Figure 4–7. Removing the Main Controller CBA
4–8
STEP 3. The Main Controller CBA is secured in the printer by seven Phillips screws. Two coun-
tersunk screws along the bottom outside edge of the CBA and one countersunk screw in
the upper righthand corner (locations 1, 2, & 3) and four that secure the I/O Panel to
the back of the printer (locations 4 thru 7).
The Main Controller CBA can now be removed from the printer.
Reinstalling
To reinstall the original Main Controller CBA or install a new one, reverse the sequence
and actions of the removal steps.
Make sure that the ground strap on the bottom front corner of the CBA is correctly
connected.
After installing a new Main Controller CBA, run the meter tests (as explained in the
Paper Out, Paper Motion Flt, Shuttle Fault, Platen Open, and Ribbon Fault messages in
Chapter 3) and the Hammer Calibration routines provided in the TEST Menu of the
printer. Use the printouts you made earlier to set up communications and other printer
operations.
4–9
Procedure 5—The Fan Assembly

Removing
Optional: Remove the Main Controller CBA (see Procedure 4).
STEP 2. Disconnect the Fan Motor power cable from the CBA (J2).
ller
i n C ontro
Ma
CBA
J2
J2
Figure 4–8. Removing the Fan Assembly
STEP 3. Remove the three mounting screws from the motor, then lift the motor out of the
printer.
Reinstalling
To reinstall the Fan Motor, reverse the sequence and actions of the above steps.
4–10
Procedure 6—The Printer Power Supply

Removing
STEP 1. Disconnect the Static Ground from the printer and remove the hood from the back of
the printer and any printed forms along with the Paper Stacking Tray if they are present.
Sound Deadening Hood
Static Ground
Figure 4–9. Removing the Sound Deadening Hood
STEP 2. Remove the printer control panel (see Procedure 2) and disconnect the power supply
from the Main Controller CBA (J302).
The Power Supply cable to the Main Controller CBA goes through a quick release
cable clamp located in the right inside back corner next to the CBA. When you
unplug the connector from the CBA, you should be able to pull forward on the
cable to remove it from the clamp.
4–11
STEP 3. Remove the three screws at locations 1, 2, and 3. The panel with the power supply
attached can now be removed from the printer.
2.
3.
1.
J302
Figure 4–10. Removing the Power Supply Panel
If you are replacing the power supply, there is no other disassembly required. The new
power supply comes mounted on a panel with all necessary hardware attached.
Reinstalling
STEP 1. To reinstall the power supply, mount the power supply assembly into the printer and
reinstall the three screws that secure it to the printer.
STEP 2. Connect the power supply cable to the Main Controller CBA (J302) and reinstall the
control panel.
STEP 3. Hang the Sound Baffling Hood on the back of the printer and connect the static ground
strap to the printer, then plug the power cable back into the printer.
4–12
Procedure 7—The Power Switch

Removing a Defective Switch

STEP 1. Unplug the Power Supply from the Main Controller CBA (J302), then remove the Power
Supply from the printer (see Procedure 6).
STEP 2. Unplug the blade connectors from the back of the Power Switch.
Yellow/Green
Brown
Blue
J302
Locking Tabs
Figure 4–11. Removing the Printer Power Switch
STEP 3. Depress the locking tabs of the switch and remove the switch from the panel.
Installing a New Switch

STEP 4. Insert the new switch into the switch opening on the Power Supply Panel and press it in
until the locking tabs snap into place.
STEP 5. Connect the wire harness from the power supply, matching the wire colors to the switch
connections as shown above.
STEP 6. Reinstall the Power Supply Panel into the printer.
4–13
Procedure 8—The Left End Cover

Removing
STEP 1. Remove the printer lid (see Procedure 1).
STEP 2. Remove the screws in locations 1 and 2.
STEP 3. Loosen the screws in locations 3, 4, and 5 (screw in position 5 is only on pedestal
configuration). On pedestal models, the screw in position 5 can only be accessed if the
pedestal door is partially open.
Remove Screws
1.
2.
3.
5.
4.
Loosen Screws
Figure 4–12. Removing the Left End Cover
STEP 4. Lift up on the end cover until it clears the printer and can be removed.
4–14
Reinstalling
STEP 1. Align the lip of the cover with the lip on the printer just above screw location 5, then
insert the lip around the base of the cover into the mounting channel on the printer.
STEP 2. Press down on the cover until it seats in the channel.
STEP 3. Reinstall the screws at locations 1 and 2.
STEP 4. Tighten the screws at locations 3, 4, and 5 (Screw in position 5 is only on pedestal
configuration).
STEP 5. Reinstall the printer lid.
4–15
Procedure 9—The Ribbon Platform

Removing
STEP 1. Open the printer lid, raise the platen gap lever, and remove the Ribbon Cartridge.
STEP 2. Remove the printer control panel (see Procedure 2) and lay it in the bottom of the
printer.
STEP 3. Remove the Right End Cover (see Procedure3).
STEP 4. Disconnect the Ribbon Motor cable from the Main Controller CBA (J502). To remove
the cable along with the Ribbon Platform you will need to remove the Ferrite Bead
encircling the group of cables that contains the Ribbon Platform cable. The subroutine
that follows explains how.
Step 4a. Use a pair of needlenose pliers to press in on the two latch tabs on the bead.
Pry the two halves apart and remove the bead. The cable can now be re-
moved.
J502
J9
01
J8 J J6
01 J 60203 J60
J5 J5 60 4
01 03 1
Ferrite Bead
Locking Tabs
Ferrite Beads
Figure 4–13. Disconnecting the Ribbon Motor Cable
4–16
STEP 5. Remove the three mounting screws that secure the Ribbon Platform in the printer, then
lift the Ribbon Platform out of the printer.
Step 3. Remove the three mounting screws
Reinstall Note:
Place this screw first.
Remove the Ribbon
Cartridge
Ribbon Platform
Open Form
Thickness Lever
Figure 4–14. Removing the Ribbon Platform
On printers with the optional Ribbon Fault Sensor installed you will also need to discon-
nect the sensor cable (J901).
Reinstalling
To reinstall the Ribbon Platform, reverse the sequence and actions of removal steps.
4–17
Procedure 10—The Ribbon Motor

Removing
STEP 1. Remove the Ribbon Platform (see Procedure 9).
STEP 2. Remove the four screws securing the Ribbon Motor in place on the platform. The
Ribbon Motor can now be removed from the Ribbon Platform.
Ribbon Motor
J502
Figure 4–15. Removing the Ribbon Motor
Reinstalling
STEP 1. Insert the Motor shaft through the hole in the Ribbon Platform, then align the screw
holes (make sure that the motor cable is on the side toward the control panel) and
reinstall the motor mounting screws.
STEP 2. Reinstall the Ribbon Platform.
4–18
Procedure 11—The Ribbon Fault Sensor (Printer Option, will not be on all
models)
Removing
STEP 1. Remove the Control Panel (see Procedure 2).
STEP 2. Disconnect the Ribbon Motor (J502) and Ribbon Fault Sensor (J901) from the Main
Controller CBA.
STEP 3. Remove the Ferrite Beads encircling the cables next to the CBA (see Figure 4–13).
STEP 4. Remove the Ribbon Cartridge and the Ribbon Platform (see Procedure 9).
STEP 5. The Ribbon Fault Sensor is secured to the Ribbon Platform by two tabs on the sensor.
Push in on the tabs and the sensor will slip out of the Ribbon Platform.
STEP 6. Disconnect the sensor cable from the sensor.
Ribbo
n Platf
orm
J901
Sensor Cable Ribbon Fault

Sensor
Figure 4–16. Removing the Ribbon Fault Sensor (Printer Option)
Reinstalling
Reinstallation of the sensor is the reverse sequence of removal.
After you have installed the sensor, perform a meter test of the sensor (as explained
under the Ribbon Fault message in Chapter 3) to ensure it is operating properly.
4–19
Procedure 12—The Paper Out Sensor

Removing
STEP 2. The Paper Out Sensor is located underneath the Ribbon Platform. It is mounted on the
printer frame with one screw. Remove the screw, disconnect the cable (J602) from the
Main Controller CBA and remove the Ferrite Bead encircling the cable bundle next to
the CBA (see Figure 4–13). The sensor can now be removed from the printer.
.010" (Shim Stock)
J602
Figure 4–17. Removing And Reinstalling the Paper Out Sensor
Reinstalling
STEP 1. Place a piece of shim stock .010" thick across the hole where the sensor mounts.
STEP 2. Place the sensor on the tab where it mounts and start the mount screw. Screw the
mount screw in until it is snug but not tight.
STEP 3. Make sure that both peaks of the sensor just touch the shim stock, then tighten the
mount screw completely.
STEP 4. Reconnect the cable to the Main Controller CBA and reinstall the Ferrite Bead.
STEP 5. Run a Meter Test on the sensor (as explained under the Paper Out message in Chapter 3)
to make sure it is operating properly, then finish by reinstalling the rest of the compo-
nents you removed.
4–20
Procedure 13—The Hammer Bank

Removing
STEP 1. Remove the Printer Lid (see Procedure 1) and the Control Panel (see Procedure 2).
STEP 2. Remove the Right End Cover (see Procedure 3).and Ribbon Platform (see Procedure 9).
STEP 4. Disconnect the ribbon cable bracket just in front of the Hammer Bank (2 Phillips
screws), the ribbon cable connector (J703) from the Main Controller CBA, and remove
the cable from the clamp near the CBA.
If you are replacing rhe Hammer Bank, remove the Ferrite Bead from the cable next to
the CBA to install on the new Hammer Bank Cable.
Hammer Bank
Ribbon
Guides
Left Ribbon Shield

Flexure
DO NOT remove the

mounting brackets on
2. Ribbon Cable
the ends of the Hammer Bracket
Bank. This will destroy
the factory alignment of 1.
these components. Flexure
Alignment Studs
3.
4. 5.
CBA
Figure 4–18. Removing the Hammer Bank
STEP 6. Remove the Phillips screws in locations 1 thru 5. Remove the left flexure from its
alignment studs, hold it away from the studs and lift out the Hammer Bank.
Reinstalling
When you are ready to reinstall the Hammer Bank, reverse the above sequence of steps.
When you reinstall the Hammer Bank, make sure that the Ribbon Shield does not get
hung up on the printer frame below the Hammer Bank. This can damage the Ribbon
Shield and interfere with printer operation.
Before you reinstall the Ribbon Platform, adjust the hammer to platen gap if necessary
(see Procedure 28).
Perform a Hammer Lead Time Calibration Routine (as explained in Chapter 2 under the
PrntCal Parameter) to adjust for optimum print quality.
4–21
Procedure 14—The Ribbon Shield

Removing
STEP 1. Remove the Hammer Bank (see Procedure 13).
STEP 2. Loosen the three screws that secure the Ribbon Shield to the Hammer Bank, remove the
shield and set it aside.
Be careful when handling the Ribbon Shield. It can be bent easily, which can affect
operation of the printer. It also has very sharp edges that can put a real hurt on you if
you aren’t careful how you handle it.
DO NOT loosen or remove the mounting screws on the Ribbon Shield Alignment Plate
This will destroy the factory alignment of these components.
Ribbon Shield
Alignment Plate
Hammer
Interconnect
CBA
Loosen Screws
3x
Ribbon Shield
Figure 4–19. Removing the Ribbon Shield
4–22
Reinstalling
To reinstall the Ribbon Shield, reverse the sequence and actions of the removal steps.
Make sure the shield is flush against the Ribbon Shield Alignment plate and the bottom
edge of the Hammer Bank before tightening the mount screws.
Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust as
necessary (see Procedure 28).
After completing the installation, perform a Hammer Lead Time Calibration Routine (as
explained in Chapter 2, under the PrntCal Parameter) to adjust for optimum printed
output.
4–23
Procedure 15—The Hammer Module/Hammer Coil

Removing and Replacing

If you are repairing the Hammer Bank bacause of a Hammer Coil failure, you may
replace either the defective coil or the entire Hammer Module. However, if you are
repairing the Hammer Bank because of a defective Hammer, you must replace the
entire Hammer Module. This guarantees proper hammer equalization and compo-
nent alignment.
STEP 1. Remove the Hammer Bank from the printer (see Procedure 13).
STEP 2. Remove the Ribbon Shield (see Procedure 14), and set it aside.
Be careful when If you are replacing just the Hammer Coil do not remove the entire module from the
handling the Ribbon Hammer Bank. Perform the subroutine that follows. If you are changing the entire
Shield. It can be module, skip to STEP 3.
bent easily, which Step 2a. Locate the module with the bad coil and remove the hammer plate only by
can affect operation removing the three screws that secure it to the module, then you can remove
of the printer. It it from the module.
also has very sharp
edges that can put a Step 2b. Each coil is held in place by two tabs. Using a very small screwdriver, reach in
from the back side of the Hammer Bank and break off one of the tabs.
real hurt on you if
you aren’t careful
Coil Unit
how you handle it.
CBA
Contact Pins
Locking Tabs
Coil Post & 3x
Flux Plate
Assembly Hammer Plate
Break off a
LockingTab
to remove
Coil CBA
Magnet te
rn Pla
Retu
Figure 4–20. Changing a Hammer Coil
4–24
Step 2c. Now grasp the bad coil with a pair of longnose pliers and remove it from the
Hammer Bank.
Step 2d. Do not use pliers to install the new coil. Grasp the new coil with your
fingers, plug the male prongs into the slots in the Hammer Bank CBA and
press the coil in until the tabs lock into place.
Step 2e. Reinstall the hammer plate and use the Hammer Alignment Tool to realign the
hammers before tightening the mount screws.
Step 2f. Reinstall the Ribbon Shield.
Step 2g. Reinstall the Hammer Bank into the printer, then check the hammer to platen
gap and adjust as necessary. Finish reinstallation by installing all remaining
components that you removed back into the printer.
STEP 3. The module has three hammer assemblies and is held in place by two Phillips screws on
the backside of the Hammer Bank. Remove these screws and the module can be re-
moved from the Hammer Bank.
Ribbon Shield
Hammer Allignment Plate
Interconnect
CBA
Hammer Interconnect CBA

Ha
mm
er
Ba
Hammer Bank Carriage

nk
Ca
rria
ge
Module Mounting
Screws (2)
3-Pack
Hammer
Module
Figure 4–21. Removing a Hammer Module
4–25
STEP 4. Install the new module on the Hammer Bank. Be very careful when installing the
new module. The male prongs can be bent easily and may not align properly when
they are plugged in. Use the Hammer Alignment Tool to realign the hammers, tighten
the two mount screws, then reinstall the Ribbon Shield.
07329
9
CB
A
Figure 4–22. Aligning the Hammers
STEP 5. Reinstall the Hammer Bank by reversing the sequence of steps required to remove it.
necessary (See Procedure 28).
output.
4–26
Procedure 16—The Shuttle Mechanism

Removing
STEP 4. Remove the Shuttle Drive Belt.
STEP 5. Remove the Phillips screws (4 each) that secure the Shuttle Mechanism to the Printer
Frame. Lift out the Shuttle Mechanism.
Optional:
Better access to the
Shuttle Mechanism
mounting screws
can be gained by
removing the
Main Controller J Shuttle
igg
CBA. Cam
le gears
Bearing
1
2 3
Sensor
Cam Bearing
Slot
Located on the rear of the Shuttle Mechanism

1 4 2 is a small cam mechanism that fits into a slot
on the printer frame. You may have to jiggle
the shuttle gears to free the cam bearing from
the slot.
Figure 4-23. Removing the Shuttle Mechanism

Reinstalling
To reinstall the Shuttle Mechanism, reverse the sequence and actions of the removal
procedure.
After completing the installation, perform a Hammer Lead Time Calibration Routine
(see Chapter 2, under the PrntCal Parameter) to adjust for optimum printed output.
4–27
Procedure 17—The Paper Guide

Remove 2 Screws
U IDE
ERG ved
)
AP mo
P (Re
Bank
mer
Ham
) rm
ed tfo
ov Pla
Printer
em n
(R ibbo
Frame
R
Figure 4–24. Removing the Paper Guide
Be careful when handling the Paper Guide. It be bent easily, which can cause paper
handling problems, and it is also very sharp and can cause injury to the unwary.
Removing
STEP 2. Remove the screws at each end of the Paper Guide that secure it to the printer frame.
Reinstalling
To reinstall the Paper Guide, reverse the sequence and actions of the removal steps.
When you reinstall the Paper Guide, make sure to push down on the center to
ensure that it is flat against the printer frame before you tighten the mount screws.
Before you reinstall the Ribbon Platform, adjust the hammer to platen gap if necessary
(see Procedure 28).
output.
4–28
Procedure 18—The Platen

Removing
STEP 2. Remove the Paper Guide (see Procedure 17).
Be careful when handling the Paper Guide. Not only can it be bent easily, which can
cause paper handling problems, but it is also very sharp and can cause injury to the
unwary.
STEP 3. Remove the springs (one on each end of the Platen) that hold the Platen in place,
disconnect the Platen Open Sensor cable from the end of the Platen, then lift the Platen
out of the printer.
Curved Spring Platen Adjust Plate

Washers
Remove Springs-
Right and Left ends
of the Platen
Paper Guide
Platen - Right End
Platen
Open
Sensor
Platen Open
Sensor
Form
Platen Thickness
Adjust Lever
Plate
Pla
ten
Platen - Left End
Figure 4–25. Removing the Platen
The Platen Open Sensor is held in place on the Platen by two small plastic tabs. Be
careful not to damage them when you disconnect the sensor cable from the Platen. It
may help to disconnect it if you first disconnect the sensor cable (J601) from the Main
Controller CBA to allow some slack in the cable.
4–29
Reinstalling
STEP 1. Reconnect the Platen Open Sensor to the Platen.
STEP 2. Place the alignment plates on the Platen and reinsert the Platen into the printer.
It is possible that the end assemblies of the platen may come off of the platen when
you remove it. When you reassemble the platen make sure that ALL parts are
included. Some of them are small (for example, the spring washers on the left end
of the platen) and may be lost. Check Figure 4–25 to ensure that all parts are
installed.
STEP 3. Place the springs back on the ends of the Platen and secure it in place.
STEP 4. Reinstall the Paper Guide.
When you reinstall the Paper Guide, make sure to push down on the center to
ensure that it is flat against the printer frame before you tighten the mount screws.
STEP 5. Reinstall the Hammer Bank.
output.
Procedure 19—The Platen Open Sensor

Removing
STEP 1. Remove the Platen from the printer (see Procedure 18).
STEP 2. Disconnect the Platen Open Sensor cable (J601) from the Main Controller CBA and
remove the Ferrite Bead that encircles it next to the CBA (see Figure 4–13).
STEP 3. Remove the Platen from the printer (see Procedure 17).
STEP 4. The Platen Open Sensor is secured to the end of the platen by two plastic tabs. Release
the tabs and the sensor will come free.
4–30
J601
Platen
Alignment
Plate
Platen Open
Sensor
Detent
Plate
Form
Thickness
Lever
Platen
Figure 4–26. Removing the Platen Open Sensor
Reinstalling
STEP1. Snap the sensor into place on the end of the Platen. The new sensor comes with the
cable attached.
STEP 2. Plug the Platen Open Sensor cable (J601) into the CBA and reinstall the Platen. Now
perform a meter test of the sensor (as explained under the Platen Open message in
Chapter 3) to ensure that it is functioing properly.
STEP 3. Finish the installation by reinstalling all other components you have removed.
output.
4–31
Procedure 20—The Form Thickness Lever

Before beginning the procedure, turn the printer off and disconnect the power cable.
Removal
STEP 2. Remove the Platen (see Procedure 18).
STEP 3. There are no screws or any other fastening devices securing the Form Thickness Lever
onto the Platen. The whole mechanism snaps together. Use a small plastic faced
hammer to tap outward LIGHTLY on the inside of the lever plate. A few LIGHT taps
and the lever should come free of the Platen. In addition, the Detent Plate and Platen
Gap Adjustment Plate will come free.
It is possible that both Platen

Alignment
end assemblies of the Plate
platen may come off
of the platen when gh
you remove it. When p Li tl
y
Ta
Detent
you reassemble the Plate
platen make sure that
ALL parts are in- Form
cluded. Some of them Thickness
Lever
are small (for ex-
ample, the spring Pla
ten
washers on the left
end of the platen) and
may be lost. Check
Figure 4–25 to ensure
that all parts are
installed.
Figure 4–27. Removing the Form Thickness Lever
Reinstalling
The Form Thickness Lever Plate is keyed so it will only fit onto the Platen in the proper
alignment.
Reassemble the Platen mechanism, then reinstall the platen by reversing the sequence
and actions of the removal process.
After completing the installation, perform a Hammer Lead Time Calibration Routine
(see Chapter 2, under the PrntCal Parameter) to adjust for optimum printed output.
4–32
Procedure 21—The Shuttle Stepper Motor

Removal
STEP 2. Unplug the Shuttle Stepper Motor from the Main Controller CBA (J501) and remove the
Shuttle Drive Belt.
STEP3. Remove all but one of the mounting screws from the Shuttle Stepper Motor, then while
supporting the motor with one hand remove the last screw. The Shuttle Stepper Motor
can now be removed from the printer.
Stepper Motor
J501
Shuttle Drive Belt
J90
1
J8 J6J60 J
01 J 02 3 60
J5 J502 J 60 4
01 50 1
3
t rol ler
C o n
Main BA
C
Figure 4–28. Removing the Shuttle Stepper Motor
If you are replacing the Shuttle Stepper Motor, continue to STEP 4.
STEP 4. Loosen the set screw that secures the Shuttle Belt Drive Pulley to the motor output shaft
and remove the pulley from the old motor for installation on the new motor.
STEP 5. Remove the Ferrite Bead from the cable bundle near the Main Controller CBA (see Figure
4–13) so the motor can be removed from the printer.
4–33
Reinstalling
STEP 1. Reinstall the Shuttle Belt Drive Pulley onto the output shaft of the new motor. There
should be approximately 1/8" of motor output shaft protruding past the locking collar of
the pulley.
Approx. 1/8"
Pulley Set
Screw
J501
Figure 4-29. Installing the Shuttle Drive Pulley
STEP 2. Insert the motor shaft and pulley through the hole provided for them in the mounting
bracket on the printer, making sure that the motor cable is on the side nearest the Main
Controller CBA, and reinstall the mounting screws.
STEP 3. Reinstall the Shuttle Drive Belt and plug the motor cable into the Main Controller CBA
(J501) and reinstall the Ferrite Bead.
STEP 4. Reinstall the Right End Cover and Printer Control Panel.
explained Chapter 2, under the PrntCal Parameter) to adjust for optimum printed
output and a Meter Test on the Shuttle Motion Sensor.
4–34
Procedure 22—The Shuttle Drive Belt

Removing
STEP 1. Remove the Printer Control Panel (see Procedure 2) and place it in the bottom of the
printer.
STEP 2. Reach inside the Control Panel opening, grasp the belt and pull it up off of the Shuttle
pulley then remove it from the Shuttle Motor Pulley.
Shuttle Motor
Shuttle Drive Belt
Hammer Bank
Figure 4-30. The Shuttle Drive Belt
Reinstalling
STEP 1. Place the belt around the Shuttle Motor pulley, then place it around the Shuttle pulley.
STEP 2. Reinstall the Control Panel.
4–35
Procedure 23—The Shuttle Motion/Capture Sensor

Removing
STEP 2. The Shuttle Motion/Capture Sensor is mounted on the bracket behind the upper shuttle
wheel. It is secured by one Allen-head screw. Use an Allen driver to loosen the screw,
then disconnect the cable from the Main Controller CBA (J604) and remove the Ferrite
Bead from the cable bundle near the CBA (see Figure 4–13). Now the sensor can be
removed from the printer.
J90
1
J8 J6J60 J
0 1 J6 02 3 604
J5 J502 J 01
01 50
3
ler
C o ntrol
Main BA
C
J604
Figure 4-31. Removing the Shuttle Motion/Capture Sensor
Installing
STEP 1. Mount the sensor on the bracket behind the upper shuttle wheel. Do Not tighten the
mount screw yet, just make it snug. You need to be able to move the sensor to adjust it.
STEP 2. Connect the sensor cable to the Main Controller CBA, perform the Meter Test on the
sensor (as explained in Chapter 2, under the Meter Parameter) to make sure it is prop-
erly adjusted, then tighten the mount screw and install the Ferrite Bead (see Figure
4–13).
STEP 3. Reinstall the Right End Cover and.the Control Panel.
4–36
Procedure 24—The Paper Advance Motor

Removing
STEP 1. Disconnect the Static Ground, then remove the Sound Baffling Hood from the back of
the printer and any printed forms along with the paper stacking tray if they are present.
STEP 2. Remove the Printer Control Panel (see Procedure 2).
STEP 3. Remove the Left End Cover of the printer (see Procedure 8).
STEP 4. Remove the Power Supply (see Procedure 6). Do not let the power supply hang by its
wire harness. Disconnect the harness from the Main Controller CBA (J302) and set the
Power Supply aside.
er over
Powply C
Sup
J503
Motor Harness Coupling
Drive Belt
Paper Advance Motor
Figure 4–32. Removing the Paper Advance Motor
STEP 5. Disconnect the wire harness coupling just inside the power supply opening.
STEP 6. Loosen the three Phillips mounting screws on the Paper Advance Motor mounting
bracket.
STEP 7. With your left hand, reach inside the Power Supply opening and grasp the case of the
motor and slide the motor up to release tension on the drive belt, then remove the drive
belt.
4–37
STEP 8. Remove the belt drive pulley and motor flywheel from the motor shaft. They are
secured to the motor output shaft by Allen-head set screws.
Paper Advance
Motor Flyweel
and Pulley
Paper Advance
Motor
Set Screw
Figure 4–33. Removing the Paper Advance Motor Flywheel and Pulley
STEP 9. Remove the Phillips mount screws and take the motor out of the printer.
Reinstalling
STEP 1. Insert the motor through the power supply opening and reinstall the mount screws
loosely.
STEP 2. Reinstall the belt drive pulley and motor flywheel onto the motor. The Flywheel should
be installed .16" from the Motor body.
STEP 3. Slide the motor up and reinstall the drive belt.
When you reinstall the Paper Drive Belt, DO NOT place too much tension on the belt.
This will cause rapid wear and need for replacement.
STEP 4. Apply a slight downward pressure on the motor to remove any slack in the drive belt,
then tighten the Phillips mounting screws.
STEP 5. Reconnect the wire harness coupling just inside the power supply opening.
STEP 6. Reinstall the Power Supply.
Optional: Before continuing with motor installation, you may want to plug in the
control panel and perform a motor test with the FORM FEED Key, LINE FEED Key, and
the ▲ Key. Make sure you enable the fault overrides berfore attempting these tests.
STEP 7. Reinstall the Left End Cover.
STEP 8. Reinstall the Control Panel.
STEP 9. Reinstall the Paper Tray and Sound Baffling Hood.
4–38
Procedure 25—The Paper Drive Pulleys and Belt

Removing and Replacing Paper Drive Components

STEP 1. Remove the Left End Cover (see Procedure 8).
STEP 2. Loosen the mount screws on the Paper Advance Motor.
If you are replacing the motor drive pulley:

Step 1. Lift up on the motor and remove the drive belt.
Step 2. Loosen the two set

screws that hold the
pulley onto the
motor shaft. Paper Advance
Motor Flyweel
Step 3. Remove the old and Pulley
pulley and replace it
with the new pulley. Paper Advance
Motor
Step 4. Push the new pulley
up against the motor Set Screw
flywheel, then tighten
the set screws.
Figure 4–34. Replacing the Motor Drive Pulley
If you are replacing the drive belt:

Step 1. Lift up on the motor and remove the old drive belt.
Step 2. Lift up on the motor again and install the new drive belt.
Step 3. Push down lightly on the motor to remove any slack from the belt and tighten
the motor mount screws.
If you are replacing the pulley on the tractor drive shaft:

Step 1. Lift up on the motor and remove the drive belt.
Step 2. Remove the snap ring that holds the pulley onto the drive shaft.
Step 3. Remove the old pulley and place the new pulley onto the shaft.
When installing the tractor drive shaft pulley, push in on the right end of the shaft
to keep it snug against the bearing.
Step 4. Reinstall the snap ring.
After you have put the snap ring back on, push on both ends to make sure that there is
no side to side movement in the shaft.
4–39
When you are finished replacing the component, make sure that the drive belt is prop-
erly installed and motor mount screws are tight.
Optional: Before continuing with this installation, you may want to plug in the control
panel and perform a paper movement test with the FORM FEED Key, LINE FEED Key,
and the ▲ Key. Make sure you enable the fault overrides before attempting these tests.
Check to ensure that the paper moves properly through the tractors.
To finish the job, reinstall the left end cover and the printer lid.
Procedure 26—The Tractors

Removing
STEP 2. Loosen the Phillips screws that secure the Paper Advance Motor, slide the motor up to
release tension on the Paper Drive Belt so it can be removed easily.
STEP 3. Remove the snap ring that secures the right end of the tractor drive shaft into the
bearing.
STEP 4. Remove the snap ring that secures the drive pulley onto the left end of the tractor drive
shaft. Remove the drive pulley and set it aside.
r
to
ac
Tr
Drive Shaft
Snap Ring
Drive Shaft Bearing
Drive Belt
Tractor Drive Shaft
Pulley
Figure 4–35. Removing the Tractor Drive Shaft Pulley
STEP 5. Remove the snap ring that secures the drive shaft into the bearing guide cap on the right
end of the tractor drive shaft, the slide the drive shaft out the left side mounting hole
and get it completely out of your way. Do not lose the snap rings.
4–40
STEP 6. Remove the nut on the left end of the tractor guide bar and slide the bar to the right a
couple of inches.
STEP 10. Unlock the left tractor and slide it off the end of the guide shaft, then remove the snap
ring, and paper rollers so that the right tractor can be removed.
STEP 11. The Paper Motion Sensor is secured onto the left tractor with a Phillips screw (see
Procedure 27). Remove the screw and take the sensor off of the tractor.
Paper Motion Sensor
tor
Trac
ht
Rig
tor
Trac
Left
Unlock To Slide
Tractor Guide Bar

Tractor Drive Shaft
(Removed)
Figure 4–36. Removing the Tractors
Figure 4–37. Tractor Drive Components
4–41
Replacing
STEP 1. Slide the right tractor onto the guide bar.
STEP 2. Reinstall the paper rollers and spring, then install the snap ring approximately 5 inches
from the left end of the guide bar.
STEP 3. Attach the Paper Motion Sensor to the left tractor (make sure the sensor is installed flush
against the mount screw), then reinstall the left tractor onto the guide bar. Make sure
that the alignment indicators on the tractors are properly aligned before installing the
tractor drive shaft.
STEP 4. Reinstall the tractor guide bar into the left side of the printer frame.
Finish the installation by reversing operations and sequence of the removal steps for the
tractor drive shaft, drive wheel, etc.
Optional: After you have installed all of the paper movement components, you may
want to plug in the control panel and perform a paper movement test with the FORM
FEED Key, LINE FEED Key, and the ▲ Key. Make sure you enable the fault overrides
before attempting these tests. Check to ensure that the paper moves properly through
the tractors.
When you reinstall the Paper Drive Belt, DO NOT place too much tension on the belt.
This will cause rapid wear and need for replacement.
Procedure 27—The Paper Motion Sensor

Removing
STEP 3. Remove the Power Supply Panel (see Procedure 6).
STEP 4. Loosen the Phillips screws that secure the Paper Advance Motor, slide the motor up to
release tension on the Paper Drive Belt so it can be removed easily.
Be careful of the paper guide plate and Ribbon Shield when working on the tractors.
Not only can they be bent easily but the edges are very sharp and can injure the care-
less.
STEP 5. Remove the snap ring that secures the right end of the tractor drive shaft into the
bearing.
STEP 6. Remove the snap ring that secures the drive wheel onto the left end of the tractor drive
shaft. Remove the drive wheel and set it aside.
4–42
STEP 7. Remove the tractor drive bar and set it aside out of your way. Do not lose the snap
rings.
STEP 8. Remove the nut on the left end of the tractor guide bar and slide the bar to the right a
couple of inches.
J603 Sensor
Drive Shaft Sleeve

(shaft removed)
Left Tractor
Rotate
uide
Paper G
Tractor
Tractor
Guide bar
Figure 4–38. Removing the Paper Motion Sensor
STEP 9. Tilt the Left Tractor forward so you can access the Phillips screw that secures the sensor
to the tractor.
STEP 10. Loosen the Phillips screw, unplug the sensor cable from the CBA (J603) and remove the
Ferrite Bead that encircles the cable bundle near the CBA (see Figure 4–13), then remove
the entire sensor assembly from the printer.
Installing
STEP 1. Route the cable on the new sensor through the same path as the old one and plug it
into the CBA (J603), then reinstall the Ferrite Bead.
STEP 2. Attach the sensor to the left tractor with the Phillips screw.
To finish the installation of the Paper Motion Sensor reverse the sequence and actions of
Removal STEPs 1 thru 8.
After you have finished installing the sensor perform a meter test of the sensor (as
explained in Chapter 23, under the Meter Parameter) and adjust its position as neces-
sary to achieve the proper meter results.
4–43
Procedure 28—Adjusting the Platen Gap

Checking the Platen Gap

STEP 1. If you are reassembling the printer after maintenance, check the platen gap before
installing the Ribbon Platform or the Right End Cover.
If the printer is assembled, you will find it easier to check the platen gap if you remove
the Ink-ribbon and the Ribbon Platform (see Procedure 9). In addition, you will find it
easier to adjust the right end of the platen, if you remove the Right End Cover (see
Procedure 3) for access to the right end adjusting plate of the platen.
STEP 2. Insert a .015" feeler gage or piece of shim stock between the Ribbon Shield and the
Platen at the right and left ends and in the middle of the hammerbank. As you insert
the gage, feel for the hammer balls. The gage should fit snugly between the hammer
balls and the platen. If you cannot feel the hammer balls or if you have to force the
shim between the hammer balls and the platen, the platen gap must be adjusted using a
5/64" Allen wrench or T-handle driver.
If the gap is too loose, turn the Allen-head set screws in the adjusting plates in a
clockwise direction to move the platen out. Adjust the gap until the gage fits snugly
between the hammer balls and platen.
If the gap is too tight, turn the Allen-head set screws in the adjusting plates in a
counter-clockwise direction to move the platen in. Adjust the gap until the gage fits
snugly between the hammer balls and platen.
Platen Gap Adjust Plates
Figure 4–19. Adjusting the Platen Gap
After you are finished adjusting the platen gap, reassemble the printer and perform a
print test to check the print quality and perform a Hammer calibration routine if neces-
sary.
4–44
Appendix A:
Schematics
Appendix A
Ribbon Sensors
Fault Detect l n
pt
ure
on tr
o r bo tle
C a C ot
i C ut C pe
n
on el pe e ib e
R rivtor ut or
VCND le C VCND r M VCND r O VCND n O In C an Parivtor A D o Sh ot
V
48ND G utt _ G pe G pe G ate a_ P A D o A
io
n
ShND PaND PaND Pl ND at A- M A- M A- M
G ND ot _D B
612350 Controller CBA G B_ n-M G G G G el B B
n be B- B- B-
R ibbo PaND tro k ut D D D
G C l_S loc _O N N N
R CC G G G
U C_5 1 1 1 1 VC ne l_C ata
1 M 2 2 2 2 1 Pa ne l_D 1 1 1
2 3 3 3 3 2 Pa ne 2 2 2
3 4 4 4 4 3 Pa 3 3 3
4 4 4 4 4
5 5 5 5 5
6 6
7
Hammer
Bank
1 GND
2 48V Fan
3 GND
1 GND
2 GND Power
3 48V Supply
4 48V
A-1
Controller CBA 612350
A-2
A-3
A-4
A-5
A-6
Appendix B:
Illustrated Parts Breakdowns (IPBs)
Appendix B
21
10
Cover Set - T6045 19
612157 15
12
22
19
21
19
11 16
20
Rear View
19
B-1
Cover Set T6045
612157
Item Number Description Part Number
10 Cabinet-Rh Assy 079876
11 Cabinet-Lh Assy 079875
12 Cover Assy-Lid 079616

15 Gas Spring 731060
16 Stop, Hinge 079684
19 Screw-#8-32 x 5/8 SEMS REF


Flat Head-Cross Recessed
22 Hood Assy-Paper Exit 079622
B- 2
36 Assembly - Basic Printer T6045
29a 29b 612369 612408
22 3x
106
401
402 30
309
38
105 15c
x4
107 RFD Version
Only
104 RFD Version

110 Only
35 4x
108 RFD Version
Only
15a
42
22
23
41
212 15b
221 40
22
37 J901 J603
27 3x J604 J602 J801
J601
46
J503
J502
J901 J501
Ribbon Fault Detect
39 J604
Stand Version 3x
Only Shuttle Sensor
33
J603
Paper Motion Sensor
J602
Paper Out Sensor
Cable
J601 Hammer
Platen Open Sensor Bank
J801
31 Stand Version Control Panel
Only
J503
32 Stand Version Paper Drive Motor
Only
J502 47
Ribbon Drive Motor 18 44
19
J501 20
Shuttle Drive Motor 21
B-3
Assembly - Basic Printer T6045
612369 612408
Item Number Description Part Number Item Number Description Part Number
15a Hammer Bank Assy 080219 41 Screw - #8-32 x 0.25 SEMS REF
15b Shuttle Assy 080145 42 Control Panel Assembly 078538
15c Ribbon Shield Assy 080225 44 Mount- Flat Cable 730628
18 Fan Assy 079644 46 Support- Cable, Nylon, Twist Lock 731038
19 Screw - #8-32 x 1.375 REF 47 Bead-Ferrite, Clamp-on 730910
20 Washer - #8 Split Lock REF 104 Motor-Ribbon Drive 075138
21 Washer - #8 Flat REF 105 Screw - #8-32 x 0.50, Flat Head REF
22 Screw - #8-32 x 0.375 SEMS REF 106 Hole Plug 731207
23 Belt, Flat (Shuttle) 730007 107 Disk-Mounting, RFD Sensor 079243
27 Cabinet Front Panel Assy REF 108 Sensor-Ribbon Fault Detect 731002
29a Platform Assy- Ribbon, Standard 079708 110 Cable Assy., RFD 080024
29b Platform Assy- Ribbon, RFD 080070 212 Cable Assy.-Paper Out Sensor 080045
30 Power Supply Assy- Shindengen 079601 221 Screw - #4-40 x 0.50 SEMS REF
31 Upper Spring 079868 309 Module-Power Entry/Switch 731108
32 Bracket-Front 079869 401 Hammer Module Assy 080077
33 Jaw Assy 079870 402 Hammer Coil Assy 080072
35 Screw - 6-32 x 0.25 REF
36 Screw - 8-32 x 0.50 REF
37 Screw - #6-32 x 0.312 Res Flat Head REF
38 Screw - #8-32 x 5/16 Flat Hd. CRPT REF

39 Screw - #8-32 x 0.75 SEMS REF
40 Controller Kit 612420
B- 4
21 24
20
17
23
Print Mechanism T6045

56
Paper Guides
26
Shuttle Motor 18
Platen Assy 29
23
612409
27
56
30
54
44 67
45
54 64
57
B-5
Print Mechanism T6045
Paper Guides
Shuttle Motor
Platen Assy
612409
17 Platen & Dampener Assy. 075119
18 Plug- End Platen 611093-1

20 Lever- Platen 075133
21 Plate- Detent, Platen Lever 611096-1
23 Washer- Curved Spring, 3/8 400995-20

24 Cable Assy- Sensor, Platen Open 075135
26 Pin- Platen Support 079498

27 Plate- Platen Gap Adjust 079497
29 Screw-Set #8-32x0.625 730213
30 Spring-Platen Adjust 731114

44 Spring- Extension 731461
45 Motor Assy-Paper/Shuttle Drive 078259
54 Screw- #6-32 x 0.50 REF

56 Screw-#8-32 x 0.50 SEMS REF
57 Screw- #4-40x0.50 Sems REF
64 Cable Assy- Shuttle Sensor 080044

67 Pulley Assy- Flat Belt 075490
B- 6
Mount Pulley
Print Mechanism
38
Flush to
Flywheel
Paper System Assy - T6045
612409 40
35
32
39
50 33 36
403
45
52 42
43
37 46
Left Hand End Plate
36 42 37
34
59
45
40
32
49
58
47 56
52
53
50
B-7
Print Mechanism
Paper System T6045
612409
32 Bearing- Double Sealed, W/Ring 731090

33 Shaft- Paper Drive 075482
34 Shaft- Tractor Support 080023
35/36 Tractor Kit- Paper Drive 080115

37 Ring- Retaining (Tractor Stop) 400641-13
38 Ring- Retaining 400641-18
39 Bushing- Square Shaft 075480

40 Nut- #5/16-18 Hex Keps 400783-15
42 Spring- Paper 602631-1
43 Idler 075477
45 Motor Assy- Paper/Shuttle Drive 078259
46 Cable Assy-Extension, Paper Motor 079677
47 Belt- Timing, Paper Drive 079676

49 Pulley- Paper Drive 079444
50 Pulley Assy-Paper Motor, Modified 079810
52 Flywheel- Paper Motor 079809

53 Screw- Set, #6-32x0.50 400690-37
56 Screw-#8-32 x 0.50 SEMS REF
58 Paper Guide- Tractor 079516

59 Screw- #4-40x0.187 Sems REF
403 Paper Motion Sensor 079706
B- 8
612350 Controller CBA
B-9
Reference Designator(s) Item Number(s) Reference Designator(s) Item Number(s) Reference Designator(s) Item Number(s)
U1 27 35 R61 R74 R75 R76 66 C77 C78 104
U2 29 33 R22 81 C87 103
U3 U4 U5 U6 U8 U9 22 127 R23 63 C88 C97 105
U7 19 R24 R25 73 C29 C31 C37 C48 C52 C57 C61
U10-U17 37 R5 R29 R73 61 C69 C71 C76 C80 C84 C88-C91 Not Installed
U18 20 R31 R59 R64 R68 62 CR1 CR3-CR10 38
U19 24 R32 R45 78 CR2 41
U20 U21 21 R34 R48 68 CR11 39
U22 26 R35 R47 69 CR12 42
U23 13 R37 R49 80 CR13 40
U24 15 R38 R41 79 CR14 43
U25 23 R42 58 Y1 Y2 45
U26 12 R53 57 Y3 46
U27 25 36 R54 76 Y4 44
U28 14 R55 77 Q1 83
U29 28 R58 54 Q2 82
U30 30 R69 56 Q3 84
RP1-RP4 RP11-RP14 52 R72 59 VR1 85
RP5-RP10 RP16-RP18 50 R26 R65 R50A LED1 Not Installed VR2 86
RP15 49 C1 C4-C9 C13 C14 95 RT1 108
RP19 51 C3 C10-C12 C15 C24 C39 F1 Not Installed
RP20 48 C41 C43-C45 C53 C54 L1 L18 112
RP21 RP22 47 C58 C63 C65 C66 L2-L15 L19-L22 111
RP23 53 C79 C81 C83 C86 C92-C96 99 L16 109
PCB 9 C16 C25-C27 C38 C55 L17 110
R1 75 C69 C70 C82 96 J2 116
R2 R7 R33 R46 65 C17-C23 C40 C42 98 J14 123
R3 R39 R40 67 C28 C32 C51 C72 C74 C85 94 J15 122
R4 R6 72 C30 102 J302 121
R8 R9 R62 R63 R67 55 C33 C34 C35 C36 90 J501-J503 118
R10 R57 R66 64 C46 C47 C49 C50 101 J601-J604 117
R11 R20 70 C55 C75 100 J703 124
R12 R13 R14 R70 R71 60 C59 C60 C64 88 J801 119
R15 R56 74 C62 89 J901 120
R16-R19 R30 R36 R43 R44 71 C67 97
R21 R27 R28 R50 R51 R52 R60 66 C73 106
B- 10
Print Mechanism
Paper System T6045 42 Diode MUR810 731075
612409 43 Diode Zener 1N5251B 731191
44 Crystal 32.768 Khz 731243
Item Number Description Part Number 45 Crystal 12.288 Mhz 731243
46 Crystal 3.6864 Mhz 731242

9 PCB-Coho Controller REV X4 079507 47 Resistor SIP 1.2K 8 Pin 731031
12 I.C. 74F14 731082 48 Resistor SIP 33 10 Pin Isol 731032
13 I.C. 74LS244 730130 49 Resistor SIP 10K 6 Pin 730419
14 I.C. 74F251 731115 50 Resistor SIP 47 8 Pin Isol 730174
15 I.C. 74LS374 730129 51 Resistor SIP 47 10 Pin Isol 730170
19 I.C. LM358 403741-01 52 Resistor SIP 510 8 Pin Isol 403006-09
20 I.C. 145407 730450 53 Resistor SIP 10K 8 Pin 730494
21 I.C. PSTATIC RAM 518128 731067 54 Resistor 47 1/4W 5% 730339
22 I.C. 3952 731071 55 Resistor 120 1/4W 5% 400072-75
23 I.C. X24C08 731069 56 Resistor 243 1/4W 1% 402285-38
24 I.C. MC68340 731064 57 Resistor 470 1/4W 5% 730104
25 I.C. EPM7032 080053 58 Resistor 510 1/4W 5% 400072-90
26 I.C. HAMVLSI 075118 59 Resistor 820 1/4W 5% 400072-95
27 Firmware-CTL Processor 8797 080162 60 Resistor 1K 1/4W 5% 730105
28 Firmware-28F400 080160 61 Resistor 2.10K 1/4W 1% 402285-168
29 Firmware-87C750 080052 62 Resistor 3.3K 1/4W 5% 730106
30 I.C. 28F200 731121 63 Resistor 4.99K 1/4W 1% 402285-168
33 Socket I.C. 24 Pin Slimline 730132 64 Resistor 5.1K 1/4W 5% 400073-18
35 Socket-PLCC 68 Pin 730012 65 Resistor 10K 1/4W 1% 402285-201
36 Socket-PLCC 44 Pin 731111 66 Resistor 10K 1/4W 5% 730108
37 Array-Trans/Diode SMA4032 730980 67 Resistor 12K 1/4W 5% 400073-27
38 Diode Zener 1N5339B 5.6V 400049-21 68 Resistor 13K 1/4W 1% 402285-212
39 Diode Zener 1N5359B 24V 400049-80 69 Resistor 15K 1/4W 1% 402285-218
40 Diode Zener 1N5908 731072 70 Resistor 20K 1/4W 5% 400073-32
41 Diode UF4004 403880-04 71 Resistor 24K 1/4W 5% 400073-34
B-11
Print Mechanism
Paper System T6045
612409
Item Number Description Part Number Item Number Description Part Number
72 Resistor 121 1/4W 1% 402285-09 100 Capacitor .33Mfd 50V 730119
73 Resistor 100K 1/4W 5% 400073-49 101 Capacitor 10Mfd 25V 730442
74 Resistor 330K 1/4W 5% 400073-61 102 Capacitor 22Mfd 25V Tant 730120
75 Resistor 100K 1/4W 1% 402285-301 103 Capacitor 100Mfd 63V 731083
76 Resistor 10M 1/4W 5% 731189 104 Capacitor 470Mfd 16V 731084
77 Resistor 20M 1/4W 5% 731190 105 Capacitor 8200Mfd 63V 731085
78 Resistor .3 1W 403026-02 106 Capacitor 100Mfd 20V 401387-37
79 Resistor .5 1W 403026-06 108 Thermistor 730099
80 Resistor 1.0 1W 403026-03 109 Inductor 22uH 731098
81 Resistor 750K 1/4W 5% 400073-70 110 Inductor 150uH 731097
82 Transistor SJE2895 Special 730469 111 Bead-Ferrite, Leaded 730098
83 Transistor 2N3904 401340-01 112 Filter-EMI Suppressor 730097
84 Transistor 2N5550 402278-01 113 Adhesive-Loctite 410 400658-36
85 Regulator-Voltage LM317 402668-01 114 Accelerator-Adhesive 400658-35
86 Regulator-Voltage LM2576VT-5 731080 116 Connector-3 Pin 730163
88 Capacitor 10pfd 50V 10% 730334 117 Connector Phone-4 Pin 403760-01
89 Capacitor 22pfd 50V 10% 730195 118 Connector-5 Pin 403726-05
90 Capacitor 33pfd 50V 10% 730617 119 Connector-6 Pin 730012
94 Capacitor 1000pfd 50V 10% 731017 120 Connector-7 Pin 403726-07
95 Capacitor 4700pfd 50V 10% 402910-133 121 Connector Power-4 Pin 731119
96 Capacitor 1200pfd 100V 10% 402910-126 122 Connector-25 Pin 730147
97 Capacitor .01Mfd 50V 10% 730196 123 Connector-36 Pin 730385
98 Capacitor .1Mfd 100V 10% 402910-149 124 Connector-44 Pin 402330-02
99 Capacitor .1Mfd 50V 730142 127 Heatsink I.C. DIP 403883-03
B- 12
Appendix C:
Downloading Printer Firmware
Appendix C
T6045 Firmware Update Procedure

The following instructions explain how to download updated printer firmware.
STEP 1. Power up the T6045 normally and print out a Configuration Report. This will give you a
hard copy of the printer setup. You will need this to restore any parameters that you
have set in the printer. Power the T6045 down.
STEP 2. Connect the T6045 to your computer using the parallel interface.
STEP 3. Power up the T6045 while holding down the following four keys on the control panel:
VIEW Key, LINE FEED Key, ▼ Key, and MODE Key. Hold them down until the follow-
ing message scrolls on the control panel display: “Mannesmann Tally Flash Loader.”
The display then stops scrolling and says: “Flash Dnld Ready.”
STEP 4. Change the directory to the floppy drive. From the DOS Command Prompt enter:
<filename> -P
This will cause the compressed file to expand directly to the PRN device.
The time required to update the firmware depends upon the speed of the computer you
are using. Typically the times will vary from 3—10 minutes.
STEP 5. After the download is complete, check the hard copy of the configuration and set up the
appropriate parameters.
The firmware download is now complete.
You may or may not get an NVRAM fault at the end of the download. If you do, it
does not indicate a problem with the printer. Simply depress the CLEAR Key on the
printer control panel and the message will clear. The printer is now ready for use.
C–1
Supplement:
Platen
Supplement:
Chapter 4 – Removing and Reinstalling the Platen
Chapter 4 Supplement – Removing and Reinstalling the Platen
Supplement to Manual 079786

MT6045 Line Impact Printer
Maintenance Manual
This Supplement presents descriptions and explanations about additions/

changes to the operation of your printer. Please read through this document
before operating your printer. In addition, you may want to make references to
this document in applicable areas of your Maintenance Manual.
081518
1
T6045 Maintenance Manual Supplement
Procedure 18– The Platen

Removing
STEP 3. Remove the two springs (one on each end of the platen) that hold the platen in place.
Disconnect the Platen Open Sensor from the left end of the platen, then lift the Platen out of
the printer.
It may help if you first disconnect the sensor cable (J601) from the Main Controller CBA
to allow some slack in the cable.
The Platen Open Sensor is held in place on the Platen by two small plastic tabs.
Be careful not to damage them when you disconnect the sensor from the
Platen.
Remove Springs-
Right and Left ends
of the Platen
Platen
Open
Sensor
Platen (upgrade)
P/N 081383
Figure 1. Removing the Platen
2
Chapter 4 Supplement – Removing and Reinstalling the Platen
Reinstalling
STEP 1. Reconnect the Platen Open Sensor to the Platen Assembly.
STEP 2. Place the Detent and the adjustment plates on the Platen and reinsert the Platen into the printer.
Ensure that there is grease between the Platen Adjustment Plate and the Frame End
Plate.
It is possible that the end assemblies of the platen may come off of the platen when you
remove it. When you reassemble the platen make sure ALL parts are included. Some
parts are small (for example, the spring washers on the right end of the platen) and are
easily lost. Refer to the figure below to identify the parts and the installation sequence.
Platen Platen
Adjust Plate
Platen Adjust Plate
Platen Open
Sensor
Detent Platen
Curved Spring
Form Washers
Thickness
Lever
Platen - Left End Platen - Right End
Figure 2. Platen End Assemblies
STEP 3. Place the springs back on the ends of the Platen and secure it in place.
STEP 4. Reinstall the Hammer Bank.
Before you reinstall the Ribbon Platform, check the hammer to Platen gap and adjust as
After completing the installation, perform a Hammer Lead Time Calibration to maintain
optimum print quality (see PrntCal Parameter in Chapter 2).
Platen assemblies (081383) must be used with Detent (080931). Old style Platens
(075119) are not directly interchangeable with new Platens.
3
Procedure 20—The Form Thickness Lever

Before beginning the procedure, turn the printer off and disconnect the power cable.
Removal
STEP 2. Remove the Platen (see Procedure 18).
STEP 3. Remove the Platen adjustment plate and detent plate.
STEP 4. Remove the phillips head screw securing the Form Thickness Lever to the Platen. You can
now remove the Forms Thickness Lever by sliding the lever over the Platen support pin.
Platen
It is possible that both Platen
end assemblies of the Support Pin
platen may come off of
the platen when you
remove it. When you
reassemble the platen Detent
make sure that ALL Form
Thickness
parts are included. Lever
Some of them are
small (for example, the
spring washers on the
right end of the platen)
and may be lost. Platen
Check Figure 2 to Adjust Plate
ensure that all parts
are installed. Figure 3. Removing the Form Thickness Lever
Reinstalling
Reassemble the Platen mechanism, then reinstall the platen by reversing the sequence and
actions of the removal process.
When you reinstall the Hammer Bank, make sure that the Ribbon Shield does
not get hung up on the printer frame below the Hammer Bank. This can damage
the Ribbon Shield and interfere with printer operation.
After completing the installation, perform a Hammer Lead Time Calibration Routine (see
Chapter 2, under the PrntCal Parameter) to adjust for optimum printed output.
When installing a new Forms Thickness Lever, push down on the tip of the lever while
tightening the screw. The screw should be tightened to 18 inch lbs.
4
Supplement:
Removing and Replacing the Hammer Module/Hammer Coil
Hammer Module
Supplement:
Supplement - Removing and Replacing the Hammer Module
Supplement to Manual 079786

MT6045 Line Impact Printer
Maintenance Manual
This Supplement presents descriptions and explanations about additions/

changes to the operation of your printer. Please read through this document
before operating your printer. In addition, you may want to make references to
this document in applicable areas of your Maintenance Manual.
081724
1
The Hammer Module/Hammer Coil

Removing and Replacing

If you are repairing the Hammer Bank because of a Hammer Coil failure, you may
replace either the defective coil or the entire Hammer Module. However, if you are
repairing the Hammer Bank because of a defective Hammer, you must replace the
entire Hammer Module. This guarantees proper hammer equalization and component
alignment.
STEP 1. Remove the Hammer Bank from the printer (see Procedure 13, Maintenance Manual).
STEP 2. Remove the Ribbon Shield (see Procedure 14, Maintenance Manual), and set it aside.
If you are replacing just the Hammer Coil do not remove the entire module from the
Hammer Bank. Perform the subroutine that follows. If you are changing the entire
module, skip to STEP 3.
Be careful when handling the Ribbon Shield. It can be bent easily, which can affect
operation of the printer. It also has very sharp edges that can potentially hurt you if
you are not careful while handling it.
Step 2a. Locate the module with the bad coil and remove the hammer plate only, by
removing the three screws that secure it to the module, then you can remove
it from the module.
Step 2b. Each coil is held in place by two tabs. Using a very small screwdriver, reach in
from the back side of the Hammer Bank and break off one of the tabs.
Coil Unit
CBA
Contact Pins
Locking Tabs
Coil Post & 3x
Flux Plate
Assembly Hammer Plate
Break off a
LockingTab
to remove
Coil CBA
Magnet te
rn Pla
Retu
Figure S–1. Changing a Hammer Coil
2
Supplement - Removing and Replacing the Hammer Module
Step 2c. Now grasp the bad coil with a pair of longnose pliers and remove it from the
Hammer Bank.
Step 2d. Do not use pliers to install the new coil. Grasp the new coil with your
fingers, plug the male prongs into the slots in the Hammer Bank CBA and
press the coil in until the tabs lock into place.
Step 2e. Reinstall the hammer plate and use the Hammer Alignment Tool to realign the
hammers before tightening the mount screws.
Step 2f. Reinstall the Ribbon Shield.
Step 2g. Reinstall the Hammer Bank into the printer, then check the hammer to platen
gap and adjust as necessary. Finish reinstallation by installing all remaining
components that you removed back into the printer.
STEP 3. The module has three hammer assemblies and is held in place by two Phillips screws on
the backside of the Hammer Bank. Remove these screws and the module can be re-
moved from the Hammer Bank.
Ribbon Shield
Hammer Allignment Plate
Interconnect
CBA
Hammer Interconnect CBA

Ha
mm
er
Ba
Hammer Bank Carriage

nk
Ca
rria
ge
Module Mounting
Screws (2)
3-Pack
Hammer
Module
Figure S–2. Removing a Hammer Module
3
STEP 4. Install shim spacers underneath the Shim

spares replacement modules as Spacer(s)
appropriate. Two shim spacers are
included in each module kit (#080077). Hammer Bank Carriage
Install the new module on the Hammer

Hammer Bank. Be very careful when Module Module
installing the new module. The Mounting
Screws (2)
male prongs can be bent easily and
may not align properly when they
are plugged in. After the screws for
the module are tightened, check the Figure S–3. Installing Shim Spacer
height of the module for accuracy.
Depending on module height, you may or may not need to add shims.
Add Shims Remove Shims Correct
Figure S–4. Checking Module Height
After the module height is correct, use the Hammer Alignment Tool to realign the
hammers, tighten the two mount screws, then reinstall the Ribbon Shield.
07329
9
CB
A
Figure S–5. Aligning the Hammers
STEP 5. Reinstall the Hammer Bank by reversing the sequence of steps required to remove it.
necessary (See Procedure 28, Maintenance Manual).
explained in Chapter 2, Maintenance Manual, under the PrntCal Parameter) to adjust
for optimum printed output.
4
Supplement:
T6050 Information
Supplement
T6050
T6050 Supplement
T6050 Supplement to the T6045 Maintenance Manual
This supplement presents descriptions and explanations about additions and/or

changes to the maintenance of your printer.
1097-083031
1
T6050 Supplement
T6050
The T6050 is an upgrade variant of the T6045, with an increased print speed to 500 lines
per minute (LPM). It shares most of the mechanical parts and the power supply with
the T6045 printer. All of the Remove/Replace Instructions in the T6045 Maintenance
Manual apply to the T6050.
T6050 Recommended Spare Parts Lists

PART NAME PART #
Electronics
Power Supply Assy. (Shindengen) 080234
Power Supply Assy. (Autec) 080667
Main Controller PCB (Serial/Parallel) 082928
Main Controller PCB (PSIO ready for LANPlex II) 083026
Main Controller PCB (FourPlex) 082937
Main Controller PCB (Tx/Cx, IPDS) 082939
PSIO (for LANPlex II) 082383
Hammer Bank Assy. 082854
Hammer Bank Module Kit 082835
Paper Shuttle/Drive Motor 078259
Ribbon Drive Motor 075138
Fan Assy. 079644
Power Switch/Module 731108
Power Cord 730078
Smart "T" Cable (Twinax) 731529
Coax Cable Adaptor 080306
Sensors
Paper Out Sensor 080045
Paper Motion Sensor 611138-3
Shuttle Sensor 080044
Platen Open Sensor 080185
2
T6050 Supplement
T6045/T6050 Recommended Spare Parts Lists (continued)
PART NAME PART #

Mechanics
Tractor Kit 080115
Paper Drive Belt 079676
Paper Pulley (Motor) 080100
Paper Pulley (Tractor Shaft) 079444
Shuttle Drive Belt 730007
Shuttle Assy. 082855
Ribbon Shield Assy. 080225
Tractor Paper Guide 079516
Platen 081693
Tool Kit 080069
Grounding Clip, Tractor Shelf 081470
Manuals
Operator Manual MPL 1095
Operator Manual - 4Plex MPL 1095
Operator Manual - LANPlex MPL 1095
Maintenance Manual MPL 1018
Ribbons
Fabric Ribbon, 25 million char., box of 4 080255
3
4
T6050 Serial/Parallel Controller Board - Spares PN 082928
T6050 Supplement
T6050 Supplement
5
6
T6050 Controller Serial/Parallel PN 082928
Page 1 of 5 T6050 Supplement
Page 2 of 5
T6050 Supplement
7
8
Page 4 of 5
T6050 Supplement
9
10
T6050 Supplement
11
12
T6050 Supplement
Spares - PN 082928- T6050 Controller Serial/Parallel

T6050 Supplement
13
T6050 Supplement
14
T6050 Serial/Parallel Controller Board with PSIO (for LANPlex II) - Spares PN 083026 T6050 Supplement
15
T6050 Supplement
cont.
cont.
16
T6050 Controller Serial/Parallel w/PSIO PN 083026
Page 1 of 5
T6050 Supplement
17
18
Page 3 of 5
T6050 Supplement
19
20
Page 5 of 5
T6050 Supplement
21
T6050 Supplement
22
Spares - PN 083026 - T6050 Controller Serial/Parallel w/PSIO
T6050 Supplement
23
T6050 Supplement
24
T6050 Supplement
25
26
T6050 Twinax/Coax Controller Board - (4-Pex) Spares PN 082937
(4-Plex s/IPDS) Spares PN 082939 T6050 Supplement
T6050 Supplement
27
T6050 Controller Twinax/Coax PN 082937
28
T6050 Controller Twinax/Coax/IPDS PN 082939
Page 1 of 6
T6050 Supplement
Page 2 of 6
T6050 Supplement
29
30
Page 3 of 6
T6050 Supplement
Page 4 of 6
T6050 Supplement
31
32
Page 5 of 6
T6050 Supplement
Page 6 of 6
T6050 Supplement
33
T6050 Supplement
34
Spares - PN 082937 - T6050 Controller Twina/Coax
Spares - PN 082939 - T6050 Controller Twina/Coax/IPDS
T6050 Supplement
35
T6050 Supplement
36
T6050 Supplement
37
T6050 Supplement
38
Index
Index
Index
A F
Acoustics 1–9 Fatal Fault Message 3–3
Adjusting the Platen Gap 4–44 Fault Correction Procedure 3–1
AIAG Label Graphics Benchmarks 1–7 Fault Override 3–2
Aligning the Hammers 4–26 Fault Override Key Operations 2–12
Faults 3–1
B Firmware Version Report 2–3
Flt Clr Timeout Message 3–4
Bad Packet Message 3–3 Font Dnld Error Message 3–4
Bad VFU Channel Message 3–3
Bad VFU Count Message 3–3 G
Buffer Overflow Message 3–3
General Operation
C Printing 1–3
Startup 1–3
Calibration 2–1 Graphics Benchmarks 1–7
Calibration Data (CalData) Report 2–3 AIAG Labels 1–7
Changing a Hammer Coil 4–24 POSTNET Labels 1–7
Character Matrixes 1–5
Characters Per Inch 1–4 H
Chnl Not Found Message 3–3
Clear Parameter 2–11 Hammer Bank Cable Continuity Check Points 3–15
Configuration Report 2–3 Hammer Bank Cabling And Pinouts 3–15
Control CPU 1–2 Hammer Bank CBA Cable 3–15
Controller Board Theory of Operation Hammer Bank CBA Continuity Check Points 3–15
Control CPU 1–2 Hammer Calibration 2–8
Hammer/Motor Logic and Drivers 1–2 Hammer Coil/Module Troubleshooting Table 3–16
Main CPU 1–1 Hammer Driver Pinouts 3–18
Parallel and Serial Interfaces 1–3 Hammer Pulse Parameter 2–10
Shuttle/Ribbon Microcontroller 1–2 Hammer Troubleshooting 3–12, 3–17
Cooling System 1–10 Hammer/Motor Logic and Drivers 1–2
CPI Combinations 1–5 Hammer Drive ASIC 1–3
Ctrl Fault Message 3–3 Paper Motor Drive 1–2
Ctrl Link Flt Message 3–3 Ribbon Motor Drive 1–2
Shuttle Motor Drive 1–2
D Hardware Troubleshooting 3–8 thru 3–19
Heap Overflow Message 3–4
Data Overrun Message 3–3 Heat Load Contribution 1–11
Diagnostic Category 2–8 Heavy (Forms) Parameter 2–10
Disconnecting the Gas Spring 4–2 HELP Menu 2–2
Disconnecting the Ribbon Motor Cable 4–16 Hex Dump 3–2
Display Messages 3–3 Hex Dumps 2–2
Dot Densities 1–5 Hm Puls Parameter 2–10
Dot Densities and Plot Speeds 1–6
Downloading Printer Firmware C–1 I
Drivers 1–2
Dump Mode 3–2 Industry and Agency Standards 1–11
Ink-Ribbon Specification 1–8
E Installing the Shuttle Drive Pulley 4–34
Electro-Magnetic Emissions 1–11
Environment 1–10
1
J Override Four Faults 2–12

Override Paper Out Fault 2–12
J703 Connector Pinouts 3–15
Illustrated Part Breakdowns (See Appendix B) P
L Panel Fault Message 3–5
Paper Description 1–9
Language Character Sets 1–8 Paper Movement Problems 3–15
Last Fault (LastFlt) Report 2–3 Paper Movement Speed 1–8
Lines Per Inch 1–6 Paper Out Message 3–5
Link Fault Message 3–4 Paper Out Threshold Parameter 2–11
Paper/Printing Corrective Action 3–15
M Parallel and Serial Interfaces 1–3
Parity Error Message 3–6
Main CPU 1–1 Part Lists (See Appendix B)
Main CPU Fault Message 3–4 Pattern Category 2–6
Max DSH Parameter 2–11 Physical Configurations 1–8
Max T Parameter 2–10 Physical Dimensions 1–11
Maximum Dots Per Second Parameter 2–11 Platen Gap, adjusting 4–44
Maximum Temperature Parameter 2–10 Platen Open Message 3–6
Menu Operations Plot Data Output Speed 1–7
Control Panel Key Combinations Operations Plot Parameter 2–7
All Fault Reporting 2–12 Plot Print Tests 2–7
Four Faults Only 2–12 POSTNET Label Speeds 1–7
Paper Out Fault 2–12 POutThr (Paper Out Threshold) Parameter 2–11
Help Menu 2–2 Power Requirements 1–9
Hex Dumps 2–2 Power Supply 1–9
Print Tests 2–1 Power Requirements 1–9
Printer Information Displays 2–3 Preventive Maintenance 1–10
Printer Reports 2–3 Print Parameter 2–6
Selecting and Running a Print Test 2–8 Print Tests 2–1, 2–6, 2–7
Technical Access Mode 2–1 Print2 Parameter 2–6
TEST Menu 2–4 Printer Calibration Parameter 2–8
Messages 3–1 Printer Dimensions 1–11
Meter Parameter 2–9 Printer Information Printouts
Motors Parameter 2–10 Help Menu 2–2
Reports 2–3
N Printer Information Printouts and Displays 2–3
No VFU Loaded Message 3–4 Printer Performance
Nonoperating Environment 1–10 Plot Speeds 1–7
Nonvolatile Memory 1–9 Print Speeds 1–6
NVRAM Fault Message 3–4 Printing Problems 3–15
PrntCal (Print Calibration) Parameter 2–8
O
R
Offline Data In Message 3–4
Offline Dump On Message 3–4 R & R Procedures
Online Dump On Message 3–5 The Fan Assembly 4–10
Operating Environment 1–10 The Hammer Bank 4–21
Overflow VFU Message 3–5 The Hammer Coil 4–24
Override All Faults 2–12 The Hammer Module 4–24
The Left End Cover 4–14
The Main Controller CBA 4–8
2
Index
The Paper Advance Motor 4–37 Required Tools 4–1

The Paper Drive Pulleys and Belt 4–39 Ribbon Fault Message 3–7
The Paper Motion Sensor 4–42 Ribbon Motor Test 2–9, 2–10
The Paper Out Sensor 4–20 Ribbon Speed Parameter 2–10
The Power Switch 4–13 Running a Meter Test 2–9
The Printer Lid 4–2
The Printer Power Supply 4–11 S
The Ribbon Fault Sensor 4–19
The Ribbon Motor 4–18 Safety 1–10
The Ribbon Platform 4–17 Safety, Industry and Agency Standards 1–11
The Ribbon Shield 4–22 Selecting and Running a Hammer Calibration Routine
The Right End Cover 4–6 2–8
The Shuttle Drive Belt 4–35 Self Testing Message 3–7
The Shuttle Motion Sensor 4–36 Schematics (See Appendix A)
The Shuttle Stepper Motor 4–33 Sht Spd Parameter 2–10
The Tractors 4–40 Shuttle Fault Message 3–7
RAM Test Fail Message 3–6 Shuttle Motor Test 2–10
Rbn Spd Parameter 2–10 Shuttle Speed Parameter 2–10
Recommended Spare Parts List (See Appendix B) Shuttle/Ribbon Microcontroller 1–2
Reinstalling the Control Panel 4–5 Specifications
Reinstalling the Right End Cover 4–7 Acoustics 1–9
Removing a Hammer Module 4–25 Characters Per Inch 1–4
Removing And Reinstalling the Paper Out Sensor Cooling System 1–10
4–20 Dot Densities and Plot Speeds 1–6
Removing the Control Panel 4–4 Emulations 1–4
Removing the Fan Assembly 4–10 Environment
Removing the Hammer Bank 4–21 Nonoperating 1–10
Removing the Left End Cover 4–14 Operating 1–10
Removing the Lid 4–3 Graphics Benchmarks 1–7, 1–8
Removing the Main Controller CBA 4–8 Heat Load Contribution 1–11
Removing the Paper Advance Motor 4–37 Industry and Agency Standards 1–11
Removing the Paper Advance Motor Flywheel 4–38 Electro-Magnetic Emissions 1–11
Removing the Paper Advance Motor Pulley 4–38 Safety 1–11
Removing the Paper Motion Sensor 4–43 Language Character Sets 1–8
Removing the Power Supply Panel 4–12 Lines Per Inch 1–6
Removing the Printer Power Switch 4–13 Nonvolatile Memory 1–9
Removing the Ribbon Fault Sensor 4–19 Paper Description 1–9
Removing the Ribbon Motor 4–18 Paper Movement Speeds 1–8
Removing the Ribbon Platform 4–17 Power Supply 1–9
Removing the Ribbon Shield 4–22 Preventive Maintenance 1–10
Removing the Right End Cover 4–6 Printer Dimensions 1–11
Removing the Shuttle Motion Sensor 4–36 Safety 1–10
Removing the Shuttle Stepper Motor 4–33 Type Styles
Removing the Sound Deadening Hood 4–11 Draft and Data Processing 1–4
Removing the Tractor Drive Shaft Pulley 4–40 Gothic and Courier 1–4
Removing the Tractors 4–41 OCR-A and OCR-B 1–4
Replacing the Motor Drive Pulley 4–39 Weight 1–8
Replacing the Paper Advance Motor Pulley 4–39
Replacing the Paper Drive Belt 4–39
Replacing the Tractor Drive Pulley 4–39
Report Parameter 2–3
3
T
Technical Access Mode 2–1
TEST Menu 2–4
Diagnostic Category
Clear Parameter 2–11
Heavy (Forms) Parameter 2–10
Hm Puls (Hammer Pulse) Parameter 2–10
Max DSH (Maximum Dots Per Second) Parameter
2–11
Max T (Maximum Temperature) Parameter 2–10
Meter Parameter 2–9
Motors Parameter 2–10
POutThr (Paper Out Threshold) Parameter 2–11
PrntCal (Printer Calibration) Parmeter 2–8
Ribn Spd (Ribbon Speed) Parameter 2–10
Sht Spd (Shuttle Speed) Parameter 2–10
Pattern Category 2–6
Plot Parameter 2–7
Print2 Parameter 2–6
Print Parameter 2–6
Testing 2–1
The Shuttle Drive Belt 4–35
Thermal Fault Message 3–7
Tools, Required 4–1
Tractor Drive Components 4–41
Troubleshooting 2–1, 3–1, 3–8
Paper/Print Problems 3–15
Type Styles 1–4
Character Matrixes 1–5
Characters Per Inch 1–5
Dot Densities 1–5
U
Upgrading Printer firmware C–1
W
Weight 1–8
4
Tally Worldwide Locations
U.S.A. France
Tally Printer Corporation Tally
P.O. Box 97018 19 avenue de L’lle Saint-Martin
Kent, Washington 98064-9718 F-92237 Nanterre Cedex
U.S.A. France
Tech Support: 425-251-5532 Téléphone: +33-1-413011-00
Product Service: 1-800-426-4813 Fax: +33-1-413011-10
Spares: 1-800-338-3010 http://www.Tally.com
Information: 1-425-251-5500
Fax: 1-425-251-5520 Germany
http://www.Tally.com Tally GmbH
Postfach 29 69
Asia D-89019 Ulm/Donau.
Tally AMT Printers Pte. Ltd., Germany
Singapore (TAS) Telephone: +49-7308-800
63, Hillview Avenue Fax: +49-7308-85903
No. 08/22, Lam Soon Indutrial Bldg. http://www.Tally.de
Singapore 669569
http://www.Tally.com Italy
Tally S.R.L.
Austria Via Borsini 6
Tally Ges. m.b.H. I-20094 Corsico (Milan)
Eduard Kittenberger Gasse 95B Italy
A-1232 Vienna Telephone: +39-02-48608-1
Austria Fax: +39-02-48601-141
Tel.: +43-1-86340-0 http://www.Tally.it
Fax: +43-1-86340-240
http://www.Tally.co.at Spain
Tally S.R.L.
Canada Aleixandre 8
Tally Corp. 2° A 28033
125 Traders Blvd., Unit #9 Madrid
Mississauga, Ontario Telephone: (91) 7219181
Canada L4Z 2E5 Fax: (91) 7219936
Telephone: +905-890-4646 http://www.Tally.com
Fax: +905-890-4567
http://www.Tally.com
England
Tally Ltd.
Molly Millars Lane, Wokingham
Berkshire RG11 2QT
England
Telephone: +44-118-978-8711
Fax: +44-118-979-1491
http://www.Tally.co.uk

Tally Dot Matrix Printer T6045 and 6050 Supplement Parts and Service Manual

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Tally Dot Matrix Printer T6045 and 6050 Supplement Parts and Service Manual

Hochgeladen von

Copyright:

Verfügbare Formate

T6045

with T6050 Supplement

Chapter 1: Theory Of Operation and Specifications

Chapter 2: Menu Operations

Hardware Troubleshooting Guides ........................................................................................................3–8

Chapter 4: Remove and Reinstall

Chapter 4 – Removing and Reinstalling the Platen

Tally Worldwide Locations

Chapter 1: Theory Of Operation And Specifications

Chapter 2: Menu Operations

Chapter 4: Remove and Reinstall

Appendix B: Illustrated Parts Breakdowns (IPBs)

Appendix C: Downloading Printer Firmware

T6045 Controller Board Theory of Operation

1. Main CPU - Motorola MC68340

One 4 M-bit (512 Kbytes) Flash Memory

Two 128 K x 8-bit Pseudo-Static RAM IC’s

One 8 K-bit (1 Kbytes) Serial EEPROM memory

One Altera EPM7032 EPLD

All optical sensors are off-board.

Hammer/Motor Logic and Drivers

Shuttle Motor Drive

Ribbon Motor Drive

Hammer drive ASIC

Parallel and Serial Interfaces

Parallel Interface - Altera EPM7032 PLD and 74LS374/74LS244

Gothic and Courier

Draft and Data Processing

OCR–A and OCR–B

Characters Per Inch

Data Processing Base Matrix: 9 x 12 Base Matrix: 7 x 12 Base Matrix: 5 x 12

Enhanced Draft Base Matrix: 9 x 8 Base Matrix: 13 x 8 Base Matrix: 9 x 8

Data Processing Base Matrix: 9 x 12 Base Matrix: 13 x 12 Base Matrix: 9 x 12

Near Letter Gothic Base Matrix: 19 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

Courier Base Matrix: 19 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

Optical Character OCR-A Base Matrix: 9 x 16

OCR-B Base Matrix: 19 x 24

Table 1–2 T6045 Line Printer Performance – Rolling ASCII

Print Type Test Uppercase Lowercase

Lines Per Inch

Dot Densities and Plot Speeds

Table 1–3. Plot Data Output Speed

Dot Plot Print Speed

Table 1–4. AIAG Label Graphics Benchmarks

Table 1–5. POSTNET Label Speeds

POSTNET Label Benchmark Results

Paper Movement Speed

Print Mode Maximum Slew Speed

Language Character Sets

Standard Tabletop Printer

Table 1–8. Actual Weight: By Configuration

Table 1–9. Shipping Weight: By Configuration

Table 1–10. Acoustics

Printer Sound Power per Sound Pressure Level

Table 1–11. Power Requirements

External Power Current Requirements

• 5 – 22 Hz 0.010 in, double amp.

Sweep rate of 1 octave/min.

Heat Load Contribution

Figure 1–1. Physical Dimensions

Industry and Agency Standards.

Technical Access Mode

Entering Tech Access Mode

Exiting Tech Access Mode