Datamax M-Class Mark II Maintenance Manual

M-Class Mark II

Maintenance Manual

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Firmware (Software) Agreement:

The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and is
licensed for used only on a single printer in the user’s Trade or Business. The User agrees not to, and

not to authorize or permit any other person or party to, duplicate or copy the Firmware or the
information contained in the non-volatile or programmable memory. The firmware (Software) is

protected by applicable copyright laws and Licensor retains all rights not expressly granted. In no event
will Licensor or its suppliers be liable for any damages or loss, including direct, incident al, economic,
special, or consequential damages, arising out of the use or inabilit y to use the Firmware (Software).

CAUTION

Lithium Battery: There is a danger of explosion or fire if the battery is incorrectly

replaced. Replace only with the same or equivalent type recommended by the
manufacturer. Discard used batteries according to the manufacturer’s instructions.

Information in this document is subject to change without notice and does not represent a commitment on
the part of Datamax-O’Neil. No part of this manual may be reproduced or transmitted in any form or by
any means, for any purpose other than the purchaser's personal use, without the expressed written
permission of Datamax-O’Neil.

All rights reserved.

Part Number 88-2347-01 Rev. B

COPYRIGHT © 2010, DATAMAX-O’NEIL

Contents

1
2
3
4

Overview
Adjustments and Maintenance
Troubleshooting
Removal and Replacement

i

ii

Overview

1

1.0 Introduction ........................................................................................ 1

1.1 About this Printer ................................................................................. 2

i

ii

1.0 Introduction

Overview

This manual, which primarily includes technical information relating to the electrical and
mechanical components, is intended for use by qualified serv ice personnel in the
maintenance and repair of M-Class Mark II printers. For related information, refer to the
following documents, available for download at http://www.datamax-oneil.com/

 For operating information, reference the Operator’s Manual (part number 88-2340-01).

 For software information, reference the Class Series 2 Programmer’s Manual (part

number 88-2341-01).

Important Information:

In this manual, the exclamation point inside an equilateral triangle is intended
to alert the technician to the presence of important operating, maintenance or
servicing information. Always, as with all electrical equipment, follow basic
safety precautions to avoid personal injury or printer damage.

1-1

Overview

1.1 About this Printer

The following drawing illustrates the basic exterior components an d controls of the printer.
The model number can be found on the Serial Tag affixed to the rear of the unit. Use this
model number when referencing specific information within this manual. (Because optional
items are not present on all models, certain printer configurations may not appear in some
of the illustrations in this manual.)

Access Cover

Ribbon Supply Hub

Ribbon Take-Up Hub

Centerplate

Front Panel

Printhead Assembly

Printhead Latch

Fascia

Media Sensor

Media Guide

Media Supply Assembly

(Hanger or Hub)

Ribbon Idler

Internal Rewinder

Media Idler

1-2

Adjustments and Maintenance

2

2.0 Introduction........................................................................................ 1

2.1 Maintenance ....................................................................................... 1

2.1.1 Cleaning the Printhead ................................................................2

2.1.1.1 Cotton Swab Procedure.................................................. 3

2.1.1.2 Cleaning Card Procedure ................................................ 4

2.1.1.3 Cleaning Film Procedure................................................. 5

2.1.2 Cleaning the Media Sensor........................................................... 6

2.1.3 Cleaning the Platen..................................................................... 6

2.1.4 Cleaning the Ribbon Path............................................................. 7

2.2 Media Sensor Calibration ......................................................................9

2.2.1 Calibrating Non-Display Models.....................................................9

2.2.1.1 Automatic Calibration..................................................... 9

2.2.1.2 Manual Calibration....................................................... 10

2.2.2 Calibrating Display-Equipped Models............................................ 11

2.2.2.1 Quick Calibration......................................................... 11

2.2.2.2 Standard Calibration.................................................... 12

2.2.2.3 Advanced Entry Calibration........................................... 15

2.3 Media Width Adjustment..................................................................... 21

2.4 Printhead Burn Line Adjustment........................................................... 22

2.5 Printhead Pressure Adjustment............................................................ 23

i

2.6 Ribbon Path Alignment ....................................................................... 23

2.7 Darkness Adjustment ......................................................................... 26

2.8 Downloading Firmware and Fonts......................................................... 26

2.9 Resetting the Printer .......................................................................... 27

2.9.1 Non-Display Models................................................................... 27

2.9.2 Display-Equipped Models ........................................................... 27

2.10 Printhead Voltage Adjustment.............................................................. 28

ii

Adjustments and Maintenance

2.0 Introduction

This section covers maintenance and alignment procedures.

2.1 Maintenance

Recommended items, techniques, and schedules to help you safely and effectively maintain
the printer are detailed below. Keep the following items on hand to clean the printer:

• Isopropyl alcohol • Soapy water/mild detergent

• Cotton swabs • Compressed air

• Soft-bristle brush • Printhead Cleaning Cards or Printhead Cleaning Film

For your safety and to avoid damaging the printer, turn OFF and unplug the
printer before cleaning. Always take proper precautions when using isopropyl

CAUTION

Area / Item Cleaning Interval * Method / Supplies

Printhead

Platen and

Assist Rollers

Peel Assembly

Media & Ribbon

Path, & Media

Sensor

alcohol, a flammable liquid.

Recommended Maintenance Schedule

After each roll of ribbon if using
thermal transfer media, or after
each roll of media (or as needed)
if using direct thermal media.

After each roll of labels, after each
roll of ribbon, or as needed.

After each roll of labels, after each
roll of ribbon, or as needed.

As needed, based on a weekly
visual inspection.

Cotton swab dampened with
isopropyl alcohol; and, if necessary,
use Printhead Cleaning Cards or
Cleaning Film (see Section 2.1.1).

Cotton swab or cloth dampened with
isopropyl alcohol wiped across the
entire roller (see Section 2.1.3).

Cotton swab dampened with
isopropyl alcohol; wipe until clean.

Compressed air or a soft brush.
Isopropyl alcohol, as needed (see
Section 2.1.2 and 2.1.4).

Exterior

Surfaces

*Whichever interval comes first.

As needed, based on a weekly
visual inspection.

Mild detergent applied with a
dampened cloth; wipe until clean.

2-1

Adjustments and Maintenance

2.1.1 Cleaning the Printhead

NEVER use a sharp object to clean the Printhead; damage can result.

CAUTION

If print quality declines (symptoms can include non-compliant bar codes, print dropouts,
streaks on the label), the typical cause is debris build-up on the printhead. Furthermore, if
the build-up is not removed it may lead to element failure, greatly reducing the life of the
printhead.

Faulty Label:
Instead of consistent patterns, streaks in the print

indicate a dirty or faulty printhead.

According to the media, ribbon, and printing parameters used, different methods are
recommended for cleaning the printhead. In all cases, perform the f ollowing preliminary
operations:

Preliminary Cleaning Steps:

1. Stop printing. Raise the cover, unlock the Printhead Latch then raise the Printhead
Assembly and allow the printhead to cool.

2. Remove media and ribbon from the printer then proceed according to your cleaning
requirements.

2-2

Adjustments and Maintenance

2.1.1.1 Cotton Swab Procedure

This procedure is recommended if using direct thermal media, or thermal transfer media
with a wax ribbon.

1. Perform the Preliminary Cleaning Steps, as described in Section 2.1.1.

2. Turn OFF and unplug the printer. Using a Cotton Swab moistened (not soaked) with
isopropyl alcohol, gently clean the entire Printhead surface, paying special attention to
the Burn Line, until all build-up is removed.

3. Allow the printhead to dry. Reinstall media (and ribbon, if needed). Lower and latch
the Printhead Assembly. (If necessary, perform a Media Width Adjustment; see Section

2.3.) Close the cover. Plug in and turn ON the prin ter. Run several sample labels and
examine the print quality. If streaks are still present, see Section 2.1.1.2; otherwise,
this completes the procedure.

2-3

Adjustments and Maintenance

2.1.1.2 Cleaning Card Procedure

This procedure is recommended for printers using direct thermal media, or thermal transfer
media and a wax-based ribbon. Also use this procedure if symptoms continue after the
Cotton Swab Procedure (Section 2.1.1.1) has been tried.

1. Perform the Preliminary Cleaning Steps, as described in Section 2.1.1.

2. Place a Cleaning Card (part number 70-2013-01) under the printhead.

3. Lower and latch the Printhead Assembly. Disengage the Media Width Adjustment; see
Section 2.3.

4. Close the cover. Proceed according to printer type:

• Display-Equipped Models –

Press and hold TEST for approximately four seconds. (As an alternate, CLEAN HEAD
NOW can be selected in the menu system.)

• Non-Display Models –

Repeatedly press FEED until the Cleaning Card exits the printer.

5. Reinstall media (and ribbon, if necessary). Lock the Printhead Latch. If necessary,
perform a Media Width Adjustment, see Section 2.3. Close the cover. Run a few sample
labels and examine them. If streaking is still present, go to Section 2.1. 1.3; otherwise,
this completes the procedure.

2-4

Adjustments and Maintenance

2.1.1.3 Cleaning Film Procedure

This procedure is recommended for printers using a resin ribbon with thermal transfer
media, or for printers that typically use a Heat Value of 22 or higher. Also use this
procedure if symptoms continue after the previous cleaning methods have been tried.

1. Perform the Preliminary Cleaning Steps, as described in Section 2.1.1.

2. Place a sheet of Cleaning Film (part number 70-2087-01) under the printhead.

3. Lower and latch the Printhead Assembly. Disengage the Media Width Adjustment; see
Section 2.3.

4. Close the cover. Proceed according to printer type:

• Display-Equipped Models –

Press and hold TEST for approximately four seconds. (As an alternate, CLEAN HEAD
NOW can be selected in the menu system.)

• Non-Display Models –

Repeatedly press FEED until the Cleaning Card exits the printer.

5. Turn OFF and unplug the printer. Open the cover, unlock and raise the Printhead
Assembly. Using a cotton swab moistened (not soaked) with isopropyl alcohol, gently
clean the entire Printhead surface.

6. Allow the printhead to dry. Reinstall media and ribbon. Lower and latch the Printhead
Assembly. If necessary, perform a Media Width Adjustment; see Section 2.3. Close the
cover. Plug in and turn ON the printer. Run a few sample labels and examine them; if
streaking is still present, see Section 3.1.

2-5

Adjustments and Maintenance

2.1.2 Cleaning the Media Sensor

If paper dust or debris accumulates in the Media Sensor, it can affect label detection. To
prevent problems, clean as follows:

1. Turn OFF and unplug the printer. Raise the cover.

2. Unlock and raise the Printhead Assembly. Remove any media.

3. Clean the Media Sensor using compressed air or a soft brush. Use a cotton swab
dampened with isopropyl alcohol as needed to remove adhesive accumulations.

4. Allow to dry. Reinstall media. If necessary, adjust the Media Sensor. Plug in and turn
on the printer.

2.1.3 Cleaning the Platen

The platen contaminated with grit, label adhesive, or ink can lead to a decline in print
quality and, in extreme cases, cause labels to adhere and wrap the roller. Clean the platen
as follows:

2-6

Adjustments and Maintenance

1. Turn OFF the Power Switch and unplug the power cord from the AC Receptacle.

2. Raise the Cover. Unlock and raise the Printhead Assembly.

3. Remove media and ribbon.

4. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, wipe the
Platen clean. Manually rotate the rollers as necessary, wiping, rotating, and repeating
until the surfaces of each are clean. Allow to dry.

2.1.4 Cleaning the Ribbon Path

Ribbon path components contaminated with ink buildup and grit can inhibit smooth flow and
result in wrinkling related problems. Clean the ribbon path compon ents as follows:

1. Turn OFF the Power Switch and unplug the power cord from the AC Receptacle.

2. Raise the Cover. Remove media and ribbon.

2-7

Adjustments and Maintenance

3. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, wipe the
Ribbon Idler and Ribbon Post clean.

4. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, wipe the
Ribbon Shield clean. Allow to dry.

2-8

Adjustments and Maintenance

2.2 Media Sensor Calibration

This printer can use many different media compositions, configurations and colors. In

addition to adjusting the Media Sensor and selecting the SENSOR TYPE, to ensure that each
label is detected correctly and reliably, calibration is required. Depending upon th e printer
type, there are different calibration methods.

2.2.1 Calibrating Non-Display Models

In Calibration Mode, button functions adjust the Media Sensor to the media being used.
Calibration can be performed either automatically or manually, as detailed below.



Notes: Printer faults remain disabled during calibration, but can still occur while printing

Test Labels. Also, if needed, factory defaults can be restored.

2.2.1.1 Automatic Calibration

Automatic Calibration lets the printer establish the optimum media sensing values, as
follows:



Note: Before calibrating ensure that media is loaded, and that the Media Sensor

selected and positioned. Also, be sure that the printhead assembly is latched
and that the cover is closed.

1. Turn OFF the printer.

2. Depress and hold CANCEL while turning ON the printer. Continue to hold the button until
the STOP Light turns OFF.

3. Press PAUSE. About ten inches of media will be output during the process.

4. Upon completion, one of the following lights will flash fiv e t imes t o denote the result:

• STOP Light

= Successful calibration. Go to Step 5, below.

• ERROR Light



Note: To discard calibration changes and revert to the previous settings, turn OFF the

printer before performing Step 5.

= Unsuccessful calibration. Retry and if unsuccessful, see Section 2.2.1.2.

2-9

Adjustments and Maintenance

5. Simultaneously press PAUSE and CANCEL briefly. Wait until the STOP Light goes OFF.

The printer is ready for operation.

2.2.1.2 Manual Calibration

Manual Calibration should be used if Automatic Calibration f a ils, or in cases where sensing
problems continue to occur. Proceed as follows to manually calibrate th e Media Sensor:



Note: Before calibrating, be sure that the Media Sensor selected and positioned. Also,

be sure that the printhead assembly is latched and that the cover is closed.

1. Turn OFF the printer and remove the media.

2. Press and hold CANCEL while turning ON the printer. Continue to hold the button until
the STOP Light turns OFF.

3. Press and hold FEED until the STOP Light turns ON.

4. Press CANCEL. The ERROR Light will flash as “empty” is analyzed.

5. Position the backing material (or, if using reflective media, the black mark) in the Media
Sensor. Close the printhead assembly and press FEED. The ERROR Light will flash as

“Top of Form” is analyzed.

6. Place the media with the backing attached (or, if using reflective media, an area other
than the black mark) in the Media Sensor. Close the printhead assembly and press
PAUSE. The ERROR Light will flash as “label” is analyzed.

7. Simultaneously press PAUSE and CANCEL briefly, and then one of the following lights
will flash five times to denote the calibration result:

• STOP Light

= Successful calibration. Go to Step 8, below.

• ERROR Light

= Unsuccessful calibration. Retry.

2-10

Adjustments and Maintenance

8. Install media. Test the calibration by pressing FEED. A label should feed from the
printer. Press CANCEL. A Test Label should be produced.



Note: To discard calibration changes and revert to the previous settings, turn OFF the

printer before performing Step 9.

9. Simultaneously press PAUSE and CANCEL briefly. Wait until the STOP Light goes OFF.

The printer is ready for operation.

2.2.2 Calibrating Display-Equipped Models

Three different calibration methods are available.

2.2.2.1 Quick Calibration

This is the easiest calibration method.



Note: Quick Calibration is not required for continuous media. If UNCALIBRATED is

displayed, use Standard Calibration (Section 2.2.2.2).

Perform a Quick Calibration as follows:

1. Ensure that media is loaded, that the Media Sensor is adjusted, and that the printer is
idle.

2. Press and hold FEED.

The printer will begin advancing media; allow at least one label gap or mark to pass
through the sensor. Upon successful completion, CALIBRATION COMPLETE will be
displayed, as the label is advanced to the next TOF and READY appears. (WARNING
LOW BACKING may appear if using notched media or media on a transparent liner;
however, the calibration was successful).



Note: Media with large TOF spaces may require a change in the PAPER EMPTY

DISTANCE.

2-11

Adjustments and Maintenance

Calibration Hints:

In certain cases, the printer may have trouble differentiating between the label and liner.

If CANNOT CALIBRATE is displayed, or if the printer stops feeding mid-label, try the
following:

 Press and hold FEED to allow two gaps (or marks) to pass through under the sensor.

If CANNOT CALIBRATE is displayed again, or if the printer stops feeding mid-label, try the
following:

 Press and hold FEED to allow three or more gaps (or marks) to pass through the

sensor. If this method fails, use Standard Calibration (see Section 2.2.2.2).

2.2.2.2 Standard Calibration

During the Standard Calibration process, the printhead assembly can be raised for visual
access to the media and the sensor. In addition, displayed sensor readings can be used to
indicate the best position over the media. These features are helpful when using small,
position-critical TOF notches or marks. Three readings are required:

• Empty: No media in the sensor;

• Gap (or Mark): Only the backing, notch, or reflective mark in the sensor; and,

• Paper: The label (with the liner attached) in the sensor.

Make sure the SENSOR TYPE has been selected. Then, perform the Standard Calibration

steps:



Note: The procedure below assumes that the ADVANCED MENU is selected.

Step Action Displayed Message Comment

1 Turn ON the printer. UNCALIBRATED

(continued)

Wait briefly for initialization
before proceeding.

2-12

Adjustments and Maintenance

Step Action Displayed Message Comment

Press MENU and then

2

raise the printhead
assembly.

3 Press ENTER.

Scroll to SENSOR

4

CALIBRATION and
press ENTER.

Press ENTER, and then

5

to proceed press YES.

6

Remove the media

from the Media Sensor
and then press ESC.

Proceed according to
the media type, and
then press ESC:

• Die-cut: Peel labels

from the backing.
Insert the backing
under the Sensor Eye
Mark;

7

• Notched: Insert the

notch under the
Sensor Eye Mark; or,

• Reflective: Insert the

black mark facedown
under the Sensor Eye
Mark.

• Continuous: Go to

Step 8.

ADVANCED MENU
MEDIA SETTINGS

MEDIA SETTINGS

MEDIA TYPE

SENSOR CALIBRATION

PERFORM CALIBRATION

PERFORM CALIBRATION

PERFORM CALIBRATION?

PERFORM CALIBRATION

REMOVE LABEL STOCK

PRESS ESC KEY

yyy

PERFORM CALIBRATION

SCAN BACKING
PRESS ESC KEY

yyy

You are in the ADVANCED

MENU.

You are entering MEDIA
SETTINGS.

Press EXIT to leave this
procedure.

Press NO to exit.

This sets the “empty”

parameter, where yyy is a
numeric value representing
the current sensor reading.

For reflective media, SCAN
MARK will be indicated.

This sets the TOF parameter,
where yyy is a numeric value
representing the current
sensor reading.

Never position a perforation
under the sensor when
sampling.

(continued)

2-13

Adjustments and Maintenance

Step Action Displayed Message Comment

8

Position a label (with

backing, if any) under
the Sensor Eye Mark,
and then press ESC.

9

Observe the message.

10 Press ESC and then

EXIT. Load media.
Adjust the Media
Sensor.

Press and hold FEED
until at least one label
has been output.

PERFORM CALIBRATION

SCAN PAPER

PRESS ESC KEY

yyy

PERFORM CALIBRATION

GAP MODE

CALIBRATION COMPLETE

yyy

READY

This sets the parameter for the
paper value, where yyy is a
numerical value representing
the current sensor reading.

If using preprinted media,
ensure the label area under
the sensor is free of preprinted
text, graphics or borders.

The calibration result is given.
For reflective media,

REFLECTIVE MODE will be
indicated, and for continuous
media, CONTINUOUS MODE.

If other than Complete is
displayed, see the note below.

The printer is calibrated.
If another message is

displayed, see the note below.



Notes: (1) When calibrating notched media or media on a transparent liner, WARNING

LOW BACKING is normal message; and, (2) If CALIBRATION UNSUCCESSFUL
appears, see Section 2.2.2.3.

2-14

Adjustments and Maintenance

2.2.2.3 Advanced Entry Calibration



Note: Advanced Entry Calibration should only be used if needed, after trying

Standard Calibration.

Advanced Entry is an alternate calibration method for special-case media. This procedure
consists of two parts: (1) compiling sensor readings using different algorithms; and, (2)
determining the best algorithm then sampling and entering the values. Make sure that the
SENSOR TYPE has been selected and then proceed with the steps below:

Step Action Displayed Message Comment

1 Turn ON the printer. UNCALIBRATED

Press MENU and then

2

raise the printhead
assembly.

3 Press ENTER.

Scroll to SENSOR

4

CALIBRATION and
press ENTER.

Scroll to ADVANCED

5

ENTRY and press
ENTER.

Scroll to TRAN SENSOR
GAIN (for die-cut
media) or REFL

6

SENSOR GAIN (for
reflective media) then
press ENTER.

ADVANCED MENU
MEDIA SETTINGS

MEDIA SETTINGS

MEDIA TYPE

SENSOR CALIBRATION

PERFORM CALIBRATION

ADVANCED ENTRY

PAPER SENSOR LEVEL

TRAN SENSOR GAIN

yyy (0 - 31)

25

Wait briefly for initialization

before proceeding.

You are in the ADVANCED
MENU.

You are entering MEDIA
SETTINGS.

Press EXIT to leave this
procedure.

You are entering the advanced
procedure.

Press ESC to abort this
procedure. (The following
examples detail die-cut media
calibration, and unless
otherwise noted the reflective
media procedure is the same.)

Install media. Position
the Sensor Eye Mark

7

over the label, then
lower and latch the
printhead assembly.

(continued)

TRAN SENSOR GAIN
yyy (0 - 31)
25

2-15

Do not position a perforation
in the Media Sensor; and if
using preprinted media,
ensure the label area placed in
the sensor is free of text,
graphics, lines, etc.

Adjustments and Maintenance

Step Action Displayed Message Comment

Use the buttons to set

the Gain Number to 00
and then press ENTER.

Record the sensor

8

reading as a Label
Value for Gain Number
00 in a table (32 rows

TRAN SENSOR GAIN
yyy (0 - 31)

00

This is the Label Value for a
gain setting of 00, where
“yyy” represents the current
sensor reading.

by four columns, with
headings similar to
those shown below.)

Sample Calibration Table

Gain Number Label Value TOF Value Difference Value

00 252
01
02

…

31

Step Action Displayed Message Comment

Use the buttons to

increment the Gain
Number by one and

9

then press ENTER.
Record the Label Value.
Repeat this process for

TRAN SENSOR GAIN
yyy (0 - 31)

01

Remaining Label Values,

where “yyy” represents the
current sensor reading.

each Gain Number.

Sample Calibration Table

Gain Number Label Value TOF Value Difference Value

00 252
01 250
02 248

……

31 09

(continued)

2-16

Adjustments and Maintenance

Step Action Displayed Message Comment

Raise the printhead

assembly then proceed
according to the media
type:

• Die-cut: Peel labels

from the backing
then insert the
backing under the

10

Sensor Eye Mark;

• Notched: Insert the

notch under the
Sensor Eye Mark; or,

TRAN SENSOR GAIN
yyy (0 - 31)

Do not position a perforation

in the Media Sensor; and if
using preprinted media,
ensure the label area placed
in the sensor is free of text,

31

graphics, lines, etc.

• Reflective: Insert the

black mark facedown
under the Sensor
Eye Mark.

Lower and latch the
printhead assembly.

Set the Gain Number to
00 and then press

11

ENTER.
Record the reading as a

TOF Value for Gain
Number 00 in the table.

Gain Number Label Value TOF Value Difference Value

00 252 248
01 250
02 248

……

31 09

TRAN SENSOR GAIN
yyy (0 - 31)

00

Sample Calibration Table

This is the TOF Value for a
gain setting of 00, where
“yyy” represents the current
sensor reading.

(continued)

2-17

Adjustments and Maintenance

Step Action Displayed Message Comment

Increment the Gain
Number by one and
then press ENTER.

12

Record the TOF Value.
Repeat this process for
each Gain Number.

Gain Number Label Value TOF Value Difference Value

00 252 248
01 250 245
02 248 234

………

31 09 14

TRAN SENSOR GAIN
yyy (0 - 31)

01

Sample Calibration Table

Remaining TOF Values, where
“yyy” represents the current
sensor reading.

Step Action Displayed Message Comment

Calculate the best Gain
Setting. In your sample
calibration table. Where
both the Label Value
and TOF Value are at
least 20, subtract the
amounts and record
the result as a

13

Difference Value (see
below).

TRAN SENSOR GAIN
yyy (0 - 31)

31

In this example, Gain Number

18 is chosen because, where
both values are at least
twenty, it has the highest

Difference Value.
Identify the largest
Difference Value and its
corresponding Gain
Number. This Gain
Number will be used to
resample the media.

Gain Number Label Value TOF Value Difference Value

00 252 248 4
01 250 245 5
02 248 234 14

…………
15 188 63 125
16 184 51 133
17 179 38 141
18 174 25 149
19 170 19 N/A

…………
31 132 14 N/A

(continued)

Sample Calibration Table

2-18

Adjustments and Maintenance

Step Action Displayed Message Comment

Use the buttons to set the
Gain Number determined

14

in the previous step. Press
ENTER to enable the
setting.

Make another table (see
example below) using new
measurements:

(A) Raise the printhead

assembly. Place the
label under the Sensor
Eye Mark then latch
the printhead
assembly. Record the
sensor value as P.

(B) Raise the printhead

15

assembly. Place the
backing, notch or
mark under the
Sensor Eye Mark.
Latch the printhead
assembly. Record the
sensor value as G (or
M).

TRAN SENSOR GAIN

yyy (0 - 31)

18

TRAN SENSOR GAIN

yyy (0 - 31)

18

This example uses Gain

Number 18.

Where “yyy” is a
numerical value
representing the current
sensor reading.

The re-sampled values
may differ from those
previously noted.

(C) Raise the printhead

(continued)

assembly. Remove
media. Latch the
printhead assembly.
Record the sensor
value as E.

Selected Gain Table

Gain Number Paper Gap (or Mark) Empty

18 173 42 9

2-19

Adjustments and Maintenance

Step Action Displayed Message Comment

Press ESC. Use the
buttons to scroll to PAPER
SENSOR LEVEL (or if
using reflective media,
REFL PAPER LEVEL) and

16

then press ENTER.

PAPER SENSOR LEVEL

(0 - 255)

This is the Paper value.

Use the buttons to set the

173
Paper value determined in
Step 15 and then press
ENTER.

Press ESC. Scroll to GAP
SENSOR LEVEL (or, if
using reflective media,
MARK SENSOR LEVEL)

17

and then press ENTER.
Set the Gap (or Mark)

GAP SENSOR LEVEL

(0 - 255)

042

This is the Gap (or Mark)

value.

value determined in Step
15 and then press ENTER.

Press ESC. Scroll to
EMPTY SENSOR LEVEL
and then press ENTER.

18

Set the Empty value
determined in Step 15 and

EMPTY SENSOR LEVEL

(0 - 255)

009

This is the Empty value.

then press ENTER.

Press EXIT and, when
prompted, press YES at

19

the SAVE CHANGES
prompt.

READY

The procedure is

finished, the process
almost complete.

Load media and position
the Media Sensor. Press

20

and hold FEED until at
least one label has been

READY

The printer is ready for

use (otherwise, see note
below).

output.

 Note: If the Advanced Entry Calibration fails, enter MEDIA SETTINGS  CALIBRATION

 ADVANCED ENTRY  SENSOR GAIN and lower the selected setting number by

one (desensitizing the sensor). Enter the new setting; save the changes; exit
the menu; and, then test your media. Repeat this process until a usable sensor
setting is obtained.

2-20

Adjustments and Maintenance

2.3 Media Width Adjustment

To maintain print quality and prevent component wear when using less than full width
media, perform a Media Width Adjustment as follows:

1. Load media, then generate a batch of labels:

• Non-Display Models: Simultaneously press PAUSE and FEED.

• Display-Equipped Models: Select a quantity of Print Quality Labels.

2. Loosen the Thumbscrew 1/4 turn (just enough to maintain tension while allowing
adjustment). Slide the Thumbscrew to the left (see Example 1, below).

3. Next, while observing the printed labels, move the Thumbscrew to the right until the
labels contain a complete, even image (Example 2) and then tighten the Thumbscrew.

Example 1 – Over adjustment:

Too much adjustment causes the image to fade across the label,
requiring a decrease in the Media Width Adjustment.

Example 2 – Correct adjustment:

Proper adjustment produces a complete image, with even print
contrast.



Note: Under-adjustment can cause ribbon wrinkling, lateral label

movement, and excessive wear on printer components.

2-21

Adjustments and Maintenance

2.4 Printhead Burn Line Adjustment

Print quality can change when using extremely thin or thick media. Typically, thick media
requires a forward adjustment, while thin media requires a backward adjustment. Perform
an adjustment as follows:

1. Load media (and ribbon, if required).

2. Loosen both Locking Screws approximately ¼ turn counterclockwise.

3. Turn the Adjustment Screws counterclockwise until the burn line is past the platen roller
vertex, then print a Test Label as follows:

• Non-Display Models: Simultaneously press PAUSE and FEED.

• Display-Equipped Models: Select a Print Quality Label.

4. The image should be light and uneven and then tighten (just until snug) the Locking
Screws – enough to remove the play in the printhead assembly, while allowing the
Adjustment Screws to move the printhead.

5. Turn each Adjustment Screw clockwise about a ¼ turn (or 1/8 turn for finer
adjustments, see note below). Print another T est Label and examine the print quality.
Repeat until the labels are produced with an even print contrast and an acceptable print
quality.



Note: When the Locking Screws are snug, turning the Adjustment Screws

counterclockwise will NOT move the printhead outward; if you have adjusted the
printhead too far inward, restart the entire procedure.

6. Tighten the Locking Screws then print a final Test Label to verify the adjustment.

2-22

Adjustments and Maintenance

2.5 Printhead Pressure Adjustment

The pressure applied to the media affects print quality. However, a pressure adjustment
should only be performed after attempting to improve print quality using (1) HEAT and/or
(2) PRINT SPEED, and then only by the minimum amount needed for improvement:

1. Load 4-inch (102 mm) wide media and ribbon.

2. Disengage the Media Width Adjustment (its left-most
position); see Section 2.3.

3. Print a Test Label:

• Non-Display Models: Simultaneously press

PAUSE and FEED.

• Display-Equipped Models: Select a Print Quality

Label.

4. Making equal adjustments to each screw to achieve even print contrast across the
media, rotate the Printhead Pressure Adjustment Screws counterclockwise to increase
the pressure or clockwise to decrease the pressure. Set the Media Width Adjustment;
see Section 2.3.



Notes: (1) Narrow thermal transfer media can sometimes require an increased setting

on the left screw to prevent ribbon smudging; (2) Excessive pressure can reduce
the service life of the printhead and platen; and, (3) Unequal pressure may
cause ribbon and label tracking problems.

2.6 Ribbon Path Alignment

When irregular voids extend diagonally through printed images on t hermal transfer­equipped models, the cause may be ribbon overlap (wrinkling). Before performing this
alignment, check other factors which can cause ribbon wrinkle:

• Misadjusted Media Width setting (Section 2.3);

• Misadjusted Printhead Pressure setting (Section 2.5);

• Severely misadjusted Printhead Burn Line (Section 2.4);

2-23

Adjustments and Maintenance

• A worn platen (Section 2.1.3) or associated component (e.g., bearings); and,

• A dirty or worn ribbon path component (Section 2.1.4).

If all items are in good order, then Ribbon Path alignment may be needed, as follows:

1. Load 4-inch (102 mm) media. Load a matching width ribbon, but do not secure the
leader to the Ribbon Take-up Hub. Instead, allow the media and ribbon to feed together
from the printer.

2. Disengage the Media Width Adjustment; see Section 2.3.

3. Press FEED several times to normalize the path of the ribbon and media.

4. Press FEED several more times, observing the ribbon for rippling and bagging as it
travels down from the Ribbon Supply Hub and under the Printhead Assembly. If smooth,
proceed to Step 5; otherwise, loosen the Ribbon Idler Screw then, while repeatedly
pressing FEED, slowly turn the Ribbon Idler Cam until the ribbon is dispensed smoothly.
Carefully tighten the Ribbon Idler Screw and feed several more labels to verify
adjustment; repeat if necessary.

2-24

Adjustments and Maintenance

5. Attach the ribbon to the Ribbon Take-Up Hub then proceed according to printer type –

• Non-Display Models: Simultaneously press PAUSE and FEED.

• Display-Equipped Models: Select a quantity of Ribbon Test Labels.

6. Begin printing. Observe the ribbon for rippling and bagging as it travels from the
Printhead Assembly to the Ribbon Take-Up Hub. If smooth and the printed images show
no evidence of ribbon wrinkling, proceed to Step 7; otherwise, slightly loosen the Ribbon
Shield Adjustment Screws then move either side of the Ribbon Shield forward or back
until the ribbon is smooth and the printed images are free of voids. Carefully tighten the
Ribbon Shield Adjustment Screws. Print several labels to verify the adjustment and
repeat if necessary.

7. Install operating media and ribbon. Set the Media Width Adjustment (see Section 2.3).
Send your label format to the printer and examine the prin ted labels; readjust the
Ribbon Shield slightly, if needed.

2-25

Adjustments and Maintenance

2.7 Darkness Adjustment

The Darkness Adjustment compensates for changes in print contrast that may occur when
the printhead (or a non-display Front Panel PCB) is replaced. Compare labels printed before
replacement to those printed after replacement to reveal possible contrast changes. Then, if
necessary, perform a Darkness Adjustment to restore the contrast level:

• Non-Display Models:

Turn the Darkness Adjustment
clockwise to darken the print or
counterclockwise to lighten.

• Display-Equipped Models:

Enter the menu and go to PRINT
CONTROL / CUSTOM ADJUSTMENTS /
DARKNESS, then increase the setting to darken printing or decrease it to lighten.



Note: Improper Darkness Adjustment increases can shorten the printhead service life.

For darker print, increase the HEAT setting and/or slow the PRINT SPEED.

2.8 Downloading Firmware and Fonts

The operating programs and fonts are stored in Flash memory. As updates and/or new
program features become available, they can be downloaded as follows:

1. Identify the new version of firmware for the printer model from http://www.datamax-

oneil.com

2. Download the firmware onto the computer’s hard drive. Ensure that the printer is
connected to the host via the parallel port and powered ON. Then, depending upon the
model, use the DOS copy command to download the firmware to the printer:

• Non-Display Models (.dlf extension)

copy filename.dlf lpt1/b

• Display-Equipped Models (.zs extension)



Note: Other programs (e.g., hyper-terminal, and certain Windows

programs) may also be used to download this file.

2-26

copy filename.zs lpt1/b



Driver

Adjustments and Maintenance

3. The READY Light will flash during the download to the printer. Following a successful
download, the STOP Light will illuminate and a reset will occur. The previous setup will
be unaffected unless substantial firmware structural changes have occurred. Print a
Database Configuration Label to verify your new firmware version.



Note: An illuminated ERROR Light denotes an unsuccessful download; however, the

original firmware will remain operational. (A reset will occur, if not cycle power
OFF and ON). Afterward, resend the file. If the problem persists, ensure that the
downloaded file is correct for the model and that the host to printer interface is
functional; otherwise, Flash memory may be defective (see Section 4.4).

2.9 Resetting the Printer

To reset the printer proceed according to the type.

2.9.1 Non-Display Models

To return the Factory Default settings, turn OFF the printer then press and hold all three
buttons and turn ON the printer. Continue to depress the buttons until the

off (about 20 seconds).

STOP

Light turns

2.9.2 Display-Equipped Models

Depending upon the method used, there are three reset levels possible:

• Soft Reset

To reset the printer and clear any temporary host settings, press and hold CANCEL for
approximately 4 seconds.

• Level One Reset

To return the factory default settings or restore the Factory Setting File, turn OFF the
printer then press and hold PAUSE and CANCEL while turning ON the printer. Continue
to depress the keys until READY appears.

2-27

Adjustments and Maintenance

• Level Two Reset

To return the firmware default settings and clear calibration and adjustment parameters,
turn OFF the printer then press and hold PAUSE, FEED, and CANCEL while turning ON
the printer. Continue to depress the keys until READY appears.



Note: Calibration must be performed after a Level Two Reset; see Section 2.2.

2.10 Printhead Voltage Adjustment

Use extreme caution as voltage measurement is required; if the applied

CAUTION

The printhead voltage adjustment is required when (1) replacing the power supply; or, (2) if
the factory voltage setting has been changed. No voltage adjustment is required during a
routine printhead replacement. Adjust the Printhead Voltage as follows:

1. Turn OFF and unplug the printer.

2. Remove the cover; see Section 4.1.

3. Using a multi-meter set to measure DC volts, connect the negative probe to chassis
ground and then proceed according to the revision of the installed Power Supply:

voltage exceeds 28 VDC, printhead damage can result.

• If equipped, connect the positive probe to the Q3 Heat Sink; or,

Power Supply PCB

RP1

Q3 Heat

Sink

2-28

Adjustments and Maintenance

• If not equipped, connect the positive probe to the D19 Upper Lead.

RP1

Power Supply PCB

Upper Lead

(anode)

D19

4. Raise the Printhead Assembly. Locate and note the Printhead Resistance Value on the
printhead label.

Printhead

Resistance Value

Printhead
Assembly

5. Ensure that media is loaded. Close the Printhead Assembly then plug in and turn ON the
printer.

2-29

Adjustments and Maintenance

6. Wait briefly. After READY is displayed, press FEED (to temporarily en able the voltage).
Adjust the voltage using RP1 on the Power Supply PCB according to the resistance range
listed in the appropriate table below.

Over-voltage can permanently damage or shorten printhead service life.

WARNING

Printhead Voltage Adjustment

Model

Printhead Resistance

(Ohms)

Applied Voltage

(+/- 0.1 VDC)

M-4206 800 24.0

680 – 710 22.4
711 – 740 22.9
741 – 770 23.4
771 – 800 23.8

M-4210

801 – 830 24.2
831 – 860 24.7
861 – 890 25.1
891 – 920 25.5
953 – 994 22.4

995 – 1036 22.9

M-4306

7. Turn OFF and unplug the printer. Remove the multi-meter probes and reinstall the
covers.

1037 – 1078 23.4
1079 – 1121 23.8
1122 – 1163 24.2
1164 – 1205 24.7
1206 – 1247 25.1
1248 – 1289 25.5

2-30

Troubleshooting

3

3.0 Overview............................................................................................1

3.1 Troubleshooting................................................................................... 1

3.1.1 Initial Steps ............................................................................... 1

3.2 General Problem Resolution................................................................... 1

3.2.1 Problem Isolation........................................................................ 2

3.2.1.1 No Power ......................................................................3

3.2.1.2 ERROR Light ON............................................................. 5

3.2.1.2.1 Media Sensor Fault........................................... 6

3.2.1.2.2 Ribbon Sensor Fault ......................................... 7

3.2.1.3 STOP Light ON ............................................................... 8

3.2.1.4 No Print / Poor Quality ....................................................8

3.2.1.5 No Communications...................................................... 11

3.3 Message Resolution............................................................................ 12

3.3.1 Warning Messages .................................................................... 12

3.3.2 Fault Messages......................................................................... 13

3.4 Hex Dump Mode................................................................................ 19

i

ii

Troubleshooting

3.0 Overview

This chapter covers techniques for isolating and correcting printer problems.

3.1 Troubleshooting

Use the following procedures to isolate and correct malfunctions. When problems are
isolated to a Printed Circuit Board (PCB), assembly replacement is suggested, as component
level repair is not generally feasible in the field.



Note: Unless otherwise noted, see the Operator’s Manual for configuration, interfacing

and setup information.

3.1.1 Initial Steps

(1) Before servicing always unplug the printer; (2) ensure that the unit has
been placed on a level, stable surface; and, (3) use extreme care if measuring

CAUTION

Perform the following actions before troubleshooting then proceed according to the
symptom:

voltages.

• Remove any dirt or dust accumulations (see Section 2.1);

• Confirm t hat the AC outlet voltage is within specification;

• Confirm that the environment is acceptable;

• Confirm correct media and loading; and,

• If installed, disable the Present Sensor.

3.2 General Problem Resolution

To troubleshoot non-display models, or display-equipped models when no message is
generated, begin with Problem Isolation (Section 3.2.1). Follow the instruction under
Procedure then take the appropriate Action to find the defective item (listed by probability)
or, when necessary, further instructions.

3-1

Troubleshooting

3.2.1 Problem Isolation

Step Procedure Result Action

Plug in and turn ON the printer. Wait for
initialization, about one minute.

Do all three Indicator Lights remain ON?



1

Note: (1) Initialization may take longer

when equipped with certain options;
and, (2) display-equipped models
only, if the display remains dark,
press and hold MENU to adjust the
contrast; otherwise, if it does not
change, see Section 4.2.1.

Press FEED.

2

Does the printer attempt to move media?

Press FEED.

3

Is the ERROR Light ON?

4 Is the STOP Light ON?

Yes

Replace the Main Logic
PCB; see Section 4.4.

No Go to Step 2.

Yes Go to Step 3.

No Go to Section 3.2.1.1.

Yes Go to Section 3.2.1.2.

No Go to Step 4.

Yes Go to Section 3.2.1.3.

No Go to Step 5.

Print a Print Quality Label.

5

Are labels printed with acceptable quality?

Send a label format from the host.

6

Was the format printed?

Yes Go to Step 6.

No Go to Section 3.2.1.4.

Test complete. If
problems continue,

Yes

check the parameters
of your labeling
program or code.

No Go to Section 3.2.1.5.

3-2

Troubleshooting

3.2.1.1 No Power



Note: Ensure that the AC outlet is functioning properly and that the power cord is

securely connected to the outlet and printer. Also, some circuitry is protected by
resettable fuses; when tripped, cycling power resets those fuses.

Step Procedure Result Action

Yes Go to Step 2.

Is the power cord properly connected between

1

the printer and a functioning AC outlet?

No Correct as needed.

Press FEED.

2

Does any mechanical movement occur?

Turn OFF and unplug the printer. Remove the
cover (see Section 4.1). Check the cable
between the Front Panel PCB and the Main

3

Logic PCB.
Is the cable properly connected and free of

damage?

Turn OFF and unplug the printer. Check fuses
F1 and F2 on the Power Supply PCB (see

4

Section 4.5.1).
Are the fuses good?

If equipped, disconnect all options (see note).
Plug in and turn ON the printer.



Note: If RFID equipped, disconnect the

5

cable from J7 of the Power Supply
PCB; NEVER disconnect the
transducer cable.

Yes Go to Step 3.

No Go to Step 4.

Yes

No

Replace the Front Panel
PCB; see Section 4.2.1.

Connect the cable (or,
if damaged, replace it).

Yes Go to Step 5.

No

Yes

Replace the fuse(s);
see Section 4.5.1.

Troubleshoot the
option.

No Go to Step 6.

Is the STOP, ERROR, or READY Light ON?

(continued)

3-3

Troubleshooting

Step Procedure Result Action

Turn OFF and unplug the printer. Disconnect
the cable from J2 on the Power Supply PCB,

6

and then plug in and turn ON the printer.
Is the STOP, ERROR, or READY Light ON?

Turn OFF and unplug the printer. Disconnect
the cable from J6 on the Power Supply PCB,

7

and then plug in and turn ON the printer.
Is the STOP, ERROR, or READY Light ON?

Turn OFF and unplug the printer. Disconnect
the cable from J7 on the Main Logic PCB, and

8

then plug in and turn ON the printer.
Is the STOP, ERROR, or READY Light ON?

Turn OFF and unplug the printer. Disconnect
J5 from the Main Logic PCB. Plug in and turn
ON the printer. Using a multi-meter, check the
following voltages at the connector:

Replace the printhead

Yes

(see Section 4.3) or, if
defective, the cable.

No Go to Step 7.

Yes

Replace the Drive
Motor; see Section 4.7.

No Go to step 8.

Replace the Media

Yes

Sensor; see Section

4.6.

No Go to step 9.

Yes

Replace the Main Logic
PCB; see Section 4.4.

9

• +5 VDC @ Pin 1;

• +3 VDC @ Pin 2; and,

• + 20 VDC @ Pin 4.

Are the voltages present?

No

Replace the Power
Supply PCB; see
Section 4.5.

3-4

Troubleshooting

3.2.1.2 ERROR Light ON



Note: If troubleshooting a display-equipped model, see the specific message (Section

3.3).

Step Procedure Result Action

Load media. Set the SENSOR TYPE. Ensure a
correct MAXIMUM LABEL LENGTH setting. If
installed, remove ribbon and set the MEDIA

1

TYPE to Direct. Ensure that the printhead is
latched and then press FEED.

Is the ERROR Light ON?

Press FEED.

2

Do labels advance?

Did a complete label advance without the

3

ERROR Light illuminating?

Did a complete label advance with the ERROR

4

Light illuminating?

Yes Go to Step 2.

No Test complete.

Yes Go to Step 3.

No Go to Step 7.

Yes

Go to Section

3.2.1.2.2.

No Go to Step 4.

Yes Go to Step 5.

No

Go to Section

3.2.1.2.1.

Disable all options. Press FEED.

5

Did a complete label advance without the
ERROR Light illuminating?

3-5

Yes

No

Test complete. If
applicable, install
ribbon. Retest. If
problems persist, go to
Section 3.2.1.2.2.

Enable the attached
options, retesting after
each enable, until
problem option is
found, and then
troubleshoot the
option.

Troubleshooting

3.2.1.2.1 Media Sensor Fault

Step Procedure Result Action

Examine the Media Sensor for obstructions.

1

Is the Media Sensor in good order?

Turn OFF and unplug the printer. Remove the
cover (see Section 4.1). Locate J7 on the Main
Logic PCB and inspect the connection at the

2

PCB and at the Media Sensor.
Are the connection and the assembly in good

order?

Plug in and turn ON the printer. Perform
calibration.

3

Was calibration successful?

Yes Go to Step 2.

No

Clean the sensor; see
Section 2.1.2.

Yes Go to Step 3.

Connect cable or, if

No

damaged, replace the
Media Sensor; see
Section 4.6.

Yes Go to Step 4.

1) Replace the Media
Sensor (see Section

4.6); or,

No

2) Replace the Main
Logic PCB (see
Section 4.4).

Yes Go to Step 5.

Press FEED then listen for Drive Motor
operation.

4

Does the motor operate?

Turn OFF and unplug the printer. Remove the
cover. Inspect all drive train components.

5

Are the drive train components good working?

No

Yes

No

1) Replace the Power
Supply PCB (see
Section 4.5);

2) Replace the Main
Logic PCB (see
Section 4.4); or,

3) Replace the Drive
Motor (see Section

4.7).

Inspect parts for
extreme wear or
misalignment including
the platen (see Section

4.8), printhead (see
Section 2.4), and
pressure (see Section

2.5).
Replace the defective

part(s).

3-6

Troubleshooting

3.2.1.2.2 Ribbon Sensor Fault

Step Procedure Result Action

Install ribbon. Set the MEDIA TYPE to Thermal
Transfer. Press FEED.

1

Is the ERROR Light ON?

Ensure that the ribbon core fits tightly on the
Ribbon Supply Hub. Press FEED.

2

Does the ribbon move forward without slipping
when FEED is pressed?

Yes Go to Step 2.

No Test complete.

1) Remove the
Thermal Transfer
assembly (see
Section 4.9) then
examine the timing
disk for wear, or
debris build-up on

Yes

the sensor (Main
PCB). If necessary,
clean it or replace
the hub; or,

2) Replace the Main
Logic PCB (see
Section 4.4).

1) Install a ribbon with
the proper core
size;

No

2) Check the Ribbon
Hubs for mechanical
binding; or,

3) Verify correct media
and ribbon
combination.

3-7

Troubleshooting

3.2.1.3 STOP Light ON



Note: If troubleshooting a display-equipped model, see the specific message (Section

3.3).

Procedure Result Action

1) Stuck button or
loose cable. If
necessary, replace
the Front Panel PCB

Yes

Reset the printer to factory defaults (see
Section 2.9.1). After initialization, press FEED.

Is the STOP light ON?

No

(see Section 4.2.1);
or,

2) Replace the Main
Logic PCB (see
Section 4.4).

Pause Mode was
enabled (verify the
desired operational
settings).

3.2.1.4 No Print / Poor Quality



Note: (1) If printed results are uneven, light or splotchy try increasing HEAT or

reducing PRINT SPEED as no further adjustments may be needed; (2) during the
procedure below, synthetic media may not produce the intended results due to
the requirements of the material; and, (3) in extreme conditions, over­temperature protection circuitry can interrupt printing to prevent damage.

Step Procedure Result Action

Print a Test Label.

1

Is anything printed on the label?

Does the label contain streaks or areas of

2

print dropout?

(continued)

Yes Go to Step 2.

No Go to Step 8.

Yes Go to Step 3.

No Go to Step 7.

3-8

Troubleshooting

Step Procedure Result Action

1) Bad media. Switch
sources then retest;

2) Wrong firmware
(see Section 2.8);

3) Wrong, dirty, or
defective printhead.
Clean (see Section

2.1.1) or replace it
(see Section 4.3);

Do streaks or dropouts run in the direction of

3

media travel?

Yes

or,

4) Dirty or worn
platen. Clean (see
Section 2.1.3) or
replace it (see
Section 4.8).

Do dropouts run perpendicular to the direction

4

of media travel?

Are printed characters or images

5

inconsistently irregularly sized, compressed or
enlarged?

Do the lines or missing data run diagonally,

6

intermittently and erratically through the
label?

No Go to Step 4.

Yes Go to Step 5.

No Go to Step 6.

1) Defective gear or
worn drive
component (see
Section 4.7);

Yes

2) Replace the Power
Supply PCB (see
Section 4.5); or,

3) Replace the Main
Logic PCB (see
Section 4.4).

No Go to Step 6.

Misadjusted ribbon

Yes

path component (see
Section 2.6).

No Go to Step 7.

(continued)

3-9

Troubleshooting

Step Procedure Result Action

1) Misadjusted Media
Width (see Section

2.3);

2) Misaligned
printhead (see

Does the print fade across the width of the

7

label?

Yes

Section 2.4); or,

3) Dirty or worn
platen. Clean (see
Section 2.1.3) or
replace it (see
Section 4.8).

No Go to Step 10.

8

9

10

Turn OFF and unplug the printer. Remove the
cover. Raise the printhead assembly. Examine
the printhead cables that connect to J8 of the
Main Logic PCB and to J2 of the Power Supply
PCB.

Are the cables connected and undamaged?

Using a multi-meter, connect the red lead to
J2 pin 1 (bottom left of connector) of the
Power Supply PCB and connect the black lead
to chassis ground. Plug in and turn ON the
printer. Print a Test Label while observing the
multi-meter.

Is approximately +24 VDC present?

Does the printed label contain correct
information, free of failure?

Yes Go to Step 9.

Properly connect the

No

cable(s) or replace if
damaged.

Yes

Replace the printhead
(see Section 4.3).

Replace the Power

No

Supply PCB (see
Section 4.5).

Yes Test complete.

No

Replace the Main Logic
PCB (see Section 4.4).

3-10

Troubleshooting

3.2.1.5 No Communications



Note: If troubleshooting an Ethernet equipped printer, refer to the documentation that

accompanied the option.

Step Procedure Result Action

Turn OFF the printer. Connect an interface
cable between the host and printer. Turn ON

1

the printer, and then send it a label format.
Did the label print?

Examine the label.

2

Is the label printed as designed?

Examine the communication parameters.

3

Have the same parameters been selected for
the printer and host?

Yes Go to Step 2.

No Go to Step 3.

Yes Test is complete.

Verify label setup and
format layout; for

No

missing data, check
image location,
memory allocations and
supported symbologies.

Yes Go to Step 4.

No Reconfigure to match.

Place the printer into Hex Dump Mode (see
Section 3.4) and then send it a label format.

4

Did Hex / ASCII data print?

3-11

Yes

No

Check control code
selection and label
format.

1) Replace the
interface cable; or,

2) Replace the Main
Logic PCB (see
Section 4.4).

Troubleshooting

3.3 Message Resolution

All functions are monitored during operation and when a problem is detected a
corresponding message will be displayed. (If no messages accompany the problem, see
Section 3.2.) In the tables below locate the Displayed Message, the Description, and then
use the Possible Solutions (listed by probability) to isolate th e malfunction.



Note: Warning and Fault Messages are not displayed in Menu or Test Mode.

3.3.1 Warning Messages

Warning Messages (lasting about five seconds) receive a medium display priority and, if
multiples occur, the priority Warning will be displayed.

Warning Messages

Displayed Message Description Possible Solution(s)

DOT FAILURE

GAP MODE

WARNING LOW BACKING

GOODBYE

HEAD NEEDS CLEANING

Defective printhead
elements have been
detected.

Only a small difference
between the ‘empty’
and ‘gap’ sensor values
has been established.

Power shutdown is in
progress.

The scheduled
maintenance interval
has been reached.

Replace the printhead if print
quality becomes unacceptable (see
Section 4.3).

No action required. Typically
caused by transparent media
backing or notched media, this
may result in a slight ‘Out of Stock’
indication delay when the supply is
emptied.

The power switch was turned OFF
or AC line voltage has been lost.

Clean the printhead (see Section

2.1.1).

HOST CHANGES PENDING

Changes await the
printer’s configuration.

3-12

To save the changes, send a host
reset command; or, to discard
changes perform a soft reset (see
Section 2.9).

Troubleshooting

Warning Messages (continued)

Displayed Message Description Possible Solution(s)

Possible low or fluctuating AC line
voltage; try moving the printer to
another circuit. Other causes can
include a faulty Power Supply PCB,

LOW VOLTAGE

+24 VDC has dipped
below threshold.

Main Logic PCB, or printhead.

If the condition persists, possible
faulty Main Logic PCB (see Section

4.4).

RTC RAM FAILURE

Permanent memory
save function failed.

Wait. Allow the printhead to cool

TEMPERATURE PAUSE

High printhead
temperature has been
detected.

before resuming operation. If the
condition persists, verify that
environmental conditions are within
specification for the printer.

3.3.2 Fault Messages

Fault Messages receive the highest display priority and, if multiples occur, messages will
cycle.



Note: To return operation after a fault, correct the condition and then press FEED.

Fault Messages

Displayed Message Description Possible Solution(s)

24 V OUT OF TOLERANCE

ADC FAULT

+24 VDC supply is not
within operating range.

An analog to digital
conversion has failed.

3-13

Cycle power OFF and ON. If the
fault does not clear, adjust the +24
VDC supply voltage or replace the
Power Supply PCB; see Section 4.5.

WARNING! Use extreme

caution when measuring voltages.

Cycle power OFF and ON. If the
fault does not clear, replace the
Main Logic PCB; see Section 4.4.

Troubleshooting

Fault Messages (continued)

Displayed Message Description Possible Solution(s)

Cycle power OFF and ON. Then,
ensure that media thickness is
within specification for the cutter.
Retry. If the fault continues, try the
following:

WARNING! Turn OFF and
unplug the printer before
proceeding.

CUTTER FAULT

DMA FAULT

GAP MODE

CANNOT CALIBRATE

Blade positioning has
failed.

Direct Memory Access
has failed.

Consistently low sensor
readings have occurred.

1) Ensure that the cutter is properly
installed and that the cable is
connected and undamaged.

2) Clean the cutter and ensure that
the mechanism is unobstructed.

3) The cutter may be defective;
replace it.

4) The Main Logic PCB may be
defective; see Section 4.4.

Cycle power OFF and ON. If the
fault does not clear, replace the
Main Logic PCB; see Section 4.4.

Press any key to continue then try
the following:

1) Retry calibration, ensuring that
media was inserted in the sensor
during the appropriate step.

2) Clean the sensor (see Section

2.1.2) then retry calibration.

3) Try Advanced Entry Calibration;
see Section 2.2.2.3.

3-14

Troubleshooting

Fault Messages (continued)

Displayed Message Description Possible Solution(s)

Press any key to continue then try
the following:

1) Retry calibration, ensuring that
media was removed from the
sensor during the appropriate
calibration steps.

2) Clean the sensor (see Section

2.1.2) then retry calibration.

GAP MODE

FAULTY SENSOR

Consistently high

sensor readings have
occurred.

3) The sensor may be defective; see
Section 4.6.

4) The Main Logic PCB may be
defective; see Section 4.4.

HEAD CLEANING FAULT

OUT OF STOCK

The scheduled
maintenance interval
has been exceeded
three times.

Media cannot be
detected.

Clean the printhead (see Section

2.1.1).

Try the following:

1) Ensure that media is properly
loaded; and, if using die-cut
media with a transparent liner or
large notches, ensure the PAPER
EMPTY DISTANCE has been
adjusted.

2) Adjust the Media Sensor position.

3) Perform calibration; see Section

2.2.2.

4) The Media Sensor may be
defective or the cable loose; see
Section 4.6.

5) The Main Logic PCB may be
defective; see Section 4.4.

3-15

Troubleshooting

Fault Messages (continued)

Displayed Message Description Possible Solution(s)

Calibration was
incomplete; power

Press FEED. If the fault does not
clear, calibrate the printer; see
Section 2.2.2.

POSITION FAULT

was removed or a
reset occurred during
a fault; or, an update
was made to the
Application Version.

PRINT ENGINE FAULT

RAM FAULT

REFLECTIVE MODE

CANNOT CALIBRATE

A print logic problem
has been detected.

A memory error has
been detected.

Consistently low sensor
readings have occurred.

Cycle power OFF and ON. If the
fault does not clear, replace the
Main Logic PCB; see Section 4.4.

Cycle power OFF and ON. If the
fault does not clear, replace the
Main Logic PCB; see Section 4.4.

Press any key to continue then try
the following:

1) Retry calibration, ensuring that

the media was inserted in the
sensor during the appropriate
step.

2) Ensure that the reflective mark is

made of carbon-based ink.

3) Clean the sensor (see Section

2.1.2) then retry calibration.

4) Try Advanced Entry Calibration;

see Section 2.2.2.3.

3-16

Troubleshooting

Fault Messages (continued)

Displayed Message Description Possible Solution(s)

Press any key to continue then try
the following:

1) Retry calibration, ensuring the

reflective mark was inserted
facedown in the sensor during
the appropriate calibration step.

REFLECTIVE MODE

FAULTY SENSOR

RIBBON FAULT

Consistently high
sensor readings have
occurred.

The thermal transfer
MEDIA TYPE is
selected, but Ribbon
Supply Hub movement
has not been detected.

2) Ensure that the reflective mark is

made of carbon-based ink.

3) Clean the sensor (see Section

2.1.2) then retry calibration.

4) The sensor may be defective; see
Section 4.6.

5) The Main Logic PCB may be

defective; see Section 4.4.

Press any key to continue then try
the following:

1) Ensure that ribbon is correctly
loaded and that the printhead is
latched.

2) Check the ribbon hubs for
obstructions that could inhibit
movement.

3) Ensure that the ribbon core fits
snugly on the ribbon hub.

4) Ensure the media and ribbon
combination is correct.

STROBE TIMING FAULT

A printhead clocking
problem has been
detected.

3-17

5) The timing disk may be
defective; see Section 4.9.

6) Possible dirty ribbon sensor or
defective Main Logic PCB; see
Section 4.4.

Cycle power OFF and ON. If the
fault does not clear, replace the
Main Logic PCB; see Section 4.4.

Troubleshooting

Fault Messages (continued)

Displayed Message Description Possible Solution(s)

Wait. Allow the printhead to cool. If
the condition persists, verify that
the environment is within
specification; also, possible
defective printhead or printhead

TEMPERATURE FAULT

The printhead
temperature limit has
been exceeded.

cable; see Section 4.3.
Ensure that the printer is calibrated,

that media is loaded, and that the
printhead is latched. Then press
FEED and proceed accordingly:

If media advances –

1) Ensure that the Media Sensor,

Media Guide, and Media Width
Adjustment are properly set.

TOP OF FORM FAULT

TOF (gap or mark)
was not found within
the MAXIMUM LABEL
LENGTH setting, or
occurred in an
unexpected place.

2) Ensure the correct MAXIMUM

LABEL LENGTH setting.

3) Ensure the media and ribbon

combination is correct.

4) The Media Sensor may be

defective or the cable loose; see
Section 4.6.

5) The platen or a drive

component may be worn or
defective; see Section 4.8.

6) The pressure may need to be

increased; see Section 2.5.

7) The printhead may need to be

aligned; see Section 2.4.

If media does not advance –

1) Possible defective Drive Motor or

other drive component.

2) Possible defective Power Supply

PCB; see Section 4.5

3) Possible defective Main Logic

PCB; see Section 4.4.

3-18

Troubleshooting

3.4 Hex Dump Mode

Hex Dump Mode is a diagnostic tool for isolating communications and DPL syntax errors,
by allowing input (host) data to output (printer) data comparisons. All data received by the
printer will be output in hexadecimal code along with the printable ASCII equivalents, as
shown below. To identify possible handshaking problems, repeatedly send the format and
sections of missing data can become apparent. To debug DPL label formats reference the
Class Series 2 Programmer’s Manual.

After sending a label format to the printer, the output will be immediate and in the form
shown below. As a final note, many software programs use bit mapping to construct the
label making diagnosis difficult. Contact Datamax-O’Neil Technical Support with any
questions.

To print a Hex Dump, load four-inch wide media (and ribbon, if thermal transfer printing)
then proceed according to the type:

• Non-Display Models: Turn ON the printer. Then, when all three lights turn ON, press and

hold FEED until the



Note: To exit Hex Dump Mode, turn the printer OFF and ON.

STOP Light

turns OFF.

• Display-Equipped Models: Turn ON the printer. Enter DIAGNOSTICS and enable HEX

DUMP MODE. Exit the menu and save the changes.



Note: To exit Hex Dump Mode, enter DIAGNOSTICS and disable HEX DUMP MODE

then exit the menu, saving the changes.

3-19

Troubleshooting

3-20

Removal and Replacement

4

4.0 Introduction........................................................................................1

4.1 Side Cover Assembly............................................................................1

4.2 Front Cover......................................................................................... 3

4.2.1 Front Panel PCB........................................................................ 4

4.3 Printhead............................................................................................ 5

4.3.1 Printhead Assembly ..................................................................6

4.3.1.1 Head Pressure Cams and Springs .................................. 9

4.4 Main Logic PCB.................................................................................. 11

4.5 Power Supply PCB.............................................................................. 13

4.5.1 Fuses.................................................................................... 14

4.6 Media Sensor .................................................................................... 15

4.7 Drive Motor....................................................................................... 17

4.7.1 Isolator................................................................................. 19

4.8 Platen and Assist Roller ...................................................................... 20

4.9 Thermal Transfer Assembly ................................................................. 23

4.9.1 Take-up Hub & Clutch Assembly ............................................... 23

4.9.2 Supply Hub............................................................................ 24

4.10 Internal Rewinder.............................................................................. 26

4.10.1 Rewind Hub & Clutch Assembly................................................. 26

4.10.2 Spur Gear ............................................................................. 27

i

4.11 Media Supply Assembly ...................................................................... 28

4.11.1 Media Hanger......................................................................... 28

4.11.2 Media Hub............................................................................. 29

ii

Removal and Replacement

4.0 Introduction

This section details removal and replacement methods for various printer components;
where multiple equipment types or options are available, use the procedure that best
matches the configuration.

 Always disconnect AC power before performing service.

 Wear a wrist strap and follow all ESD prevention measures.

 Use extreme care and never use sharp objects on the Printhead, Platen,

CAUTION

or Assist Roller.

4.1 Side Cover Assembly

Removal:

1. Turn OFF and unplug the printer.

2. Raise the Access Cover. Remove the three Screws that secure the Side Cover Assembly
to the rear and the base of the printer.

Access

Cover

Side

Cover Assembly

Screws

4-1

Removal and Replacement

3. Loosen the two Screws that secure the Side Cover Assembly to the Centerplate.

Side

Cover Assembly

Centerplate

Screws

4. Lift the Side Cover Assembly off the printer.

Side

Cover Assembly

4-2

Removal and Replacement

Installation:

Lower the Side Cover Assembly onto the printer. Install the three removed Screws into the
rear and base of the printer, and tighten the two Screws on the Centerplate.

4.2 Front Cover

Removal:

1. Turn OFF and unplug the printer.

2. Remove the Side Cover Assembly; see Section 4.1.

3. Push up on the Tab (shown) and gently pull the Front Cover forward, off the printer.

Tab

Front

Cover

Installation:

1. Align the tabs on the Front Cover to the slots in the chassis and then push until the
cover snaps into place.

2. Install the Side Cover Assembly; see Section 4.1.

4-3

Removal and Replacement

4.2.1 Front Panel PCB

Removal:

1. Remove the Front Panel; see Section 4.2.

2. Proceed according to equipped type:

• If servicing a non -display

model, remove the two
Screws that secure the Front
Panel PCB. Disconnect the

Front Panel

Cable

Front Panel Cable. Remove
the PCB.

• If servicing a display-

equipped model, lift the tabs
and remove the Bezel.
Remove the two Screws that
secure the Front Panel PCB.
Disconnect the Front Panel
Cable. Remove the PCB.

Screws

Front Panel

PCB

Front Panel

PCB

Screws

Front Panel

Cable

Installation:

1. Insert the Front Panel Cable through the opening in the chassis and connect it to the
Front Panel PCB.

Front Bezel

4-4

Removal and Replacement

2. Secure the Front Panel PCB to the chassis using the two Screws.

3. If servicing a display-equipped model, install the Bezel over the Front Panel PCB;
otherwise, go to Step 4.

4. Install the Front Panel; see Section 4.2.

5. If servicing a non-display model, adjust the darkness; see Section 2.7.

4.3 Printhead

 If over-voltage is suspected, see Section 2.10.
 Handle the printhead with extreme care and never use a sharp object on

CAUTION

Removal:

1. Turn OFF and unplug the printer. Open the cover; if ribbon is installed, remove it.

2. With the Printhead Assembly latched, loosen the Printhead Mounting Screw (it will
remain in the assembly).

the printhead surface.

Printhead
Mounting

Screw

Printhead
Assembly

3. Unlatch then raise the Printhead Assembly. Carefully slide the Printh ead out of the
assembly (see detail, below) then disconnect the two cables and remove the Printhead.

4-5

Removal and Replacement

Installation:

1. While carefully holding the Printhead, connect both cables.

2. Carefully slide the Printhead under the Guard and onto the Locator Pins in the Printhead
Assembly. Secure the Printhead with the Printhead Mounting Screw (do not over­tighten).

Printhead
Assembly

Guard

Printhead

Locator

Pins

Cable

Connectors

3. Clean the Printhead; see Section 2.1.1.

4. Reload ribbon (if removed) then lower and latch the Printhead Assembly.

5. Adjust the darkness; see Section 2.7.

4.3.1 Printhead Assembly

Removal:

1. Remove the Side Cover Assembly (see Section 4.1) and the Front Cover (see Section

4.2).

2. Remove the Printhead; see Section 4.3.

3. Remove the Drive Gear Screw, Idler Post, and Drive Gear from the Centerplate.

4-6

Removal and Replacement

4. Remove the Pivot Pin Screw from the Platen Block Hinge.

Platen

Block Hinge

Centerplate

Pivot

Pin Screw

Drive
Gear

Idler
Post

Drive

Gear Screw

5. Extract the Pivot Pin from the Platen Block Hinge and Printhead Assembly. Then, remove
the Printhead Assembly (the Front Lift Spring and the Rear Lift Spring will follow) and
route the printhead cables out of the Guard; see Section 4.3.

Rear

Lift Spring

Front

Lift Spring

Printhead
Assembly

Platen

Block Hinge

Pivot Pin

4-7

Removal and Replacement

Installation:

1. Place the Rear Lift Spring (short leg toward the Centerplate) onto the shoulder of the
Platen Block Hinge then lower the Printhead Assembly until aligned with the Plate Block
Hinge.

2. Place the Front Lift Spring (bent leg to captivate the Printhead Assembly) inline, against
the Printhead Assembly, then insert the Pivot Pin (solid end forward). Raise the
assembly and position the Front Lift Spring leg.

Rear

Platen

Lift Spring

Block Hinge

Front

Lift Spring

Pivot Pin

Centerplate

leg

Printhead
Assembly

3. Install and secure the Pivot Pin Screw. Test the Printhead Assembly for proper
movement and lift.

4. Attach the Drive Gear and Idler Post to the Centerplate with the Drive Gear Screw.

5. Carefully route the printhead cables through the Guard and then install the Printhead;
see Section 4.3.

6. Install the Front Cover (see Section 4.2) and the Side Cover Assembly (see Section 4.1).

4-8

Removal and Replacement

4.3.1.1 Head Pressure Cams and Springs

Removal:

1. Remove the Printhead Assembly; see Section 4.3.1.

2. Remove the two Screws that secure the Ribbon Shield and then remove it from the
Printhead Assembly.

Screws

Ribbon

Shield

3. Loosen the Locking Screws and the Adjustment Screws.

Locking

Screws

Adjustment

Screws

Printhead
Assembly

4-9

Removal and Replacement

4. Slide the Bottom Carriage backward until the Catches are free and then separate the
Bottom Carriage from the Top Carriage.

Catches

Bottom

Carriage

Top

Carriage

5. Remove the Cams and Springs from the Top and Bottom Carriages.

Bottom

Carriage

Cams

Springs

Top

Carriage

Installation:

1. Place the Springs into the Sockets in the Top Carriage and then place the Cams, with
the Indicators oriented for least pressure (see drawing), onto the Springs.

Indicators

Bottom

Carriage

Top

Cams

Carriage

Springs

Sockets

4-10

Removal and Replacement

2. Place the Bottom Carriage into the Top Carriage, sliding it forward until the Catches
engage, and then tighten the Locking Screws.

3. Snug, but do not tighten, the Adjustment Screws.

4. Install the Ribbon Shield onto the Top Carriage and secure it usin g the two Screws.

Screws

Top

Carriage

Ribbon

Shield

5. Install the Printhead Assembly; see Section 4.3.1.

6. Align the Printhead; see Section 2.4.

7. Adjust the Printhead Pressure; see Section 2.5.

8. If Thermal Transfer equipped, align the Ribbon Path; see Section 2.6.

4.4 Main Logic PCB

Removal:

1. Turn OFF and unplug the printer.

2. Remove the Side Cover Assembly; see Section 4.1.

3. Remove all cables connected to the Main Logic PCB.

4-11

Removal and Replacement

4. Remove the two Screws on the PCB Back Plate of the Main Logic PCB then slide out the
Main Logic PCB.

Main

Logic PCB

PCB Back

Plate

Screws

Installation:

1. Position the Main Logic PCB in the printer. Using the two Screws, secure the PCB Back
Plate to the printer.

2. Connect the cables to the Main Logic PCB.

Main Logic PCB

J11

J9

J14

J10

J8

J12

J7

J4J16

J5

J6

3. Install the Side Cover Assembly; see Section 4.1.

4. Calibrate the Media Sensor; see Section 2.2.

4-12

Removal and Replacement

4.5 Power Supply PCB

Removal:

1. Turn OFF and unplug the printer.

2. Remove the Side Cover Assembly;
see Section 4.1.

3. Remove all cables connected to the
Power Supply PCB.

4. Remove the two Screws that secure
the AC Input Connector and Retainer
to the printer.

5. Remove the Screw (and Lock
Washer) that secures the Ground
Wire.

6. Remove the two Short Screws that
secure the Power Supply PCB and
the two Long Screws that secure the
Power Supply Heatsink to the
printer.

7. Remove the Power Supply PCB from

Screws

Power

Supply

PCB

Ground Screw/

Ground Wire

Short

Screws

AC Input
Retainer

AC Input
Connector

Long

Screws

the printer.

Installation:

1. Position the Power Supply PCB in the printer and secure it using the two Short Screws
(PCB) and the two Long Screws (Heatsink).

4-13

Removal and Replacement

2. Secure the Ground Wire using the Screw and Lock Washer to the chassis.

3. Position the AC Input Retainer onto the AC Input Connector then secure it using the two
Screws.

4. Connect the cables to the Power Supply PCB.

Power Supply PCB

J4

J2
J5

J6

5. Adjust the Printhead Voltage; see Section 2.10.

6. Install the Side Cover Assembly; see Section 4.1.

4.5.1 Fuses

 Only use replacement fuses of the same type and rating as the originals;

failure to comply could cause serious damage, including fire; and,

CAUTION

Removal:

1. Turn OFF and unplug the printer.

 Use care if replacing Fuse F1, which may blow du ring a failure in the

primary switching circuit and indicate a more serious electrical problem.

2. Remove the Side Cover Assembly; see Section 4.1.

3. Locate and test Fuses F1 and F2 on the Power Supply PCB.

4-14

Removal and Replacement

Power Supply PCB

Fuse F2

Fuse F1

Installation:

1. Only replace the defective fuse(s) with the same type and rating as the factory original:

• Fuse F1: Medium acting, 3 amps @ 250 Volts, 5 x 20 mm; and,

• Fuse F2: Fast acting, 3 amps @ 250 Volts, 5 x 20 mm.

2. Install the Side Cover Assembly; see Section 4.1.

4.6 Media Sensor

Removal:

1. Turn OFF and unplug the printer.

2. Remove the Side Cover Assembly; see Section 4.1.

3. Open the J7 Strain Relief on the Main Logic PCB then remove the Media Sensor Cable.

4. Unlatch the printhead assembly then remove the Screw and the Outer Bearing Plate.

5. Slide the Media Sensor & Cable Assembly out of the printer.

4-15

Media Sensor &

Cable Assembly

Screw

Removal and Replacement

Outer Bearing

Plate

Installation:

1. Route the Cable Assembly through the Centerplate opening and then slide in Media
Sensor.

Media

Sensor

Centerplate

2. Replace the Outer Bearing Plate and start, but do NOT tighten, the Screw.

3. Ensure that the Leveling Cam is loose and then latch the Printhead Assembly.

4. While pushing downward on the Printhead Assembly (see arrow, below), pull down on
the Outer Bearing Plate and tighten the Screw.

4-16

Removal and Replacement

Printhead Assembly

Outer Bearing Plate

Leveling Cam

Screw

5. Connect the Media Sensor Cable to J7 on the Main Logic PCB; see Section 4.4. Press the
connector lock down and then close the Strain Relief.

6. Install the Side Cover Assembly; see Section 4.1.

7. Plug in and turn ON the printer. Perform the Media Width Adjustment; see Section 2.3.

4.7 Drive Motor

Removal:

1. Turn OFF and unplug the printer.

2. Remove the Side Cover Assembly (see Section 4.1) and the Front Cover (see Section

4.2). Also, if the printer is equipped with an Assist Roller, remove the fascia and any
output attachment (e.g., tearplate, arc plate, etc; see Section 4.8 for details).

3. Raise the Printhead Assembly and proceed according to equipped type: If equipped with
an Assist Roller, remove the Screw that secures the Inner Bearing Plate and then
remove the Inner Bearing Plate from the Platen Block; otherwise, go to Step 4.

4-17

Screw

Removal and Replacement

Printhead

Assembly

Inner

Bearing Plate

Platen

Block
Assist
Roller

4. Disconnect the Drive Motor Cable from the Power Supply PCB.

5. Remove the two Screws and Lock Washers that secure the Drive Motor then carefully
remove the Drive Motor.

Isolator

Drive

Motor

Lock

Washers

Screws

Drive

Motor Cable

Installation:

1. Carefully insert the motor’s gear into the drive gear train, rotating the Drive Motor so
that it rests flush against the Isolator, with gears meshed, aligned to the screw holes.

4-18

Removal and Replacement

2. Secure the Drive Motor to the Isolator using the two Lock Washers and Screws.

3. Connect the Drive Motor Cable to the J6 of the Power Supply PCB; see Section 4.5.

4. Proceed according to equipped type: If equipped with an Assist Roller, replace the Inner
Bearing Plate and secure it to the Platen Block using the Screw; otherwise, go to Step 6.

5. If removed, install the tearplate and fascia or other previously attached output device.

6. Install the Front Cover (see Section 4.2) and Side Cover Assembly (see Section 4.1).

4.7.1 Isolator

Removal:

1. Turn OFF and unplug the printer.

2. Remove the Drive Motor; see Section 4.7.

3. Remove the two Screws that secure the Isolator to the Centerplate then remove the
Isolator.

Centerplate

Isolator

Screws

4-19

Removal and Replacement

Installation:

1. Place the Isolator against the Centerplate opening as shown and secure it using the two
Screws.

2. Install the Drive Motor; see Section 4.7.

4.8 Platen and Assist Roller

Removal:

1 Turn OFF and unplug the printer.

2. Remove the Fascia and Tearplate (or any other attached output device) and then raise
the Printhead Assembly.

Printhead
Assembly

Tearplate

Thumbscrew

Fascia

3. Remove the Screw that secures the Inner Bearing Plate, and then remove the Inner
Bearing Plate from the Platen Block.

4-20

Screw

Removal and Replacement

Inner

Bearing Plate

4. Remove the Screw that secures the Outer Bearing Plate then remove the Outer Bearing
Plate and slide the Bushing(s) out of the Platen Block.

Platen

Block

Platen &

Assist Rollers

Outer

Bearing Plate

Screw

Bushings

Platen

Block

4-21

Removal and Replacement

5. Remove the Platen and / or Assist Roller from the Platen Block.

Installation:

1. Position the Platen and / or Assist Roller into the Platen Block.

2. While holding the roller(s) in place, meshed with the drive gear, install the Inner Bearing
Plate and Screw.

3. Install the Bushing(s) over the roller shaft(s) and into the Platen Block.

4. Replace the Outer Bearing Plate and start, but do NOT tighten, the Screw.

5. Ensure that the Leveling Cam is loose and then latch the Printhead Assembly.

6. While pushing downward on the Printhead Assembly (see arrow, below), pull down on
the Outer Bearing Plate and tighten the Screw.

Printhead Assembly

Leveling Cam

Screw

Outer Bearing Plate

7. Install the Tearplate and Fascia or other output device.

4-22

Removal and Replacement

4.9 Thermal Transfer Assembly

Removal:

1. Turn OFF and unplug the printer.

2. Remove the three Screws that secure the Thermal Transfer Assembly and then remove
the Thermal Transfer Assembly from the Centerplate.

Thermal Transfer Assembly

Screws

Centerplate

Installation:

Position the Thermal Transfer Assembly over the opening in the Centerplate and secure it
using the three Screws.

4.9.1 Take-up Hub & Clutch Assembly

Removal:

1. Remove the Thermal Transfer Assembly; see Section 4.9.

2. Remove the C-Clip and Outer Bearing from the Take-Up Hub Shaft.

3. Slide the Take-up Hub and Inner Bearing out of the Assembly Casting then remove the
Clutch Assembly.

4-23

Take-up Hub

Assembly

Casting

Removal and Replacement

Take-up

Hub Shaft

Inner

Bearing

Outer

Bearing

Clutch

C-Clip

Assembly

Installation:

1. Position the Clutch Assembly and the Inner and Outer Bearings, as shown, in the
Assembly Casting.

2. Slide the Take-up Hub Shaft through the Inner Bearing, Clutch Assembly, and Outer
Bearing then insert the C-Clip onto the Take-up Hub Shaft to secure the components
within the Assembly Casting.

3. Install the Thermal Transfer Assembly; see Section 4.9.

4.9.2 Supply Hub

Removal:

1. Remove the Thermal Transfer Assembly; see Section 4.9.

2. Remove the Screw and Washer that secures Supply Hub in the Assembly Casting.

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Removal and Replacement

3. Slide the Supply Hub and Plastic Spacer out of the Assembly Casting.

Supply

Screw

Hub Shaft

Supply

Washer

Hub

Assembly

Casting

Plastic

Spacer

Installation:

1. Slide the Supply Hub Shaft through the Plastic Spacer and partially into the Assembly
Casting.

2. After ensuring that the Pin on the Supply Hub Shaft engages the Notch in the Assembly
Casting, slide the Supply Hub Shaft completely through then install the Washer and
secure the components to the Assembly Casting with the Screw.

Notch

Pin

Supply

Hub

Shaft

3. Install the Thermal Transfer Assembly; see Section 4.9.

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Removal and Replacement

4.10 Internal Rewinder

Removal:

1. Turn OFF and unplug the printer.

2. Remove the three Screws that secure the Internal Rewinder and then remove the
Internal Rewinder from the Centerplate.

Centerplate

Screws

Internal Rewinder

Installation:

Position the Internal Rewinder over the opening in the Centerplate and secure it using the
three Screws.

4.10.1 Rewind Hub & Clutch Assembly

Removal:

1. Remove the Internal Rewinder; see Section 4.10.

2. Remove the C-Clip and Outer Bearing from the Rewind Hub Shaft.

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Removal and Replacement

3. Slide out the Rewind Hub and Inner Bearing, and then remove the Clutch Assembly from
the Assembly Casting.

Rewind

Hub

Rewind

Hub Shaft

Clutch

Assembly

Inner

Bearing

Outer

Bearing

Assembly

Casting

C-Clip

Installation:

1. Position the Clutch Assembly in the Assembly Casting.

2. Install the Inner Bearing then slide the Rewind Hub Shaft through the Clutch Assembly
and Assembly Casting.

3. Install the Outer Bearing and secure the components with the C-Clip.

4. Install the Internal Rewinder; see Section 4.10.

4.10.2 Spur Gear

Removal:

1. Remove the Internal Rewinder; see Section 4.10.

2. Remove the Screw, Idler Post, and the Spur Gear from the Assembly Casting.

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Removal and Replacement

Assembly

Casting

Spur
Gear

Screw

Idler
Post

Installation:

1. Place the Idler Post into the Spur Gear, and then secure the components in the
Assembly Casting with the Screw.

2. Install the Internal Rewinder; see Section 4.10.

4.11 Media Supply Assembly

4.11.1 Media Hanger

Removal:

1. Remove the Main Logic PCB; see Section 4.4.

2. Remove the three Hanger Screws that secure the Media Hanger to the Centerplate and
then remove the Media Hanger.

Centerplate

Media

Hanger

Hanger
Screws

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Removal and Replacement

Installation:

1. Position the Media Hanger against the Centerplate and then secure it in place using the
three Screws.

2. Install the Main Logic PCB; see Section 4.4.

4.11.2 Media Hub

Removal:

1. Remove the Power Supply PCB; see Section 4.5.

2. Remove the Screw that secures the Media Hub Assembly to the Hub Mount and then
remove the assembly.

Media Hub Assembly

Shaft

Hub Mount

Screw

Installation:

1. Position the Media Hub Assembly into the Hub Mount and then secure it in place using
the Screw.

2. Install the Power Supply PCB; see Section 4.5.

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Removal and Replacement

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