Zebra | 2746e | Service manual | Zebra 2746e Service manual

Commercial
Thermal Printers
Service Manual
2746e
980428-001 Rev. A
©2003 ZIH Corp.
FOREWORD
This manual provides maintenance, diagnosis, service and repair information for the 2746e printer
models manufactured by Zebra Technologies Corporation, Camarillo, California.
TECHNICAL SUPPORT
If for any reason you require product technical support, please contact the Distributor where you first
purchased your equipment. If they cannot help you or at their direction, contact Zebra Repair
Administration.
COPYRIGHT NOTICE
This document contains information proprietary to Zebra Technologies Corporation. This document
and the information contained within is copyrighted by Zebra Technologies Corporation and may
not be duplicated in full or in part by any person without written approval from Zebra. While every
effort has been made to keep the information contained within current and accurate as of the date of
publication, no guarantee is given or implied that the document is error-free or that it is accurate
with regard to any specification. Zebra reserves the right to make changes, for the purpose of
product improvement, at any time.
TRADEMARKS
2746e is service marks and Zebra Technologies is a trademark of Zebra Technologies Corporation.
Windows and MS-DOS are registered trademarks of Microsoft Corp. All other marks are trademarks
or registered trademarks of their respective holders.
OPERATOR CAUTIONS AND WARNINGS
These pages describe general safety and maintenance procedures that an operator must follow.
They are referenced throughout the service manual. The manual may include other warnings and
cautions not displayed here.
ii
980428-001 Rev. A
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REQUIRED TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exterior Cover. . . . . . . . . . . . . . .
Printhead . . . . . . . . . . . . . . . . .
Power Supply Access and Replacement . .
Set AC Voltage . . . . . . . . . . . . . .
DC Power Verification & Adjustment . . .
AC Power Inlet & Switch . . . . . . . . .
DC Power Cable . . . . . . . . . . . . .
AC Power Cable . . . . . . . . . . . . .
Securing the Wire Harness . . . . . . . .
Main PCBA . . . . . . . . . . . . . . . .
Label Roll Support Assembly (Roll Holder)
RTC Installation . . . . . . . . . . . . . .
Motor Cable . . . . . . . . . . . . . . . .
Printhead Cable . . . . . . . . . . . . . .
Label Guide & Sensor. . . . . . . . . . .
Label Sensor PCBAs . . . . . . . . . . .
Control Panel . . . . . . . . . . . . . . .
Head-up Sensor. . . . . . . . . . . . . .
Label Taken Sensor . . . . . . . . . . . .
Peel Mechanism . . . . . . . . . . . . . .
Label Guide Tab . . . . . . . . . . . . .
Motor . . . . . . . . . . . . . . . . . . .
Ribbon Pulley (60 tooth) . . . . . . . . .
Ribbon Drive Belt . . . . . . . . . . . . .
Platen Belt (120 tooth) . . . . . . . . . .
Ribbon Collar & Spring . . . . . . . . . .
Ribbon Tubes & Shaft Support . . . . . .
Rewind Pulley, Tube & Shaft Support. . .
Platen Bearing & Replacement Kit . . . .
Lower Print Mechanism . . . . . . . . . .
Printhead Carriage . . . . . . . . . . . .
Cutter Cable. . . . . . . . . . . . . . . .
Feet . . . . . . . . . . . . . . . . . . . .
Printer Configuration Check. . . . . . . .
Platen Belt and Motor Adjustment. . . . .
Tube Tension - Verify & Adjust . . . . . .
Ribbon Path Adjustment . . . . . . . . .
Printer Information Utility . . . . . . . . .
Packaging for Shipment . . . . . . . . . .
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12
16
17
19
20
21
22
23
24
28
29
30
31
33
35
38
41
43
45
47
48
49
50
51
52
53
54
55
58
60
62
64
66
67
68
69
71
73
75
CLEANING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 77
RECOMMENDED SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
980428-001 Rev. A
3
Warning - Shock Hazard
The printer should never be operated in a location where it can get wet.
Personal injury could result.
Warnung - Stromschlaggefahr - Der Drucker sollte nie an feuchten
Standorten in Betrieb genommen werden. Es besteht erhöhte Verletzungs
und Unfallgefahr.
Warning - Static Discharge
The discharge of electrostatic energy that accumulates on the surface of
the human body or other surfaces can damage or destroy the printhead or
electronic components used in this device. DO NOT TOUCH the
printhead or the electronic components under the printhead assembly.
Caution - Printer Setup & Handling
1)When installing or modifying the printer setup or configuration,
ALWAYS TURN POWER OFF Before:
A) Connecting any cables.
B) Performing any cleaning or maintenance operations.
C) Moving the printer.
2) Damage to the printer interface connector, accessories or enclosure
may result from placing the printer on it’s front bezel or backside during
unpacking or handling.
Media Cautions & Tips
If poor quality, adhesive backed labels are used, with labels that DO NOT
lay flat on the backing liner, the exposed edges may stick to the label
guides and rollers inside the printer, causing the label to peel off from the
liner and jam the printer.
Media Reload Tip
If you should run out of labels while printing, DO NOT turn the power
switch OFF (0) while reloading or data loss may occur. The printer will
automatically resume printing when a new media roll is loaded.
Print Quality Tip
Print density (darkness) is affected by the heat energy (density setting)
applied and by the print speed. Changing both Print Speed and Density
may be required to achieve the desired results.
iv
980428-001 Rev. A
INTRODUCTION
This service manual is intended for the field service engineer or technician. It’s scope covers routine
maintenance, troubleshooting and repair procedures for the printer.
Follow the parts replacement procedures as closely as possible. If you are unsure of any procedure,
please contact your service representative or call the Zebra Technologies technical support group at
(805) 579-1800. See our web site at www.zebra.com for a complete list of international support
options: printer drivers, software, firmware, FAQ’s, contacts, supplies, etc..
Zebra Technologies stocks all Zebra replacement parts for the printer. Be sure your facility stocks
sufficient parts so that scheduled maintenance can take place in a timely manner.
Unpacking the Printer
Printers are carton shipped and wrapped inside a protective bag. Keep all packing materials in case
you need to re-ship the printer later or store the printer for any length of time.
Preparing a Static-Safe Work Area
Prepare a static-safe work area before opening the printer for repair. The area must include a
properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for the
technician. ESD protective devices are available from most electronic supply stores or by contacting
3M corporation at (800) 328-1368.
Environmental and Shock Protection
Extreme temperature and humidity fluctuations or mishandling can damage the printer and power
supply. Allow 30 minutes or more before opening the printer’s plastic bag. This time allows the
printer to stabilize temperature especially after storage in a cool, dry location and then placement in
a warmer, more humid location. Warm, humid air condenses on the cool components of the printer
and this condensation may damage the components.
Move the printer carefully. While the printer has sturdy construction, mechanical
damage can certainly result from falls or rough handling.
980428-001 Rev. A
1
Models
Many of the earlier model Zebra printers are similar in appearance to the Zebra 2746e thermal
printer. The printer features that identify the 2746e printer from similar Zebra printers are:
Print Odometer
Printer Color - Light Grey and teal (bluish green) control button on the front panel
Flash Programmed Printer Memory - No Memory Cartridge (see the rear panel of printer)
Carbon Fiber (Black) 1 inch (inner diameter) Media Roll Holder
Label Dispense (Peel) and Batch Mode Switch (see the rear panel of printer)
A High Tension Label Dispense (Peel) Mechanism
Head-Up Sensor (small sensor slot in the center panel)
300 Watt Power Supply
Expanded Language Support (14 MS DOS™ and 7 Windows™ code pages)
Industry Standard Bar Code including PDF417 and Maxicode two dimensional bar codes
Optional Cutter
Optional Real Time Clock (RTC) with a ten year battery life
2746e
Thermal transfer thermal printer has ribbon tubes
above the printhead mechanism and can print in
Direct Thermal and Thermal Transfer print
modes.
2
980428-001 Rev. A
Conventions
This manual uses the following notations to call attention to important information.
ICON / SYMBOL
MEANING
WARNING - critical safety information.
CAUTION - problem avoidance messages.
STATIC SENSITIVE - follow procedures that protect against the discharge
of electrostatic energy that accumulates on the surface of the human body
or other objects as this discharge can damage or destroy the printhead
and other electronic components.
HEAT - The printhead becomes hot while printing. Protect against
personal injury. DO NOT touch the printhead. Use only the cleaning pen
to perform maintenance.
NOTE - important instructions and reminders.
HINT - helpful information.
980428-001 Rev. A
3
4
980428-001 Rev. A
TROUBLESHOOTING GUIDE
PROBLEMS
SOLUTIONS
With the STATUS
indicator light GREEN, 1. Verify the labels are the correct type.
the printer appears to
be working, but nothing 2. Check the roll and verify that the print surface faces up for printing.
is printed.
Status indicators do
not light when power
switch is on (I)
1. Check power connections from the printer to the outlet.
2. Remove power supply and check fuse. If blown, replace the power
supply.
3. Verify power supply voltage settings, AC input voltage (110VAC or
220VAC), and DC voltage (980428-152).
4. Printer works, but no indicator light. Replace the control panel.
Printer appears to be
working with the
indicator light
GREEN, but nothing
is printed.
1. Check the connections between the printer and the cable as well as
the cable and the computer.
2. Verify the labels are the correct type.
3. Check the roll and verify that the print surface faces up for direct
thermal printing.
4. Check printhead wire bundle connections at main PCBA.
Printing is uniformly
faded or poor quality.
1.
2.
3.
4.
980428-001 Rev. A
Wipe the printhead with the cleaning pen.
Adjust print speed/darkness in software or with programming.
Check the roll and verify that the media print surface is facing up.
Verify the correct media is in use.
5
PROBLEMS
Printing has streaks,
white (non printing)
lines, uneven printing
(a side or sides), or
faded print areas.
SOLUTIONS
1. Wipe the printhead with the cleaning pen. See Cleaning and
Maintenance section for information on optimizing printhead life and
print quality.
2. Use the "SAVE-A-PRINTHEAD" cleaning film (P/N 44902) to remove
contamination build-up.
3. The printhead is a consumable item and may be worn out, requiring
replacement. Check the printhead’s life with the printer information
utility, see the ‘Printer Information Utility’,980428-157.
4. Static damage from touching the head has blown out pixels or the
electronic logic circuitry in the printhead assembly. Replace the head
or secondarily the main board.
5. The main board has failed components.
6. The printhead cable is loose or damaged.
Printing stops and the
STATUS indicator
lights RED.
Printer is in dump
mode but nothing
prints after sending
file.
1. Possible problem sensing labels with transmissive (gap) sensor.
Perform AutoSense adjustment. Align the transmissive (gap) sensor
position, see the user’ manual.
2. Possible problem with label media.
a) Gap between the bottom of a label and the top of the next label
should be at least 1/16" (1.6mm).
b) For tags, see Tag Media Sensing, page .
c) Use only Zebra approved labels and tags.
3. Possible label jam.
4. Check that the media is correctly routed.
5. Possible software/programming problem.
a) Check the printer memory configuration.
b) Refer to the EPL2 Programming manual for the correct data
syntax.
6. Transmissive sensor is dirty. Clean the media path.
1. File does not contain a form feed code that will advance sheet. Press
the Feed button to print data in the printer’s buffer.
ASCII characters print 1. Printer may be in dump mode. Press the Feed button to reset to
normal operation.
in place of expected
label art and bar
2. Check serial port configuration using the Y command. See the EPL2
codes.
programmer’s manual.
6
980428-001 Rev. A
PROBLEMS
SOLUTIONS
1. Align the transmissive (gap) sensor near the narrowest gap between
labels.
Printing stops and
status indicator lights
red
2. Perform the AutoSense adjustment.
3. Check that gap between labels is at least 1/16 inch (1.6mm)
4. For tags, see the discussion of Tag Media Sensing.
5. Check for media jam.
6. Check media is correctly routed.
7. Check printer memory configuration and correct data syntax.
8. Transmissive (gap) is dirty. Clean media path.
1. Check for out-of-media condition or missing labels in the middle of a
roll.
Status indicator
remains red.
Rubbing noise when
pressing Feed button.
2. Check for damage or missing labels in the middle of the roll.
3. Check for correct media routing.
4. If using direct thermal printing, check that programmed mode or
printer driver is set for direct thermal printing. See the programmer’s
book for details.
5. Transmissive (gap) sensor may be dirty. Clean media path.
6. Check the printer carriage is closed and latched.
1. Media is not loaded and the platen is rubbing against the printhead.
Insert media between carriage and platen.
1. Printer is set for dispense/peel mode. Move switch to batch position.
Cutter makes
incomplete cuts or
2. Form length is set wrong. Change length through printer driver or
cuts in the wrong spot.
programming language. See the EPL2 programming manual.
Printer firmware must
be updated.
The printer firmware is updated by way of the parallel port.
1. Use the download utility to send firmware to the printer.
2. Optionally, you can download from the c:\ prompt by typing
copy/b filename lpt1: from the directory holding the update file.
The printer's light should start flashing green-orange, and then every few
seconds will flash red a couple of seconds. Once the update is done, the
light goes dark then comes on green.
printhead Life
The printhead has a limited life and is considered a consumable item. The media rubs across the
printhead print elements and wears away the surface. This process is affected by many factors
relating to the media material, operational settings and environment. To maximize your printhead
life, use the "SAVE-A-PRINTHEAD" cleaning film (P/N 44902) contamination build-up after every
roll.
980428-001 Rev. A
7
Identifying printhead Problems
The printhead wears with printer use. If the print quality does not improve after cleaning, the
printhead may require replacement. Printing with worn damaged print elements may create
unreadable bar codes. printhead damage can be caused by improper cleaning (unapproved fluids or
implements), electro static discharge (ESD), and touching the printhead (contaminates, ESD and
body oil acids). The following are examples of printhead wear or damage.
Weak or Damaged Print Elements
(Full-On Print Pattern)
8
Weak or Damaged Print Elements or Print Logic
(Rotating Print Element Pattern)
980428-001 Rev. A
REQUIRED TOOLS
Make use of the following tools while performing replacement procedures:
Torque wrench with 1/4" hex receptacle)
Phillips driver #1 (tip for 1/4" hex receptacle)
Phillips driver #2 (tip for 1/4" hex receptacle)
Allen key socket tip drivers (tip for 1/4" hex receptacle);
sizes: 1/16", 5/64", 3/32", 1/8", 3mm, 4mm
Nut driver, sizes: 7mm, 8mm, 1/4"
Flat Blade screwdriver (small)
needle-nose pliers
pliers for E-ring retainers (12R)
pliers for axial retainers
tweezers
Clutch torque bit (and torque gauge are spare 105902-060)
.005" shim
Loctite 222 thread locker or equivalent
980428-001 Rev. A
9
10
980428-001 Rev. A
REPLACING PARTS
To access some parts, you need to dissemble other parts; therefore, other procedures must be
followed before and after performing a particular replacement.
980428-001 Rev. A
11
Exterior Cover
Preparations
The printer's exterior cover needs to be removed to perform most of
the disassembly and replacement procedures for the printer.
NOTE
Do not remove the cover until you have read all of the removal
procedure steps or damage to the printer or personal injury may
result.
Before starting the procedure, open the printer, then remove any media from the printer.
Shock Hazard
Always turn off the printer before performing any maintenance or
repair operations. Wait for the indicator light to be dark, then unplug
the power cord.
Tools:
#2 Philips screw driver
Removal
1.
Remove the two (2) upper screws and two
(2) lower screws shown.
Installation
1.
12
Place the cover in position. Secure the cover
with the two (2) upper screws (and washers)
and the two (2) lower screws (and washers)
shown
980428-101 Rev. 1 Prelim.
2.
Lift the cover straight up about 3-5 inches.
Detach the label taken sensor’s cable from
the center panel. The cable is attached to
the front of the printer’s center wall. Slide
the cable out of seam in the center and front
panels.
3.
Disconnect the label taken sensor cable
from main PCBA located in the rear of the
printer.
Disconnect Sensor
Cable at JP26
980428-101 Rev. 1 Prelim.
13
Installation
1.
Ensure that the label taken sensor’s cable is
secured in the two cable anchors under the
left side cover.
Place the cover into position and reverse the
cover removal process.
Anchors
2.
Attach label taken sensor cable to the main
PCBA at JP26.
JP26
14
Attach Cable to
Main PCBA
980428-101 Rev. 1 Prelim.
3.
Slide the cable into the seam between the
front and center panels. Remove as much
excess loop in the cable towards the rear of
the printer and main PCBA.
4.
Put the cover on the printer. Verify that the
cable has not been pinched between the
cover and printer.
5.
Push the excess cable back into the seam
between the front and center panel.
6.
Re-attach the cover to the printer with the
washers and screws.
7.
Verify the cable has a minimal service loop
(1/4 to ½ inch) that does not pull tight when
the cover is in the full open position.
Protect against static discharge when handling the printer with the
cover removed. Your work area must be static-safe and should
include a properly grounded conductive cushioned mat to hold the
printer and a conductive wrist strap for yourself.
980428-101 Rev. 1 Prelim.
15
Printhead
Preparations
Before starting the procedure, open the printer, then remove any media from the printer.
Tools:
3mm Allen wrench hex key or driver
Removal
1.
Open the printhead assembly.
2.
Lower the printhead by loosening the
mounting Allen head screw which is
accessed through a hole in the top of the
printhead assembly.
3.
Detach the printhead (ribbon) cable.
Installation
1.
Connect the replacement printhead. Pin 1
on the printhead and cable is toward the
center panel of the printer.
2.
Align the printhead with the two bracket
alignment pins.
3.
Secure printhead to printhead bracket by
tightening the printhead bracket screw.
Recommended - Tighten the Allen head
screw to 4.7 ±1 in. lb.
4.
Close and open the printhead and recheck
that the printhead cable still secure and
connected to the printhead and moves
freely without binding..
5.
Clean the printhead after completing
installation, see Cleaning and Maintenance.
6.
Reset the printhead odometer with the
Printer Information service utility program,
see procedure 980428-157.
16
980428-102 Rev. 1 Prelim.
Power Supply Access and Replacement
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
#2 Philips screw driver
Power Supply Access
1.
Cut the two (2) cable ties securing the cable
harness to the top of the power supply.
Caution - Do not cut the cables.
2.
Remove the screw securing the grounding
lug and wire to the top of the power supply.
3.
With the printer tilted towards the right side,
hold the power supply while removing the
two (2) screws (and washers) that secure it
to bottom panel.
3.
Swing the power supply out and down next
to the printer to gain access to the AC
Cut Cable Ties
voltage setting jumpers, power supply
cables or make a DC voltage adjustment.
Caution - The connectors on the cable
harness may come loose or inadvertently
disconnected if special care is not taken.
Power Supply Removal
4.
Disconnect the AC and DC power cable
from the power supply.
Installation
1.
Reverse the power supply removal and
access processes.
-- If replacing the power supply, the AC
voltage should be set prior to installing the
power supply, see procedure 980428-104.
-- The DC voltage setting should be verified
prior to attaching the power supply to the
printer, see procedure 980428-105.
Important - Re-attach the ground wire to
the power supply in the following order:
1) Star Washer 2) Ground wire and lug
(from toroid) 3) Star Washer 4) Nut.
Tighten the nut to 7.5 ±2 in. Lb. torque
980428-103 Rev. 1 Prelim.
17
Installation
1.
Reverse the power supply removal and
access processes.
-- If replacing the power supply, the AC
voltage should be set prior to installing the
power supply, see procedure 980428-104.
-- The DC voltage setting should be verified
prior to attaching the power supply to the
printer, see procedure 980428-105.
Important - Re-attach the ground wire to
the power supply in the following order:
1) Star Washer 2) Ground wire and lug
(from toroid) 3) Star Washer 4) Nut.
Tighten the nut to 7.5 ±2 in. Lb. torque
2.
Add two (2) cable tie anchors to the front
and rear of the power supply (as shown).
3.
Re-tie the main PCBA harness. Use the
"Securing the Harness" procedure,
980428-009.
18
Add Cable
Anchor Ties
980428-103 Rev. 1 Prelim.
Set AC Voltage
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
The power supply must be detached from the bottom panel for access. (980428-103)
Set Voltage
Disconnect the power supply from the cable
harness and printer base.
1
1.
230VAC
2.
3.
Move the voltage selection jumper wire to
the appropriate voltage pin. Verify the
correct voltage is marked next to the
jumpers pin.
AC
Input
110VAC
DC
Supply
Voltage
to PCBA
With a marking pen, print the new voltage
setting on the voltage label on outside of the
power supply case.
Re-assemble Printer
1.
Remount the power supply using the screws
and washers.
2.
Important - Re-attach the ground wire to
the power supply in the following order:
1) Star Washer 2) Ground wire and lug
(from toroid) 3) Star Washer 4) Screw.
Tighten the nut to 7.5 ±2 in. Lb. torque
3.
Re-anchor the cable harness to the top of
the power supply.
4.
Verify that the cables and ties have not
become loose or damaged. Verify that the
cable tie points have not moved, allowing
the cables to touch belts or gears.
5.
Re-attach the exterior cover.
NOTE
Fuse Warning
If the power supply's fuse has blown, the power supply most likely has
a critical component failure. The majority of fuse failures require a
power supply replacement.
980428-104 Rev. 1 Prelim.
19
DC Power Verification & Adjustment
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
The power supply must be detached from the bottom panel for access. (980428-103)
Shock Hazard
Always turn off the printer before removing the exterior cover.
The printer must be turned on after the cover is removed to perform
this procedure. See the following procedure.
DC Voltage Verification
1.
Disconnect the DC power cable (JP6) from
main PCBA.
2.
Insert the positive voltage probe of a digital
voltmeter into one of the cable's connector
plug's socket pins with a red wire connected
to it. Insert the other probe into a socket pin
that has a black wire attached to it.
3.
Turn the printer on. Measure the voltage.
The voltage should be 25 ±2 VDC. Turn
off the power.
DC Power
JP6
If the voltage is out of range, the voltage
needs to be adjusted.
4.
Disconnect the
DC Power
Cable Here
Re-attach the DC power cable to the main
PCBA.
DC Voltage adjustment
2.
Un-mount the power supply as if you were
to replacing it, see procedure 980428-103.
Leave the AC power connector plugged in.
Connect the voltmeter to the DC power
cable as described above.
3.
Turn the power on and adjust the voltage to
25 VDC. Turn the power off.
4.
Re-attach the power supply and re-tie the
main PCBA harness. Use the "Securing the
Harness" procedure.
20
1
1.
230VAC
AC
Input
110VAC
DC
Supply
Voltage
to PCBA
980428-105 Rev. 1 Prelim.
AC Power Inlet & Switch
Preparations
The exterior cover must be removed prior to proceeding. (Procedure 980428-101)
The power supply must be unscrewed from the printer's bottom plate. (Procedure 980428-103)
Power Switch Removal
1.
Push the retaining tabs into the side of the
power switch or AC power filter module
and slide it out of the back panel.
Power Switch Installation
1.
Disconnect the old switch's wires, one at a
time, and reconnect them to the new switch
in the same position. Note the switch's
orientation, 1 (one) to the outside and 0
(zero) towards the center panel.
2.
Push the new switch into the back panel
until flush with the back panel. Wiggle it
from the inside to very that it has locked in
place.
AC Power Inlet Removal
1.
Push the retaining tabs into the side of the
AC power inlet module and slide the
module out of the back panel.
AC Module Installation
1.
Disconnect the old module's wires, one at a
time, and reconnect them to the new switch
in the same position. Note the module's
orientation, ground towards the bottom
plate.
2.
Push the new module into the back panel
until flush with the back panel. Wiggle it
from the inside to very that it has locked in
place.
980428-106 Rev. 1 Prelim.
Switch and AC
Power Inlet Module
Retaining Tabs
21
DC Power Cable
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
The power supply must be detached from the bottom panel for access. (980428-103)
Note the main cable harness routing and cable tie positions. (980428-009)
DC Voltage Verification
Removal
1.
Cut the two (2) tie-wraps securing the main
cable harness to the power supply. Caution
- Do not cut the cables!
2.
Disconnect the ground wire from the top of
the power supply.
3.
Remove the two screws holding the power
supply to the base plate. Set the power
supply next to the printer.
4.
Disconnect the power cable (JP6) from
main PCBA.
5.
Disconnect the power cable from the power
supply.
DC Power
JP6
Disconnect the
DC Power
Cable Here
Installation
1.
Connect the power cable (JP6) to the main
PCBA.
2.
Connect the power cable to the power
supply.
3.
Re-attach the power supply to the base.
4.
Important - Re-attach the ground wire to
the power supply in the following order:
1) Star Washer 2) Ground wire and lug
(from toroid) 3) Star Washer 4) Screw.
Tighten the nut to 7.5 ±2 in. Lb. torque
5.
Re-tie the main PCBA harness. Use the
"Securing the Harness" procedure,
980428-009.
22
980428-107 Rev. 1 Prelim.
AC Power Cable
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
For best results, the detach the power supply from the printer bottom. (Procedure 980428-103)
Tools:
5/16 in. Nut Driver, #1 Phillips Screwdriver
Removal & Replacement
1.
After the power supply is laying on its side
next to the printer, disconnect the AC power
cable’s connector from the power supply.
2.
With a nut driver, disconnect the green
ground wire from the printer’s bottom
panel.
3.
Remove and immediately replace the
individual AC cable components from the
AC Power Cable spares kit.
4.
Important - Attach the chassis ground to
the bottom panel of the printer in the
following order: 1) Star Washer 2) Ground
wire and lug (½ inch from toroid) 3) Star
Washer 4) Nut.
Tighten the nut to 7.5 ±2 in. Lb. torque.
5.
Re-attach the AC power cable to the power
supply.
6.
Re-attach the power supply. See procedure
980428-009, note the power supply ground
and cable tie points.
Power Supply
Ground
Chassis Ground
Important - Re-attach the ground wire to
the power supply in the following order:
1) Star Washer 2) Ground wire and lug
(from toroid) 3) Star Washer 4) Screw.
Tighten the nut to 7.5 ±2 in. Lb. torque
Chassis Ground
980428-108 Rev. 1 Prelim.
23
Securing the Wire Harness
The printer was designed to meet or exceed all regulatory agency (CE, FCC, UL, CSA, etc.) safety
and electro-magnetic requirements. The positioning and anchoring of the cables and connectors are
critical to meet these requirements.
The following diagrams the physical location of the printer's primary cable groups and cable tie
points.
Controls and
Sensors
Motor
Printhead
Cable Tie
and
Anchor
Cable Tie
Cable Tie
DC
Power
Cable Ties
and
Anchors
DC Power
Motor
Verify all cables are connected prior to proceeding.
Verify the Main PCBA is pressed into the center panel's circuit board standoffs (and
secured with its mounting hardware).
24
980428-109 Rev. 1 Prelim.
Cable Clearance Check Procedure
The printer cables and connectors must not interfere (touch) with any
moving components (belts, gears or springs).
Placement of cable tie points, tie anchors, and cable tension and slack areas are outlined in the
following steps:
Control Panel Tie Point
1.
Cable Tie
Pull the control panel cable until minimum
1/4" service loop (slack) is present between
the cable tie and control panel PCBA.
Tighten the tie and cut off the excess.
Front Power Supply Cable Tie Point
1.
Loosely tie the DC power, control panel,
head-up, label sensor, and motor cables
with a cable tie through the front anchor tie
on top of the power supply.
2.
Push the label sensor slide to the maximum
distance into the user side of the printer. Pull
the sensor cables through the power supply
anchor tie towards the main PCBA, taught
but not strained. Tighten the tie.
3.
Pull the control panel cable through the
power supply anchor tie towards the main
PCBA, taught but not strained.
4.
While holding the head-up cable one-half
inch parallel to the center panel of the
head-up PCBA, connect the head-up cable
to the control panel cable with a cable tie.
Cable Tie
Front
Anchor Tie
Pull the head-up cable taught to the power
supply’s front cable anchor tie.
980428-109 Rev. 1 Prelim.
25
5.
Pull the DC power cable through power
supply’s front cable anchor tie until no more
than 2 inches and no less than 1 inch of
service loop away from the front side of the
power supply.
Front
Anchor Tie
6.
Position the motor cable’s spiral wrapping
to where one-third of the wrapping is
through the center panel towards the motor.
While holding the spiral wrapped portion
motor cable exiting the center panel parallel
to the printer base and roughly
perpendicular to the center panel, pull the
motor cable towards the main PCBA
through the power supply’s front cable
anchor tie.
7.
26
Tighten the cable tie on the power supply’s
front cable anchor and remove (cut) the
excess off.
980428-109 Rev. 1 Prelim.
Rear Power Supply Cable Tie Point
1.
Pull the control panel, label sensor and
head-up cables exiting the front cable
anchor tie to the rear cable anchor and tie
them loosely in place. Arrange the bundle
neatly. Pull the cable to the rear, taught
through the rear tie and tighten it tight.
Remove (cut) the excess tie.
2.
Fold the excess cable from the sensors and
controls into the bundle. Tie the bundle with
a cable tie approximately one inch from
their connectors on the main board. Finish
tightening the tie wrap.
3.
Verify there is approximately 1/8 inch
service loop on all the cables going from
the rear anchor tie to the connectors on the
main PCBA.
Final Check
1.
2.
Verify the printer cables and connectors are
not interfering (touching) with any moving
components (belts, gears or springs).
Rear
Anchor Tie
Verify all ties are snug.
980428-109 Rev. 1 Prelim.
27
Main PCBA
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
If needed, load the Printer Information Software Utility into printer test PC. (980428-157)
Tools:
#1 Philips screw driver
Removal
1.
Use the Print Information software utility to
extract the printer’s serial number and head
life prior to PCBA removal, if possible.
2.
Disconnect all the external cables and
power cords from the printer.
3.
Disconnect the motor, DC power, and the
printhead cables from the main PCBA.
4.
Remove the four (4) mounting screws
holding the main PCBA to the center panel.
5.
With the sensor and control cables still
attached to the main PCBA, gently lift the
main PCBA off the stand-offs.
6.
Set the old main PCBA gently aside, next to
the power supply. Have care not to
disconnect the sensor and control cables.
Screws
Installation
1.
Mount the main PCBA on the stand-offs
and secure the main PCBA to the center
panel with the four (4) mounting screws.
2.
Swing the old main PCBA next to new
PCBA with both boards’ sensor and control
connectors and cables accessible.
3.
One at a time, disconnect the sensor and control cables from the old board and plug them
immediately into to the matching location on the new PCBA. Remove the RTC from the old
PCBA (if present) and place it on the on the new PCBA. See RTC Installation, 980428-112.
4.
Connect the motor, DC power, and the printhead cables to the new main PCBA.
5.
Power up the printer and load media to verify operation with the AutoSense routine.
6.
Use the Printer Information utility to set the previous PCBA’s serial number into the new
PCBA and head life reporting parameters (inches or millimeters) to track printer and head life.
28
980428-110 Rev. 1 Prelim.
Label Roll Support Assembly (Roll Holder)
Preparations
Before starting the procedure, open the printer, then remove any media from the printer.
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
#1 & #2 Philips screwdrivers
Removal & Replacement
1.
Remove the four (4) screws securing the
Main PCBA to the chassis. Pull the main
PCBA off the stand-offs. Leave the cables
attached and gently lay the PCBA against
the printer and work surface.
2.
Remove the four (4) mounting screws
securing the Label Roll Support assembly to
the center panel.
3.
Install the new Label Roll Support assembly
with the four (4) screws and re-attach the
Main PCBA with it's screws.
Screws
980428-111 Rev. 1 Prelim.
29
RTC Installation
Preparations
The exterior cover must be removed prior to proceeding. (Procedure 980428-101)
Tools:
No additional tools needed
Installation
RTC - Real Time Clock Option
1.
Add the real time clock option chip into the
socket at location U2. Match the notch on
the socket and the dot RTC module to
properly orient the module.
The real time clock option stores the time of
day and date. The chip's battery has a life
of up to ten years.
See the EPL2 Programmer's Manual
for information about setting the real time
clock, and formatting the layout of the date
and time.
RTC Socket
Re-assembling the Printer
1.
Reattach the printer cover.
2.
Attach the power cord and interface cable.
3.
Power up the printer and run the
AutoSense routine to verify that the RTC
option has recognized by the printer.
4.
Set the clock and print display format using
the EPL2 commands TD, TS and TT.
30
980428-112 Rev. 1 Prelim.
Motor Cable
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Note the main cable harness routing and cable tie positions. (980428-109)
Tools:
Large Flat Blade Screwdriver
Removal
1.
Cut the front tie-wrap securing the main
cable harness to the power supply. Caution
- Do not cut the cables!
2.
Disconnect the power cable (JP6) from
main PCBA.
DC Power
JP8
Cut the
Cable Tie
980428-115 Rev. 1 Prelim.
31
3.
Disconnect the motor cable from the motor.
The motor connector can be pried off with a
large bladed screw driver. Pull the cable out
of the users side through the center panel’s
wall and out the service access side
4.
Remove the spiral wrap from the old cable.
Installation
1.
Add the spiral wrap to the new motor cable.
2.
Pass the cable through the center panel’s
motor access hole and plug it into the
motor.
3.
Slide the spiral wrapping until it is
positioned with two-third on the service side
of the center panel wall.
4.
Re-attach the motor cable with the main
cable bundle to the front cable anchor tie on
the power supply. Use the "Securing the
Harness" procedure, 980428-009, to
complete dressing the motor and other
cables.
32
980428-115 Rev. 1 Prelim.
Printhead Cable
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
3mm Allen wrench hex key or driver
Removal
1.
Cut the tie-wrap securing the main cable
harness to the power supply. Caution - Do
not cut the cables!
2.
Disconnect the printhead cable (JP21) from
main PCBA.
3.
Open the printhead assembly.
4.
Lower the printhead by loosening the
mounting Allen head screw which is
accessed through a hole in the top of the
printhead assembly.
5.
Detach the printhead (ribbon) cable. Set the
loose printhead on a clean, soft and static
safe surface (mat).
6.
Pull the cable out through the center panel.
7.
Remove the cable's spiral wrap.
Installation
1.
Place the spiral wrap on the new cable.
2.
Connect the cable to the JP21 on the main
PCBA. Note pin 1 on the connector and
cable. Slide the spiral wrap 2" from the
printhead end of the cable.
3.
Route the cable through the center panel.
Lower the printhead for easier access.
980428-116 Rev. 1 Prelim.
33
5.
Align the printhead with the two bracket
alignment pins.
6.
Secure printhead to printhead bracket by
tightening the printhead bracket Allen head
screw. Tighten the screw to 4.7 ±1 in. lb.
7.
Close and open the printhead and recheck
that the printhead cable still secure and
connected to the printhead. Verify that 1/4
is inside and 3/4 of the spiral wrap is outside
of the center panel. This protects the cable
from rubbing on the belt and printhead
carriage.
8.
Re-tie the main PCBA harness. Use the
"Securing the Harness" procedure
980428-009.
9.
Clean the printhead after completing
installation.
34
Pin 1 of JP21
printhead
Connector
980428-116 Rev. 1 Prelim.
Label Guide & Sensor
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Note the main cable harness routing and cable tie positions. (980428-109)
The Label Guide & Sensor assembly is mounted below the printhead assembly. The sensor slide
and cables pass through the center panel of the printer chassis and plug into the main PCBA.
Tools:
#2 Philips screw driver
Removal
1.
Cut the two (2) tie-wraps securing the
sensor cable to the power supply.
Caution - Do not cut the cables!
2.
Disconnect the label guide and sensor
cables (JP27, JP28 and JP5) from main
PCBA.
JP27
GAP-RX
JP28
GAP-TX
JP5
BLK-LNE
Cut Ties
980428-117 Rev. 1 Prelim.
35
3.
From the user’s access area (right side of
printer), open the printhead with the
printhead's release latch.
Adjust the sensor slide to the outside
position, away from the center panel of the
printer chassis.
4.
Remove the pan head screw securing the
label guide and sensor assembly to center
panel of the printer chassis (user access
side).
Screw
Release Latch
5.
Slide the label guide and sensor assembly
toward the front of the printer, (approx. 1/4"
parallel to the center panel) and pull the
assembly out away from the center panel
when it clears the panel.
Pull the sensor cables out through the center
panel.
36
980428-117 Rev. 1 Prelim.
Installation
1.
Slide the sensor guide's four (4) cables
through the sensor slide’s hole.
2.
Insert and hook the label guide’s tab onto
the center panel’s cut-out.
3.
Secure the label guide and sensor assembly
to the center panel with the pan head screw.
4.
Close the printhead.
Hook guide to center panel
5.
Re-connect the cables (JP27, JP28 and JP5)
to the Main PCBA. The five (5) conductor
cable exiting the bottom of the sensor slide
gets connected to JP5.
3 conductor - JP27
2 conductor - JP28
(bottom set)
6.
Re-tie the main PCBA harness. Use the
‘Securing the Wire Harness’ procedure,
980428-109, to properly re-attach the
cables.
980428-117 Rev. 1 Prelim.
5 conductor - JP5
(bottom set)
37
Label Sensor PCBAs
Preparations
The exterior cover must be removed prior to proceeding. (Procedure 980428-101)
Note the main cable harness routing and cable tie positions. (980428-109)
Remove the Label Sensor and Guide Assembly from the printer. (980428-117)
Tools:
#2 Philips screw driver
Removal
1.
Slide the sensor adjustment slide into the
sensor housing.
2.
Remove the three (3) screws attaching the
lower housing to the upper.
3.
Gently rock the lower housing while slowly
pulling lower housing and slide parallel to
the upper housing.
38
980428-118 Rev. 1 Prelim.
4.
Completely slide the lower and upper
housings from the slide.
5.
Remove the adhesive securing the cables at
the end of the slide. Caution - Do not
damage the slide or good cables or
good PCBAs.
6.
Slide the appropriate cable out of the cable
clips. Note how the cables are attached and
routed.
7.
While holding the slide to keep it from
spreading apart, gently pull the appropriate
PCBA from the slide.
Gap Receiver PCBA
Cable Clips
Cable Clips
Gap Emitter / Black Mark PCBA
Installation
1.
Press the new PCBA onto the slide with the
components and cables facing up.
2.
Route the cables flat against the slides
without twists and under the cable clips.
Cable Routed
Under Clips
980428-118 Rev. 1 Prelim.
39
3.
Add adhesive (hot melt glue or RTV) to the
end of the slide to secure the cables to the
slide. Remove excess adhesive immediately.
let the adhesive set before continuing.
4.
Slide the sensor adjustment slide half way
into the lower housing.
5.
Insert the cables into the slide access in the
upper housing.
6.
Finish sliding the two housings together.
Gently rock the lower housing while slowly
pushing the lower housing into the upper
housing.
7.
Re-attach the lower housing to the upper
with the three (3) screws.
8.
Install the label guide and sensor assembly
using the "Label Guide & Sensor"
procedure.
40
980428-118 Rev. 1 Prelim.
Control Panel
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Note the main cable harness routing and cable tie positions. (980428-109)
Tools:
#1 Philips screw driver
Removal
1.
Cut the three (3) tie-wraps securing the
cables to the power supply and the front
panel.
Caution - Do not cut the cables!
2.
Disconnect the control panel cable (JP35)
from main PCBA.
JP35
Cut Cable Tie
Cut Cable Ties
980428-119 Rev. 1 Prelim.
41
4.
Remove the four (4) screws holding the
control panel assembly to the front panel.
5.
Pull the control panel assembly straight out
the front panel of the printer.
Screws
Installation
1.
Insert the control panel cable into the
control panel's access hole. Pull the cable
through.
2.
Re-attach the control panel assembly to the
inside of the front panel with the four (4)
retaining screws.
Tighten to 4.7±1inch-pounds of torque.
3.
Plug the Control Panel’s cable into the main
PCBA at connector JP35.
3.
Re-attach the control panel’s cable to the
main cable bundle at the front cable anchor
tie on the power supply. Use the "Securing
the Harness" procedure, 980428-009, to
complete dressing the control panel,
head-up and other cables.
42
980428-119 Rev. 1 Prelim.
Head-up Sensor
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Note the main cable harness routing and cable tie positions. (980428-109)
Removal
1.
Cut the three (3) tie-wraps securing the
cables to the power supply and the front
panel.
Caution - Do not cut the cables!
2.
Disconnect the control panel cable (JP14)
from main PCBA.
JP14
Cut Cable Tie
Cut Cable Ties
980428-121 Rev. 1 Prelim.
43
4.
Pull the head-up sensor PCBA stand-offs.
Head-Up
Sensor
PCBA
Installation
1.
Insert the head-up sensor PCBA onto the
stand-offs with the cable facing into the
center of the printer.
2.
Plug the head-up sensor’s cable into the
main PCBA at connector JP14.
3.
Re-attach the head-up sensor’s cable to the
main cable bundle at the front cable anchor
tie on the power supply. Use the "Securing
the Harness" procedure, 980428-009, to
complete dressing the control panel,
head-up and other cables.
44
980428-121 Rev. 1 Prelim.
Label Taken Sensor
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
No additional tools needed
Removal
1.
Remove the printers cover.
2.
Slip the sensor’s cable out of the anchor ties
under the left side cover.
Anchor Ties
3.
Slip the sensor cable out of the channel in
the upper front cover.
980428-123 Rev. 1 Prelim.
45
4.
Pull the label taken sensor PCBA out of the
sensor gate’s sensor shroud. Gently pull the
shroud body away from the gate to get the
PCBA past the snap locks on the inside of
the shroud.
5.
Slide the cable out of the shroud.
Installation
1. Reverse the process.
46
980428-123 Rev. 1 Prelim.
Peel Mechanism
Tools:
#1 Philips screw driver
Removal
1.
Remove the two (2) screws holding the peeler mechanism to the lower print mechanism. The
peeler spacer plate will also become loose.
Installation
1.
Place and hold the peeler spacer plate against the lower print mechanism with the cutout
facing down. Align the plate up with the mounting two (2) holes.
2.
Place the peel mechanism against the spacer plate and insert the two (2) flat head screws.
Tighten the screws to 4.7 inch-pounds torque.
3.
Optional - Verify the label rewind tube torque setting is set to 17 ±1 inch-pounds with the
“Tube Tension Adjustment Procedure”, 980428-154.
980428-125 Rev. 1 Prelim.
47
Label Guide Tab
Tools:
Pliers and a scribe
Tab Stop Pin
Removal
1.
2.
Push the tab stop pin out of the guide tab's
slide on the label guide and sensor
assembly.
Guide Tab
Rotate the guide tab down and slide the tab
off the slide.
Installation
Slide the guide tab on the slide.
2.
Insert the tab stop pin until it is flush with
the bottom.
3.
Pull the guide tab to the outside of the slide
and verify the guide tab can rotate up.
T OR
P
EP
ER MO
1.
ST
48
980428-126 Rev. 1 Prelim.
Motor
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
4mm Allen hex key socket driver
Removal
1.
Remove the four (4) M5x14 socket head mounting screws securing the motor to the center
panel. (4mm Allen head socket - 1/4 inch hex shank for use with torque gauge).
2.
With the motor loose, disconnect the belt and then the motor cable from the motor.
Reference - Do Not Disconnect Pulley
0.070 inch
Gap
CENTER PANEL
Pulley
PULLEY
STEPPING
MOTOR
SOCKET
HEAD
SCREWS
LOCK WASHER
FLAT WASHER
HEX NUT
Spiral
Wrap
Installation
CABLE
TO
MAIN PCB
MOTOR
CABLE
CONNECTOR
1.
Attach the motor cable to the new motor.
2.
Insert motor, but leave the mounting screws loose.
3.
Re-install the belt around the 42-tooth pulley on the platen and the motor pulley.
4.
Tighten the belt by sliding the motor toward the rear panel. Secure the motor in place. Refer to
Platen Belt and Motor Adjustment procedure, 980428-153, for setting the recommended belt
tension.
980428-129 Rev. 1 Prelim.
49
Ribbon Pulley (60 tooth)
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
11/32 Allen driver
Removal
1.
2.
3.
Ribbon
Pulley
(60 Tooth)
Loosen the ribbon belt by rotating the belt
tension idler counter-clockwise. Lift the
ribbon belt off the ribbon pulley.
Ribbon
Drive Belt
(324 tooth)
Rotate ribbon pulley to view set screw from
the top of the center panel. Loosen set
screw.
Platen
Pulley
Clutch
Remove ribbon pulley from shaft.
Belt
Tension
Idler
Rewind
Pulley
Power Supply
Location
Installation
1.
Slide a nylon washer and then the ribbon
pulley onto the tube shaft. The pulley's set
screw faces the center panel.
2.
Hold ribbon take-up tube against shaft
support housing and center panel. Use a
.005 inch shim to space pulley from shaft
support housing. Tighten set screw to 11
inch-pounds torque. Use a thread lock
(Loctite) on the set screw.
3.
Place the belt on rewind pulley behind the
power supply.
4.
Place the belt over the belt tension idler and
around the outside gear of the pulley clutch.
Rotate the tension idler counter-clockwise
to provide slack. Pull the belt over the
ribbon pulley. Release the tension idler.
50
980428-131 Rev. 1 Prelim.
Ribbon Drive Belt
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Removal
1.
Cut the tie-wrap securing the main cable
harness to the power supply. Caution - Do
not cut the cables!
2.
Disconnect the printhead cable (JP21) from
main PCBA.
3.
Loosen the belt by rotating the belt
tensioner idler counter-clockwise. Lift the
ribbon belt off the ribbon pulley, rewind
pulley and then out.
Ribbon
Pulley
(60 Tooth)
Installation
1.
Slide belt into position with the print head
ribbon cable passing through the belt.
2.
Place the belt on rewind pulley behind the
power supply.
3.
Place the ribbon belt over the belt tension
idler and around the outside gear of the
pulley clutch assembly. Rotate the tension
idler counter-clockwise to provide slack. Pull
the belt over the ribbon pulley. Release the
tension idler.
4.
Reconnect the printhead cable to the main
PCBA .
5.
Re-tie the main PCBA harness. Use the
"Securing the Harness" procedure.
980428-132 Rev. 1 Prelim.
Ribbon
Drive Belt
(324 tooth)
Platen
Pulley
Clutch
Belt
Tension
Idler
Rewind
Pulley
Power Supply
Location
51
Platen Belt (120 tooth)
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
TORX tool with #T25 tip or 4mm allen head
Removal
1.
2.
Ribbon
Pulley
(60 Tooth)
Loosen the ribbon belt by rotating the belt
tension idler counter clockwise. Lift the
ribbon belt off the ribbon and clutch pulleys.
Do not disconnect the print head cable.
Ribbon
Drive Belt
(324 tooth)
Loosen the four (4) M5x14 socket head
mounting screws securing the motor to the
center panel. Manually walk the platen belt
off the pulley.
Platen
Pulley
Clutch
Installation
1.
Slide platen belt on the motor gear and then
onto the 42 tooth pulley inside of the pulley
clutch.
2.
Place the belt on rewind pulley (behind the
power supply).
3.
4.
52
Place the ribbon belt around the belt tension
idler and lower pulley. Rotate the tension
idler counter-clockwise to provide slack. Pull
the belt over the ribbon pulley. Release the
tension idler.
Belt
Tension
Idler
Drive Belt
(120 tooth)
Rewind
Pulley
Motor Mounting
Hardware
Tighten the platen belt by sliding the motor
toward the rear panel. Secure the motor in
place. Refer to Adjusting Belt Tension for
setting the recommended belt tension.
980428-136 Rev. 1 Prelim.
Ribbon Collar & Spring
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
Pliers for E-ring retainers (12R)
11/32 Allen driver
Removal
1.
Loosen supply ribbon tube's collar set screw.
2.
Slide the collar off the tube shaft and spring
off the post.
Installation
1.
Slide the nylon washer and then the collar
onto the tube shaft.
2.
Slide the end of the collar's spring on the
post below the collar.
3.
Rotate the shaft of the supply ribbon tube
has the set screw and slot facing up. The set
screw needs to face up to allow access to
adjust tube tension.
4.
Hold the ribbon tube against the center
panel. Use a .005 inch shim to space the
collar from the shaft support housing.
Tighten set screw to 11 inch-pounds torque.
Use a thread lock (Loctite) on the set screw.
980023-138 Rev. 1 Prelim.
53
Ribbon Tubes & Shaft Support
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Take-Up Ribbon Tube Or Shaft Support Housing - The ribbon belt and pulley must be
removed from the tube shaft prior to preceding. (980428-132)
Supply Ribbon Tube Or Shaft Support Housing - The ribbon supply collar and spring must be
removed from the tube shaft prior to preceding. (980428-138)
Nylon Bearing
Take-Up
Ribbon
Tubes
Supply
Tools:
#2 Philips screwdriver
Removal
1.
With the collar or pulley removed, slide the ribbon tube out of the shaft support housing.
2.
Shaft Support Housing only - Remove the two (2) mounting screws securing the shaft support
housing to the center panel.
Installation
1.
Shaft Support Housing only - Insert the two (2) nylon bearings into each end of the shaft
housing. No lubrication is needed.
2.
Shaft Support Housing only - Insert the housing into the center panel. Rotate the housing
to align the two (2) molded posts. Attach the housing to the center panel with two (2) screws.
3.
Place the nylon washer on the shaft and push it against the tube assembly.
4.
Slide the tube assembly into the shaft support housing and re-install the collar (supply) or
ribbon belt and pulley (take-up).
54
980428-139 Rev. 1 Prelim.
Rewind Pulley, Tube & Shaft Support
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
The power supply must be loosened from the printer's bottom plate. (980428-103)
Tools:
#2 Philips screw driver
11/32 Allen driver
Removal
1.
Partially disconnect the power supply and
place it next to the printer base to gain
access to the rewind assembly.
Ribbon
Pulley
(60 Tooth)
2.
Ribbon
Drive Belt
(324 tooth)
Loosen the ribbon belt by rotating the belt
tension idler counter-clockwise. Lift the
ribbon belt off the ribbon pulley.
Platen
Pulley
Clutch
Belt
Tension
Idler
Rewind
Pulley
980428-140 Rev. 1 Prelim.
Power Supply
Location
55
3.
Pulley Only - Rotate rewind pulley to view
set screw from the top of the center panel.
Loosen set screw and slide rewind pulley off
the shaft.
4.
Rewind Tube Assembly Only (to here) Slide the rewind tube assembly out of the
shaft support housing.
5.
Shaft Housing - Remove the two (2)
screws holding the shaft support housing to
the center panel.
56
980428-140 Rev. 1 Prelim.
Installation
1.
Nylon Bearing
Shaft Housing - Insert the two (2) nylon
bearings into each end of the shaft housing.
No lubrication is needed.
2.
Re-attach the shaft housing to the center
panel with the two (2) screws. Tighten the
two (2) screws retaining the label rewind
tube assembly to 11 inch-pounds torque.
3.
Rewind Tube Assembly - Insert the thin
nylon washer on the shaft of the tube
assembly.
4.
Insert the rewind tube into the shaft support
assembly.
5.
On the service side of the printer, insert
another thin nylon washer on the shaft of
the tube assembly.I
6.
Pulley - Slide rewind pulley on shaft. Use a
.005 inch shim to space pulley from shaft
support housing.
Tighten set screw to 11 inch-pounds torque.
Use a thread lock (Loctite) on the set screw.
7.
Ribbon Belt - Place the ribbon belt around
the rewind pulley, over the belt tension idler
and around the outside gear of the pulley
clutch assembly. Rotate the tension idler
counter-clockwise to provide slack. Pull the
belt over the ribbon pulley. Release the
tension idler.
8.
Re-attach the power supply and exterior
cover.
980428-140 Rev. 1 Prelim.
57
Platen Bearing & Replacement Kit
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
The power supply must be moved to access the rewind pulley.
(Procedures 980428-103, 980428-009)
The platen belt, clutch pulley and 42 tooth pulley must be removed prior to proceeding.
(980428-137)
Tools:
4mm Allen hex key socket driver
#2 Philips Screwdriver
Pliers for E-ring retainers (12R)
11/32 Allen driver
Removal
1.
Remove the E-ring from the end of the platen shaft on the outside of the lower print
mechanism.
2.
Remove nylon washers and flange bearings.
3.
Slide the platen right (from front) and remove the brass platen sleeve and then left and remove
the other sleeve from the other side of the center panel.
4.
With platen pushed into the center panel, lift the other side up and out of the lower print
mechanism.
PLATEN SLEEVE
FLANGE-TYPE BEARING
PLATEN SHAFT
42-TOOTH PULLEY
PLATEN SLEEVE
GRIP RING
PLATEN
32-TOOTH
CLUCH PULLEY
GRIP RING
NYLON WASHERS
NYLON WASHER
FLANGE-TYPE
BEARING
REAR PANEL
58
980428-143 Rev. 1 Prelim.
Installation
1.
Slide the long shaft end of the platen roller into the printer's center panel.
2.
With the platen roller's shaft perpendicular to the center panel, slide the short end of the platen
shaft into the lower print mechanism's side bracket.
3.
Place, in sequence, the following on the outside platen shaft: a platen sleeve, flange bearing
(flange outside), and a nylon washer. Lock the them on the shaft with the E-ring.
4.
From inside the center panel, pull the platen shaft tight against the lower print mechanism's
side plate. Verify the bearing is through the side plate and resting on the flange of the bearing.
5.
Place, in sequence, the following on the inside platen shaft: a platen sleeve, flange bearing
(flange outside), and a nylon washer.
6.
The platen kits parts will be secured when the 42 tooth platen pulley is mounted. See the
Platen Clutch procedure, 980428- 135, to complete installation.
980428-143 Rev. 1 Prelim.
59
Lower Print Mechanism
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
The peel mechanism must be removed prior to proceeding. (980428-125)
Tools:
#1 & #2 Philips Screw drivers
11/32 Allen driver
Removal
1.
Remove the peel mechanism from the lower print mechanism.
2.
Remove the E-ring from the end of the platen shaft on the outside of the lower print
mechanism. Remove the nylon washer and flange bearing.
3.
Remove the two (2) screws securing the (curved) label rewind plate from the lower mechanism.
4.
Remove the three screws securing the side plate to the lower print mechanism. Slide the plate
off the platen shaft and latch assembly. Note the washer on the outside of the latch pivot shaft.
60
980428-144 Rev. 1 Prelim.
5.
Remove the lower print mechanisms extrusion bracket that the peel mechanism and label
rewind plate were mounted to.
6.
Slide the latch assembly out of the assembly's shaft pivot in the center panel and the spring off
the post.
Latch Assembly
Post
Spring
Washers
Installation
1.
Loosely attach the extrusion to the center panel with a single screw in the bottom screw hole.
Let the extrusion swing down to the outside of the printer.
2.
Slide a metal washer on each end, two (2) total, of the latch assembly's shaft. Insert the latch
assembly's shaft into the center panel.
2.
Hook the spring to the post on the center panel and the latch assembly's prong.
3.
Swing the extrusion up and attach it to the center panel with the other two screws to finish
mounting the extrusion. Be careful, do not knock the latch assembly out of the center panel.
Tighten the all three (3) screws to 11 inch-pounds torque.
4.
Place the side plate on the latch assembly and attach the plate to the extrusion with three (3)
screws and washers. Tighten the three (3) screws to 11 inch-pounds torque.
5.
Place, in sequence, the following on the outside platen shaft: a platen sleeve, flange bearing
(flange outside), and a nylon washer. Lock the them on the shaft with the E-ring.
6.
Attach the (curved) label rewind plate with the two (2) flat head screws to the lower print
mechanism. Tighten the screws to 4.7 inch-pounds torque.
7.
Attach the peel mechanism onto the lower print mechanism with two (2) flat head screws and
washers. Tighten the screws to 4.7 inch-pounds torque.
980428-144 Rev. 1 Prelim.
61
Printhead Carriage
Preparations
Before starting the procedure, open the printer, then remove media from the printer.
The exterior cover must be removed prior to proceeding. (980428-101)
Remove the printhead and set it on a clean, soft and static safe surface (mat). (980428-102)
Tools:
#2 Philips and a flat blade screwdrivers
Removal
1.
Open the printhead and unhook the printhead carriage spring from the other side of the center
panel. Push down on the spring while holding the printhead up to release the spring.
2.
Remove the three (3) remaining screws retaining the printhead side plate to the center panel of
the printer. Lift the printhead carriage out. Note the carriage pivot and cable routing.
CENTER
PANEL
Printhead Spring on Inside of Center
Panel
PRINT HEAD
CARRIAGE
ASSEMBLY
PRINTHEAD
SIDE PLATE
ACCESS HOLE
WASHERS
SCREWS
PRINT HEAD
RIBBON
CABLE
LOCK WASHERS
PRINT HEAD
62
980428-146 Rev. 1 Prelim.
Installation
1.
Slide the printhead cable through the printhead carriage assembly.
2.
Place the printhead carriage's pivot shaft into the pivot hole in the center panel.
2.
Place the printhead side plate on the carriage printhead pivot hole on the opposite side.
Loosely secure the carriage and side plate to the extrusion bracket with three (3) screws and
washers.
3.
Push the side plate to match the upper print mechanism's extrusion profile (rear and top).
Tighten the three (3) screws to 15.8 inch-pounds of torque.
4.
Reposition the printhead spring to the carriage. Lift the printhead carriage up and push the
spring arm down and then into the carriage to engage.
5.
Re-attach the printhead.
6.
Verify the printhead's cable does not extend below the upper printhead extrusion.
Print Head
Cable
Check that Cable routing does not extend
below this area with the print head
in the open or closed positions
980428-146 Rev. 1 Prelim.
63
Cutter Cable
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Note the main cable harness routing and cable tie positions. (980428-109)
Removal
1.
Cut the front tie-wrap securing the main
cable harness to the power supply. Caution
- Do not cut the cables!
2.
Cut the tie-wrap securing the cutter cable to
the motor cable, if the cutter cable is already
installed.
3.
Disconnect the cutter cable (JP15 from
main PCBA, if present.
Cutter
JP15
Cut Tie-wraps
64
980428-147 Rev. 1 Prelim.
4.
Remove the spiral wrap from the motor
(and cutter) cable. Do not pull the motor
cable's connector out of the motor.
Motor Connector
and Plug
Installation
1.
Connect the cutter cable (JP15) to the main
PCBA.
2.
Insert the cutter through the center panel
next to the motor cable.
3.
Tie the cutter cable to the motor cable about
1.5 inches from the motor cable's connector
on the main PCBA.
4.
Attach the cutter cable to the main cable
bundle at the front cable anchor tie on the
power supply.
5.
Add the spiral wrap to the cutter and motor
cables. The spiral wrap should extend as far
from the center panel as the tension idler
spring in the printer to prevent pinching the
cable.
6.
Use the "Securing the Harness" procedure to
dress the wiring to clear moving parts and
provide service loops.
Spring
Spiral
Wrap
Note - See the user's manual or cutter
mounting instruction to mount and use the
cutter.
Cutter Cable
Exits Here
980428-147 Rev. 1 Prelim.
65
Feet
Preparations
Before starting the procedure, open the printer, then remove media from the printer.
Tools:
#1 Philips screwdriver
Instructions
1.
Close the printer cover.
2.
Roll the printer on the left side.
3.
Remove the feet by removing the screw in
the center of the foot.
4.
Secure the front feet with the longer screws.
The shorter screws are used to secure the
back feet.
66
980428-149 Rev. 1 Prelim.
Printer Configuration Check
Checking the Installation
1.
Turn on the printer and run your printer's AutoSense routine to get a dump mode printout.
FEED
PAUSE & CANCEL
PAUSE
3 sec.
1 sec.
Sample: DUMP Mode
Printout
FEED
4 MO3257 3.18.01
Serial port : 96,N,8,1
Image buffer size:245K
Fmem:000,0K,019.9K avl
Gmem:000K,0241K avl
Emem:000K,0241K avl
I8,0,001 rY
S8 D12 R032,000 ZT UN
q0784 Q1227,034
Option:D
11 12 13
now in DUMP
This action tests the printer's media drive and
printing capabilities.
4” UKQ1837
V4.03
Serial port : 96,N,8,1
You can also check the printout for the upgrade
or option you loaded.
Image buffer size:0507K
Fmem:000.5K,060.9K avl
Gmem:024K,0045K avl
Emem:000K,0045K avl
I8,0,001 rN
S4 D10 R064,000 ZT UN
q1600 Q1209,026
Option:
17 21 25
Firmware version number
Memory (available bytes)
Real time clock option (if installed)
Date: 02-19-00
Time: 12:44:00
now in DUMP
If you replaced the main PCBA, the firmware may need updating. Verify the version number on the
dump mode printout, download current firmware to the printer. The latest firmware version and the
firmware downloading software for your Zebra printer can be found at Zebra web site at:
http://www.zebra.com
Also, you will need to reload all of your specific soft fonts, forms or graphics that were previously
loaded into the printer before you start any new print jobs at require these items.
980428-150 Rev. 1 Prelim.
67
Platen Belt and Motor Adjustment
Preparations
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
4mm Allen hex key socket driver
Adjustment
1.
While applying 6-8 lbs. pressure on the motor, towards the rear of the printer, tighten the
motor mounting screws to 23.7±2 inch-pounds of torque. (This step sets belt tension).
2.
Verify the belt teeth have aligned with pulley cogs. Rotate belt one revolution. Do a rough
check of belt tension by applying light to moderate pressure on the belt as shown.
Max. Allowable
Deflection = .125"
68
980428-153 Rev. 1 Prelim.
Tube Tension - Verify & Adjust
Preparations
Before starting the procedure, open the printer, then any remove media from the printer.
The exterior cover must be removed prior to proceeding. (980428-101)
Tools:
3/32" Allen driver
Torque Tube Tool and Torque Wrench
Measuring Tension
The ribbon and label rewind tubes have unique tube tension settings for their internal clutches.
Spare ribbon and label rewind tubes have had a run-in period and are preset to nominal torque
settings for your printer. The run-in period is critical to guaranteeing a long and consistent tube
tension setting.
Models
Tube Type
Torque Setting (inch-pounds)
ALL
Ribbon Tubes
16-18
TLP2746, 2348Plus and 2348+
Label Rewind Tube
16-18
TLP2044 & TLP2046
Label Rewind Tube
24-28
LP2348 with peel bar
Label Rewind Tube
24-28
LP2348 with peel mechanism
Label Rewind Tube
16-18
Similar printer models are included for reference only.
Verify Tension
1.
Insert the torque tool into the end of the tube to be measured.
2.
Hold the appropriate tube's pulley or collar and rotate the tool and watch the tube and torque
reading. Note when the tube slips. The reading just prior to the slip is the torque setting.
980428-154 Rev. 1 Prelim.
69
Tension Adjustment
1.
Hold the appropriate tube's pulley or collar and rotate the outside of the tube until the slot on
the end of the tube aligns with the inside set screw of the tube assembly.
2.
Loosen the set screw.
3.
Push the tube's clutch spring into the tube with the torque tools tip. The tool's prongs touch the
clutch spring's stop collar. Pushing the clutch stop collar in increases torque and out decreases
torque. Tighten the stop collars set screw to 11 inch-pounds torque.
4.
Measure tube tension.
5.
Repeat until adjusted properly.
Do not disassemble the tube!
Do not replace parts in the tube assembly.
70
980428-154 Rev. 1 Prelim.
Ribbon Path Adjustment
Preparations
Load 4 inch wide ribbon and media in the printer.
MOVIE
Presetting
1.
2.
Loosen the three (3) horizontal adjustment
screws and push the side plate to align with
the upper print mechanism's extrusion
bracket profile (rear and top). Tighten the
three (3) screws to 15.8 inch-pounds of
torque.
Loosen the vertical adjustment screw and
adjust ribbon adjustment shaft to be in the
center of the vertical slot on the side plate.
Tighten the screw to 15.8 inch-pounds of
torque.
Horizontal
Adjust Screws
Vertical Adjust
Screw
Adjusting the Ribbon Path
1.
2.
Close the print head and print or feed
several labels.
Note the direction of the ribbon stress lines.
Take-Up
Ribbon Tube
(Front View)
Stress lines slanted to left side of printer
indicate that the side bracket needs to be
adjusted horizontally back towards rear of
printer until stress lines run vertically on
ribbon.
Stress lines slanted to right of printer
indicate that side bracket needs to be
adjusted horizontally forward towards front
of printer until stress lines run vertically on
ribbon.
3.
Loosen the three (3) horizontal adjustment
screws and adjust. Tighten the three (3)
screws to 15.8 inch-pounds of torque when
the stress lines are vertical and barely
visible.
980428-156 Rev. 1 Prelim.
Take-Up
Ribbon Tube
(Front View)
71
4.
Loosen the vertical adjustment screw and
adjust the ribbon adjustment shaft to correct
stress lines in ribbon behind print head
assembly while feeding media. Move the
shaft in the vertical slot up or down.
Position should be set so stress lines run
vertically from ribbon supply roll.
Take-Up Ribbon
Tube
Supply
Ribbon
Tube
Vertical Slot Adjustment
5.
Note the ribbon stress line in the front of the
printer while feeding or printing labels.
Steps 3 and 4 should be repeated until the
front (take-up) and rear (supply) ribbon
wrinkle and stress lines are vertical and
minimized.
6.
Verify the print head's cable does not extend
into the ribbon path.
Print Head
Cable
Ribbon
Check for cable routing interference with ribbon path
72
980428-156 Rev. 1 Prelim.
Printer Information Utility
The Printer Information utility is a proprietary service program intended for Zebra authorized
customers and service organizations. The utility also includes Help files describing the functions and
connection methods. The utility automates functions available through the EPL2 printer
programming language. It is used to:
Re-set printhead life when printheads are replaced
Set the printer’s serial number into a new main printer PCBA.
Set the units for odometer display in Inches or Millimeters.
Print a printer and printhead life information summary.
Preparations
A Windows™ based PC (Windows 95, 98, ME, 2000 or NT4)
Pre-Install USB aware printer drivers to enable automatic USB printer detection.
Tools:
Printer Information Utilities Installation File:
PrinterInformation.exe
The utility loads as a self extracting and installing Windows program.
An interface cable for the one of the available and supported interface ports:
Parallel (LPT1 or LPT2)
Serial (RS-232 COM1-COM4)
USB
Ethernet (10BASE-T UTP RJ-45 connection. Auto senses IEEE- 802.3, Ethernet II,
IEEE- 802.2, and IEEE 802.2/SNAP frame formats)
Connecting to the Printer
1.
Connect the printer to the desired PC interface: parallel, serial, USB or Ethernet.
2.
Start the Printer Infomation utility.
3.
In the Printer menu, select Add or Auto-Detect for connecting to the printer via the USB or
Ethernet interfaces. Choose the printer’s interface, serial or parallel. With the Auto-Detect, the
printer will appear in the printer listings.
4.
The printer name may be changed with the Modify selection in the Printer menu.
Printing Status Labels
1.
Select the Print in the Printer menu and chose from: Test Page (Printer Status / Dump
Mode Label), Odometers (active printhead and printer odometer readings), and Head
History (Prints all printhead odometer memory stored readings (up to 10) and the printer
odometer reading).
Setting the Odometer Display
1.
In the Tools menu, select Options to change the odometer unit between millimeters and
inches.
980428-157 Rev. 1 Prelim.
73
Resetting the printhead
1.
After replacing the printhead, select the Reset Head Odometer in the Printer menu.
Only do this procedure once per printhead! The printer records each printhead
odometer reading in ten (10) memory storage locations. Resetting the printhead odometer
increments the printhead odometer memory location pointer and clears that printhead record.
After all ten (10) printhead odometer storage locations have been filled, the printer will return
to the first location to begin re-use of the printhead odometer record locations. See the Head
History report to check printhead odometer readings and usage.
2.
Important - Clean the printhead if it was not cleaned immediately after installation. Oils
and acids from handling will damage the printhead if not removed immediately.
Note - The printer’s odometer can not be set or reset. New PCBA’s odometers are set to zero by
default.
980428-157 Rev. 1 Prelim.
74
Packaging for Shipment
To ship or store the printer, make sure all components are packed as shown in the figure below.
Printer Preparation
1.
Close the printhead.
2.
Place and lock the rewind bracket in the
rear of the printer base.
3.
Close the label dispenser (peeler).
4.
Mount the lower front cover.
5
Tape (masking tape) the rewind clip to the
rewind tube.
Packaging the Printer
Move the printer carefully. While the printer has
sturdy construction, mechanical damage can
certainly result from falls or rough handling.
1.
Place the printer into the large plastic
shipping bag to prevent the dust and
vibration damage from the foam rubbing on
the outside surfaces.
2.
Put the two (2 ) foam end caps on the
printer.
3.
Seal the bottom of the shipping carton with
reinforced shipping tape.
4.
Place the printer with the foam end caps
into the shipping carton with the printer’s
feet down.
E
FRAGIL
UP
KEEP
DRY
FRAGIL
E
KEEP
DRY
UP
E
FRAGIL
UP
KEEP
DRY
FRAGIL
E
980428-160 Rev. 1 Prelim.
KEEP
DRY
UP
75
5.
Place the power cord, cables, software, etc.
in the bubble pack plastic bag and
completely seal it with plastic tape or self
sealing strip.
6.
Seal the top of the shipping carton with
reinforced shipping tape.
Unpacking Instructions
1
3
UP
KEEP
DRY
E
FRAGIL
UP
KEEP
DRY
FRAGIL
E
UP
E
FRAGIL
2
76
DRY
FRAGIL
E
KEEP
DRY
UP
KEEP
4
980428-160 Rev. 1 Prelim.
CLEANING AND MAINTENANCE
The printers are manufactured and tested under a strict quality management program. Zebra
Technologies uses only high quality components and materials in its Zebra printers. Although only
minimal routine maintenance is required, following these simple maintenance guidelines will ensure
longer life with quality printing performance.
Shock Hazard
Always turn off the printer before performing any maintenance or
repair operations. Wait for the indicator light to be dark, then unplug
the power cord.
Extending The Life Of Your printhead
The printhead is the most critical component in your printer, and possibly the most delicate. It is a
consumable item just like the brakes on your car, which will eventually wear over time. However,
with ongoing careful attention and maintenance, you can extend the life of the printhead!
Below are photographs of three printheads. The first printhead is brand new. The second has
printed over 1 million linear inches of thermal transfer labels and has been properly maintained.
The third printhead has printed far fewer labels, but without proper care and maintenance, signs of
abrasion and contamination build-up are evident.
New
980428-001 Rev. A
Over 1 Million Inches
(Properly Maintained)
Less Than 1 Million Inches
(Without Proper Care)
77
Preventive Maintenance
For optimum performance, clean the printhead regularly after every roll of direct thermal labels.
To start, only use the cleaning pen or pre-soaked (isopropyl alcohol) cleaning swabs provided.
Lightly blow or brush away any loose dust and lint particles within the print mechanism (i.e. rollers,
media sensors, and printhead). NEVER use any hard, metallic, or abrasive objects—such as a
screwdriver—to remove adhesives or other contaminants that may have built up on the printhead or
platen roller.
Periodically use the Save-a-printhead cleaning film to remove printhead contamination buildup.
(Part No.105950-047) The need to use cleaning film will very with media used, environmental
conditions and printer settings.
Avoid the Contributing Factors to Premature printhead Failure
Print Head Care
The main factors that contribute to reduced head life are:
♦Touching the printhead! Static electricity can discharge and damage the printhead. The body's
oils and acids also damage the printhead.
♦Cleaning - For optimum performance, clean the printhead regularly after every roll of direct
thermal labels.
♦Abrasion - Over time, the movement of media/ribbon across the printhead will wear through the
protective ceramic coating, exposing and eventually damaging the print elements (dots).
♦Use of proper media - Use only approved Zebra media. Non-approved media may contain
chemicals or pre-printed inks that can destroy or dramatically reduce the printhead's life.
♦Temperature - printhead density (heat) setting. Set the density to the lowest possible setting that
prints a good image.
♦Print Speed - Fast print speeds have higher friction levels on the printhead's surface.
♦Regular printhead Conditioning - Use our Save-a-printhead cleaning film to remove
printhead contamination buildup quickly and easily. (Part No.105950-047)
Basic Cleaning
The printer’s media path allows for cleaning and clearing of media jams. The user can clean the
printhead, platen roller and areas adjacent to the media path surfaces.
Keep your printer clean by periodically wiping it with a soft, lint free cloth dampened with 95% or
higher isopropyl alcohol. Do not use abrasive cleaners as they will damage the surfaces.
The cleaning pen is for cleaning the printhead only!
Do not use the cleaning pen for general cleaning.
78
980428-001 Rev. A
Cleaning the Media Path
Use a brush or vacuum to clean the media path (except the printhead).
If a label jams inside the printer, remove the label and any adhesive residue immediately. Adhesive
may spread throughout the printer's media path if not completely removed. Many adhesives are
permanent and have short "set" times.
Cleaning the printhead
As you use your printer, the printhead may become contaminated resulting in poor print quality.
Whenever new labels are loaded into the printer, the printhead should be cleaned with a cleaning
pen.
Never touch the printhead. Always clean the printhead with a
cleaning pen or a cotton swab moistened with 95% or higher
isopropyl alcohol to gently remove dirt and dust.
1.
Open the printer and the printhead carriage.
2.
Gently rub the cleaning pen across the
amber area of the printhead.
Allow the printhead to dry for 1 minute
before loading labels.
Do Not Clean the printhead with sharp
objects! Only used approved cleaning
materials.
980428-001 Rev. A
79
Save-a-Printhead Cleaning Film - Kit P/N 44902
What is Save-a-Printhead cleaning film?
A specially coated film that removes contamination buildup without damaging the printhead.
What are the benefits of Save-a-Printhead cleaning film?
Extends the life of your printhead.
Reduces maintenance downtime and the cost of replacing a printhead.
An inexpensive, easy and quick way to remove contaminants without having to remove the
printhead.
When should you use Save-a-Printhead cleaning film?
When you see degrading print quality that looks like faded print or a failed print element(s)
that cannot be corrected by cleaning with the pre-soaked cleaning swabs.
Save-a-Printhead Cleaning Film Maintenance Procedure
1.
Remove power from the printer.
2.
Open the printhead, remove media from the print mechanism.
3.
Clean the printhead.
4.
Position the Save-a-Printhead film in the print path, placing the glossy side down away from
the printhead (matte side up).
5.
Close and latch the printhead.
6.
Slowly pull the full length of the film through the print mechanism.
7.
Again, clean the printhead.
8.
Reload media, close and latch the printhead.
9.
Print labels and inspect for improved print quality. If quality has not improved, contact our
Technical Support staff.
Cleaning Film Usage Issues
Only one pass is required to remove contamination buildup.
Each strip of film can be used up to 10 times.
Discard the strip when residue buildup or other contamination is apparent.
80
980428-001 Rev. A
RECOMMENDED SERVICE
To maximize service life (before maintenance is required), the total service life, and eliminate
potential problems that are harder to detect or test for, it is recommended the the service technical
perform the following procedures:
Clean the printhead (See Cleaning and Maintenance)
Removes loose contaminate build-up to prep the printhead for conditioning.
Condition the printhead (See Cleaning and Maintenance)
Use the Save-a-Printhead cleaning film to remove printhead contamination buildup. (Part
No.105950-047)
Verify the DC voltage setting (see the DC Power Verification & Adjustment procedure,
980428-105) If the DC voltage setting is too low, the motor torque may be too low to print or
dispense (peel) labels in the worst case print conditions. If the voltage is set too high the
electronic components may be damaged.
Verify the label rewind tube’s torque setting (see the Tube Tension Verification and
Adjustment procedure, 980428-154). The rewind tube’s clutch torque level slowly degrades
with use. Labels may not dispense properly if this setting is too low to pull the backing off the
labels.
Print a Printer Status / Dump Mode Label with the AutoSense routine (see user’s
manual) and once with the Printer Information utility (see procedure 980428-157). This
verifies that the printer can print ( take special note to the slanted lines as a basic printhead
test), sense labels, and communicate with software.
Last Step After Test & Repair - Clean the printhead
980428-001 Rev. A
81
82
980428-001 Rev. A
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