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TallyGenicom 6600 Series - User Manual

TallyGenicom 6600 Series
474 pages
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6600 Series Printers
Maintenance Manual
Approved Final
May 19, 2011

Table of Contents

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Summary

Maintenance Overview

TallyGenicom 6600 Cartridge Ribbon Printer (CRP) Series

Overview of TallyGenicom's line matrix printing platform and its features.

Order the Correct Spares

Guide to ordering the correct replacement components for the printer.

How to Identify a 6600 Cartridge Ribbon Printer

Explains how to interpret the printer model number for identification.

Zero Tear Pedestal (ZTP) Printers

Details on ZTP printers that print small jobs without losing sheets.

Printer Configuration Code

Explanation of the printer's configuration code for cabinet type, board revision, and ASIC levels.

Forms Handling

Description of how pedestal and cabinet models handle forms.

Important Maintenance Notes

Key principles for servicing the printer to ensure optimal performance and prevent damage.

Notices

Explanation of notice headings for safety and information.

Safety Notices

Critical safety precautions to be followed during maintenance procedures.

Controls and Indicators

Overview of the printer's control panel elements and indicators.

Tools and Test Equipment

List of tools required for field level maintenance of the printer.

Plugging in the Printer

Requirements for power cords and interface cables for proper printer connection.

TallyGenicom Customer Support Center

Contact information and required details for technical support.

TallyGenicom Supplies Department

Contact information for ordering genuine TallyGenicom supplies.

Preventive Maintenance

Cleaning the Printer

Guidance on periodic cleaning for printer longevity and reliability.

Cleaning the Shuttle Frame Assembly

Procedure for cleaning the shuttle frame assembly.

Cleaning the Card Cage Fan Assembly

Procedure for cleaning the card cage fan assembly.

Troubleshooting

Troubleshooting Aids

Overview of tools and techniques for isolating printer malfunctions.

Start Here...

A flowchart to guide users through initial troubleshooting steps.

Troubleshooting Display Messages

Explanation of printer messages displayed on the LCD.

List of Messages

A list of error messages, their explanations, and solutions.

Troubleshooting Other Symptoms

Techniques for troubleshooting malfunctions not indicated by display messages.

Communications Failures

Analysis and solutions for host-printer communication problems.

Diagnostic Printer Tests

Description of built-in diagnostic tests for print quality and operation.

Boot Diagnostics Menu

Accessing and using the boot diagnostics menu for troubleshooting.

Factory Menu

Accessing and using the factory menu for settings and operational parameters.

Exception Menu

Accessing additional troubleshooting information for specific fault messages.

Hex Code Printout

Procedure for generating a hex code printout for data reception troubleshooting.

Hard Reset (Cycle Power)

Procedure for performing a hardware reset by cycling power.

Adjustments and Tests

Preparing the Printer for Maintenance

Steps to prepare the printer before performing maintenance or adjustments.

Returning the Printer to Normal Operation

Steps to return the printer to service after maintenance or adjustments.

Belt, Paper Feed Timing, Adjustment

Procedure for adjusting the paper feed timing belt tension.

Belt, Platen Open, Adjustment

Procedure for adjusting the platen open belt tension.

Paper Scale Alignment

Procedure for aligning the paper scale to the print.

Platen Gap Adjustment

Procedure for adjusting the platen gap for optimal print quality.

Hammer Phasing Adjustment

Procedure for checking and adjusting hammer phasing for vertical alignment.

Loading Flash Memory

Instructions for loading emulation and operating system software into flash memory.

Reprogramming the Security Key

Procedure for reprogramming the security key using an SPX module.

Shuttle Electrical Short Check

Procedure to check for metallic debris and shorts in hammer coils.

Power Supply Operational Check

Procedure to test printer power supply output voltages.

Replacement Procedures

List of Removal; Installation Procedures

Index of components with removal and installation procedures.

Belt, Paper Feed Timing

Procedure for removing and installing the paper feed timing belt.

Belt, Platen Open

Procedure for removing and installing the platen open belt.

Controller Board

Procedure for removing and installing the printer's controller board.

Shuttle Frame Assembly

Procedure for removing and installing the shuttle frame assembly.

Power Supply Board

Procedure for removing and installing the printer's power supply board.

Security Key

Procedure for removing and installing the security key.

Illustrated Parts Breakdown

Organization of this Chapter

Structure of the chapter detailing electrical and mechanical assemblies.

Illustrations of Printer Components

Drawings of printer components with part numbers and notes.

Principles Of Operation

Line Matrix Printing

Explanation of how line matrix printers create characters using ink dots.

Printing Rates

Factors affecting printing speed in lines per minute (lpm) and characters per minute (cpm).

Printing Mechanism

Description of the printer's key operational components and their timing.

Shuttle Frame Assembly

Description of the shuttle frame assembly housing the hammer bank and drive motor.

Hammer Bank Assembly

Description of the hammer bank assembly and its varying configurations.

Paper Transport System

Explanation of the DC stepper motor system for paper feeding and movement.

Ribbon Transport System

Explanation of the ribbon cartridge system and its components.

Integrated Print Management System

Explanation of the feature that monitors and communicates ribbon life status.

Logical Control of the Printer

Overview of the printer's subsystems: control panel, controller board, power supply, print mechanism.

Controller Board

Description of the controller board's role in printer functions.

Data Controller

Details on the Data Controller's components and responsibilities.

Power Supply Board

Description of the printer's power supply board and its AC/DC power systems.

Printer Interface

Description of the points where data cables connect and supported interfaces.

Wire Data

Interconnection Diagram

Diagram showing the connections between printer components.

Main Wire Harness Test Tables

Tables for testing winding continuity and shorts in wire harnesses.

Circuit Board Pinouts

Pin configurations for the V6 Controller Board and Power Supply.

Cable Assemblies

List and diagrams for various printer cable assemblies.

SureStak Power Stacker

Introduction

Overview of the SureStak Power Stacker option for printers.

Stacker Operation

Description of how the power stacker mechanically directs paper.

Setting Up The Power Stacker

Procedure for setting up the power stacker before operation.

Loading And Starting The Power Stacker

Procedure for loading paper and starting the power stacker.

Stacker Problems

Common problems encountered with the power stacker and troubleshooting references.

Removing The Power Stacker

Step-by-step instructions for removing the stacker assembly.

Installing The Power Stacker

Step-by-step instructions for installing the power stacker assembly.

Replacing the Constant Force Spring

Procedure for replacing the constant force spring.

Replacing the Timing Belts

Procedure for replacing the timing belts.

Replacing the Roller Drive Shaft

Procedure for replacing the roller drive shaft.

Illustrated Parts Breakdown

Exploded drawings and part lists for the power stacker assembly.

Zero Tear Pedestal (ZTP) Printer

Overview

General overview of the 6600 Zero Tear Pedestal (ZTP) printer.

Operation

Explanation of how ZTP printers present forms for tear-off.

Load Paper and Set Up the Tractors

Procedure for loading paper and setting up the tractors on ZTP printers.

Remove Paper

Procedure for removing paper from the ZTP printer.

Adjust The Paper Guides

Procedure for adjusting the paper guide leaves on ZTP printers.

Position the Paper Out Sensor

Procedure for positioning the paper out sensor for optimal performance.

Set the Tear Bar Distance

Procedure for setting the tear off distance on ZTP printers.

Set the Top Of Form

Procedure for setting the top of form on ZTP printers.

Control Panel Menus

Explanation of ZTP specific settings in the control panel menus.

Performance Limitations

Details on ZTP printer performance limitations regarding forms type.

Adjustments and Tests

Procedures for ZTP printer adjustments and tests.

Preparing the ZTP Printer for Maintenance

Steps to prepare the ZTP printer before maintenance.

Returning the Printer to Normal Operation

Steps to return the ZTP printer to normal operation after servicing.

Belt, Paper Feed Timing, Adjustment

Procedure for adjusting the paper feed timing belt on ZTP printers.

Paper Specifications And Forms Design

Introduction

Overview of paper specifications and form design guidelines.

General Paper Specifications

Minimum paper specifications for optimal printer performance.

Paper Guidelines

Terms and definitions related to continuous form paper.

Form Design Checklist

Checklist for key considerations when designing and ordering forms.

Customer Support

TallyGenicom Customer Support Center

Technical support information and required details for calling support.

TallyGenicom Supplies Department

Contact information for ordering genuine TallyGenicom supplies.

Corporate Offices

Contact information for TallyGenicom's global corporate offices.

TallyGenicom 6600 Series Specifications

General IconGeneral
Print TechnologyImpact Dot Matrix
Warranty1 year limited warranty
InterfaceParallel, Serial
EmulationsIBM ProPrinter, Epson FX
Paper Handlingtractor feed
Noise Level55 dB

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