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AstroNova QuickLabel QL-900 Service Manual

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  • Page 2 QL-900 Service Guide Part Number 22834722-EN-E Revision 1.0 11/2023 AstroNova, Inc.® 600 East Greenwich Ave., West Warwick, RI 02893 Tel: (877) 757-7978 Fax: (401) 822-2430 info@astronovaproductid.com www.AstroNovaProductID.com Confidential, Not for Redistribution...
  • Page 3 This manual is copyrighted with all rights reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without written permission of AstroNova. Trademarks QL-900®...

  • Page 4: Table Of Contents

    Contents Contents Chapter 1: Introduction ............8 Intended Audience .
  • Page 5 Contents Chapter 4: Disassembly and Assembly Procedures ........36 Printer Basic Disassembly .
  • Page 6 Contents Clamshell Disassembly ..........76 Replace Touchscreen Interface PC Board .
  • Page 7 Contents Chapter 5: Maintenance ............129 Maintenance Schedule .

  • Page 8: Introduction

    Introduction Chapter 1: Introduction Intended Audience This service guide is intended for use by qualified service and maintenance personnel. For operation and configuration information, refer to the QL-900 User Guide. This service guide assumes that you have read the QL-900 User Guide and that you have it available for reference. Note: This service guide is for use by authorized service and maintenance personnel.

  • Page 9: Safety When Working With Electricity

    Introduction Protective Clothing If a possible danger to your eyes is present, wear protective goggles, especially in the following cases: • when knocking in or knocking out pins and similar parts with a hammer • when using spring hooks • when loosening or inserting springs, snap rings and gripping rings •...
  • Page 10 Introduction Tools • Do not use worn or damaged tools. • Use only tools and testing equipment that is suitable for the respective task. If an Accident Occurs • Proceed in a very cautions and calm manner. • Avoid endangering yourself. •...

  • Page 11: Chapter 2: Troubleshooting

    Troubleshooting Chapter 2: Troubleshooting This section is arranged by first the condition that might occur, and then by possible problems, causes, and recommended solutions. Power Problems Condition Problem Solution Power is ON, nothing happens. No power to printer. Check that power cord is plugged Check that power outlet is live.

  • Page 12: Feeding Problems

    Troubleshooting Feeding Problems Condition Problem Solution Failure to feed No power to printer. Check that power buttons are ON (Control Panel and Main Power) and that the power cord is plugged Material is out of specification. Maximum thickness is 0.3 mm. Motor failure.

  • Page 13: Printhead

    Troubleshooting Printhead Condition Problem Solution Missing parts of letters or text. Air and bubbles blocking nozzles. Clean printhead using recirculation, priming, or cycles of depriming and Printhead is dry. priming found on the printer touchscreen or in the Printer Toolbox. Rehydrate the printhead using distilled water and a wet, clean, lint-free cloth.

  • Page 14: Printing Problems

    Troubleshooting Printing Problems Condition Problem Solution Ink tank installed, no ink level Ink tank contacts are dirty, Remove ink tank(s). indication in Toolbox preventing printer/ink tank Clean prism and QA chip contacts. communication. See QL-900 User Guide. Extra lines; losing data Database problem.

  • Page 15: Errors And Warnings

    Troubleshooting Condition Problem Solution Feeding problems Misfeeds. Label Rolls: Adjust unwinder/ winder speed. Fanfold Labels: Check if labels are stuck together. Check if labels are sticking together. At start of a job, media runs and Printer not set for type of media Reset printer for type of media stops without printing.
  • Page 16 Troubleshooting Message Solution Multiple Inks Low Reorder ink. Multiple Ink Tanks Out Replace empty ink tanks. Multiple Ink Tanks are missing Insert missing ink tanks. Clean electrical contacts and reseat ink tanks. Multiple Unauthorized Ink Tanks Remove and reinsert the ink tank. Replace the ink tank. Paper Jam Remove jammed media.

  • Page 17: Toolbox System Status Messages

    Troubleshooting Toolbox System Status Messages Use the touchscreen or Toolbox screen to quickly determine and locate a problem in the printer. The status indicator shows ERROR in a red box. The printer graphic icon highlights the printer and system affected. The system status information displays the basic problem (in red). Ink levels display the ink status.
  • Page 18 Troubleshooting System Status Source Solution PAPERPATH_PAPERJAM Media jam detected. Carefully remove jammed media from the printer and close the print Depending on where the media The printer has detected that one engine. System status message in stops/jams, it is also possible for (or more) media sensors are red should go away.
  • Page 19 Troubleshooting System Status Source Solution DATA_PATH_UNDERRUN Media is not moving from the entry Check/Clean the media transport sensor to the exit sensor within a rollers. Check/Clean the sensors specified time. and reflector. Possible issue with format or Try changing the orientation setting orientation of job being sent.
  • Page 20 Troubleshooting System Status Source Solution [Crit 63 03-phead offline Dirty/Damaged printhead contacts Try restarting the printer. cancelpage restart] at the printhead or board. Try replacing the printhead. If the problem persists, call for service. ONLINE Service station position sensors Check service station position. are damaged or malfunctioning.
  • Page 21 Troubleshooting System Status Source Solution WIPER OVERTEMP Wiper motor is overheated due to Wait for the wiper motor to cool performing a wiper transfer down. The printer will automatically (removing excess ink off service resume operation. station wiper) too often or for Tip: To reduce this issue, set the multiple or extended periods.

  • Page 22: Software Problems

    Troubleshooting System Status Source Solution MAINTENANCE_JAM Printhead or ink tank door opened Close doors (printhead and ink during process. tank) and tap the Clear Error Note: To determine the error, button. Motor that drives component has check the touchscreen to see if it detected a problem or movement is Check for anything that may be displays one of the following...

  • Page 23: Misfeeds

    Troubleshooting Print Area: • Open the ink tank door. Pull the clamshell latch [A] toward you to unlatch the clamshell. • • Raise the clamshell [B]. • Clear the jam, then carefully lower the clamshell. Caution: Do not allow the clamshell to drop or slam closed. Misfeeds To correct misfeeds: Roll Feed - Unwinder/Winder may be moving too fast or slow for the job being printed.
  • Page 24 Troubleshooting 3. Press the individual Test buttons to run the test on that system. Press Test All to test all the systems listed in sequence. Press Clear to delete the results. 4. The numbers to the right of the Test buttons show the normal operating result for that system. After running a test on that system, the result appears to the right of that number.

  • Page 25: Advanced Service Menus

    Troubleshooting Test Name Components/Systems Tested Wiper Wiper Motor Advanced Service Menus Opening the Service Menus screen, and then entering the password under Service Menus, opens the Advanced Service Menus. Now you can use the following options: Printer Control Config., Commands Help, and Exit Service Menus. Note: The password is “630”.
  • Page 26 Troubleshooting Printer Control Configuration Screen Used to help in troubleshooting or servicing the printer by adjusting the factory settings to test for or solve a problem. Also used to customize the printer's output for special print jobs. • Printout Control - Change and set print parameters and printer functions. •...
  • Page 27 Troubleshooting Printer Commands Help Screen Provides a list and descriptions of available EWS service commands. Clicking Exit Service Menus closes Service Menu options and returns to User Interface screen. QL-900 Service Guide Confidential, Not for Redistribution...

  • Page 28: Adjustments

    Adjustments Chapter 3: Adjustments Drive Motor Belt Tension Adjustment 1. Remove the Non-Operator Side Cover. 2. Loosen (2) mounting screws and washers [A]. 3. Move the motor assembly right or left to tension the Belt [B]. When properly tensioned, there should be about 1/8” of deflection in the belt. Tighten the idler pulley screw.

  • Page 29: Printhead Lift Motor Drive Belt Tension Adjustment

    Adjustments 3. Loosen the idler pulley screw and washer [A]. Move the idler pulley assembly up or down to tension the belt [B]. When properly tensioned, there should be about 1/8” of deflection in the belt. Move the belt back and forth to reset the belt position and check for additional slack. Recheck and re-tension the belt as necessary.

  • Page 30: Printhead Lift Assembly Belts Tension Adjustment

    Adjustments 4. Using the 47-110-20T Head Belt Tensioning Tool: • Use the “F” end of the tool. Fit the tensioning tool fork around the midpoint of the belt [B]. Let the tool hang from the belt. • Slide the idler pulley assembly up or down to tension the motor drive belt. •...

  • Page 31: Service Station Motor Drive Belt Tension Adjustment

    Adjustments 4. Loosen the idler/tensioner pulley assembly [A] (1 on each side). This should release tension on the inner lifter belts. 5. Move the idler pulley assembly up or down to tension the belt [B]. When properly tensioned, there should be about 1/8” of deflection in the belt. Move the belt back and forth to reset the belt position and check for additional slack.

  • Page 32: Service Station Positioning Belts Tension Adjustment

    Adjustments 3. Loosen (2) screws [A] securing the service station motor assembly to the clamshell frame. Note: Loosen the non-adjustable screw only just enough to allow the motor assembly to pivot. 4. Using the 47-110-20T Head Belt Tensioning Tool: • Use the “R”...
  • Page 33 Adjustments Operator Side 1. Loosen the service station positioning belt tension pulley [A] (1 screw). 2. Move the pulley assembly right or left to tension the positioning belt [B]. When properly tensioned, there should be about 1/8” of deflection in the belt. Move the belt back and forth to reset the belt position and check for additional slack.

  • Page 34: Testing Belt Tension

    Adjustments 2. Move the service station belt tensioner pulley up or down to tension both the motor drive belt [B] and positioning belts [C]. When properly tensioned, there should be about 1/8” of deflection in the belts. Move the belt back and forth to reset the belt position and check for additional slack.
  • Page 35 Adjustments 2. Check that no media is loaded in the printer. 3. Press the individual Test buttons to run the test on that system. Press Test All to test all the systems listed in sequence. Press Clear to delete the results. 4.

  • Page 36: Chapter 4: Disassembly And Assembly Procedures

    Disassembly and Assembly Procedures Chapter 4: Disassembly and Assembly Procedures Printer Basic Disassembly 1. Turn power OFF. 2. Disconnect power cord. 3. Disconnect interface cable. Service Disassembly Warnings and Cautions Warnings The following disassembly should only be performed by a qualified, trained service representative. Always power down the printer before connecting or disconnecting any wiring harnesses or cable connections to avoid serious shock or injury.

  • Page 37: Printer Covers

    Disassembly and Assembly Procedures Printer Covers Operator Side Covers Left-Hand Cover 1. Raise the clamshell and open ink tank door. Remove (2) screws at the top [A] and bottom [B] of the left-hand cover. 2. Remove (1) screw [C] from side frame. 3.

  • Page 38: Control Panel

    Disassembly and Assembly Procedures Non-Operator Side Cover 1. Remove (3) screws [C] from the top and (1) screw [D] from the side of the non-operator side cover. 2. Remove (3) screws from bottom [E] of non-operator side cover. 3. Carefully pull the cover away from printer. Disconnect the fan assembly wire harness from the interface board wire harness at the connector.

  • Page 39: Top Cover

    Disassembly and Assembly Procedures Top Cover 1. Open the top cover. 2. Remove (2) screws and (2) pivots, [A] and [B], that secure the top cover to the clamshell side covers. 3. Reassemble in reverse order. Ink Tank Door 1. Open the ink tank door. 2.

  • Page 40: Exit Cover

    Disassembly and Assembly Procedures Exit Cover 1. Remove (4) screws. 2. Remove the cover. 3. Reassemble in reverse order. Major Components under Non-Operator Side Covers Description Description Network Connector Data Cables USB Connector Exit Fan Wire Harness DB9 Interface Connector Cutter Assembly Main Power Plug, Switch, Fuse Top Cover Switch...

  • Page 41: Major Components Under Exit End Cover

    Disassembly and Assembly Procedures Description Description USB Cable Fast Internet Switch (behind Interface Board) MPCA Board 5V DC Power Supply Ink Waste Hose Major Components under Exit End Cover Description Description Cutter Assembly Ink Station Main Peristaltic Pump Cutter Wire Harness DPCA 1 Ink Door Switch Wire Harness DPCA 2...

  • Page 42: General Disassembly And Assembly

    Disassembly and Assembly Procedures General Disassembly and Assembly Replace 24V DC Power Supply 1. Remove the non-operator side cover. 2. Remove (3) screws [A] securing the outlet port assembly (located at the feed end of the printer). Carefully move it out of the way. DO NOT stretch, pinch, or strain the wire harnesses. 3.

  • Page 43: Replace Side Fan Assembly

    Disassembly and Assembly Procedures Replace Side Fan Assembly 1. Remove the non-operator side cover. Disconnect the fan wire harness at the connector [A]. 2. Remove the side fan assembly (2 screws, 2 nuts) [B] from the side cover. 3. Install the fan with (2) mounting screws and nuts. 4.

  • Page 44: Replace Interface Pc Board

    Disassembly and Assembly Procedures Replace Interface PC Board Caution: Make sure that you are properly grounded before handling PC board. Static electricity can damage board. 1. Remove the non-operator side cover. 2. Disconnect the PC board power cord [1] from the J2 terminal on the PC board. 3.

  • Page 45: Replace 5V Dc Power Supply

    Disassembly and Assembly Procedures Replace 5V DC Power Supply Caution: Make sure that you are properly grounded before handling PC board. Static electricity can damage board. 1. Remove the non-operator side cover. 2. Disconnect the two wire harnesses [1] from the power supply terminals. Caution: Do not damage wires during removal.

  • Page 46: Adjust 5V Dc Power Supply Voltage

    Disassembly and Assembly Procedures Adjust 5V DC Power Supply Voltage Caution: Make sure that you are properly grounded before handling PC board. Static electricity can damage board. 1. Remove the non-operator side cover. 2. Insert voltmeter probes into the CN101 terminal [1] on the 5VDC power supply. 3.

  • Page 47: Replace Top Cover Switch

    Disassembly and Assembly Procedures Replace Top Cover Switch 1. Remove the non-operator side cover. 2. Disconnect the switch assembly wire harness (SW) from the interface board wire harness (SW) [A]. Carefully cut wire ties to release the wire harness. 3. Remove (2) screws and a washer [B] to remove the switch assembly and bracket. 4.

  • Page 48: Replace Printhead Home Sensor

    Disassembly and Assembly Procedures 3. Open top cover. Remove (2) screws [A] securing the pump assembly to the clamshell frame. 4. Disconnect the peristaltic pump assembly wire harness [B] from the circuit board attached to the assembly. 5. Carefully pull the pump assembly away and disconnect the ink hoses from the hose barbs. Watch for drips.

  • Page 49: Replace Main Pc Board (Mpca)

    Disassembly and Assembly Procedures 5. Reassemble in reverse order. Note: Be sure to carefully route and wire tie the wire harness. Replace Main PC Board (MPCA) Caution: Make sure that you are properly grounded before handling PC board. Static electricity can damage board.

  • Page 50: Replace Dpca Boards

    Disassembly and Assembly Procedures 4. Slowly pull the motor assembly through the opening in the side frame. Disconnect the POS red and NEG black wire harnesses [C] from the motor assembly. 5. Remove the motor assembly. 6. Reassemble in reverse order. Note: Adjust the motor position to properly tension the belt.

  • Page 51: Replace Exit Media Guide Assembly

    Disassembly and Assembly Procedures Replace Exit Media Guide Assembly 1. Remove the non-operator side cover and right-hand operator side cover. 2. Remove screws [A] securing the exit media guide assembly to the side frames (1 screw per side). 3. Remove the exit media guide assembly. 4.

  • Page 52: Replace Exit Support And/Or Exit Vent Fan Cover

    Disassembly and Assembly Procedures Replace Exit Support and/or Exit Vent Fan Cover 1. Remove the non-operator side cover and right-hand operator side cover. 2. Disconnect the fans wire harnesses at connectors [A]. Cut wire ties if necessary. 3. Remove screws [B] securing the exit support and the exit vent fan cover to the side frames (1 screw per side).

  • Page 53: Replace Cutter Assembly

    Disassembly and Assembly Procedures 3. Disconnect the fan assemblies wire harnesses at the connector(s) [A]. Cut wire ties if necessary. 4. Remove (2) screws securing the fan assemblies to the exit vent fan cover (2 screws per fan). Note: Wire harnesses are labeled for easy reconnection. 5.

  • Page 54: Replace Ink Door Switch

    Disassembly and Assembly Procedures 6. Reassemble in reverse order. Note: Be sure to carefully re-route and reconnect the wire harness to prevent pinching and kinking. Replace Ink Door Switch 1. Open the ink tank door. 2. Remove the exit cover (4 screws). 3.

  • Page 55: Replace Ink Tank Latches

    Disassembly and Assembly Procedures 4. Remove (2) screws [C] securing the encoder sensor assembly to the side frame and pull away from the encoder wheel. Note: Be careful not to damage the encoder wheel. 5. Remove (1) screw and washer [D] holding the encoder wheel to the roller shaft. Remove the encoder wheel.

  • Page 56: Remove Ink Station

    Disassembly and Assembly Procedures 5. Remove (1) screw securing the switch assembly to the switch bracket. 6. Reinstall in reverse order, but do not tighten the switch bracket mounting screws yet. Let the sensor assembly sit in the lowest position. Align the Clamshell Switch 1.
  • Page 57 Disassembly and Assembly Procedures 4. Disconnect waste pump wire harness J17E-2 from DPCA-2 [C]. 5. Disconnect the hose from the top of the ink waste pump [D]. 6. Disconnect (5) color-coded hoses from under the peristaltic pump [E]. 7. Disconnect (5) color-coded hoses going to the dual pinch valve at the hose barb connectors [F].
  • Page 58 Disassembly and Assembly Procedures 9. Remove (3) mounting screws and washers securing the ink station to the printer base [H]. 10. Remove (2) screws securing the ink station to the operator side frame [I]. 11. Carefully slide the ink station out of the printer. Note: Make sure the wire harnesses and ink hoses do not snag on anything.

  • Page 59: Ink Station Components

    Disassembly and Assembly Procedures Ink Station Components 1. Buffer Boxes (x3) 2. QA Chip Assembly (x3) 3. Ink Tank Level PCA 4. Peristaltic Pump (Waste Pump for the Service Station) 5. Dual Pinch Valve Replace Buffer Boxes (3 per Printer) 1.
  • Page 60 Disassembly and Assembly Procedures 2. Remove the old tubing inserts (2) [B] from the used buffer box (or from the ink barbs if pulled loose from the buffer box). Cut pieces of tubing (TYGON AN80007 1/8” ID x 1/4” OD, 1/16” thick wall tubing) into 6.5-7mm (17/64”-9/32”) pieces to use as new inserts.

  • Page 61: Replace Qa Chip Assembly (3 Per Printer)

    Disassembly and Assembly Procedures Replace QA Chip Assembly (3 per Printer) 1. Each QA chip assembly [A] is held in place by (1) screw accessed through the center of the chip assembly. Carefully disconnect the wire harnesses [B] from the printed circuit boards. Buffer Boxes and QA Chip Assemblies: 2.

  • Page 62: Replace Peristaltic Waste Pump Assembly

    Disassembly and Assembly Procedures Replace Peristaltic Waste Pump Assembly Remove old Pump Assembly 1. Remove (2) screws [A] that attach the pump assembly to the ink station base. (Located under the ink station base.) 2. Disconnect the wire harness connector [B] from the pump motor circuit board terminal. 3.

  • Page 63: Replace Dual Pinch Valve Assembly

    Disassembly and Assembly Procedures Replace Dual Pinch Valve Assembly Remove old Valve Assembly 1. Remove (2) screws [A] that attach the valve assembly to the ink station base. (Located under the ink station base.) 2. Unplug (2) wire harness connectors [B] from the valve assembly. 3.

  • Page 64: Clean Dual Pinch Valve Sensors

    Disassembly and Assembly Procedures Clean Dual Pinch Valve Sensors If the “Valve: Unknown” icon (?) appears for other than a few seconds in the “Valve:” section of the printer icon on the touchscreen or in the Printer Toolbox, it may indicate that the DPV sensors are blocked.

  • Page 65: Replace Dual Pinch Valve Sensor Pc Board

    Disassembly and Assembly Procedures Replace Dual Pinch Valve Sensor PC Board To perform this operation you will need a Dual Pinch Valve Wrench (#42-301-08). The Pinch Valve Wrench holds the spring-loaded pinch valve shaft in place when replacing the PC board. Remove Dual Pinch Valve Assembly 1.
  • Page 66 Disassembly and Assembly Procedures Replace Pinch Valve Sensor PC Board 1. Secure the spring-loaded shaft using the Dual Pinch Valve Wrench. Position the wrench exactly as shown. Note: Wrench fits around the shaft (as shown). See that the wrench head and screw head [A] fit around the pinch valve housing rib (as shown).

  • Page 67: Replace Top Forwarding Wheels Assembly

    Disassembly and Assembly Procedures 5. Reinstall pinch valve assembly in reverse order. System Test: Press the Valve Test button to check that the system is operating properly. Replace Top Forwarding Wheels Assembly 1. Remove (2) mounting screws [A]. 2. Remove the top forwarding wheels assembly. 3.

  • Page 68: Replace Media Guide

    Disassembly and Assembly Procedures 4. Install in reverse order. Replace Media Guide 1. Remove the left operator side cover and non-operator side cover. 2. Remove (2) mounting screws [A] (1 on each side). 3. Install in reverse order. Align Media Guide (use a small straight-edge ruler) 1.

  • Page 69: Replace Center Plate Assembly

    Disassembly and Assembly Procedures 2. Position a ruler along the two media guides on the center plate [C]. 3. Position the media guide so it touches the edge of the ruler. 4. Tighten the media guide screw. Replace Center Plate Assembly 1.

  • Page 70: Replace Exit Media Guide Bottom Plate Assembly

    Disassembly and Assembly Procedures 4. Install in reverse order. Replace Exit Media Guide Bottom Plate Assembly 1. Remove the right-hand operator side cover and the non-operator side cover. 2. Remove (6) mounting screws [A] (3 per side). 3. Disconnect wire harness at the SENSOR connector [B]. 4.

  • Page 71: Replace Exit Media Sensor

    Disassembly and Assembly Procedures Replace Exit Media Sensor 1. Remove the right-hand operator side cover and non-operator side cover. 2. Disconnect wire harness at the SENSOR connector [A]. Cut wire ties if necessary. 3. Remove the exit media guide assembly. 4.

  • Page 72: Replace Exit Star Wheel Assembly

    Disassembly and Assembly Procedures Replace Exit Star Wheel Assembly 1. Remove the exit media guide top assembly. 2. Remove (5) screws [A] securing the exit media guide top and the exit wheels guide to the exit media guide top assembly. 3.
  • Page 73 Disassembly and Assembly Procedures 3. Remove (2) screws [A] securing the bearing housings to the side frames (1 bearing housing each side). 4. Disengage the roller pulley [B] from the belt and remove the feed roller from the printer. 5. Install in reverse order. Note: Check/adjust tension on the belt.

  • Page 74: Replace Transport Rollers

    Disassembly and Assembly Procedures Replace Transport Rollers The transport rollers include the intermediate [1], print [2] and exit [3] rollers. 1. Remove the right-hand operator side cover and non-operator side cover. 2. Remove the center plate assembly. Remove the Intermediate Roller 1.
  • Page 75 Disassembly and Assembly Procedures Remove the Print Roller 1. Remove the encoder guard and encoder wheel [D]. Remove the encoder shaft extension [E]. Hold the extension with pliers and unscrew while holding the roller in place. You may have to remove the ink drip tray and exit guide top assembly for access.

  • Page 76: Clamshell Disassembly

    Disassembly and Assembly Procedures Clamshell Disassembly Replace Touchscreen Interface PC Board Before beginning: Save any stored jobs in the Print Job Library or videos saved to the printer's Video Library with a USB flash drive using the control panel USB port. See “Using the Control Panel USB Port”...

  • Page 77: Replace Touchscreen Micro Sd Card

    Disassembly and Assembly Procedures Replace Touchscreen Micro SD Card Before beginning: Save any stored jobs in the Print Job Library or videos saved to the printer's Video Library with a USB flash drive using the control panel USB port. See “Using the Control Panel USB Port”...

  • Page 78: Remove Adjustable Sensor Assembly

    Disassembly and Assembly Procedures 5. Reinstall in reverse order. If also using a new SD card, you can upload any saved job or video files using the control panel USB port and the USB flash drive you saved those files on previously. Remove Adjustable Sensor Assembly 1.

  • Page 79: Remove Latch Release Assembly

    Disassembly and Assembly Procedures 5. To remove the sensor PCB assembly: Turn the media sensor assembly over. Remove (2) mounting screws [C]. Cut the wire tie securing the wire harness to the sensor bracket. 6. Install in reverse order. Remove Latch Release Assembly 1.

  • Page 80: Remove Printhead Lift Motor Assembly And/Or Drive Belt

    Disassembly and Assembly Procedures Remove Printhead Lift Motor Assembly and/or Drive Belt 1. Remove the control panel cover. Disconnect the touchscreen Ethernet cable if necessary. Carefully set the control panel cover assembly aside. 2. Loosen the idler/tensioner assembly [A]. Slide the assembly in the slot to loosen the drive belt [B].

  • Page 81: Remove Printhead Lift Motor Assembly Large Pulley

    Disassembly and Assembly Procedures Remove Printhead Lift Motor Assembly Large Pulley 1. Remove the control panel cover. Disconnect the touchscreen Ethernet cable if necessary. Carefully set the control panel cover assembly aside. 2. Loosen the idler/tensioner assembly [A]. Slide assembly in the slot to loosen the drive belt [B]. 3.

  • Page 82: Remove Service Station Sled Motor Drive Belt

    Disassembly and Assembly Procedures 4. Remove the drive belt [C] from the motor assembly pulley. Remove the motor assembly from the printer. 5. Install in reverse order. Note: Tension the drive belt. See “Service Station Motor Drive Belt Tension Adjustment” on page 31.
  • Page 83 Disassembly and Assembly Procedures 3. Loosen the tensioner assembly screw [A] (1 each side). This should release the tension on the inner lifter belts. 4. Operator side. Loosen the tensioner assembly [B] for the large pulley belt. Remove the belt from the large pulley. Remove the e-clip securing the large pulley [C] from the mounting stud.

  • Page 84: Remove Printhead Lifter Belts

    Disassembly and Assembly Procedures 7. Pull the side frame away from the clamshell enough to release the drive shaft assembly. Note: You can also replace the blue plastic bearings if necessary. 8. Install in reverse order. Note: Install the shaft assembly back through the inner lifter belts and the wire ties securing the ink hoses.
  • Page 85 Disassembly and Assembly Procedures Remove the Lift Assembly Drive Shaft [C] 1. Control panel side: Remove (4) screws securing the clamshell side panels [D] (2 each side). Loosen (6) screws securing the top supports [E] (3 screws per side). 2. Remove e-clip [F] from the non-operator side of the lift motor drive shaft. 3.
  • Page 86 Disassembly and Assembly Procedures 7. Reassemble in reverse order. Note: Remember to reinstall the lift belt clamp bracket on the new belt. Make sure the brackets are oriented correctly depending on which side the belt is being installed. Loop belts over the drive shaft before installing the drive shaft in the printer.

  • Page 87: Remove Printhead Nest Assembly

    Disassembly and Assembly Procedures Remove Printhead Nest Assembly Before starting, make sure you have deprimed the system to prevent ink drips and spills. Turn the printer power OFF. 1. Remove the control panel cover. 2. Remove the clamshell rear cover. 3.
  • Page 88 Disassembly and Assembly Procedures 8. Remove (2) bearings [C] (1 screw each). 9. Gently maneuver the printhead holder assembly out of the printer. 10. Install in reverse order. Note: Do not mix ink hoses! Apply a light coating of white lithium grease to the track followed by the metal rollers on the printhead lift assembly [D].

  • Page 89: Remove Printhead Locator Assembly

    Disassembly and Assembly Procedures Remove Printhead Locator Assembly Printhead Locator Assembly includes: • Printhead lever latch and springs • Lever latch solenoid and latch open/closed sensor and wire harness • Pump side and valve side ink revolvers with ink hoses attached •...
  • Page 90 Disassembly and Assembly Procedures 5. Carefully cut the wire ties [A] securing the wire harness to the printhead nest frame. Note: You will also have to cut the wire ties [B] closing the black wire bundle wrap cover to separate the wire harness from the rest of the wiring bundle. 6.

  • Page 91: Remove Pen Driver Printed Circuit Assembly (Pca)

    Disassembly and Assembly Procedures 8. Disconnect the pump ink revolver (non-operator side) ink hoses from the barb connectors on the peristaltic pump (non-operator side) [E]. Note the order and position of the hoses for later installation: 1= K1 (black), 2 = M, 3 = Y, 4 = C, 5 = K2 (gray). Carefully pull the hoses through the clamshell frame.

  • Page 92: Replace Ink Revolvers

    Disassembly and Assembly Procedures 5. Install in reverse order. Replace Ink Revolvers First deprime the system and remove the printhead partridge. New Ink Revolvers include attached leader hoses and hose connectors. Note: The procedure is slightly different for the valve side ink revolver and the pump side Ink revolver (both are labeled).
  • Page 93 Disassembly and Assembly Procedures 4. Work one hose at a time. Valve side: Ink hoses are connected to the dual pinch valve (DPV). Disconnect the valve revolver ink hoses at the hose barbs [B]. Note: Hose barbs may be double-ended or 2-piece. Carefully match and connect the existing ink hoses to the hose leads on the new ink revolver.
  • Page 94 Disassembly and Assembly Procedures 6. Slide the old Ink revolver forward in its track and remove. 7. Slide the new ink revolver back into its track and align the yoke on the rear with the hinge bracket. Make sure the new revolver is turned correctly. 8.

  • Page 95: Replace Ink Revolver Gaskets

    Disassembly and Assembly Procedures Replace Ink Revolver Gaskets Note: Not all printers may be equipped with a removable revolver cap. Only revolvers with the screw [A] indicated below can be serviced in this way. 1. Deprime the system and remove the printhead cartridge. 2.
  • Page 96 Disassembly and Assembly Procedures 4. Remove the printhead cartridge by tilting it toward the ink lines, then carefully lifting it out of the printhead compartment. Place it in the protective packaging cap. 5. Use needle-nose pliers or tweezers to gently pull the rounded end of the spring out from beneath the plastic tab in the housing.
  • Page 97 Disassembly and Assembly Procedures 8. Discard the printhead latch according to local regulations. Install new Printhead Latch 1. Align the right tab of latch with the right hinge and gently press into place. Repeat for the left side. 2. [A] Use needle-nose pliers to install the right spring into the plastic tab in the base of the housing.

  • Page 98: Replace Printhead Lever Latch Solenoid

    Disassembly and Assembly Procedures Testing 1. Restart the printer if necessary. 2. Using the touchscreen, tap Menu then Test Print on the drop-down menu. Tap Print Color Bars to confirm the unit is functioning properly. Replace Printhead Lever Latch Solenoid To Replace the Lever Latch Solenoid: 1.
  • Page 99 Disassembly and Assembly Procedures 4. Remove the printhead cartridge by tilting it toward the ink lines, then carefully lifting it out of the printhead compartment. Place it in the protective packaging cap. 5. Remove five (5) screws securing the latch support base assembly to the printhead lift base. 6.

  • Page 100: Inspect The Service Station

    Disassembly and Assembly Procedures 7. Cut two cable ties securing the solenoid wire harness to the printhead lift base. Disconnect the solenoid connector [A] from the wiring harness. 8. Carefully lift the base assembly just enough to remove the solenoid assembly from under the base assembly.

  • Page 101: Service Station Components

    Disassembly and Assembly Procedures To Access the Service Station for Inspection and Cleaning: 1. Using the touchscreen, select Menu, then tap Maintenance from the drop-down menu. Tap Inspect Sled. The service station [A] moves out from under the printhead assembly. 2.

  • Page 102: Remove Capping Station

    Disassembly and Assembly Procedures 6. Service Station Base 7. Capping Station Inserts (2) 8. Wiper Roller Assembly Springs (4) Remove Capping Station 1. Using the touchscreen, select Menu, then tap Maintenance from the drop-down menu. Tap Inspect Sled. The service station [A] moves out from under the printhead assembly. 2.

  • Page 103: Remove Wiper Roller Assembly

    Disassembly and Assembly Procedures 3. Release the roller by pushing the non-geared end toward the capping Station [A]. This will unsnap it out of the bracket. Then lift the wiper roller out of the wiper roller assembly. 4. Install in reverse order. Be sure to insert the gear end of the roller first and check that the gear teeth mesh with the other gears.

  • Page 104: Remove Wiper Roller Assembly Springs

    Disassembly and Assembly Procedures 5. Lift the wiper roller assembly out of the printer. Note: Be careful not to lose the springs [C] located under the assembly (2 at each end of the assembly). 6. Install in reverse order. Run System Test to check operation. System Test: Press the Wiper Test button to check that the system is operating properly.

  • Page 105: Remove Service Station Base Plate

    Disassembly and Assembly Procedures 2. Use a medium Phillips head screwdriver to slowly and carefully push the spring into the mount until the end of the spring is level or slightly below the edge of the mount [E]. 3. Exert slightly more downward pressure to seat the spring. You may feel or hear a slight click. 4.

  • Page 106: Remove Service Station Sled

    Disassembly and Assembly Procedures 6. Lift the service station assembly and base out of the printer. Be careful and watch for dripping ink. Note: Capping Station - Do not lose the (2) inserts the capping station rests on (located behind the release tabs).
  • Page 107 Disassembly and Assembly Procedures 9. Carefully lift the clamshell off of the printer. DO NOT pull or strain the ink hoses or wire harnesses. Note: You may have to detach the ink hoses from the hose loom. Note the order for reassembly.

  • Page 108: Remove Service Station Positioning Belts

    Disassembly and Assembly Procedures 12. Install in reverse order. Note: Grooves on the slides face out toward the operator and non-operator sides. The lower groove in the slides fits around the flange edge of the clamshell base plate (media guide). The upper side of the belt is held between the groove in the top of the slides and the mounting ends of the service station sled.
  • Page 109 Disassembly and Assembly Procedures Operator Side 1. Remove (1) screw [A] securing the support rod. Remove (4) screws [B] securing the clamshell side panels to the clamshell frame (2 screws per side). Loosen (3) screws [C] securing the top supports (3 screws per side). Loosen the service station belt tension pulley [D].
  • Page 110 Disassembly and Assembly Procedures 5. Install in reverse order. Note: Check/adjust the positioning belts tension. See “Service Station Positioning Belts Tension Adjustment” on page 32. System Test: Press the Sled Test button to check that the system is operating properly. Important: Make sure the service station is installed parallel to the printhead locator assembly.
  • Page 111 Disassembly and Assembly Procedures 2. Remove the E-clip securing the service station belt tensioner pulley [C] and remove the larger black pulley. 3. Operator side: Remove (2) screws securing the support strut bracket [D] to the clamshell frame. 4. Remove clamshell. Remove (4) screws [E] securing the clamshell hinges to the printer (2 screws per hinge).
  • Page 112 Disassembly and Assembly Procedures 6. Carefully lift the clamshell assembly so you can access and remove (1) screw securing the service station slide [F] to the service station sled. (Access through the printhead opening in the underside of the clamshell assembly.) Try to keep the assembly level to prevent any ink spills.

  • Page 113: Remove Service Station Home Sensor

    Disassembly and Assembly Procedures 9. Pull the side frame away from the clamshell enough to release the service station motor drive shaft assembly [K]. 10. Remove the belt. Note how the belt is routed through the pulleys. 11. Install in reverse order. Note: Check/adjust the positioning belts tension.

  • Page 114: Remove Clamshell Media Guide Assembly (Base Plate W/Transport Wheels)

    Disassembly and Assembly Procedures Remove Clamshell Media Guide Assembly (Base Plate w/Transport Wheels) 1. Remove the control panel cover. 2. Remove the rear clamshell cover and non-operator side cover. 3. Raise the clamshell. Open the exit conveyor cover. 4. Disconnect the service station sled home sensor wire harness J553 [A] from the MPCA. Cut wire ties as necessary to release the wire harness.

  • Page 115: U1C-L Unwinder

    Disassembly and Assembly Procedures 6. Remove the assembly from the printer. Note: This also provides access to the transport wheels located on the media guide assembly. 7. Install in reverse order. U1C-L Unwinder Remove Top Cover 1. [A] Carefully pull up and remove the speed control knob. 2.

  • Page 116: Rear Cover Access Points

    Disassembly and Assembly Procedures Rear Cover Access Points [A] Spindle shaft bearing cover [B] Tension arm shaft screw access [C] Motor mounting screw access Note: Do not remove the rear cover due to increased possibility of damaging internal parts. Front Panel Cover 1.

  • Page 117: Main Drive Belt

    Disassembly and Assembly Procedures Main Drive Belt 1. [A] Remove the top cover. 2. [B] Remove the C-clip holding spindle shaft in place and slide the shaft assembly forward. 3. [C] Slide the drive belt off of the shaft pulley and motor pulley. Note: You may have to remove the two motor mounting screws and push the motor assembly back through the bracket to get enough clearance to remove/replace the belt.

  • Page 118: Main Drive Motor

    Disassembly and Assembly Procedures Main Drive Motor 1. [A] Disconnect the motor wire harness (J2) from the unwinder printed circuit board. 2. [B] Remove (2) Allen head motor mounting screws from the bracket assembly using the two motor mounting screw access ports in the rear cover. 3.

  • Page 119: Large Gear

    Disassembly and Assembly Procedures 4. [D] Install in reverse order. Note: When reconnecting the wiring, make sure to reconnect the correct J3 marked wire (one connects the interface cable used with the printer, one connects the external power connector, for use with an external power source). Large Gear 1.

  • Page 120: Potentiometer Assembly

    Disassembly and Assembly Procedures Potentiometer Assembly 1. [A] Disconnect the potentiometer from the printed circuit board (J1-B). 2. [B] Remove (1) Phillips head screw from the end of the gear shaft. 3. [C] Loosen the set screw in the small gear. Slide the gear off of the shaft. 4.
  • Page 121 Disassembly and Assembly Procedures 2. Raise the tension arm assembly [A] (Unwinder 3.4"). You can use a block of wood cut to the correct height to hold the arm assembly in position. Note: When calibrating the unwinder [A], make sure the block is positioned under the shaft, NOT the rollers.

  • Page 122: W1C-L Winder

    Disassembly and Assembly Procedures 7. To check speed: Put an empty 3” core on the reel shaft hub. Use a hand held tachometer to check the rotation speed of the reel measured from the core's surface. Raise and lower the tension arm to its uppermost and lowermost positions to get CW and CCW rotation.

  • Page 123: Front Panel Cover

    Disassembly and Assembly Procedures Front Panel Cover 1. [A] Remove the Spindle lock from the Label Roll Spindle/Guide. 2. [B] Loosen (do not remove) the retaining clip just enough to slide the hub assembly forward on the spindle. 3. [C] Slide the inner and outer guide rings to the end of the tension arm shaft. 4.

  • Page 124: Main Drive Motor

    Disassembly and Assembly Procedures 3. [C] Slide the drive belt off of the shaft pulley and motor pulley. Note: You may have to remove the two motor mounting screws and push the motor assembly back through the bracket to get enough clearance to remove/replace the belt. 4.

  • Page 125: Printed Circuit Board

    Disassembly and Assembly Procedures 4. [D] Install in reverse order. Note: Loop the drive belt around the motor pulley spindle as you push the motor and pulley back through the bracket. Check the belt tension (deflection between 0.085" and 0.065"). Adjust by loosening the motor mounting screws and repositioning the motor in the mounting slots and re-tightening screws.

  • Page 126: Large Gear

    Disassembly and Assembly Procedures Large Gear 1. [A] Remove (1) Phillips head screw securing the tension arm wire to the tension arm shaft using the rear cover access port. 2. [B] Remove the C-clip (1 one each side of bracket). 3.

  • Page 127: Recalibrate Winder

    Disassembly and Assembly Procedures 4. [D] Remove 1/2” nut and washer. Remove the potentiometer. Install in reverse order. Recalibrate the winder. See “Recalibrate Winder” on page 127. Recalibrate Winder Tools needed: Phillips screwdriver, 5/32 Allen wrench, handheld tachometer (optional). When replacing the potentiometer or other parts on the winder, it may be necessary to recalibrate the winder to maintain optimum performance.
  • Page 128 Disassembly and Assembly Procedures 4. With the power ON, and the reel shaft moving in its normal operating direction (clockwise), slowly turn the potentiometer [B] counterclockwise until rotation stops. Important: Make sure the shaft is rotating in its normal operating direction (clockwise). 5.

  • Page 129: Maintenance

    Maintenance Chapter 5: Maintenance General, periodic maintenance is needed to keep the printer in good working order. Many tasks can be performed by operators with basic supplies and without special tools. Refer to the QL-900 User Guide for details. Other tasks should only be performed by trained service personnel. These tasks are described in this chapter.

  • Page 130: Maintenance Schedule

    Maintenance Maintenance Schedule Part Action AS NEEDED MAINTENANCE (Depending on Printer usage) Cleaning (remove media fibers and ink Media path, service station (wiper roller, residue) platen) Ink drip tray Empty and clean weekly or as needed. Ink revolver couplings Inspect and clean after every printhead removal.

  • Page 131: Inspect/Clean Service Station

    Maintenance Part Action Ink tubing, connections, peristaltic pump, Inspect for leaks, kinks, pinches, proper pinch valve & vents, buffer boxes, ink revolver operation. couplings, service station drain hose. Service station drain hose: Check for debris or dried ink clogging the hose. Flush with distilled water so drain pump suction can clear the hose.

  • Page 132: Inspect Service Station

    Maintenance Inspect Service Station To Access the Service Station for Inspection and Cleaning: 1. Using the touchscreen, select Menu, then tap Maintenance from the drop-down menu. Tap Inspect Sled. The service station [A] moves out from under the printhead assembly. 2.
  • Page 133 Maintenance 7. Capping Station Inserts (2) 8. Wiper Roller Assembly Springs (4) Wiper Roller 1. Using the touchscreen, select Menu, then tap Maintenance from the drop-down menu. Tap Inspect Sled. The service station [A] moves out from under the printhead assembly. Note: This will reset the roller service life count to “0”.
  • Page 134 Maintenance 3. Gently release the tabs [A] (one located at each end) securing the assembly to the service station base. 4. Lift the capping station [B] out of the printer. Note: Be careful and watch for dripping ink. Do not lose the (2) inserts the capping station rests on (located behind the release tabs).

  • Page 135: Clean Exit Media Star Wheels

    Maintenance Clean Exit Media Star Wheels For easier access when cleaning the exit star wheel assemblies: 1. Remove 2 screws [A] securing the exit media top guide to the exit media guide. 2. Remove the exit media guide top assembly. 3.

  • Page 136: Clean Cutter Assembly

    Maintenance Clean Cutter Assembly Inspect and clean the cutter as needed (at least once a year) to remove accumulated residue and debris. Warning: Make sure the printer is powered off before performing this task! 1. Open the ink tank door. Release the latch to open clamshell. Open the exhaust fan cover.
  • Page 137 Maintenance 3. Use a very gentle up and down motion to clean the contact pins. Note: Hold down the plastic cover to keep moisture away from the rest of the circuit board. Caution: Contact pins are easily bent or damaged! Use only a very gentile up and down motion for cleaning.

  • Page 138: Safety Precautions

    In addition, follow any specific occupational safety and health standards for your workplace or area. This manual is intended solely for the use and information of AstroNova, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards.

  • Page 139: Ink Flow Diagrams

    Ink Flow Diagrams Appendix B: Ink Flow Diagrams QL-900 Service Guide Confidential, Not for Redistribution...
  • Page 140 Ink Flow Diagrams QL-900 Service Guide Confidential, Not for Redistribution...
  • Page 141 Ink Flow Diagrams QL-900 Service Guide Confidential, Not for Redistribution...

  • Page 142: Printer Wiring Diagrams

    Printer Wiring Diagrams Appendix C: Printer Wiring Diagrams QL-900 Service Guide Confidential, Not for Redistribution...

  • Page 143: Print Engine Main Printed Circuit Assembly (Mpca)

    Printer Wiring Diagrams Print Engine Main Printed Circuit Assembly (MPCA) QL-900 Service Guide Confidential, Not for Redistribution...

  • Page 144: Printer Interface Pc Board Wiring Diagram

    Printer Wiring Diagrams Printer Interface PC Board Wiring Diagram QL-900 Service Guide Confidential, Not for Redistribution...

  • Page 145: Print Engine Dpca-1 And Dpca-2 Wiring Diagram

    Printer Wiring Diagrams Print Engine DPCA-1 and DPCA-2 Wiring Diagram QL-900 Service Guide Confidential, Not for Redistribution...

  • Page 146: Printer Wiring Diagram

    Printer Wiring Diagrams Printer Wiring Diagram QL-900 Service Guide Confidential, Not for Redistribution...
  • Page 147 Index Index Adjustable Sensor Assembly ........78 Ink Door Switch ............54 Assembly ..............36 Ink Flow Diagrams ..........139 Ink Revolver Gaskets ..........95 Ink Revolvers ............92 Belt Tension, Testing ..........34 Ink Station ..............56 Black Mark Sensor ...........69 Ink Station Components ...........59 Buffer Boxes ............59 Ink Tank Latches ............55 Ink Tank Level PCA ..........61 Intended Audience .............8...
  • Page 148 Index Safety ..............138 Top Cover Switch .............47 Safety Precautions .............8 Top Forwarding Wheels ...........67 Service Station ........100 Top Forwarding Wheels Assembly ......67 Service Station Base Plate ........105 Touchscreen ............77 Service Station Home Sensor ........113 Touchscreen Interface PC Board ......76 Service Station Motor Drive Belt ......31 Touchscreen Micro SD Card ........77 Service Station Positioning Belts .....32...

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