Service Manual from Serial No. 10000 Barcode / Label Printer MACH4 The Business Class.
Service Manual for the following products 2 Part No. Description Type 5541082 Transfer printer MACH4/200B 5541083 Transfer printer MACH4/300B 5541086 Transfer printer MACH4/600B 5541092 Transfer printer MACH4/200P 5541093 Transfer printer MACH4/300P 5541096 Transfer printer MACH4/600P 5541102 Transfer printer MACH4/200C 5541103 Transfer printer MACH4/300C 5541106 Transfer printer MACH4/600C Edition: 2/2008 - Part No.
Table of Contents 1 1.1 1.2 1.3 1.4 Important Information............................................................................................................................. 4 General Safety Instructions....................................................................................................................... 4 Protective Devices.................................................................................................................................... 4 Handling Electricity ..
1 Important Information 1.1 General Safety Instructions This service manual is intended for use by qualified service and maintenance personnel. For more operation and configuration information, refer to the user or configuration manual. Follow the general safety rules below: • Keep the area around the device clean at all times! • Work with safety in mind. • Parts of device that are removed during the maintenance work must be put in a safe place. • Avoid risks of tripping over.
1 Important Information 1.3 Handling Electricity The following work may only be done by trained and qualified electricians: • Work on electrical components. • Work on an open device still connected to the mains supply. General precautions before starting maintenance work: • Find out where the emergency and power switches are so that they can be quickly thrown in an emergency. • Disconnect the current supply before carrying out the following work: -- Installing or removing power units.
2 Replacing Assembly Units 2.1 Device Overview 6 View A 1 2 3 4 5 6 7 8 9 10 11 13 16 15 12 14 A Fig. 1 Overview 1 RS-232 serial interface 2 USB 2.
2 Replacing Assembly Units 2.2 Tools • Do not use any worn of damaged tools. • Only use tools and testing devices that are suitable for the task at hand. cab special tools: • Tape holder test collar (cab item number: 5540932) • Assembling aid (cab item number: 5541180) • Cylindrical dynamometer (spring scale), 0 - 10 N (cab item number: 5906108) Standard tools: • Screw driver Torx, size TX 10/200 • Hex screwdriver, straight, size 2.
2 Replacing Assembly Units 2.3 Replacing the Control Panel 1 Fig. 2 2 3 4 2 8 5 3 Replacing the control panel 1 Control panel 2 Lug 3 Bearing i 4 Plug connector 5 Axle Notice! When replacing Control Panel B or P by a Control Panel C in order to convert the printer to the cutter version the peel-off edge must be removed. To convert the printer in the opposite direction the peel-off edge must be inserted ( 2.8 on page 13). 1. Hinge down the control panel (1). 2.
2 Replacing Assembly Units 2.4 Replacing the Cover 1 Fig. 3 1 2 3 4 2 3 9 5 4 6 7 4 Replacing the cover Toothed lug Damping wheel Hinged aperture cover Axle 5 Cover 6 Locking ring 7 Guide for outer casing 1. Open the cover (5), remove the media hub and label stock. 2. Disconnect the damping mechanism by pressing both toothed lugs (1) towards the center of the device. 3. Press the cover further back until the axles (4) come out of the guide (7). 4.
2 Replacing Assembly Units 2.5 Replacing the Outer Casing 10 Danger! Danger to life and limb from electric shock! XX Disconnect the device from the mains supply before opening the outer casing. 1 Fig. 4 2 3 4 Replacing the outer casing 1 Two screws 2 Outer casing 3 Two Screws 4 Cover The outer casing can be removed complete with the cover. 1. Open the cover (4), remove the roll hub and material. 2. Unscrew 2 screws (1) from the front of the casing. 3.
2 Replacing Assembly Units 2.6 Replacing the Print Mechanism 11 Danger! Danger to life and limb from electric shock! XX Disconnect the device from the mains supply before opening the outer casing. 1 2 9 3 8 4 7 5 6 Fig. 5 1 2 3 4 5 Replacing the print mechanism Print mechanism Cables Grounding cable CPU PCB Screw 6 7 8 9 Screw Bottom guide Elongated hole Lug 1. Remove the outer casing with the cover ( 2.5 on page 10). 2. Disconnect the print mechanism cables (2) from the CPU PCB (4). 3.
2 Replacing Assembly Units 2.7 Replacing the Printhead 12 Danger! Danger to life and limb from electric shock! XX Disconnect the device from the mains supply before opening the outer casing. 1 Fig.
2 Replacing Assembly Units 2.8 Replacing the Print Roller 13 Danger! Danger to life and limb from electric shock! XX Disconnect the device from the mains supply before opening the outer casing. 50 40 30 20 10 0 10 50 1 Fig. 7 2 3 4 5 6 Replacing the print roller 1 Apertures 2 Holding lugs 3 Print roller unit 4 Roller holder 5 Peel-off edge 6 Print roller 1. Open the cover and hinge down the control panel, press the release button and hinge up the print module. 2.
2 Replacing Assembly Units 2.9 Replacing the Brake of the Ribbon Supply Hub Fig. 8 1 2 3 4 14 Replacing the coupling brake of the ribbon supply hub Ribbon supply hub Cover Three screws Brake 5 Coupling mounting tool 6 Holder 7 Lock washer 1. Hinge up the printhead assembly, unscrew the three screws (3), and remove the cover (2). 2. For easier handling: -- Ensure that the hub (1) is attached. -- Press the holder (6) of the friction coupling inwards, turn it into the position 1 and release.
2 Replacing Assembly Units 2.10 Replacing the Drive of the Cutting Unit Fig. 9 1 2 3 4 5 6 15 Replacing the drive of the cutting unit Control panel Two plastic latches Cutting unit Clock wheel Shaft Two eccentrics 7 8 9 10 11 Two screws Two connectors Two nuts Base plate Drive 1. Turn the control panel (1) down, unlock the cutting unit (3) at the both plastic latches (2) and lift it. 2. Loosen the nuts (9). 3.
2 Replacing Assembly Units 2.11 Replacing the Blades of the Cutting Unit Fig. 10 1 2 3 4 5 6 16 Replacing the blades of the cutting unit Control panel Two plastic latches Cutting unit Base plate Screw Three screws 7 8 9 10 11 Clamp Lower blade Paper guide Upper blade Three screws 1. Turn the control panel (1) down and hinge it up ( 2.3 on page 8). 2. Unlock the cutting unit (3) at the both plastic latches (2) and lift it. 3. Turn the screw (5) clockwise using a 2.
2 Replacing Assembly Units 2.12 Replacing the CPU PCB 17 Danger! Danger to life and limb from electric shock! XX Disconnect the device from the mains supply before opening the outer casing. 1 2 8 3 9 4 5 6 10 7 Fig. 11 1 2 3 4 5 Replacing the CPU PCB Control panel cable Sensors cable Cable for printhead power supply Printhead signal cable Power unit cable 6 7 8 9 10 Stepping motor cable Grounding cable Grounding cable power input module Screw Fan cable 1.
2 Replacing Assembly Units 2.13 Replacing the Power Unit 18 Danger! Danger to life and limb from electric shock! XX Disconnect the device from the mains supply before opening the outer casing, and wait at least one minute to allow the power unit to discharge. 1 Fig. 12 1 2 3 4 5 2 3 4 5 6 7 8 5 9 Replacing the power unit Power unit cover Base tub latch Screw Recess Screw 6 7 8 9 Power unit cable Power unit Mains input plug Bottom lug 1.
3 Adjustments 3.1 Measuring the Winding Torques 19 The winding torques on the ribbon rewind hub and ribbon supply hub are measured by determining the tensile force on the test collar mounted on the hub.
3 Adjustments 20 Measuring the torque of the coupling and brake on the rewind hub: 1. Wind the cord several times round the test collar ( fig. 13 A on page 19) and mount it on the rewind hub (1). The spring lugs of the hub must slot into the smaller slot in the test collar. 2. Attach a spring scale [10 N] (3) to the end of the cord, raise it vertically until the test collar starts to turn. 3.
3 Adjustments 3.3 Adjusting the Print Mechanism 21 Major adjustment of the print mechanism beyond format-based settings is only required if the printhead assembly has been removed or parts in this area have been replaced. Excluded from this is the replacement of the printhead, after which readjustment is generally not required.
3 Adjustments Screw for adjusting the printhead bend (4) • Turning the screw clockwise will slightly bend the middle of the printhead downwards which will increase the printhead pressure in the center. In case the normal methods to prevent ribbon wrinkling are not successful, the printhead can be bent a little bit by turning the screw clockwise. This must be done extremely carefully.
4 Block Diagram Fig. 16 Block diagram 1 Fig.
5 Index 24 B I R Blades of the cutting unit replacing......................................16 Brake of the ribbon rewind hub winding torque.............................19 Brake of the ribbon supply hub..........14 replacing......................................14 Interface ethernet..........................................6 serial..............................................6 USB...............................................6 Release button of the print module.....6 C CompactFlash card slot..
