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Datamax ?-class series Maintenance Manual

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Maintenance Manual
Corporate Headquarters
4501 Parkway Commerce Blvd.
Orlando, Fl 32808
Phone: 407-578-8007
Fax: 407-578-8377
Asia-Pacific
Datamax International
19 Loyang Way
Herbert House
#01-01 CILC Building
12 Elizabeth Way, Pinnacles
Singapore 508724
Harlow, Essex CM19 5FE UK
Phone: +65 542-2611
Phone: +44 1279 772200
Fax: +65 542-3611
Fax: +44 1279 424448

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  • Page 1 Maintenance Manual Corporate Headquarters 4501 Parkway Commerce Blvd. Orlando, Fl 32808 Phone: 407-578-8007 Fax: 407-578-8377 Asia-Pacific Datamax International 19 Loyang Way Herbert House #01-01 CILC Building 12 Elizabeth Way, Pinnacles Singapore 508724 Harlow, Essex CM19 5FE UK Phone: +65 542-2611...
  • Page 2 Information in this document is subject to change without notice and does not represent a commitment on the part of Datamax Barcode Products Corporation. 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 Corporation.
  • Page 3 Contents Overview Adjustments and Maintenance Troubleshooting Removal and Replacement Printer Assemblies...

  • Page 5: Overview

    Overview Introduction ..................1 About this Printer ................2...
  • Page 7 If necessary, refer to the following documents for additional printer information (available for download at http://www.datamaxcorp.com/): For operating information, reference the Operator’s Manual, part number 88-2313-01. For software documentation (Datamax Programming Language), reference the Class Series Programmer’s Manual, part number 88-2316-01. Important Information: The exclamation point inside an equilateral triangle is intended to alert the technician to the presence of important operating, maintenance or servicing information.
  • Page 8 Overview 1.1 About this Printer The following drawing illustrates the printer’s exterior components and controls. Some items are optional and may not be present on all models. The printer’s 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. Ribbon Take-Up Hub Access Cover Ribbon Supply Hub...

  • Page 9: Table Of Contents

    Adjustments and Maintenance Introduction......................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 Media Sensor Calibration ..................7 2.2.1 Calibrating Non-Display Models..............
  • Page 10 Darkness Adjustment ..................23 Downloading Firmware and Fonts ..............24 Resetting the Printer................... 25 2.9.1 Non-Display Models................. 25 2.9.2 Display-Equipped Models ................ 25 2.10 Printhead Voltage Adjustment ................26...

  • Page 11: Introduction

    Adjustments and Maintenance 2.0 Introduction This section covers the necessary maintenance and alignment procedures for the printer. 2.1 Maintenance This section details the recommended items, techniques, and schedules to help you safely and effectively maintain the printer. Keep the following items on hand to clean the printer: •...

  • Page 12: Cleaning The Printhead

    Adjustments and Maintenance 2.1.1 Cleaning the Printhead NEVER use a sharp object on the Printhead; damage can result. CAUTION If print quality declines (symptoms can include non-compliant bar codes, print dropouts, streaks on the labels), 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.

  • Page 13: Cotton Swab Procedure

    Adjustments and Maintenance 2.1.1.1 Cotton Swab Procedure This procedure is recommended for printers 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.

  • Page 14: Cleaning Card Procedure

    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.

  • Page 15: Cleaning Film Procedure

    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.

  • Page 16: Cleaning The Media Sensor

    Adjustments and Maintenance 2.1.2 Cleaning the Media Sensor If paper dust or debris accumulates in the Media Sensor, it can affect the printer’s ability to detect labels. To prevent problems, clean as follows: Turn ‘Off’ and unplug the printer. Raise the cover. Unlock the Printhead Latch and raise the Printhead Assembly.

  • Page 17: Media Sensor Calibration

    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 ‘ ,’ to ensure that each label is detected SENSOR TYPE correctly and reliably, calibration is required. Depending upon the model of your printer, there are different calibration methods.

  • Page 18: Manual Calibration

    Adjustments and Maintenance 2.2.1.2 Manual Calibration Manual Calibration should be used after attempting the Automatic Calibration (Section 2.2.1.1), or in cases where media sensing problems continue to occur. Proceed as follows to manually calibrate the media sensor: Note: Before calibrating, be sure the media sensor is set for the media type you are calibrating and that it is properly positioned (see the Operator’s Manual for details);...

  • Page 19: Calibrating Display-Equipped Models

    Adjustments and Maintenance 2.2.2 Calibrating Display-Equipped Models There are three different calibration methods available. 2.2.2.1 Quick Calibration This is the easiest calibration method and should work for most die-cut and reflective media types. This procedure is not required for continuous media. If ‘Uncalibrated’ is displayed, follow the Standard Calibration procedure in Section 2.2.2.2.

  • Page 20: Standard Calibration

    Adjustments and Maintenance 2.2.2.2 Standard Calibration During the Standard Calibration process, the printhead assembly can be raised for visual access to the media and media 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: •...
  • Page 21 Adjustments and Maintenance Standard Calibration (continued) Step Action Displayed Message Comment Proceed according to media This sets the parameter for the TDBO!CBDLJOH! QSFTT!BOZ!LFZ!!!=zzz?! type: ‘gap’ or ‘mark’ value. Or, for reflective media: Die-cut media: Peel media Where ‘yyy’ is a numerical value from the backing and then representing the current sensor TDBO!NBSL!
  • Page 22 Adjustments and Maintenance Standard Calibration (continued) Step Action Displayed Message Comment Observe the message on the The calibration was successful. If HBQ!NPEF! DBMJCSBUJPO!DPNQMFUF display. another message was displayed, see the note below. Or, for reflective media: SFGMFDUJWF!NPEF!! DBMJCSBUJPO!DPNQMFUF Or, for continuous media: DPOUJOVPVT!NPEF!! DBMJCSBUJPO!DPNQMFUF Exit the menu tree by...

  • Page 23: Advanced Entry Calibration

    Adjustments and Maintenance 2.2.2.3 Advanced Entry Calibration Advanced Entry Calibration is an alternate calibration method for special-case media types only. This procedure has two parts: (1) recording sensor readings using differing algorithms and, (2) selecting, re- sampling, and manually entering calibration values. Advanced Entry Calibration will override all previous calibration settings;...
  • Page 24 Adjustments and Maintenance Advanced Entry Calibration (continued) Step Action Displayed Message Comment Press the Key. You are beginning the Advanced BEWBODFE!FOUSZ! TFOTPS!HBJO Entry Calibration. Press the Key. If using preprinted media, ensure HBJO!USBO!!!!!=zzz?! +11!!!!!!!!=1!.!42? the label area under the sensor is Place the label under the free of preprinted text, graphics, -Or-...
  • Page 25 Adjustments and Maintenance Advanced Entry Calibration (continued) Step Action Displayed Message Comment Proceed according to your Where ‘yyy’ is a numerical value HBJO!USBO!!!!!=zzz?! +11!!!!!!!!)1!.!42* media type: representing the current sensor reading. Die-cut stock: strip the Or, for reflective media: media from the backing and HBJO!SFGM!!!!!=zzz?! then reinsert it into the +11!!!!!!!!)1!.!42*...
  • Page 26 Adjustments and Maintenance Advanced Entry Calibration (continued) Gain Label Difference For example, if your Number Value Value Value compiled data had the values shown in this table, Gain Number 8 would be chosen because it has the highest Difference Value (146), where both the Label Value and the TOF Value are...
  • Page 27 Adjustments and Maintenance Advanced Entry Calibration (continued) Paper Gap (or Mark) Empty For example, at Gain Number 8, these were the sensor readings for each of the media conditions. (Actual readings will vary.) Step Action Displayed Message Comment Press the Key.

  • Page 28: Media Width Adjustment

    Adjustments and Maintenance 2.3 Media Width Adjustment To maintain even pressure distribution across media that is less than the width of the platen roller, the printer requires a Media Width Adjustment. Whenever using media that is less than four inches wide, proceed as follows: 1.

  • Page 29: Printhead Burn Line Adjustment

    (for example, heavy tag stock), print quality can change. Typically, thicker media requires a slight forward adjustment, while thinner media requires a slight backward adjustment. If you have questions, contact a qualified technician or Datamax Technical Support before proceeding. To adjust the Burn Line: 1.

  • Page 30: Printhead Pressure Adjustment

    Adjustments and Maintenance 2.5 Printhead Pressure Adjustment To accommodate a variety of media types, the pressure applied by the printhead assembly is adjustable. This pressure is factory set to work with most media types, so this adjustment should only be performed after attempting to improve print quality through the use of the (1) heat and/or (2) print speed.

  • Page 31: Ribbon Alignment

    Adjustments and Maintenance 2.6 Ribbon Alignment Correct ribbon alignment ensures smooth, taut ribbon flow during the print process. When irregular voids extend diagonally through the printed images on thermal transfer-equipped models, the cause may be due to ribbon overlapping (wrinkling). Begin troubleshooting by checking the Media Width Adjustment (Section 2.3), Printhead Pressure Adjustment (Section 2.5), and the Printhead Burn Line Adjustment (Section 2.4).
  • Page 32 Adjustments and Maintenance 5. Attach the ribbon to the Ribbon Take-Up Hub then proceed according to printer type – Non-Display models: Simultaneously press the buttons. PAUSE FEED Display-equipped models: Select a quantity of Quick Ribbon Test labels (see the Operator’s Manual for details).

  • Page 33: Darkness Adjustment

    Adjustments and Maintenance 2.7 Darkness Adjustment The Darkness Adjustment allows compensation for changes that may occur in print contrast following a printhead replacement. Depending upon the printer model, this adjustment is accomplished as follows: Non-Display models: Turning the Darkness Adjustment in a clockwise direction will darken the print, while a counterclockwise adjustment will lighten the print.

  • Page 34: Downloading Firmware And Fonts

    The operating programs and fonts for the printer are stored in Flash memory on the Main PCB. When program updates and/or new features are added, they can be downloaded to the printer as follows: 1. Identify the new version of firmware for your model of printer from the Datamax website at www.datamaxcorp.com 2.

  • Page 35: Resetting The Printer

    Adjustments and Maintenance 2.9 Resetting the Printer To reset the printer proceed according to the model. 2.9.1 Non-Display Models Turn ‘Off’ the printer. Press and hold all three buttons and turn ‘On’ the printer. Continue to depress the buttons down until the light turns off (about 17 seconds).

  • Page 36: Printhead Voltage Adjustment

    Adjustments and Maintenance 2.10 Printhead Voltage Adjustment This procedure requires voltage measurement: Use extreme caution. CAUTION The printhead voltage adjustment is required (1) when replacing the power supply, or (2) if the factory voltage setting of the power supply has been changed. No voltage adjustment is required during routine printhead replacements.
  • Page 37 Adjustments and Maintenance Raise the Printhead Assembly. Locate and note the Printhead Resistance Value on the label on the Printhead. Printhead Resistance Value Printhead Assembly Ensure that media is loaded. Close the Printhead Assembly then plug in and turn ‘On’ the printer. Wait for the printer to initialize.
  • Page 38 Adjustments and Maintenance Printhead Voltage Adjustment Table Model Number Resistance Range (in Ohms) Power Supply Voltage Tolerance (in VDC) 561 – 586 22.3 – 22.5 M-4206 587 – 611 22.8 – 23.0 & 612 – 635 23.2 – 23.4 M-4208 636 –...
  • Page 39 Troubleshooting Overview ......................1 Troubleshooting....................1 3.1.1 Initial Steps ....................1 General Problem Resolution................. 1 Warning & Fault Message Resolution ..............3 3.3.1 Warning Messages ..................3 3.3.2 Fault Messages ..................5...
  • Page 41 Troubleshooting 3.0 Overview This chapter discusses a number of topics related to troubleshooting the printer, covering techniques necessary for isolating and correcting printer faults. When faults are isolated to a PCB board, it is recommended that the entire board be replaced, as it is not generally feasible to perform component level service in the field.
  • Page 42 Troubleshooting General Problem Resolution Problem Possible Causes The Power LED is not • The power switch is not in the ‘ON’ position (see the Operator’s Manual). ‘ON’ • The power cord is not properly connected to printer and/or AC outlet (see the Operator’s Manual), or the cord is damaged.
  • Page 43 Troubleshooting General Problem Resolution (continued) Problem Possible Causes • Incorrect media/ribbon combination (see the Operator’s Manual). The printer does not • The printer is set to ‘direct thermal,’ but thermal transfer media is installed print, or the print quality is poor. (see the Operator’s Manual).
  • Page 44 Troubleshooting Warning Messages Displayed Message Description Possible Solution(s) Power has been removed The printer power switch was turned HPPECZF! and shutdown is in ‘Off’, the line fuse has blown, or the AC progress. line voltage has been lost. The scheduled printhead Clean the printhead.
  • Page 45 Troubleshooting 3.3.2 Fault Messages Fault Messages receive the highest display priority. If more than one fault is detected, the display will cycle between messages. Note: To return to normal operation after the printer enters a fault condition, the fault must be corrected and then the FEED key pressed to clear the condition.
  • Page 46 Troubleshooting Fault Messages (continued) Displayed Message Description Possible Solution(s) The printer has detected 1) Try cycling the printer power ‘Off’ and ENB!GBVMU! a Direct Memory Access ‘On’ to clear the fault. failure. 2) Replace the main logic board; see Section 4.4. Consistently low sensor Press any key to continue.
  • Page 47 Troubleshooting Fault Messages (continued) Displayed Message Description Possible Solution(s) Media cannot be 1) Ensure that the media is properly PVU!PG!TUPDL! detected. loaded; and, if using media with a clear liner or large notches between labels, ensure that the ‘Paper Out Distance’ has been set (see Operator’s Manual for details).
  • Page 48 Troubleshooting Fault Messages (continued) Displayed Message Description Possible Solution(s) Consistently low sensor Press any key to continue. SFGMFDUJWF!NPEF! DBOOPU!DBMJCSBUF! readings were detected. 1) Ensure that the reflective mark was inserted facedown in the media sensor during the appropriate calibration step. 2) Ensure that the reflective mark is made of carbon-based ink.
  • Page 49 Troubleshooting Fault Messages (continued) Displayed Message Description Possible Solution(s) A printhead strobe 1) Try cycling the printer power ‘Off’ and TUSPCF!UJNJOH!GBVMU! problem has been ‘On’ to clear the fault. detected. 2) Replace the main logic board; see Section 4.4. The temperature range of Allow the printhead to cool.
  • Page 50 Troubleshooting Fault Messages (continued) Displayed Message Description Possible Solution(s) The TOF mark could not Proceed according to the symptom: UPQ!PG!GPSN!GBVMU! be found within the maximum label length If the media is moving – setting; or, the TOF was 1) Adjust the media guide and the media found in an unexpected sensor.

  • Page 51: Removal And Replacement

    Removal and Replacement Introduction......................1 Side Covers ......................1 4.1.1 Plastic Covers................... 1 4.1.2 Metal Covers .................... 3 Front Cover & Front Panel PCB ................6 Printhead ......................9 Main PCB ......................10 Power Supply PCB ..................... 11 4.5.1 Fuse Replacement ................. 13 Media Sensor .....................

  • Page 53: Introduction

    Removal and Replacement 4.0 Introduction This section details removal and replacement procedures for the various printer parts. Wear a wrist strap and follow standard ESD prevention measures. Use extreme care when near the printhead; never use a sharp object on the surface. CAUTION Never use a sharp object on the platen roller.
  • Page 54 Removal and Replacement 3. Open the cover; move the cover to the rear of the printer, as shown. Be sure the Slide on the cover is clear of the Catch on the frame of the printer. Slide Catch 4. Lift the cover up and off the printer. Installation: 1.

  • Page 55: Metal Covers

    Removal and Replacement 4.1.2 Metal Covers Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the single Screw on the rear of the printer and two Screws securing the side cover. Screws...
  • Page 56 Removal and Replacement 3. Open the cover and remove the two Screws from the inside of the printer, as shown. Screws...
  • Page 57 Removal and Replacement 4. Lift the cover up and off the printer. Cover Assembly Installation: 1. Position the Cover onto the printer. Re-install the five previously removed Screws.

  • Page 58: Front Cover & Front Panel Pcb

    Removal and Replacement 4.2 Front Cover & Front Panel PCB Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the side covers (see Section 4.0). 3. Push up on the Tab (shown) and gently pull the Front Cover from the printer. Front Cover...
  • Page 59 Removal and Replacement 4. On the upper right corner of the Main PCB, open the Strain Relief on the Front Panel Cable by pushing inward on the Catch. 5. Raise the Blue Cable Lock and remove the Front Panel Cable from its Connector. Front Panel Cable Strain Relief...
  • Page 60 Removal and Replacement 6. Remove the two Screws securing the Front Panel PCB to the printer (if you have a Display-Equipped Model, first remove the Bezel, as shown below). Move the Front Panel PCB away from the printer slightly, disconnect the Front Panel Cable, and then remove the Front Panel PCB. Front Panel Non-Display Models: Cable...

  • Page 61: Printhead

    Note: Printheads are fragile; use extreme care when handling and never use a sharp object on the surface. If you have questions, contact a qualified technician or Datamax Technical Support before proceeding. 1. Turn ‘Off’ and unplug the printer. Open the cover; if ribbon is installed, remove it. Touch a bare metal part of the printer’s frame to discharge any static electricity that may be present on your body.

  • Page 62: Main Pcb

    Removal and Replacement 4.4 Main PCB Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the side covers (see Section 4.0). 3. Remove all Cables from their respective connectors on the Main PCB. 4. Remove the two Screws on the PCB Back Plate of the Main PCB and gently slide the Main PCB out of the printer.

  • Page 63: Power Supply Pcb

    Removal and Replacement 4.5 Power Supply PCB For fuse replacement only, see Section 4.5.1. Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the side covers (see Section 4.0). 3. Remove all Cables from their respective connectors on the Power Supply PCB. 4.
  • Page 64 Removal and Replacement 7. Remove the two Short Screws securing the Power Supply PCB and the two Long Screws securing the Power Supply Heatsink. 8. Remove the Power Supply PCB from the printer. Power Supply Ground Screw/ Ground Wire Short Screws Long Screws...

  • Page 65: Fuse Replacement

    Removal and Replacement 4.5.1 Fuse Replacement Only use a replacement fuse with the rating and type as the original fuse; failure to comply could cause serious damage, including fire. CAUTION Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the cover; see Section 4.1. 3.

  • Page 66: Media Sensor

    Removal and Replacement Media Sensor Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the side covers (see Section 4.0). 3. On the bottom right corner of the Main PCB, open the Strain Relief and remove the Media Sensor Cable from its connector.
  • Page 67 Removal and Replacement Installation: 1. Slide the Media Sensor & Cable Assembly into the Printer. 2. Replace the Outer Bearing Plate and start, but do not tighten the Screw. 3. Ensure that the Leveling Cam is loose, and then close and latch the Printhead Assembly. 4.

  • Page 68: Drive Motor

    Removal and Replacement 4.7 Drive Motor Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the side covers (see Section 4.0). 3. Remove the front cover (see Section 4.1). 4. Remove the Front Fascia, Thumbscrew, and Tearplate. Tearplate Thumbscrew Front Fascia 4-16...
  • Page 69 Removal and Replacement Remove the Screw and Inner Bearing Plate. Screw Inner Bearing Plate 6. Remove the Drive Motor Cable from the Power Supply PCB connector. 7. Remove the two Screws and Lock Washers securing the Drive Motor and remove the Drive Motor and cable from the printer.
  • Page 70 Removal and Replacement Installation: 1. Position the Drive Motor in the printer and secure using the two previously removed Screws and Lock Washers. 2. Connect the Drive Motor Cable to its appropriate connector on the Power Supply PCB. 3. Re-install the Screw and Inner Bearing Plate. 4.

  • Page 71: Platen Rollers

    Removal and Replacement 4.8 Platen Rollers Removal: Turn ‘Off’ and unplug the printer. 2. Remove the side covers (see Section 8.0). 3. Remove the front cover (see Section 8.1). 4. Remove the Front Fascia, Thumbscrew, and Tearplate. Tearplate Thumbscrew Front Fascia 4-19...
  • Page 72 Removal and Replacement 5. Remove the Screw and Inner Bearing Plate. Screw Inner Bearing Plate 4-20...
  • Page 73 Removal and Replacement 6. Remove the Screw, Outer Bearing Plate, and Bushings from the printer. 7. Remove the Platen Roller(s) from the Printer. Outer Bearing Plate Platen Rollers Bushings Screw 4-21...
  • Page 74 Removal and Replacement Installation: 1. Position the Platen Roller(s) in the printer. 2. Re-install the Inner Bearing Plate and Screw. 3. Re-install the Bushings, replace the Outer Bearing Plate and start, but do not tighten the Screw. 4. Ensure that the Leveling Cam is loose, and then close and latch the Printhead Assembly. 5.

  • Page 75: Ribbon Hubs

    Removal and Replacement 4.9 Ribbon Hubs 4.9.1 Take-up Hub Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the three Screws securing the Thermal Transfer Assembly to the printer. 3. Remove the Thermal Transfer Assembly. Thermal Transfer Assembly Screws Centerplate 4.

  • Page 76: Supply Hub

    Removal and Replacement Installation: 1. Position the Clutch Assembly in the Thermal Transfer Assembly. 2. Re-install the Inner and Outer Bearings. 3. Slide the shaft on the Take-up Hub through and secure with the previously removed C-Clip. 4. Re-install Thermal Transfer Assembly and the three Screws. 4.9.2 Supply Hub Removal:...
  • Page 77 Removal and Replacement 4. Remove the Screw and Washer securing the Supply Hub to the Thermal Transfer Assembly. 5. Slide the Supply Hub and Plastic Spacer off the Thermal Transfer Assembly. Thermal Transfer Assembly Screw Washer Plastic Spacer Supply 4-25...
  • Page 78 Removal and Replacement Installation: 1. Re-install the Plastic Spacer and Supply Hub. 2. Be sure the Pin on the Supply Hub Shaft engages the Notch on the Thermal Transfer Assembly. Notch Supply Shaft 3. Re-install the previously removed Screw and Washer. 4.

  • Page 79: Internal Rewinder

    Removal and Replacement 4.10 Internal Rewinder Removal: 1. Turn ‘Off’ and unplug the printer. 2. Remove the three Screws securing the Internal Rewinder to the printer. 3. Remove the Internal Rewinder. Centerplate Screws Internal Rewinder 4. Remove the C-clip and Outer Bearing from the Internal Rewinder. 5.
  • Page 80 Removal and Replacement Installation: 1. Position the Clutch Assembly in the Internal Rewinder. 2. Re-install the Inner and Outer Bearings. 3. Slide the shaft on the Rewind Hub through and secure with the previously removed C-Clip. 4. Re-install Internal Rewinder and the three Screws. 4-28...
  • Page 81 Printer Assemblies M-4206 Front Covers ....................2 Side Covers ....................4 Printer Assembly 1 of 3................6 Printer Assembly 2 of 3................8 Printer Assembly 3 of 3................10 Main Board and Internal Cables .............. 12 Media Supply Hub ................... 14 Printhead Assembly .................
  • Page 82 M-4306 Front Covers .................... 38 Side Covers, Metal .................. 40 Printer Assembly 1 of 3................42 Printer Assembly 2 of 3................44 Printer Assembly 3 of 3................46 Main Board and Internal Cables .............. 48 Media Supply Hub..................50 Printhead Assembly ................. 52 Options Thermal Transfer ..................
  • Page 83 M-4206 Printer Assemblies M-4206...
  • Page 84 M-4206 Printer Assemblies Front Covers...
  • Page 85 M-4206 Printer Assemblies Front Covers ITEM NUMBER PART NUMBER DESCRIPTION 16-2895-01 COVER-LEFT FRONT 16-2897-01 COVER RIGHT FRONT 16-2926-01 LIGHT PIPE 16-2927-01 BUTTONS FRONT PANEL 16-2707-01 BLOCK FILLER...
  • Page 86 M-4206 Printer Assemblies Side Covers (15-3013-01)
  • Page 87 M-4206 Printer Assemblies Side Covers (15-3013-01) ITEM NUMBER PART NUMBER DESCRIPTION 16-2896-01 COVER-LEFT REAR 16-2705-01 COVER RIGHT REAR 16-2925-01 PIN HINGE 16-2726-01 WINDOW MEDIA 10-3098-01 TAPE, 1/32 DOUBLE COATED...
  • Page 88 M-4206 Printer Assemblies Printer Assembly 1 of 3 (53-2153-01)
  • Page 89 M-4206 Printer Assemblies Printer Assembly 1 of 3 (53-2153-01) ITEM NUMBER PART NUMBER DESCRIPTION 15-2850-01 ASSY-PRINTHEAD MOUNT 12-3165-01 PIN PRINTHEAD PIVOT 12-3157-01 BLOCK PLATTEN/PRINTHEAD PIVOT 12-3160-01 RETAINER LEFT 12-3161-01 RETAINER BEARING 12-3279-01 LEVER PRINT HEAD CAM LIFT 15-3000-01 ASSY M3 X 8 THUMB SCREW 17-3039-01 SPRING HEAD LIFT REAR 16-2965-01...
  • Page 90 M-4206 Printer Assemblies Printer Assembly 2 of 3 (53-2153-01)
  • Page 91 M-4206 Printer Assemblies Printer Assembly 2 of 3 (53-2153-01) ITEM NUMBER PART NUMBER DESCRIPTION 12-3005-01 CENTERPLATE 15-2763-01 MEDIA SUPPLY ASSY 24-2613-01 ASSY-SENSOR 12-3006-01 SHAFT GUIDE 10-2913-01 FOOT STICK-ON 51-2358-00 CCA FRONT PANEL M-CLASS 10-2903-02 SCREW TRILOBULAR M4 PHILIPS HEAD 8 10-2903-04 SCREW TRILOBULAR M4 PHILIPS HEAD 12 17-3040-01...
  • Page 92 M-4206 Printer Assemblies Printer Assembly 3 of 3 (53-2153-01) 5-10...
  • Page 93 M-4206 Printer Assemblies Printer Assembly 3 of 3 (53-2153-01) ITEM NUMBER PART NUMBER DESCRIPTION 24-2612-01 ASSEMBLY STEPPER MOTOR 17-3009-01 ISOLATOR VIBRATION 17-2810-01 GEAR SPUR DELRIN 24 PITCH 48 TEETH 17-3002-01 GEAR-IDLER 24 PITCH 36 TOOTH 12-2905-01 POST IDLER 10-2913-01 FOOT STICK-ON 10-0526-01 WASHER #8 SPLIT LOCK 11-5277-01...
  • Page 94 M-4206 Printer Assemblies Main Board and Internal Cables 5-12...
  • Page 95 M-4206 Printer Assemblies Main Board and Internal Cables ITEM NUMBER PART NUMBER DESCRIPTION CABLE ROUTING (FROM / TO) 32-2519-01 CABLE ASSEMBLY, MOTOR CONTROL POWER SUPPLY J5 TO MAIN BOARD J4 32-2520-01 CABLE ASSEMBLY, MAIN CCA POWER POWER SUPPLY J4 TO MAIN BOARD J5 32-2526-01 CABLE ASSEMBLY, PRINTHEAD DATA MAIN BOARD J8 TO PRINTHEAD...
  • Page 96 M-4206 Printer Assemblies Media Supply Hub (15-2763-01) 5-14...
  • Page 97 M-4206 Printer Assemblies Media Supply Hub (15-2763-01) ITEM NUMBER PART NUMBER DESCRIPTION 10-2903-04 SCREW TRILOBULAR M4 PHILIPS HEAD 12 12-2904-01 EXTRUSION MEDIA SUPPORT 16-2951-01 CAP MEDIA SUPPLY 16-2527-01 RETAINER MEDIA SUPPLY 5-15...
  • Page 98 M-4206 Printer Assemblies Printhead Assembly (15-2850-01) 5-16...
  • Page 99 M-4206 Printer Assemblies Printhead Assembly (15-2850-01) ITEM NUMBER PART NUMBER DESCRIPTION 15-3010-01 ASSY-PRINTHEAD MOUNT 12-3014-01 BRACKET PRINTHEAD ADJUST 15-3012-01 ASSY PRINTHEAD PIVOT 11-5352-01 GUIDE RIBBON 16-2529-01 CAM-HEAD PRESSURE 15-3011-01 ASSY-LATCH 12-3163-01 BRACKET RIBBON ROLLER 12-3051-01 CAM IDLER RIBBON 12-3052-04 SHAFT RIBBON IDLER 16-2934-01 COVER PRINTHEAD CABLE 10-3030-01...
  • Page 100 M-4206 Printer Assemblies 5-18...
  • Page 101 M-4208 Printer Assemblies M-4208 5-19...
  • Page 102 M-4208 Printer Assemblies Front Covers 5-20...
  • Page 103 M-4208 Printer Assemblies Front Covers ITEM NUMBER PART NUMBER DESCRIPTION 16-2897-01 COVER RIGHT FRONT 16-2929-01 COVER LEFT FRONT 16-2730-01 COVER LEFT FRONT BEZEL 16-2731-01 BUTTONS, CONTROL PANEL 16-2707-01 BLOCK FILLER 5-21...
  • Page 104 M-4208 Printer Assemblies Side Covers, Metal (15-3035-01) 5-22...
  • Page 105 M-4208 Printer Assemblies Side Covers (15-3035-01) ITEM NUMBER PART NUMBER DESCRIPTION 15-3006-01 ASSY, ELECTRONICS COVER 11-5562-01 COVER, MEDIA SIDE 16-2928-01 WINDOW MEDIA 10-3064-01 NUT, SELF THREADING 10-2104-01 WASHER #8 FLAT 10-2905-01 HEX NUT, SELF-LOCKING 5-23...
  • Page 106 M-4208 Printer Assemblies Printer Assembly 1 of 3 (53-2153-02) 5-24...
  • Page 107 M-4208 Printer Assemblies Printer Assembly 1 of 3 (53-2153-02) ITEM NUMBER PART NUMBER DESCRIPTION 15-2850-01 ASSY-PRINTHEAD MOUNT 12-3165-01 PIN PRINTHEAD PIVOT 12-3157-01 BLOCK PLATTEN/PRINTHEAD PIVOT 12-3160-01 RETAINER LEFT 12-3161-01 RETAINER BEARING 12-3279-01 LEVER PRINT HEAD CAM LIFT 15-3000-01 ASSY M3 X 8 THUMB SCREW 17-3039-01 SPRING HEAD LIFT REAR 16-2965-01...
  • Page 108 M-4208 Printer Assemblies Printer Assembly 2 of 3 (53-2153-02) 5-26...
  • Page 109 M-4208 Printer Assemblies Printer Assembly 2 of 3 (53-2153-02) ITEM NUMBER PART NUMBER DESCRIPTION 12-3005-01 CENTERPLATE 15-2763-01 MEDIA SUPPLY ASSY 24-2613-01 ASSY-SENSOR 12-3006-01 SHAFT GUIDE 10-2913-01 FOOT STICK-ON 45-2016-01 LCD MODULE, M-CLASS 10-2903-02 SCREW TRILOBULAR M4 PHILIPS HEAD 8 10-2903-04 SCREW TRILOBULAR M4 PHILIPS HEAD 12 17-3040-01 SPRING HEAD LIFT FRONT...
  • Page 110 M-4208 Printer Assemblies Printer Assembly 3 of 3 (53-2153-02) 5-28...
  • Page 111 M-4208 Printer Assemblies Printer Assembly 3 of 3 (53-2153-02) ITEM NUMBER PART NUMBER DESCRIPTION 24-2612-01 ASSEMBLY STEPPER MOTOR 17-3009-01 ISOLATOR VIBRATION 17-2810-01 GEAR SPUR DELRIN 24 PITCH 48 TEETH 17-3002-01 GEAR-IDLER 24 PITCH 36 TOOTH 12-2905-01 POST IDLER 10-2913-01 FOOT STICK-ON 10-0526-01 WASHER #8 SPLIT LOCK 11-5277-01...
  • Page 112 M-4208 Printer Assemblies Main Board and Internal Cables 5-30...
  • Page 113 M-4208 Printer Assemblies Main Board and Internal Cables ITEM NUMBER PART NUMBER DESCRIPTION CABLE ROUTING (FROM / TO) 32-2519-01 CABLE ASSEMBLY, MOTOR CONTROL POWER SUPPLY J5 TO MAIN BOARD J4 32-2520-01 CABLE ASSEMBLY, MAIN CCA POWER POWER SUPPLY J4 TO MAIN BOARD J5 32-2526-01 CABLE ASSEMBLY, PRINTHEAD DATA MAIN BOARD J8 TO PRINTHEAD...
  • Page 114 M-4208 Printer Assemblies Media Supply Hub (15-2763-01) 5-32...
  • Page 115 M-4208 Printer Assemblies Media Supply Hub (15-2763-01) ITEM NUMBER PART NUMBER DESCRIPTION 10-2903-04 SCREW TRILOBULAR M4 PHILIPS HEAD 12 12-2904-01 EXTRUSION MEDIA SUPPORT 16-2951-01 CAP MEDIA SUPPLY 16-2527-01 RETAINER MEDIA SUPPLY 5-33...
  • Page 116 M-4208 Printer Assemblies Printhead Assembly (15-2850-01) 5-34...
  • Page 117 M-4208 Printer Assemblies Printhead Assembly (15-2850-01) ITEM NUMBER PART NUMBER DESCRIPTION 15-3010-01 ASSY-PRINTHEAD MOUNT 12-3014-01 BRACKET PRINTHEAD ADJUST 15-3012-01 ASSY PRINTHEAD PIVOT 11-5352-01 GUIDE RIBBON 16-2529-01 CAM-HEAD PRESSURE 15-3011-01 ASSY-LATCH 12-3163-01 BRACKET RIBBON ROLLER 12-3051-01 CAM IDLER RIBBON 12-3052-04 SHAFT RIBBON IDLER 16-2934-01 COVER PRINTHEAD CABLE 10-3030-01...
  • Page 118 M-4208 Printer Assemblies 5-36...
  • Page 119 M-4306 Printer Assemblies M-4306 5-37...
  • Page 120 M-4306 Printer Assemblies Front Covers 5-38...
  • Page 121 M-4306 Printer Assemblies Front Covers ITEM NUMBER PART NUMBER DESCRIPTION 16-2897-01 COVER RIGHT FRONT 16-2929-01 COVER LEFT FRONT 16-2730-01 COVER LEFT FRONT BEZEL 16-2731-01 BUTTONS, CONTROL PANEL 16-2707-01 BLOCK FILLER 5-39...
  • Page 122 M-4306 Printer Assemblies Side Covers, Metal (15-3035-01) 5-40...
  • Page 123 M-4306 Printer Assemblies Side Covers, Metal (15-3035-01) ITEM NUMBER PART NUMBER DESCRIPTION 15-3006-01 ASSY, ELECTRONICS COVER 11-5562-01 COVER, MEDIA SIDE 16-2928-01 WINDOW MEDIA 10-3064-01 NUT, SELF THREADING 10-2104-01 WASHER #8 FLAT 10-2905-01 HEX NUT, SELF-LOCKING 5-41...
  • Page 124 M-4306 Printer Assemblies Printer Assembly 1 of 3 (53-2153-03) 5-42...
  • Page 125 M-4306 Printer Assemblies Printer Assembly 1 of 3 (53-2153-03) ITEM NUMBER PART NUMBER DESCRIPTION 15-2850-01 ASSY-PRINTHEAD MOUNT 12-3165-01 PIN PRINTHEAD PIVOT 12-3157-01 BLOCK PLATTEN/PRINTHEAD PIVOT 12-3160-01 RETAINER LEFT 12-3161-01 RETAINER BEARING 12-3279-01 LEVER PRINT HEAD CAM LIFT 15-3000-01 ASSY M3 X 8 THUMB SCREW 17-3039-01 SPRING HEAD LIFT REAR 16-2965-01...
  • Page 126 M-4306 Printer Assemblies Printer Assembly 2 of 3 (53-2153-03) 5-44...
  • Page 127 M-4306 Printer Assemblies Printer Assembly 2 of 3 (53-2153-03) ITEM NUMBER PART NUMBER DESCRIPTION 12-3005-01 CENTERPLATE 15-2763-01 MEDIA SUPPLY ASSY 24-2613-01 ASSY-SENSOR 12-3006-01 SHAFT GUIDE 10-2913-01 FOOT, STICK-ON 45-2016-01 LCD MODULE, M-CLASS 10-2903-02 SCREW TRILOBULAR M4 PHILIPS HEAD 8 10-2903-04 SCREW TRILOBULAR M4 PHILIPS HEAD 12 17-3040-01 SPRING HEAD LIFT FRONT...
  • Page 128 M-4306 Printer Assemblies Printer Assembly 3 of 3 (53-2153-03) 5-46...
  • Page 129 M-4306 Printer Assemblies Printer Assembly 3 of 3 (53-2153-03) ITEM NUMBER PART NUMBER DESCRIPTION 24-2612-02 ASSEMBLY STEPPER MOTOR 17-3009-01 ISOLATOR VIBRATION 17-2810-01 GEAR SPUR DELRIN 24 PITCH 48 TEETH 17-3002-01 GEAR-IDLER 24 PITCH 36 TOOTH 12-2905-01 POST IDLER 10-2913-01 FOOT STICK-ON 10-0526-01 WASHER #8 SPLIT LOCK 11-5277-01...
  • Page 130 M-4306 Printer Assemblies Main Board and Internal Cables 5-48...
  • Page 131 M-4306 Printer Assemblies Main Board and Internal Cables ITEM NUMBER PART NUMBER DESCRIPTION CABLE ROUTING (FROM / TO) 32-2519-01 CABLE ASSEMBLY, MOTOR CONTROL POWER SUPPLY J5 TO MAIN BOARD J4 32-2520-01 CABLE ASSEMBLY, MAIN CCA POWER POWER SUPPLY J4 TO MAIN BOARD J5 32-2526-01 CABLE ASSEMBLY, PRINTHEAD DATA MAIN BOARD J8 TO PRINTHEAD...
  • Page 132 M-4306 Printer Assemblies Media Supply Hub (15-2763-01) 5-50...
  • Page 133 M-4306 Printer Assemblies Media Supply Hub (15-2763-01) ITEM NUMBER PART NUMBER DESCRIPTION 10-2903-04 SCREW TRILOBULAR M4 PHILIPS HEAD 12 12-2904-01 EXTRUSION MEDIA SUPPORT 16-2951-01 CAP MEDIA SUPPLY 16-2527-01 RETAINER MEDIA SUPPLY 5-51...
  • Page 134 M-4306 Printer Assemblies Printhead Assembly (15-2850-01) 5-52...
  • Page 135 M-4306 Printer Assemblies Printhead Assembly (15-2850-01) ITEM NUMBER PART NUMBER DESCRIPTION 15-3010-01 ASSY-PRINTHEAD MOUNT 12-3014-01 BRACKET PRINTHEAD ADJUST 15-3012-01 ASSY PRINTHEAD PIVOT 11-5352-01 GUIDE RIBBON 16-2529-01 CAM-HEAD PRESSURE 15-3011-01 ASSY-LATCH 12-3163-01 BRACKET RIBBON ROLLER 12-3051-01 CAM IDLER RIBBON 12-3052-04 SHAFT RIBBON IDLER 16-2934-01 COVER PRINTHEAD CABLE 10-3030-01...
  • Page 137 Option Assemblies Options 5-55...
  • Page 138 Option Assemblies Thermal Transfer (CSI: 78-2483-01; CSO: 78-2483-02) Direct Thermal 5-56...
  • Page 139 Option Assemblies Thermal Transfer (CSI: 78-2483-01; CSO: 78-2483-02) ITEM NUMBER PART NUMBER DESCRIPTION 12-3002-01 HOUSING SUPPLY/TAKE-UP CSI 12-3002-02 HOUSING SUPPLY/TAKE-UP CSO 12-3006-01 SHAFT GUIDE 15-2768-11 SUPPLY ASSY RIBBON CSI 15-2768-12 SUPPLY ASSY RIBBON CSO 15-2776-21 CLUTCH ASSY RIBBON 17-3028-01 BEARING FLANGED 440C 3/8 X 7/8 10-0563-01 E-RING 3/8 TRUARC 5133-37 17-2869-01...
  • Page 140 Option Assemblies Internal Rewind (78-2484-01) Without Rewind 5-58...
  • Page 141 Option Assemblies Internal Rewind (78-2484-01) ITEM NUMBER PART NUMBER DESCRIPTION 12-2925-01 HOUSING MEDIA TAKEUP 15-2840-01 ASSY HUB RIBBON REWIND 15-2802-41 CLUTCH ASSEMBLY MEDIA 17-3028-01 BEARING FLANGED 440C 3/8 X 7/8 17-2860-01 GEAR SPUR DELRIN 24TEETH 12-2905-01 POST IDLER 10-2903-06 SCREW TRILOBULAR M4 PHILIPS HEAD 25 10-0563-01 E-RING 3/8 TRUARC 5133-37 13-2409-01...
  • Page 142 Option Assemblies Peel and Present (78-2482-01 & 78-2482-02) 5-60...
  • Page 143 Option Assemblies Peel and Present (78-2482-01 & 78-2482-02) ITEM NUMBER PART NUMBER DESCRIPTION 12-3168-01 MOUNT-PEEL MECH 12-3275-01 COVER-PEEL MECH 16-2923-01 LATCH-PEEL MECHANISM 16-2877-01 COVER PRESENT SENSOR 16-2938-01 COVER WIRE PEEL MECHANISM 16-2869-01 MOUNT-PINCH ROLLER 16-2930-01 COVER-PEEL MECH BACK 16-2349-01 ROLLER - CLAMP 16-2349-02 ROLLER- CLAMP 16-2838-01...
  • Page 144 Option Assemblies Cutter (78-2480-01) 5-62...
  • Page 145 Option Assemblies Cutter (78-2480-01) ITEM NUMBER PART NUMBER DESCRIPTION 12-3097-02 BASE ENCLOSURE CUTTER 16-2791-01 COVER ENCLOSURE CUTTER 51-2360-00 CCA CUTTER M-CLASS 24-2616-01 ASSEMBLY, CUTTER, DRIVE MECHANISM 10-2903-01 SCREW TRILOBULAR M4 PHILIPS HEAD 6 10-2903-01 SCREW TRILOBULAR M4 PHILIPS HEAD 8 15-2918-01 ASSY CUTTER 4"...
  • Page 146 Option Assemblies Present Sensor (78-2481-01) 5-64...
  • Page 147 Option Assemblies Present Sensor (78-2481-01) ITEM NUMBER PART NUMBER DESCRIPTION 11-5344-01 TEAR BAR 16-2826-01 COVER PRESENT SENSOR 16-2919-01 BASE PRESENT SENSOR 16-2877-01 COVER PRESENT SENSOR 51-2367-01 CCA PRESENT SENSOR MCLASS 15-2939-01 ASSY PRESENT SENSOR 5-65...
  • Page 148 Option Assemblies LAN (78-2584-01) 5-66...
  • Page 149 Option Assemblies LAN (78-2584-01) ITEM NUMBER PART NUMBER DESCRIPTION 51-2398-00 CCA, INTERNAL ETHERNET PRINT SERVER 17-3047-01 STANDOFF 32-2554-01 RIBBON CABLE 5-67...

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