Tally T6090 Maintenace Manual

T6090

Maintenance Manual

Line Impact Printer

with T6065, T6091,

T6100 & T6101 Supplements

This Manual is published by Tally Printer Corporation for use with
the computer printer described herein. Translations, reprinting or
copying by any means of this manual, complete or in part, in any
different form requires our explicit approval. Tally Printer
Corporation reserves the right to revise this manual without notice,
for any reason. This includes, but is not limited to, utilization of
advances in the state-of-the-art and changes in the equipment or
configuration thereof. Liability for difficulties arising from
unknown or unforeseen technical limitations is disclaimed.

FCC Statement

This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15, Subpart B of the
FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference, in which
case the user will be required to correct the interference at his own
expense.

Ref. Manual Number 080933

Tally Printer Corporation

8301 South 180th Street

Kent, Washington 98032

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© Jan. 1997
Tally Printer Corporation
All rights reserved
Printed in the United States

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Table of Contents

Table of Contents

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Table Of Contents

Subject Listing

Chapter 1. Electronic Hardware Ar chitecture, Performance And Specifications

Technical Overview ....................................................................................................................................................... 1–1

T6090 Electronic Hardware Architecture ......................................................................................... ............................ 1–1

Engine Control Module ......................................................................................................................................... 1–1

Control Processor...........................................................................................................................................1–1

Sensor Inputs .......................................................................................................................................... 1–1

Shuttle Processor............................................................................................................................................ 1–1

Hammer/Motor logic and drive ..................................................................................................................... 1–2

EEPROM ........................................................................................................................................................ 1– 2

T6090 Personality Module .................................................................................................................................... 1–2

Serial and Parallel Interfaces ................................................................................................................................. 1– 3

Serial............................................................................................................................................................... 1–3

Parallel............................................................................................................................................................ 1 –3

Motorola MC68340 ............................................................................................................................................... 1–3

Flash Memory ................................................................................................................... ..................................... 1–3

DRAM ........................................................................................................................... ......................................... 1–3

Altera EPM7064 ....................................................................................................................................................1–3

Specifications ................................................................................................................................................................. 1–4

Serial/Parallel Emulations ..................................................................................................................................... 1–4

Font Styles.............................................................................................................................................................. 1 –4

Courier and Gothic......................................................................................................................................... 1–4

Data Processing and Draft ............................................................................................................................. 1–4

OCR–A and OCR–B ......................................................................................................................................1–4

Characters Per Inch ................................................................................................................................................ 1–4

Lines Per Inch ........................................................................................................................................................ 1–5

Dot Densities and Plot Speeds............................................................................................................................... 1–6

Graphic Benchmarks.............................................................................................................................................. 1–6

Paper Slew Speed ................................................................................................................................................... 1–7

Ribbons................................................................................................................................................................... 1–7

Forms/Paper Description ....................................................................................................................................... 1–7

Acoustics ................................................................................................................................................................ 1–8

Power Supply ......................................................................................................................................................... 1–8

Cooling System ...................................................................................................................................................... 1–8

Safety......................................................................................................................... ............................................. 1–8

Preventive Maintenance ......................................................................................................................................... 1–9

Environment ........................................................................................................................................................... 1–9

Operating ........................................................................................................................................................1–9

Nonoperating.................................................................................................................................................. 1–9

Heat Load Contribution ....................................................................................................................................... 1–10

Physical Configurations ....................................................................................................................................... 1–10

Weight ......................................................................................................................... ................................. 1–10

Printer Dimensions ............................................................................................................................................... 1–11

Industry and Agency Standards ........................................................................................................................... 1–11

Electromagnetic Emissions.................................................................................................................................. 1–11

Agency Approvals ................................................................................................................................................ 1–11

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T6090 Maintenance Manual

Chapter 2. Menu Operations

Introduction .................................................................................................................................................................... 2–1

Technical Access Mode ................................................................................................................................................. 2–1

Entering Tech Access Mode .................................................................................................................................. 2 – 1

Exiting Tech Access Mode .................................................................................................................................... 2–1

Testing, Troubleshooting, and Calibration .................................................................................................................... 2–1

Printer Tests............................................................................................................................................................ 2–1

Hex Dumps...................................................................................................................... ....................................... 2–2

Printer Information Printouts and Displays...........................................................................................................2–2

HELP Menu ................................................................................................................................................... 2–2

Printing a HELP Menu ........................................................................................................................... 2–2

Report Parameter (Menu Level 2) ................................................................................................................. 2– 2

Report selections (Menu Level 3) .......................................................................................................... 2–3

Selecting a Printer Report....................................................................................................................... 2–3

TEST Menu ...................................................................................................................... .............................................. 2–3

Pattern Category (Menu Level 1) .......................................................................................................................... 2–5

Print Parameter (Menu Level 2) .................................................................................................................... 2–6

Print selections (Menu Level 3).............................................................................................................. 2–6

Print2 Parameter (Menu Level 2) .................................................................................................................. 2–6

Print2 selections (Menu Level 3)............................................................................................................ 2–6

Plot Parameter (Menu Level 2)...................................................................................................................... 2–6

Plot selections (Menu Level 3) ............................................................................................................... 2–7

Selecting And Running a Print Test........................................................................................................ 2–7

Diagnostic Category (Menu Level 1) .................................................................................................................... 2 – 8

PrntCal (Print Calibration) Parameter (Menu Level 2)................................................................................. 2–8

Selecting And Running a Hammer Calibration Routine ........................................................................ 2–8

Selecting And Running a Current Calibration Routine .......................................................................... 2–9

Selecting And Running a Paper Out Calibration Routine ...................................................................... 2–9

Meter Parameter (Menu Level 2) .................................................................................................................. 2–9

Meter selections (Menu Level 3) .......................................................................................................... 2–10

Motors Parameter (Menu Level 2) .............................................................................................................. 2–10

Motors selections (Menu Level 3)........................................................................................................ 2–10

Sht Spd (Shuttle Speed) Parameter (Menu Level 2) ...................................................................................2–10

Shuttle Speed selections (Menu Level 3) ............................................................................................. 2–11

Rbn Spd (Ribbon Speed) Parameter (Menu Level 2) ................................................................................. 2–11

Speed selections (Menu Level 3)......................................................................................................... 2–11

RibnThr (Ribbon Threshold) Parameter (Menu Level 2) ........................................................................... 2–11

Threshold selections (Menu Level 3) ................................................................................................... 2–11

POutThr (Paper Out Threshold) Parameter (Menu Level 2) ...................................................................... 2–11

Threshold selections (Menu Level 3) ................................................................................................... 2–11

PMoThr (Paper Motion Threshold) Parameter (Menu Level 2) ................................................................. 2–11

Threshold selections (Menu Level 3) ................................................................................................... 2–11

Heavy (Heavy Forms) Parameter (Menu Level 2) ...................................................................................... 2–11

Heavy Forms selections (Menu Level 3) .............................................................................................. 2–11

Max T (Maximum Temperature) Parameter (Menu Level 2) ..................................................................... 2–11

EnStar (Energy Star) Parameter (Menu Level 2) ........................................................................................ 2–12

Energy Star selections (Menu Level 3) ................................................................................................ 2–12

Clear Parameter (Menu Level 2) ................................................................................................................. 2–12

Clear selections (Menu Level 3).......................................................................................................... 2–12

Fault Override (FltOvrd) Category (Menu Level 1) ........................................................................................... 2–12

Pap Mot (Paper Motion) Parameter (Menu Level 2) ..................................................................................2–12

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Table Of Contents

Pap Out (Paper Out) Parameter (Menu Level 2) ......................................................................................... 2–12

Rib Mot (Ribbon Motion) Parameter (Menu Level 2)................................................................................2–12

Shuttle Parameter (Menu Level 2)............................................................................................................... 2–12

Temp (Temperature) Parameter (Menu Level 2)......................................................................................... 2–12

Platen Parameter (Menu Level 2) ................................................................................................................ 2–13

Ctrl (Control Processor) Parameter (Menu Level 2)................................................................................... 2–13

Link Parameter (Menu Level 2)................................................................................................................... 2–13

Hvy Frm (Heavy Forms) Parameter (Menu Level 2) ..................................................................................2–13

Panel Parameter (Menu Level 2) ................................................................................................................. 2–13

Control Panel Key Operations For Controlling Fault Reporting ........................................................................ 2–13

ALL Fault Reporting .................................................................................................................................... 2–13

Four Faults Only .......................................................................................................................................... 2–13

Paper Out Only.............................................................................................................................................2–13

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

Hardware Troubleshooting Guides.............................................................................................................................. 3–10

The printer does not power up when switched on...............................................................................................3–10

When the printer is powered up, nothing works except the fan. .................................................................. ...... 3–10

The printer powers up but the Control Panel does not function. ................................................................. ....... 3–11

The Control Panel Display functions partially, nonsensically, or not at all. ...................................................... 3–11

There is no printed output but the printer appears to be operating normally. .................................................... 3–12

Printed output appears light ................................................................................................................................. 3–12

Printed output appears shaky or fuzzy ................................................................................................................ 3–13

Two adjacent character columns not printing .....................................................................................................3–14

The Printer is out of paper – No Paper Out fault is reported .............................................................................. 3–15

No Paper Motion – No Paper Motion fault is reported....................................................................................... 3–15

Paper Handling Problems ............................................................................................................................................ 3–16

T6090 Engine Controller To Hammer Bank CBA Cables ..........................................................................................3–17

Troubleshooting The Hammer Driver Transistors ......................................................................................................3–20

Chapter 4. Removal And Reinstallation Procedures

Introduction .................................................................................................................................................................... 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 Engint Controller CBA ...................................................................................................................4– 8

Procedure 5 – The Personality Module CBA and Enclosure...................................................................................... 4–10

Procedure 6 – The Fan Motor Assembly ..................................................................................................................... 4–12

Procedure 7 – Power Supply........................................................................................................................................ 4–13

Procedure 8 – The Left End Cover .............................................................................................................................. 4–15

Procedure 9 – The Ribbon Platform ............................................................................................................................ 4–16

Procedure 10 – The Ribbon Motor .............................................................................................................................. 4–18

Procedure 11 – The Hammer Bank ............................................................................................................................. 4–19

Procedure 12 – The Ribbon Shield.............................................................................................................................. 4–21

Procedure 13 – Hammer Bank Air Duct ..................................................................................................................... 4–23

3

T6090 Maintenance Manual

Hammer Module Replacement & Realignment
T6091 Printer
T6065 Printer
T6100/T6101 Printers

Supplements

Tally Worldwide Locations

Procedure 14 – Hammer Module................................................................................................................................. 4–24

Procedure 15 – The Shuttle Assembly ........................................................................................................................ 4–26

Procedure 16 – The Platen ........................................................................................................................................... 4–27

Procedure 17 – The Platen Open Sensor .......................................................................................... ........................... 4–29

Procedure 18 – The Shuttle Motor .............................................................................................................................. 4–30

Procedure 19 – Shuttle Motion Sensor........................................................................................... ............................. 4–32

Procedure 20 – The Shuttle Drive Belt........................................................................................................................ 4–34

Procedure 21 – The Paper Advance Motor.................................................................................................................. 4–35

Procedure 22 – Tractor Belt Phasing/Paper Drive Belt Adjustment ........................................................................... 4–37

Procedure 23 – Upper Tractor Assembly .................................................................................................................... 4–39

Procedure 24 – Lower Tractor Assembly .................................................................................................................... 4–41

Procedure 25 – Platen Gap Adjustment Procedure ..................................................................................................... 4–43

Appendix A. Schematics

Engine Controller CBA................................................................................................................................................. A –1

Ser/Par Personality Module CBA ................................................................................................................................. A–6

FourPlex Personality Module CBA ............................................................................................................................ A–11

Appendix B. Recommended Spare Parts List, Illustrated Parts Breakdowns,

and Component Lists

Recommended Spare Parts List .................................................................................................................................... B–1

Cover Set ...................................................................................................................... ................................................. B–2

Basic Assembly ............................................................................................................................................................. B–4

Print Mechanism/Shuttle .............................................................................................................................................. B–6

Paper Movement System .............................................................................................................................................. B–8

Hammer Bank and Electronics ................................................................................................................................... B–10

Engine Controller ........................................................................................................................................................ B–12

Serial/Parallel Personality Modules (080900 & 080898 ) ......................................................................................... B–16

FourPlex Personality Module (080750 ) .......................................................................................... .......................... B–20

Appendix C. Downloading Printer Firmware

Firmware Update Procedure ......................................................................................................................................... C–1

4

Chapter 1

Table 1–1. Personality Module Configurations ........................................................................... 1–2

Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations......................... 1–5

Table 1–3. Plot Data Output Speed.............................................................................................. 1–6

T able 1–4. Graphics Benchmarks ................................................................................................ 1–7

Table 1–5. POSTNET Label Speeds............................................................................................ 1–7

T able 1–6. Slew Speed ................................................................................................................. 1–7

T able 1–7. Acoustics .................................................................................................................... 1–8

T able 1–8. Power Requirements .................................................................................................. 1–8

T able 1–9. Heat Load Contributions .......................................................................................... 1–10

Table 1–10. Actual Weight: Main Components.......................................................................... 1–10

Table 1–11. Actual Weight: By Configuration ........................................................................... 1–10

Table 1–12. Shipping Weight: By Configuration........................................................................ 1–10

T able 1–13. Printer Dimensions................................................................................................... 1–11

Chapter 2

T able 2–1 T est Menu............................................................................................................. ...... 2–4

Table Of Contents

Table Listing

Chapter 3

T able 3–1. Display Messages ....................................................................................................... 3–3

Table 3–2. Paper/Printing Corrective Action ............................................................................. 3–16

T able 3–3. Connector Pinouts .................................................................................................... 3–17

Table 3–4. J703 Connector to Hammer Bank CBA Continuity Check Points .......................... 3–18

Table 3–5. T6090 Hammer Coil/Module Troubleshooting ....................................................... 3–19

T able 3–6. J703 Hammer Driver Pinouts................................................................................... 3–21

Table 3–7. J704 Hammer Driver Pinouts................................................................................... 3–22

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T6090 Maintenance Manual

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 Engine Controller CBA ...................................................................... 4–8

Figure 4–8. Removing the Personality Module CBA ................................................................. 4–10

Figure 4–9. Removing the Personality Module Enclosure ......................................................... 4–11

Figure 4–10. Removing the Fan Assembly.................................................................................... 4–12

Figure 4–11. Disconnecting the Static Ground. and Removing the Sound Deadening Hood...... 4–13

Figure 4–12. Removing the Power Supply.................................................................................... 4–14

Figure 4–13. Removing the Left End Cover ................................................................................. 4–15

Figure 4–14. Disconnecting the Ribbon Platform Components ................................................... 4–16

Figure 4–15. Removing the Ribbon Platform ............................................................................... 4–17

Figure 4–16. Removing the Ribbon Motor ................................................................................... 4–18

Figure 4–17. Disconnecting the Hammer Bank ............................................................................ 4–19

Figure 4–18. Removing the Hammer Bank................................................................................... 4–20

Figure 4–19. Removing the Ribbon Shield ................................................................................... 4–21

Figure 4–20. Removing Hammer Bank Air Duct.......................................................................... 4–23

Figure 4–21. Removing and Replacing the Hammer Module. ..................................................... 4–24

Figure 4–22. Using the Hammer Alignment Tool ......................................................................... 4–25

Figure 4–23. Shuttle Assembly Removal ...................................................................................... 4–26

Figure 4–24. Removing the Platen ................................................................................................ 4–27

Figure 4–25. Platen End Assembies .............................................................................................. 4–28

Figure 4–26. Removing the Platen Open Sensor .......................................................................... 4–29

Figure 4–27. Removing the Shuttle Motor.................................................................................... 4–30

Figure 4–28. Reinstalling Shuttle Motor Pulley............................................................................ 4–31

Figure 4–29. Removing the Shuttle Motion/Capture Sensor ........................................................ 4–32

Figure 4–30. The Shuttle Drive Belt.............................................................................................. 4–34

Figure 4–31. Removing the Paper Drive Motor ............................................................................ 4–35

Figure 4–32. Paper Advance Motor Assembly.............................................................................. 4–36

Figure 4–33. Phasing/Belt Adjustments ........................................................................................ 4–37

Figure 4–34. Phasing Gauge Installation ...................................................................................... 4–37

Figure 4–35. Paper Drive Belt Adjustment ................................................................................... 4–38

Figure 4–36. Removing Upper Tractor Assembly......................................................................... 4–39

Figure 4–37. Upper Tractor Alignment ......................................................................................... 4–40

Figure 4–38. Removing Lower Tractor Assembly ........................................................................ 4–41

Figure 4–39. Lower Tractor Alignment......................................................................................... 4–42

Figure 4–40. Platen Gap Adjustment............................................................................................. 4–43

Figure Listing

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Introduction

Introduction

Introduction

This manual presents operational theory, specifications, troubleshooting, and Removal and
Replacement procedures for the T6090 Printer.

The following chapter explanations will give you an overview of the contents of this manual.

Chapter 1: Electronic Hardware Architecture, Performance, and Specifications

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

Chapter 2: Menu Operations

Chapter 2 presents the Menu Operations concerned with troubleshooting and maintaining the
printer.

Chapter 3: Troubleshooting

This chapter lists the display messages you may encounter, their cause, and possible corrective
actions.

Chapter 4: Removal and Reinstallation Procedures

This chapter presents instructions for removing and reinstalling/replacing various components
of the printer.

Introduction

Appendix A: Schematics

The schematics in this appendix will assist you in troubleshooting problems and locating
components that control printer operations.

Appendix B: Recommended Spare Parts List, Illustrated Parts Breakdowns,

and Components Lists

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

Appendix C: Downloading Printer Firmware

This appendix explains how to download firmware to the printer.

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Chapter 1

Electronic Hardware Architecture,

Performance & Specifications

Paper Path

Architecture, Performance

Electronic Hardware

& Specifications

Chapter 1: Electronic Hardware Architecture, Perfor mance & Specifications

Technical Overview

The T6090 is a medium speed, line impact dot matrix printer. It has a maximum speed of 900
lines per minute in uppercase draft text mode. The T6090 is designed for long term opera­tions, supporting a workload of 160,000 pages per month with minimal maintenance.

T6090 Electronic Hardware Architecture

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

Engine Control Module

The primary components of the Engine Control Module are:

• Control Processor – Intel 87C196KB

• Shuttle Processor– Philips/Signetics 87C750

• Sensor Inputs

• Hammer/Motor logic and drive

• EEPROM – X24C08

Control Processor

• 12.288 MHz clock

• High speed outputs for driving the paper motor and hammer firing

• High speed inputs for synchronizing timing of the shuule position

• 8 channel 10 bit Analog to Digital Converter for sensor readings (paper out, paper
motion, shuttle motion, ribbon motion, platen gap, hammer current, power supply
voltage, ambient temperature)

• Serial channel for communication (19.2K bps) with Main CPU

• Port control of Shuttle/Ribbon microcontroller

• Port control of control panel, ribbon clock, and hammer loading

Sensor Inputs

• Paper motion sensor – optical

• Paper out sensor – optical

• Platen gap sensor – optical

• Shuttle motion/capture sensor – optical

• Ambient temperature – thermistor

• Power supply voltage – resistor divider

Shuttle Processor

• 12.288 MHz clock

• Drives stepping phases to the Shuttle and Ribbon motors

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T6090 Maintenance Manual

Hammer/Motor logic and drive

• 2 hammer driver ASICs – each of the 66 outputs drives a transistor

• 17 quad Hammer drive transistor arrayss – SMA4032

• 17 Zener Diodes for absorbing coil drive energy– 1N5347B

• 6 H-bridge Motor drive chips (2 for ribbon, 2 for shuttle and 2 for paper) – Allegro
3952

EEPROM

The EEPROM stores engine calibration and printer configuration settings.

T6090 Personality Module

Interface control is provided by the Personality Module. There are four Personality Modules
available, two of which have optional configurations. The configurations vary in terms of host
interface, memory configuration, and installed software.

The primary components of the Personality Module are:

• Main processor – Motorola MC68340

• Flash EPROM – comprised of 4M-bit and/or 2M-bit parts (determined by the type of
interface)

• DRAM – .5 Meg, 1 Meg, or 2 Meg (determined by the type of interface)

• EPLD – Altera EPM7064

• Parts specific to the type of interface (Serial/Parallel, Lan, Twinax/Coax and
Dataproducts). (See Table 1-1.)

The following table shows the modules and optional configurations:

Table 1–1. Personality Module Configurations

Personality Module Standard Ser/Par Extended Ser/Par LANPlex FourPlex

Host I/Os IEEE 1284 IEEE 1284 IEEE 1284 IEEE 1284

RS-232-C RS-232-C RS-232-C RS-232-C

Dataproducts

Standard Graphics IG, Code V, PGL, IG, Code V, PGL, IG, Code V, PGL, Code V, PGL,
Languages & MTPL & MTPL & MTPL
Optional Configurations Dataproducts Standard IPDS2 Graphics

or Longlines
Flash ROM 768 K 768 K 1.5 meg 1 Meg
RAM 512 K 512 K 2 Meg 512 K

1

Dataproducts may be set up for Standard or Longlines operation.

2

With IPDS Option, Code V and PGL are not included.

3

With IPDS Option, 512 K RAM is upgraded to 1 Meg.

1

Ethernet Twinax

Coax

3

1–2

Chapter 1: Electronic Hardware Architecture, Perfor mance & Specifications

Serial and Parallel Interfaces

Serial

• MC145406 (+/- 12V) chip is used for the RS-232 drivers and receivers

• Internal programmable bps generator (300 bps to 38.4K bps)

• Both DTR/Busy and XON/XOFF is supported

• Standard secondary RTS on pins 11 and 19. Primary RTS is capable of being
jumpered to pin 4

Parallel

• Altera EPM7064 and 74LS374/74LS244 – supports IEEE-1284 compatibility and
nibble modes

Motorola MC68340

• 25MHz clock

• 16-bit CPU bus

• Two direct Memory Access (DMA) channels – One for hammer loading, and one for
the IEEE-1284 parallel Interface

• Two serial channels – One for the control CPU communication, and one for the
external serial interface

Flash Memory

The amount of Flash Memory depends on the configuration of the personality module.

DRAM

The amount of DRAM depends on the configuration of the personality module.

Altera EPM7064

• Dynamic random access memory (DRAM) control

• Logic for IEEE-1284 Parallel interface

• Glue logic (chip selects, hammer data and clock, row and column selection for
DRAM)

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T6090 Maintenance Manual

Specifications

Serial/Parallel Emulations

Nine emulations are available on the T6090: MT660, Genicom ANSI, HP2564C, Printronix
P600, Printronix P6000, IBM Proprinter III XL, Epson FX-100+, DEC LG01, and MTPL.

Font Styles

There are 6 resident type styles available on your printer. They include: Courier, Data Process­ing, Draft, Gothic, OCR-A, and OCR-B. All font styles and the two output modes (Enhanced
and Constant Density Fonts for Draft and DP) are selected through the printer control panel.

Courier and Gothic

These two font styles provide near letter quality (NLQ) printing on your printer. They print at
higher dot densities and use denser character matrixes. NLQ type styles provide greater
readability for reports and other text output.

Data Processing and Draft

Data Processing and Draft styles appear in two modes: Constant Density (CDF) and En­hanced. Constant Density Fonts print at the same dot density regardless of the CPI. This
produces consistent print speed even when changing from one CPI to another.

Enhanced Mode provides higher resolution and a greater range of CPI’s than CDF Mode.
Because Enhanced Mode uses a variety of dot densities, you should expect a change in print
speed of text when switching from one CPI to another.

OCR-A and OCR-B

These font styles print at 10 CPI only. They are used mainly for Optical Character Recogni­tion.

Characters Per Inch

The T6090 offers a variety of CPI’s for use in printer output. Available CPI’s are dictated by
the font style selected. Each CPI is based on one of twelve character matrixes and twelve dot
densities. Each matrix uses a specific number of dot columns for character composition and
intercharacter gap. CPI’s are grouped in any given type style by the base CPI matrix used for
the group. These base CPI’s are 10, 12, and 15.

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Chapter 1: Electronic Hardware Architecture, Perfor mance & Specifications

Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations

Print Modes Type Styles 10 CPI Group 12 CPI Group 15 CPI Group

Constant Density Draft Base Matrix: 9 x 8 Base Matrix: 7 x 8 Base Matrix: 5 x 8

Dot Density: 60 x 48 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

Dot Density: 60 x 72 Dot Density: 60 x 72 Dot Density: 60 x 72
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

Dot Density: 60 x 48 Dot Density: 80 x 48 Dot Density: 120 x 48
CPIs: 5 &10 CPIs: 6, 6.67, 12, CPIs: 7.5, 8.33, 8.57,

& 13.33 15, 16.67, 17.14, & 20

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

Dot Density: 60 x 72 Dot Density: 80 x 72 Dot Density: 120 x 72
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 Quality Gothic Base Matrix: 19 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

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

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

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

Lines Per Inch

Nine lines per inch (LPI) settings are available through the control panel. They include 1.5, 2,
3, 4, 5, 6, 8, 9, and 10 LPI. In some emulations the availability of certain LPI’s are restricted.

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T6090 Maintenance Manual

Dot Densities and Plot Speeds

The T6090 printer supports Horizontal row plots (single and multiple row), Vertical column
plots, and specialized Graphic plots. Your printer supports the following horizontal DPI’s: 40,
48, 50, 60, 72, 80, 90, 96, 100, 120, 144, 150, 160, 180, 200, and 240. Your printer supports
the following vertical DPI’s: 48, 72, 96,144, and 288. All other selections are emulated
through the use of scaling techniques.

Table 1–3. Plot Data Output Speed

Dot Plot Print Speed

Hor./Vert. Inches Per Min.

60 x 48 100
60 x 72 67

120 x 72 33
120 x 144 16
240 x 288 4

Graphics Benchmarks

Two benchmark tests were used to rate graphics output on the T6090 printer. The first was an
AIAG label containing bar codes and block characters inside a box. The second was a
POSTNET label with one line of POSTNET bar code and four lines of text.

The AIAG test consisted of a series of labels printed two across repeated vertically with a 0.1"
vertical space. The test was performed in two variations: Normal AIAG printed with 60 DPI
bar codes and Dark AIAG printed with 120 DPI bar codes.

The POSTNET test consisted of rows of labels printed four across with one blank line between
each row. In addition, the POSTNET test was run with 4 variations: Draft and Data Process­ing (DP) type styles for text/bar codes printed at 6 and 8 LPI.

Tests were timed, then results were converted into labels per hour.

1–6

Chapter 1: Electronic Hardware Architecture, Perfor mance & Specifications

Table 1–4. Graphics Benchmarks

Table 1–5. POSTNET Label Speeds

Paper Slew Speed

Table 1–6. Slew Speed

AIAG Label Benchmark Results

Graphics Dots Per In.

Language 60 120

Code V 1950 LPH 1300 LPH

PGL 1950 LPH 1300 LPH

POSTNET Label Benchmark Results

Lines Type Style

Per Inch Draft Data Processing

6 LPI 32000 LPH 29000 LPH
8 LPI 33000 LPH 30500 LPH

Ribbons

The T6090 is designed to operate optimally with Tally ribbon cartridges. These cartridges are
designed for easy access and loading.

Forms/Paper Description

The T6090 is designed to use continuous, sprocket feed type paper, 3 to 16.53 inches in width,
and 3 to 12 inches in length. One to six part paper may be used with a maximum thickness of
.025 inches. (Reference specifications: ISO 2784, DIN 9771, and DIN 6721.)

Print Mode Maximum Slew Speed

Normal 16 Inches Per Second

Heavy Forms 12 Inches Per Second

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T6090 Maintenance Manual

Acoustics

The noise generated by the T6090 printer varies according to its configuration as shown in the
table that follows:

Table 1–7. Acoustics

Configuration ISO 7779-C (9 position average)

Printer with Pedestal 6.9 bels 52 dBA

Quick Access Configuration 7.9 bels 62 dBA

Power Supply

The printer requires single phase, 47 to 63 Hz. 90 to 264 VAC input power. The 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 1–8. Power Requirements

Printer Sound Power per Sound Pressure Level

Tabletop Unit 7.4 bels 57 dBA

Cooling System

Cooling system malfunctions are detected and a failure will result in shuttle motion, paper
motion, and printing functions being inhibited. The malfunction will be reported on the
control panel display.

Safety

Personnel hazard areas have restricted access with appropriate warning labels. Catastrophic
equipment failures are inhibited with protective functions in major areas of overload potential.

External Power Current/Wattage Requirements

Supply @ Nominal Voltage

AC Volts Frequency Average Peak Average Average

(RMS) (Hz) Operating Operating Idle (<5 min.) Idle (>5 min.)

110 50 2.56 A/166 W 6.30 A/506 W 0.88 A/41 W 0.64 A/25 W
110 60 2.57 A/171 W 6.29 A/508 W 0.85 A/42 W 0.62 A/25 W
220 50 1.39 A/168 W 3.91 A/496 W 0.41 A/42 W 0.31 A/26 W

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Chapter 1: Electronic Hardware Architecture, Perfor mance & Specifications

Preventive Maintenance

The T6090 is designed to eliminate the requirement of scheduled maintenance procedures,
such as alignment, adjustment, or lubrication. Preventive maintenance is limited to periodic
cleaning. Dust and paper fibers should be removed periodically with a soft cloth and brush or
a vacuum cleaner. Clean the printer case with a damp cloth and soapy water. DO NOT use
any abrasive cleaners or solvents, as they will damage the case.

Environment

Operating

Temperature

Dry Bulb: 50°F to 104°F (10°C to 40°C)

Humidity: 10 to 90% noncondensing with a maximum wet bulb

Altitude: To 8,000 ft. (2438 meters)
Mechanical Shock: Half sine wave shock pulse of 10 g peak and 10 +/- 3 ms

Vibration: Applied to each of the three axes:

temperature of 82°F (28°C) and a minimum dew point of
36°F (2°C )

duration, three times in the vertical direction.

• 5 – 22 Hz 0.010 in. double amp.

• 22 – 500 Hz 0.25 g peak

• 500 – 22 Hz 0.25 g peak

• 22 – 500 Hz 0.010 in. peak

Nonoperating

The printer must be allowed to reach room temperature before operating. Three hours out of
the shipping container is usually enough time for stabilization. Complies with NSTA Program
1 & 2.

Sweep rate of 1 octave/min.

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.

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T6090 Maintenance Manual

Heat Load Contribution

The average heat load contribution to the environment is approximately 580 BTUs per hour
(170 Watts) with a maximum potential of 1677 BTUs per hour (491 Watts) under continuous
full-load printing conditions.

Table 1–9. Heat Load Contributions

Printing Conditions (110 VAC/60 Hz) Current/Wattage BTU/Hr

Power On, not printing 0.64 A/42 W (>5 min.) 143
100% Uppercase Rolling ASCII 2.57 A/268 W 915
Black Page Plot 6.29 A/491 W 1677

Physical Configurations

The T6090 printer is available in the following configurations:

Standard Tabletop Printer
Optional Printer with Stand
Optional Printer with Quietized Pedestal

Weight

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.

Table 1–10. Actual Weight: Main Components

Component Weight

Tabletop Printer 90 lbs

Stand 30 lbs

Pedestal 52 lbs

Table 1–11. Actual Weight: By Configuration

Option Weight

Tabletop Printer 90 lbs

Printer plus Stand 120 lbs

Printer plus Pedestal 142 lbs

Table 1–12. Shipping Weight: By Configuration

Option Weight

Tabletop Printer 110 lbs

Printer with Stand 150 lbs

Printer plus Pedestal 185 lbs

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Chapter 1: Electronic Hardware Architecture, Perfor mance & Specifications

Printer Dimensions

Table 1–13. Printer Dimensions

Dimension Printer Configuration

Parameter Tabletop Unit On the Open Stand On the Quietized Pedestal

Height 15.8" 41.4" 40.6"

Height/Lid Open 28.4" 54.3" 53.2"

Width 31.5" 31.5" 31.5"

Depth with Exit Hood 23.5" 23.7" 23.2"

Depth with Paper Tray N/A 28.7" 29.5"

Industry and Agency Standards

The T6090 is designed to meet the requirements of several industry and Government agency
standards.

Electromagnetic Emissions

EMI: FCC part 15, subpart J, Class A and CISPR 22 Class B
ESD: IEC 801-2 (ref Q1012)
RF Susceptability: IEC 801-3
Line Transients: IEC 801-4
Power FActor Correction: IEC 555-2

Agency Approvals

United States

The T6090 complies with UL 1950, C22.2 No. 950-M89, and IEC 950(TUV) via EN 60950
(cb scheme) safety requirements.

The T6090 printer is Energy Star compliant.

Europe

IEC 950 (1986) plus Amendment 1 (1988) and 2 (1990) and National Deviations CA, DE, FI,
GB, NL, NO, SE, US
(CAN/CSA-C22.2 No. 950-M89 and CSA TIL F-18 (May 19, 1992)
(UL Std no. 1950-1989)

1–11

Paper

Path

Chapter 2

Menu Operations

Paper Path

Menu Operations

Introduction

All testing, troubleshooting, and calibration procedures are located in the multilevel menu
system of the T6090 printer. They are located in the CONFIGuration and TEST menus and
can be accessed through the Printer Control Panel.

Technical Access Mode

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

Entering Tech Access Mode

Place the printer Offline. Depress the LINE FEED Key and ENTER Key simultaneously.
When the printer enteers Tech AccessMode the printer alarm sounds and the display flashes,
"Tech Access On." Release the keys immediately when the alarm sounds..

Exiting Tech Access Mode

There are two methods for leaving Tech Access.

1. Place the printer Offline. Depress the LINE FEED Key and ENTER Key simulta-

neously. Release the keys immediately when the alarm sounds.

2. Cycle power on the printer.

Chapter 2: Menu Operations

T esting, Troubleshooting, and Calibration

The printer is equipped with the following types of Print Tests, Hex Dumps, and Printer
Information Printouts.

Printer T ests

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

T6090 Maintenance Manual

Hex Dumps

These dumps are located in the Configuration Menu, in the Printer Category, under the
Dmp Mod (Dump Mode) Parameter in normal menu operations. Hex Dumps can be used

to check printer functions and data processing operations and are also used to help solve
problems that can affect printer performance. 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 others can be found in the Configuration
Menu, under the Printer Category.

HELP Menu

The HELP Menu is a printout that lists selections that are available for each parameter in the
multilevel menus on the printer and indicates with an asterisk (*) which ones are currently
active.

Before printing out the HELP Menu, make sure that there is at least 13 inches of print­able width on the installed paper.

Printing a HELP Menu In Tech Access Mode

STEP 1. Take the printer Offline.
STEP 2. Depress the LINE FEED Key and ENTER Key simultaneously until the printer

alarm sounds, then release them immediately to place the printer in Tech Access
Mode.

STEP 3. Depress the MODE Key to enter the multilevel menu system, then scroll (▲ 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, generate
printouts. The second pair of reports (LastFlt and Version) are displays. The Report Param-
eter is located in the CONFIGuration Menu, under the Printer Category.

Report selections (Menu Level 3)

Configs Prints a report showing the setups of the configurations.
CalData Prints a report showing timing signals and voltage levels that govern certain basic

printer functions.

LastFlt The Control Panel Display shows the Last Fault that occurred
Version The Control Panel Display shows the version number of the currently installed

firmware.

To clear the displays, depress any key on the printer control panel.

Selecting a Printer Report

STEP 1. Take the printer Offline.
STEP 2. Depress the MODE Key to enter the multilevel menu system, then scroll (▲ Key) to

the CONFIG selection.

Chapter 2: Menu Operations

STEP 3. Depress the FORMS/1 Key to access the CONFIG Menu categories, then scroll

(▲ Key) until the Printer Category is displayed.

STEP 4. Depress the CPI/2 Key to access the Printer Category parameters, then scroll

(▲ Key) until the Report Parameter is displayed.

STEP 5. Depress the LPI/3 Key to access the Report selections, then scroll (▲ Key) to the

desired selection.

STEP 6. Depress the ENTER Key to begin the Report printout or display.

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T6090 Maintenance Manual

TEST Menu

The TEST Menu contains the parameters for testing printer operation, adjusting print quality,
and controlling fault reporting. There are three categories in this menu: Pattern, Diagnostics,
and Fault Override.

The table that follows presents the categories, parameters, and parameter selections that will
appear in the TEST Menu while the printer is in Tech Access Mode.

Table 2–1 Test Menu

To access ➛ Categories Parameters Selections

Depress this key ➛

Use the ▲ Key to scroll to the
desired selection.

Use the ENTER Key to select
a value or option.

FORMS

Level 1

1

Pattern Print Upper

Diag PrntCal Hammer

CPI

Level 2

2

Print2 PaperSv

Plot Grid

Meter Pap Out

Motors Ribbon

Sht Spd 23–48

LPI

3

All Chrs
63/69
ECMA
Columns

ThermCy
Lower
1 Line
All H's
All E's
All #'s
All +'s
Parens
Rubout
Ribbon

Cross
Gray
Black
Block

Current
Pap Out

Pap Mot
Sht Sen
Rib Mot
Tmp Sen
Power
Platen
Current
Keypad

Shuttle

Level 3

2–4

Table 2–1, Continued

To access ➛ Categories Parameters Selections

Chapter 2: Menu Operations

Depress this key ➛

Use the ▲ Key to scroll to the
desired selection.

Use the ENTER Key to select
a value or option.

FORMS

Level 1

1

FltOvrd Pap Mot OFF

CPI

Level 2

2

Rbn Spd 1–250
Ribn Thr 1–255
POut Thr 0–255
PMotThr 0–255
Max T 1–255
Heavy OFF

ON

EnStar On

Off

Clear CalData

Counts
NVRAM

ON

Pap Out OFF

ON

Rib Mot OFF

ON

Shuttle OFF

ON

Temp OFF

ON

Platen OFF

ON

Ctrl OFF

ON

Link OFF

ON

Hvy Frm OFF

ON

LPI

3

Level 3

2–5

T6090 Maintenance Manual

Pattern Category (Menu Level 1)

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

Print Parameter (Menu Level 2)

This parameter is also available in normal menu operations. It has five selections.

Print selections (Menu Level 3)

Upper Prints a rolling pattern of 63 UPPERCASE ASCII characters.
All Chrs Prints all Character Sets available on your printer.
63/69 Prints rolling ASCII with spaces.
ECMA Prints pattern designed to produce a specific audible noise pattern specified by

European Computer Manufacturers Association used for acoustics testing.

Columns This test labels each column in the current print line. The line length used is

based on the current margin settings.

To stop any of the above tests, depress the ENTER Key or the CLEAR Key.

Print2 Parameter (Menu Level 2)

This parameter is available in Tech Access only. It has 11 print test selections.

Print2 selections (Menu Level 3)

Except for the 1 Line test all of the tests below run continuously. They will continue to run
until you depress either the ENTER Key or the CLEAR Key.

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 uppercase
characters that is advanced by one character on each line. Each pass is four lines
long. The printer then backs up three lines and prints another four line pass. The
printer then continues printing in this fashion until it makes 30 passes. On the
30th pass the printer does not back up.

ThermCy This option prints the PaperSv pattern for 15 minutes, stops printing for five

minutes, then starts the cycle over. It is used to test the temperature cycling
abilities of the printer.

Lower This option prints a rolling pattern of all 95 lowercase ASCII characters.
1 Line This option prints one line only of upper-and lowercase characters.
All H's This option prints lines composed of the uppercase letter H.
All E's This option prints lines composed of the uppercase letter E.
All #'s This option prints lines composed of the # symbol.
All +'s This option prints lines composed of the + sign.
Parens This option prints lines composed of the left paren followed by a vertical bar

followed by the right paren.

Rubout This option prints lines composed of the currently selected fill character.
Ribbon This option prints lines composed of rolling ASCII uppercase characters.

2–6

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 crosshatch 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 66

hammers (printing every other dot vertically and horizontally), which should lay
down an even gray tone across the page. Any changes in the gray tone indicates a
variation in the gap between the hammer module and the platen, most commonly
indicating either a worn hammer module or a replacement module in need of
alignment.

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.

Chapter 2: Menu Operations

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.

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T6090 Maintenance Manual

Selecting And Running a Print Test

STEP 1. Take the printer Offline and place it in Tech Access Mode.
STEP 2. Access the TEST Menu.
STEP 3. Depress the FORMS/1 Key to access the TEST Menu categories, then scroll

(▲ Key) until the Pattern Category is displayed.

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 print tests are continuous and will
continue to print until you depress the CLEAR Key or ENTER Key.

Diagnostic Category (Menu Level 1)

This category contains parameters for testing various printer components, for setting opera­tional thresholds, and for calibrating certain sensors. You are guided through these diagnostic
procedures by instructions on the Control Panel Display. There are 12 diagnostic parameters.

PrntCal (Print Calibration) Parameter (Menu Level 2)

This parameter provides a means to calibrate the hammer timing pulses to obtain the best print
quality. There are three selections for PrntCal: Hammer, Current, and Pap Out.

Selecting And Running a Hammer Calibration Routine

STEP 1. Take the printer Offline and place it in Tech Access Mode.
STEP 2. Access the TEST Menu.
STEP 3. Depress the FORMS/1 Key to access the TEST Menu categories, then scroll

(▲ 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, then scroll (▲ Key) until

the Hammer selection is displayed.

STEP 6. Depress the ENTER Key to begin the Hammer Calibration Routine.

The printer generates coarse test patterns using hammer lead times from 23Hz
(prints twice), 30Hz, 34Hz, 40Hz, and 45Hz.

STEP 7. Examine each line of the printed output for each lead time and select the one that

has the best dot placement, then scroll to that setting on the Control Panel and
depress the ENTER Key to select it.

2–8

After you make the last selection (for 45Hz) the printer prints out the settings for the various
lead times and the calibration routine is over.

Repeat the Print calibration routine with "Heavy Forms" turned on and with heavy
forms installed on the printer.

Chapter 2: Menu Operations

Selecting And Running a Current Calibration Routine

Step 1. Take the printer offline and place it in Tech Access Mode.
Step 2. Access the TEST Menu.
Step 3. Depress the Forms/1 key to access the TEST Menu categories, then scroll (▲ Key)

until the Diag Category is displayed.

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, then scroll (▲ Key) until

Current is displayed.

Step 6. Looking at the Control Panel display, depress the ENTER key. The printer firm-

ware performs a calibration routine and the new value will be displayed. (Values
will vary from printer to printer). Once the value is displayed you have completed
the routine.

Selecting And Running a Paper Out Calibration Routine

Step 1. Take the printer offline and place it in Tech Access Mode.
Step 2. 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 Printcal Parameter is displayed.

Step 5. Depress the LPI/3 key to access the Printcal selections, then scroll (▲ Key) until

PapOut is displayed.

Step 6. Depress the ENTER key to begin the first part of the Paper Out Calibration

Routine. Follow steps on display.

When removing paper, the tractor door must be closed to ensure proper reading.

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T6090 Maintenance Manual

Meter Parameter (Menu Level 2)

This parameter has nine selections. The sensor tests that are available under this parameter
can be used to adjust the sensor for optimum performance or to test sensors to ensure that they
are operating properly.

Meter selections (Menu Level 3)

Sht Sen (see explanation below)
Pap Out (see explanation below)
Pap Mot (see explanation below)
Rib Mot (see explanation below)
Tmp Sen (reads current voltage drop across the thermistor)
Power (used on printer Production Line only)
Platen (used on printer Production Line only)
Current (used on printer Production Line only)
Keypad (displays each key name when it is depressed)

Each Meter Test is initiated by depressing the ENTER Key when the desired selection is
displayed.

The first 4 tests are used to check positioning of the sensor itself. Each sensor is checked in a
"covered" and "uncovered" mode.

For the Paper Out and Paper Motion sensors, depress the ENTER Key then check them with
paper installed (covered) and paper removed (uncovered). The Paper Out Sensor should read
less than .2 volts with paper removed and greater than 4 volts with paper installed. The Paper
Motion Sensor only needs to have a differential of greater than 2 volts between the high and
low reading to function properly.

The Shuttle Motion Sensor should read less than 0.5 volts with the open portion of the upper
gear over it (uncovered), and greater than 4.5 volts with the solid portion of the gear over it
(covered).

The Ribbon Motion Sensor is read with the silver portion of the wheel inside the Ribbon
Cartridge over it (uncovered), then with the black portion over it (covered). The readings
should be greater than 4V uncovered and less than .2V covered.

Motors Parameter (Menu Level 2)

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

Motors selections (Menu Level 3)

Ribbon
Shuttle

2–10

The selected test is initiated by depressing the ENTER Key. After the motor reaches its
assigned speed the test can be stopped by depressing the ENTER Key again. This sequence
may be repeated until you are satisfied with the operation of the motor.

Chapter 2: Menu Operations

Sht Spd (Shuttle Speed) Parameter (Menu Level 2)

Provides a means to vary the Shuttle Motor speed for a Shuttle Motor Test.

Shuttle Speed selections (Menu Level 3)

23—48 Hz.

Rbn Spd (Ribbon Speed) Parameter (Menu Level 2)

Provides a means to vary the Ribbon Motor speed for a Ribbon Motor Test.

Speed selections (Menu Level 3)

1—250
Default

RibnThr (Ribbon Threshold) Parameter (Menu Level 2)

This parameter allows you to set the Ribbon Sensor Threshold value for the Ribbon Motion
Sensor .

Threshold selections (Menu Level 3)

1—255

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

PMoThr (Paper Motion Threshold) Parameter (Menu Level 2)

This parameter allows you to set the Paper Motion Threshold value for the Paper Motion
Sensor to compensate for reflectivity variances for different types of paper.

Threshold selections (Menu Level 3)

0—255

Heavy (Heavy Forms) Parameter (Menu Level 2)

This Parameter allows you to slow the slew speed and increase the hammer fire for heavy
forms.

Heavy Forms selections (Menu Level 3)

OFF
ON

2–11

T6090 Maintenance Manual

Max T (Maximum Temperature) Parameter (Menu Level 2)

Max T is the thermal limit for the printer. If the thermistor on the Engine Controller PCB
exceeds this limit, the Thermal Fault message will appear on the Control Panel Display.

DO NOT change the factory setting.

EnStar (Energy Star) Parameter (Menu Level 2)

This parameter allows you to control Energy Star Operation on the printer.

Energy Star selections (Menu Level 3)

OFF
ON

Clear Parameter (Menu Level 2)

This parameter provides you with a means of clearing part or all of NVRAM.

Clear selections (Menu Level 3)

CalData Clears the calibration data from NVRAM. When CalData is selected you will

have to perform a Hammer Calibration Routine before using the printer.
Counts Clears the count information from NVRAM.
NVRAM Clears ALL NVRAM.

Fault Override (FltOvrd) Category (Menu Level 1)

This category provides you a means of controlling fault reporting from the Engine Manager to
the Control Processor. Each of the following parameters has two selections: OFF and ON.

When the parameter is set to OFF, faults are reported as they happen (Fault Override is dis­abled). When the parameter is set to ON, faults are not reported on the display (Fault Override
is Enabled).

Pap Mot (Paper Motion) Parameter (Menu Level 2)

This parameter provides fault override for Paper Motion Faults.

Pap Out (Paper Out) Parameter (Menu Level 2)

This parameter provides fault override for Paper Out Faults.

Rib Mot (Ribbon Motion) Parameter (Menu Level 2)

This parameter provides fault override for Ribbon Motion Faults.

Shuttle Parameter (Menu Level 2)

This parameter provides fault override for Shuttle Fault reporting.

Temp (Temperature) Parameter (Menu Level 2)

The Temp Parameter provides fault override for Temperature Threshold fault reporting.

2–12

Chapter 2: Menu Operations

Platen Parameter (Menu Level 2)

This parameter provides fault override for the Platen Open Sensor.

Ctrl (Control Processor) Parameter (Menu Level 2)

This parameter provides fault override for the control processor fault reporting status.

Link Parameter (Menu Level 2)

This parameter provides fault override for control processor to main processor communica­tions.

Hvy Frm (Heavy Forms) Parameter (Menu Level 2)

This parameter overrides automatic platen gap sensing.

Panel Parameter (Menu Level 2)

This parameter provides fault override for Panel Fault reporting.

Control Panel Key Operations For Controlling Fault Reporting

In addition to being able to use the above parameters to set up individual fault overrides, you
may also use three different key sequences to set up fault overrides. You may set up all fault
overrides, four specific overrides, or just Paper Out Fault override.

To use the following options the printer must be in Tech Access Mode.

ALL Fault Reporting

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

Four Faults Only

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

Paper Out Only

To turn OFF fault reporting for the Paper Out sensor, depress the FORMS/1 Key and EN­TER Key simultaneously until the printer alarm sounds. To turn it back ON, depress the same

keys until the printer alarm sounds.

The displays that appear when you are enabling the options above can be somewhat
confusing. Just remember, when you turn on fault overrides you are losing fault
protection.

2–13

Paper

Path

Chapter 3

Troubleshooting

Paper Path

Troubleshooting

Introduction

Messages

Faults

Chapter 3: Troubleshooting

This chapter deals with troubleshooting problems on the T6090 printer. Messages that
indicate printer faults and errors are explained and corrective action given. The few
paper handling and print quality problems that may occur are also explained. Trouble­shooting tables and diagnostic flow charts have been included.

Messages on the Control Panel Display report both normal operation and fault situa­tions. 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.

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 4: 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. Other­wise place the printer back Online and test it during normal print operations.

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T6090 Maintenance Manual

Fault Override

To allow continued printer operation during serious faults, which usually shut down
printer operation, you may use the Fault Override Category in the printer menus system.
This allows you to troubleshoot serious faults in order to repair them.

One Fault Override Parameter (Paper Motion) is available in the Standard Multilevel
Menus. Once it is enabled it remains enabled until it is disabled through the Control
Panel, a printer reset escape sequence is received by the printer, or printer power is
cycled.

Eight more are available in the Tech Access Mode, under the TEST Menu. They can only
be enabled while the printer is in Tech Access Mode. However, they will remain in
whichever setting (On or Off) you select when you leave Tech Access Mode.

All of the Fault Override Parameters are explained in Chapter 2, under TEST Menu.

This feature must be used with extreme caution. Any time you disable one of the Fault
Sensing Systems on your printer you lose protection from situations that may result in
damage to the printer.

Dump Mode

Dump Mode is used to troubleshoot problems that may arise when processing data. You
can print out only control codes, control codes and spaces, or control codes, spaces and
text in hexadecimal format for use as a debugging tool. The Dump Mode Parameter is
explained in Chapter 2: Menu Operations.

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Chapter 3: Troubleshooting

Table 3–1. Display Messages

MESSAGE Explanation and Corrective Action

Bad Packet

Bad TWICO Int.

Bad VFU Channel

Bad VFU Count

Buffer Overflow

Chnl Not Found

Ctrl Fault (n)

Ctrl Link Flt

Data Overrun

Explanation:
Corrective Action:

Explanation:
Corrective Action

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:

Corrective Action:

Explanation:
Corrective Action:

Explanation:

Corrective Action:

Explanation:
Corrective Action:

Explanation:

Corrective Action:

This message indicates that a fault has occurred in the communica­tions between the I/O processor and the main processor.
Cycle power and try again. If the problem returns, remove and
replace the Personality CBA. If the problem returns, download new
printer firmware.

The Personality Module CBA is damaged or corrupted.

: Cycle power and try again. If this does not clear the problem, remove

and replace the Personality Module CBA.
A VFU channel command has been received from the host request-

ing an illegal channel.
Correct data from host and retransmit.

An incorrect number of bytes has been detected in a VFU
download.
Correct data from host and retransmit.

A buffer overflow has been detected on the currently active host
interface. It is most likely caused by a host failure to respond to a
busy signal.

1. Ensure correct protocol has been selected.

2. Check wiring of I/O cable between host and printer. (See Appen-
dix C in the Operator/Application Manual for a detailed explana­tion.)

3. Ensure correct protocol has been selected.

VFU Channel requested by the host computer cannot be found.
Correct data from host and retransmit.

This message indicates that a fault has occurred in the control
processor.
If n = :

(4) Control CPU Reset
(7) Control CPU RAM Fault

(8) Control CPU Checksum Failure
Cycle printer power. If this does not clear the problem, remove and
replace the Engine Controller CBA If the problem still exists, replace
the Personality Module CBA.

The Control Processor has detected a fault in the Main Processor to
Control Processor link.
Cycle power and try again. If it fails again, remove and replace the
Personality CBA. If this does not clear the problem, remove and
replace the Engine CBA.

A data overrun has been detected on the currently active host inter­face. This is most likely caused by an incorrectly configured ser ial
protocol bit rate, data bits, parity or host failure to respond to a busy
signal.
Check setting on Serial Protocol bit rate, Data Bits, and Parity
parameters through the printer control panel.

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T6090 Maintenance Manual

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Fatal Fault n

Flt Clr Timeout

Font Dnld Error

Heap Overflow

Link Fault (n)

Main CPU Fault

No VFU Loaded

NVRAM Fault

Offline Data In

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:

Corrective Action:

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:
Corrective Action:

A fault has been detected in the software.
Cycle power and try again. If this does not clear the problem, remove
and replace the Personality CBA. If it fails again, remove and replace
the Engine Controller CBA.

The Main CPU cannot clear a fault in the Control CPU.
Remove and Replace the Engine Controller CBA.

An error has been detected during a font download.
Correct data and retransmit from host.

Graphics memory space is full and the printer cannot accept or
process data. Printer will reset and data will be lost.
Insert line terminators in data stream so the printer will process the
data, then retransmit the data.

This message indicates that data flow has been interrupted between
the main processor and the control processor.
If n = :
(0) Maximum Packet Length Exceeded
(1) Inter processor Link Transmit Timeout
(2) Illegal Packet Length
(3) Illegal Packet Type
(5) Inter processor Link Receive Timeout
(6) Sweep Done Timeout
(9) Inter processor Link Receive Overrun
(10) Status Request Timeout
(11) T emper ature Request Timeout
Cycle printer power. If that does not clear the problem, download new
printer firmware.

A fault has been detected in the main processor during powerup
diagnostics.
Remove and replace the Personality Module CBA.

A VFU command was received from the host before a VFU was
Downloaded.
Download the required VFU information, then retransmit the data.

The nonvolatile data checksum has failed because the variable values
have been altered in a destructive manner.
Depress the CLEAR Key. If the message does not clear, cycle printer
power. If the message still does not clear, remove and replace the
Engine Controller CBA.

The printer is in Offline condition and nonprinted data is in the buffer.
There is no corrective action required. Under normal conditions the
printer will continue to print when it is placed back Online. If you do
not want the buffered data to print, enter the Clear Menu by depress­ing the CLEAR Key before going back Online and select the Clear
Buffers entry to clear the buffered data.

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Chapter 3: Troubleshooting

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Offline Dump On

Online Dump On

Overflow VFU

Panel Fault

Paper Motion Flt

Explanation:
Corrective Action:

Explanation:

Corrective Action:
Explanation:

Corrective Action:
Explanation:

Corrective Action:

Explanation:

Corrective Action:

The printer is in Offline condition and Dump Mode is enabled.
No corrective action is necessary. Place the printer back Online when
you are ready to print. (See the explanation at the beginning of this
chapter and in Chapter 2, under Hex Dumps for explanations about
how the data from the host is printed.)

The printer is ready to accept and print data from the host through
Dump Mode. (See the explanation at the beginning of this chapter
and in Chapter 2, under Hex Dumps for explanations about how the
data from the host is printed.)
No corrective action is required.

An excessive number of bytes has been sent by the host in a VFU
download.
Correct data and retransmit from host.

The control processor has detected a fault in the circuitry for the
control panel. Depending on the location of the fault, this message
may not display.
Remove and replace the Control Panel. If this does not clear the fault,
remove and replace the Engine Controller CBA.

The control processor has detected that the paper has failed to move
the required distance after sending a command to the Paper Drive
Motor.
Check for paper feed problems. If there are any paper feed problems,
correct them, then depress the CLEAR key to clear the fault and
continue operation.
If this does not clear the problem, check for paper debris blocking the
sensor.
If problem still exists, check cable connection at the Engine CBA. If it
fails again, check the sensor’s voltage output (in the meter parameter
of the Control Panel). The reading should be approx. +5.0 Volts
without paper and ≤ + 3.0 Volts with paper. Ideally the voltage reading
should differ at least 2V between paper in and paper out. If the
differential is less than 2V, or the voltage does not change or is zero,
the Upper Tractor set (Includes Paper Motion Sensor) needs to be
replaced.
If all the above does not clear the problem, remove and replace the
Engine Controller CBA.

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T6090 Maintenance Manual

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Paper Out

Parity Error

Platen Open

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:

Corrective Action:

Paper is not being detected in the lower paper path below the print
mechanism.
If this message is correct, refer to the ENTER Key Section of
Chapter 2 of the Operator/Application Manual, then load paper. (See
Loading Paper Section of Chapter 1 of the Operator/Application
Manual.)
If this message is in error, check the sensor connection on the Engine
Controller CBA and sensor position on its mounting bracket. If the
connection is OK and the sensor is properly installed, then recalibrate
the Paper Out Sensor. (See TEST Menu in Chapter 2 for the proce­dure.) If the problem still exists, the Lower Tractor Set (includes
Paper Motion Sensor) needs to be replaced.
If all of the above checks and fixes do not clear the problem, remove
and replace the Engine Controller CBA.

Parity is enabled and a mismatch on Bit 8 has been detected on the
currently active host interface.
If there is a mismatch between the setting of the printer and the
setting of the host, you can change printer parity by referring to the
Configuration Menu section of Chapter 2 of the Operator's Manual.
If there is no mismatch between the printer and host settings, then the
data sent from the host has been corrupted. Retransmit the data from
the host. If the condition repeats, set up the printer for Dump Mode
(see Configuration Menu Section in Chapter 2 of the Operator's
Manual) and retransmit the data again. If you find no errors in the
Dump Mode data, remove and replace the Personality Module CBA.
If this still does not correct the problem, the likely cause is in the I/O
cable or the host.

The Form Thickness Lever is set beyond the maximum setting
for paper thickness. This message may display when you are loading
paper or a Ribbon Cartridge into the printer. This condition disables
the printer and the only keys that will function on the control panel are
the form movement keys.
When you are loading paper or a Ribbon Cartridge, this message will
clear when you lower the For m Thickness Lever and close the Platen
Gap. If this message appears at any other time or will not clear, check
the sensor connection on the Engine Controller CBA and perform a
meter test on the sensor. (See TEST Menu in Chapter 2 for the
procedure.) The sensor should read less than .2 volts with the Form
Thickness Lever closed and greater than 4 volts with the form Thick­ness Lever fully opened. If the readings do not differ, download new
printer firmware.

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Chapter 3: Troubleshooting

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Print Fault

RAM Test Fail

Self Testing

Setup Address

Explanation

Corrective Action

Explanation:
Corrective Action:

Explanation:
Corrective Action:

Explanation:
Corrective Action:

: Faulty communication between the main and control processor has

occurred causing a dot row to misprint. The printer automatically
recovers from this condition.

: Under normal circumstances there is no corrective action other than to

depress the CLEAR Key to remove the fault message from the
display. If this does not clear the problem, remove and replace the
Personality CBA. If, however, this problem persists, remove and
replace the Engine Controller CBA.

A fault has been detected in the Main Processor primary RAM or a
fault exists in the RAM address lines.
Remove and replace the Personality Module CBA.

The printer is performing internal diagnostic tests.
If this message does not clear automatically after a few seconds,
remove and replace the Personality Module CBA.

The printer address has not been set up or a configuration with
address set to UNDEFIN has been loaded.
Set up the printer address using the multilevel menus on the printer.
The procedure is located in Chapter 4 of the Operator Manual, under
the Configuration Menu.

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T6090 Maintenance Manual

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Shuttle Fault

Explanation:

Corrective Action:

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

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Chapter 3: Troubleshooting

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Thermal Fault

Explanation:
Corrective Action:

The ambient temperature has exceeded the limit (Max T).
Check to see if the Cirscuit Cooling and Hammer Bank fans are

working. If both fans are working, you have a faulty Engine Controller
CBA.

If only one of the two fans is not working, check power at the Engine
Controller CBA for the fan that is not operating. If power is OK,
remove and replace the fan. If power is not OK remove and replace
the Engine Controller CBA.

If neither fan is working, either the Engine Controller CBA or the
Power Supply is malfunctioning. Check voltage output of the Power
Supply. If it is OK remove and replace the Engine Controller CBA. If
it is not OK, check the power source voltage. If the power source
voltage is OK, remove and replace the Power Supply. If the power
source voltage is incorrect, call an electrician.

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T6090 Maintenance Manual

Hardware Troubleshooting Guides

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

The printer does not power up when switched on

There are four things that can cause this problem.

1. 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 Engine 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 source voltage is correct. If the power source voltage is OK, the
problem is in the cord.

If input power at the plug-in is OK, check power from the On/Off switch to
the Power Supply. If there is no power at the back of the On/Off switch when
it is switched On, the On/Off switch is defective. Remove and replace the
Power Supply.

If input power is OK on the back of the On/Off switch, check input power on
the Power Supply. If there is no input power at the Power Supply, the cabling
from the On/Off switch to the Power Supply is defective.

STEP 3. If input power to the printer Power Supply is OK, check output voltage of the Power

Supply. Power Supply output voltage should be approximately 48 VDC. If the output
voltage is incorrect, remove and replace the Power Supply.

When the printer is powered up, nothing works except the fan.

The only thing that can cause this problem is a malfunctioning Engine Controller CBA.
Remove and replace the Engine Controller CBA.

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Chapter 3: Troubleshooting

The Printer powers up but the Control Panel does not function.

There are four things that can cause this problem.

1. A bad connection.

2. A bad control panel.

3. A bad Engine Controller CBA.

4. Loss of 5 V power supply.

If the red Power On Indicator is the only one that does not function, the problem is
most likely a malfunctioning Control Panel.

Troubleshooting Procedure

STEP 1. Check the form movement keys to see if they function.

If the form movement keys function properly, the problem is either in the Control Panel
or in the Engine Controller CBA.

Try another Control Panel first. If that does not correct the problem, then remove and
replace the Engine Controller CBA.

STEP 2. If the form movement keys do not function properly, check the Control Panel connec-

tion to the Engine Controller CBA.
If the connection is OK, the problem is in either the Control Panel or in the Engine

Controller CBA. Try another Control Panel first. If that does not correct the problem,
then remove and replace the Engine Controller CBA.

The Control Panel Display functions partially, nonsensically, or not at all.

There are three things that can cause this problem.

1. A bad connection.

2. A malfunctioning Control Panel.

3. A malfunctioning Engine Controller CBA.

Troubleshooting Procedure

STEP 1. Check the Control Panel connection to the Engine Controller CBA.
STEP 2. If the connection is OK, the problem is in either the Control Panel or in the Engine

Controller CBA.
Try another Control Panel first. If that does not correct the problem, then remove and

replace the Engine Controller CBA.

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T6090 Maintenance Manual

There is no printed output but the printer appears to be operating normally.

There are three things that can cause this problem.

1. The Form Thickness Lever may be open too far but not far enough to cause a
Platen Open message.

2. The Ribbon Cartridge may not be functioning properly or is not installed.

3. Platen alignment may be incorrect.

Troubleshooting Procedure

STEP 1. Check the Form Thickness Lever and make sure it is closed properly.
STEP 2. Make sure the Ribbon Cartridge is installed and functioning properly. If the Ribbon

Cartridge is not functioning properly, replace it.

STEP 3. If STEPs 1–2 do not correct the problem, check and adjust the platen alignment guides.

The Platen Gap should be approximately .013 " with the Form Thickness Lever fully
closed. (See Procedure 24 in Chapter 4.)

Printed output appears light

There are three things that can cause this problem.

1. The Form Thickness Lever may be open too far but not far enough to cause a
Platen Open message.

2. The Ribbon Cartridge may be worn out or is not moving.

3. Platen alignment may be incorrect.

Troubleshooting Procedure.

STEP 1. Check the Form Thickness Lever and make sure it is closed properly.
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 approximately .013 " with the Form Thickness Lever fully
closed. (See Procedure 24 in Chapter 4.)

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Printed output appears shaky or fuzzy

There are six things that can cause this problem.

1. The Form Thickness Lever may be open too far but not far enough to cause a

Platen Open message.

2. The shuttle mechanism is worn—the shuttle counterweight gears or the bearings

are worn.

3. The hammers are not firing properly.

4. Platen alignment may be incorrect.

5. Damaged platen.

6. The Shuttle Sensor is misaligned.

Troubleshooting Procedure

STEP 1. Check the Form Thickness Lever and make sure it is closed properly.
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.

Chapter 3: Troubleshooting

STEP 3. Perform a Hammer Calibration procedure. This procedure is explained in Chapter 2, in

the TEST Menu Section, under the Diagnostic Category (PrntCal Parameter).
If the hammers can not be calibrated, the problem is in the Engine Controller CBA.

Replace the Engine Controller CBA following the procedure explained in Chapter 4.

STEP 4. Check and adjust the platen alignment guides. The Platen Gap should be .012 " – .014"

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.
STEP 6. Make sure the Shuttle Sensor is properly aligned. (See Procedure 18 in Chapter 4.)

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T6090 Maintenance Manual

Two adjacent character columns not printing

There are five things that can cause this problem.

1. Broken Hammer.

2. Defective Hammer Coil; either shorted or open.

3. Defective Hammer Bank Cable.

4. Malfunctioning Engine Controller CBA.

5. The hammer may be sticking due to contamination, such as paper and ink
buildup.

Troubleshooting Procedure

STEP 1. Remove the right end cover of the printer.
STEP 2. Inspect the Hammer Bank cables for rub spots, cracked insulation, burn spots, etc.

If any physical defects are found in the cables, remove and replace the Ham­mer Bank Assembly and correct the cause of the problem with the cable.

Test the printer to see if the problem is still present. If it 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 Hammer Bank 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 12 Ω (Ohms) ±

.3 Ω at 70° F. If the coil resistance is outside of this range, remove and replace the

Hammer Module.

If the Hammer Coil is defective, check the Hammer Driver on the Engine Controller

CBA also. Defective Hammer Drivers can cause problems with Hammer Coils. Instruc-

tions 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.

3–14

STEP 8. If there are no physical defects, shorts, or opens, the likely cause of the problem is a

malfunctioning Engine Controller CBA. Remove and replace the Engine Controller

CBA.

Chapter 3: Troubleshooting

The Printer is out of paper — No Paper Out fault is reported

There are three things that can cause this problem.

1. Fault override for paper out sensor is on, disabling the paper out sensor.

2. Calibration values have been lost for the paper out sensor.

3. Malfunctioning Engine CBA.
STEP 1. Check to see if the fault override is enabled for Paper Out sensing.
STEP 2. If Fault Overrides are not enabled, check the sensor connections and recalibrate the

Paper Out sensor. (See Chapter 2, under Diag Category.)

STEP 3. If none of the above checks eliminates the problem, the most likely cause is a malfunc-

tioning Engine Controller CBA. Remove and replace the Engine Controller CBA.

If you have no idea how long the printer has been banging away with no paper
installed, check the platen for damage. If necessary, remove and replace the platen
and any damaged hammers.

No Paper Motion — No Paper Motion fault is reported

There are three things that can cause this problem

1. Fault override for paper motion sensor is on, disabling the paper motion sensor.

2. Defective Paper Motion Sensor.

3. Malfunctioning Engine Controller CBA.
STEP 1. Check to see if the fault override is enabled for Paper Motion sensing.
STEP 2. Use the PapMot Meteer Test to check the sensor If it does not check correctly, remove

and replace the upper tractor set.

STEP 3. If none of the above checks eliminates the problem, the most likely cause is a malfunc-

tioning Engine Controller CBA. Remove and replace the Engine Controller CBA.

If you have no idea how long the printer has been banging away with no paper
motion, check the platen for damage. If necessary, remove and replace the platen
and any damaged hammers.

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T6090 Maintenance Manual

Paper Handling Problems

The following table lists the few paper handling problems you may encounter along
with corrective actions you may take.

Table 3–2. Paper/Printing Corrective Action

Problem Cause Corrective Action

The paper holes are wider than
normal after passing through the
tractors.

Printed characters on heavy­weight or multi-part paper are
smeared.

The printed characters are too
light.

The printed characters are shaky. The Form Thickness Lever is not set

The printed characters in one
line are shorter than normal.

The paper holes are elongated
after passing through the tractors.

The paper comes out of the
tractors or the paper tears at the
right or left holes along the edges.

Horizontal paper tension is too tight. Unlock and readjust the tractors.

The Form Thickness Lever is not set
correctly.

The Form Thickness Lever is out of
adjustment or the ribbon is worn out.

correctly.

Vertical paper tension is too loose.

Vertical paper tension is too tight.

(1) The vertical or horizontal

paper tension is incorrect.

(2) The tractors are too far apart. Unlock and realign the tractors.

Raise the Form Thickness Lever.

Readjust the Form Thickness Lever.
If this does not correct the problem,
replace the ribbon cartridge with a
new one.

Adjust the Form Thickness Lever.

Move the Paper Tension Lever until
the paper is taut but not too tight.

Move the Paper Tension Lever
until the paper is taut but not too
tight.

To change the vertical tension,
raise the Paper Tension Lever to
increase tension, and lower it to
decrease tension.

To change the horizontal tension,
unlock the upper right and/or
lower right tractor and move it left
or right to make the necessary
adjustment.

3–16

(3) Upper tractors not aligned

with the lower tractors.

(4) The Form Thickness Lever is

not set correctly.

Unlock and realign the tractors
so that the lower set is directly
under the upper set.

Raise the Form Thickness Lever.

Chapter 3: Troubleshooting

T6090 Engine Controller To Hammer Bank CBA Cables

Table 3–3. Connector Pinouts

Common = 48V Power

P703 P704

PIN Function PIN Function PIN Function PIN Function

1 Hammer 33 2 Hammer 32 1 Hammer 66 2 Hammer 65
3 Hammer 31 4 Common 3 Hammer 64 4 Common
5 Hammer 30 6 Hammer 29 5 Hammer 63 6 Hammer 62
7 Hammer 28 8 Common 7 Hammer 61 8 Common

9 Hammer 27 10 Hammer 26 9 Hammer 60 10 Hammer 59
11 Hammer 25 12 Common 11 Hammer 58 12 Common
13 Hammer 24 14 Hammer 23 13 Hammer 57 14 Hammer 56
15 Hammer 22 16 Common 15 Hammer 55 16 Common
17 Hammer 21 18 Hammer 20 17 Hammer 54 18 Hammer 53
19 Hammer 19 20 Common 19 Hammer 52 20 Common
21 Hammer 18 22 Hammer 17 21 Hammer 51 22 Hammer 50
23 Hammer 16 24 Common 23 Hammer 49 24 Common
25 Hammer 15 26 Hammer 14 25 Hammer 48 26 Hammer 47
27 Hammer 13 28 Common 27 Hammer 46 28 Common
29 Hammer 12 30 Hammer 11 29 Hammer 45 30 Hammer 44
31 Hammer 10 32 Common 31 Hammer 43 32 Common
33 Hammer 9 34 Hammer 8 33 Hammer 42 34 Hammer 41
35 Hammer 7 36 Common 35 Hammer 40 36 Common
37 Hammer 6 38 Hammer 5 37 Hammer 39 38 Hammer 38
39 Hammer 4 40 Common 39 Hammer 37 40 Common
41 Hammer 3 42 Hammer 2 41 Hammer 36 42 Hammer 35
43 Hammer 1 44 Common 43 Hammer 34 44 Common

3–17

T6090 Maintenance Manual

1234 5 6 78 91011

3 6 9 1215182124273033

Hammerbank Firing Line — Top View — Left to Right

Power

Supply Pins

Hammers

{

Hammer

Modules

{

Hammerbank CBA Soldered Connections

J6

J5

P703 Pin Numbers

Connector Alignment

P704 Pin Numbers

P703 Hammerbank Ribbon Cable P704 Hammerbank Ribbon Cable

43 1357911131517192123252729313335373941

44 24681012141618202224262830323436384042

43 1357911131517192123252729313335373941

44 24681012141618202224262830323436384042

2 5 8 1114172023262932

1 4 7 1013161922252831

48V 48V 48V 48V 48V 48V 48V 48V 48V 48V 48V

35 38 41 44 47 50 53 56 60 63 66

36 39 43 45 48 51 54 57 59 62 65

34 37 40 43 46 49 52 55 58 61 64

48V 48V 48V 48V 48V 48V 48V 48V 48V 48V 48V

Table 3–4. P703 & P704 Connector to Hammer Bank CBA Continuity Check Points

3–18

Chapter 3: Troubleshooting

Table 3–5. T6090 Hammer Coil/Module Troubleshooting

Print Hammer Hammer CBA Print Hammer Hammer CBA

Columns Coil Module Driver Columns Coil Module Driver

1 & 2 1 1 U20 67 & 68 34 12 U12
3 & 4 2 1 U20 69 & 70 35 12 U11
5 & 6 3 1 U20 71 & 72 36 12 U11
7 & 8 4 2 U19 73 & 74 37 13 U11

9 & 10 5 2 U19 75 & 76 38 13 U11
11 & 12 6 2 U19 77 & 78 39 13 U10
13 & 14 7 3 U19 79 & 80 40 14 U10
15 & 16 8 3 U18 81 & 82 41 14 U10
17 & 18 9 3 U18 83 & 84 42 14 U10
19 & 20 10 4 U18 85 & 86 43 15 U9
21 & 22 11 4 U18 87 & 88 44 15 U9
23 & 24 12 4 U17 89 & 90 45 15 U9
25 & 26 13 5 U17 91 & 92 46 16 U9
27 & 82 14 5 U17 93 & 94 47` 16 U8
29 & 30 15 5 U17 95 & 96 48 16 U8
31 &3 2 16 6 U16 97 & 98 49 17 U8
33 & 34 17 6 U16 99 & 100 50 17 U8

35 &36 18 6 U16 101 & 102 51 17 U7
37 & 38 19 7 U16 103 & 104 52 18 U7
39 & 40 20 7 U15 105 & 106 53 18 U7
41 &4 2 21 7 U15 107 & 108 54 18 U7
43 & 44 22 8 U15 109 & 110 55 19 U6
45 & 46 23 8 U15 111 & 112 56 19 U6
47 & 48 24 8 U14 113 & 114 57 19 U6
49 & 50 25 9 U14 115 & 116 58 20 U6
51 & 52 26 9 U14 117 & 118 59 20 U5
53 & 54 27 9 U14 119 & 120 60 20 U5
55 & 56 28 10 U13 121 & 122 61 21 U5
57 & 58 29 10 U13 123 & 124 62 21 U5
59 & 60 30 10 U13 125 & 126 63 21 U4
61 & 62 31 11 U13 127 & 128 64 22 U4
63 & 64 32 11 U12 129 & 130 65 22 U4
65 & 66 33 11 U12 131 & 132 66 22 U4

Driver Information is intended for Service Center only.

3–19

T6090 Maintenance Manual

Troubleshooting The Hammer Driver Transistors

The Hammer Driver Transistors are located on the Engine Controller CBA. When you
are having problems like Hammer Coil shorting or Hammers not firing, these compo­nents should be checked along with the other components involved in the function.

To check the Hammer Driver for the malfunctioning hammer, use an Ohmmeter on its
lowest scale. Test the collector (C) to base (B) by placing the Positive (+) lead on the
collector terminal and the Negative ( – or Common) lead on the base terminal. If the
reading is either a short (0 Ohms) or an open (∞, infinity), the driver is bad and you
should replace the Engine Controller CBA. If this check is OK, then test the base (B) to
emitter (E) by placing the positive (+) lead on the base terminal and the negative (– or
Common) lead on the emitter terminal. If the reading is either a short (0 Ohms) or an
open (∞, infinity), the driver is bad and you should replace the Engine Controller CBA.
Use the following table to locate the correct driver terminals to check for the hammer(s)
you are having trouble with.

Base of each segment of the driver goes to the LSI Chip, which turns On/Off

The
each segment. The
sponding Hammer Coil.

Collector of each driver segment is connected to the corre-

3–20

Table 3–6. J703 Hammer Driver Pinouts

Chapter 3: Troubleshooting

Circuit Side of Engine Controller CBA

Top Of CBA

J703

Pin Numbers

123456789101112

H9

}

}

H30

}

H26

}

H22

}

H18

}

H14

}

H10

}

H6

}

H2

U12

U13

U14

U15

U16

U17

U18

U19

U20

BC CB

H32

BC CB BC CB

H28

BC CB BC CB

H24

BC CB BC CB

H20

BC CB BC CB

H16

BC CB BC CB

H12

BC CB BC CB

H8

BC CB BC CB

H4

BC CB BC CB

H33

H29

H25

H21

H17

H13

H5

H1

H31

H27

H23

H19

H15

H11

H7

H3

3–21

T6090 Maintenance Manual

Table 3–6. J704 Hammer Driver Pinouts

Circuit Side of Engine Controller CBA

Top Of CBA

J704

Pin Numbers

123456789101112

U4

BC CB BC CB

H63

H64

} } } } } }

H65

U5

BC CB BC CB

H59

H60

H61

U6

BC CB BC CB

H55

H56

H57

U7

BC CB BC CB

H51

H52

H33

U8

BC CB BC CB

H47

H48

H49

U9

BC CB BC CB

H43

H44

U10

BC CB BC CB

H39

H40

H45

} } }

H41

U11

BC CB BC CB

H35

H36

H37

U12

BC CB BC CB

H66

H62

H58

H54

H50

H46

H42

H38

H34

3–22

Paper

Path

Chapter 4

Removal & Reinstallation Procedures

Removal & Reinstallation

Procedures

Paper Path

Introduction

WARNING!

HIGH VOL TAGE 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.

Chapter 4: Removal and Reinstallation Procedures

This chapter covers removal and reinstallation of selected field replaceable components and
assemblies of your 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 T ools

The following list presents the tools you will need to perform the procedures in this chapter.
All of the tools (except where noted) are included in the T6090 Tool Kit that is available
through our Spares Department.

Volt/Ohm Meter – not included in the tool kit
Platen Gap Shim Gauges – .012", .014"
Hammer Alignment Tool
Snap Ring Pliers
6" Phillips Screwdriver #1 Tip – not included in tool kit
6" Phillips Screwdriver #2 Tip – not included in tool kit
3" Phillips Screwdriver #1 Tip – not included in tool kit
8" Longnose Pliers – not include in tool kit
5/64 Hex Key Allen Wrench
1/16 Hex Key Allen Wrench – not included in tool kit
.050 Hex Key Allen Wrench
Phasing strip/gauge
5/32 Hex Allen T-Handle
Paper Belt Tension Gauge

4 –1

T6090 Maintenance Manual

Procedure 1 – The Printer Lid

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Raise the printer lid. Grasp the gas spring near where it connects to the printer cabinet. Insert

a narrow screwdriver under the spring clip on the gas spring where it attaches to the printer.
Lift the clip straight up until it unlocks and the gas spring can be easily taken off its post.

Pivot Post

Spring Clip

Small Flat Blade Screwdriver

Figure 4–1. Disconnecting the Gas Spring

The printer lid is heavy and will immediately try to come crashing down onto
whichever part of your anatomy is within reach when you remove the end of the
gas spring from its post. So be careful when you disconnect the gas spring!

4–2

Chapter 4: Removal and Reinstallation Procedures

Step 3. Slide

Lid to Left

and Off

Hinges

Step 2.

Remove
Hinge Stop

STEP 2. Grasp the printer lid by the front edge with one hand while you use a Phillips screwdriver to

remove the hinge-stop to the immediate left of the right hinge.

STEP 3. After you remove the hinge-stop, slide the lid assembly to the left to remove it from the

Reinstalling

Figure 4–2. Removing the Lid

printer. If the lid does not slide off easily, loosen the hinge screws , then try to slide the lid off
again.

To reinstall the printer lid, reverse the removal steps.

4 –3

T6090 Maintenance Manual

Procedure 2 – The Control Panel

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Raise the printer lid.
STEP 2. Insert a small, flat screwdriver straight into the slot located to the left of the Control Panel.
STEP 3. Push the screwdriver straight in until the Control Panel’s latch releases and the left edge of the

panel can be lifted up.

STEP 4. Lift Panel out gently, minimize any stress to the Control Panel cable.

If you are installing a new Control Panel, reach inside and unplug the Control Panel cable from
the Engine Controller CBA (J801).

If you are removing the Right End Cover, carefully insert Control Panel back through its
opening and rest it in the inside of the printer.

Panel Latch

Latch Release

Access Slot

Figure 4–3. Removing the Control Panel

4–4

Reinstalling

STEP 1. If the Control Panel was removed from the printer, plug the new panel into the Engine Control-

STEP 2. Insert the right edge of the Control Panel into the opening and push it all the way to the right.
STEP 3. Lower the left edge down until it rests on the edge of the opening. Push in on the latch until the

STEP 4. Push down on the left edge of the Control Panel until it is securely latched into place.

Chapter 4: Removal and Reinstallation Procedures

ler CBA (J801). Then advance to STEP 2.
If the Control Panel is still connected to the Engine Controller CBA and is lying in the inside

of the printer, lift it out of the opening gently.

Make sure the Control Panel cable is clear of the Shuttle gears. If the cable gets
entangled in the shuttle gears it may be damaged and it may also damage the
shuttle.

panel slides easily into the opening.

Figure 4–4. Reinstalling the Control Panel

4 –5

T6090 Maintenance Manual

Procedure 3 – The Right End Cover

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Printer Control Panel. (See Procedure 2)
STEP 2. Remove the screws at positions 1 and 2.
STEP 3. Loosen the screws at positions 3, 4, and 5.
STEP 4. Pull up on the front edge of the cover until it comes free of the channel it sits in. When the

front edge comes free you can lift straight up on the cover and remove it from the printer.

Step 2.

Remove 2 Screws

2.

1.

Reinstalling

4–6

3.

5.

4.

Step 4.

Step 3.

Loosen Screws

Figure 4–5. Removing the Right End Cover

STEP 1. Make sure that all connections are secure and all cables are kept away from the areas where

the cover contacts the printer.

STEP 2. Set the end cover over the Engine Controller CBA and Shuttle. Align the short lip on the front

inside edge of the cover over the lip (1) on the printer and the channel in front (2) and side (3)
of the printer.

Chapter 4: Removal and Reinstallation Procedures

Place in
front of
printer lip

1.

Place in
channel

2.

Place in
channel

3.

Figure 4–6. Reinstalling the Right End Cover

STEP 3. It may be a tight fit and require considerable downward pressure to get the cover to set down

completely. Before pressing down, make sure that all cables are clear of the contact area
between the cover and printer.

STEP 4. Reinstall the screws in position 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

T6090 Maintenance Manual

Procedure 4 –The Engine Controller CBA

Before beginning this procedure, turn the printer off and disconnect the power cable.

If you are going to replace the Engine Controller CBA, print out a Configuration report
and a Calibration Data report before you remove the old CBA. This will give you the
information you need to make sure the printer is properly set up after you finish.

Removing

STEP 1. Remove the Right End Cover (see Procedure 3).
STEP 2. Remove the Personality Module (see Procedure 5).
STEP 3. Disconnect all cables and connectors attached to the Engine Controller CBA.

Shuttle Sensor J604

Paper Drive Motor J503
Ribbon Drive Motor J502

Shuttle Drive Motor J501

Fan J2

Power Supply J302

J603 Paper Motion Sensor

J602 Paper Out Sensor

J601 Platen Open Sensor

J801 Control Panel

J901 Ribbon
Fault Detect

J704 Hammer Bank
J703 Hammer Bank

J3 Ribbon
Platform Blower

Figure 4–7. Removing the Engine Controller CBA

STEP 4. The Engine Controller CBA is secured in the printer by two Phillips screws and four counter-

sunk screws along the bottom outside edge of the CBA. Remove these screws. The Engine
Controller CBA can now be separated from the Personality Module CBA.

4–8

The Engine Controller CBA can now be removed from the printer.

Reinstalling

Chapter 4: Removal and Reinstallation Procedures

To reinstall the original Engine Controller CBA or install a new one, reverse the sequence and
actions of the removal steps.

After installing a new Engine Controller CBA, run the meter tests (as explained in the Paper
Out, Paper Motion Flt, Shuttle Fault, Platen Open, and Ribbon Fault messages in Chapter 3
and the Hammer Calibration routines provided in the TEST Menu of the printer. Use the
printouts you made earlier to set up communications and other printer operations.

4 –9

T6090 Maintenance Manual

Procedure 5 – The Personality Module CBA and Enclosure

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing The Personality Module

STEP 1. Loosen the knurled screws securing the Personality Module CBA into its enclosure, then slide

it out and set it aside.

4–10

Figure 4–8. Removing the Personality Module CBA
STEP 2. Remove the Right End Cover (see Procedure 3).
STEP 3. Remove the Engine Controller CBA (see Procedure 4).

Chapter 4: Removal and Reinstallation Procedures

STEP 4. Remove the cables from the cable support located on top of the enclosure.
STEP 5. Remove the five screws securing the enclosure to the back of the printer. Once the screws are

removed you can remove the enclosure from the printer.

Cable Support

Reinstalling

Figure 4–9. Removing the Personality Module Enclosure

To reinstall the Personality Module and its Enclosure, reverse the sequence and actions of the
above steps.

4 –11

T6090 Maintenance Manual

Procedure 6 –The Fan Assembly

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Right End Cover (see Procedure 3).
STEP 2. Remove the Engine Controller CBA (see Procedure 4).
STEP 3. Remove the Personality Module CBA and its Enclosure (see Procedure 5).
STEP 4. Remove the three screws securing the Fan Assembly to the base of the printer. You can now

lift the fan out of the printer.

Reinstalling

4–12

Figure 4–10. Removing Fan Assembly.

To reinstall the Fan Assembly, reverse the sequence of the above steps.

Procedure 7 – Power Supply

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove any printed forms along with the Paper Stacking Tray, if they are present. Disconnect

the Static Ground from the printer and remove the hood from the back of the printer.

Chapter 4: Removal and Reinstallation Procedures

Sound Deadening Hood

Static
Ground
Wire

Paper Rack

Figure 4–11. Disconnecting the Static Ground and Removing the Sound Deadening Hood

4 –13

T6090 Maintenance Manual

STEP 2. Remove Right End Cover (see Procedure 3) and disconnect the Power Supply from the Engine

Controller CBA (J302 ) and remove the cable from the cable supports (2 ea) that route the
cable to the Engine Controller CBA.

STEP 3. Remove the five screws securing the Power Supply to the printer. You can now remove the

Power Supply from the Printer.

Reinstalling

4–14

Figure 4–12. Removing the Power Supply

To install the Power Supply, reverse the sequence of the above steps.

Chapter 4: Removal and Reinstallation Procedures

Procedure 8 – The Left End Cover

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the printer lid (see Procedure 1).
STEP 2. Remove the screws in locations 1 and 2.
STEP 3. Loosen the screws in locations 3, 4, and 5 . On pedestal models, the screw in position 5 can

only be accessed if the pedestal door is partially open.

2.

3.

4.

1.

5.

Figure 4–13. Removing the Left End Cover

STEP 4. Lift up on the end cover until it clears the printer and can be removed.

Reinstalling

STEP 1. Align the lip of the cover with the lip on the printer just above screw location 5, then insert the

STEP 2. Press down on the cover until it seats in the channel.
STEP 3. Reinstall the screws at locations 1 and 2.
STEP 4. Tighten the screws at locations 3, 4, and 5.
STEP 5. Reinstall the printer lid.

lip around the base of the cover into the mounting channel on the printer.

4 –15

T6090 Maintenance Manual

Procedure 9 – The Ribbon Platform

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Open the Printer lid, raise the Form Thickness Lever, and remove the Ribbon cartridge.
STEP 2. Remove the Control Panel and lay it in the bottom of the printer (see Procedure 2).
STEP 3. Remove the Right End Cover (see Procedure 3).
STEP 4. Disconnect the Ribbon Motor cable from the Engine Controller CBA (J502). Disconnect the

Ribbon Platform Fan Assembly cable from the Engine Controller CBA (J3). You will need to
remove both cables from a cable clamp and remove a ferrite bead encircling the group of
cables that contains the Ribbon Motor cable.

STEP 4a. To remove the ferrite bead, use a pair of needlenose pliers (or equivalent) to press in

on the two tabs on the bead. Pry the two halves apart and remove the bead.

Ferrite Bead

Locking Tabs

J502

J3

Figure 4–14. Disconnecting the Ribbon Platform Components

4–16

Chapter 4: Removal and Reinstallation Procedures

STEP 5. Remove the three mounting screws that secure the Ribbon Platform to the printer. Now you

can lift the Ribbon Platform out of the printer.

Remove the three
mounting screws

Ribbon
Platform

Raise
Form Thickness
Lever

Reinstalling

Figure 4–15. Removing the Ribbon Platform

To reinstall the Ribbon Platform, reverse the sequence of removal steps.

4 –17

T6090 Maintenance Manual

Procedure 10 – The Ribbon Motor

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Ribbon Platform (see Procedure 9).
STEP 2. Remove the panduit that secures the Ribbon Motor cable to the platform. The motor can now

be removed.

STEP 3. Remove the four screws that secure the motor to the Ribbon Platform.

Reinstalling

STEP 1. Insert the motor shaft through the hole in the Ribbon Platform, then align the screw holes

STEP 2. Reinstall the Ribbon Platform.

Ribbon Motor

J502

Figure 4–16. Removing the Ribbon Motor

(make sure that the motor cable is on the side toward the Control Panel) and reinstall the motor
mounting screws. Secure the Ribbon Motor cable to the platform with a panduit.

4–18

Chapter 4: Removal and Reinstallation Procedures

Flexloop
Bracket

Cable
Clamp

Ferrite
Bead

Procedure 11 – The Hammer Bank

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Printer lid and the Control Panel (see Procedures 1 and 2).
STEP 2. Remove the Right End Cover (see Procedure 3).
STEP 3. Remove the Ribbon Platform (see Procedure 9).
STEP 4. Disconnect the Hammer Bank cables from the Engine Controller CBA (J703 & J704). Re-

move the two screws from the flex loop bracket and remove the Hammer Bank cables from the
cable clamp near the flex loop bracket.

Figure 4–17. Disconnecting the Hammer Bank

If you are replacing the Hammer Bank, remove the ferrite bead from the cable and
install it on the new Hammer Bank cable.

4 –19

T6090 Maintenance Manual

STEP 5. Remove the three screws from the Right Bearing Block.
STEP 6. Remove the two screws from the Left Bearing Block. Slide the loosened Bearing block to the

left off of the Hammer Bank shaft.

Left Hand Bearing

Block Screws

Hammer Bank

Right Hand Bearing

Block Screws

STEP 7. Remove the shuttle Motor Belt. Grasp the Shuttle Assembly firmly and carefully pull the

Reinstalling

Shuttle Assembly

Figure 4–18. Removing the Hammer Bank

Hammer Bank towards you until the bearing underneath the shuttle pulls free from the stabi­lizer block. The Hammer Bank can now be separated from the printer.

If you are installing a new Hammer Bank, you will need to remove the Shuttle Assembly
and install it on your new Hammer Bank. To remove the Shuttle see Procedure 15.

When you are ready to reinstall the Hammer Bank, reverse the above sequence of removal
steps.

Before you install the Ribbon Platform, you must reset the Platen gap described later in this
chapter (see Procedure 25).

Perform a Hammer Calibration to adjust for optimum print quality. (Hammer calibration is
explained in Chapter 2, under PrntCal Parameter.)

4–20

Chapter 4: Removal and Reinstallation Procedures

Procedure 12 – The Ribbon Shield

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Left End Cover (see Procedure 8).
STEP 2. Remove the Right End Cover (see Procedure 3).
STEP 3. Remove the Ribbon Platform (see Procedure 9).
STEP 4. Remove the Hammer Bank (see Procedure 11).
STEP 5. Using a .050" Allen wrench, (in tool kit 081147) remove the four screws that secure the

Ribbon Shield to the Hammer Bank.

Be careful when handling the Ribbon Shield. It can be bent easily, which can
affect operation of the printer. It also has very sharp edges that can put a real
hurt on you if you aren’t careful how you handle it.

Ribbon Shield

Screws, 4x

Hammer Bank

Assembly

Ribbon
Shield

Figure 4–19. Removing the Ribbon Shield

4 –21

T6090 Maintenance Manual

Reinstalling

To reinstall the Ribbon Shield, reverse the sequence and actions of the removal steps. Make
sure the shield is flush against the Hammer Bank, and the tips of the hammers themselves are
centered in the holes of the Ribbon Shield.

After installing a new Ribbon Shield, check for proper platen gap alignment (see Proce­dure 25) and perform a Hammer Calibration. (Hammer calibration is explained in

Chapter 2, under PrntCal Parameter.)

4–22

Chapter 4: Removal and Reinstallation Procedures

Procedure 13 – Hammer Bank Air Duct

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removal

STEP 1. Remove the Hammer Bank (see Procedure 11).
STEP 2 Remove the cable clamp bracket and screw.
STEP 3. Remove the six screws that attach the airduct to the Hammer Bank. You now can remove the

airduct from the Hammer Bank.

Hammer Bank

Air Duct

Cable Clamp

Air Duct Mounting

Screws, 6x

Reinstallation

To reinstall, reverse the sequence of removal.

Cable Clamp

Screw

Figure 4–20. Removing Hammer Bank Air Duct

4 –23

T6090 Maintenance Manual

Hammer
Interconnect
CBA

Ribbon Shield

Alignment Plate

6-Pack Hammer

Module

Hammer Bank Carriage

Module Mounting
Screws (2)

Hammer Interconnect CBA

Fold Back Tape

Procedure 14 – Hammer Module

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Hammer Bank from the printer (see Procedure 11).
STEP 2. Remove the Ribbon Shield from the Hammer Bank (see Procedure 12).

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.

STEP 3. Remove the Air Duct and Cable Clamp from the Hammer Bank (see Procedure 13).
STEP 4. Each module has six hammers and is held in place on the carriage by two screws on the

backside of the Hammer Bank. Remove these screws and the individual module can be
removed.

Before removing a defective module, insert strips of tape between it and the
modules immediately adjacent to it. This will protect the coils on adjacent
modules during removal and reinstallation.

4–24

Figure 4–21. Removing and Replacing the Hammer Module.

Reinstalling

STEP 1. Install the new Module on the Hammer Bank. Use the Hammer Alignment Tool (#080614

Chapter 4: Removal and Reinstallation Procedures

available in tool kit, #081147) to realign the Hammers. Tighten the two mounting screws, then
reinstall the Ribbon Shield.

Hammer AllignmentTool

Figure 4–22. Using the Hammer Alignment Tool

STEP 2. Reinstall the Hammer Bank.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust as
necessary (see Procedure 25).

P/N 080614

6-Pack
Hammer
Modules

After completing the installation, perform a Hammer Calibration to maintain optimum print
quality (see PrntCal Parameter in Chapter 2).

4 –25

T6090 Maintenance Manual

Procedure 15 – The Shuttle Assembly

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Right End Cover (see Procedure 3).
STEP 2. Remove the Ribbon Platform (see Procedure 9).
STEP 3. Remove the Hammer Bank (see Procedure 11).
STEP 5. Using a 5/32" T-handled allen driver, (in tool kit 081147) remove the two hex screws connect-

ing the Hammer Bank to the right bearing block. The shuttle assembly can now be separated
from the Hammer Bank.

Tie

You will need to rotate
the shuttle gears to get
appropriate access to
remove the screws
securing the shuttle
assembly to the
Hammer Bank shafts.

Tie Block

Screws

Blocks

Shuttle
Assembly

Shuttle Screws

Extreme care must
be taken not to strip
the screws when
reinstalling the hex
screws that connect
the Hammer Bank to
the shuttle assem­bly.

Reinstalling

To reinstall the shuttle assembly, reverse the sequence and actions of the removal procedure.

Loosen the two tie block screws for easier installation. Remember to tighten up any loose
screws before reinstalling the Hammer Bank into printer.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust as
necessary (see Procedure 25).

After completing the installation, perform a Hammer Lead Time Calibration Routine (see
Chapter 2, under the PrntCal Parameter) to adjust for optimum printed output.

Right
Bearing Block

Figure 4–23. Shuttle Assembly Removal

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Procedure 16 – The Platen

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Hammer Bank (see Procedure 11).
STEP 2. Remove the Left End Cover (see Procedure 8).
STEP 3. Remove the two springs (one on each end of the platen) that hold the platen in place.

Disconnect the Platen Open Sensor from the left end of the platen, then lift the Platen out of
the printer.

It may help to disconnect it if you first disconnect the sensor cable (J601) from the Main
Controller CBA to allow some slack in the cable.

The Platen Open Sensor is held in place on the Platen by two small plastic tabs.
Be careful not to damage them when you disconnect the sensor from the
Platen.

Chapter 4: Removal and Reinstallation Procedures

Platen Open

Sensor

Remove Springs­Right and Left ends
of the Platen

Figure 4–24. Removing the Platen

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T6090 Maintenance Manual

Reinstalling

STEP 1. Reconnect the Platen Open Sensor to the Platen.

It is possible that the end assemblies of the platen may come off of the platen when you
remove it. When you reassemble the platen make sure ALL parts are included. Some
parts are small (for example, the spring washers on the right end of the platen) and are
easily lost. Refer to the figure below to identify the parts and the installation sequence.

Platen Adjust Plate

Platen
Adjust
Plate

Platen - Left End

Platen Open
Sensor

Form
Thickness
Lever

Platen

Curved Spring

Washers

Platen - Right End

Figure 4–25. Platen End Assemblies
STEP 2. Place the springs back on the ends of the platen and secure it in place.
STEP 3. Reinstall the Hammer Bank.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust as
necessary (see Procedure 25).

After completing the installation, perform a Hammer Calibration to maintain optimum print
quality (see PrntCal Parameter in Chapter 2).

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Chapter 4: Removal and Reinstallation Procedures

Procedure 17 – The Platen Open Sensor

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removing

STEP 1. Remove the Platen from the printer (see Procedure 16).
STEP 2. Disconnect the Platen Sensor cable (J601) from the Engine Controller CBA, remove the cable

from any cable supports and remove the ferrite bead encircling the cables.

STEP 4. The Platen Open Sensor is secured to the end of the platen detent plate by two plastic tabs,

release the tabs and the sensor will come free.

Platen
Alignment Plate

J601

Platen
Open Sensor

Reinstalling

STEP 1. Snap the new sensor into place on the Platen detent plate. Plug the Platen Open Sensor cable

STEP 3. Turn power on and open the platen all the way. The control panel display should read

STEP 4. Finish the installation by reinstalling all other components you have removed.

Detent

Plate

Platen

Assembly

Figure 4–26. Removing the Platen Open Sensor

(J601) into the Engine Controller CBA and reinstall the platen.

PLATEN OPEN if new sensor is functioning properly.

Before you reinstall the Ribbon Platform, check the hammer to platen gap and adjust as
necessary (see Procedure 25).

After completing the installation, perform a Hammer Calibration Routine (as explained in
Chapter 2, under the PrntCal Parameter) to adjust for optimum printed output.

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T6090 Maintenance Manual

Procedure 18 – The Shuttle Motor

Before beginning this procedure, turn the printer off and disconnect the power cable.

Removal

STEP 1. Remove the Right End Cover (see Procedure 3).
STEP 2. Unplug the Shuttle Stepper Motor (J501) from the Engine Controller CBA. Remove the

shuttle motor cable from any cable supports and remove the ferrite bead encircling the cable.
STEP 3. Remove the Shuttle Drive Belt (see Procedure 20 ).
STEP 4. Remove all but one of the four mounting screws from the Shuttle Motor, then while supporting

the motor with one hand remove the last screw. The Shuttle Motor can now be removed from

the printer.

Mounting
Bracket

Shuttle Motor
Pulley

J501

Shuttle
Motor

Figure 4–27. Removing the Shuttle Motor

STEP 5. Loosen the set screw that secures the Shuttle Motor Drive Pulley to the motor output shaft,

then remove the pulley from the old motor for installation onto the new motor.

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