Tally T6215 Maintenance Manual

T6215

Maintenance Manual

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 interfe rence, in which case the user will be required to correct the interference at
his own expense.

Manual Reference #083644

Tally Printer Corporation

8301 South 180th Street

Kent, Washington 98032

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© May 2000
Tally Printer Corporation
All rights reserved
Printed in the United States

Table of Contents

Table of Contents

Table Of Contents

Table of Contents

Preface

About This Manual.................................................................................................................................. Pref–1

Chapter 1. Technical Overview ........................................................................................................ Pref–1

Chapter 2. Menu Operations ............................................................................................................ Pref–1

Chapter 3. Faults and Troubleshooting ............................................................................................. Pref–1

Chapter 4. Removing and Replacing Components ............................................................................ Pref–1

Appendix A. Schematics and Illustrated Parts Breakdowns ............................................................... Pref–1

Appendix B. Downloading Printer Firmware .................................................................................... Pref–1

Conventions ...................................................................................................................................... Pref–1

Chapter 1: Technical Overview

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

T6215 Electronic Hardware Architecture..................................................................................................... 1–1

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

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

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

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

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

Serial and Parallel Interfaces ................................................................................................................. 1–2

Serial ............................................................................................................................................... 1–2

Parallel ............................................................................................................................................ 1–2

Main Processor ..................................................................................................................................... 1–2

Motorola Cold Fire 5307 ................................................................................................................. 1–2

Altera EPM7064 .............................................................................................................................. 1–2

Table 1–1. Host Interface Configurations ........................................................................................ 1–2

Hammer Drive Module ......................................................................................................................... 1–3

Specifications .............................................................................................................................................. 1–3

Serial/Parallel Emulations ...................................................................................................................... 1–3

Font Styles ............................................................................................................................................. 1–3

Courier and Gothic ......................................................................................................................... 1–3

Data Processing and Draft ............................................................................................................... 1–3

OCR-A and OCR-B.......................................................................................................................... 1–3

Characters Per Inch ............................................................................................................................... 1–3

Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations................................. 1–4

Lines Per Inch ....................................................................................................................................... 1–4

Dot Densities and Plot Speeds ............................................................................................................... 1–5

Table 1–3. Plot Data Output Speed................................................................................................. 1–5

Graphics Benchmarks ........................................................................................................................... 1–5

Table 1–4. AIAG Label Benchmark Results ..................................................................................... 1–5

Table 1–5. POSTNET Label Benchmark Results .............................................................................. 1–5

Paper Slew Speed .................................................................................................................................. 1–6

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T6215 Maintenance Manual

Table 1–6. Slew Speed.................................................................................................................... 1–6

Ribbons ................................................................................................................................................. 1–6

Forms/Paper Description ....................................................................................................................... 1–6

Acoustics .............................................................................................................................................. 1–6

Power Supply ........................................................................................................................................ 1–6

Table 1–7. Power Requirements ..................................................................................................... 1–6

Cooling System ..................................................................................................................................... 1–6

Safety .................................................................................................................................................... 1–7

Preventive Maintenance ........................................................................................................................ 1–7

Environment .......................................................................................................................................... 1–7

Operating ........................................................................................................................................ 1–7

Nonoperating .................................................................................................................................. 1–7

Heat Load Contribution ......................................................................................................................... 1–7

Table 1–8. Heat Load Contribution ................................................................................................. 1–7

Physical Configuration .......................................................................................................................... 1–8

Weight ............................................................................................................................................ 1–8

Printer Dimensions ................................................................................................................................ 1–8

Table 1–9. Printer Dimensions ........................................................................................................ 1–8

Industry and Agency Standards.............................................................................................................. 1–8

Electromagnetic Emissions .................................................................................................................... 1–8

Agency Approvals ................................................................................................................................. 1–8

Chapter 2: Menu Operations

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

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

How To Enter Tech Access Mode........................................................................................................... 2–1

How to Exit 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 In Tech Access Mode .............................................................................. 2–2

Report ............................................................................................................................................. 2–3

Report selections ....................................................................................................................... 2–3

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

TEST Menu.................................................................................................................................................. 2–4

Table 2–1 Test Menu....................................................................................................................... 2–4

Pattern Category .................................................................................................................................... 2–6

Print ................................................................................................................................................ 2–6

Print selections .......................................................................................................................... 2–6

Print2 .............................................................................................................................................. 2–6

Print2 selections ........................................................................................................................ 2–6

Plot ................................................................................................................................................. 2–7

Plot selections ........................................................................................................................... 2–7

Selecting And Running a Print Test ............................................................................................ 2–8

ii

Table Of Contents

Hammer .......................................................................................................................................... 2–8

Fault Override Category ........................................................................................................................ 2–8

Paper Motion .................................................................................................................................. 2–8

Paper Out........................................................................................................................................ 2–8

Ribbon Motion ................................................................................................................................ 2–9

Shuttle ............................................................................................................................................. 2–9

Temp ............................................................................................................................................... 2–9

Platen .............................................................................................................................................. 2–9

Control ............................................................................................................................................ 2–9

Link ................................................................................................................................................. 2–9

Sync ................................................................................................................................................ 2–9

Diagnostic Category .............................................................................................................................. 2–9

Calibrations ..................................................................................................................................... 2–9

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

Figure 2–1. Hammer Leadtime Calibration Printout Sample (partial) ............................................. 2–11

Selecting And Running a Platen Gap Calibration Routine ........................................................ 2–11

Meter ............................................................................................................................................ 2–12

Accessing the Meter Measurement Tests: ................................................................................. 2–12

Motors........................................................................................................................................... 2–13

Accessing the Motor Tests: ....................................................................................................... 2–13

Motor selections ...................................................................................................................... 2–13

Shuttle Speed ................................................................................................................................ 2–13

Shuttle Speed selections: ......................................................................................................... 2–13

Ribbon Speed ................................................................................................................................ 2–13

Speed selections: .................................................................................................................... 2–13

Ribbon Threshld ............................................................................................................................ 2–14

Threshold selections: ............................................................................................................... 2–14

Paper Out Thold............................................................................................................................ 2–14

Energy Star .................................................................................................................................... 2–14

Clear ............................................................................................................................................. 2–14

Clear selections ....................................................................................................................... 2–14

Shuttle Off ..................................................................................................................................... 2–14

Shuttle Change .............................................................................................................................. 2–14

Ribbon Ink, Dots per Pump ........................................................................................................... 2–14

Serial Dump .................................................................................................................................. 2–14

Control Panel Key Operations For Controlling Fault Reporting ............................................................ 2–15

ALL Fault Reporting ....................................................................................................................... 2–15

Four Faults Only............................................................................................................................ 2–15

Paper Out Only ............................................................................................................................. 2–15

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T6215 Maintenance Manual

Chapter 3: Faults and Troubleshooting

Faults .................................................................................................................................................... 3–1

Table 3–1. Display Messages .......................................................................................................... 3–3

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

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

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

Character columns not printing ........................................................................................................... 3–13

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

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

Figure 3–1. Power On Troubleshooting Sequence........................................................................ 3–18

Figure 3–1a. Power On Troubleshooting Sequence, Continued.................................................... 3–19

Figure 3–2. Print Data Troubleshooting Sequence ........................................................................ 3–20

Figure 3–2a. Print Data Troubleshooting Sequence, Continued .................................................... 3–21

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

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

Figure 3–2d. Print Data Troubleshooting Sequence, Continued.................................................... 3–24

Chapter 4: Removing and Replacing Components

Introduction ................................................................................................................................................ 4–1

Required Tools ...................................................................................................................................... 4–1

Service Procedures ...................................................................................................................................... 4–2

Procedure 1: Ribbon Platform Removal....................................................................................................... 4–3

Figure 1. Loosening screws on Ribbon Platform. ............................................................................ 4–3

Figure 2. Unplugging Ribbon Drive Motor cable. .......................................................................... 4–3

Procedure 2: Ribbon Motor Removal .............................................................................................. 4–4

Figure 3. Removing motor screws. ................................................................................................. 4–4

Figure 4. Unplugging Ribbon Motor cables. .................................................................................. 4–4

Procedure 3: Ribbon Motion Sensor PCA Removal...................................................................................... 4–5

Figure 5. Removing PCA screws. ................................................................................................... 4–5

Procedure 4: Control Panel Removal........................................................................................................... 4–6

Figure 6. Unplugging Control Panel cable. .................................................................................... 4–6

Procedure 4a: Control Panel Circuit Board removal ............................................................................. 4–7

Figure 7. Removing circuit board screws. ...................................................................................... 4–7

Procedure 5: Hammer Bank Removal.......................................................................................................... 4–8

Figure 8. Removing plastic cable cage. .......................................................................................... 4–8

Figure 9. Unplugging Hammer Bank ribbon cables........................................................................ 4–8

Figure 10. Removing screws on retainer clips. ............................................................................... 4–9

Figure 11. Removing nuts from underneath Hammer Bank. ........................................................... 4–9

Figure 12. Lifting Hammer Bank from printer. .............................................................................. 4–10

Figure 13. Replacing Shuttle Drive belt. .......................................................................................4–10

Procedure 6: Ribbon Shield Removal ........................................................................................................ 4–11

Figure 14. Removing the Ribbon Shield. ...................................................................................... 4–11

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Table Of Contents

Procedure 7. 13-pack Hammer Replacement ........................................................................................... 4–12

Figure 15. Measuring old hammer for replacement size ............................................................... 4–12

Figure 16. Aligning the new hammer pack................................................................................... 4–13

Procedure 8: Coil Board Replacement...................................................................................................... 4–14

Figure 17. Coil board replacement. ............................................................................................. 4–14

Procedure 9: Shuttle Removal ................................................................................................................... 4–15

Figure 18. Removing Shuttle screws. ........................................................................................... 4–15

Figure 19. Removing screws from inside shuttle. ......................................................................... 4–15

Procedure 10: Platen Removal .................................................................................................................. 4–16

Figure 20. Location of circuit board. ............................................................................................ 4–16

Figure 21. Removing the Platen Springs. ...................................................................................... 4–17

Figure 22. Removing screws from the platen stop. ....................................................................... 4–18

Figure 23. Transferring components from old to new platen......................................................... 4–19

Figure 24. Adding grease. ............................................................................................................ 4–20

Procedure 11: Platen Gap Adjustment ...................................................................................................... 4–22

Figure 25. Platen Adjustment screws and use of shim. ................................................................. 4–23

Procedure 12: Print Mechanism Access (Tilting) ....................................................................................... 4–24

Figure 26. Unplugging the Power Supply cable. .......................................................................... 4–24

Figure 27. Print Mechanism tilted and held by strut. .................................................................... 4–25

Procedure 13: Distribution PCA Removal ................................................................................................. 4–26

Figure 28. Removing screws on mounting bracket. ...................................................................... 4–26

Procedure 14: Lower Tractor Removal...................................................................................................... 4–27

Figure 29. Location of Paper Out sensor cables. .......................................................................... 4–27

Figure 30. Removing Retaining (Snap) rings. ................................................................................ 4–27

Figure 31. Ground spring. ............................................................................................................. 4–28

Figure 32. Round and square shafts. ............................................................................................. 4–28

Procedure 15: Upper Tractor Removal ..................................................................................................... 4–30

Procedure 16: Tractor Phasing/Paper Drive Belt Tension Adjustment ........................................................ 4–31

Figure 33. Tractor phasing and paper drive belt. .......................................................................... 4–31

Figure 34. Paper Tension Lever in middle position. ...................................................................... 4–32

Figure 35. Placing the Phasing Gauge .......................................................................................... 4–32

Figure 36. Placing Tension Gauge................................................................................................ 4–33

Figure 37. Placing Paper Tension Gauge. ..................................................................................... 4–34

Procedure 17: Paper Drive Motor Removal .............................................................................................. 4–35

Figure 38. Paper Drive Motor location. ........................................................................................ 4–35

Procedure 18: Shuttle Motor Removal ...................................................................................................... 4–36

Figure 39. Shuttle Motor .............................................................................................................. 4–36

Procedure 19: Control PCA Assembly Removal ........................................................................................ 4–37

Figure 40. Front of Control PCA assembly after cover has been removed. .................................... 4–37

Procedure 20: Power Supply Assembly Removal...................................................................................... 4–38

Figure 41. Power Supply Assembly. ............................................................................................. 4–38

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T6215 Maintenance Manual

Appendix A: Illustrated Parts Breakdowns and Schematics

Illustrated Parts Breakdowns and Schematics .............................................................................................. A–1

Appendix B:

Firmware Update Procedure ....................................................................................................................... B–1

vi

Preface

Preface

About This Manual

This manual presents maintenance, alignment, and troubleshooting procedures for the
T6215 printer. Also included are all schematics and diagrams necessary for repair and
maintenance. The following chapter and appendix summaries will provide you with a
survey of the manual contents.

Chapter 1. Technical Overview

In Chapter 1, you will find detailed descriptions of the technical aspects of your printer.
In addition, design and operational specifications are discussed.

Chapter 2. Menu Operations

In Chapter 2, you will find the Menu Operations concerned with troubleshooting and
maintaining your printer.

Chapter 3. Faults and Troubleshooting

This chapter contains a listing of the error and fault messages that may appear on the
Control Panel Display and various troubleshooting procedures and problem fixes.

Chapter 4. Removing and Replacing Components

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

Preface

Appendix A. Schematics and Illustrated Parts Breakdowns

In appendix A schematics are given to assist you in troubleshooting problems and
locating components that control your printer operations. Also included are exploded
views of all printer components along with detailed parts listings.

Appendix B. Downloading Printer Firmware

In this appendix, instructions are given on downloading firmware for your printer.

Conventions

We use the following conventions throughout this manual.

Notes may be considered as supplementary information.

This symbol marks information about actions that may damage the equipment
or injure the user.

These statements list special instructions, warnings, or reminders about printer
operations.

Pref–1

T6215 Maintenance Manual

Pref–2

Blank

Page

Chapter 1:

Technical Overview

Chapter 1

Technical Overview

The T6215 is a high speed, low cost, line impact dot matrix printer. It's maximum
print speed is 1500 lines per minute in uppercase draft text mode. It prints many
fonts in a number of languages, and plots raster graphics and images at a wide
variety of dot densities. The T6215 comes standard with Serial and Parallel inter­faces and supports other interfaces through the use of user-installable PSIO inter­face cards. OEM add-in cards are supported via an internal IEEE 1284 connector.
The T6215 does not accept the T6090/T6180 "Personality Module" cards.

T6215 Electronic Hardware Architecture

The electronic design of the T6215 is implemented in two basic modules: the
Engine Control Module and the Hammer Driver Module.

Engine Control Module

The primary components of the Engine Control Module are:

• Main Processor - Motorola Cold Fire

• Flash Memory - 2 M-bytes

• SDRAM - 2 M-bytes

• EPLD - Altera EPM 7064

• Interface - specific devices

• Control Processor – Intel 87C196KC

• Sensor Inputs

• Motor logic and drive

• EEPROM – 24C64

Chapter 1. Technical Overview

®

5307

Control Processor

Sensor Inputs

• 20 MHz clock

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

• High speed inputs for synchronizing timing of the shuttle 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 and Ribbon microcontroller

• Port control of control panel, and hammer loading

• Paper motion – optical

• Paper out – optical

• Platen gap – Hall-effect

• Shuttle motion – optical

• Ambient temperature – thermistor

• Power supply voltage – resistor divider

• Ribbon motion - optical

• Ribbon weld detect - optical

1–1

T6215 Maintenance Manual

Motor logic and drive

• 8 Hz bridge Motor drive chips (2 for ribbon, 2 for shuttle, 2 for paper,
and 2 for ribbon ink pump) – Allegro 3952

EEPROM

The EEPROM stores engine calibration and printer configuration settings.

Serial and Parallel Interfaces

Serial

• MC145407 (5V) chip is used for the RS-232 drivers and receivers

• 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 74LS374/74LCX244 – supports IEEE-1284 compat­ibility and nibble modes

Main Processor

Motorola Cold Fire 5307

• 56MHz clock

• 32-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 of CPU communication, and
one for the external serial interface

• Internal SDRAM controller

Altera EPM7064

• Logic for IEEE-1284 Parallel interface

• Logic for PSIO Interface

The following table shows host interface configuration options

Table 1–1. Host Interface Configurations

Personality Module Standard Ser/Par LANPlex FourPlex

Host I/Os IEEE 1284 IEEE 1284 IEEE 1284

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

Ethernet Twinax

Coax

Optional Configurations IPDS IPDS

1–2

Hammer Drive Module

Specifications

Serial/Parallel Emulations

Nine emulations are available on the T6215: 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.

Chapter 1. Technical Overview

• resident on shuttle/hammer assembly

• hammer drive ASICs

• hammer drive transistors

• cold drive energy damping diodes

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 T6215 offers a variety of CPIs for use in printer output, which are dictated by
the font style selected. Each CPI is based on one of twelve character matrixes and
twelve dot densities. Each matrix uses a specific number of dot columns for
character composition and intercharacter gap. CPIs are grouped in any given type
style by the base CPI matrix used for the group. These base CPIs are 10, 12, and

15.

1–3

T6215 Maintenance Manual

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

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

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

& 13.33 15, 16.67, 17.14, & 20

Near Letter Gothic Base Matrix: 17 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

Quality Dot Density: 90 x 96 Dot Density: 90 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: 17 x 16 Base Matrix: 13 x 16 Base Matrix: 9 x 16

Dot Density: 90 x 96 Dot Density: 90 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: 17 x 24

Dot Density: 90 x 144
CPIs: 10

Lines Per Inch

1–4

Ten lines per inch (LPI) settings are available through the control panel. They include

1.5, 2, 3, 4, 5, 6, 8, 9, 10, and 12 LPI. In some emulations the availability of certain
LPI’s are restricted.

Dot Densities and Plot Speeds

The T6215 printer supports Horizontal row plots (single and multiple row), Vertical
column plots, and specialized Graphic plots.

It supports the following horizontal DPIs: 40, 48, 60, 80, 90, 120, 180, and 240.
Scaled densities available on your printer are 50, 72, 75, 96, 100, 144, 150, 160,
and 200. All other selections will be approximated by conversion to the next
higher density.

Your printer supports the following vertical DPIs: 48, 72, 96,144, and 288. All
other selections are emulated through the use of scaling techniques.

Table 1–3. Plot Data Output Speed

Chapter 1. Technical Overview

Dot Plot Print Speed

Hor./Vert. Inches Per Min.

60 x 48 187
60 x 72 125

120 x 72 62

240 x 288 7.8

Graphics Benchmarks

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

The AIAG test consisted of a series of labels printed two across repeated vertically
with a 0.1 inch 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. Code V and
PGL had the same results.

Table 1–4. AIAG Label Benchmark Results

60 (Normal) 120 (Dark)

3660 LPH 2460 LPH

Table 1–5. POSTNET Label Benchmark Results

4-Up Draft 60,950 LPH

1–5

T6215 Maintenance Manual

Paper Slew Speed

Table 1–6. Slew Speed

Ribbons

The T6215 is designed to operate optimally with Tally ribbon cartridges. These
cartridges are designed for easy access and loading.

Forms/Paper Description

The T61215 is designed to use continuous, sprocket feed type paper, 3.0 to 17.25
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.)

Form Weight Maximum Slew Speed

Light and Medium 36 Inches Per Second

Heavy 20 Inches Per Second

Acoustics

The noise generated by the T6215 printer is 6.7 Bel (sound power level) and 52
dB(A) (sound pressure level) per ISO 7779:1999E.

Power Supply

The printer requires single phase, 47 to 63 Hz. 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 1–7. Power Requirements

AC Volts Frequency Average Peak Average Average

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.

External Power Current/Wattage Requirements

Supply @ Nominal Voltage

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

110 50 2.00 A/215 W 5.5 A/600W 0.5A/55 W 0.3 A/30 W

110 60 2.00 A/215 W 5.5 A/600 W 0.5 A/55 W 0.3 A/30 W

220 50 1.00 A/215 W 2.8 A/600 W 0.3 A/55 W 0.2 A/30 W

1–6

Safety

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

Preventive Maintenance

The T61215 is designed to eliminate the requirement of scheduled maintenance
procedures, such as alignment, adjustment, or lubrication. 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

Chapter 1. Technical Overview

Temperature

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

Humidity: 10 to 90% noncondensing with a maximum

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

Altitude: To 8,000 ft. (2438 meters)

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.

Heat Load Contribution

The average heat load contribution to the environment is approximately 1075
BTUs per hour (315 Watts) with a maximum potential of 3000 BTUs per hour (880
Watts) under continuous full-load printing conditions.

Table 1–8. Heat Load Contribution

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

Power On, not printing 55 188

100% Uppercase Rolling ASCII 400 1370

Black Page Plot 600 2050

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 Asso-

ciation) requirements.

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T6215 Maintenance Manual

Physical Configuration

The T6215 printer is only available in the Quietized Cabinet.

Weight

The printer has an actual weight of 185 lbs and a shipping weight of 225 lbs.

Printer Dimensions

Table 1–9. Printer Dimensions

Door Opening (paper loading) 22.7"

Dimension Parameter Printer Measurement

Height 40.0"

Height/Lid Open 62.2"

Width 28.8"
Depth 28.3"

Industry and Agency Standards

The T6215 is designed to meet the requirements of several industry and Govern­ment agency standards.

Electromagnetic Emissions

EMI: FCC part 15, subpart J, Class A and EN5022 Class B
ESD: EN 61000-4-2 (REF. Q1012)
RF: EN 61000-4-3
Power Line: 61000-4-4
Transients: 61000-4-5
RF: 61000-4-6
Energy Star Compliant

Agency Approvals

United States

The T6215 complies with ANSI UL 1950, C22.2 No. 950-95, and EN 60950:1992
including Amendments 1, 2, 3, and 4 safety requirements.

IEC 60950: 1991 plus Amendment 1, 2, 3, and 4, and National Deviations AT,
AU, BE, CA, CH, CZ, DE, DK, ES, FI, FR, GB, GR, HU, IE, IT, JP, KR, NL, NO, SE,
SG, SL, US and Group Differences per CB Bulletin 94AI (Mar 99)

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Chapter 2:

Menu Operations

Chapter 2

Introduction

The Test menu contains procedures for calibrating sensors, turning motors on and off, changing
hammer lead time, running various printer tests, etc. These procedures are located in the Config
and Test menus and can be accessed through the Control Panel.

Technical Access Mode

Technical (Tech) Access Mode is provided for the repair technician. It allows you to access
tests, calibration, and diagnostic procedures, unavailable in normal menu operations, for use in
troubleshooting. Once Tech Access is enabled, these menu items appear on the Control Panel
Selections Printout (the Help menu printout).

How To Enter Tech Access Mode

Place the printer Offline. Press Line Feed and Enter simultaneously and hold for 3 seconds.
Release the keys when the alarm sounds and "Tech Access On" displays. At this point, the
printer defaults to the Powerup configuration.

How to Exit Tech Access Mode

There are two methods for leaving Tech Access Mode.

Chapter 2. Menu Operations

1. Place the printer Offline. Press Line Feed and Enter simultaneously. Release the keys

when the alarm sounds.

OR

2. Cycle power.

Upon leaving Tech Access mode, the printer defaults to the Powerup configuration.

Testing, Troubleshooting and Calibration

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

Printer Tests

Printer tests appear in both normal menu operations and in Tech Access Mode. These tests
consist of the following patterns and types:

• ASCII print patterns

• Plot Mode patterns

• Calibration routines

• Electronic hardware tests

Detailed explanations of the print tests follow in the Test Menu section of this chapter.

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T6215 Maintenance Manual

Hex Dumps

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

Style 1 Text, spaces, and control codes print out in hexadecimal format.

Make sure that wide paper (136 columns — 13+ inches of printable width) is loaded on the
printer before running a Style 1 Hex Dump.

Style 2 Control codes print out in hexadecimal format while text and spaces print out in

their original form.

Style 3 Control codes and spaces print in hexadecimal format, while text prints out in its

original form.

Printer Information Printouts and Displays

There are fifteen printouts and displays accessible through the printer control panel. The first
printout is the Help menu and the rest are Printer Reports (Current Config, All Configs, Configs
1-10, Calibrations, Last Fault, and Version). These reports can be accessed via the Configuration
menu, Printer category, under the Report parameter.

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. Place the printer Offline.

STEP 2. Press the Line Feed and Enter keys simultaneously until the printer alarm sounds, then

release them to place the printer in Tech Access Mode.

STEP 3. Press the Menu/Back Key to enter the multilevel menu system, then scroll (▲ Keys) to

the Help menu.

STEP 4. Press Enter to begin printing the Help menu.

This printout will end when the entire Help menu is printed out.

2–2

Report

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

Report selections

Configs Prints a report showing the setups of the configurations.
Calibrations Prints a report showing the current values of the Paper Out and Paper Motion

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

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 Menu/Back key to enter the multilevel menu system, then scroll (▲ Key)

Chapter 2. Menu Operations

sensors and the hammer lead time and shuttle amplitude.

firmware.

to the Config menu. Press Enter

Step 3. Scroll (▲ Key) until the Printer Category displays. Press Enter.

Step 4. Scroll (▲ Key) until the Report Parameter is displayed. Press Enter.

Step 5. Scroll (▲ Key) to the desired selection.

Step 6. Press Enter to begin the report printout or display.

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T6215 Maintenance Manual

TEST Menu

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

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

Table 2–1 Test Menu

Use the ▲ Key to scroll to the
desired selection.

Use the ENTER Key to select
a value or option.

Categories Parameters Selections

Pattern Print Upper

All Characters
63/69
ECMA
Columns

Print2 Paper Save

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

Plot Grid

Cross
Gray
Black
Block

Fault Override Paper Motion OFF

ON

Ribbon Motion OFF

ON

Paper Out OFF

ON

Shuttle OFF

ON

Temp OFF

ON

Platen OFF

ON

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Chapter 2. Menu Operations

Categories Parameters Selections

Control OFF

ON

Link OFF

ON

Sync OFF

ON

Diag Calibrations Hammer

Paper Out
Platen Gap Cal

Meter Paper Out

Paper Motion
Ribbon Weld
Hammer Bus
Temp Sensor
Power
Platen
Keypad

Motors Ribbon

Shuttle
Ribbon Pump

Blower

Shuttle Speed 37-80

Ribbon Speed 1–250

Paper Out Thold 0–255

Energy Star On

Off

Clear Calibrations

Counts
NVRAM

Shuttle Off 10 Sec

20 Sec

30 Sec

60 Sec

Shuttle Change 1-30

Ribbon Ink,

Dots/Pump 500-2000

Serial Dump Disabled

Enabled

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T6215 Maintenance Manual

Pattern Category

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

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

Print selections

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 a 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, press Enter or Clear.

Print2

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

Print2 selections

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.

Paper Save 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.

Thermal Cycle 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.

2–6

Plot

Plot selections

Chapter 2. Menu Operations

All E's This option prints lines composed of the uppercase letter E.

All #'s This option prints lines composed of the # symbol.

All +'s This option prints lines composed of the + sign.

Parens This option prints lines composed of the left paren followed by a vertical bar

followed by the right paren.

Rubout This option prints lines composed of the currently selected fill character.

Ribbon This option prints lines composed of rolling ASCII uppercase characters.

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.

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.

Proper alignment of the hammer bank components is indicated by clean lines and
uniform patterns.

Cross This option prints a crosshatch pattern of diagonal lines that can be used to check

linearity of dot placement. Clean lines and uniform pattern are used to indicate
linear shuttle action.

Gray This option prints a grayscale pattern at 60 x 72 DPI. This test fires all hammers

(printing every other dot vertically and horizontally), which should lay down an
even gray tone across the page. Any change 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 x 72 DPI matrix. The Black Page Print

Mode is the most dense print test that can be run for verifying the proper operation
of the printer’s power supply. This test places the greatest electrical current load on
the power supply as well as increasing the thermal load on the electronics.

When performing this test, it is considered normal for the print rate to slow as the
current and thermal limits are reached. If the power supply shuts down, rather than
simply slowing down, the power supply may need replacement.

Block This option prints alternating bars at 60 x 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

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T6215 Maintenance Manual

shading. If not, parameters such as individual hammer module heights and align­ments should be checked.

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 with the Menu/Back key, then scroll until it displays.

Step 3. Scroll (▲ Key) until the Pattern Category is displayed. Press Enter.

Step 4. Scroll (▲ Key) until the desired Print Test parameter (Print, Print2, or Plot) is dis-

played. Press Enter

Step 5. Scroll (▲ Key) to the desired test pattern.

Step 6. Press Enter 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 the Enter key.

Fault Override Category

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

Paper Motion

This parameter provides fault override for Paper Motion Faults.

Paper Out

This parameter provides fault override for Paper Out Faults.

2–8

Ribbon Motion

This parameter provides fault override for Ribbon Motion Faults.

Shuttle

This parameter provides fault override for Shuttle Fault reporting.

Temp

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

Platen

This parameter provides fault override for the Platen Open Sensor.

Control

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

Link

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

Sync

This parameter provides fault override for the "Lost Sync (28)" error in Twinax Interface Mode.
Check printer cable connection.

Chapter 2. Menu Operations

Diagnostic Category

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.

Calibrations

This parameter provides a means to calibrate the hammer timing pulses to obtain the best print
quality, and to calibrate the Paper Out sensor. There are three selections for Calibrations:
Hammer, Paper Out, and Platen Gap Cal.

After an initial calibration (the standard "hammer" calibration), if print quality is acceptable, no
further calibration is needed. The additional procedures need only be performed if certain types
of quality defects persist. As with "Hammer" calibration procedure, this option must be invoked
separately for single-part and multi-part form platen gap settings.

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T6215 Maintenance Manual

Selecting And Running a Hammer Calibration Routine

This procedure generates a test pattern consisting of an assortment of characters and character
shapes while stepping through a range of lead times during this hammer timing calibration. The
lead times are measured in clock cycles and are printed along the left side of the paper (see
Figure 2–1). The tests are run at one shuttle frequency and then repeated for other frequencies.

Step 1. Take the printer Offline and place it in Tech Access Mode.

Step 2. Access the Test menu.

Step 3. Scroll (▲ Key) until the Diag Category is displayed. Press Enter.

Step 4. Scroll (▲ Key) until the Calibration Parameter is displayed. Press Enter.

Step 5. 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 several
shuttle frequencies.

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.

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.

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Chapter 2. Menu Operations

Figure 2–1. Hammer Leadtime Calibration Printout Sample (partial)

Selecting And Running a Platen Gap Calibration Routine

Step 1. Take the printer offline and place it in Tech Access Mode.

Step 2. Access the TEST Menu.

Step 3. Scroll (▲ Key) until the Diag Category is displayed. Press Enter.

Step 4. Scroll ( ▲ Key) until the Calibrations Parameter is displayed. Press Enter.

Step 5. Scroll (▲ Key) until Platen Gap Cal is displayed.

Step 6. Depress the ENTER key to begin the first part of the Platen Gap Calibration routine.

Step 7. The message "Set Platen to E and press Enter" displays. Turn the Platen Gap wheel to

the letter E and then press Enter.

Step 8. The message "Set platen to C and press Enter" displays. Turn the Platen Gap wheel to

the letter C and press Enter.

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T6215 Maintenance Manual

Meter

The Meter Parameter provides real-time dynamic measurements of various sensor readings
within the printer. They can be used to adjust the sensor for optimum performance or to test
sensors to ensure that they are operating properly. These test measurements are displayed
directly on the Control Panel Display. There are seven selections for Meter: Paper Out, Paper
Motion, Ribbon Weld, Temp Sensor, and Keypad. Power and Platen will not be discussed in
this manual because they are used on the printer production line only.

Accessing the Meter Measurement Tests:

Step 1. Take the printer offline and place it in Tech Access Mode.

Step 2. With the printer display reading OFFLINE, depress the Menu/Back key and use the

▲/▼ keys to scroll to Test

Step 3. Press Enter and scroll (▲ Key) to Diag.

Step 4. Press Enter and scroll (▲ Key) to Meter.

Step 5. Press Enter and scroll (▲ Key) to one of the following measurement tests at Level 3.

Each Meter Test is initiated by pressing the Enter key when the desired selection
displays.

Paper Out Sensor

The Paper Out Sensor should read less than .2 volts with paper removed and greater than 4
volts with paper installed. No other operator actions are required during this test.

Paper Motion Sensor

The Paper Motion Sensor only needs to have a differential of greater than 2 volts between the
high and low reading to function properly. No other operator actions are required during this
test.

Ribbon Weld

The Ribbon Weld Sensor is read by sliding a piece of white paper between the ribbon and the
sensor. The readings should be greater than 4 volts uncovered and less than .2 volts covered.

Temp Sensor

The printer has a sensor on the Engine Controller Board for monitoring the air temperature in
the area of the engine controller CBA. When Temp Sensor is selected, the display shows the
temperature in milli-volts.

Keypad

This test verifies that the logic board can receive a signal from each key on the control panel.
Once you have entered the Keypad Test, depressing each key should make its label appear on
the Control Panel Display (i.e., Mode, View, Line Feed, etc.). Exit the Keypad Test by depressing
the Clear key three times.

2–12

Motors

This parameter provides a means for testing individual motor circuits by turning them on or off.
They can be tested at the current selection (Default) or you can select a variety of speeds at
which to test them. (See Shuttle Speed parameter and Ribbon Weld parameter.)

Accessing the Motor Tests:

Step 1. Take the printer offline and place it in Tech Access Mode.

Step 2. With the printer display reading OFFLINE, depress the Menu/Back Key and use the

Step 3. Press Enter and scroll (▲ Key) to Diag.

Step 4. Press Enter and scroll (▲ Key) to Motor.

Step 5. Press Enter and scroll (▲ Key) to either Ribbon or Shuttle. Each Motor Test is initiated

Motor selections

Ribbon
Shuttle
Ribbon Pump (Remove ribbon before performing this test.)
Blower

Chapter 2. Menu Operations

▲/▼ keys to scroll to TEST.

by depressing the Enter key when the desired selection is displayed.

Remove the ribbon before performing the Ribbon Pump test!

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. (The Paper Feed Motor may be
tested using the LF (line feed) or FF (form feed) functions.).

Shuttle Speed

This option provides a means to vary the Shuttle Motor speed for a Shuttle Motor Test.

Shuttle Speed selections:

20-99 Hz.

Ribbon Speed

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

Speed selections:

1–250
Default

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T6215 Maintenance Manual

Ribbon Threshld

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

Threshold selections:

1–255

Paper Out Thold

This parameter allows you to set the Paper Out Threshold value for the Paper Out Sensor. By
using this, you can compensate for the reflectivity of different types of paper. Selections are 1-

255.

Energy Star

This parameter allows you to control Energy Star Operation. Selections are OFF and ON.

Clear

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

Clear selections

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

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

Shuttle Off

This parameter allows you to set the amount of time the shuttle remains at speed after the last
printed data. Options are 10 Sec, 20 Sec, 30 Sec, and 60 Sec.

Shuttle Change

The printer checks for incoming data that uses a different shuttle speed. This parameter allows
you to determine how much of that data is required before an actual shuttle speed change
occurs. Options are 1-30.

Ribbon Ink, Dots per Pump

This parameter allows you to adjust the number of dots printed before the next pump of the ink
is added to the ribbon. Options are 500-2000.

Serial Dump

When this parameter is enabled, the data the printer receives from the parallel port of PSIO
cards is replicated and sent out from the serial port. This allows you to connect a serial cable
from the printer to a computer and capture the data using a serial capture utility.

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Chapter 2. Menu Operations

Control Panel Key Operations For Controlling Fault Reporting

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

To use these, 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 Up Arrow 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.

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T6215 Maintenance Manual

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Blank

Page

Chapter 3:

Faults and Troubleshooting

Chapter 3

Introduction

Messages

Faults

Chapter 3. Faults and Troubleshooting

This chapter deals with troubleshooting problems on the T6215 printer. Messages that
indicate printer faults and errors are explained and corrective action given. The few paper
handling and print quality problems that may occur are also explained. Troubleshooting
tables and diagnostic flow charts have been included.

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 automatically

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:

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.

Removal/Replacement Proce-

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T6215 Maintenance Manual

Fault Override

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

One Fault Override Parameter (Paper Motion) is available in the Standard Multilevel Menu.
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

.

3–2

Chapter 3. Faults and 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 Engine Controller Board. If the problem returns,
download new printer firmware.

The Twinax PSIO is damaged or corrupted.

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

remove and replace the Twinax PSIO Assembly.

A VFU channel command has been received from the host
requesting 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

Appendix C in the Operator 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 Board.

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 Engine Controller Board.

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

Dead CPU

Explanation:
Corrective Action:

The Main CPU has quit talking to the Control CPU.
Cycle power to the printer. If the error recurrs, call Tally.

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T6215 Maintenance Manual

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Fake Mode

Fatal Fault n

Font Dnld Error

Graphics Check

Hammer Time

Hammer Voltage

Heap Overflow

I/O Timeout

Link Fault (n)

No VFU Loaded

NVRAM Fault

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:

Explanation:

Corrective Action:

Explanation:

Corrective Action:

The shuttle motor is disabled, but the printer is “faking” shuttle
timing.
Plug in the platen sensor if it is not already. If it’s plugged in
already, the platen sensor may be damaged. Replace it.

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

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

Unknown graphics character for Twinax/Coax
Correct data and retransmit from host.

A fault has been detected in the software.
Depress the Clear key to clear the fault and continue operation

A transistor has been detected out of range.
Check for a malfunctioning blower and if necessary, remove and

replace. If the problem persists, remove and replace the Hammer
Drive Board.

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.

The NIC ca+rd is recognized, but the NIC doesn’t respond in the
given amount of time.

Cycle power. If that does not work, the card jumper might be
wrongly set, or there is a bad I/O card.

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

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 Board.

3–4

Chapter 3. Faults and Troubleshooting

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Offline Data In

Offline Dump On

Online Dump On

Overflow VFU

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 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.

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 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
Controller Board. 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 Board.

3–5

T6215 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 Manual, then load paper. (See Load­ing Paper Section of Chapter 1 of the Operator Manual.)

If this message is in error, check the sensor connection on the
Engine Controller Board and sensor position on its tractor. 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 Out Sensor) needs to be replaced.
If all of the above checks and fixes do not clear the problem,
remove and replace the Engine Controller Board.

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 3 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 3 of
the Operator's Manual) and retransmit the data again. If you find
no errors in the Dump Mode data, remove and replace the Inter­face Board.
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 Form Thickness Lever and close the
Platen Gap. If this message appears at any other time or will not
clear, run the Platen Calibrate procedure (see Test Menu in
chapter 2). Note: This requires initiating Tech Access mode and
supressing all faults (by holding down Enter and FF) to clear the
fault, making menu navigation possible.

3–6

Chapter 3. Faults and Troubleshooting

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Print Fault

Ribbon Fault Explanation: The ribbon is no longer moving. The ribbon has stalled

Self Testing

Setup Address

Explanation

Corrective Action

Corrective Action: Depress the CLEAR key, then put the printer back Online. If

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 Engine Controller Board.

because a ribbon weld broke, ribbon jammed, snagbged, or
the platen gap is too small. The ribbon shield may no be
adjusted correctly, causing ribbon faults.

the fault returns, check the platen gap and ribbon shield. Also
check the ribbon by turning the capstan, the ribbon should
move freely. If the problem reoccurs, replace the ribbon.
The printer is performing internal diagnostic tests.

If this message does not clear automatically after a few seconds,
remove and replace the Engine Controller Board.

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 3 of the Operator
Manual, under the Configuration Menu.

3–7

T6215 Maintenance Manual

Table 3–1, Continued

MESSAGE Explanation and Corrective Action

Shuttle Fault

Skip Ribbon Weld

Explanation:

Corrective Action:

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 printer 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.
If 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 Engine Controller Board
connection. If the connection and cable are OK and the sensor is
properly installed, 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 Board 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 Board. If the voltage is incorrect, check voltage
at the Power Supply. If power supply voltage is OK, replace the
Engine Controller Board. 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 source. Call an electrician.

This is an advisory message. The message appears when
the welded part of the ribbon is moving across the

Hammer Bank.

None. Wait for the ribbon to finish moving, and the message
will disappear.

3–8

Chapter 3. Faults and 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 Circuit Cooling and Hammer Bank fans are

working. If both fans are working, you have a faulty Engine
Controller Board.
If only one of the two fans is not working, check power at the
Engine Controller Board 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 Board.
If neither fan is working, either the Engine Controller Board or the
Power Supply is malfunctioning. Check voltage output of the
Power Supply. If it is OK remove and replace the Engine Control­ler Board 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 input voltage is not correct, there is a problem with
the site power source. Call an electrician.

3–9

T6215 Maintenance Manual

Hardware Troubleshooting Guides

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

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.

Input power voltages can be lethal. Be very careful while performing these
procedures.

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?
Are the Power Supply connections to the Engine Controller Board 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 and should be replaced.

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.

3–10

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 V DC. If the output voltage is
incorrect, remove and replace the Power Supply.

Chapter 3. Faults and Troubleshooting

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

There are four things that can cause this problem.

1. A bad connection.

2. A bad control panel.

3. A bad

4. Loss of 5 V power supply.

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

Engine Controller Board

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 Board.

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

.

Step 2. If the form movement keys do not function properly, check the Control Panel connection to

the Engine Controller Board.

If the connection is OK, the problem is in either the Control Panel or in the Engine Control­ler Board. Try another Control Panel first. If that does not correct the problem, then
remove and replace the Engine Controller Board.

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 Board

Troubleshooting Procedure

Step 1. Check the Control Panel connection to the Engine Controller Board.

Step 2. If the connection is OK, the problem is in either the Control Panel or in the Engine Control-

ler Board.

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

.

3–11

T6215 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 platen may be open too far but not far enough to cause a Platen Open
message.

2. The Ribbon Cartridge may not be functioning properly.

3. Platen alignment may be incorrect.

Troubleshooting Procedure

Step 1. Check the Platen Gap Lever and make sure it is closed properly.

Step 2. Make sure the Ribbon Cartridge is functioning (tracking) 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 Platen Gap Wheel fully closed. (See

Procedure 9 in Chapter 4.)

Printed output appears light

There are three things that can cause this problem.

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

2. The Ribbon Cartridge may be worn out.

3. Platen alignment may be incorrect.

Troubleshooting Procedure

Step 1. Check the Platen Gap 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 steps 1–2 do not correct the problem, check and adjust the platen alignment guides. The

Platen Gap should be approximately .013 inches with the Platen Gap Wheel fully closed.
(See Procedure 9 in Chapter 4.)

3–12

Chapter 3. Faults and Troubleshooting

Printed output appears shaky or fuzzy

There are six things that can cause this problem.

1. The platen 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 Platen Gap 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.

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 Platen Gap Adjustment Wheel 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.)

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 Board.

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

3–13

T6215 Maintenance Manual

Troubleshooting Procedure

Step 1. Open the cover and paper guide areas.

Step 2. Inspect the Hammer Bank cables for rub spots, cracked insulation, burn spots, etc.

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

Test the printer to see if the problem is still present. If it isn’t, reinstall the cover,
etc. 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 to the affected coils.

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 Board
also. Defective Hammer Drivers can cause problems with Hammer Coils. Instructions for
checking Hammer Drivers are located at the end of this chapter.

Step 6. Is the hammer broken or defective? If so, remove and replace the Hammer Module.

Step 7. Check between the Hammer Plate and the Hammer Module Return Plate and between the

Hammer Head and Hammer Coil for ink and paper buildup. Clean the Hammer Bank by
prying out gently on the hammer with your finger and running a piece of paper behind the
hammer to remove the contamination. For stubborn buildup you may use a little isopropyl
alcohol on the paper to loosen the contamination.

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

malfunctioning Engine Controller Board. Remove and replace the Engine Controller Board.

3–14

Chapter 3. Faults and Troubleshooting

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

There are four things that can cause this problem.

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. The Paper Out Sensor is bad.

4. Malfunctioning Engine Controller Board.

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. Use the Meters function (explained earlier in the troubleshooting table) to verify operation

of the sensor. If the sensor is bad, replace the lower tractor set.

Step 4. If none of the above checks eliminate the problem, the most likely cause is a malfunction-

ing Engine Controller Board. Remove and replace the Engine Controller Board.

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 Board.

Step 1. Check to see if the fault override is enabled for Paper Motion sensing.

Step 2. Use the PapMot Meter 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 eliminate the problem, the most likely cause is a malfunction-

ing Engine Controller Board. Remove and replace the Engine Controller Board.

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.

3–15

T6215 Maintenance Manual

Paper Handling Problems

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

Table 3–2. Paper/Printing Corrective Action

Problem Cause Corrective Action

The paper holes are wider Horizontal paper tension is too Unlock and readjust the tractors.
than normal after passing tight.
through the tractors.

Printed characters on heavy The Platen Gap Open the Platen Gap
weight or multi-part paper are is not set correctly, or there is Wheel, or calibrate platen.
smeared. an incorrect Platen calibration.

The printed characters The Platen Gap Adjustment Wheel Readjust the Platen Gap
are too light. is out of adjustment or the ribbon Wheel. If this does not correct the

is worn out, or there is an problem, replace the ribbon
incorrect platen calibration. cartridge with a new one, or cali-

brate platen.

The printed characters The Platen Gap Adjustment Wheel Adjust the Platen Gap
are shaky. is not set correctly, or there is an Wheel, or calibrate the platen

incorrect platen calibration

The printed characters in Vertical paper tension is too loose. Move the Paper Tension Lever until
one line are shorter than the paper is taut, but not too tight.
normal.

The paper holes are Vertical Paper tension is too tight. Move the Paper Tension Lever until
elongated after passing the paper is taut, but not too tight.
through the tractors.

The paper comes out of (1) The vertical or horizontal To change the vertical tension, raise
the tractors or the paper paper tension is incorrect. the Paper Tension Lever to increase
tears at the right or left tension and lower it to decrease
holes along the edges. 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.

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

(3) Upper tractors are not aligned Unlock and realign the tractors so

with the lower tractors. that the lower set is directly under

the upper set.

3–16

(4) The Platen Gap Adjustment Adjust the Platen Gap

Wheel is not set correctly, or Wheel, or calibrate the platen.
there is an incorrect platen
calibration.

Chapter 3. Faults and Troubleshooting

Troubleshooting The Hammer Driver Transistors

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

To check the Hammer Driver for the malfunctioning hammer, use an Ohmmeter on its
lowest scale. 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 Board. 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 Board. Use the schematics
for the Engine Controller Board in the back of this manual 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/

The
Off each segment. The
corresponding Hammer Coil.

Collector of each driver segment is connected to the

3–17

T6215 Maintenance Manual

START

POWER ON

Power On Troubleshooting Sequence

FAN

NO

RUNS

?

Is

Power

LED On

?

YES YES

Is

Display

On?

CONNECTIONS

DISPLAY

NO NO

REPLACE

FRONT PANEL PCB

NO

POWER SUPPLY PCB

CHECK

IS

ON?

REPLACE

OK?

NO

IS

FAN

MOTOR

WORKING

?

YES

POWER SUPPLY PCB

NO NO

REPLACE

RESEAT OR

REPLACE CONN.

IS

120V

PRESENT

@ P103?

YES

REPLACE FAN

ASSEMBLY

REPLACE

CONTROLLER BOARD

IS

120V

Present

@ P103?

NO

YES

3–18

DISPLAY READS

"Self Testing"

?

YES

NO

Go to Next Page

PERSONALITY

MODULE

REPLACE

POWER SUPPLY

Figure 3–1. Power On Troubleshooting Sequence

Chapter 3. Faults and Troubleshooting

Power On Troubleshooting Sequence Cont.

From Page

3-18

Is

Display Data

Correct?

Displays

Paper

Out ?

No

No

No

Yes

Yes

Check

Connections

Recalibrate

Paper Out

Sensor

Still
Have
Error

?

No

OK?

Replace

Front Panel

Still

Incorrect

?

No

No

Note: Assumes Paper Is Installed

See Chapter 2,
"Menu Operations"

Yes

Yes

Replace

Sensor

Recalibrate

Paper Out

Sensor

Replace Conn.

Yes

Yes

See Chapter 2,
"Menu Operations"

Reseat or

Replace

Logic PCB

Still
Have
Error

?

No

No

Yes

Replace

Logic PCB

End

Figure 3–1a. Power On Troubleshooting Sequence, Continued

3–19

T6215 Maintenance Manual

START

DOES

SHUTTLE

ENERGIZE

AND COME TO

CORRECT

SPEED?

YES

NO

DOES

SHUTTLE

RUN

?

YES

B

NO

CONNECTION P501

Print Data Troubleshooting Sequence

IS

PLATEN

BROKEN

SHUTTLE

BROKEN

CHECK

BELT

?

IS

BELT

?

OK

?

YES

NO

YES

NO

NO

YES

CONTROL PROCESSOR OPERATING IN "FAKE" MODE

(SEE CHAPTER 3) MAY BE NO SHUTTLE PROBLEM.

CONNECT PLATEN SENSOR BEFORE
ATTEMPTING SHUTTLE DIANOSTICS.

REPLACE

DRIVE BELT

B

RESEAT OR

REPLACE CONN.

DOES

SHUTTLE

RUN AT

SLOWER

THAN NORMAL

SPEED?

NO

Go to Next Page

IS

THERE

48V

@P501

?

NO

REPLACE

POWER SUPPLY PCB

YES

NOTE:

HAS

SHUTTLE

TRIED TO GO FULL

SPEED, FAILED,

THEN SETTLED AT

SLOWER

SPEED?

PLUG SHUTTLE MOTOR

PAPER MOTOR

SOCKET AND PRESS LF/FF

DOES

TURN

?

YES

NO

MOTOR

REPLACE

SHUTTLE MOTOR

NOTE: This may or may not be a problem.
The program allows this if start-up ramps are
not correct. The shuttle will run at the slower
speed then progess toward normal speed in

steps. Check program settings first.

YES

REPLACE

LOGIC PCB

3–20

Figure 3–2. Print Data Troubleshooting Sequence

MOST PROBABLE CAUSE IS A

MECHANICAL DIFFICULTY-

CHECK FOR

BINDING, ETC.

IS SHUTTLE

MOTION

ERRATIC?

YES

AT MOTOR AND COUNTERWEIGHT

CONTROLLER

BOARD

IS SHUTTLE

BELT INTACT/

IN PLACE?

NO

YES

NO

YES

NO

YES

ARE

PULLEYS

OK?

IS

SENSOR

OK?

RESEAT OR

REPLACE BELT

REPLACE BAD

PULLEY ASSEMBLY

THEN ADJUST

SHUTTLE SENSOR

RETEST

SHUTTLE SENSOR

REPLACE

CONTROLLER BOARD

NO

YES

IS

SHUTTLE

MOTION

OK?

NO

Go To Next Page

Chapter 3. Faults and Troubleshooting

Figure 3–2a. Print Data Troubleshooting Sequence, Continued

3–21

T6215 Maintenance Manual

3–22

Figure 3–2b. Print Data Troubleshooting Sequence, Continued

Chapter 3. Faults and Troubleshooting

Figure 3–2c. Print Data Troubleshooting Sequence, Continued

3–23

T6215 Maintenance Manual

IS

PRINT

DENSITY

LIGHT

YES

?

NO

ADJUST PAPER

THICKNESS WHEEL.

IS

PRINT

QUALITY

OK?

YES

NO

NO

IS

PAPER

THICKNESS

WHEEL SET

?

YES

IS
RIBBON
MOTOR

MOVING
RIBBON?

YES

NO

CHECK

CONNECTION P502

END

NO

OK

?

YES

IS

THERE

48V

@P502

?

NO

REPLACE

POWER SUPPLY

RESEAT OR

REPLACE CONN.

YES

PLUG RIBBON MOTOR

INTO PAPER MOTOR

CONNECTOR

AND PRESS LF KEY.

DOES

MOTOR

TURN?

NO

REPLACE RIBBON

MOTOR

YES

REPLACE

CONTROLLER

BOARD

3–24

Figure 3–2d. Print Data Troubleshooting Sequence, Continued

Chapter 4

Chapter 4:

Removing and Replacing Components

Introduction

Required Tools

Chapter 4: Removing and Replacing Components

This chapter covers removal and reinstallation of selected field replaceable compo­nents and assemblies of your printer.

Unplug the printer and remove paper and ribbon for all procedures in this chapter.

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.

Unless otherwise noted, reinstallation of components is in the reverse order of installa­tion or removal.

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

• Paper belt tension gauge

• T-Handle Allen Driver - 9/64"

• Platen Gap Shim Gauge - 0.011"

• Hammer Module Alignment tool

• Tractor Phasing Gauge

• Nut Driver - 11/32"

• Retaining ring pliers

• Hex Allen key - 3/32"

• Phillips screwdriver 6", #2

• Phillips screwdriver 3", #1

• Needle-nosed pliers

• Flat-head screwdriver

• Torx tool, size 9

4–1

T6215 Maintenance Manual

Service Procedures

1. Ribbon Platform removal .............................................................................. 4–3

2. Ribbon Motor removal.................................................................................. 4–4

3. Ribbon Motion Sensor PCA (Printed Circuit Assembly) removal ................... 4–5

4. Control Panel removal .................................................................................. 4–6

5. Hammer Bank removal ................................................................................. 4–8

6. Ribbon Shield removal ................................................................................. 4-11

7. 13-pack Hammer replacement ..................................................................... 4-12

8. Coil Board replacement ................................................................................ 4-14

9. Shuttle removal ............................................................................................. 4–15

10. Platen removal .............................................................................................. 4–16

11. Platen Gap adjustment.................................................................................. 4–22

12. Print Mechanism access (tilting) .................................................................... 4–24

13. Distribution PCA removal ............................................................................. 4–26

14. Lower Tractor removal .................................................................................. 4–27

15. Upper Tractor removal .................................................................................. 4–30

16. Tractor phasing/Paper Drive Belt tension adjustment .................................... 4–31

17. Paper Drive Motor removal .......................................................................... 4–35

18. Shuttle Motor removal .................................................................................. 4–36

19. Control PCA removal .................................................................................... 4–37

20. Power Supply Assembly removal .................................................................. 4–38

4–2

WARNING!

HIGH VOLTAGE POTENTIAL

High levels of AC voltage are present in the

power supply. Always ensure that the power cord

is unplugged before performing maintenance

on the printer.

Chapter 4: Removing and Replacing Components

Procedure 1: Ribbon Platform Removal

Step 1. Open the top cover of the printer.

Step 2. Open the Platen Gap lever.

Step 3. Loosen the screws on the left and right top of the ribbon platform and lift the

platform.

Screw 1

Screw 2

Figure 1. Loosening screws on Ribbon Platform.

Step 4. Find the Ribbon Drive Motor cable on the underside of the Ribbon Platform

and unplug it.

Figure 2. Unplugging Ribbon Drive Motor cable.

4–3

T6215 Maintenance Manual

Procedure 2: Ribbon Motor Removal

In printers set up to use the 250-million character ribbon, there are two mo­tors in the ribbon platform: one is used as the ribbon drive motor and the
other drives the re-inking mechanism.

Step 1. Remove the Ribbon Platform (see Procedure 1).

Step 2. There are four screws per motor on the top side of the platform. Remove

these screws.

Motor 1

Motor 2

Figure 3. Removing motor screws.

Step 3. Unplug the orange and white motor cables and remove the motor(s).

Motor

Cables

4–4

Figure 4. Unplugging Ribbon Motor cables.

Chapter 4: Removing and Replacing Components

Procedure 3: Ribbon Motion Sensor PCA Removal

Step 1. Remove the Ribbon Platform (see Procedure 1).

Step 2. Turn the platform over and unplug the orange motor cable(s) and the gray

sensor cable.

Step 3. Remove the two screws that hold the PCA to the platform.

Sensor Cable

Motor Cable

Step 4. Remove the PCA.

Motor Cable

Screw

PCA

Screw

Figure 5. Removing PCA screws.

4–5

T6215 Maintenance Manual

Procedure 4: Control Panel Removal

Step 1. Remove the Ribbon Platform.

Step 2. Reach underneath the Control Panel assembly and unplug the gray Control

Panel cable.

Unplug Control Panel Cable

Control Panel

Figure 6. Unplugging Control Panel cable.

Step 3. Loosen the four screws underneath the Control Panel at the bottom edge of

the frame.

Step 4. Lift the Control Panel assembly from the printer.

Step 5. Loosen the two screws holding the Control Panel to the metal frame.

Step 6. Lift the Control Panel from the metal frame.

The Control Panel Assembly can be adjusted so that it aligns snugly with the
top cover. To do this, loosen the screws and adjust the assembly until it fits
properly in the opening of the printer cover. Don't forget to tighten the
screws.

4–6

Chapter 4: Removing and Replacing Components

Procedure 4a: Control Panel Circuit Board removal

Step 1. Remove all six screws holding the circuit board to the Control Panel.

Step 2. Lift the circuit board from the panel.

Figure 7. Removing circuit board screws.

To reinstall, seat the keypad, then mount the circuit board. Do not over­tighten the six mounting screws.

4–7

T6215 Maintenance Manual

Procedure 5: Hammer Bank Removal

The Hammer Driver CBA has components which are static sensitive! Use the
appropriate ESD grounding procedures when handling the Hammer Bank
Assembly.

Step 1. Remove the Ribbon Platform (See Procedure 1), and open the Platen Gap

lever.

Step 2. Remove the Control Panel (See Procedure 4).

Step 3. Remove the two screws holding the plastic cable cage assembly in the top

middle of the Hammer Bank. Remove the cage and the white cable lifter.

Screw

Plastic
Cable Cage

Screw

Figure 8. Removing plastic cable cage.

Step 4. Unplug the now-exposed Hammer Bank ribbon cables.

Unplug all

4 Cables

4–8

Figure 9. Unplugging Hammer Bank ribbon cables.

Chapter 4: Removing and Replacing Components

Retainer clip

Retainer clip

Access holes

for screws

Access holes

for screws

Step 5. Slide the Shuttle Drive Belt from the pulley on the right side of the

Hammer Bank.

Step 6. Remove two screws securing the retainer clips at the front (toward you) of the

Hammer Bank. To do this, use the access holes in the Hammer Driver CBA.

Lift out the retainer clips.

Figure 10. Removing screws on retainer clips.

Step 7. Remove two KEPS nuts from underneath the Hammer Bank. Both are on your

right, and accessible through the front door of the printer. Use an 11/32" nut
driver.

Hammer Bank
Nuts, 2 places

Figure 11. Removing nuts from underneath Hammer Bank (view is from inside front

door of printer).

4–9

T6215 Maintenance Manual

Step 6. Slide the upper left tractor as far to the left as it will go. Lift the Hammer Bank

and shuttle out of the printer, being careful not to damage the ribbon shield.

Hammer Bank

and attached

Shuttle

Figure 12. Lifting Hammer Bank from printer.

When reinstalling the Hammer Bank, install and tighten the retainer clips (Step

4), before installing and tightening the KEPS nuts (Step 5).

When reinstalling the Shuttle Drive belt (Step 3), press the belt against the
lower shuttle motor pulley with one hand, and "roll" the belt onto the upper
shuttle pulley.

Shuttle Drive Belt

Reach underneath
and hold belt.

Roll belt onto pulley

with other hand.

4–10

Figure 13. Replacing Shuttle Drive belt.

Chapter 4: Removing and Replacing Components

Procedure 6: Ribbon Shield Removal

Step 1. Remove the Hammer Bank (see Procedure 5).

Step 2. Remove the three screws and lift the Ribbon Shield from the Hammer Bank.

Guide Pin

Spring Plate,
2 places

Screw, 3 places

Guide Pin

Hammer Bank Assy

Figure 14. Removing the Ribbon Shield.

Ribbon
Shield Assy

When reintalling the Ribbon Shield, make certain that the shield is seated over
the two guide pins before tightening screws.

4–11

T6215 Maintenance Manual

Procedure 7. 13-pack Hammer Replacement

Step 1. Remove the Hammer Bank assembly from the printer (see Procedure 5).

Step 2. Remove the Ribbon Shield (see Procedure 6).

Step 3. Using your Torx tool, remove the hammer mounting screws.

Step 4. Remove the hammer by sliding it forward until it can be lifted.

Step 5. Measure the defective hammer pack to determine proper replacement size.

To do this, insert the old hammer into each of the slots on the Hammer
Alignment tool. Use this guide to determine correct replacement part:

If the defective hammer pack does not fit into either slot A or B, use Spares Kit
#083686 (High).

If the defective hammer pack fits into slot A, but not B, use Spares Kit
#083758 (Medium).

If the defective hammer pack fits into both slots A and B, use Spares Kit
#083759.

"Fit" means that the hammer pack easily slides all the way into the slot.

Defective

hammer Pack

Slot A Slot B

Hammer Alignment Tool

Slot B

Slot A

Hammer Alignment Tool

4–12

Figure 15. Measuring old hammer for replacement size

Chapter 4: Removing and Replacing Components

Step 6. Place the new hammer pack in position on the bank and replace screws, but

do not tighten.

Step 7. Use the Hammer Alignment tool to align the impact elements of the new

hammer (holes 2 and 3) with the impact elements of the neighboring ham­mers (holes 1, 4, and 5). Wiggle the tool slightly until it snaps onto the
impact elements. See Figure 16.

5

4

3

New

Hammer

Pack

2

1

1

2

3

4

5

Figure 16. Aligning the new hammer pack.

Step 8. With the hammer alignment tool holding the hammer in place, tighten the

hammer mounting screws.

Step 9. Replace the Ribbon Shield.

Step 10. Replace the Hammer Bank.

4–13

T6215 Maintenance Manual

Procedure 8: Coil Board Replacement

Step 1. Follow steps 1-4 of the 13-pack Hammer replacement procedure (see Proce-

dure 7).

Step 2. Remove the coil board mounting screw.

Step 3. Lift the coil board from the carriage. To do this, you may need to gently pry it

with a tool.

Step 4. Press the replacement coil board onto the carriage. Make sure that each

bobbin is fully seated. The coil posts should stick slightly above the tops of
the bobbins.

Step 5. Replace the coil board mounting screw.

Step 6. Follow steps 6-10 of Procedure 7.

4–14

Figure 17. Coil board replacement.

Procedure 9: Shuttle Removal

Step 1. Remove the Ribbon Platform (see Procedure 1).

Step 2. Remove the Hammer Bank (see Procedure 5).

Step 3. Remove the two screws which hold the shuttle frame to the Hammer Bank.

Chapter 4: Removing and Replacing Components

Figure 18. Removing Shuttle screws.

Step 4. Remove two screws (9/64" Allen) through the center of the shuttle and to the

outside edge of the shuttle, then lift the shuttle from the Hammer Bank.

Hex Head Screw

Figure 19. Removing screws from inside shuttle.

Hex Head Screw

When reinstalling the Shuttle to the Hammer Bank, start all four screws until

they are snug, but do not tighten. Tighten the two Allen screws first.

4–15

T6215 Maintenance Manual

Procedure 10: Platen Removal

Step 1. Remove the Ribbon Platform (see Procedure 1).

Step 2. Remove the Control Panel assembly (see Procedure 4).

Step 3. Remove the Hammer Bank (see Procedure 5).

Step 4. Remove the two screws (#6 Phillips) that attach the circuit board from under-

neath the left side of the printer. It's located just above the Power Supply
Assembly. Let the board dangle by the cables.

Circuit board
located here.

Figure 20. Location of circuit board.

Step 5. Tilt the Print Mechanism (see Procedure 10).

Step 6. Remove both the left and the right platen springs by inserting a flat-blade

screw driver between two of the spring's coils. Pull the spring forward until it
lifts from the mounting pin.

Be careful not to send the spring flying!

4–16

Chapter 4: Removing and Replacing Components

Platen Spring

Platen Spring,
left side

Figure 21. Removing the Platen Springs.

Step 7. Rotate the Platen Gap Adjustment Wheel until it is all the way open (on "H").

Step8. Remove the three screws that attach the platen stop to the side plate.

Platen Spring,
right side

There are two washers under each screw. The nylon washer goes next to the
platen stop and the curved-spring washer goes next to the screw.

4–17

T6215 Maintenance Manual

Platen

Platen Gap
Adjustment Wheel

Platen Stop

#6 Phillips

screws

Platen Stop

Figure 22. Removing screws from the platen stop.

Step 9. Pull the platen stop away from the side plate enough for the platen pin to clear

it.

Step 10. LIft the platen toward you, bringing the two platen gap adjust plates and the

right side curved-spring washer along with it.

Step 11. Both the Platen Gap Adjust plates and the right curved-spring washer must be

transferred to the new platen. The right Platen Gap Adjust plates and the
curved-spring washer can be transferred directly. Do this now.

4–18

#6 Screws,
2 places

Chapter 4: Removing and Replacing Components

Platen Gap Adjust
Plate, 2 places

Platen Spring
Lever

Platen

Curved Spring Washer

Figure 23. Transferring components from old to new platen.

Step 12. Remove the spring lever from the left side. It is attached with two #6 Phillips

screws.

Step 13. Reattach the spring lever to the new platen. Add Lubriplate grease (see

Appendix A):

• Between the left Platen Gap Adjustment plate and the platen,

• Between the right curved-spring washer and the right Platen Gap Adjustment

plate, and

• Between the curved-spring washer and the platen.

4–19

T6215 Maintenance Manual

Grease

Step 14. Grease the sideplates of the print mechanism where they will come in contact

with the Platen Gap Adjustment plates.

Step 15. Place the new platen into the print mechanism. The platen pins slide into the

slots on the sideframes. The Platen Gap Adjustment plates interface with two
5/16" standoffs mounted to the inside of the sideplates.

Grease

Grease

Grease

Figure 24. Adding grease.

Grease inside of
both frame end
plates

The hook in the Platen Gap Adjustment plate goes over the lower standoff and
the setscrew of the Platen Gap Adjustment plate contacts the upper standoff.

4–20

Keep the long axis of the platen perpendicular to the sideplates to prevent
wedging of the platen.

Step 16. Move the platen stop back in contact with the sideplate, so that its tab is

located under the lower right edge of the platen. Place the washers over the
posts in the sideplates and reattach the three screws.

Step 17. Reattach the springs, being careful they do not come loose and snap toward

you.

Chapter 4: Removing and Replacing Components

Step 18. Lower the print mechanism into the cabinet (see Procedure 10).

Step 19. Reattach the circuit board to the left Platen Gap Adjustment Plate.

Step 20. Reinstall the Hammer Bank (see Procedure 5).

Step 21. Reset the platen gap (see Procedure 9).

Step 22. Calibrate the Platen Sensor (see Chapter 2).

4–21

T6215 Maintenance Manual

Procedure 11: Platen Gap Adjustment

You must perform this procedure whenever you have removed and replaced

the Hammer Bank and Shuttle.

Step 1. Remove the Ribbon Platform (see Procedure 1).

Step 2. Remove paper, if loaded.

Step 3. Set the Platen Gap Wheel to the green indicator.

Step 4. Look for the adjustment screws on the right and left sides of the printer (see

Figure 25).

Step 5. Insert the 0.011" shim from your tool kit between the platen and impact

elements. The shim should slip behind the ribbon shield and plastic finger

guard, and in front of the platen (see Figure 25).

Step 6. Using the Allen wrench, turn each screw slightly until the shim fits snugly but

not too tightly between the platen and impact elements.

The shim should slide up and down with firm pressure, but it should not be so
tight that excess force is needed. It should also not be so loose that the shim
falls though when it is let go. The platen gap should be equal along the whole
platen, so make sure you test the entire length and adjust both the right and
left screws accordingly.

4–22

Chapter 4: Removing and Replacing Components

Platen Gap
Adjustment Wheel

Platen
Adjustment
Screw

Green Indicator

Allen Wrench

Platen
Adjustment
Screw

0.011" Shim

Ribbon shield
and plastic
finger guard

Figure 25. Platen Adjustment screws and use of shim.

4–23

T6215 Maintenance Manual

Procedure 12: Print Mechanism Access (Tilting)

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

Lock the wheels on the printer cabinet before performing this procedure.

Step 1: Remove the Ribbon Platform (see Procedure 1).

Step 2. Remove the Control Panel assembly (see Procedure 4).

Step 3. Unplug the Power Supply cable (four large red and black wires), and the

Hammer Bank cable (large blue cable) from the Power Distribution Board.

Unplug Power

Supply Cable

Figure 26. Unplugging the Power Supply cable.

4–24

Chapter 4: Removing and Replacing Components

Step 4. Lift the Print Mechanism. Place the strut in the top and bottom detents, with

the shoulder on the strut in the bottom detent.

Detent

Strut

Detent

Figure 27. Print Mechanism tilted and held by strut.

4–25

T6215 Maintenance Manual

Procedure 13: Distribution PCA Removal

Step 1. Remove the Ribbon Platform (see Procedure 1).

Step 2. Tilt the Print Mechanism (see Procedure 10).

Step 3. Disconnect all cables at the Distribution PCA.

Step 4. Remove the two screws that hold the mounting bracket to the frame and lift

the assembly out of the printer.

Bracket

Screw

Figure 28. Removing screws on mounting bracket.

Screw

If one of the Surge Capacitators is being removed, ensure proper polarity
when it is reinstalled.

4–26

Chapter 4: Removing and Replacing Components

Procedure 14: Lower Tractor Removal

Step 1. Remove the Ribbon Platform (see Procedure 1).

Step 2. Tilt the Print Mechanism (see Procedure 10).

Step 3. Unplug the Paper Out sensor cable from J1 of the Platen/Paper Sensor PCA.

(The Paper Out Sensor is part of the Lower Left Tractor Assembly).

Paper Out

Sensor Cable

Figure 29. Location of Paper Out sensor cables.

Step 4. Remove the retaining (snap) rings from both ends of the squared shaft (located

inside the frame at each end). Leave the rings sitting loosely on the shaft.

Snap Ring

Snap Ring

After Removal

Figure 30. Removing Retaining (Snap) rings.

4–27

T6215 Maintenance Manual

Do not remove the pulley or drive belt from the shaft. If the pulley and/or the
drive belt is removed, you will need to rephase the upper and lower tractor
sets. (See Procedure 14).

Step 5. Remove the ground spring from the right side of the square shaft.

Step 6. Slide the square shaft to the right a few inches. When you replace it, make

sure it sticks out enough to touch the ground spring.

Ground Spring

.

Figure 31. Ground spring.

Step 7. Loosen the nut on the left side of the round shaft using an adjustable wrench

or pliers. Unscrew the round shaft and slide it to the right a few inches.
Remove the nut from the shaft.

Square Shaft

After Sliding

to Right

Slide to Right

Unscrew Bar and

Figure 32. Round and square shafts.

4–28

Chapter 4: Removing and Replacing Components

Step 8. You should now have enough space to be able to slide both tractors to the

left and off the shafts. Keep track of the position of the springs and washers
on the support shaft as you remove them.

Each tractor has a raised bump which corresponds to a corner of the square
shaft. Make sure to replace the old or new tractor with the bump correspond­ing to the same corner.

4–29

T6215 Maintenance Manual

Procedure 15: Upper Tractor Removal

This is very similar to Procedure 12 on the previous pages.

Step 1. Open the printer cover and remove the paper. Remove the snap rings from

both ends of the square tractor shaft (located inside the frame at each end).
Leave the snap rings loosely on the shaft.

Do not remove the pulley or drive belt. If the pully and/or the drive belt is
removed, you will need to rephase the upper and lower tractor sets (see Pro­cedure 14).

Step 2. Slide the square shaft a few inches to the right through the upper tractor

pulley. When you replace the shaft and the ground spring, make sure the
shaft touches the spring.

Step 3. Remove the ground spring on the outside right of the square shaft.

Step 4. Loosen the nut on the left side of the round shaft using an adjustable wrench

or pliers. Unscrew the round shaft and slide it to the right a few inches.
Remove the nut from the shaft.

Step 5. You should now have enough space to be able to slide both tractors to the

left and off the shafts. Keep track of the position of the springs and washers
on the support shaft as you remove them.

Each tractor has a raised bump which corresponds to a corner of the square
shaft. Make sure to replace the old or new tractor with the bump correspond­ing to the same corner.

4–30