Commercial Thermal Printers Service Manual 2746e 980428-001 Rev. A ©2003 ZIH Corp.
FOREWORD This manual provides maintenance, diagnosis, service and repair information for the 2746e printer models manufactured by Zebra Technologies Corporation, Camarillo, California. TECHNICAL SUPPORT If for any reason you require product technical support, please contact the Distributor where you first purchased your equipment. If they cannot help you or at their direction, contact Zebra Repair Administration.
CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REQUIRED TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REPLACING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Exterior Cover. . . . . . . . . . . . . . . Printhead . . . . . . . . . . . . . . . . . Power Supply Access and Replacement . . Set AC Voltage . . . . . . . . . . . . . .
Warning - Shock Hazard The printer should never be operated in a location where it can get wet. Personal injury could result. Warnung - Stromschlaggefahr - Der Drucker sollte nie an feuchten Standorten in Betrieb genommen werden. Es besteht erhöhte Verletzungs und Unfallgefahr. Warning - Static Discharge The discharge of electrostatic energy that accumulates on the surface of the human body or other surfaces can damage or destroy the printhead or electronic components used in this device.
INTRODUCTION This service manual is intended for the field service engineer or technician. It’s scope covers routine maintenance, troubleshooting and repair procedures for the printer. Follow the parts replacement procedures as closely as possible. If you are unsure of any procedure, please contact your service representative or call the Zebra Technologies technical support group at (805) 579-1800. See our web site at www.zebra.
Models Many of the earlier model Zebra printers are similar in appearance to the Zebra 2746e thermal printer.
Conventions This manual uses the following notations to call attention to important information. ICON / SYMBOL MEANING WARNING - critical safety information. CAUTION - problem avoidance messages. STATIC SENSITIVE - follow procedures that protect against the discharge of electrostatic energy that accumulates on the surface of the human body or other objects as this discharge can damage or destroy the printhead and other electronic components. HEAT - The printhead becomes hot while printing.
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TROUBLESHOOTING GUIDE PROBLEMS SOLUTIONS With the STATUS indicator light GREEN, 1. Verify the labels are the correct type. the printer appears to be working, but nothing 2. Check the roll and verify that the print surface faces up for printing. is printed. Status indicators do not light when power switch is on (I) 1. Check power connections from the printer to the outlet. 2. Remove power supply and check fuse. If blown, replace the power supply. 3.
PROBLEMS Printing has streaks, white (non printing) lines, uneven printing (a side or sides), or faded print areas. SOLUTIONS 1. Wipe the printhead with the cleaning pen. See Cleaning and Maintenance section for information on optimizing printhead life and print quality. 2. Use the "SAVE-A-PRINTHEAD" cleaning film (P/N 44902) to remove contamination build-up. 3. The printhead is a consumable item and may be worn out, requiring replacement.
PROBLEMS SOLUTIONS 1. Align the transmissive (gap) sensor near the narrowest gap between labels. Printing stops and status indicator lights red 2. Perform the AutoSense adjustment. 3. Check that gap between labels is at least 1/16 inch (1.6mm) 4. For tags, see the discussion of Tag Media Sensing. 5. Check for media jam. 6. Check media is correctly routed. 7. Check printer memory configuration and correct data syntax. 8. Transmissive (gap) is dirty. Clean media path. 1.
Identifying printhead Problems The printhead wears with printer use. If the print quality does not improve after cleaning, the printhead may require replacement. Printing with worn damaged print elements may create unreadable bar codes. printhead damage can be caused by improper cleaning (unapproved fluids or implements), electro static discharge (ESD), and touching the printhead (contaminates, ESD and body oil acids). The following are examples of printhead wear or damage.
REQUIRED TOOLS Make use of the following tools while performing replacement procedures: Torque wrench with 1/4" hex receptacle) Phillips driver #1 (tip for 1/4" hex receptacle) Phillips driver #2 (tip for 1/4" hex receptacle) Allen key socket tip drivers (tip for 1/4" hex receptacle); sizes: 1/16", 5/64", 3/32", 1/8", 3mm, 4mm Nut driver, sizes: 7mm, 8mm, 1/4" Flat Blade screwdriver (small) needle-nose pliers pliers for E-ring retainers (12R) pliers for axial retainers tweezers Clutch torque bit (and torque
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REPLACING PARTS To access some parts, you need to dissemble other parts; therefore, other procedures must be followed before and after performing a particular replacement. 980428-001 Rev.
Exterior Cover Preparations The printer's exterior cover needs to be removed to perform most of the disassembly and replacement procedures for the printer. NOTE Do not remove the cover until you have read all of the removal procedure steps or damage to the printer or personal injury may result. Before starting the procedure, open the printer, then remove any media from the printer. Shock Hazard Always turn off the printer before performing any maintenance or repair operations.
2. Lift the cover straight up about 3-5 inches. Detach the label taken sensor’s cable from the center panel. The cable is attached to the front of the printer’s center wall. Slide the cable out of seam in the center and front panels. 3. Disconnect the label taken sensor cable from main PCBA located in the rear of the printer. Disconnect Sensor Cable at JP26 980428-101 Rev. 1 Prelim.
Installation 1. Ensure that the label taken sensor’s cable is secured in the two cable anchors under the left side cover. Place the cover into position and reverse the cover removal process. Anchors 2. Attach label taken sensor cable to the main PCBA at JP26. JP26 14 Attach Cable to Main PCBA 980428-101 Rev. 1 Prelim.
3. Slide the cable into the seam between the front and center panels. Remove as much excess loop in the cable towards the rear of the printer and main PCBA. 4. Put the cover on the printer. Verify that the cable has not been pinched between the cover and printer. 5. Push the excess cable back into the seam between the front and center panel. 6. Re-attach the cover to the printer with the washers and screws. 7.
Printhead Preparations Before starting the procedure, open the printer, then remove any media from the printer. Tools: 3mm Allen wrench hex key or driver Removal 1. Open the printhead assembly. 2. Lower the printhead by loosening the mounting Allen head screw which is accessed through a hole in the top of the printhead assembly. 3. Detach the printhead (ribbon) cable. Installation 1. Connect the replacement printhead. Pin 1 on the printhead and cable is toward the center panel of the printer. 2.
Power Supply Access and Replacement Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: #2 Philips screw driver Power Supply Access 1. Cut the two (2) cable ties securing the cable harness to the top of the power supply. Caution - Do not cut the cables. 2. Remove the screw securing the grounding lug and wire to the top of the power supply. 3.
Installation 1. Reverse the power supply removal and access processes. -- If replacing the power supply, the AC voltage should be set prior to installing the power supply, see procedure 980428-104. -- The DC voltage setting should be verified prior to attaching the power supply to the printer, see procedure 980428-105. Important - Re-attach the ground wire to the power supply in the following order: 1) Star Washer 2) Ground wire and lug (from toroid) 3) Star Washer 4) Nut. Tighten the nut to 7.5 ±2 in. Lb.
Set AC Voltage Preparations The exterior cover must be removed prior to proceeding. (980428-101) The power supply must be detached from the bottom panel for access. (980428-103) Set Voltage Disconnect the power supply from the cable harness and printer base. 1 1. 230VAC 2. 3. Move the voltage selection jumper wire to the appropriate voltage pin. Verify the correct voltage is marked next to the jumpers pin.
DC Power Verification & Adjustment Preparations The exterior cover must be removed prior to proceeding. (980428-101) The power supply must be detached from the bottom panel for access. (980428-103) Shock Hazard Always turn off the printer before removing the exterior cover. The printer must be turned on after the cover is removed to perform this procedure. See the following procedure. DC Voltage Verification 1. Disconnect the DC power cable (JP6) from main PCBA. 2.
AC Power Inlet & Switch Preparations The exterior cover must be removed prior to proceeding. (Procedure 980428-101) The power supply must be unscrewed from the printer's bottom plate. (Procedure 980428-103) Power Switch Removal 1. Push the retaining tabs into the side of the power switch or AC power filter module and slide it out of the back panel. Power Switch Installation 1. Disconnect the old switch's wires, one at a time, and reconnect them to the new switch in the same position.
DC Power Cable Preparations The exterior cover must be removed prior to proceeding. (980428-101) The power supply must be detached from the bottom panel for access. (980428-103) Note the main cable harness routing and cable tie positions. (980428-009) DC Voltage Verification Removal 1. Cut the two (2) tie-wraps securing the main cable harness to the power supply. Caution - Do not cut the cables! 2. Disconnect the ground wire from the top of the power supply. 3.
AC Power Cable Preparations The exterior cover must be removed prior to proceeding. (980428-101) For best results, the detach the power supply from the printer bottom. (Procedure 980428-103) Tools: 5/16 in. Nut Driver, #1 Phillips Screwdriver Removal & Replacement 1. After the power supply is laying on its side next to the printer, disconnect the AC power cable’s connector from the power supply. 2. With a nut driver, disconnect the green ground wire from the printer’s bottom panel. 3.
Securing the Wire Harness The printer was designed to meet or exceed all regulatory agency (CE, FCC, UL, CSA, etc.) safety and electro-magnetic requirements. The positioning and anchoring of the cables and connectors are critical to meet these requirements. The following diagrams the physical location of the printer's primary cable groups and cable tie points.
Cable Clearance Check Procedure The printer cables and connectors must not interfere (touch) with any moving components (belts, gears or springs). Placement of cable tie points, tie anchors, and cable tension and slack areas are outlined in the following steps: Control Panel Tie Point 1. Cable Tie Pull the control panel cable until minimum 1/4" service loop (slack) is present between the cable tie and control panel PCBA. Tighten the tie and cut off the excess. Front Power Supply Cable Tie Point 1.
5. Pull the DC power cable through power supply’s front cable anchor tie until no more than 2 inches and no less than 1 inch of service loop away from the front side of the power supply. Front Anchor Tie 6. Position the motor cable’s spiral wrapping to where one-third of the wrapping is through the center panel towards the motor.
Rear Power Supply Cable Tie Point 1. Pull the control panel, label sensor and head-up cables exiting the front cable anchor tie to the rear cable anchor and tie them loosely in place. Arrange the bundle neatly. Pull the cable to the rear, taught through the rear tie and tighten it tight. Remove (cut) the excess tie. 2. Fold the excess cable from the sensors and controls into the bundle. Tie the bundle with a cable tie approximately one inch from their connectors on the main board.
Main PCBA Preparations The exterior cover must be removed prior to proceeding. (980428-101) If needed, load the Printer Information Software Utility into printer test PC. (980428-157) Tools: #1 Philips screw driver Removal 1. Use the Print Information software utility to extract the printer’s serial number and head life prior to PCBA removal, if possible. 2. Disconnect all the external cables and power cords from the printer. 3.
Label Roll Support Assembly (Roll Holder) Preparations Before starting the procedure, open the printer, then remove any media from the printer. The exterior cover must be removed prior to proceeding. (980428-101) Tools: #1 & #2 Philips screwdrivers Removal & Replacement 1. Remove the four (4) screws securing the Main PCBA to the chassis. Pull the main PCBA off the stand-offs. Leave the cables attached and gently lay the PCBA against the printer and work surface. 2.
RTC Installation Preparations The exterior cover must be removed prior to proceeding. (Procedure 980428-101) Tools: No additional tools needed Installation RTC - Real Time Clock Option 1. Add the real time clock option chip into the socket at location U2. Match the notch on the socket and the dot RTC module to properly orient the module. The real time clock option stores the time of day and date. The chip's battery has a life of up to ten years.
Motor Cable Preparations The exterior cover must be removed prior to proceeding. (980428-101) Note the main cable harness routing and cable tie positions. (980428-109) Tools: Large Flat Blade Screwdriver Removal 1. Cut the front tie-wrap securing the main cable harness to the power supply. Caution - Do not cut the cables! 2. Disconnect the power cable (JP6) from main PCBA. DC Power JP8 Cut the Cable Tie 980428-115 Rev. 1 Prelim.
3. Disconnect the motor cable from the motor. The motor connector can be pried off with a large bladed screw driver. Pull the cable out of the users side through the center panel’s wall and out the service access side 4. Remove the spiral wrap from the old cable. Installation 1. Add the spiral wrap to the new motor cable. 2. Pass the cable through the center panel’s motor access hole and plug it into the motor. 3.
Printhead Cable Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: 3mm Allen wrench hex key or driver Removal 1. Cut the tie-wrap securing the main cable harness to the power supply. Caution - Do not cut the cables! 2. Disconnect the printhead cable (JP21) from main PCBA. 3. Open the printhead assembly. 4. Lower the printhead by loosening the mounting Allen head screw which is accessed through a hole in the top of the printhead assembly. 5.
5. Align the printhead with the two bracket alignment pins. 6. Secure printhead to printhead bracket by tightening the printhead bracket Allen head screw. Tighten the screw to 4.7 ±1 in. lb. 7. Close and open the printhead and recheck that the printhead cable still secure and connected to the printhead. Verify that 1/4 is inside and 3/4 of the spiral wrap is outside of the center panel. This protects the cable from rubbing on the belt and printhead carriage. 8. Re-tie the main PCBA harness.
Label Guide & Sensor Preparations The exterior cover must be removed prior to proceeding. (980428-101) Note the main cable harness routing and cable tie positions. (980428-109) The Label Guide & Sensor assembly is mounted below the printhead assembly. The sensor slide and cables pass through the center panel of the printer chassis and plug into the main PCBA. Tools: #2 Philips screw driver Removal 1. Cut the two (2) tie-wraps securing the sensor cable to the power supply.
3. From the user’s access area (right side of printer), open the printhead with the printhead's release latch. Adjust the sensor slide to the outside position, away from the center panel of the printer chassis. 4. Remove the pan head screw securing the label guide and sensor assembly to center panel of the printer chassis (user access side). Screw Release Latch 5. Slide the label guide and sensor assembly toward the front of the printer, (approx.
Installation 1. Slide the sensor guide's four (4) cables through the sensor slide’s hole. 2. Insert and hook the label guide’s tab onto the center panel’s cut-out. 3. Secure the label guide and sensor assembly to the center panel with the pan head screw. 4. Close the printhead. Hook guide to center panel 5. Re-connect the cables (JP27, JP28 and JP5) to the Main PCBA. The five (5) conductor cable exiting the bottom of the sensor slide gets connected to JP5.
Label Sensor PCBAs Preparations The exterior cover must be removed prior to proceeding. (Procedure 980428-101) Note the main cable harness routing and cable tie positions. (980428-109) Remove the Label Sensor and Guide Assembly from the printer. (980428-117) Tools: #2 Philips screw driver Removal 1. Slide the sensor adjustment slide into the sensor housing. 2. Remove the three (3) screws attaching the lower housing to the upper. 3.
4. Completely slide the lower and upper housings from the slide. 5. Remove the adhesive securing the cables at the end of the slide. Caution - Do not damage the slide or good cables or good PCBAs. 6. Slide the appropriate cable out of the cable clips. Note how the cables are attached and routed. 7. While holding the slide to keep it from spreading apart, gently pull the appropriate PCBA from the slide. Gap Receiver PCBA Cable Clips Cable Clips Gap Emitter / Black Mark PCBA Installation 1.
3. Add adhesive (hot melt glue or RTV) to the end of the slide to secure the cables to the slide. Remove excess adhesive immediately. let the adhesive set before continuing. 4. Slide the sensor adjustment slide half way into the lower housing. 5. Insert the cables into the slide access in the upper housing. 6. Finish sliding the two housings together. Gently rock the lower housing while slowly pushing the lower housing into the upper housing. 7.
Control Panel Preparations The exterior cover must be removed prior to proceeding. (980428-101) Note the main cable harness routing and cable tie positions. (980428-109) Tools: #1 Philips screw driver Removal 1. Cut the three (3) tie-wraps securing the cables to the power supply and the front panel. Caution - Do not cut the cables! 2. Disconnect the control panel cable (JP35) from main PCBA. JP35 Cut Cable Tie Cut Cable Ties 980428-119 Rev. 1 Prelim.
4. Remove the four (4) screws holding the control panel assembly to the front panel. 5. Pull the control panel assembly straight out the front panel of the printer. Screws Installation 1. Insert the control panel cable into the control panel's access hole. Pull the cable through. 2. Re-attach the control panel assembly to the inside of the front panel with the four (4) retaining screws. Tighten to 4.7±1inch-pounds of torque. 3. Plug the Control Panel’s cable into the main PCBA at connector JP35.
Head-up Sensor Preparations The exterior cover must be removed prior to proceeding. (980428-101) Note the main cable harness routing and cable tie positions. (980428-109) Removal 1. Cut the three (3) tie-wraps securing the cables to the power supply and the front panel. Caution - Do not cut the cables! 2. Disconnect the control panel cable (JP14) from main PCBA. JP14 Cut Cable Tie Cut Cable Ties 980428-121 Rev. 1 Prelim.
4. Pull the head-up sensor PCBA stand-offs. Head-Up Sensor PCBA Installation 1. Insert the head-up sensor PCBA onto the stand-offs with the cable facing into the center of the printer. 2. Plug the head-up sensor’s cable into the main PCBA at connector JP14. 3. Re-attach the head-up sensor’s cable to the main cable bundle at the front cable anchor tie on the power supply. Use the "Securing the Harness" procedure, 980428-009, to complete dressing the control panel, head-up and other cables.
Label Taken Sensor Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: No additional tools needed Removal 1. Remove the printers cover. 2. Slip the sensor’s cable out of the anchor ties under the left side cover. Anchor Ties 3. Slip the sensor cable out of the channel in the upper front cover. 980428-123 Rev. 1 Prelim.
4. Pull the label taken sensor PCBA out of the sensor gate’s sensor shroud. Gently pull the shroud body away from the gate to get the PCBA past the snap locks on the inside of the shroud. 5. Slide the cable out of the shroud. Installation 1. Reverse the process. 46 980428-123 Rev. 1 Prelim.
Peel Mechanism Tools: #1 Philips screw driver Removal 1. Remove the two (2) screws holding the peeler mechanism to the lower print mechanism. The peeler spacer plate will also become loose. Installation 1. Place and hold the peeler spacer plate against the lower print mechanism with the cutout facing down. Align the plate up with the mounting two (2) holes. 2. Place the peel mechanism against the spacer plate and insert the two (2) flat head screws. Tighten the screws to 4.7 inch-pounds torque. 3.
Label Guide Tab Tools: Pliers and a scribe Tab Stop Pin Removal 1. 2. Push the tab stop pin out of the guide tab's slide on the label guide and sensor assembly. Guide Tab Rotate the guide tab down and slide the tab off the slide. Installation Slide the guide tab on the slide. 2. Insert the tab stop pin until it is flush with the bottom. 3. Pull the guide tab to the outside of the slide and verify the guide tab can rotate up. T OR P EP ER MO 1. ST 48 980428-126 Rev. 1 Prelim.
Motor Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: 4mm Allen hex key socket driver Removal 1. Remove the four (4) M5x14 socket head mounting screws securing the motor to the center panel. (4mm Allen head socket - 1/4 inch hex shank for use with torque gauge). 2. With the motor loose, disconnect the belt and then the motor cable from the motor. Reference - Do Not Disconnect Pulley 0.
Ribbon Pulley (60 tooth) Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: 11/32 Allen driver Removal 1. 2. 3. Ribbon Pulley (60 Tooth) Loosen the ribbon belt by rotating the belt tension idler counter-clockwise. Lift the ribbon belt off the ribbon pulley. Ribbon Drive Belt (324 tooth) Rotate ribbon pulley to view set screw from the top of the center panel. Loosen set screw. Platen Pulley Clutch Remove ribbon pulley from shaft.
Ribbon Drive Belt Preparations The exterior cover must be removed prior to proceeding. (980428-101) Removal 1. Cut the tie-wrap securing the main cable harness to the power supply. Caution - Do not cut the cables! 2. Disconnect the printhead cable (JP21) from main PCBA. 3. Loosen the belt by rotating the belt tensioner idler counter-clockwise. Lift the ribbon belt off the ribbon pulley, rewind pulley and then out. Ribbon Pulley (60 Tooth) Installation 1.
Platen Belt (120 tooth) Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: TORX tool with #T25 tip or 4mm allen head Removal 1. 2. Ribbon Pulley (60 Tooth) Loosen the ribbon belt by rotating the belt tension idler counter clockwise. Lift the ribbon belt off the ribbon and clutch pulleys. Do not disconnect the print head cable. Ribbon Drive Belt (324 tooth) Loosen the four (4) M5x14 socket head mounting screws securing the motor to the center panel.
Ribbon Collar & Spring Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: Pliers for E-ring retainers (12R) 11/32 Allen driver Removal 1. Loosen supply ribbon tube's collar set screw. 2. Slide the collar off the tube shaft and spring off the post. Installation 1. Slide the nylon washer and then the collar onto the tube shaft. 2. Slide the end of the collar's spring on the post below the collar. 3.
Ribbon Tubes & Shaft Support Preparations The exterior cover must be removed prior to proceeding. (980428-101) Take-Up Ribbon Tube Or Shaft Support Housing - The ribbon belt and pulley must be removed from the tube shaft prior to preceding. (980428-132) Supply Ribbon Tube Or Shaft Support Housing - The ribbon supply collar and spring must be removed from the tube shaft prior to preceding. (980428-138) Nylon Bearing Take-Up Ribbon Tubes Supply Tools: #2 Philips screwdriver Removal 1.
Rewind Pulley, Tube & Shaft Support Preparations The exterior cover must be removed prior to proceeding. (980428-101) The power supply must be loosened from the printer's bottom plate. (980428-103) Tools: #2 Philips screw driver 11/32 Allen driver Removal 1. Partially disconnect the power supply and place it next to the printer base to gain access to the rewind assembly. Ribbon Pulley (60 Tooth) 2.
3. Pulley Only - Rotate rewind pulley to view set screw from the top of the center panel. Loosen set screw and slide rewind pulley off the shaft. 4. Rewind Tube Assembly Only (to here) Slide the rewind tube assembly out of the shaft support housing. 5. Shaft Housing - Remove the two (2) screws holding the shaft support housing to the center panel. 56 980428-140 Rev. 1 Prelim.
Installation 1. Nylon Bearing Shaft Housing - Insert the two (2) nylon bearings into each end of the shaft housing. No lubrication is needed. 2. Re-attach the shaft housing to the center panel with the two (2) screws. Tighten the two (2) screws retaining the label rewind tube assembly to 11 inch-pounds torque. 3. Rewind Tube Assembly - Insert the thin nylon washer on the shaft of the tube assembly. 4. Insert the rewind tube into the shaft support assembly. 5.
Platen Bearing & Replacement Kit Preparations The exterior cover must be removed prior to proceeding. (980428-101) The power supply must be moved to access the rewind pulley. (Procedures 980428-103, 980428-009) The platen belt, clutch pulley and 42 tooth pulley must be removed prior to proceeding. (980428-137) Tools: 4mm Allen hex key socket driver #2 Philips Screwdriver Pliers for E-ring retainers (12R) 11/32 Allen driver Removal 1.
Installation 1. Slide the long shaft end of the platen roller into the printer's center panel. 2. With the platen roller's shaft perpendicular to the center panel, slide the short end of the platen shaft into the lower print mechanism's side bracket. 3. Place, in sequence, the following on the outside platen shaft: a platen sleeve, flange bearing (flange outside), and a nylon washer. Lock the them on the shaft with the E-ring. 4.
Lower Print Mechanism Preparations The exterior cover must be removed prior to proceeding. (980428-101) The peel mechanism must be removed prior to proceeding. (980428-125) Tools: #1 & #2 Philips Screw drivers 11/32 Allen driver Removal 1. Remove the peel mechanism from the lower print mechanism. 2. Remove the E-ring from the end of the platen shaft on the outside of the lower print mechanism. Remove the nylon washer and flange bearing. 3.
5. Remove the lower print mechanisms extrusion bracket that the peel mechanism and label rewind plate were mounted to. 6. Slide the latch assembly out of the assembly's shaft pivot in the center panel and the spring off the post. Latch Assembly Post Spring Washers Installation 1. Loosely attach the extrusion to the center panel with a single screw in the bottom screw hole. Let the extrusion swing down to the outside of the printer. 2.
Printhead Carriage Preparations Before starting the procedure, open the printer, then remove media from the printer. The exterior cover must be removed prior to proceeding. (980428-101) Remove the printhead and set it on a clean, soft and static safe surface (mat). (980428-102) Tools: #2 Philips and a flat blade screwdrivers Removal 1. Open the printhead and unhook the printhead carriage spring from the other side of the center panel.
Installation 1. Slide the printhead cable through the printhead carriage assembly. 2. Place the printhead carriage's pivot shaft into the pivot hole in the center panel. 2. Place the printhead side plate on the carriage printhead pivot hole on the opposite side. Loosely secure the carriage and side plate to the extrusion bracket with three (3) screws and washers. 3. Push the side plate to match the upper print mechanism's extrusion profile (rear and top). Tighten the three (3) screws to 15.
Cutter Cable Preparations The exterior cover must be removed prior to proceeding. (980428-101) Note the main cable harness routing and cable tie positions. (980428-109) Removal 1. Cut the front tie-wrap securing the main cable harness to the power supply. Caution - Do not cut the cables! 2. Cut the tie-wrap securing the cutter cable to the motor cable, if the cutter cable is already installed. 3. Disconnect the cutter cable (JP15 from main PCBA, if present.
4. Remove the spiral wrap from the motor (and cutter) cable. Do not pull the motor cable's connector out of the motor. Motor Connector and Plug Installation 1. Connect the cutter cable (JP15) to the main PCBA. 2. Insert the cutter through the center panel next to the motor cable. 3. Tie the cutter cable to the motor cable about 1.5 inches from the motor cable's connector on the main PCBA. 4. Attach the cutter cable to the main cable bundle at the front cable anchor tie on the power supply. 5.
Feet Preparations Before starting the procedure, open the printer, then remove media from the printer. Tools: #1 Philips screwdriver Instructions 1. Close the printer cover. 2. Roll the printer on the left side. 3. Remove the feet by removing the screw in the center of the foot. 4. Secure the front feet with the longer screws. The shorter screws are used to secure the back feet. 66 980428-149 Rev. 1 Prelim.
Printer Configuration Check Checking the Installation 1. Turn on the printer and run your printer's AutoSense routine to get a dump mode printout. FEED PAUSE & CANCEL PAUSE 3 sec. 1 sec. Sample: DUMP Mode Printout FEED 4 MO3257 3.18.01 Serial port : 96,N,8,1 Image buffer size:245K Fmem:000,0K,019.9K avl Gmem:000K,0241K avl Emem:000K,0241K avl I8,0,001 rY S8 D12 R032,000 ZT UN q0784 Q1227,034 Option:D 11 12 13 now in DUMP This action tests the printer's media drive and printing capabilities.
Platen Belt and Motor Adjustment Preparations The exterior cover must be removed prior to proceeding. (980428-101) Tools: 4mm Allen hex key socket driver Adjustment 1. While applying 6-8 lbs. pressure on the motor, towards the rear of the printer, tighten the motor mounting screws to 23.7±2 inch-pounds of torque. (This step sets belt tension). 2. Verify the belt teeth have aligned with pulley cogs. Rotate belt one revolution.
Tube Tension - Verify & Adjust Preparations Before starting the procedure, open the printer, then any remove media from the printer. The exterior cover must be removed prior to proceeding. (980428-101) Tools: 3/32" Allen driver Torque Tube Tool and Torque Wrench Measuring Tension The ribbon and label rewind tubes have unique tube tension settings for their internal clutches. Spare ribbon and label rewind tubes have had a run-in period and are preset to nominal torque settings for your printer.
Tension Adjustment 1. Hold the appropriate tube's pulley or collar and rotate the outside of the tube until the slot on the end of the tube aligns with the inside set screw of the tube assembly. 2. Loosen the set screw. 3. Push the tube's clutch spring into the tube with the torque tools tip. The tool's prongs touch the clutch spring's stop collar. Pushing the clutch stop collar in increases torque and out decreases torque. Tighten the stop collars set screw to 11 inch-pounds torque. 4.
Ribbon Path Adjustment Preparations Load 4 inch wide ribbon and media in the printer. MOVIE Presetting 1. 2. Loosen the three (3) horizontal adjustment screws and push the side plate to align with the upper print mechanism's extrusion bracket profile (rear and top). Tighten the three (3) screws to 15.8 inch-pounds of torque. Loosen the vertical adjustment screw and adjust ribbon adjustment shaft to be in the center of the vertical slot on the side plate. Tighten the screw to 15.8 inch-pounds of torque.
4. Loosen the vertical adjustment screw and adjust the ribbon adjustment shaft to correct stress lines in ribbon behind print head assembly while feeding media. Move the shaft in the vertical slot up or down. Position should be set so stress lines run vertically from ribbon supply roll. Take-Up Ribbon Tube Supply Ribbon Tube Vertical Slot Adjustment 5. Note the ribbon stress line in the front of the printer while feeding or printing labels.
Printer Information Utility The Printer Information utility is a proprietary service program intended for Zebra authorized customers and service organizations. The utility also includes Help files describing the functions and connection methods. The utility automates functions available through the EPL2 printer programming language. It is used to: Re-set printhead life when printheads are replaced Set the printer’s serial number into a new main printer PCBA.
Resetting the printhead 1. After replacing the printhead, select the Reset Head Odometer in the Printer menu. Only do this procedure once per printhead! The printer records each printhead odometer reading in ten (10) memory storage locations. Resetting the printhead odometer increments the printhead odometer memory location pointer and clears that printhead record.
Packaging for Shipment To ship or store the printer, make sure all components are packed as shown in the figure below. Printer Preparation 1. Close the printhead. 2. Place and lock the rewind bracket in the rear of the printer base. 3. Close the label dispenser (peeler). 4. Mount the lower front cover. 5 Tape (masking tape) the rewind clip to the rewind tube. Packaging the Printer Move the printer carefully.
5. Place the power cord, cables, software, etc. in the bubble pack plastic bag and completely seal it with plastic tape or self sealing strip. 6. Seal the top of the shipping carton with reinforced shipping tape. Unpacking Instructions 1 3 UP KEEP DRY E FRAGIL UP KEEP DRY FRAGIL E UP E FRAGIL 2 76 DRY FRAGIL E KEEP DRY UP KEEP 4 980428-160 Rev. 1 Prelim.
CLEANING AND MAINTENANCE The printers are manufactured and tested under a strict quality management program. Zebra Technologies uses only high quality components and materials in its Zebra printers. Although only minimal routine maintenance is required, following these simple maintenance guidelines will ensure longer life with quality printing performance. Shock Hazard Always turn off the printer before performing any maintenance or repair operations.
Preventive Maintenance For optimum performance, clean the printhead regularly after every roll of direct thermal labels. To start, only use the cleaning pen or pre-soaked (isopropyl alcohol) cleaning swabs provided. Lightly blow or brush away any loose dust and lint particles within the print mechanism (i.e. rollers, media sensors, and printhead).
Cleaning the Media Path Use a brush or vacuum to clean the media path (except the printhead). If a label jams inside the printer, remove the label and any adhesive residue immediately. Adhesive may spread throughout the printer's media path if not completely removed. Many adhesives are permanent and have short "set" times. Cleaning the printhead As you use your printer, the printhead may become contaminated resulting in poor print quality.
Save-a-Printhead Cleaning Film - Kit P/N 44902 What is Save-a-Printhead cleaning film? A specially coated film that removes contamination buildup without damaging the printhead. What are the benefits of Save-a-Printhead cleaning film? Extends the life of your printhead. Reduces maintenance downtime and the cost of replacing a printhead. An inexpensive, easy and quick way to remove contaminants without having to remove the printhead.
RECOMMENDED SERVICE To maximize service life (before maintenance is required), the total service life, and eliminate potential problems that are harder to detect or test for, it is recommended the the service technical perform the following procedures: Clean the printhead (See Cleaning and Maintenance) Removes loose contaminate build-up to prep the printhead for conditioning.
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