Printronix-T5000 SM PDF

Maintenance Manual
SL5000 e , T5000 e SR, T5000 e, and T5000 Thermal Printers

TM TM
SL5000 e, T5000 e, T5000e SR, and T5000
Thermal Printers
Maintenance Manual
Communication Notices
Federal Communications Commission (FCC) Statement: This equipment
has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provided reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference, in which case the user
will be required to correct the interference at his own expense.
Properly shielded and grounded cables and connectors must be used in order
to meet FCC emission limits. Printronix is not responsible for any radio or
television interference caused by using other than recommended cables and
connectors or by any unauthorized changes or modifications to this
equipment. Unauthorized changes or modifications could void the users
authority to operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: (1) this device may not cause harmful
interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
Canadian Department of Communications Compliance Statement: This
Class A digital apparatus complies with Canadian ICES-003.
Avis de conformite aux normes du ministere des Communcations du
Canada: Cet appareil numerique de la classe A est conform norme NMB-
003 du Canada.
European Community (EC) Conformity Statement:
This product is in conformity with the protection requirements of EC Council
Directive 89/336/EEC on the approximation of the laws of the Member States
relating to electromagnetic compatibility. Printronix cannot accept
responsibility for any failure to satisfy the protection requirements resulting
from a non-recommended modification of the product, including the fitting of
non-Printronix option cards.
German Conformity Statement:
Zulassungsbescheinigung Gesetz ber die elektromagnetische
Vertrglichkeit von Geraten (EMVG) vom 30. August 1995
Dieses Gert ist berechtigt in bereinstimmung mit dem deutschen das EG-
Konformittszelchen - CE - zu fhren.
Der Auteller der Konformittserklrung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gert erfllt die Schutzanforderungen nach EN 55022 und EN 55024

Klasse A.
EN 55022 Klasse A Gerte bedrfen folgender Hinweise:
Nach dem EMVG: Gerte drfen an Orten, fr die sie nicht asreichend
entstrt sind, nur mit besonderer Genehmigung des Bundesminesters fr
Post und Telekommunikation oder des Bundesamtes fr Post und
Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn
keine elektromagnetischen Strungen zu erwarten sind. (Auszug aus dem
EMVG, Paragraph 3, Abs. 4) Dieses Genehmigungsverfahren ist nach
Paragraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung
(Amtsblatt 14/93) kostenpflichtig.
EN 55022: Dieses ist eine Kategorie A Vorrichtung. Betrieb in den
Wohnbereichen kann elektrische Strung verursachen. Es ist die
Verantwortlichkeit des Benutzers, passende Gegenmanahmen zu ergreifen.
EN 55024: Begrenzung Werte fr Gebrauch in bevlkerten Bereiche,
kommerziellen und Industriegebieten sind innen bereinstimmung mit den
spezifizierten Anforderungen Hinsichtlich Strfreiheit.Anmerkung: Um die
Einhaltung des EMVG sicherzustellen sind die Gerte, wie in den
Handbchern angegeben, zu installieren und zu betreiben.
This product has been tested and found to comply with the limits for Class A
Information Technology Equipment according to European Standard EN
55022. The limits for Class A equipment were derived for commercial and
industrial environments to provide reasonable protection against interference
with licensed communication equipment.
Warning
This is a Class A product. In a domestic
environment this product may cause radio
interference in which case the user may be
required to take adequate measures.
Trademark Acknowledgements
Compatibility Software Copyright 1989 Phoenix Technologies Ltd., All
Rights Reserved.
Alien and Alien Technology are registered trademarks of Alien Technology
Corporation.
Code V is a trademark of Quality Micro Systems, Inc.
EIA is a registered service mark of the Electronic Industries Association.
Epson is a registered trademark of Seiko Epson Corporation.
HP is a registered trademark of Hewlett-Packard Company.
IBM is a registered trademark of International Business Machines
Corporation.
IGP, LinePrinter Plus, PGL, Printronix, and PSA are registered trademarks of
Printronix, Inc.
IPDS is a trademark of International Business Machines Corporation.
LaserJet is a registered trademark of Hewlett-Packard Company.
Microsoft, MS-DOS, and Windows are registered trademarks of Microsoft
Corporation.
PCL is a registered trademark of Hewlett-Packard Company.
PhoenixPage PCL 5 is a registered trademark of Phoenix Technologies Ltd.
PostScript is a registered trademark of Adobe Systems.
PPI1, PPI2, SL5000e, and T5000e are trademarks of Printronix, Inc.
Proprinter is a registered trademark of International Business Machines
Corporation.
QMS is a registered trademark of Quality Micro Systems, Inc.
TEC is a registered trademark of the Toshiba TEC Corporation.
Zebra is a registered trademark of Zebra Technologies Corporation.
Copyright 2000, 2004, Printronix, Inc.

Table Of Contents
1 Maintenance Overview ....................................... 13

Printronix Customer Support Center.................................................... 13
About This Manual............................................................................... 13
To Replace Parts .......................................................................... 13
To Order Parts .............................................................................. 14
Notes And Notices ........................................................................ 14
Manual Conventions ..................................................................... 15
Related Manuals ........................................................................... 15
The T5000 Series Label Printer........................................................... 15
Standard Features ........................................................................ 17
Optional Features.......................................................................... 17
Thermal Printer Media................................................................... 19
Ribbons ......................................................................................... 19
Thermal Printer Technology .......................................................... 19
Controls And Indicators ....................................................................... 23
Control Panel ................................................................................ 23
Plugging In The Printer ................................................................. 27
Power Switch ................................................................................ 27
Operating Modes........................................................................... 27
2 Preventive Maintenance ..................................... 29

Cleaning The Printer............................................................................ 29
Exterior .......................................................................................... 29
Interior ........................................................................................... 29
General Cleaning .......................................................................... 29
Cleaning The Printhead, Platen Roller And Media Sensors.......... 30
Printer Inspection................................................................................. 32
3 Troubleshooting .................................................. 33
Introduction .......................................................................................... 33
What You Should Know About Print Quality ................................. 33
How To Maximize Printhead Life................................................... 33
Troubleshooting At A Glance ........................................................ 34
Start Here ............................................................................................ 35
How To Troubleshoot .......................................................................... 36
Printer Self-Tests And How To Verify Printer Operation ............... 37
7
Table of Contents
Troubleshooting Display Messages..................................................... 38

List Of Messages .......................................................................... 39
Troubleshooting Other Symptoms ....................................................... 72
General Symptom List................................................................... 72
Communications Failures .................................................................... 88
Troubleshooting A New Installation ..................................................... 91
Printer Configuration ..................................................................... 91
GAP NOT DETECTED.................................................................. 91
PRINT HEAD UP .......................................................................... 91
Ribbon ........................................................................................... 91
Documentation .............................................................................. 91
4 Replacing Parts................................................... 93
About This Chapter.............................................................................. 93
Preparing The Printer For Maintenance ........................................ 93
Restoring The Printer To Operation .............................................. 94
Tools And Materials ...................................................................... 95
Torque Requirements ................................................................... 95
Removal And Replacement Procedures.............................................. 96
Belt, Platen .................................................................................... 97
Belt, Rewinder ............................................................................... 98
Control Panel Assembly ................................................................ 99
Controller PCBA (Printed Circuit Board Assembly)..................... 100
Cooling Fan, Power Supply With Center Mounted Fan .............. 102
Cooling Fan, Power Supply With Rear Mounted Fan ................. 103
Damper, Media............................................................................ 104
Dashpot....................................................................................... 105
Expansion-CT ............................................................................. 106
Frame Side Cover ....................................................................... 107
Gear, Ribbon Drive, Final............................................................ 108
Gear, Ribbon Drive, Intermediate ............................................... 109
Head Pressure Block Assembly .................................................. 110
Media Cover ................................................................................ 113
Media Hanger Beam ................................................................... 114
Media Sensor Assembly, Lower, Dual Media Sensor Models .... 115
Media Sensor Assembly, Single Media Sensor Models.............. 117
Memory Modules, Flash And DRAM ........................................... 118
Motor, DC Ribbon Drive .............................................................. 121
Motor, Stepper ............................................................................ 122
NIC Assembly ............................................................................. 123
Plate, Rear Panel, Vented and Ventless Models ........................ 127
Platen .......................................................................................... 128
8
Table of Contents
Power Supply Assembly.............................................................. 129

Printhead Assembly, Dual Media Sensor Models ....................... 130
Printhead Assembly, Single Media Sensor Models..................... 132
Printhead Cover/Upper Media Sensor,
Dual Media Sensor Models ......................................................... 134
Resistors, Terminating ................................................................ 135
Rewinder (Option) ....................................................................... 137
Rewinder, Torque Check and Adjustment, V1 ............................ 138
Rewinder, Torque Check and Adjustment, V2 ............................ 141
Security PAL ............................................................................... 144
Sensor, Head Up......................................................................... 146
Sensor, Label Taken, Frame Mounted........................................ 147
Sensor, Label Taken, Front Cover Mounted ............................... 148
Spindle Assembly, Ribbon Supply Or Take-Up........................... 149
Support Assembly, Lower ........................................................... 150
Support Assembly, Upper ........................................................... 151
Tear Bar Assembly, Adjustable ................................................... 152
Tensioner, Rewinder Belt ............................................................ 155
5 Illustrated Parts Breakdown .............................. 157

Organization Of This Chapter ............................................................ 157
Illustrated Parts Breakdown............................................................... 157
Hardware Kit ............................................................................... 202
Hardware Kit, Cutter Options ...................................................... 203
A ASCII Codes ..................................................... 205
B Downloading Software ...................................... 209

Flash Memory .................................................................................... 209
Downloading Software Through the Serial or Parallel Port ......... 210
Downloading Software Through the NIC..................................... 213
Downloading Optional Fonts to Flash Memory ........................... 216
C Wire Data .......................................................... 219

Circuit Board And Cable Pinouts ....................................................... 219
D Media Cutters and Tray .................................... 245

Introduction ........................................................................................ 245
Cutter Installation and Removal......................................................... 246
Cutter Tray Installation And Removal ................................................ 251
Cutter Assembly Replacement .......................................................... 253
Troubleshooting ................................................................................. 255
9
Table of Contents
Maintenance ...................................................................................... 256

Standard Cutter ........................................................................... 256
Heavy Duty Cutter ....................................................................... 257
Specifications..................................................................................... 257
Spare Parts........................................................................................ 258
E Online Data Validator ........................................ 269

Contents ............................................................................................ 269
Safety Notices.................................................................................... 270
Overview............................................................................................ 271
Installation and Removal, Later Models............................................. 272
Install The Ferrite ........................................................................ 272
Install The Brackets..................................................................... 277
Attach The Power/Data Cable To The Validator ......................... 279
Installation and Removal, Early Models............................................. 280
Install The Ferrite ........................................................................ 280
Install The Brackets..................................................................... 285
Attach The Power/Data Cable To The Validator ......................... 287
Basic Setup........................................................................................ 288
Enabling And Disabling The Validator......................................... 289
Adjusting The Scanning Beam .......................................................... 290
Shifting The Scanning Beam....................................................... 294
Calibration.......................................................................................... 295
Bar Code Validation Demo Page ................................................ 297
Configuring The Validator .................................................................. 298
Bar Code Failures.............................................................................. 298
Bad Bar Code Error Detection .................................................... 298
Missing Bar Code Error Detection............................................... 298
Error Action ................................................................................. 299
Error Messages ........................................................................... 301
Maintenance ...................................................................................... 306
Spare Parts, Later Models ................................................................. 307
Spare Parts, Early Models ................................................................. 308
F Dual NIC Wireless Interface .............................. 309

Installation and Removal ................................................................... 309
Install The Dual NIC Wireless Interface ...................................... 310
Install The Radio Card, Protective Cover, And Antenna ............. 313
Spare Parts........................................................................................ 315
10
Table of Contents
G RFID Encoder and Antenna Assemblies .......... 317

Installation And Removal ................................................................... 317
Prepare The Printer ........................................................................... 317
Remove The Frame Side Cover ........................................................ 318
Install The RFID Encoder, Early Models............................................ 319
Replace The RFID Antenna And Encoder Assemblies,
Later Models ...................................................................................... 326
Remove the RFID Encoder Assembly......................................... 326
Replace The RFID Antenna Assembly........................................ 328
Install The RFID Encoder Assembly ........................................... 331
Route The Data And Power Cables ............................................ 333
Finish The Installation........................................................................ 334
Error Messages ................................................................................. 335
Spare Parts........................................................................................ 337
11
Table of Contents
12
1 Maintenance Overview
Printronix Customer Support Center

The Printronix Customer Support Center offers technical support with:
Installation
Configuration and setup
Operation and supplies loading
Specifications of the proper print media and ribbon
Answers to post-sale service support questions
Call the Printronix Customer Support Center at:

(714) 368-2686 in the Americas
(31) 24 6489 489 in Europe, Middle East, and Africa
(65) 654 84114 in Asia Pacific
or visit the Printronix web page at www.printronix.com
http://www.printronix.com/public/servicesupport/default.aspx
About This Manual

This is a field service maintenance manual for T5000 Series thermal label
printers. Refer to the Table of Contents or the Index to locate the maintenance
information you need.
To Replace Parts
1. Go to Chapter 4, page 93.
2. Find the removal procedure for the part.
3. Read the entire procedure before you start and make sure you
understand all notes and notices, which are defined on page 14.
4. Gather the tools you will need.
5. Do the procedure.
13
Chapter 1 About This Manual
To Order Parts
Go to the Illustrated Parts Breakdown (IPB) on page 157, which contains
drawings of all printer assemblies. Next to each illustration is a list of the parts
shown and their part numbers. When locating parts, note the following:
If a part number is listed you can order that part or assembly. If a
component is part of a field kit, order the kit.
Parts marked Ref (reference) are not spared or are part of another
assembly.
Part numbers are not listed for common fasteners.
In illustrations, magnified details are shown with locator arrows and
letters:
that is magnified here, on

This arrow points to an area . . . the same page or a
subsequent page.
A
A
Assemblies you can order as kits are shown in the following manner:
80
85
To get item 80, 85, or 87, for
example, order item 90, which 87
is a kit containing all these 90
parts.
Notes And Notices

For your safety and to protect valuable equipment, always read and comply
with information highlighted under the following special headings:
WARNING A warning describes conditions that can harm you as well as damage
the equipment.
CAUTION A caution describes conditions that can damage the printer or related
equipment.
IMPORTANT Information vital to proper operation of the printer.

NOTE: Helpful and timesaving tips about printer operation and maintenance.
14
Manual Conventions
Manual Conventions
Control panel keys are printed in bold, uppercase letters.
Example: Press the PAUSE key to take the printer offline.
Control panel keys are often shown by their symbol or icon (located on
the control panel directly below the key).
Example: Press the to select it.
Liquid Crystal Display (LCD) messages are printed in uppercase letters
inside quotation marks ( ).
Example: When OFFLINE appears on the LCD, you may release the
PAUSE key.
LCD fault messages display the specific fault in uppercase letters on the
top line. A corrective action in upper and lowercase letters displays on the
bottom line.
Example: PAPER OUT
Load Paper
Key combinations (pressing keys at the same time) are indicated by the
+ (plus) symbol.
Example: Press + to unlock the key.
Related Manuals
This manual does not explain how to install, operate, configure the printer, or
how to program application software for operation with the printer. That
information is in the following manuals, available online at www.printronix.com:
T5000 Thermal Printer Users Manual
T5000 Quick Reference Manual
Network Interface Card Users Manual
Online Data Validator Users Manual
IGP/PGL Emulation Programmers Reference Manual
IGP/VGL Emulation Programmers Reference Manual
IPDS Programmers Reference Manual
LinePrinter Plus Emulation Programmers Reference Manual
Printer Protocol Interpreter 1.0 (PPI1) Programmers Reference Manual
Printer Protocol Interpreter 2.0 (PPI2) Programmers Reference Manual
The T5000 Series Label Printer

NOTE: As used in this manual, the terms T5000 and printer refer to all
models within the T5000 series. SR refers to all models that are
Smart Ready. SL refers to all SmartLine models.
The T5000 Series is a family of direct thermal and thermal transfer printers
designed to print labels and tags from any MS-DOS, Windows, or ASCII-
based computer.
15
Chapter 1 The T5000 Series Label Printer
Printronix Dynamic Print Control provides exceptional print quality. A circuit

monitors the data to be printed and automatically adjusts the energy applied
to the thermal printhead for maximum performance.
The printer can communicate with the host computer via RS-232 and RS-422
serial, Centronics-compatible parallel, IEEE 1284 compliant parallel, and
(optionally) coax/twinax, ethernet 10/100Base-T, or wireless ethernet host
connections. The interface cable needed to connect the printer to the host
device is supplied by the user.
The T5000, Smart Ready, and SmartLine series are comprised of the
products detailed in Table 1.
Table 1. The T5000, Smart Ready, and SmartLine Series
Max Print Printing Max Print

Model
Speed (ips) Density (dpi) Width (inches)
SL5204e MP 10 203 4.1
SL5204e C1 10 203 4.1
T5204e SR 10 203 4.1
T5204e 10 203 4.1
T5204e-DT* 10 203 4.1
T5204 10 203 4.1
T5206e 10 203 6.6
T5206 10 203 6.6
T5208e 8 203 8.5
T5208 8 203 8.5
T5304 8 300 4.1
T5304-DT* 8 300 4.1
SL5304e C1 8 300 4.1

SL5304e MP 8 300 4.1
SL5304e SR 8 300 4.1
T5306e 8 300 6.6
T5306 8 300 6.6
T5308e 6 300 8.5
T5308 6 300 8.5
NOTE: ips = inches per second

dpi = dots per inch
DT = Direct Thermal print mode only
16
Standard Features
Standard Features
Emulations:
Printronix LinePrinter Plus (LP+). Provides direct compatibility with
Printronix P-series printers.
Epson FX-1050, Proprinter IIIXL, and Serial Matrix printers.
Printronix IGP/PGL and IGP/VGL. Provides printer system
commands for text, barcodes, graphics, lines, and boxes.
Thermal Transfer and Direct Thermal Printing: On all printers
(except -DT models, which print only in direct thermal mode)
Bar Codes: Support for over 20 types of bar codes
Resident Fonts: OCRA, OCRB, Courier, Letter Gothic, and
CG Triumvirate Bold Condensed
Download: Forms, fonts, and graphics into printer memory
High Resolution Printhead: For sharp graphics and text
Label Taken Sensor: For detecting removal of labels in Tear-Off mode
(and in Peel-Off mode when optional rewinder is installed)
Tear-Off Mode: For positioning the label at the tear off position and
detecting its removal before printing the next label
Tear-Off Strip Mode: For printing a specified number of labels and
positioning the last label at the tear off position
8MB DRAM memory
4MB Flash memory
Auto Label Mapping: For compatibility with programs written for
Printronix line matrix printers.
Ventless System: For operation in environments with airborne
particulate matter without compromising performance (SL5000e,
T5000e SR, and T5000e dual media sensor models only)
Optional Features
The following options are also available for T5000 printers:
PPI1 and PPI2 Interpreters: PPI1 (Zebra) and PPI2 (TEC)
interpreters are powerful integration tools that allow the T5000e to
function in virtually all legacy ZPL and TEC application environments
without requiring modifications to the host data stream. PPI1 (Zebra)
enables you to print files formatted for Zebra printers to the Printronix
T5000e. PPI2 (TEC) prints files formatted for TEC printers to the
Printronix T5000e.
Fonts: A selection of fonts can be loaded from the host computer into
printer memory. Once loaded, these fonts are accessed in the same way
as the resident fonts. See Table 11 on page 216 for a list of optional fonts.
17
Memory Expansion (for non-IPDS printers only):

16MB DRAM SIMM (Single In-line Memory Module): Provides
additional memory to accommodate long label formats.
10MB Flash SIMM: Provides additional memory for forms, logos, and
fonts.
Heavy Duty Media Cutter: Automatically cuts up to 0.010 thick printed
tag stock as the media exits the printer. Available for 4, 6, and 8 inch
printers.
Standard Duty Media Cutter: Automatically cuts up to 0.008 thick
printed tag stock as the media exits the printer. Available for 4 inch
printers only.
Media Tray: Used with the media cutter option to catch and collect cut
media.
Peel-Off Mode: Used with the optional label rewinder to peel off labels
one at a time, before printing the next label.
Batch Rewind Mode: Used with optional label rewinder to wind printed
labels into a removable roll.
Internal Label Rewinder: In label peel-off mode, prints and peels off
labels one at a time before printing the next label and rewinds the liner
into a discardable roll. In batch rewind mode, rewinds printed labels into a
removable roll up to 5 inches maximum diameter.
Twinax/Coax Host Interface: Provides connection to a host computer
system using a coaxial or twinaxial interface.
Dual NIC (10/100BaseT & 802.11b wireless): The Dual NIC (Network
Interface Card) provides both 10/100BaseT or 802.11b wireless
connectivity in one. The card provides wireless connectivity without the
expansive cabling and reconfigurations required from a wired network. It
also provides 10/100BaseT for wired network and wireless back up. The
remote management software, a powerful printer management tool, is
standard with the Dual NIC (10/100Base T & 802.11b wireless).
NIC (10/100BaseT) Internal or External: The NIC 10/100BaseT
connectivity option provides wired networks in either an internal or
external option that allows you to attach the printer to a LAN (Local Area
Network) instead of directly to a host computer. The remote management
software is standard with this option.
IPDS: Available for coax/twinax, a NIC, or a combination of both. The
printer may be ordered with this option installed and the required
hardware to support it, or it can be field installed by an authorized service
representative at a later date. The printer must have a coax/twinax
interface or NIC, 300 dpi printhead, 16 MB DRAM, and 10 MB flash
memory installed to support this field-installed option.
TN5250/TN3270: Enables your printer to communicate with an IBM host
through a NIC using the 5250/3270 datastream. This feature allows you
to use an application generated for the twinax/coax emulation to be
printed through the NIC.
18
Thermal Printer Media
Online Data Validator: Analyzes each bar code to ensure it meets

stringent scanning standards. This 100-percent inspection, commenced
immediately after the label is printed, validates the symbology
specifications of both linear and PDF417 bar code images. Bad bar code
labels are cancelled and good replacement labels are printed
automatically.
Power Cart: The Power Cart is an ergonomically designed cart with a
durable steel frame and battery support systems for maximum
maneuverability. The combination of the wireless T5000e and the rugged
Power Cart delivers a mobile on demand bar code printing system.
Thermal Printer Media

Because there are two modes of operation, there are two kinds of thermal
printer paper:
Direct thermal paper: This paper is coated with chemicals that act as
accelerators, ink, and ink binders. In direct thermal mode, the heat from
the thermal printhead contacts the paper and causes a chemical reaction
on the surface of the paper.
Thermal transfer paper: This film or synthetic paper substitute is
designed to accept transferred images well and to resist scratching. Most
thermal transfer papers can be die-cut for easy label applications.
Printronix offers a selection of thermal transfer paper sizes and face
stocks, which ensures high print quality and long life when used with
Printronix ribbons.
Ribbons
Use only Printronix Genuine Thermal Ribbons in this printer. Printronix
thermal ribbons are engineered to enhance thermal printing capabilities and
to prevent premature wear of the printhead.
Thermal Printer Technology

Unlike a dot matrix, laser, or LED printhead printer, a thermal printer has a
printhead containing heating elements that are used with paper or a ribbon
specially designed for use with a heated printhead. The T5000 printer uses an
inline thermal printhead, which produces high resolution output quickly and
efficiently. The architecture of the T5000 is shown in Figure 1.
The Printing Process

The thermal printhead allows two modes of operation:
Direct Thermal Mode: The thermal printhead selectively heats tiny
rectangular dots on its surface. When the heated dots contact specially
coated thermal paper, the dyes and developers in the coating react to the
heat and develop an image. This mode of printing is often used for short-
term labeling applications.
19
Thermal Transfer Mode: The heated dots contact a thermal ribbon; the
thermal ribbon reacts to the heat by bonding the image to the paper. This
method is especially suitable for print applications requiring long-term
storage, abrasion resistance, durability in extreme environmental
conditions, and resistance to tampering. (Models designated -DT do not
print in this mode.)
Dynamic Print Control

Print quality in thermal printers depends on how well the thermal ribbon and
thermal transfer paper respond to the heat of the thermal printhead. The
thermal printhead must reach a specific temperature to print, then must cool
down in the shortest possible time after printing. Print quality therefore
depends on precise control of the energy supplied to the thermal dots. If
uneven print density occurs, it is usually caused by the stored heat from dots
printed previously.
The T5000 printer uses Dynamic Print Control technology to ensure even
print density. Dynamic Print Control is printer software that monitors and
adjusts printhead temperatures. Based on stored results of previously printed
dots, the printer predicts the amount of heat required to print subsequent dots
and regulates the electrical energy applied to the printhead. This prevents
uneven print density and permits the printing of narrow-ladder bar codes and
vertical grid lines that are absolutely straight.
20
Thermal Printer Technology
Media Sensor,
Single Media Sensor
Models Only
Cutter
P2 J2 J1 P1 P301
PCBA Option
J301
Validator Option Control

Panel
P13 P9 P11 P18

J13 J9 J11 J18
Cutter Option
J21 P21
Serial J38 J33 J12 P12

J2 Port J P
Flash DRAM 1 1 Upper Media
DB25 SIMM SIMM 5 5
Diagnostic Port P8, Ribbon Sensor
J16
DB9 16 Supply
Controller
Expansion Port Motor
J3 J14 P14 Stepper
J4
Motor
P10
Head Up
J10
Sensor
Ribbon
P8, Take-up
J112 J8 Label
16 Motor
P112 Taken
J6 J5 J17 Sensor
J203 P6 P5 P17
Parallel Lower Media
Port Sensor
P401
Expansion-CT
Option J401
P403 Thermal
CN403 Print
AC Power P402 Head
Line 1 J201
Line 2/neutral Fan Power Supply J402
Ground (green/
yellow wire)
Ethernet NIC Wireless Dual

Option NIC Option
Figure 1. Functional Block Diagram, Dual Media Sensor Models
21
Cutter
J1 P1 P301
PCBA Option
J301

Panel
P13 P9 P11 P18

J13 J9 J11 J18
Cutter Option

J2 Port Flash DRAM
DB25 SIMM SIMM
Diagnostic Port P8, Ribbon
J16
DB9 16 Supply
Controller
Expansion Port Motor
J3 J14 P14 Stepper
J4
Motor
P10
Head Up
J10
Sensor
Ribbon
P8, Take-up
J112 J8 Label
16 Motor
P112 Taken
J6 J5 J17 Sensor
J203 P6 P5 P17
Parallel Media
Port Sensor
P401
Expansion-CT
Option J401
P403 Thermal
CN403 Print
AC Power P402 Head
Line 1 J201
Ground (green/
yellow wire)

Option NIC Option
Figure 2. Functional Block Diagram, Single Media Sensor Models
22
Control Panel
Controls And Indicators

Control Panel
Most of the controls and indicators for the printer are on the control panel at
the top left of the printer. The control panel contains an LCD and the control
keys shown in Figure 3. The functions of the keys are summarized on the
following pages.
NOTE: Two control panel overlays are available: the international overlay
uses graphic symbols to indicate key function, the English language
overlay adds English labels to the blue keys, as shown in Figure 3.
The overlays are otherwise identical.
Online Status
Indicator
OFFLINE
Liquid Crystal
Display (LCD)
Job In Process
Indicator
Figure 3. Control Panel
23
24
Function in Online Function in Offline Function in Menu
Chapter
Indicator Description
Mode Mode Mode
1
Online Status Indicates when the Stays lit when the Off when the printer is Off.
printer is online, offline, printer is online, ready offline.
or when there is a fault to print, and accept
condition. data from the host.
Flashes during a fault Flashes during a fault Flashes during a fault

condition. condition. condition.
Liquid Crystal A backlit Liquid Crystal Displays ONLINE, Displays OFFLINE. Displays OFFLINE
Display (LCD) Display (LCD) with two the interface type, and and a main menu,
rows of 16 characters emulation in use. submenu, or option.
each.
During a fault During a fault During a fault
condition, displays the condition, displays the condition, displays the
specific fault message specific fault message specific fault message
and the corrective and the corrective and the corrective
Status and Display Indicators
action. action. action.
Job In Process Indicates when the Flashes when Flashes when None
printer is receiving or receiving data. receiving data.
processing data.
Stays lit when data has Stays lit when data has
been processed and is been processed and is
waiting to be printed. waiting to be printed.
Off when no data is Off when no data is

being received or when being received or when
no data remains in the no data remains in the
buffer. buffer.
Button Description
Mode Mode Mode
PAUSE Key Sets printer to Offline Sets printer to Online Sets printer to Offline
Toggles the printer between Mode. Mode. Mode.
online and offline modes.
JOB SELECT Key None Selects a pre-stored Scrolls left through

printer configuration. main menus.
DECREMENT Key in Decrements option

- Menu mode values within
submenus.
Control Panel Keys
FEED Key Advances the media Advances the media

one label length. one label length.
Scrolls the current

UP Key in Menu mode
menu selection one
level up.
TEST PRINT Key None Scrolls through the Scrolls right through
Pressing the (ENTER) key Test Print patterns. main menus.
with a Diagnostic Test displayed
initiates the test. Pressing the
(ENTER) key again terminates
the test.
INCREMENT Key in Increments option

+ Menu mode values within
submenus.
25
Control Panel
26
Button Description
Mode Mode Mode
Chapter
CANCEL Key Clears all data in the Clears all data in the
1
When the CANCEL key is enabled, printer data buffer printer data buffer
pressing it will clear all data in the when enabled. when enabled.
printer buffer and prevent printing of
that data.
Note: The factory default is Disable.
However, when the Coax/Twinax
interface option is installed, the
factory default is Enable.
DOWN Key in Menu mode Scrolls the current

menu selection one
level down.
MENU Key Takes the printer Selects the Menu Scrolls between main
Offline and selects the mode. menu selections.
Menu mode.
Control Panel Keys (continued)
ENTER Key None None Selects the current

Pressing the (ENTER) key in menu value and
Menu mode selects the displayed displays an asterisk
option or value. An asterisk (*) then (*) next to the value.
appears next to the option or value
indicating it has been selected.
Note: If the ENTER key is locked,
ENTER SWITCH LOCKED
displays on the LCD for one second.
Press the (DOWN) and
(ENTER) keys at the same time to
unlock the ENTER key and select
an option or value.
Plugging In The Printer
Plugging In The Printer

In compliance with international safety standards, this printer is equipped with
a three-pronged electrical plug on the power cord. When this power cord is
plugged into a correctly wired power outlet, the ground conductor ensures that
the printer chassis is at ground (earth) electrical potential.
WARNING Failure to properly ground the printer can result in electrical shock to
the operator.
Do NOT use adapter plugs or remove the grounding prong from the power
cable plug. If an extension cord is required, make sure it is a three-wire cable
with a properly grounded plug.
Power Switch
IMPORTANT After powering off the printer, always wait at least two seconds before
powering it back on.
The power switch is a rocker switch located on the bottom back panel of the
printer. To apply power, rotate the switch to the | (ON) position. When you first
power on the printer, a series of initialization messages will appear on the
control panel LCD. To remove power, rotate the power switch to the O (OFF)
position.
Operating Modes
The operating mode is selected with control panel keys or results from certain
operations, such as powering on the printer.
There are four operating modes:
Online The printer is ready to receive data and will immediately print
data sent from the host. Pressing the PAUSE key toggles the
printer between online and offline modes. The ONLINE status
indicator is lit when the printer is in online mode.
Offline Communication with the host computer is suspended so you can
load media, navigate through the printer configuration menus to
make changes or verify option settings, or do other operator
tasks. Pressing the PAUSE key toggles the printer between
online and offline modes. The ONLINE status indicator is off
when the printer is in offline mode.
Menu Pressing the MENU key takes the printer offline and into Menu
mode. In this mode you can navigate through all configuration
and status menus and change printer configuration.
Fault A fault condition exists that must be cleared before printing can
continue. The ONLINE status indicator flashes, the alarm beeps if
configured to do so, and a fault message displays.
27
Chapter 1 Controls And Indicators
28
2 Preventive Maintenance
Cleaning The Printer

The T5000 thermal printer is a simple, reliable device, designed to require
very little maintenance. Aside from the normal replenishment of print media
and ribbons, the only preventive maintenance required is periodic cleaning
and inspection for damage.
Because operating conditions vary widely, the user must determine how often
to clean the printer.
Since there is no guarantee that the user will clean the printer regularly, you
should clean it whenever you are called to service it.
Depending on the media used, the printer may accumulate residues (media
dust, adhesives, etc.) as a by-product of normal printing. To maintain top
printing quality, you should remove these residues by cleaning the printer
periodically.
CAUTION Do not use abrasive cleaners.

Do not drip liquid into the printer. Damage to the equipment will result.
Do not spray directly onto the printer if you use spray solutions. Spray a
cloth, then apply the dampened cloth to the printer.
Exterior
Clean the exterior surfaces with a clean, lint-free cloth. If necessary, use a
mild detergent or desktop cleaning solution.
NOTE: Do not use abrasive cleaning agents or solvents.
Interior
Clean the interior of the printer by removing any dirt and lint with a soft-
bristled, non-metallic brush. Use a vacuum cleaner to remove the residue.
General Cleaning
Periodically clean all rollers, guides, and assemblies. Use low pressure air to
remove dust in the printer. Use isopropyl alcohol and a cotton swab to clean
any areas where media dust, adhesives, etc. have accumulated.
29
Chapter 2 Cleaning The Printer
Cleaning The Printhead, Platen Roller And Media

Sensors
NOTE: You do not need to turn off the printer before cleaning the printhead,
platen roller, or media sensors.
Printhead Cleaning
As you use your printer, the printhead may become dirty which can result in
poor print quality. Clean the printhead each time you install new ribbon
(thermal transfer print mode) or install new media (direct thermal print mode).
Clean the printhead with the cleaning pen supplied with the printer.
By keeping your printhead clean, you will help maintain its life.
Platen Roller Cleaning

Media dust and adhesive residue on the platen roller can degrade print quality
and cause voids in your label image. Clean the platen roller at the same time
as the printhead.
Use a small amount of isopropyl alcohol on a cloth to clean the platen roller.
With the pivoting deck up the platen roller can be rotated forward by hand to
access and clean its entire surface area.
Media Sensor Cleaning

The upper and lower media sensors should be cleaned to ensure reliable
TOF and Paper Out sensing. Clean the media sensors at the same time as
the printhead.
The upper media sensor (located in the horizontal slot of the printhead cover)
can be wiped clean using a soft cloth. The lower media sensor, easily seen by
its visible red light, is located in the horizontal slot of the media guard.
Remove media dust by vacuuming or blowing air across the lens cover.
Media Damper Cleaning

The media damper (see Figure 26, page 168) and media width guide can
begin to collect adhesive and paper dust residue that can prevent proper
guiding of labels.
Use a small amount of isopropyl alcohol on a cloth to remove label adhesive
and dust from the underside of the media damper and its fixed (inbound)
guide and from the adjustable (outbound) width guide.
30
Cleaning The Printhead, Platen Roller And Media Sensors
Printhead Pivoting
Heating Deck
Elements
Peel/Tear Door
Lower Media
Sensor
(with visible
red LED)
Printhead Cover/
Upper Media Sensor Deck Lock
Lever
Platen Roller
A
Printhead
Heating
Elements
Upper
Media
Sensor
1. Rotate the deck lock lever clockwise to open the pivoting deck and
remove any media and ribbon (if loaded) to gain access to the printhead
assembly heating element area.
2. Gently rub the felt tip of the cleaning pen or a cotton swab with isopropyl
alcohol across the printhead heating elements (light brown area).
3. Allow the printhead to dry for one minute before reloading the media and
ribbon.
4. Clean the platen roller.
5. Clean the upper and lower media sensors.
31
Chapter 2 Printer Inspection
Printer Inspection
After cleaning the printer, inspect all wear items and electromechanical
components, as outlined below.
1. Remove the frame side cover (page 107).
2. Inspect the EMI clips on the frame side cover for damage. Replace any
clip that is damaged or missing. (Figure 23, page 158.)
3. Inspect the platen belt and the rewinder belt for cracks, cuts, fraying, and
wear. (Figure 24, page 162.) Replace any damaged or worn belt.
4. Inspect the ribbon drive gears and intermediate gears for cracks, chipped
or missing teeth. (Figure 25 on page 166 and Figure 35 on page 196.)
Replace any damaged gear.
5. Inspect all cable assemblies and electrical cords for cracks, cuts, fraying,
or exposed conductors. Replace any damaged or worn cables.
6. Install the frame side cover.
7. Open the media cover.
8. Inspect the ball studs for tightness and tighten as required. (Figure 23,
page 158.)
9. Open and close the media cover, checking that the dashpot holds the
cover open and that the cover closes completely. Adjust as required.
Replace the dashpot if it is damaged or does not hold the cover open.
(Figure 23, page 158.)
NOTE: On four inch printers the lower dashpot mounting bracket may have
slotted mounting holes. In such cases, if the dashpot does not hold
the cover open, you can loosen the bracket mounting screws, move
the bracket up, and retighten the screws.
10. Check that the media hanger guide assembly operates correctly and the
spring is not broken. Replace if damaged. (Figure 23, page 158.)
11. Inspect the ribbon spindles, rewinder, and media damper for damage and
smooth operation. (Figure 25, page 166.) Replace a damaged spindle or
bail.
12. Inspect the printhead and platen assemblies for obvious damage.
(Figure 27, page 170.) Replace damaged assemblies.
13. Inspect the media sensor assembly (single media sensor models) or
assemblies (dual media sensor models) for paper dust, sufficient
horizontal travel, smooth horizontal movement, and damaged or frayed
ribbon cable.
14. Restore the printer to operation (page 94).
32
3 Troubleshooting
Introduction
This chapter lists fault messages and symptoms, and gives procedures for
troubleshooting printer malfunctions.
You must operate the printer to check its performance and you may have to
reconfigure it. This manual does not cover printer operation or configuration,
so always have the Users Manual handy when you troubleshoot.
What You Should Know About Print Quality

The print quality of a thermal printer is affected most by the amount of heat
applied by the printhead to the media and by the location of the printhead in
relation to the print media.
Low-cost direct thermal media often have very high reaction temperatures,
which means that it takes a great deal of heat to make a clear image. Resin
ribbons and film media may also require higher print intensity for a quality
image.
You can increase the heat applied by the printhead in three ways:
1. Set the Print Intensity configuration parameter to a higher numerical
value with a command from the host computer or by accessing the
MEDIA CONTROL menu with the control panel. (Refer to Configuring
the Printer in the Users Manual.) This causes more heat to be
transferred to the print media, thus generating a darker image.
2. Run the printer slower.
3. Do both 1 and 2.
IMPORTANT Keep the printhead clean. Foreign material on the printhead interferes
with heat transfer. If smears, voids, or white lines appear on printed
forms, clean the printhead (page 30).
How To Maximize Printhead Life

1. Remind the customer to clean the printhead with a cleaning pen after
each roll of ribbon (thermal transfer) or media roll (direct thermal). The
cleaning pen (P/N 203502-001) will last for eight printhead cleanings.
Refer to the Users Guide.
33
Chapter 3 Introduction
2. Avoid excessive printhead pressure, usually indicated by white wear

spots on the printhead element. Reduce the pressure until you see print
quality problems, then increase the pressure slightly until you have good
print quality.
3. Avoid excessively high Intensity settings. Intensity is the burn
temperature that the printhead operates at. Lower temperatures will
increase the life of printheads. Reduce the Intensity setting until you see
print quality problems, then increase the setting slightly until you have
good print quality.
4. Clean and inspect the platen roller for excessive wear (light print) and
gouges (repeating voids).
5. Customer responsibilities: configuration, printhead installation, and
preventative maintenance. Refer to the Users Guide.
Troubleshooting At A Glance
Start Here.......................................................................................... page 35
How To Troubleshoot........................................................................ page 36
Troubleshooting Display Messages .................................................. page 38
Troubleshooting Other Symptoms .................................................... page 72
Troubleshooting A New Installation................................................... page 91
34
Troubleshooting At A Glance
Start Here
Are you here because of an Go to Troubleshooting

error message? YES Display Messages,
NO page 38.
Power on the printer and

observe the control panel for
the following sequence of
events (retry as required):
1. TESTING HARDWARE
PLEASE WAIT appears on
display.
2. DIAGNOSTICS PASSED
appears on display.
3. LOADING FONTS FROM
FLASH appears on display.
4. Printer goes ONLINE or
OFFLINE, depending on
users configuration. Make a configuration Is this a newly
Did steps 1 through 4 occur? YES printout. (Refer to YES installed printer? YES
the Users Manual.)
NO Does machine NO
configuration print?
NO
IML was
successful. Other
symptoms are
Go to LCD message listed in Table 3,
display is illuminated page 73.
and the printer
appears to be Go to
working, but nothing Troubleshooting
is printed, page 75. A New
Installation,
page 91.
Is the control panel display Is there a faint Go to Printer does not

backlit? YES horizontal bar on the YES initialize, the display is
NO display? backlit and a faint
horizontal bar appears on
NO the top line. No message
displays, page 76.
Go to Printer fails to turn 1. Power down, remove

on, the display is not frame side cover, and
backlit, and the fan is not reseat control panel cable.
running, page 76. 2. Replace control panel
and cable.
3. Troubleshoot using Half-
Split Method outlined on
page 36.
35
Chapter 3 How To Troubleshoot
How To Troubleshoot
You will be more successful in troubleshooting printer problems if you use
standard fault isolation techniques, which are summarized below:
1. Ask the operator to describe the problem.
2. Verify the fault by running a diagnostic printer test or by replicating the
conditions reported by the user.
3. Look for a matching message or symptom in Table 2 on page 39 or
Table 3 on page 73. If you find a match, follow the troubleshooting
instructions.
4. If you cannot find the symptom in either troubleshooting table, use the
Half-Split Method to find the malfunction:
a. Start at a general level and work down to details.
b. Isolate faults to half the remaining system at a time, until the final half
is a field-replaceable part or assembly.
WARNING ALWAYS disconnect the AC power cord from the printer or the power
outlet before doing any maintenance procedure. Failure to remove
power could result in injury to you or damage to equipment. If you must
apply power during maintenance, you will be instructed to do so in the
maintenance procedure.
5. Replace the defective part or assembly. Do not attempt field repairs of
electronic components or assemblies. Most electronic problems are
corrected by replacing the printed circuit board assembly, sensor, or
cable that causes the fault indication.
6. Test printer operation after every corrective action. (See Printer Self-
Tests And How To Verify Printer Operation below.)
7. Install any parts you replaced earlier that did not solve the problem.
8. Stop troubleshooting and return the printer to normal operation when the
reported symptoms disappear.
36
Printer Self-Tests And How To Verify Printer Operation
Printer Self-Tests And How To Verify Printer Operation

The printer automatically performs a sequence of self-tests when it is
powered on. If the self-test software detects a fault, an error message
displays on the LCD.
Always verify printer operation before returning it to normal operation:
1. Access the Print Mode option in the QUICK SETUP or MEDIA CONTROL
menu and make sure the printer is set for the type of print media installed.
(Refer to Configuring the Printer in the Users Manual.)
a. Direct indicates direct thermal printing, which uses no ribbon and
requires heat-sensitive media.
b. Transfer indicates thermal transfer printing, which requires a ribbon.
2. Access the printer test patterns in one of two ways:
a. Select the Printer Tests option under the DIAGNOSTICS menu.
Press + or to cycle through the different tests.
OR
b. Press PAUSE to take the printer offline. Then press TEST PRINT to
cycle through the different tests.
Press (ENTER) to print one of the test patterns, described below.
Printer Tests
This menu item selects the test pattern to be printed. Use these patterns to
check the print quality and operation of the printer.
Auto Calibrate: Senses paperout, gap, notch, hole, or mark, and
calibrates the printer for the currently installed media.
Checkerboard: Prints a pattern that helps identify marginal printhead
elements, quality of edge sharpness, and uneven print quality.
Grey: Prints a pattern that helps identify burned out printhead elements
and uneven print quality.
Grid: Prints a pattern that helps identify edge sharpness and uneven print
quality.
Current Config: Prints the current printer configuration and helps identify
the text print quality.
Left Test: Prints a pattern containing a series of ladder-type bar code
symbols, starting with four and decrementing by one symbol on each print
until a single symbol prints on the left side. This pattern helps identify
ribbon wrinkle problems.
Right Test: Prints a pattern containing a series of ladder-type bar code
symbols, starting with four and decrementing by one symbol on each print
until a single symbol prints on the right side. This pattern helps identify
ribbon wrinkle problems.
E-Net Test Page: Prints the ethernet statistics stored on the NIC. This
menu item appears only if the NIC is installed.
37
Chapter 3 Troubleshooting Display Messages
Barcode Demo: Prints one demo page containing some text and two
good bar codes (Code 39 and Code 128) positioned at the left and right
margins of the label media. The test automatically produces output for 4,
6, and 8 inch printers at 203 and 300 dpi.
NOTE: The Barcode Demo will stop automatically. This demo uses the Label
Length and Label Width settings to adjust the page automatically.
Valid. Report: Prints a report of the validation statistics since the printer
was turned on or since the last data reset. (This item appears only if the
validator is installed.)
When you have selected the desired test pattern, press (ENTER) to begin
printing the pattern. In the case of the Checkerboard, Grey, and Grid test
patterns, the number of times the pattern repeats is determined by the setting
of the Test Count menu item. If the Test Count menu item is set at
Continuous, you can stop printing by pressing again.
Troubleshooting Display Messages

The printer uses built-in test equipment to monitor its operation and the
condition of the print media. Various messages display indicating the status of
the printer and media stock levels. Three kinds of messages can appear on
the LCD:
Status messages
Configuration menus and menu options
Fault messages
Most fault messages are cleared from the LCD by correcting the fault
condition and then pressing the PAUSE key. Fault messages that can only be
cleared by shutting down and restarting the printer are indicated by an
asterisk (*) appended to the message.
When printer logic detects a fault condition, three things happen:
The status indicator on top of the printer flashes on and off.
The audible alarm beeps if it has been enabled in the PRINTER
COUNTROL menu. Press PAUSE to silence the alarm.
The control panel LCD displays a fault message.
38
List Of Messages
List Of Messages
Find the message in the Message List below and follow the suggested
procedure.
After correcting an error, press the PAUSE key to erase the message and put
the printer in the offline mode. If an error is not cleared, the printer will try to
print again but will display the error message until the error is cleared.
Table 2. Message List
Message Explanation Solution
I I I I I I I I I I I I I I I I 1. The Flash SIMM (Single 1. Install the Flash SIMM.

In-line Memory Module) is
2. If the message reappears,
not installed.
OR replace the Flash SIMM
2. The Flash SIMM has with a new Flash SIMM.
I
corrupt boot code. 3. Download the latest level of
I
software.
replace the control panel
and cable.
replace the controller
PCBA. Write down the
message and return it with
the defective board.
Proceed to the next step.
6. Download the latest level of
software.
06 HOST REQUEST Status message in the CT Not a printer problem.

emulation: the host computer or
print controller requires
attention.
08 HOLD PRINT Status message in the CT Press PAUSE to put the printer
TIMEOUT emulation: the printer was online.
offline more than 10 minutes
and the Intervention Required
parameter is set to Send to
Host.
39
15 COMM CHECK Communication message that 1. Reseat the twinax host data
appears in the CT emulation cable connection and the
and means the line is not active twinax I/O cable connection
on a twinax interface. at the expansion-CT board,
and then press PAUSE to
clear the message.
2. Disconnect the twinax auto-
termination (Smart T)
cable from the printer. Test
the cable for these
resistances:
Pin 1 - 2 = 110
Pin 3 - 4 = 110
Pin 1, 2, 3, 4 - Shield = 55
Pin 5 - Shield = 0
Pin 14 - 1, 4 = 0
Pin 7 - 2, 3 = 0
If resistances are not
correct, replace the twinax
auto-termination cable.
3. Power on the printer. Send
a print job to the printer. If
the message reappears,
replace the Flash SIMM.
4. Power on the printer. Send
a print job to the printer.
Verify that all other devices
are working properly. (Refer
to line problem
determination procedures,
as recommended by the
host system.) If the
message is gone, the host
has reestablished
communication with the
printer. If all other twinax
devices work properly and
the message still appears,
replace the expansion-CT
board. Write down the
22 INVALID ADDR Invalid address: poll time-out on Have the system administrator
the twinax interface, indicating make sure the printer address
the unit address is not is correct.
recognized by the printer.
40
List Of Messages
27 CU TIMED OUT Controller Unit Timed Out: Poll Check cable connection and
time-out error. The printer was host system. (Refer to line
not polled for one minute across problem determination
a coax interface. procedures, as recommended
by the host system.)
28 CU NOT ENAB Controller Unit Not Enabled: Check cable connection and
The printer was not enabled for host system. (Refer to line
one minute or more on a coax problem determination
interface. procedures, as recommended
by the host system.)
33 HEAD OPEN Status message in the CT Close and latch the pivoting
TIMEOUT emulation: the printer was deck. Press PAUSE to put the
offline more than 10 minutes printer online.
and the Intervention Required
parameter is set to Send to
Host.
40V POWER FAIL +40VDC Power Failed: an 1. Power off the printer.
internal power failure. Remove the side frame
cover. Check that the power
NOTE: The power supply
supply cable is fully seated
delivers +24VDC and
in connector J17 on the
+40VDC. The controller
controller board.
PCBA uses the
+24VDC to develop 2. Using a voltmeter, test
+5VDC and +3.3VDC between TP4 GND and TP1
for its logic circuits. +40VDC (+35 to +45VDC).
If the voltage is not in this
range, unplug the ribbon
motors and stepper motor
one at a time and cycle
power each time. If the
message persists, replace
the power supply assembly.
3. Power on the printer. If the
message reappears,
203 DPI Head Installed Normal power-up message. No action required.

The printer is running its
initialization routine and
indicating the DPI resolution of
the installed printhead.
41
300 DPI Head Installed Normal power-up message. No action required.

The printer is running its
initialization routine and
indicating the DPI resolution of
the installed printhead.
BAD VFU CHANNEL The user tried to use an Use defined channels.
undefined VFU channel.
Bar Code Improper Data validation error: the bar Fix the application so it sends
Data Format code is not properly encoded. data in the correct bar code
For example, a check sum is format.
incorrect, a required number of
characters is not met, or the
required terminator characters
are not included. This problem
is almost always caused by
incorrect form or host
application design.
Bar code quiet Data validation error: the blank 1. Fix the application.
zone too small zone(s) left or right of the bar
2. Disable Quiet Zone in the
code is not big enough to meet
VALIDATOR menu.
the minimum requirement.
Typically, this occurs in forms
where bar codes are placed too
close to other elements, the bar
code is too close to an edge of
the media, or the medias
position is shifting.
The minimum quiet zone on
each end of the bar code should
be ten times the minimum
element width or 1/4 inch,
whichever is greater. In
addition, between bar codes,
the validator requires a
minimum distance of 20 times
the minimum element width or
1/2 inch, whichever is greater.
42
List Of Messages
This is the High Volt Alert that 1. Raise the value in the High
BATT HIGH VOLT can be set by the user (factory Volt Alert option in the
default = 16.0 Volts). This fault BATTERY CONTROL
detection is only supported menu.
when the ICP (Intelligent 2. If High Volt Alert = 16.0
Control Panel) option is Volts and fault message
connected to the printer serial remains, call your
port and Battery Monitor = authorized service center.
Enable in the BATTERY
CONTROL menu.
This is the Low Volt Alert that 1. Plug the power cart cable
BATT LOW VOLT can be set by the user (factory into an AC receptacle to
default = 8.5 Volts). This fault recharge the battery.
detection is only supported 2. If recharging the battery
when the ICP (Intelligent fails to clear the fault,
Control Panel) option is replace the battery or
connected to the printer serial batteries.
port and Battery Monitor =
Enable in the BATTERY NOTE: Follow the battery
CONTROL menu. manufacturers safety
precautions when
installing a new battery.
BUFFER OVERFLOW The host computer sent data Make a configuration printout.
through a serial interface after Verify that the printer matches
the printer buffer was full. the host serial interface
configuration settings for Data
Protocol, Baud Rate, Data Bits,
Stop Bits, Parity, Data Terminal
Ready, and Request to Send.
Set printer serial interface
parameters to match those of
the host.
BUFFER OVERRUN The print buffer has overflowed 1. Make a configuration
on a serial interface. printout. Verify that the
printer matches the host
serial interface
configuration settings for
Data Protocol, Baud Rate,
Data Bits, Stop Bits, Parity,
Data Terminal Ready, and
Request to Send.
2. Send a print job to the
printer. If the message
reappears, go to
Communications
Failures, page 88.
43
Calibration The validator has detected that Press PAUSE to clear the
warning it needs calibration. This message. Calibrate the
message is a reminder and validator. See Calibration on
does not halt printing. page 295.
CANNOT CALIBRATE Run Calibrate procedure was 1. Select another Media
Disable Peel-Off attempted with Peel-Off Media Handling option in the
Handling selected. QUICK SETUP or MEDIA
CONTROL menu.
NOTE: You can perform Auto
Calibrate in Peel-Off 2. Enable Cal in Peel Mode in
mode if Cal in Peel the CALIBRATE CTRL
Mode = Enable. Be menu.
prepared to catch
NOTE: Admin User must =
labels during the
Enable.
calibrate procedure.
Checksum Failure The bar code data fails the Verify that the checksum digit
checksum check or is missing exists in the bar code and that it
the checksum digit. is the correct value.
CLEARING PROGRAM The program successfully No action required.

FROM FLASH loaded into printer RAM and the
checksum matched. The old
program is now being deleted
from flash memory.
Contrast too low Data validation error: the Increase Print Intensity or
Check media contrast between bars and reduce Print Speed in the
spaces is not sufficient. This QUICK SETUP menu or via
can be caused by too little heat host software, change media, or
in the thermal transfer or by use disable Symbol Contrast in the
of colored media or ribbons. VALIDATOR menu.
44
List Of Messages
CUTTER FAULT 1. The cutter option was not 1. Clear obstructions from the
Jam or Cut Fail able to complete a full cut cutter assembly.
cycle due to a jam. 2. Check that the thickness of
2. The cutter PCBA detected the media does not exceed
current overload and 0.01 inch (0.254 mm).
opened circuit breaker on
3. Wait a few minutes for the
the cutter PCBA.
cutter circuit breaker to
3. The cutter is open (in the automatically reset. Press
down position). PAUSE to clear the fault
message and resume
4. On a later model cutter, the
printing.
upper cutter enclosure is
not installed. 4. Make sure the cutter
assembly is closed and
locked in the operating
position with the upper
cutter enclosure installed.
5. Make sure the two interlock
switches are enabled and
not damaged. If damaged,
replace the cutter
assembly.
6. Replace the cutter driver
PCBA.
DEACTIVATING Normal message that displays No action required.

HOST SERIAL when you set Validator Funct. =
Enable in the VALIDATOR
menu or Battery Monitor =
Enable in the BATTERY
CONTROL menu.
DIAGNOSTICS The printer passed its memory No action required.

PASSED and hardware initialization tests.
DIRECT THERMAL This is the normal reminder 1. Remove ribbon from the
Remove Ribbon message when you change the ribbon supply and ribbon
Print Mode setting from take-up spindles in the
Transfer to Direct in the QUICK printer.
SETUP or MEDIA CONTROL
2. If ribbon is required for
menu.
printing, change the Print
Mode back to Transfer.
DO NOT POWER OFF This is a standard warning Do not power off the printer until
message that displays while the downloading is complete.
printer is downloading software.
45
DOWNLOADING TO Normal message when the No action required.

VALIDATOR printer is downloading NOTE: The validator software
emulation software with a update can be verified
validator option installed. in the F/W Revision
NOTE: Many software builds menu option of the
contain updates to the VALIDATOR menu.
validator option. It displays as:
Version: X305.
E-NET INIT The NIC is initializing. No action required.
E-NET READY The NIC has finished initializing. No action required.
E-NET RESET The NIC is being reset. No action required.
EC SOFTWARE FAIL* The printer cannot find the 1. Cycle power: power down
See Manual engine controller program or the the printer, wait 15
validation checksum is corrupt. seconds, then power the
printer on. If the message
reappears, go to the next
step.
2. Download the emulation. If
ENTER to Stop 1. A diagnostic test pattern 1. This is a normal message.
has been selected and is Press the (ENTER) key to
running. stop printing the test
pattern.
2. A diagnostic test pattern is
selected, but will not print. 2. Remove the frame side
Peel-Off or Tear-Off Media panel. Make sure the label
Handling method is taken sensor cable is
selected. connected to J18 on the
controller board.
ERROR: DC PROGRAM The printer cannot find the data 1. Download the emulation
NOT VALID controller program or the software again.
validation checksum is 2. If the message reappears,
corrupted. replace the Flash SIMM.
46
List Of Messages
ERROR: DRAM AT The printer found a defective 1. Reseat or replace DRAM

ADDRESS XXXXXXXX memory location. SIMM at J33.
2. Replace Controller PCBA.
Write down the message
and return it with the
defective board.
ERROR: FLASH The printer encountered an 1. Download the emulation

DID NOT PROGRAM error trying to program flash software again.
memory.
ERROR: IPDS needs The printer has detected a 203 Power off the printer and
300 DPI Head! DPI printhead installed, with replace the 203 DPI printhead
IPDS software downloaded. with a 300 DPI printhead.
NOTE: IPDS software supports
only the 300 DPI
printhead.
ERROR: NO DRAM The printer could not find any Reseat or replace the DRAM
DETECTED DRAM. SIMM at J33. If the message
reappears, replace the
controller PCBA. Write down
the message and return it with
ERROR: PROGRAM The printer requires more 1. Install a 16MB DRAM SIMM
NEEDS MORE DRAM DRAM memory in order to run at J33.
the downloaded program.
47
ERROR: PROGRAM The printer requires more flash 1. Install a 10 MB Flash SIMM
NEEDS MORE FLASH memory in order to run the at J38.
downloaded program. 2. If the message reappears,
ERROR: PROGRAM The printer is not compatible Use the correct emulation
NOT COMPATIBLE with the downloaded program. software option(s) for this model
printer.
ERROR: PROGRAM The printer does not see a There is no program in printer
NOT VALID program in flash memory. memory. Download the program
again.
ERROR: SECURITY PAL The security PAL is not present 1. Check the security PAL at
NOT DETECTED or has failed. U7 on the Controller PCBA.
If the PAL is absent, install
correct PAL. If the correct
security PAL is present,
replace the security PAL.
ERROR: SHORT AT Hardware failure in DRAM or 1. Replace the DRAM SIMM

ADDRESS XXXX main PCBA controller circuitry. at J33.
2. If the message appears
with the new DRAM,
48
List Of Messages
ERROR: WRITING Hardware or software fault in 1. Download the emulation

TO FLASH flash memory. software again.
ERROR: WRONG The printer received the 1. Download the emulation

CHECKSUM complete program but the software again. If the
checksum did not match. The message reappears,
data were corrupted during replace the DRAM SIMM.
download.
2. Download the program
using a new software CD.
If the message reappears,
ERROR OCCURRED An interim message that Wait. When the asterisk (*)
FLUSHING QUEUES* displays while the printer stops rotating, a different fault
discards host data it cannot use message will appear;
because a fault condition exists. troubleshoot the final message.
While this message displays, (This message can also appear
the asterisk (*) rotates. if the printer does not have
enough flash memory.)
49
The printer detected that the 1. Verify that the fan rotates
FAN WARNING power supply fan did not rotate when the printer is first
for at least a 45 second period powered up and when the
when it is was supposed to. printer moves media or
NOTE: This is a warning prints.
message and will not 2. Ensure that the fan cable is
halt printing. When too properly connected to
high of internal JP401 on the power supply
temperature is PCBA.
detected, the printer will 3. Verify that the correct
stop printing and power supply is installed in
display PWR SUPPLY the printer. A power supply
HOT, PRINTER HOT, with the fan at the back of
or PRINT HEAD HOT, the printer cannot be used
based on the source. in a ventless model printer.
4. Replace the power supply
fan.
5. Replace the power supply.
6. Replace the controller
PCBA.
FILE EXISTS The printer operator tried to Enter the PRINTER CONTROL
Enable Overwrite save a file using the name of an menu and enable the Overwrite
existing stored file. Files feature to overwrite an
existing file. (Refer to the Users
Manual.)
FILE SYS FULL There is not enough flash Install a larger Flash SIMM and
Add Flash memory to store a file. download the emulation
software again.
FILE SYS FULL There is not enough flash Enter the PRINTER CONTROL
Delete Files memory to store the file. menu. Use the Delete Files
selection to delete unwanted
files. (Refer to the Users
Manual.)
FILE SYS FULL There is no flash memory left in Enter the PRINTER CONTROL
Optimize & Reboot which to store files. menu and use the Optimize &
Reboot feature. (Refer to the
Users Manual.)
50
List Of Messages
FILE SYS INVALID The file system was not 1. Install the Flash SIMM that
Optimize & Reboot detected. The flash memory was removed.
was corrupted or the Flash 2. Enter the PRINTER
SIMM was removed. CONTROL menu and use
the Optimize & Reboot
feature. (Refer to the Users
Manual.)
FILE SYS WRITE Problem writing to flash 1. Reseat Flash SIMM at J38.
Check Flash memory.
FPGA FILE The program file was not 1. Download the program file
NOT FOUND downloaded successfully. again.
FRAMING ERROR Serial framing error over a serial Match the serial interface
interface. settings of the printer to those of
the host computer.
51
GAP NOT DETECTED The printer is set for Gap or 1. If the customer is not using
Check Media Mark sensing, but a gap, mark, die-cut labels, set the
or notch is not being detected. Gap/Mark Sensor to
This can occur if: Disable in the QUICK
1. Media with no gap or black SETUP or CALIBRATE
mark is installed, and Gap CTRL menu.
or Mark is selected in the 2. Inspect the horizontal
CALIBRATE CTRL menu. position of the media
2. The media sensor is not sensor. Check the paper
horizontally positioned path. Clean the sensor
relative to the gap, notch, assembly.
hole, or black mark on the 3. Position the upper sensor
media, or the media width directly over the lower
guide is not set correctly, sensor if the customer is
causing the media to be using either Advanced Gap
misaligned. or Advanced Notch with
later model printers.
3. If Advanced Gap or
Advanced Notch is selected 4.
on later model printers in a. Do the Auto Calibrate
the CALIBRATE CTRL procedure. (Refer to the
menu, the upper media Users Manual.) This
sensor may not be procedure improves the
positioned over the lower ability of the sensor to
media sensor. detect the type of
media in use. Save
4. An Auto Calibrate was not
your calibration after
performed using the
you calibrate.
installed media. There is
not enough contrast b. Run a Profile Printout
between the label and liner. from the CALIBRATE
CTRL menu to obtain a
visual indication
regarding the contrast
difference between the
label and the gap,
notch, or mark.
c. If the Gap Threshold is
too high or the Paper
Out Threshold is too
low the sensor may not
detect the gap. Lower
the Gap Threshold or
raise the Paper Out
Threshold value. (Refer
to the Users Manual.)
52
List Of Messages
GAP NOT DETECTED d. Make sure the media

Check Media sensor cable has a
good connection to J12
(single media sensor
models) or J15 and J21
(dual media sensor
models) on the
controller board.
e. Verify that the media is
within the specification
of the printer. Refer to
the Users Manual.
f. Replace the media
sensor(s).
GRF CHK ERROR In the CT emulation over a Press PAUSE twice.

PRESS PAUSE twinax interface, the printer
received a non-printable
character.
The printhead or power supply 1. Allow printer to continue

Half Speed Mode is approaching a hot state. Half printing. Full speed will
Speed Mode aids the cooling resume automatically when
process and should permit a lower printhead or power
completion of print jobs. supply temperature is
achieved.
Half Speed Mode helps prevent
a PRINT HEAD HOT or PWR 2. Let the printer cool down.
SUPPLY HOT fault, which will Full speed will be restored
stop the printer. when printing is resumed.
3. Lower Print Intensity and
Print Speed to reduce
frequency of Half Speed
Mode.
53
HEAD POWER FAIL The printhead lost power. 1. Check the connection of the
Call For Service phone-style power supply
control cable at J5 on the
controller PCBA and
CN403 on the power
supply. Disconnect the
power supply control cable
and check continuity.
Replace the cable if it fails
continuity test.
2. Check connections of other
cables going from the
controller board to the
power supply. Reseat all
cables. Replace damaged
cables.
3. If printing in Direct Thermal
mode (i.e., no ribbon),
check the voltage between
TP4 GND and TP1
+40VDC (+35 to +45VDC)
on the controller board. If
voltage is out of tolerance,
replace the power supply
assembly.
4. Power on the printer. If the
message reappears,
IGP/PGL ERROR Appears when the Fault option 1. Clear the IGP/PGL error.
is selected from Error Report on 2. Deselect Fault from Error
the control panel. Report on the control panel.
INSUFFICIENT RAM There is not enough RAM 1. Install a larger DRAM SIMM
Reboot/Add RAM available for certain printer at J33.
functions or emulations.
54
List Of Messages
LABEL MISSING The Label Taken Sensor did not 1. Press PAUSE to continue
Check Paper Path detect the label present over printing and then wait for
the tear bar with Tear-Off or the Remove Label
Peel-Off Media Handling mode message to display before
enabled. removing the label.
1. The label was removed 2. Open the pivoting deck,
before the printer stopped reinstall the label, close the
printing or before the deck, press PAUSE and
Remove Label message continue printing.
was displayed. 3. Open the pivoting deck and
2. The label slipped behind remove wrapped labels
the platen roller. from the platen. Clean all
adhesive from the platen.
3. The label wrapped around
Reinstall labels, close the
the platen roller.
deck, press PAUSE and
4. Tear-Off or Peel-Off Media continue printing.
Handling mode was
4. Select the correct Media
mistakenly selected.
Handling mode in the
QUICK SETUP menu.
LOADING PROGRAM The new program is loading into No action required.

FROM PORT XX% printer RAM. XX indicates how
much of the program has
loaded.
LOADING PROGRAM The printer has deleted the No action required.

INTO FLASH previous program from flash
memory and is loading the new
program into flash memory.
MENU MODE Normal message that displays No action required.

QUICK SETUP when you first press the MENU
key to place the printer in Menu
mode.
NON VOLATILE The printer assigns a certain 1. If the message appears at

MEMORY FAILED amount of simulated NVRAM power-up, replace the Flash
for storage of saved SIMM.
configurations. Large 2. If the message appears
emulations reduce the amount while saving a
of space available for saving configuration, the printer is
configurations, which means out of memory and will not
that sometimes fewer than 8 save the current or
configurations can be saved. If subsequent configurations.
this message appears at power- (Previously saved
up, it means the Flash SIMM is configurations remain
defective. available.)
55
OPTION NOT 1. A cutter option must be 1. Check that the cutter option
INSTALLED installed and in the up is installed, connected, in
(operating) position with the the up position, and the
upper enclosure installed upper enclosure properly
when the printer is powered installed before powering
on for the controller to on the printer.
detect it. 2. Install the cutter option or
2. The media cutter option change to the correct Media
was not detected. The RJ11 Handling selection in the
plug from the cutter QUICK SETUP or MEDIA
assembly to the cutter CONTROL menu.
PCBA in the bottom-left 3. Check the cable from the
front opening of the frame is cutter assembly to the
disconnected. cutter PCBA. Reconnect
3. Cut Media Handling in the the cable to J1 on the cutter
MEDIA CONTROL menu driver PCBA.
was accidentally selected.
4. Remove the frame side
cover and check the cable
from cutter PCBA to the
controller PCBA.
Reconnect the cable to J9
on the controller PCBA.
56
List Of Messages
PAPER OUT The printer does not detect print 1. Verify that the media is
Load Paper media. This message is usually within the specification of
caused by a break in the media, the printer. Refer to the
the media has run out, or the Users Manual.
media is not routed correctly. 2. Install new media. If a break
NOTE: When the printer is first occurred, reinstall the
powered up with no media. Press PAUSE to
media installed, it will clear the fault. Ensure that
not detect Paper Out the pivoting deck is
until an attempt is made completely closed. Clean
to move media (i.e., the sensor assembly.
paper feed or slew). 3. Verify that the media is
installed correctly. Verify
that the media sensor is
horizontally positioned
under the media.
4. On a later model, ventless
printer, if the printer is
powered on and the lower
media sensor is not emitting
a red light, an older version
of software may have been
downloaded to the printer
that is not compatible with
the newer hardware.
Download the latest level of
software.
5. The media sensor(s) may
need to be calibrated.
Do the Auto Calibrate
procedure to improve the
ability of the sensor(s) to
detect the media in use.
6. Check if the Gap Threshold
is too high or the Paper Out
Threshold is too low. Lower
the Gap Threshold or raise
Paper Out Threshold value.
(Refer to the Users
Manual.).
57
PAPER OUT 7. If the printer detected a

Load Paper false PAPER OUT when
changing from Advanced
Gap or Advanced Notch to
Gap or Mark sensing or
vice-versa, press PAUSE
and run Auto Calibrate
8. Make sure the media
sensor cable has a good
connection to J12 (single
media sensor models) or
J15 and J21 (dual media
sensor models) on the
controller board.
9. Replace the media
sensor(s).
PAPER OUT In the CT emulation with a coax Load media and print a
TIMEOUT interface, a time-out message is diagnostic test pattern
sent to the host if paper is not (page 37). If the message
loaded within 10 minutes after reappears, replace the
PAUSE was pressed to clear a controller PCBA. Write down
paper out fault. the message and return it with
PARITY ERROR The printed output may contain 1. Make a configuration

random ? (question mark) printout. Verify that the
characters. printer matches host serial
configuration settings for
Data Protocol, Baud Rate,
Data Bits, Stop Bits, Parity,
Data Terminal Ready, and
Request to Send. Set
printer serial interface
parameters to match those
of the host.
serial data cable.
reappears, go to
Communications
Failures, page 88.
58
List Of Messages
Poor scanning Data validation failure: 1. Adjust Print Intensity and

Check heat&head decodeability. The difference Print Speed in the QUICK
between wide and narrow SETUP menu or via host
elements is too close for the software.
validator to reliably discern. 2. Adjust the printhead
This usually indicates an pressure. (Refer to the
improperly set heat/speed/ Quick Setup Guide or
pressure combination or the Users Manual.)
loss of a printhead element.
Poor scanning Data validation failure: percent 1. Check for a wrinkled ribbon
Check media decode. The validator detected or debris on media. Roll
gross inconsistencies within the wrinkled area onto take-up
height of the bar code. These spindle.
types of failures are likely 2. Adjust the printhead
attributed to large blemishes pressure blocks. (Refer to
within the bar code, caused by the Quick Setup Guide or
ribbon wrinkle or debris on Users Manual.)
media.
Poor scanning Data validation failure: 1. Check that paper and

Inspect head hardware defect. The validator ribbon are clean,
detected unexpected dark spots unwrinkled, and installed
in spaces or light spots in bars. correctly.
This usually indicates a poor
2. Clean the printhead.
ribbon/media combination, a
dirty printhead, or a burned 3. If message reappears,
pixel. replace the printhead.
POWER LOSS SAVED The printer has detected a low 1. Using a voltmeter, test
NON-VOLATILE RAM voltage level for +24VDC and between TP4 GND and TP2
has saved the printer +24VDC (+22 to +26VDC).
configuration values to NVRAM. If the voltage is not in
tolerance, power off the
printer and check the power
supply cables to the
controller PCBA for shorts,
opens, and clean, tight
connections.
2. Cycle power. If the
messages reappears,
assembly.
message reappears,
59
POWER SAVER MODE The printer is in a low-energy No action required.

idle state. The fan, printhead,
and all motors are off, only the
+5 VDC logic circuits are active.
POWER SUPPLY VOLT* The power supply has failed. 1. Make sure the power
supply voltage matches that
of the source power outlet.
message reappears, check
power supply cables for
shorts, opens, and clean,
tight connection.
message reappears,
replace the power supply.
message reappears,
PRINT HEAD COLD 1. The Printhead/Controller 1. Make sure the printhead/

See Manual cable assembly is controller cable assembly is
disconnected. connected to J401 at the
printhead and J6 on the
2. The environment is too cold
controller PCBA.
for the printhead to sustain
operating temperature. 2. Move the printer to a
warmer location.
60
List Of Messages
PRINT HEAD HOT The printhead is close to 1. Allow the printhead to cool
See Manual overheating. This fault causes for five minutes, then press
the printer to stop printing and PAUSE. Resume printing.
prevents permanent damage to 2. A dirty printhead can inhibit
the printhead. heat dissipation. Clean the
printhead.
3. Printhead Print Intensity
may be set too high for the
media being used. In the
QUICK SETUP or MEDIA
CONTROL menu, reduce
the Print Intensity value.
(Refer to the Users
Manual.) (Print Intensity
can also be set too high by
software sent from the host
computer.)
message reappears, load
the emulation software
again. (See Appendix B.)
message reappears,
replace the printhead.
PRINT HEAD UP 1. The pivoting deck is not 1. Close and latch the pivoting
Close Print Head closed and latched deck.
completely.
2. Make sure the head up
2. Head up sensor cable is sensor cable has a good
disconnected from the connection to J11 on the
controller PCBA. controller PCBA.
3. The head up sensor is bad. 3. Replace the head up
sensor assembly.
61
PRINTER HOT The printer has detected higher 1. Print jobs do not create
See Manual than usual temperatures on the such temperatures. Make
controller PCBA. sure the fan works during
the power on sequence and
This fault can only by cleared by
that the fan and all air vents
powering the printer off, waiting
(on vented models) are
a few minutes, and then
unobstructed.
powering the printer back on.
2. Inspect the printer
environment for severity.
The printer must not be
operated in ambient
temperatures higher than
40 Celsius (104
Fahrenheit). If the printer is
located in such an
environment, relocate it to a
cooler, cleaner area.
4. Remove the power supply
and check continuity
between connector P17, pin
8, and the power supply.
This is the FAN NEG line. If
there is no continuity,
replace the power supply.
5. Power the printer off for five
minutes. If the message
reappears after the printer
is powered back on, replace
the controller PCBA. Write
down the message and
return it with the defective
board.
PRINTER UNDER The remote management Press any key on the printer.
REMOTE CONTROL software has control of the
printer.
62
List Of Messages
PWR SUPPLY HOT The power supply is operating 1. Make sure the fan works
See Manual at higher than normal and that all air vents are
temperatures. This fault causes unobstructed (vented
the printer to stop printing. models).
NOTE: The power supply fan 2. If you have a ventless rear
will operate during any panel, verify that the tab on
media motion (feeding, the panel is not interfering
slewing, or printing) and with the fan on the power
for a short period during supply. If it is, order the
printer power up. correct power supply for a
ventless printer.
3. Make sure the fan is
connected to JP401 on the
power supply.
4. Inspect the printer
environment for severity.
The printer must not be
operated in ambient
temperatures higher than
40 Celsius (104
Fahrenheit). If the printer is
located in such an
environment, relocate it to a
cooler, cleaner area.
5. If the fan is operating and
assembly.
63
RBN TAKEUP FULL 1. The ribbon take-up spindle 1. If this message is briefly
Remove Used Rbn is full. flashing on the display while
2. The printer is falsely continuing to move media
detecting a take-up full back and forth, see
state. General Symptom List
RIBBON on page 87.
3. False detection in Direct
2. Discard the ribbon on the
Thermal mode.
take-up spindle. Attach the
unused ribbon to a new
cardboard core.
3. In Direct Thermal mode
(i.e., no ribbon), check the
stepper motor connection at
J14 on the controller PCBA.
4. If the take-up spindle is not
full:
a. Check that the
printhead pressure dial
is set to 4 or higher.
b. Verify that the ribbon is
not rubbing on the
frame.
c. Very slick media may
cause an inaccurate
take-up spindle
diameter detection
during ribbon calibrate
(when the pivoting deck
is opened then closed).
Increase head
pressure. If no print
quality problems exist,
you can disable Rbn
Takeup Full in the
MEDIA CONTROL
menu.
d. Power off the printer
and verify that the take-
up spindle rotates freely
with no binding.
e. If binding exists,
remove the side cover
and check the gear
train.
64
List Of Messages
RBN TAKEUP FULL f. Verify that the ribbon

Remove Used Rbn take-up motor is
connected to J8 on the
controller board.
g. Replace the ribbon
take-up motor.
REACTIVATING Normal message that displays No action required.

HOST SERIAL when you set Validator Funct. =
Disable in the VALIDATOR
menu or Battery Monitor =
Disable in the BATTERY
CONTROL menu.
This is the Time To Go Alert the 1. Plug the power cart cable
RECHARGE BATTERY user can set (factory default = into an AC receptacle to
1.0 Hour). This fault detection is recharge the battery.
only supported when the ICP 2. If recharging the battery
(Intelligent Control Panel) fails to clear the fault,
option is connected to the replace the battery or
printer serial port and Battery batteries.
Monitor = Enable in the
BATTERY CONTROL menu.
1. A label was detected at the 1. Remove the label from the
Remove Label front of the printer by the front of the printer to allow
label taken sensor. This is the next label to print.
the normal reminder
2. Verify that a front door
message when Peel-Off or
assembly is installed on the
Tear-Off Media Handling
printer and that it is properly
has been selected.
closed. Ensure that no
2. A label was removed, but debris is obstructing the
the Remove Label door mirror or the Label
message remained. Taken Sensor. Verify that
the Label Taken Sensor is
3. The incorrect Media
connected to J18 on the
Handling method is
Controller PCBA. Replace
selected.
the Label Taken Sensor.
3. In the QUICK SETUP or
MEDIA CONTROL menu,
change Media Handling to
the correct selection.
65
RESETTING The printer finished loading the No action required.

PLEASE WAIT program into flash memory and
is automatically resetting itself.
RESTORING Normal download initialization No action required.
BOOT CODE message.
RFID MAX RETRY Error Handling = Overstrike in Press PAUSE to clear the
Check System the RFID CONTROL menu, and message.
the Label Retry count has been See Troubleshooting on
exhausted. page 336.
RFID Comm Err RFID error: communication Press PAUSE to clear the
Check Cable cannot be established with the message.
RFID encoder. Reader will be See Troubleshooting on
set to Disable in the RFID page 336.
CONTROL menu and the
previous port settings restored.
RFID TAG FAILED Error Handling = Stop in the Press PAUSE to clear the
Check Media RFID CONTROL menu, and the message.
RFID encoder could not read See Troubleshooting on
the RFID tag. page 336.
RIBBON BROKEN 1. The ribbon is broken 1. Reattach the ribbon to the

Reload Ribbon between the ribbon take-up ribbon take-up spindle.
spindle and the printhead.
2. Check the ribbon loading
2. If the ribbon is not broken, it instructions and reload the
may be routed incorrectly. ribbon.
3. The ribbon is not installed. 3. Install the ribbon.
4. Inspect the intermediate
and final ribbon drive gears
for correct engagement and
broken teeth. Replace any
gear that is damaged.
RIBBON DETECTED This is a user help message. Remove the ribbon from the
Remove Ribbon The printer senses a ribbon, but printer if Direct Thermal media
the Print Mode is set for Direct is to be used. Change the Print
printing, where no ribbon is Mode from Direct to Transfer if
required. Thermal Transfer printing is to
be used (ribbon required).
66
List Of Messages
RIBBON FAULT In the CT emulation with a coax 1. Clean the printer.

TIMEOUT interface, the ribbon has not 2. Power on the printer. Install
moved for 10 minutes after media. Print a diagnostic
PAUSE was pressed to clear a test pattern (page 37). If a
ribbon fault. fault message reappears,
The ribbon supply spindle is 1. Replace the ribbon.
Ribbon Low getting low.
2. Change the Ribbon Low
NOTE: This message is a value in the MEDIA
reminder that will not CONTROL menu to a lower
prevent or halt printing value.
operation.
3. Disable Ribbon Low in the
MEDIA CONTROL menu.
RIBBON OUT 1. The ribbon supply spindle is 1. Install the ribbon.
Load Ribbon empty.
2. Route the ribbon through
2. The ribbon is broken the ribbon path and attach it
between the ribbon supply to the take-up core.
spindle and the printhead.
3. Make sure the ribbon
3. If the ribbon is installed and supply motor is connected
not broken, the ribbon to J16 on the controller
supply motor may not be PCBA.
connected to J16 on the 4. Power off the printer.
controller PCBA. Rotate the ribbon supply
4. The ribbon supply drive spindle manually and check
gears may be binding or for binding. If binding
have broken teeth. occurs, check intermediate
and final drive gears for
5. The ribbon supply motor
damage. Replace as
may be bad.
necessary.
5. Temporarily connect the
ribbon supply motor to J8
on the controller (the ribbon
take-up motor connection)
and check motor tension
and rotation. If the take-up
motor operates but the
supply motor does not,
replace the ribbon supply
motor.
67
SECURITY CODE The software running or being Install the correct PAL at U7 or
VIOLATION downloaded does not match the use the correct emulation
security PAL code. program. (PAL and program
must match.)
SELECT DOWNLOAD Normal message when the 1. Complete the downloading
PORT=XXXXXXXXXX printer is being setup for software procedure. See
downloading software using the Downloading Software
serial or parallel port. PORT= Through the Serial or
displays selected serial port and Parallel Port on page 210.
parameters or Centronics port. 2. Exit this procedure by
cycling printer power.
Signal Data validation error: the 1. Dim the ambient lighting.

Clipping validator cannot read clearly
2. Replace the validator.
because either the ambient light
is too bright or there is a
hardware failure inside the
validator itself.
SOFTWARE ERROR* Application software tried to 1. Cycle power. If the

Recycle Power perform an illegal printer message reappears, power
function or damaged logic off the printer.
circuits were detected on the 2. Disconnect the input data
controller PCBA. cable from the host
computer. Power on the
reappears, download the
emulation software again.
3. Cycle power. Run the print
job again. If the message
controller PCBA. Write
down the message and
return it with the defective
board.
If the message does not
appear, there is an
application software error.
Request assistance from
your local support group.
68
List Of Messages
Speed Exceeds Print Speed is set above 6 IPS Change Print Speed in the
Validator Limit as the Power-Up configuration QUICK SETUP menu or via
with the validator option host software to 6 IPS or less
installed. An attempt was made when using the validator option
to set Print Speed above 6 IPS and save the new value as the
in the QUICK SETUP menu or Power-Up configuration in the
via host software. CONFIG CTRL menu.
TCP Port Busy Error message reported by the Change the Diagnostics Port
remote management software setting to Debug Ethernet:
when the NIC is installed. The 1. Power on the printer.
network address given in the
printer properties was reached, 2. If the printer is online, press
but the diagnostics port is busy. PAUSE to take the printer
When the Diagnostics Port offline.
setting is Serial, the remote 3. On the control panel, press
management software cannot the and keys at the
interact with the NIC, even same time to unlock the
though the NIC will respond to key.
other TCP/IP utilities.
4. Press +, , , and at the
same time to enter the
Factory Menu.
5. Press until Diagnostic
Port displays.
6. Press + until Debug
Ethernet displays.
7. Press to select it.
8. Press and at the same
time to lock the key.
9. Press PAUSE twice to put
the printer back online.
10. Save the changes and set
up a new power-up
configuration, if necessary.
The remote management
software should now be
able to access the printer.
For other communication
errors, print out the E-Net
Test Page (page 37) and
verify the IP Address,
Netmask, Gateway, and
TCP Port settings.
69
Test Page An attempt was made to print Replace the dual NIC wireless
Not Available an E-Net test page. The dual interface.
NIC wireless interface may be
defective.
TESTING HARDWARE Normal message at power-up. 1. No action required.
PLEASE WAIT The printer is running its
2. If the printer does not
initialization routines.
complete initialization and
continues displaying this
message when the CT
emulation software is
installed, the expansion-CT
board may not be
connected to the controller
PCBA.
Unscannable code Data validation error: missing 1. Check that paper and
check media bar code. An expected bar code ribbon are clean,
is missing or was printed so unwrinkled, and installed
poorly that the validator cannot correctly.
detect it.
2. Run a print job and check
that the validator beam is
not obstructed; remove
obstructions as necessary.
that the READ LED flashes
as bar codes exit the
printer. If the READ LED
does not flash, cycle power
and run the job again. If the
READ LED does not flash,
inspect the cables and the
cable connections. If the
cables are undamaged and
the connections are good,
replace the validator.
Validator not 1. The Validator Funct. = 1. Check that the validator

communicating Enable in the VALIDATOR signal cable is securely
menu, but when the printer connected to the validator
was first powered up it unit.
could not communicate with
2. Select Validator Funct. =
it.
Disable in the VALIDATOR
2. The validator was menu. Save this setting in
connected to the printer and the Power-Up configuration
then later removed. in the CONFIG CTRL menu
and reboot the printer.
70
List Of Messages
WAITING FOR Normal message when the 1. Complete the downloading

PROGRAM DOWNLOAD printer is powered up while software procedure. See
holding down both the ... and Downloading Software on
keys in preparation to page 209.
download software to the 2. Exit this procedure by
printer. cycling printer power.
WIRELESS ADAPTER The type of wireless card is The PCMCIA radio card that
NOT COMPATIBLE incompatible with the printer you installed may be
software. incompatible with the dual NIC
wireless interface in the printer.
Verify the approved brand and
model number of the radio card
with your printer service
representative and install the
correct version. If using the
correct radio card does not
resolve this problem, call your
service representative for
further support.
71
Chapter 3 Troubleshooting Other Symptoms
Troubleshooting Other Symptoms

Use standard fault isolation techniques to troubleshoot malfunctions not
indicated by display messages. These techniques are summarized below:
1. Ask the operator to describe the problem.
2. Verify the fault by running a diagnostic printer test or by replicating
conditions reported by the user.
3. Look for a match in the General Symptom List below. If you find a
match, follow the instructions.
4. If you cannot find the symptom in the General Symptom List, use the
Half-Split Method to find the malfunction:
a. Start at a general level and work down to details.
b. Isolate faults to half the remaining system at a time, until the final half
is a field-replaceable part or assembly.
WARNING Always disconnect the AC power cord from the printer or the power
outlet before doing a maintenance procedure. Failure to remove power
could result in injury to you or damage to equipment. If you must apply
power during maintenance, you will be instructed to do so in the
5. Replace the defective part or assembly. Do not attempt field repairs of
electronic components or assemblies. Most electronic problems are
corrected by replacing the circuit board, sensor, or cable that causes the
fault indication.
6. Test printer operation after every corrective action.
7. Reinstall any parts you replaced earlier that did not solve the problem.
8. Stop troubleshooting and return the printer to normal operation when the
reported symptoms disappear.
General Symptom List

Table 3, beginning on page 73, is a list of possible printer problems that are
not indicated by messages on the LCD. Troubleshooting procedures are
included with each symptom.
If you encounter a problem that is not listed in Table 3, troubleshoot using the
Half-Split Method described above.
72
Table 3. General Symptom List
Symptom Solution
COMMUNICATIONS FAILURES
Printer hangs during print job. 1. Redownload the latest level of software (page 209).
2. Refer to Table 4 on page 89.
Fails to print from host. See Table 4 on page 89.
Prints incorrect characters. See Table 4 on page 89.
Prints extra characters. See Table 4 on page 89.
Drops characters. See Table 4 on page 89.

Data loss. See Table 4 on page 89.
Cannot ping (NIC). See Table 4 on page 89.
Cannot print (NIC). See Table 4 on page 89.

Host cannot communicate Refer to the Network Interface Card Users Manual.
with the printer when
connected to AS/400 via
TCP/IP with the NIC installed.
NIC responds to ping and 1. Open a telnet session using the IP address of the NIC.
telnet utilities, and can print
2. Enter these commands:
from ftp, but NIC can not be
config http
accessed by a browser.
save
reset
3. Wait up to two minutes for the NIC to complete a reset
cycle.
4. Close the telnet session.
You should now be able to access the NIC through a
browser by using the IP address as a URL, e.g., http://
xxx.xxx.xxx.xxx.
If the NIC can not be accessed by the remote management
software, do the steps listed under TCP Port Busy on
page 69.
73
Symptom Solution
Cannot access the printer If the ethernet port is not enabled under the Debug menu, the
through the remote following message will appear in the Status and Error Log
management software (NIC). when you try to connect to a printer:
The network address given in the printer properties was
reached, but the printer port is busy. This may occur when
another user is accessing the same printer, or when another
logical printer is connected to the same address.
To solve the problem, the Debug Ethernet option must be
enabled to allow the remote management software to establish
a connection with the NIC:
1. Ensure a successful ping can be performed.
2. On the printer control panel, press PAUSE to take the
printer offline.
3. Press and at the same time to unlock the key.
4. Press +, , , and at the same time to enter the Factory
menu.
5. Press until Diagnostic Port displays.
6. Press + until Debug Ethernet displays. If Debug Ethernet
is already marked with an asterisk (*), continue with
step 8.
7. Press to select it.
8. Press and at the same time to lock the key.
9. Press PAUSE twice to put the printer back online.
The remote management software will now establish a
connection with the NIC.
NIC responds to ping, telnet, 1. Open a telnet session using the IP address of the NIC.
and ftp utilities, but will not 2. Enter these commands:
communicate from the host start fox prn
computer. stop prn
3. If the fox test prints, the host computer is not configured
properly.
74
Symptom Solution
CONTROL PANEL
Black squares on the control 1. Install the Flash SIMM.

panel display. 2. If the message reappears, replace the Flash SIMM with a
Flash SIMM that has working boot code.
3. Redownload software (page 209).
Control panel keys do not A wire is broken or a pin is not making contact in the control
work, but printer prints in panel cable assembly. Replace the control panel cable
ONLINE mode. assembly.
LCD message display is 1. Verify that the labels are the correct type (direct thermal).
illuminated and the printer 2. Check that the media is loaded with the direct thermal side
appears to be working, but facing up.
nothing is printed.
3. Check that the transfer ribbon is correctly routed. Route
transfer ribbon with ink side out.
4. Check that the printhead assembly is properly closed by
pressing down on both sides of the pivoting deck. Make
sure the latches on each side of the pivoting deck are
locked.
5. Verify that the ribbon and media are compatible;
incompatibility can cause extremely light printing. Match
the ribbon to the type of media being used.
6. Check that the Print Intensity is correct. Set the Print
Intensity in the QUICK SETUP or MEDIA CONTROL
menu.
7. Check that the Label Width parameter value does not
exceed the width of the media installed. Set the Label
Width in the QUICK SETUP or MEDIA CONTROL menu.
LCD is backlit, no messages A wire is broken or a pin is not making contact in the control
display, and a faint horizontal panel cable assembly. Replace the control panel cable
line appears on the display. assembly.
LCD is not backlit and control A wire is broken or a pin is not making contact in the control
panel keys do not work. panel cable assembly. Replace the control panel cable
assembly.
ONLINE status indicator is 1. Check for Out-of-Media condition or missing labels in the
flashing. middle of a roll. Load correct media.
2. Check that the ribbon and label stock are correctly routed.
Load ribbon and label stock correctly.
3. Make sure the Print Mode settings (Direct or Transfer) are
correctly selected in the QUICK SETUP or MEDIA
CONTROL menu.
75
Symptom Solution
POWER FAILURES
Printer fails to turn on, the 1. Check that printer AC power cord is correctly attached to
display is not backlit, and the the printer and to the AC power outlet.
fan is not running. 2. Test AC wall outlet for correct power range. Place the
NOTE: The power supply printer in an area that has the correct power range.
delivers +24VDC and
3. Test the AC power cord for continuity. Replace a damaged
+40VDC. The
AC power cord or one that fails continuity test.
controller PCBA uses
the +24VDC to 4. Make sure the power supply cable is connected to J17 on
develop +5VDC and the controller PCBA.
+3.3VDC for its logic 5. Using a voltmeter, test between TP2 +24VDC (+22 to
circuits. +26VDC) and TP4 GND on the controller board. If voltage
is not in tolerance, replace the power supply assembly.
6. If +24VDC is good, check TP1 for +40VDC (+35 to
+45VDC). If voltage is not in tolerance, replace the power
supply assembly.
7. If +24VDC and +40VDC are good, test at TP3 VCC for
+5VDC (+4.75 to +5.25VDC). If voltage is not in tolerance
replace the controller PCBA.
8. If all voltages are good so far, test for +3.3VDC (+3.14 to
+3.47VDC) on the center lead of U23 on the controller
PCBA. If voltage is not in tolerance, replace the controller
PCBA.
9. If all voltages are good, replace the Flash SIMM.
Printer does not initialize, the 1. The Flash SIMM at J38 on the controller PCBA has a poor
display is backlit and a faint connection or is not installed. Reseat or install the Flash
horizontal bar appears on the SIMM as required.
top line. No message
2. Using a voltmeter, test for +3.3VDC (+3.14 to +3.47VDC)
displays. The power supply
between the center lead on U23 and TP4 GND on the
fan runs constantly.
controller board. If voltage is not in tolerance, check for
+5VDC (+4.75 to +5.25VDC) between the top lead of U23
and TP4 GND or between TP3 VCC and TP4 GND. If
+5VDC is in tolerance and +3.3VDC is not, replace the
controller PCBA.
3. If +5VDC is not in tolerance, test for +24VDC (+22 to
+26VDC) between TP2 +24VDC and TP4 GND. If
+24VDC is in tolerance, replace the controller PCBA.
76
Symptom Solution
PRINT QUALITY
Label(s) did not get 1. If the serial interface is being used, verify that the correct
printed within a multi label data protocol is selected to match the host interface
print job. protocol.
A portion of the printed 2. If Clip Page = Enable in the MEDIA CONTROL menu, the
image was clipped off printer may have falsely detected a gap, hole, or black
and the beginning of the mark and then clipped (discarded) the remaining printable
next label was printed on data for the label. To fix this:
the same physical label. a. Perform Auto Calibrate. Refer to Running Auto
Calibrate in the Users Manual.
b. Decrease Gap Threshold value by 2 or 3 increments.
Refer to Gap/Mark Thresh in the Users Manual.
c. Set Clip Page to Disable. Set Label Length to correct
physical length value. Refer to Clip Page in the
Users Manual.
Short printhead life. See How To Maximize Printhead Life on page 33.
Media moves, but no image 1. Print a checkerboard diagnostic test pattern (page 37). If
prints in ONLINE mode. the pattern prints, there is a communication problem
between the host computer and the printer.
2. Make sure the J402 power supply cable has a good
connection to the right side of the printhead.
Media moves, but no image 1. Print a checkerboard diagnostic test pattern (page 37).
prints in Direct Thermal Check the print quality.
mode.
2. Media is not the type for Direct Thermal printing. Install
Direct Thermal media.
3. Direct Thermal media is installed with the wrong side up.
Reinstall media.
4. Check that the Label Width value in the QUICK SETUP or
MEDIA CONTROL menu does not exceed the media width
installed.
5. Check that the Print Intensity value is not set too high in
the QUICK SETUP or MEDIA CONTROL menu.
locked.
7. The head pressure adjustment dial may be set too low.
Readjust.
8. The printhead pressure blocks are not positioned correctly
(horizontally). Refer to the Users Manual.
77
Symptom Solution
Media and ribbon move, but 1. Print a checkerboard diagnostic test pattern (page 37) and
no image prints in Thermal check if the image appears on the used portion of the
Transfer mode. ribbon. If the image is on the ribbon, the ribbon may be
installed with the transfer side against the printhead,
instead of against the media. Reinstall the ribbon.
2. The ribbon may be designed for another model printer.
3. Verify that the ribbon and media are compatible;
incompatibility can cause extremely light printing. Match
the ribbon to the type of media being used.
4. Check that the transfer ribbon is correctly routed. Route
the transfer ribbon with the ink side out.
locked.
6. Check that the Label Width parameter value does not
exceed the width of the media installed. Set the Label
Width in the QUICK SETUP or MEDIA CONTROL menu.
7. The head pressure adjustment dial may be set too low.
Readjust.
8. The Print Intensity value is set too low in the QUICK
SETUP or MEDIA CONTROL menu or by host software.
9. The printhead pressure blocks are not positioned correctly
(horizontally). Refer to the Users Manual.
When narrow media is Verify that the Label Width value in the QUICK SETUP or
installed, the media moves MEDIA CONTROL menu agrees with the width of the installed
but no image prints. media. Too large a value will start the image too far to the right
and off the media.
Printing is faded or poor in 1. Clean the printhead.

quality. 2. Check that the pivoting deck is closed and latched. Close
the printhead by pressing down on both sides of the
pivoting deck and rotating the deck lock lever fully
counterclockwise.
3. Verify that the head pressure adjustment dial is properly
set.
4. Verify that the QUICK SETUP or MEDIA CONTROL menu
Print Speed and Print Intensity values are correct. Adjust
Print Speed and Intensity in the QUICK SETUP or MEDIA
CONTROL menu or via the host software.
5. Refer to Thermal Printer Media and Thermal Printer
Technology on page 19.
78
Symptom Solution
Print is light on the left or right Check to see if the pressure blocks are set for the width of the
side of the label. media being used. Set each block near the edge of the media.
Prints strange characters 1. If the printer serial interface is being used, check that the
instead of the correct label printer serial baud rate setting matches the baud rate of
format. the host computer. Reset the printer via software, or cycle
power.
2. Check if the printer serial host interface is set for 8 data
bits but the transmitting device is set for 7 data bits (or
vice versa). Check the current setting by viewing it on the
LCD and use the SERIAL PORT menu to adjust the
settings if necessary. (Refer to the Users Manual.)
3. If the printer parallel interface is being used, make sure the
parallel interface terminating resistors are correct for the
host computer drivers.
4. See Table 4 on page 89.
Peel-Off or Tear-Off Media 1. Verify that Peel-Off or Tear-Off Media Handling is enabled
Handling is selected, but the in the QUICK SETUP or MEDIA CONTROL menu. Print a
printer does not pause after diagnostic test pattern using Peel-Off or Tear-Off mode to
each label is printed. The verify operation.
entire file prints, not allowing
2. Peel-Off or Tear-Off mode was selected at the control
peel-off or tear-off operation.
panel, but a host software command might have changed
the selection to another mode. Do step 1.
3. If the front cover is not fully closed, the label taken sensor
cannot detect labels. Close the cover and do step 1.
4. The mirror and label taken sensor are misaligned on the
front cover. Gently bend the mirror to correct the alignment
and do step 1.
5. Replace the label taken sensor.
Peel-Off or Tear-Off Media 1. The (ENTER) key was not pressed to start the test
Handling is selected, but pattern printout. The key starts and stops all test prints.
diagnostic test patterns will Press .
not print. 2. Remove the frame side cover and make sure the label
taken sensor cable is connected to J18 on the controller
board.
79
Symptom Solution
Start of image is printed 1. In the MEDIA CONTROL menu, set Clip Page to Disable.
an erroneous distance 2. Make sure the Label Length value matches the actual
from the top-of-form. physical length of the label installed.
The printer starts to print
3. In the QUICK SETUP or MEDIA CONTROL menu, set Ver
one label and then
Image Shift to a () negative value to bring the image
another, all within the
closer to the leading edge of the label or to a (+) positive
same physical label.
value to move the image further down the label away from
the leading edge.
These symptoms could be caused by:

severely curled labels near the end of a media roll
the media sensor triggering off of a dark, preprinted image
on the label
multiple gaps within the physical label.
Loss of one or more 1. If using coax or IPDS and Early Print Complete is either
serialized labels within a enabled or ON, respectively, the printer may be working as
print job. designed. Refer to the Users Manual for information on
Early Print Complete.
Start of image is printed
in the middle of the gap. 2. In the CALIBRATE CTRL menu, set Gap Windowing to
The top part of the image Enable.
is lost when printing with 3. Set Gap Length to equal the physical gap length of the
Head First orientation media installed. The range is 0.05 to 1.00 inches.
selected.
The likely cause of these symptoms is that Clip Page = Enable
and a cross-perforation, radical fold or flaw in the liner gap has
caused the media sensor to detect this as the leading edge
(TOF) of the new label or end of label (EOF), or both.
80
Symptom Solution
Smears or voids in printed 1. Dust on label stock from shipping, storage, or the core can
image. cause print voids. Clean the labels with compressed air, a
vacuum cleaner, or use static tinsel.
2. Atmospheric dust from long-term storage can also cause
print voids. Remove a few feet of label stock, exposing the
clean inner surface. When storing labels, cover them or
place them in plastic.
3. Skin oils can adhere to the surface of label stock, causing
fingerprints which inhibit thermal transfer. Wipe label stock
with a cloth or remove a few feet of labels to expose a
clean area. Handle labels by the edges.
4. Labels with a rough or uncoated surface can also print with
voids. Use smooth (coated) label stock or use a soft wax
for printing.
5. Oozing adhesive can cause print voids. This sometimes
happens with old label stock. Use new label stock.
6. Power off the printer and thoroughly clean the printhead
with a cleaning pen or isopropyl alcohol and a cotton swab.
7. Print the checkerboard and grey diagnostic test patterns
(page 37).
8. Verify that the head pressure blocks are positioned to
match the width of the media being used. (Refer to
printhead pressure adjustment in the Users Manual.)
9. Make sure the head pressure adjustment dial is set
correctly for the thickness of the media being used. (Refer
to the Users Manual.)
10. Make sure the printhead temperature (Print Intensity) is
not too high. Use software control to adjust the heat
setting. Change the Print Intensity value in the QUICK
SETUP or MEDIA CONTROL menu. (Refer to the Users
Manual.)
11. Check that the media has not been installed inside out.
Surfaces on both sides may look identical, but can
produce big differences in print quality.
12. Make sure the correct ribbon and media combination are
being used; install a new roll of ribbon and media and
repeat step 7. Use the correct ribbon type. Genuine
Printronix Supplies are highly recommended to ensure the
best possible print quality. (Refer to the Users Manual.)
13. Check the ribbon for creases or folds across its surface.
Smooth out the ribbon to remove any creases.
14. Check that the printhead pressure blocks are correctly
positioned. (Refer to the Users Manual.)
81
Symptom Solution
Smears or voids in printed 15. Reduce the Print Speed value through the QUICK SETUP
image (continued). or MEDIA CONTROL menu or via host software. (Refer to
the Users Manual.)
16. Power off the printer. Remove the printhead and inspect it
for contamination (adhesive material, ribbon and media
residue line buildup), wear, or damage. A worn printhead
will show obvious impressions or indentations in the light
brown heating element area where ribbon or media made
contact. A damaged printhead may have nicks, scratches,
grooves, or cracks. If no problem is visible, install the
printhead and repeat step 7.
17. Install an alternate printhead if one is available and repeat
step 7.
18. If possible, install the questionable printhead in another
printer and repeat step 7.
19. If the void areas in test print patterns remain in the same
location, replace the printhead.
Vertical line through printed 1. Power off the printer and thoroughly clean the printhead
image. with a cleaning pen or isopropyl alcohol and a cotton
swab.
2. If problem persists after cleaning the printhead, inspect the
printhead for damage and replace it if necessary.
82
Symptom Solution
PRINTER OPERATION
*** 053 Insufficient memory Install more DRAM.

to create the LOGO printed
on the media.
*** 055 LOGO call not Install more DRAM.

previously defined printed on
the media.
The printer loses its values for After performing a media calibration procedure, save the
Sensed Distance, Gap/Mark current configuration under the Config. Control menu. If the
Threshold, and Paper Out customer loads a different type of media, perform a calibration
Threshold after the printer is for the new media, or load a saved custom configuration for
powered on reset or reset by the specific media. Up to 8 custom configurations can be
the host system. This will created for different type of media and print jobs. Also, make
manifest itself as a loss in sure the Power-Up Config. is not set to Factory. (Refer to the
print format registration or Users Manual.)
possible PAPER OUT errors.
Advances several labels 1. Check that labels are loaded correctly. (Refer to the Users
when FEED key is pressed. Manual.)
2. Check that the Label Length selected under the QUICK
SETUP or MEDIA CONTROL menu or the Label Length
software command sent by the host computer agrees with
the length of the media installed. (Even though gapped or
black mark forms are used to establish top-of-form
position, a larger label length will override the gap or mark
and skip a label or labels if Clip Page = Disable in the
MEDIA CONTROL menu.) In the QUICK SETUP or
MEDIA CONTROL menu, set the Label Length to match
the actual length of media being used. (Refer to the Users
Manual.)
3. Enable the Clip Page menu option in the MEDIA
CONTROL menu. This will force the printer to constantly
look for the gap or black stripe and halt at the top-of-form
position.
4. Check that the printer is optimized to detect the type of
media installed. Perform the Run Calibrate procedure for
transmissive and reflective media. (Refer to the Users
Manual.)
5. Adjust the media sensor horizontally to detect the gap,
holes, notches, or narrow width black stripe. (Refer to the
Users Manual.)
6. If problem persists, replace the media sensor.
83
Symptom Solution
Print quality is good, but 1. Make sure that the image is not formatted too close to the
the printer skips every top edge of the label. Leave white space equal to eight dot
other label. rows at the top of the label. 300 dpi = 0.0264 inches.
An occasional blank label 203 dpi = 0.04 inches.
occurs within a print job, 2. Check that Clip Page = Enable in the MEDIA CONTROL
but no labels are lost. menu. Clip Page = Enable causes any printable data to be
clipped off and lost once the next TOF position (gap,
notch, hole, or black mark) is detected. Clip Page =
Disable allows the printer to ignore a gap or mark. The
printer looks for the gap or mark after the specified Label
Length is first reached.
3. In the QUICK SETUP menu, use a negative Ver Image
Shift value to move the image toward the leading edge of
the label.
One or more labels did not 1. If the serial interface is being used, verify that the selected
print in multiple-label print job. data protocol for the printer matches that of the host
computer.
OR
2. If Clip Page = Enable in the MEDIA CONTROL menu, the
printer may have falsely detected a gap, hole, or black
A portion of the printed image
mark, and then clipped (i.e., discarded) the remaining
was clipped off and the
printable data for the label.
beginning of the next label
was printed on that same a. Do the Run Calibrate procedure. See CALIBRATE
label. CTRL in the Users Manual.
b. Increase the Gap Threshold value by two or three
increments in the CALIBRATE CTRL menu.
c. Change Clip Page to Disable and set Label Length to
the correct physical value in the MEDIA CONTROL
menu.
Print quality difference There is a known noticeable difference in print quality

noticed between printing with regarding the formatting between a printer with a 203 dpi
a 203 dpi printhead versus a printhead versus a 300 dpi printhead.
300 dpi printhead.
There is no fix for thisthis is how the printer is designed to
work. If the customer changes the printhead, they also need to
redesign their jobs or use drivers that match the new printhead
resolution.
84
Symptom Solution
Bar code print jobs print as 1. Make sure the correct microcode to support IGP or Code V
control codes for IGP or Code emulation is loaded in the printer.
V bar code jobs. 2. Verify the printer configuration has the correct active
graphics emulation selected as IGP or Code V in the
PRINTER CONTROL menu.
3. Make sure the SFCC character is set to what is being used
by the job. You can put the printer into hex-dump mode if it
is a non-IPDS printer to find what the SFCC character is.
4. If the printer also has IPDS microcode installed, ensure
the customer is not using an IPDS device profile to send
the IGP or Code V print job to the printer. If the printer is
defined as an IPDS device on the host, the customer will
then need to create another device profile that is NOT
IPDS. Refer the customer to the Coax/Twinax
Programmers Reference Manual or the Ethernet Interface
Users Manual for instruction on correctly creating a
different device profile that can utilize IGP or Code V
datastreams.
On newer style rewinders Check and adjust the rewinder torque. See page 138 or
with the plastic rewind spindle page 141.
(item 4, Figure 25, page 166)
the media rewind belt is
jumping or skipping teeth.
OR
The media or backing fails to

consistently rewind onto the
spindle when using the
rewinder.
85
Symptom Solution
RIBBON
Printer advances media, but 1. Make sure the ribbon is installed correctly.
ribbon does not advance. 2. A poor ribbon/media combination can cause insufficient
friction between media and ribbon. Verify that the correct
ribbon and media are being used.
3. The printhead pressure may not be set high enough. Set
the head pressure adjustment dial higher.
4. There may be adhesive on the printhead. Clean the
printhead.
Ribbon take-up spindle is not 1. In the QUICK SETUP or MEDIA CONTROL menu, verify
rewinding the used ribbon. that Print Mode is set to Transfer.
2. Power off the printer and verify that the take-up spindle
rotates freely with no binding.
3. If binding exists, remove the side cover and check the gear
train.
4. Verify that the ribbon take-up motor is connected to J8 on
the controller board.
5. Replace the ribbon take-up motor.
Printer cuts (melts) through 1. Verify that the printing heat setting (Print Intensity) is set to
the transfer ribbon. the proper level. In the QUICK SETUP or MEDIA
CONTROL menu, set Print Intensity to the correct level.
2. Verify that Print Speed is not too low. In the QUICK
SETUP or MEDIA CONTROL menu, set Print Speed
higher.
3. Verify that the correct ribbon is installed. The melting point
for thermal transfer varies significantly among ribbon
types.
Printing stops and ONLINE 1. Check the LCD for a fault message. Press PAUSE to
status indicator flashes. display the fault message again.
2. Inspect for a jammed label. Remove jammed label.
3. Check that the transfer ribbon and label stock are routed
correctly.
Narrow width ribbon breaks The Ribbon Width value in the MEDIA CONTROL menu is set
frequently. too large, causing too great a ribbon take-up and ribbon supply
spindle torque. Reduce the Ribbon Width value to decrease
the torque on the ribbon spindles. The Ribbon Width value
should be very close to the Label Width value.
To reduce the torque further, set Ribbon Length (in the MEDIA
CONTROL menu) from Save As Paper to Set In Menu. Then
set a value less than the installed ribbon width.
86
Symptom Solution
After closing the printhead, 1. Power off the printer and verify that the take-up spindle
the printer continuously rotates freely with no binding.
moves the media back and 2. If binding exists, remove the side cover and check the gear
forth and briefly flashes the train.
message RBN TAKEUP
FULL. 3. Verify that the ribbon take-up motor is connected to J8 on
the controller board.
4. Replace the ribbon take-up motor.
Wide width ribbon does not The Ribbon Width value in the MEDIA CONTROL menu is set
take up properly. The ribbon too narrow for the ribbon installed. Set the Ribbon Width value
moves past the platen to match the width of the ribbon installed. This will increase the
assembly with the media. torque on the ribbon take-up spindle.
The printer loses data from Use a Printronix ribbon.

the print job when an end of
NOTE: Some ribbons use a trailer: foil or mylar material at the
ribbon condition occurs while
end of a ribbon roll that is attached to the fiber core. In
printing, even when Error
order for the printer to detect a ribbon out properly and
Recover is set to Enable.
then reprint an incomplete label, the ribbon supply
spindle must first spin freely after the ribbon parts from
it.
The printer can print with a trailer of up to 6 inches
long (the distance from the supply spindle to the
printhead). If the trailer is more than 6 inches, the
printer will continue to print over the trailer, with no
image being transferred to the label. A Ribbon Out
fault will then be detected when the trailer has parted
from the ribbon supply spindle, but may not reprint the
last label.
87
Chapter 3 Communications Failures
Communications Failures
With the exception of a defective interface cable, most communications
problems between the host computer and printer are not the result of a
hardware failure. Communications problems most often result from
incompatible configuration of the host computer system, network (LAN, print
server, controller, multiplexer, etc.), or the printer. Sometimes the print
application program itself is at fault.
If the printer appears to have communication problems, print a test pattern
and a hex dump to help identify printer configuration errors that can cause
problems. Things to look for include the following:
Check that the data string sent to the printer contains the correct
information.
Verify that the correct host interface port is being used and that the
communication parameters (baud rate, parity, etc.) match those of the
host computer.
Verify that the correct interface cable is installed between the host
computer and the printer.
If the printer is using the parallel interface, verify that the terminating
resistors are correct.
If you have limited communications experience and the cause of the problem
is not readily apparent, do the following:
1. Print out the printer configuration.
2. Verify that you have the latest level of software. If not, load the latest
level.
3. Obtain a copy of the Device Host Configuration if possible.
4. Call your support group for help in analyzing the problem.
If you cannot get help, or if you have experience solving host-printer
communications problems, the following additional information is provided.
You can quickly check the ASCII portion of printer logic by sending a plain text
file from a computer to the printer to the parallel or serial port. For a
description of the ASCII interfaces, refer to the Users Manual.
88
Table 4. Common Communications Problems
Problem Interface Common Causes
Fails to print from host parallel - Interface cable defective

- Host/Network configuration
-or- - Printer logic
- Terminating resistors
Prints incorrect characters - Incorrect printer configuration. Refer customer to
the Users Manual.
-or-
serial - Host/Printer interface cable pinouts incompatible
Prints extra characters - Host/Printer/Network configuration
- Interface cable defective
-or- - Printer logic
- Incorrect printer configuration. Refer customer to
Drops characters the Users Manual.
twinax - Interface cable defective
-or- - Host-Printer definition
- Controller/Network configuration
Data loss - Printer logic
the Users Manual.
coax - Interface cable defective
- Controller/Network configuration
- Printer logic
the Users Manual.
ethernet - Interface cable defective
- Host/Printer/Network configuration
- Printer logic
the Users Manual.
- Incorrect ethernet configuration. Refer customer
to the Network Interface Card Users Manual.
- See also NIC Assembly on page 123 for a
description of the NIC dip switch settings.
89
Chapter 3 Communications Failures
Device Handshaking
Handshaking is the exchange of signals between the host computer and the
printer to indicate the status of the data being transferred. In serial data
transfer the printer uses both hardware and software handshaking and
transmits both forms simultaneously when the input buffer is full.
The printer can be used with either serial or parallel host interfaces. Parallel
interfaces are usually straightforward, with no special settings required. Serial
interfaces, however, have a variety of possible communication parameter
settings.
There are two methods of handshaking on a serial interface:
Hardware Handshaking
This is an electrical signal controlled by the logic state on pin 20 of serial
interface connector J2 at the back of the printer. The signal goes high
when the printer is ready to receive data. The signal goes low when the
printer is in the busy state, which indicates that the input buffer is full and
can no longer receive data.
Software Handshaking
XON and XOFF are software signals that control serial data flow between
the printer and the host system. When the printer input buffer is full, the
printer sends the XOFF (Hex 13) character, which signals the host to stop
sending data. When space becomes available in the input buffer, the
printer sends the XON (Hex 11) character, which tells the host that the
printer is ready to receive more data.
The Printer Interface

The printer will not function properly if an incorrectly wired interface cable or
the wrong interface cable is installed.
When the printer is first powered up, it resets itself to the following default
communication parameters:
PARAMETER DEFAULT VALUE
Baud 9600
Data Bits 8
Parity NONE
Stop Bits 1
Use the SERIAL PORT menu to change serial interface parameters. (Refer to
the Users Manual.)
90
Printer Configuration
Troubleshooting A New Installation

Customers with new printers sometimes report problems that reflect
unfamiliarity with the printer and manuals rather than true fault conditions. If a
customer reports general printer problems and the printer was recently
installed, check the following:
Printer Configuration
Many customers have difficulty configuring new printers for operation with
their computer system. Since there are many system configurations and
parameter options, configuring a printer can be challenging to those who do
not do it often. Check the customers host interface to the printer and make
sure the printer configuration conforms to the host. If the customer has not yet
made a configuration printout, show him how to print and store his printers
configuration. (Refer to the Users Manual.)
GAP NOT DETECTED

1. Do the Run Calibrate procedure. (Refer to the Users Manual.)
Sometimes the customer simply loads media and starts to print without
calibrating the media sensor(s).
2. Using the starter kit, guide the customer step-by-step through the setup
process. The starter kit helps greatly to resolve start-up problems
because the ribbon and media are designed to work well with the printer.
PRINT HEAD UP
Show the customer the printhead latch and how to close the pivoting deck.
The pivoting deck can appear to be closed when it is held down only by
friction. Make sure the latch closes.
Ribbon
1. If the customers application calls for a ribbon, make sure it is installed
correctly.
2. In the QUICK SETUP or MEDIA CONTROL menu, verify that the
customer has selected the correct mode for his application: Direct
Thermal (no ribbon required) or Transfer Thermal (ribbon required).
Documentation
Stress the importance of consulting the documents that come with the printer.
These manuals explain how to operate, care for, and troubleshoot the printer.
The manuals also have helpful tips about how to choose media and ribbons
and how to obtain the best print quality.
91
Chapter 3 Troubleshooting A New Installation
92
4 Replacing Parts
About This Chapter

This chapter contains removal/installation procedures for the parts and
assemblies that you can replace at the field service level of maintenance.
Part numbers for replacement parts are listed in Chapter 5, Illustrated Parts
Breakdown (IPB), which begins on page 157.
Preparing The Printer For Maintenance

WARNING Always unplug the printer power cord from the printer or power outlet
before doing any maintenance procedure. Failure to remove power
could result in injury to you and damage to equipment. If you must apply
power during maintenance, you will be instructed to do so in the
IMPORTANT Do not attempt field repairs of electronic components or assemblies. Do

not de-solder any circuit board components. Replace a malfunctioning
electronic assembly with an operational spare. Most electronic
problems are corrected by replacing the printed circuit board assembly,
sensor, or cable that causes the fault indication.
To prepare the printer for maintenance, follow the steps below.
1. Set the printer power switch to O (Off).
2. Unplug the printer power cord from the printer or the AC power source.
3. Disconnect all data (signal) cables from the printer interfaces.
4. Raise the media cover.
5. Unload print media.
6. Remove the ribbon.
7. Read the entire maintenance procedure before you begin working on the
printer.
8. Gather the necessary parts and tools before you begin working on the
printer.
93
Chapter 4 About This Chapter
Restoring The Printer To Operation

When you are finished servicing the printer, follow the steps below.
1. Install the frame side cover if it was removed to service the printer
(page 107).
2. Install the ribbon if thermal transfer is the required print mode.
3. Load print media.
4. Connect all data (signal) cables to the printer interfaces.
5. Plug the AC power cord into the printer and the power source.
6. Close the media cover.
7. Set the printer power switch to | (On).
8. If you replaced the controller board or the Flash SIMM, or installed the
IPDS or expansion-CT option, load the printer operating system software
into flash memory. (See Appendix B.)
9. If you replaced the printhead, select the DIAGNOSTICS menu and reset
the printhead data. (Refer to the Users Manual.)
10. Use the customers configuration printout(s) to reset and save the printer
configuration(s). (Refer to the Users Manual.)
NOTE: If you replaced the controller board, Flash SIMM, media sensors, or
downloaded new software, perform the Auto Calibrate procedure the
printer and save the configuration. (Refer to the Users Manual.)
11. Test printer operation and check print quality by printing a diagnostic test
pattern (page 37).
12. Select the emulation. (Refer to the Users Manual.)
94
Tools And Materials
Tools And Materials

You need the following tools and materials to service the printer:
Lubricant, bearing, M3 density (P/N 101805-001)
Pen, cleaning, thermal printhead (P/N 203502-001) or isopropyl alcohol
and cotton swabs
Torque wrench with 1/4 inch hex receptacle and a range of 0-20 inch-
pounds, with hex key sizes 2 mm, 2.5 mm, 3 mm, and #1 Phillips bit
Force gauge, (Chatillon NY, Gauge-r, 0-20 lb., CAT 719-20)
Volt/ohmmeter
Screwdriver, flat tip, 1/4 inch blade
Screwdriver, Phillips, #1
Needle-nose pliers, 5 inch
Hex key, angled, 2 mm, 2.5 mm, and 3 mm
Feeler gauge set, blade type, with 0.010 inch (0.254 mm) and 0.077 inch
(1.96 mm) gauges
12R Internal snap ring pliers
Static wrist strap
For rewinder (option):
Torque Watch Tool: range 0 to 12 inch-pounds (0 to 200 inch-ounces)
Must accept a inch male hex adapter
Torque Watch Adaptor, Rewinder, T5, with inch male hex adapter
(P/N 176323-001)
Torque Adjustment Tool, Rewinder, T5 (P/N 176322-001)
Tool has two pieces: Nut Driver (P/N 176322-101) and Shaft Driver
(P/N 176322-102)
Torque Requirements
Unless specified otherwise, use the following torque values when tightening
fasteners:
Hex Bolt/
Key Screw Torque (English) Torque (Metric)
Size Size
2.0 mm M3x4mm 6.0 1 inch-pound 0.68 0.113 newton-meter

M3x6mm
95
Chapter 4 Removal And Replacement Procedures
Removal And Replacement Procedures

Belt, Platen........................................................................................ page 97
Belt, Rewinder................................................................................... page 98
Control Panel Assembly.................................................................... page 99
Controller PCBA (Printed Circuit Board Assembly)......................... page 100
Cooling Fan, Power Supply With Center Mounted Fan .................. page 102
Cooling Fan, Power Supply With Rear Mounted Fan .................... page 103
Damper, Media................................................................................ page 104
Dashpot........................................................................................... page 105
Expansion-CT ................................................................................. page 106
Frame Side Cover ........................................................................... page 107
Gear, Ribbon Drive, Final................................................................ page 108
Gear, Ribbon Drive, Intermediate ................................................... page 109
Head Pressure Block Assembly...................................................... page 110
Media Cover.................................................................................... page 113
Media Hanger Beam ....................................................................... page 114
Media Sensor Assembly, Lower, Dual Media Sensor Models ........ page 115
Media Sensor Assembly, Single Media Sensor Models.................. page 117
Memory Modules, Flash And DRAM............................................... page 118
Motor, DC Ribbon Drive .................................................................. page 121
Motor, Stepper ................................................................................ page 122
NIC Assembly ................................................................................. page 123
Plate, Rear Panel, Vented and Ventless Models ............................ page 127
Platen .............................................................................................. page 128
Power Supply Assembly ................................................................. page 129
Printhead Assembly, Dual Media Sensor Models ........................... page 130
Printhead Assembly, Single Media Sensor Models ........................ page 132
Printhead Cover/Upper Media Sensor, Dual Media Sensor Models .. page 134
Rewinder (Option) ........................................................................... page 137
Security PAL ................................................................................... page 144
Sensor, Head Up............................................................................. page 146
Sensor, Label Taken, Frame Mounted............................................ page 147
Sensor, Label Taken, Front Cover Mounted ................................... page 148
Spindle Assembly, Ribbon Supply Or Take-Up .............................. page 149
Support Assembly, Lower ............................................................... page 150
Support Assembly, Upper ............................................................... page 151
Tear Bar Assembly, Adjustable....................................................... page 152
Tensioner, Rewinder Belt................................................................ page 155
96
Belt, Platen
Belt, Platen
Removal
CAUTION Do not use excessive force to remove the platen belt from the cluster
pulley, which can stretch or permanently damage the belt. A stretched
platen belt causes images to print with incorrect lengths.
1. Prepare the printer for maintenance (page 93).
3. Remove the stepper motor (page 122).
4. Slip the platen belt off the larger (outermost) cluster pulley. (Figure 24,
page 162, items 8 and 9.)
Installation
CAUTION Do not use excessive force to install the platen belt on the cluster
pulley, which can stretch or permanently damage the belt. A stretched
platen belt causes images to print with incorrect lengths.
1. Slip the platen belt over the larger (outermost) cluster pulley. (Figure 24,
2. Install the stepper motor (page 122).
97
Belt, Rewinder
Removal
3. Remove the power supply assembly (page 129).
4. Remove the stepper motor (page 122).
5. Slip the platen belt off the larger (outermost) cluster pulley. (Figure 24,
6. Remove the retaining E-ring securing the rewinder pulley to the shaft of
the rewinder spindle assembly. (Figure 24, page 162, items 6 and 16.)
7. On the media side of the printer, pull the rewinder spindle out and on the
drive side catch the rewinder pulley and nylon washer when they are
released from the spindle shaft.
8. Remove the rewinder belt from the cluster pulley.
Installation
1. Slip the rewinder belt over the smaller (innermost) cluster pulley.
(Figure 24, page 162, items 7 and 8.)
2. Slide the rewinder spindle assembly into the bearing housing in the
printer frame, leaving about 1/4 inch of shaft exposed on the pulley side.
(Figure 25, page 166, item 4.)
3. Slide the nylon washer onto the rewinder spindle shaft. (Figure 24,
page 162, item 5.)
4. Slide the rewinder pulley, with the rewinder belt installed on it, onto the
rewinder spindle shaft, and slide the rest of the shaft through the pulley.
5. Install the retaining E-ring securing the rewinder pulley to the shaft of the
rewinder spindle assembly. (Figure 24, page 162, item 16.)
6. Slip the platen belt over the larger (outermost) cluster pulley.
7. Install the stepper motor (page 122).
8. Make sure the lower portion of the rewinder belt is correctly positioned
over the belt tensioner.
9. Install the power supply assembly (page 129).
10. Install the frame side cover (page 107).
98
Control Panel Assembly
Control Panel Assembly

Removal
CAUTION To prevent electrostatic damage to electronic components, always wear

a properly grounded static wrist strap when you handle circuit boards.
3. Put on a static wrist strap and ground it to an unpainted part of the printer
frame. Touch the frame with the hand wearing the wrist strap.
4. From inside the printer, squeeze the clips on the bottom edge of the
control panel assembly and angle the control panel assembly upward and
far enough out of the cutout in the printer frame to provide access to
connector J1. (Figure 36, page 198, item 1.)
5. Disconnect ribbon cable connector P1 from connector J1 on the rear of
the control panel PCBA and remove the control panel assembly from the
printer.
Installation
2. Connect ribbon cable connector P1 to connector J1 on the rear of the
control panel PCBA.
3. Engage the tabs on the upper edge of the control panel assembly under
the lip of the cutout in the frame. (Figure 36, page 198, item 1.)
4. Align the control panel in the cutout and push the bottom edge of the
panel in until it snaps into the cutout. (You may need to push upward on
the back of each clip to lock the control panel in place.)
99
Controller PCBA (Printed Circuit Board Assembly)

Removal

4. Remove the expansion-CT, if one is installed in the printer (page 106).
5. Remove the NIC assembly, if one is installed in the printer (page 123).
6. Remove the dual NIC wireless interface, if one is installed in the printer
(page 309.)
7. Unplug the cutter board cable, if a cutter is installed in the printer.
8. Unplug the validator power/data cable, if a validator is installed on the
printer. (Figure 57, page 276.)
9. Unplug the RFID encoder cable(s), if an encoder is installed in the printer.
Early RFID encoders: Figure 83, page 319 (power cable only).
Later RFID encoders: Figure 97, page 333 (both power and data cables).
10. Remove the socket head screw on each side of the power switch.
11. Loosen the two slotted thumbscrews securing the power supply to the
base of the frame and pull the power supply one inch away from the
controller board.
12. Unplug all cable assemblies from the controller PCBA. (See the Cable
Routing diagram on page 221 for dual media sensor models or page 223
for single media sensor models.)
13. For dual media sensor models, remove the J15 (page 115) and J21
(page 120) connectors.
14. Remove the two screws that attach the controller PCBA to the rear panel.
15. Loosen the six captive screws enough to release the controller PCBA
from the printer frame. (Figure 34, page 192, items 2 and 20.)
CAUTION In the next step, failure to completely remove the old thermal pad and
install the new thermal pad will damage the controller PCBA.
16. Remove the old controller PCBA and thermal pad from the printer frame.
(Figure 34, page 192, item 8.) Install the new thermal pad on the frame.
17. If you are replacing the controller PCBA with a new or rebuilt one, remove
the Flash SIMM and DRAM SIMM from the old board, and install them on
the new or rebuilt controller PCBA (page 118).
100
Controller PCBA (Printed Circuit Board Assembly)
18. You may need to remove the security PAL (Figure 34, page 192, item 15)
at location U7 from the old controller PCBA and install it on the new
controller PCBA (page 144).
Installation
2. Reverse the steps of the removal procedure.
101
Cooling Fan, Power Supply With Center Mounted Fan

Removal
4. Disconnect the fan cable connector from connector JP401 on the power
supply board.
5. Remove the fan bracket (Figure 24, page 162, item 4) by removing the
two countersunk Phillips head screws from the bottom of the power
supply assembly.
6. Remove the four screws and nuts securing the cooling fan to the power
supply frame.
NOTE: On later model power supplies, unlock the reusable plastic fasteners
by pushing in the center post with a small mm hex key.
Installation
NOTE: On later model power supplies, if the plastic fasteners are lost or
broken, use the M4x30mm screw and nut (Figure 24, page 162, items
3 and 14) available in Hardware Kit 171629-001 (page 202).
102
Cooling Fan, Power Supply With Rear Mounted Fan
Cooling Fan, Power Supply With Rear Mounted Fan

Removal
4. Disconnect the fan cable connector from connector JP401 on the power
supply board.
5. Remove the four screws and nuts securing the cooling fan to the power
supply frame.
Installation
103
Damper, Media
Removal
3. Remove the retaining E-ring securing the damper shaft to the printer
frame. (Figure 25, page 166, item 3.) Remove the two washers.
4. Lift the lower arm of the media damper spring (Figure 25, page 166,
item 5) from the media damper and place it on the media damper stop on
the frame (Figure 25, page 166, item 16).
NOTE: The spring should remain on the frame.
5. Slide the media damper out of the frame. (Figure 25, page 166, detail A.)
6. Using a flathead screwdriver, pry the media damper shaft from the
retaining rib at its groove and push the shaft over the rib. (Figure 4).
7. Remove the media damper shaft from the media damper.
Installation
1. Insert the media damper shaft into the media damper until the groove
snaps over the retaining rib. (Figure 4.)
2. Install one nylon washer (Figure 25, page 166, item 8) on the media
damper shaft and slide the shaft into the printer frame so that the lower
arm of the media damper spring (Figure 25, page 166, item 5) rests on top
of the retainer tab on the damper and the upper arm of the spring catches
the frame tab from below.
3. Install the two washers and retaining E-ring on the end of the shaft.
(Figure 25, page 166, items 3, 8, and 9.)
NOTE: The media damper should move freely up and down without binding,
but have minimal lateral movement.
Retaining
Rib
Groove
Shaft
Figure 4. Removing the Media Damper
104
Dashpot
Dashpot
Removal
2. Using a flat tip screwdriver, pop the upper and lower ends of the dashpot
off the ball studs. (Figure 23, page 158, items 3 and 5.)
Installation
1. Apply a dab of grease to the upper and lower ball studs. (Figure 23,
page 158, item 5.)
2. Snap the upper and lower ends of the dashpot onto the ball studs.
NOTE: On four inch printers the lower dashpot mounting bracket has slotted
mounting holes. If the dashpot does not hold the cover open, loosen
the bracket mounting screws, move the bracket up, and tighten the
screws.
105
Expansion-CT
Removal

4. Loosen one screw and remove the other screw that secures the
expansion-CT subassembly to the rear of the printer frame. (Figure 34,
page 192, item 7.)
5. Carefully lift the expansion-CT subassembly out of the frame cutout.
6. Remove the expansion cable and socket strip from the expansion-CT
subassembly. (Figure 34, page 192, items 10, 11, and 12.)
7. Remove the expansion cable and socket strip (Figure 34, page 192,
items 11 and 12) by carefully lifting them straight up and out of the
expansion port.
Installation
2. Install one end of the expansion cable into the expansion port J4 on the
controller board and carefully seat the pins in the controller board.
3. Install the socket strip to the connector on the wiring side of the
expansion-CT subassembly and carefully seat the pins.
4. Plug the other end of the expansion cable into the socket strip and
carefully seat the pins.
5. Position the expansion-CT subassembly in the frame cutout.
6. Install one screw then tighten both screws securing the expansion-CT
interface plate to the rear of the printer frame.
106
Frame Side Cover
Frame Side Cover

Removal
2. Loosen the two captive screws securing the top of the frame side cover.
3. Tilt the frame side cover back from the top and lift it until the tabs along
the lower edge disengage from the slots in the printer frame.
Installation
107
Gear, Ribbon Drive, Final

Removal
3. Remove the appropriate retaining E-ring securing the final ribbon drive
gear to the spindle shaft. (Figure 25, page 166, items 2 and 3.)
4. Remove the final ribbon drive gear from the spindle shaft.
Installation
108
Gear, Ribbon Drive, Intermediate
Gear, Ribbon Drive, Intermediate

Removal
3. Remove the appropriate final ribbon drive gear (page 108).
4. Remove the appropriate DC ribbon drive motor (page 121).
5. Remove the retaining E-ring securing the intermediate ribbon drive gear
to the shaft. (Figure 35, page 196, items 1 and 2.)
6. Remove the intermediate ribbon drive gear from the spindle shaft.
Installation
1. Put a dab of grease in the bore of the intermediate gear then reverse the
steps of the removal procedure.
109
Head Pressure Block Assembly

Removal
2. Remove the printhead assembly (page 130 for dual media sensor
models, or page 132 for single media sensor models).
3. Rotate the lead screw knob until the outboard head pressure block is
exactly one inch from the inboard head pressure block. (Figure 28,
page 174 or Figure 29, page 178, item 5.)
4. Remove the retaining E-ring and the lead screw knob. (Figure 28,
page 174 or Figure 29, page 178, items 2 and 5.)
IMPORTANT Do not rotate the lead screw after you remove the lead screw knob. You
must install the head pressure blocks exactly where they were on the
shaft when you removed them.
5. Rotate the head pressure adjustment dial counterclockwise until MIN
aligns with the head pressure dial indicator. (Figure 28, page 174 or
Figure 29, page 178, items 3 and 4.)
6. From under the pivoting deck, remove the inside retaining E-ring securing
the head pressure shaft to the pivoting deck. (Figure 28, page 174 or
7. Remove the pressure block handle from the inboard head pressure block.
(Figure 28, page 174 or Figure 29, page 178, item 19.)
8. Remove the pressure block pointer from the outboard head pressure
block. (Figure 28, page 174 or Figure 29, page 178, item 6.)
9. Slowly pull the head pressure shaft out of the pivoting deck and catch the
inboard and outboard head pressure blocks as the shaft moves outward.
Pull the head pressure shaft out until both blocks are released; you do not
need to completely remove the shaft. (Figure 28, page 174 or Figure 29,
10. Remove the gimbal pivot rack from the outboard head pressure block.
(Figure 28, page 174 or Figure 29, page 178, items 18 and 20.)
110
Head Pressure Block Assembly
Installation
1. Install the gimbal pivot rack on the outboard head pressure block.
(Figure 28, page 174 or Figure 29, page 178, items 18 and 20.)
2. Position the pressure cam in the outboard head block so that the widest
flat spot rides on the plunger. Position the outboard head pressure block
in the pivoting deck and insert the head pressure shaft through both sides
and the cam. (Figure 28, page 174 or Figure 29, page 178, items 8 and
20.)
3. Position the pressure cam in the inboard head block so that the widest flat
spot rides on the plunger. Position the inboard head pressure block in the
pivoting deck and insert the head pressure shaft through both sides and
the cam.
4. Push the head pressure shaft all the way in and install the inside retaining
E-ring. (Figure 28, page 174 or Figure 29, page 178, items 2 and 8.)
5. On the head pressure adjustment dial, make sure that MIN rests on the
head pressure dial indicator, the widest flat spot of both head pressure
cams are on the plungers, and the outboard part of the gimbal pivot rack
rides on the head pressure shaft.
6. Install the pressure block pointer (6 and 8 inch printers) or handle (4 inch
printers) on the outboard head pressure block. (Figure 28, page 174 or
Figure 29, page 178, item 6.)
7. Install the pressure block handle on the inboard head pressure block.
(Figure 28, page 174 or Figure 29, page 178, item 19.)
8. Install the lead screw knob and retaining E-ring. (Figure 28, page 174 or
IMPORTANT Do not rotate the lead screw until the knob has been installed.
111
Adjusting T5x04 Head Pressure Blocks

The pressure blocks should be positioned to obtain a uniform printing density
across the media. In most cases, only the right pressure block will need
adjustment. For the best printing quality under a variety of media and ribbon
conditions, adjust T5x04 printhead pressure blocks as explained below.
1. Under normal printing conditions, align the index mark on the left
pressure block with the bold line on the left side of the pressure block
adjustment scale. If you use media and ribbon widths of less than one-
third of the printers maximum printing width, you may have to move the
left pressure block further left.
2. The usual setting for the right pressure block is to match the ribbon width
by using the scale. For example, for a 110 mm ribbon, set the index mark
to 110 on the scale, as shown below. (The scale is graduated in
millimeters.) If necessary, move the right pressure block by turning the
lead screw knob.
NOTE: If the width of the media is less than the width of the ribbon, align the
right pressure block handle with the right edge of the media. To
ensure good print quality, the width of the media should be more than
75% of the width of the ribbon.
3. To check the correctness of the pressure block positions, print a grey test
pattern (page 37). The pressure is correct if the grey test pattern is
uniform across the media.
Index Mark Left Pressure Block Index Mark Right Pressure

Block
Lead Screw
Knob
t54adpad
110 mm Mark
Bold Line Pressure Block
Adjustment Scale
Figure 5. The T5x04 Head Pressure Blocks
112
Media Cover
Media Cover
Removal
3. Using a flat tip screwdriver, pop the upper part of the dashpot off the ball
stud. (Figure 23, page 158, items 3 and 5.)
4. Hold the cover securely and loosen the screws securing the media cover
to the printer frame. (Figure 23, page 158, items 2 and 4.)
5. Remove the ball stud from the media cover. (The ball stud does not come
with a new media cover.) (Figure 23, page 158, item 5.)
Installation
113
Media Hanger Beam

Removal
CAUTION You must loosen the hanger beam screws a little at a time while gently
pulling the hanger beam away from the frame. If you try to fully remove
one screw only, the screw head will be forced against the controller
board and damage the board.
4. Hold the media hanger beam in one hand and pull the beam away from
the frame assembly as you unscrew the two mounting screws. (Figure 23,
NOTE: There are two holes in the controller board which give you access to
the media hanger beam mounting screws. The screws stay in place
behind the controller board as you loosen them, so hold and pull the
hanger beam until it is released.
Installation
CAUTION Do not force the media hanger beam against the printer frame or try to
fully tighten just one mounting screw. Damage to the controller PCBA
will result.
1. Position the media hanger beam and hold it in one hand as you tighten
each mounting screw a little at a time until the hanger beam is drawn
securely against the frame. (Figure 23, page 158, items 6 and 7.)
114
Media Sensor Assembly, Lower, Dual Media Sensor Models
Media Sensor Assembly, Lower, Dual Media Sensor

Models
Removal
Actuator
4 Pin Media
Sensor Cable
Figure 6. Removing the 4 Pin Media Sensor Cable from the J15 Connector
3. Carefully unlock the J15 connector (Figure 10, page 120) by pulling out
the top and bottom of the actuator. (Figure 6.)
CAUTION The actuator will pull out only about 1/16 inch away from the white
connector.
NOTE: Later version controller PCBAs do not have an actuator on J15; the
sensor cable just pulls out.
4. Unplug the 4 pin media sensor cable from J15 on the controller PCBA.
5. Remove the sensor cable from the wire saddles. Note the cable routing.
6. Open the pivoting deck by rotating the deck lock lever fully clockwise.
7. Use the lower media sensor handle and slide the sensor to the center of
the media guard.
8. Remove the two screws that secure the media guard to the lower support
assembly. Use a 2 mm hex wrench.
9. Push up under the media guard, slide it tightly to the right and raise it up
at the back of the lower support just high enough to slide the lower media
sensor out from the right side.
10. Remove the media guard from the printer.
11. Carefully pull the sensor cable out from under the tie wraps on the lower
support and remove the media sensor from the printer.
115
Installation
1. Reverse the steps of the remove procedure.
Actuator
4 Pin Media
Sensor Cable
Figure 7. Unlocking the J15 Connector

NOTE: Later version controller PCBAs do not have an actuator on J15; the
sensor cable just pushes in.
When inserting the media sensor cable into the J15 connector, follow these
steps:
1. Make sure the actuator is in the unlocked (pulled out) position.
2. Insert the ribbon cable with its contact pins facing toward the front of the
printer.
Figure 8. Locking the J15 Connector

3. Push in the black actuator to lock the cable in place.
116
Media Sensor Assembly, Single Media Sensor Models
Media Sensor Assembly, Single Media Sensor Models

Removal
3. Disconnect the media sensor cable from connector J12 on the controller
board. (Figure 10, page 120.)
4. Remove the sensor cable from the wire saddles. Note the cable routing.
6. Cut the two tie wraps securing the media sensor assembly to the lower
support assembly.
7. Grasp the media sensor handle from under the lower support assembly
and pry the right side of the handle toward the back of the printer to
unlock it from the media sensor assembly housing. (Figure 30, page 182,
items 5 and 8.)
8. Remove the media sensor assembly and media sensor handle from the
printer.
Installation
2. Make sure the media sensor can move horizontally along the lower
support assembly with only a small amount of force. It should not slide too
easily, or it can move during printing.
3. Install the tie wraps that secure the media sensor cable to the lower
support only after making sure the media sensor assembly can move
horizontally to each end of the lower support assembly.
117
Memory Modules, Flash And DRAM

Printer memory is held in two SIMMs (Single In-line Memory Modules) on the
controller board. The DRAM SIMM plugs into socket J33 on the controller
board. The Flash SIMM plugs into socket J38 on the controller board.
The procedure for removing and installing all SIMMs is the same, but if you
are replacing the Flash SIMM be sure to make a printout of all the desired
configurations and restore the printer configurations after installing a new
Flash SIMM. This is not necessary if you replace the DRAM SIMM.
IMPORTANT Whenever the Flash SIMM is replaced you must reload the desired
emulation and operating system software, as well as setup files, feature
files, TIFF files, and any optional font or logo files. (See Downloading
Software on page 209.)
Removal
1. If you are replacing the Flash SIMM, make a configuration printout of all
saved configurations. (Refer to the Users Manual.) If you are replacing
DRAM SIMM, go to the next step.

5. Gently pry the side locks open, angle the SIMM to the left, and remove
the SIMM from the controller board. (Figure 9.)
Installation
2. Insert the new SIMM into the socket with the notched end downward.
(Figure 9.) Angle the SIMM to the left and press it into the socket. Gently
push the ends to the right until the SIMM locks into the upright position.
Make sure both latches close all the way.
3. If the Flash SIMM was replaced, you must download the desired
emulation and operating system software, as well as setup files, feature
files, TIFF files, and any optional font or logo files. (See Downloading
Software on page 209.)
5. Select and run the OFFLINE/CONFIG. CONTROLPrint Config./
Current* menu. (Refer to the Users Manual.) Make sure the new
memory is noted on the printout.
118
Memory Modules, Flash And DRAM
J33
Controller
Board
J38
DRAM
Location U7: SIMM
Security PAL
Notch
Flash
Notch SIMM
Notch
Figure 9. Replacing Memory Modules and Security PAL
119
Label
Taken Upper Media
Sensor Sensor, Dual
Head Up J18 Media Sensor
Sensor Models
J11 J21
Media Sensor,
Lower Media Single Media
Sensor, Dual J15 Sensor
Media Sensor Models
Models
J12
J16
Ribbon
Supply
Motor
J14
Stepper
Motor
J8
Ribbon
Take-up
Motor
J17
Power
Figure 10. Controller PCBA Connectors
120
Motor, DC Ribbon Drive
Motor, DC Ribbon Drive

Removal
3. Disconnect the appropriate DC ribbon drive motor cable assembly from
the controller board:
a. Disconnect the upper (ribbon take-up) DC ribbon drive motor cable
from connector J8 on the lower right edge of the controller board.
b. Disconnect the lower (ribbon supply) DC ribbon drive motor cable
from connector J16 on the upper right edge of the controller board.
(Figure 10.)
4. Remove the DC motor cable assembly from tie wraps and wire saddles
and note the cable routing.
5. Remove the two screws securing the DC ribbon drive motor assembly to
the frame. (Figure 35, page 196, items 3 and 4.)
Installation
121
Motor, Stepper
Removal
3. Disconnect the stepper motor spring from the stepper motor mount plate.
4. Disconnect the stepper motor cable from connector J14 on the controller
5. Remove the top and bottom screws securing the stepper motor mount
plate to the printer frame. (Figure 24, page 162, items 11 and 12.)
6. Remove the stepper motor and mount plate as a unit, disengaging the
platen belt from the motor pulley as you pull the motor out.
Installation
1. Slip the platen belt over the motor pulley, then align the stepper motor
and mount plate over the mounting holes in the printer frame.
2. Install the two screws securing the top and bottom of the stepper motor
mount plate to the printer frame. (Figure 24, page 162, items 11 and 12.)
Leave the screws loose enough for the stepper motor to pivot through the
slot in the top of the mount plate. Check that the platen belt is not pinched
between the motor mount plate and the printer frame.
3. Make sure the platen belt runs over the larger (outermost) pulley on the
cluster pulley. (Figure 24, page 162, item 8.)
4. Connect the stepper motor cable to connector J14 on the controller
5. Connect the stepper motor spring to the stepper motor mount plate.
6. Tighten the two screws on the stepper motor mount plate.
122
NIC Assembly
NIC Assembly
NOTE: The NIC LAN option is a 10/100Base-T ethernet interface available
either factory installed or as a field kit. The functions of the LEDs and
DIP switches on the interface board are described on page 124.
If the NIC is installed in the printer, the NIC configuration values

appear under the ETHERNET PARAMS menu, accessed through the
control panel. The Ethernet version, Ethernet parameters, IP
Address, Gateway Address, and Subnet Mask are also listed when a
configuration printout is made. (The procedures for accessing
configuration menus and making a configuration printout are in the
Users Manual.)
Removal

4. Loosen one screw and remove the other that secures the NIC assembly
to the cutout at the rear of the printer frame. (Figure 34, page 192,
item 14.)
5. Slide the NIC assembly out of the cutout, disconnect the Centronics cable
from the parallel connector J203 on the back of the interface board, and
lift the assembly out of the printer. (Figure 34, page 192, items 6 and 9.)
Installation
123
10/100Base-T LEDs And DIP Switches

The 10/100Base-T NIC has two indicator lights and two DIP Switches, as
shown below.
DIP Switches
1 Shown in OFF
(default) position
2
00 t
p21
STAT
(Status Indicator)
NET
(Network Indicator)
Figure 11. The 10/100Base-T LEDs and DIP Switches

Inspect the two LEDs on the 10/100Base-T NIC:
1. When an IP address is configured into the printer via the control panel,
the bottom LED should be blinking on and off at the same rate.
2. When a working network cable is installed, the top LED should be on
steadily and will blink off for 1/3 second when data are received.
When these two conditions are met, you should be able to ping the printer
from a network host.
To test, first start a telnet session:
telnet IP address
Then, enter the following:
start fox prn<Enter>
stop prn<Enter>
This command sequence sends consecutively numbered lines of text from the
interface to the printer. The fox test is resident in the network interface and
verifies that the network interface can receive commands and can transfer
data successfully to the printer.
If no network cable is connected or the cable is defective and the IP address
is configured from the control panel, the top LED will be off and the bottom
LED will blink on/off.
124
NIC Assembly
The STAT (Status) Indicator In Run And Auto Reset Modes

Run Mode is the normal operating state of this interface. Auto Reset mode is
entered when the watchdog timer is triggered and the print server resets itself.
In either mode, the STAT LED flashes at a varying rate, depending on
whether the unit IP address is configured. The Run Mode and Auto Reset
Mode indicator descriptions are shown in Table 5.
Table 5. STAT LED
STAT Rate Indication
OFF Flashes ON once per Normal Mode, IP address

second configured
OFF Flashes ON 2 times IP address not configured

per second
ON Flashes OFF once Download mode
per second
ON Flashes OFF twice Error

per second
NET (Network) Indicator

The NET LED displays the status of the network link:
Table 6. NET LED
NET LED Rate Indication
ON Constantly Indicates link integrity
ON Flashes OFF 1/3 Flashes off 1/3 second every time

second a packet is transmitted
OFF Constantly Network connection has been

severed
125
DIP Switches
Two DIP switches, labeled 1 and 2, are mounted on the 10/100Base-T
interface inside the printer. The functions of these switches are explained
below.
Table 7. 10/100Base-T DIP Switch Settings
DIP Switch
Description
1 2
OFF OFF Normal operation. The interface boots up using the

(up) (up) settings in flash memory rather than the default
settings.
ON OFF Factory default settings. The interface boots up and

(down) (up) all settings stored in flash memory are erased except
the Ethernet address and key value.
OFF ON Default IP. The interface boots up with factory default

(up) (down) settings, but the stored settings in flash memory
remain intact. Setting switch 2 to ON does not clear
any settings stored in flash memory; it boots the unit in
a different state with the settings in flash memory
temporarily ignored.
ON ON If the interface is connected to a network with link

(down) (down) integrity and is then reset, the interface will boot up in
download mode. If the unit is not connected to a
network, it will print a test page.
126
Plate, Rear Panel, Vented and Ventless Models
Plate, Rear Panel, Vented and Ventless Models

Removal
3. Remove six screws securing the rear panel plate. (Figure 35, page 196,
items 5 and 6 or 6a.)
4. Remove all screws securing any blank plates. (Figure 35, page 196,
items 7 and 9.)
5. Remove all screws securing any I/O assemblies. (Figure 34, page 192,
items 7 and 14.)
6. Remove two screws near the AC power receptacle and power switch.
7. Remove the rear panel plate. (Figure 35, page 196, item 6 or 6a.)
Installation
127
Platen
Removal
4. Loosen the top and bottom screws securing the stepper motor.
5. Rotate the motor clockwise to loosen the drive belt.
6. Tighten the top screw to hold the stepper motor temporarily in place.
NOTE: Do not remove either belt from the cluster pulley. You can remove
and install the platen quicker with the belts in place.
7. Remove two M5x10mm screws and the peel/tear assembly from the
lower support assembly. (Figure 27, page 170, items 5 and 6.)
8. Remove the retaining ring and wavy washer from the right side of the
lower support assembly. (Figure 30, page 182, items 3 and 7.)
9. Loosen the screw (two screws on early models) on the cluster pulley and
push the platen shaft through the cluster pulley until it is clear of the shaft.
CAUTION On the early model aluminum cluster pulley only: if the screw(s) cannot
be loosened without damaging the screw hex socket or the hex key, use
a heat gun to heat up the cluster pulley.
Installation
1. Hold the cluster pulley in position as you install the platen through the
right side of the lower support assembly.
2. Install the wavy washer and retaining ring to the right side of the lower
support assembly. (Figure 30, page 182, items 3 and 7.)
3. Position the peel/tear assembly on the lower support assembly and install
two M5x10mm screws. (Figure 27, page 170, items 5 and 6.)
4. Using a feeler gauge, leave a 0.077 inch (1.96 mm) gap between the
cluster pulley and the frame, then torque the cluster pulley screw(s):
18 in-lb. for the early two screw version or 25 in.-lb. for the later one screw
version.. (Figure 24, page 162, items 8 and 13.)
5. Loosen the top screw on the stepper motor to allow the spring to provide
the correct tension to the platen drive belt, then tighten both screws.
6. Make sure the lower portion of the rewinder belt is over the belt tensioner.
128
Power Supply Assembly
Power Supply Assembly

Removal
3. Make sure the pivoting deck is closed and disconnect the power supply
cable assembly from the printhead assembly. (Figure 27, page 170,
items 9 and 10.)
4. Feed the power supply cable assembly through the frame cutout, from the
media side to the drive side of the printer. You may have to disconnect
and remove the printhead/controller cable first.
5. Disconnect the power supply cable from connector J17 on the controller
6. Disconnect phone-style cable P403 from connector CN403 on the power
supply board.
7. Remove the socket head screw on each side of the power switch.
8. Loosen the two slotted thumbscrews securing the power supply to the
base of the frame. (Figure 24, page 162.)
9. Remove the power supply assembly. The power switch and cooling fan
are part of the power supply assembly.
Installation
1. Position the power supply assembly with the power switch centered in the
rear cutout and align the holes at the rear of the power supply assembly
base with the holes in the bottom of the printer frame.
2. Install a socket head screw finger tight on each side of the power switch.
3. Hold the power supply assembly against the rear wall of the frame and
tighten the two slotted thumbscrews securing the power supply assembly
to the base of the frame.
4. Tighten the screw on each side of the power switch.
5. Connect the phone-style cable P403 to connector CN403 on the power
supply board.
6. Connect the power supply cable to connector J17 on the controller board.
7. Feed the power supply cable assembly through the grommet in the printer
frame and connect it to the printhead. If you disconnected and removed
the printhead/controller cable, reroute it and connect it to the printhead
assembly. (Figure 27, page 170, items 9 and 10.)
CAUTION The rubber grommet covering the edges of the frame cutout protects the
power supply and printhead/controller cable assemblies from chafing
on the metal edges. Chafed conductors can result in damage to the
printer.
8. Make sure the grommet is seated in the frame cutout.
129
Printhead Assembly, Dual Media Sensor Models

CAUTION Oils from your hands can damage the light brown area (heating
elements) of the printhead. Do not touch the light brown area when you
handle the printhead assembly.
Removal
2. Open the pivoting deck by rotating the deck lock lever fully clockwise. The
pivoting deck will swing upward, exposing the bottom of the printhead
assembly.
Printhead Retainer Clip (2)
Pivoting Deck
Lower Tab (2)

Printhead Pull-Tab
Assembly
Printhead Controller
Printhead
Cable Assembly
Cover
Release Power Supply

Tab Cable Assembly
Release
Upper Media Sensor
Tab
Cable Assembly
Figure 12. Replacing the Printhead Assembly, Dual Media Sensor Models
CAUTION To prevent electrostatic damage to electronic components, ground

yourself by touching an unpainted part of the printer frame before
removing or installing the printhead assembly.
3. Touch an unpainted part of the printer frame before touching the
printhead assembly.
4. Behind the pivoting deck, gently pull the lower tabs of the retainer clips
upward to release the printhead assembly. (You only need to pull the tabs
a small amount to release the printhead assembly.)
130
Printhead Assembly, Dual Media Sensor Models
5. Hold the printhead assembly by the printhead cover as it is released.

6. Push the release tab down on the power supply cable assembly and
remove the cable from the printhead assembly.
7. Use the pull-tab to remove the printhead controller cable assembly from
the printhead assembly.
8. Push the release tab down on the upper media sensor cable assembly
and remove the cable from the printhead assembly.
NOTE: 1. Older printers do not have this sensor or cable. (The printhead
operates correctly in older printers without this sensor.)
2. The position of the upper media sensor connector varies with the
width of the printer: it is in the middle on 4 inch models, the left side
on 6 inch models (Figure 12), and the right side on 8 inch models.
Installation
printhead assembly.
2. Position the new printhead assembly below the pivoting deck and connect
the printhead controller, power supply, and upper media sensor cable
assemblies. (Figure 12.)
NOTE: You may need to gently pull the lower tabs of the retainer clips
upward to install the printhead assembly.
3. Slide the printhead assembly upward into the pivoting deck until the
retainer clips snap it in place. Make sure that the cable assemblies do not
extend past the printhead cover and into the media or ribbon path.
131
Printhead Assembly, Single Media Sensor Models

NOTE: Newer printhead assemblies with the upper media sensor connector
on the printhead cover are designed to work with older single media
sensor printers. The upper media sensor connector will not be used.
CAUTION Oils from your hands can damage the heating elements of the printhead
(the light brown area). Do not touch the printhead heating elements
when you handle the printhead.
Removal

printhead assembly.
4. Behind the pivoting deck, gently push the lower arms of the retainer clips
upward to release the printhead assembly. You only need to push the
clips a small amount to release the printhead. (You can also push the
clips up from below the printhead.) (Figure 13, page 133.)
5. Hold the printhead by the black cover as it drops down.
6. Push its release tab down and pull the power supply cable out of the
printhead assembly.
7. Use the pull-tab to disconnect the printhead/controller cable from the
printhead assembly.
Installation
printhead assembly.
2. Position the new printhead assembly below the pivoting deck and install
the power supply and printhead/controller cable assemblies to the
printhead assembly. (Figure 13, page 133.)
3. Slide the printhead assembly upward into the pivoting deck until the
retainer clips catch it and the printhead snaps into place. You can push
the printhead retainer clips up slightly to help engage the printhead.
132
Printhead Assembly, Single Media Sensor Models
Printhead
Retainer Clip
Pivoting Deck
Printhead
Retainer Clip
Printhead/
Controller Cable
Assembly
Pull-Tab
Printhead
Assembly
Release
Tab
Power Supply
Cable Assembly
Figure 13. Replacing the Printhead Assembly, Single Media Sensor Models
133
Printhead Cover/Upper Media Sensor, Dual Media

Sensor Models
NOTE: The printhead cover/upper media sensor is not available for RFID
printheads. An entire printhead assembly must be replaced.
Removal
2. Remove the printhead assembly, dual media sensor models (page 130).
Printhead Cover/
Upper Media Sensor
Figure 14. Replacing the Old Printhead Cover/Upper Media Sensor

3. Remove the three screws securing the old printhead cover/upper media
sensor to the printhead assembly, then remove the old printhead cover.
(Figure 14.)
4. Fasten the new printhead cover onto the printhead assembly with the
three screws loose enough so that you can still adjust the printhead cover.
5. Push the printhead cover towards the heating elements (light brown area).
Pull the printhead cover back slightly so that it is not completely covering
the IC bump.
NOTE: The IC bump is the dark, raised ridge about 1/16 inch to the side of
the heating elements and extending about nine inches. When the
printhead cover is installed, the IC bump is partly covered by the
printhead cover.
6. Torque the screws to 8 in.-lb.
Installation
134
Resistors, Terminating
Resistors, Terminating
For parallel interface configurations, the printer is equipped with 470 Ohm
pull-up terminating resistors and 1K Ohm pull-down terminating resistors on
the controller board. These are suitable for most applications. (See Figure 15
on page 136.)
If the standard terminating resistor pack is not compatible with the particular
interface driver requirements of the host computer, other values of pull-up and
pull-down resistors may be required. 220 Ohm pull-up and 330 Ohm pull-
down alternate terminating resistors are provided with the printer. If you install
the 220 Ohm pull-up resistor, you must also install the 330 Ohm pull-down
resistor. Possible terminating resistor combinations are shown below.
Configuration RP2 (Pull-Up) RP1 (Pull-Down)
Factory Default 470 Ohm 1K Ohm

Alternate 1 220 Ohm 330 Ohm
Alternate 2 1K Ohm None
Removal
3. Locate the terminating resistor packs. (Figure 15, page 136.)
4. Using a chip puller, remove the packs.
Installation
1. Using a chip installation tool, install the resistor packs in the correct
socket. (Figure 15, page 136.)
135
RP1 RP2
Default: 1K Ohm Default: 470 Ohm
Alt 1: 330 Ohm Alt 1: 220 Ohm
Alt 2: None Alt 2: 1K Ohm
Figure 15. This figure shows the size and location of the terminating resistors on the
controller board.
136
Rewinder (Option)
Rewinder (Option)
Removal
NOTE: You do not need to remove the power supply cable from the
printhead if your work area is large enough to angle the power supply
toward the front of the printer.
4. Remove the retaining E-ring securing the rewinder pulley to the shaft of
the rewinder spindle assembly. (Figure 24, page 162, items 6 and 16.)
5. Slide the rewinder spindle assembly in the direction of the media side of
the printer and out of the frame. (Figure 25, page 166, item 4.)
CAUTION Do not try to force the rewinder belt off the rewinder pulley, or
permanent damage to the rewinder belt may result.
6. Remove the rewinder pulley and two nylon washers. (Figure 24,
page 162, items 5 and 6, and Figure 25, page 166, item 7.)
Installation
1. Make sure the .750x.443x.032 inch nylon washer is installed as far as
possible on the rewinder shaft inside the rewinder spindle. (Figure 25,
page 166, item 7.)
2. Slide the rewinder spindle assembly into the bearing housing, leaving
about 1/8 inch of shaft exposed on the pulley side. (Figure 25, page 166,
item 4.)
3. Spread a small dab of bearing grease around the rear of the rewinder
pulley, then stick the .900x.500x.093 inch nylon washer to the pulley so
that it surrounds the bearing in the center of the pulley. (Figure 24,
4. Slip the rewinder belt over the rewinder pulley. Slide the rewinder pulley,
with the rewinder belt installed on it, onto the rewinder spindle shaft, and
slide the shaft all the way through the pulley. (Figure 24, page 162, items
6 and 7.)
5. Install the retaining E-ring with a flat tip screwdriver. Gently tug on the
rewinder to make sure the retaining ring is secure. (Figure 24, page 162,
item 16.)
6. Make sure the lower portion of the rewinder belt is positioned correctly
over the top of the belt tensioner.
7. Install the power supply assembly (page 129).
137
Rewinder, Torque Check and Adjustment, V1

The optional V1 rewinder has an internal clutch comprised of several plates
and a compression spring. An adjustable lock nut at the end of the rewinder
shaft adjusts the length of the compression spring, which sets the torque
required for reliable automatic label Peel-Off or Batch Rewind operation. This
procedure allows you to check that the rewinder torque is correct, and to
adjust the torque if it is out of range.
Check Rewinder Torque
Deck
Optional Rewinder
Rewinder
Release Lever
Adapter 176323
1/4 inch Male

Hex Key Adapter
Rewinder Notch
Platen Roller
Deck Lock Lever (Shown Open)
Torque Watch
Tool
Figure 16. Checking the Torque of the Optional Rewinder

1. Open the media cover and rotate the printer deck lock lever fully
clockwise until the deck swings upward. (Figure 16.)
2. Turn the rewinder release lever fully clockwise and lock it in place.
(Figure 16.)
3. Remove all liner and media from the rewinder and the printer paper path.
138
4. Hold the torque watch (with adapter installed) in your right hand and insert
the adapter into the recessed opening of the rewinder. The pin on the
adapter must slide into the notch in the rewinder opening.
5. With your left hand, firmly press down on the rubber platen roller to
prevent it from rotating.
6. Slowly turn the torque watch handle clockwise while observing the dial
indicator. The rewinder will initially remain stationary, then it will either
begin turning slowly clockwise or break loose at a specific torque value.
Note this value.
7. Repeat step 5 and step 6 six times, each time noting the torque value at
which the rewinder just begins to turn or break loose. Add the values
together, then divide the sum by six to determine the average torque
value.
8. Use Table 8 below to verify that the average torque value falls within the
specified range for the width of printer in use. If the average torque is
within the range in Table 8, no adjustment is necessary. If the average
torque is outside the ranges in Table 8, adjust the rewinder torque as
explained in the next section.
Table 8. Rewinder Torque Ranges
Printer Width Torque Range
4 Inch 5 in.-lb. 1 in.-lb. (80 in.-oz. 16 in.-oz.)
8 Inch 7.5 in.-lb. 1 in.-lb. (120 in.-oz. 16 in.-oz.)
139
Adjust Rewinder Torque
Nut Driver Tool
A
Rewinder
Release Lever
Shaft Driver Tool
Torque Adjustment Tool

176322-001
Figure 17. Adjusting Rewinder Torque

1. Slide the shaft of the shaft driver tool through the opening in the knurled
handle of the (larger) nut driver tool. (Figure 17, detail A.)
2. Insert the shafts of the combined tools into the opening at the end of the
rewinder and rotate the smaller (shaft driver) knob until it mates with the
end of the rewinder shaft. (Figure 17.)
3. Hold the smaller (shaft driver) knob stationary to prevent the rewinder
shaft from turning, then slide and rotate the larger (nut driver) knob toward
the rewinder until it mates with the rewinder adjustment nut.
4. Hold the smaller (shaft driver) knob stationary and rotate the larger (nut
driver) knob clockwise to increase rewinder torque or
counterclockwise to decrease rewinder torque. Adjust the nut in
turn increments, then check the rewinder torque using the torque watch
tool and adapter, as described in Check Rewinder Torque on page 138.
The rewinder torque is correct when six consecutive readings of the
rewinder torque show values that fall within the ranges listed in Table 8.
140

The optional V2 rewinder has an internal clutch assembly with an adjustable
notched wheel. You can set the notched wheel, accessed through the slot in
the rewinder spindle, to the optimum torque required for reliable automatic
label Peel-Off or Batch Rewind operation. This procedure allows you to check
the rewinder torque value and adjust it if it is outside the recommended range.
Check Rewinder Torque
Deck
Optional V2 Rewinder
Rewinder
Release Lever
Dial Indicator
Platen Roller Inch Hex Shaft
Deck Lock Lever Torque Watch

(Shown Open) Tool
Figure 18. Checking the Torque of the Optional V2 Rewinder

1. Open the media cover and rotate the deck lock lever fully clockwise until
the deck swings upward. (Figure 16.)
2. Turn the rewinder release lever fully clockwise and lock it in place.
3. Remove all liner and media from the rewinder and the printer paper path.
141
4. Hold the torque watch tool in your right hand and insert the end onto the
inch hex shaft at the end of the rewinder.
5. With your left hand, firmly press down on the rubber platen roller to
prevent it from rotating.
6. Slowly turn the torque watch handle clockwise while observing the dial
indicator. The rewinder will initially remain stationary, then it will either
begin turning slowly clockwise or break loose at a specific torque value.
Note this value.
7. Repeat step 5 and step 6 six times, each time noting the torque value at
which the rewinder just begins to turn or break loose. Add the values
together, then divide the sum by six to determine the average torque
value.
8. Use Table 9 below to verify that the average torque value falls within the
specified range for the width of printer in use. If the average torque is
within the range in Table 8, no adjustment is necessary. If the average
torque is outside the ranges in Table 9, adjust the rewinder torque as
explained in the next section.
Table 9. Rewinder Torque Ranges
Printer Width Torque Range
8 Inch 7.5 in.-lb. 1 in.-lb. (120 in.-oz. 16 in.-oz.)
142
Adjust Rewinder Torque
Small, Flat Blade

Screwdriver
Slotted Opening
Rewinder
Spindle
Notched
Adjustment Wheel
Figure 19. Adjusting Rewinder Torque

1. Rotate the rewinder spindle by hand until the slotted opening is at the top.
(Figure 17.)
2. Locate the notched adjustment wheel in the middle of the slotted opening.
Hold the rewinder spindle with one hand and with your other hand insert
the flat blade of the small screwdriver down into the closest notch of the
adjustment wheel.
3. Pivot the screwdriver on the edge of the slotted opening and rotate the
notched adjustment wheel clockwise one notch at a time to increase
clutch torque or counterclockwise one notch at a time to decrease the
torque.
4. Once you have rotated the adjustment wheel a few notches in the desired
direction, check the rewinder torque again as described in Check
Rewinder Torque on page 141. The rewinder torque is correct when six
consecutive readings of the rewinder torque show values that fall within
the ranges listed in Table 8.
143
Security PAL
You must have a security PAL installed that supports your desired emulation.
Refer to Table 10.
NOTE: All security PALs support 4, 6, and 8 inch printers.
IGP includes VGL, PGL, and LP+ emulations.
CT = coax/twinax interface option
NOTE: Security PAL part numbers are for reference only.
Security PALs are not spared or sold separately.
Table 10. Security PAL Description
Emulations Supported Part Number
IGP 170837-002
CT/IGP 170837-002
TCP/IPDS/IGP 170837-004
IPDS/IGP/CT 170837-004
ICP/IPDS/IGP-CT 170837-004
PPI1/PGL 170837-011
PPI2/PGL 170837-010
PPI2/VGL 170837-010
CT/PPI2 170837-010
PPI1/VGL 170837-011
CT/PPI1 170837-011
TN5250/TCP/IGP 170843-001
TN/PPI/IGP 170843-003
Removal

4. Use a chip puller to remove the old PAL from location U7. (Figure 9,
page 119 and Figure 34, page 192, item 15.)
144
Security PAL
Installation
2. Use a chip installer to install the new PAL at location U7 with its notch
toward the Flash SIMM. (Figure 9, page 119 and Figure 34, page 192,
item 15.)
145
Sensor, Head Up
Removal
3. Disconnect the head up sensor cable from connector J11 on the
controller board. (Figure 10, page 120.)
4. Remove the head up sensor cable from the wire saddles and feed it
through the frame opening into the media side of the printer. (See the
cable routing diagram on page 221.)
5. Push the release tab down and pull the power supply cable out of the
printhead assembly. (Figure 13, page 133.)
6. Remove the screw securing the sensor holder to the pivoting deck.
(Figure 28, page 174 or Figure 29, page 178, items 11 and 13).
7. Remove the head up sensor from the sensor holder. (Figure 28, page 174
or Figure 29, page 178, items 10 and 11).
Installation
1. Install the head up sensor in the sensor holder. (Figure 28, page 174 or
Figure 29, page 178, items 10 and 11).
2. Install the screw securing the sensor holder to the pivoting deck.
(Figure 28, page 174 or Figure 29, page 178, items 11 and 13).
3. Connect the power supply cable to the printhead assembly. (Figure 13,
page 133.)
4. Feed the head up sensor cable over the central support of the pivoting
deck and through the frame opening into the drive side of the printer.
Insert the cable into the wire saddles. (See the cable routing diagram on
page 221.)
5. Connect the head up sensor cable to connector J11 on the controller
8. Power on the printer. Wait until the diagnostic tests and initialization
routines finish and the printer goes to ONLINE or OFFLINE, depending
on which is configured as the power on state.
The LCD should display PRINT HEAD OPEN / Close Print Head and the
audible alarm should sound if it is enabled.
10. Close and latch the pivoting deck. The audible alarm should stop.
146
Sensor, Label Taken, Frame Mounted

Removal
3. Loosen the top and bottom screws securing the stepper motor.
4. Rotate the motor clockwise to loosen the drive belt.
5. Tighten the top screw to hold the stepper motor temporarily in place.
6. Remove the screw (two screws on early models) from the cluster pulley
and slide the pulley about 1/4 inch along the platen shaft to gain access to
the label taken sensor. (Figure 24, page 162, items 8 and 13.)
7. Disconnect the label taken cable assembly from connector J18 on the
upper right corner of the controller board and remove the cable assembly
from the wire saddles in the printer frame. (Figure 10, page 120.)
8. Remove the screw securing the label taken sensor to the printer frame
and remove the sensor and cable assembly from the printer. (Figure 36,
Installation
1. Position the label taken sensor assembly in the printer frame and install
the mounting screw. (Figure 36, page 198, items 6 and 7.)
2. Insert the sensor cable assembly into the wire saddles in the printer frame
and connect the cable to connector J18 on the upper right corner of the
controller board. (Figure 10, page 120.)
3. Slide the cluster pulley onto the platen shaft (on early models, make sure
that the flat sections of the shaft are centered under the two cluster pulley
screws).
4. Use a 0.077 inch (1.96 mm) feeler gauge to leave an air gap between the
cluster pulley and the frame.
5. Torque the cluster pulley screw(s) to the flat sections of the platen shaft:
18 in-lb. for the early two screw version or 25 in.-lb. for the later one screw
version.
6. Loosen the top screw on the stepper motor to allow the spring to provide
the correct tension to the platen drive belt, then tighten both screws.
147
Sensor, Label Taken, Front Cover Mounted

This sensor is mounted on the front cover on early single media sensor
models. Later single media sensor models and all dual media sensor models
use the frame mounted label taken sensor (page 147).
Removal
3. Disconnect the label taken sensor cable assembly from connector J18 on
the upper right corner of the controller board and remove the cable
assembly from the wire saddles in the printer frame. (Figure 10,
page 120.)
4. Open the front door and remove the plastic bearing clip from the opening
in the left corner of the pan assembly. (Figure 31, page 186, item 10.)
NOTE: The sensor connector will not fit through the plastic bearing clip in the
pan assembly. You must remove the bearing clip first.
5. Place the cable connector at a slight angle and pull it through the frame
opening, then the pan opening, and finally from under the front door lip.
6. Remove the plastic bearing clip from the cable by sliding the wire through
slot in the side of the bearing.
7. Remove the screw securing the label taken sensor to the front cover and
remove the sensor and cable assembly from the printer. (Figure 31,
page 186, item 7.)
Installation
148
Spindle Assembly, Ribbon Supply Or Take-Up
Spindle Assembly, Ribbon Supply Or Take-Up

Removal
3. Remove the appropriate retaining E-ring securing the final ribbon drive
gear to the desired ribbon spindle shaft. (Figure 25, page 166, items 1, 2,
and 3).
4. Remove the final ribbon drive gear.
5. Slide the ribbon spindle assembly in the direction of the media side of the
printer and out of the frame.
Installation
1. Slide the ribbon spindle assembly into the bearing housing in the printer
frame. (Figure 25, page 166, item 1.)
2. Slide the final ribbon drive gear onto the spindle shaft and engage the
teeth of the ribbon drive gear with the outer teeth of the intermediate
gears. (Figure 25, page 166, item 2.)
3. Install the retaining E-ring securing the final ribbon drive gear to the
spindle shaft. (Figure 25, page 166, item 3).
149
Support Assembly, Lower

Removal
2. Remove the platen (page 128).
3. Remove the media sensor assembly (page 115 for dual media sensor
4. Remove two screws and the peel/tear assembly. (Figure 27, page 170,
items 5 and 6.)
5. Remove three screws (Figure 27, page 170, item 4) and the lower
support assembly (Figure 30, page 182, item 2).
Installation
NOTE: Before tightening the three screws, rotate and bias the lower support
clockwise.
150
Support Assembly, Upper
Support Assembly, Upper

Removal
2. Remove the printhead assembly (page 130 for dual media sensor
4. Remove the head up sensor (page 146).
5. Pull the grommet out of the frame on the drive (electronics) side and feed
the cables back inside the frame while they are still through the grommet.
6. Remove the four screws securing the upper support assembly to the
printer frame. (Figure 27, page 170, items 2 and 3).
Installation
CAUTION The rubber grommet covering the edges of the frame cutout protects the
power supply and printhead/controller cable assemblies from chafing
on the metal edges. Chafed conductors can result in damage to the
printer. Make sure the grommet is undamaged and in place after routing
cables through the frame.
Make sure to install the grommet with the smaller flange on the upper
support (media) side of the frame with the corner cutout in the bottom
front corner. (Figure 34, page 192, item 1.)
151
Tear Bar Assembly, Adjustable

NOTE: The adjustable tear bar assembly supports the Tear-Off Strip Media
Handling mode only. It does not support the Tear-Off Media Handling
mode.
Removal
Peel/Tear
Assembly
Screw (2)
Lower Support Assembly
Peel/Tear Door
Figure 20. Removing the Peel/Tear Assembly

2. Open the peel/tear door by pulling it upward, then forward.
3. Using a 3 mm metric hex key, remove the two screws securing the
peel/tear door assembly to the lower support assembly.
NOTE: Keep the two screws you have removed; you will use them if you
need to reinstall the peel/tear assembly.
152
Tear Bar Assembly, Adjustable
Installation
Pivoting
Deck
Platen
Roller
Lower
Support
Adjustable
Blade
Knurled Deck Lock Lever

Thumbscrew (2) Tear Bar
Bracket Lock Nut (2)
Screw (3)
Figure 21. Installing the Adjustable Tear Bar Assembly

1. Open the pivoting deck by rotating the blue deck lock lever clockwise until
the deck swings upward.
2. Mount the adjustable tear bar assembly to the printer lower support using
the two knurled thumbscrews. Verify the thumbscrews draw the bracket
firmly against the lower support.
3. Access the ends of the thumbscrews from the back of the printer lower
support. Install a lock nut on the end of each thumbscrew finger tight and
then use an 8 mm wrench or pliers and tighten each nut one full turn.
4. When the lock nuts are installed, the thumbscrews and tear bar assembly
become captive to the printer. When the thumbscrews are loosened to
the end of their travel, the tear bar assembly can be pulled away from the
platen about 3/8 inch to aid in clearing a potential label jam.
153
Platen Roller
Feeler Gauge
(0.0015 inch)
Adjustable
Tear Bar Blade
Tear Bar
Bracket
Screw (3)
Figure 22. Positioning the Adjustable Tear Bar Blade

5. Loosen the three screws securing the adjustable blade to the tear bar
bracket using a 2 mm hex key. The holes on the tear bar bracket are
elongated to permit adjustment.
CAUTION The top edges of the tear bar blade are sharp; handle with care!
6. Place a 0.0015 inch feeler gauge, or use the label liner (backing) from the
customers labels as a gauge, between the rubber platen roller and the
inside edge of the tear bar blade. Carefully push the blade toward the
platen until it makes uniform contact with the gauge.
7. When the inside edge of the blade is parallel with the platen roller with a
0.0015 inch gap, tighten the middle screw and then the end screws.
8. Verify the gap is correct between the platen roller and inside edge of the
blade by sliding the gauge the entire width of the blade.
9. Manually rotate the rubber platen roller in 90 degree increments, stopping
each time to check the gap with the gauge until you have checked one full
revolution of the platen roller.
CAUTION The tear bar blade should never make direct contact with the platen.
10. Repeat step 5 through step 9 until the gap between the platen and the
tear bar blade is correct.
12. In the QUICK SETUP menu, set Paper Feed Shift to -0.05 inches.
154
Tensioner, Rewinder Belt
Tensioner, Rewinder Belt

Removal
3. Pry the inner tabs outward and pop the tensioner out of the mounting
slots in the frame. (Figure 24, page 162, item 15.)
Installation
1. Engage the inner tabs on the mounting slots of the printer frame and push
the tensioner in until it snaps into the slots. (Figure 24, page 162, item
15.)
2. Place the bottom portion of rewinder belt over the top of the belt
tensioner.
155
156
5 Illustrated Parts
Breakdown
Organization Of This Chapter

This chapter contains drawings of the electromechanical assemblies
comprising the printer. The table following each illustration lists the illustrated
parts and their part numbers.
Items marked Ref (reference) are not spared, are part of another assembly,
or are shown elsewhere.
Illustrated Parts Breakdown

Figure 23. Covers and Media Hanger ................................................................................ page 158
Figure 24. Power Supply, Belts, and Stepper Motor ..........................................................page 162
Figure 25. Shafts and Spindles .......................................................................................... page 166
Figure 26. Media Damper ................................................................................................... page 168
Figure 27. Upper and Lower Support Assemblies .............................................................. page 170
Figure 28. Six and Eight Inch Printhead, Pivoting Deck, and Upper Support Assy ............ page 174
Figure 29. Four Inch Printhead, Pivoting Deck, and Upper Support Assy..........................page 178
Figure 30. Platen and Lower Support Assemblies ............................................................. page 182
Figure 31. Frame and Base Pan Assembly, Phase I..........................................................page 186
Figure 32. Frame and Base Pan Assembly, Phase II......................................................... page 188
Figure 33. Frame and Base Pan Assembly, Phase III........................................................ page 190
Figure 34. Controller Board and I/O Assemblies ................................................................ page 192
Figure 35. Screen, Gears, and Ribbon Drive Motors ......................................................... page 196
Figure 36. Control Panel Assembly ....................................................................................page 198
Figure 37. Cable Assemblies and Interconnections ........................................................... page 200
Hardware Kit....................................................................................................................... page 202
Hardware Kit, Cutter Options.............................................................................................. page 203
157
Chapter 5 Illustrated Parts Breakdown
1b
17
2 1a
14
13
4 16
15
5 3
1
9
10
12
11
7
Figure 23. Covers and Media Hanger
158
Item
Part No. Description Notes
No.
1 173108-001 Cover, Side, Frame, Ventless Models Do not replace a vented side
cover with this part.
1a 173108-002 Cover, Side, Frame, Vented Models Used with frames that have a
removable rear panel. See
Figure 35, page 196, item 6.
1b 171938-001 Cover, Side, Frame, Vented Models Used with frames that have a
fixed rear panel.
2 171943-001 Cover, Media, 8 inch

171943-002 Cover, Media, 6 inch
172151-001 Cover, Media, 4 inch
3 170171-004 Dashpot, 8 inch

170171-001 Dashpot, 6 inch
170171-003 Dashpot, 4 inch
4 203824-001 Screw, Flanged, Socket Head, Available only in Hardware
M4x10mm (4) Kit 171629-001 (page 202).
5 203433-001 Stud, Ball, 10mm (2)
6 203254-001 Screw, M5x10mm (2) Shown exploded in

Figure 23, but remain behind
controller board. Available in
Hardware Kit 171629-001
(page 202).
7 750471-001 Beam, Media Hanger, 8 inch

750471-002 Beam, Media Hanger, 6 inch
750471-003 Beam, Media Hanger, 4 inch
8 750474-901 Guide Assy, Media Hanger
9 203527-001 Clip, EMI (6) In Hardware Kit 171629-001

(page 202), but can also be
ordered separately.
10 Ref Bracket, Dashpot Figure 31, page 186,
Figure 32, page 188, and
Figure 33, page 190.
11 Ref Pan Assembly Figure 31, page 186,

Figure 32, page 188, and
Figure 33, page 190.
12 750923-001 Button, Damping (7) In Hardware Kit 171629-001

(page 202), but can also be
ordered separately.
13 170437-001 Label, Media Loading Not part of item 2.
159
Item
No.
14 Ref Label, Media/Ribbon Source Not part of item 2.
15 203711-001 Screw, Captive, M4x10mm (2) Available only in Hardware

Kit 171629-001 (page 202).
16 203326-001 Ring, Retaining, E, .156 Available only in Hardware

Kit 171629-001 (page 202).
17 170386-001 Window, Media Cover Part of item 2, but can also
be ordered separately.
160
(Parts lists continue on the next page.)
161
20
10
15
5
6
16
12
11
13
2 7 9
21
18
14
4
17
3 1
21
19
14
17 1a
3
Figure 24. Power Supply, Belts, and Stepper Motor
162
Item
No.
1 173344-001 Power Supply Assembly Includes items 3, 4, 14, 17,

18, and 21. Can be used on
vented and ventless model
printers.
1a 750489-001 Power Supply Assembly, Vented Includes items 3, 14, and 17.
Printers Used on vented model
printers only.

M4x10mm (2) Kit 171629-001 (page 202).
3 140822-007 Screw, M4x30mm (4) Part of items 1 and 1a.

Available only in Hardware
Kit 171629-001 (page 202).
4 Ref Fan Bracket Part of item 1.

5 204527-001 Washer, Nylon, 1.125x.500x.080 inch Available only in Hardware
Kit 171629-001 (page 202).
Optional.
6 174494-001 Pulley/Clutch Assy, Rewinder Use with the rewinder option

only. Ref.: Figure 25, item 4.
7 750581-001 Belt, Rewinder Use with the rewinder option

only.
8 171239-901 Pulley, Cluster
9 750580-001 Belt, Platen
10 203260-001 Spring, Stepper Motor Not part of item 12.

11 203824-001 Screw, Flanged, Socket Head, Not part of item 12. Available
M4x10mm (2) only in Hardware Kit
171629-001 (page 202).
12 172133-901 Field Kit, Stepper Motor Includes pulley and bracket,

but does not include items 10
and 11.
13 203252-001 Screw, Socket Head, M4x10mm Available only in Hardware

Kit, Cutter Options
175508-001 (page 203).
14 140664-002 Nut, M4 (4) Part of items 1 and 1a.
Kit 171629-001 (page 202).
15 750599-001 Tensioner, Belt Use with the rewinder option

only.
163
Item
No.
16 105678-003 Ring, Retaining, E, .3125 Available only in Hardware

Kit 171629-001 (page 202).
17 171736-001 Fan Assembly, Power Supply Part of items 1 and 1a, but
can also be ordered
separately.
18 Ref Power Supply Part of item 1.

19 Ref Power Supply, Vented Printers Part of item 1a.
20 750695-001 Cable Assy, Printhead Controller 6 and 8 inch printers only.

171774-001 Cable Assy, Printhead Controller 4 inch printers only.
21 Ref Cable Assembly, Power Supply Part of items 1 and 1a.
164
165
12 2 3
13 7
2 3
1 16
8 3
14
6 9
11
10
7
1
8
5
15
7
4a
4
A
See page 168.
Figure 25. Shafts and Spindles
166
Item
No.
1 171409-001 Field Kit, Ribbon Spindle, 8 inch Includes items 3, 7, 12 and

171408-001 Field Kit, Ribbon Spindle, 6 inch 13. Not used on -DT models.
172264-001 Field Kit, Ribbon Spindle, 4 inch
2 750569-001 Gear, Ribbon Drive, Final Not used on -DT models.
3 203278-001 Ring, Retaining, E, .375 Part of item 1. Available only
in Hardware Kit 171629-001
(page 202).
4 178614-001 Spares Kit, Rewinder, V3, 8 inch Includes items 7, 10, 11, and
178614-002 Spares Kit, Rewinder, V3, 6 inch 14. Rewinder option.
178614-003 Spares Kit, Rewinder, V3, 4 inch
4a 171407-001 Field Kit, Rewinder, 8 inch Replace with 178614-001.

171406-001 Field Kit, Rewinder, 6 inch Replace with 178614-002.
172263-001 Field Kit, Rewinder, 4 inch Replace with 178614-003.
5 750641-001 Spring, Media Damper
6 203480-001 Take-up Core, 8 inch Additional core required
203479-001 Take-up Core, 6 inch when using thermal ribbon.
203478-001 Take-up Core, 4 inch Not used on -DT models.
7 203510-001 Washer, Nylon, .750x.443x.032 Part of items 1 and 4. Also
available in Hardware Kit
171629-001 (page 202).
8 203523-001 Washer, Nylon, .380x.683x.031 Available only in Hardware
Kit 171629-001 (page 202).
9 203526-001 Washer, .390x.656x.020 Available only in Hardware
Kit 171629-001 (page 202).
10 204527-001 Washer, Nylon, 1.125x.500x.080 inch Part of item 4. Also available
(page 202).
11 174494-001 Pulley Assy, Rewinder Part of item 4. Use with the
rewinder option only.
12 203513-001 Screw, Btn Hd, M3x4mm (2) Part of item 1. Available only
(page 202).
13 170528-001 Blade, Ribbon Spindle Part of item 1, but can also
be ordered separately. Not
on -DT models.
14 105678-003 Ring, Retaining, E, .3125 Part of item 4. Also available
(page 202).
15 203403-001 Screw, Set, 8-32x.375 (2) Also available in Hardware
Kit 171629-001 (page 202).
16 Ref Media Damper Stop
167
A
From page 166.
2a
2
3a
Figure 26. Media Damper
168
Item
No.
1 750477-001 Shaft, Media Damper 6 and 8 inch printers only.

171825-001 Shaft, Media Damper 4 inch printers only.
2 175169-001 Damper, Media, 8 inch

175169-002 Damper, Media, 6 inch
175169-003 Damper, Media, 4 inch
2a 750472-001 Damper, Media, 8 inch Replace with 175169-001.

750472-002 Damper, Media, 6 inch Replace with 175169-002.
171246-001 Damper, Media, 4 inch Replace with 175169-003.
3 177719-001 Guide, Media Width
3a 175756-001 Guide, Media Width, Ext. Used with optional rewinder

or validator only.
169
1
See page 174
and page 178.
A
13 10
2
11
5
B See page 182.
3
12 7
Figure 27. Upper and Lower Support Assemblies
170
Item
No.
1 750695-001 Cable Assembly, Printhead/Controller 6 and 8 inch printers only.

See item 20, page 162.
171774-001 Cable Assembly, Printhead/Controller 4 inch printers only. See item
20, page 162.
2 172268-001 Field Kit, Upper Support Assy, 4 inch Does not include printhead
171597-001 Field Kit, Upper Support Assy, 6 inch assembly.
171598-001 Field Kit, Upper Support Assy, 8 inch

M4x10mm (4) Kit 171629-001 (page 202).

M4x10mm (3) Kit 171629-001 (page 202).
5 172474-001 Peel/Tear Assembly, 8 inch Used with pan 171962-001.
Includes item 7.
172474-002 Peel/Tear Assembly, 6 inch Used with pan 171962-002.
Includes item 7.
172474-003 Peel/Tear Assembly, 4 inch Used with pan 171962-003.
Includes item 7.
6 203254-001 Screw, M5x10mm (2) Available only in Hardware

Kit 171629-001 (page 202).
7 171892-001 Door, Peel/Tear, 8 inch Used with pan 171962-001

(Figure 33), but can be
ordered separately.
171892-002 Door, Peel/Tear, 6 inch Used with pan 171962-002
ordered separately.
171892-003 Door, Peel/Tear, 4 inch Used with pan 171962-003
ordered separately.
171892-004 Door, Peel/Tear, Cut-Down, 8 inch Designed to support peeling
171892-005 Door, Peel/Tear, Cut-Down, 6 inch short label lengths. Does not
171892-006 Door, Peel/Tear, Cut-Down, 4inch support any paper path assy.
8 172473-001 Field Kit, Paper Path Assy, 8 inch
172473-002 Field Kit, Paper Path Assy, 6 inch
172473-003 Field Kit, Paper Path Assy, 4 inch
9 Ref Cable Assembly, Power Supply Part of power supply. See

item 21, page 162.
10 Ref Pivoting Deck Part of item 2.
11 171969-001 Roller, Peel/Tear Used only on printers with

the rewinder option installed.
12 203419-001 Ring, Retaining E, .188 Available only in Hardware

Kit 171629-001 (page 202).
171
Item
No.
13 175063-901 Tear Bar, Adjustable, 4 inch Supports Continuous and

175063-902 Tear Bar, Adjustable, 6 inch Tear-Off Strip media handling
175063-903 Tear Bar, Adjustable, 8 inch modes only.
Does not support any paper
path assy.
Includes thumbscrews and
Nylock nuts.
See Tear Bar Assembly,
Adjustable on page 152.
172
173
14
A
17
B
From page 170.
13
15
13
9
27 11
22
10
24 7
7
12
13 23
21
16
23 24
B
7
28 25 26
5
13
19 18
22
2
29
7
1 31 6 20 4 3
32
8
33
2
30
Figure 28. Six and Eight Inch Printhead, Pivoting Deck, and Upper Support Assembly
174
Item
No.
1 173609-001 Field Kit, Printhead Assy, 203 dpi, 6 in Includes items 31, 32, and
173612-001 Field Kit, Printhead Assy, 300 dpi, 6 in 33. Does not include item 30.
173615-001 Field Kit, Printhead Assy, 203 dpi, 8 in
173617-001 Field Kit, Printhead Assy, 300 dpi, 8 in
2 203419-001 Ring, Retaining, E, .188 inch (3) Available only in Hardware
Kit 171629-001 (page 202).
3 170383-001 Dial, Head Pressure Adjustment Use with small knob only.
171089-001 Dial, Head Pressure Adjustment Use with large knob only.
4 170382-001 Indicator, Head Pressure Dial Use with small knob only.
171088-001 Indicator, Head Pressure Dial Use with large knob only.
5 170298-001 Knob, Lead Screw, SM, .90 in OD Small knob.

171087-001 Knob, Lead Screw, LG, 1.15 in OD Large knob.
6 170880-001 Pointer, Pressure Block
7 203281-001 Screw, Btn Hd Soc Cap, M3x6mm (7) Available only in Hardware
Kit 171629-001 (page 202).
8 750586-001 Shaft, Head Pressure, 8 inch For small knob.

171086-001 Shaft, Head Pressure, 8 inch For large knob.
750586-002 Shaft, Head Pressure, 6 inch For small knob.

M4x10mm (3) Kit 171629-001 (page 202).
10 171746-001 Sensor, Head Up
11 170193-001 Holder, Sensor
12 171277-001 Clip, Head Retainer (2) Right clip not shown.
Kit 171629-001 (page 202).
14 173838-001 Brush Assembly, Anti-Static, 8 inch

173838-002 Brush Assembly, Anti-Static, 6 inch
15 170574-001 Gimbal, Adjustable, 8 inch
170574-002 Gimbal, Adjustable, 6 inch
16 203251-001 Screw, Hx Skt Btn Hd, ZI, M3x8mm (2) Available only in Hardware
Kit 171629-001 (page 202).
17 171121-001 Ground Wire, Antistatic

18 172196-001 Rack, Gimbal Pivot, 6 and 8 inch
19 171730-001 Handle, Pressure Pad
175
Item
No.
20 171591-001 Head Pressure Block Assy, 6 inch (2)

171592-001 Head Pressure Block Assy, 8 inch (2)
21 171642-001 Field Kit, Gimbal Spring/Guard Set
22 171996-001 Bushing, Ribbon Guide, RH
23 171996-002 Bushing, Ribbon Guide, LH
24 170261-001 Shaft, Ribbon Guide, 8 inch

170261-002 Shaft, Ribbon Guide, 6 inch
25 203431-001 Washer, Curved, .194 Available only in Hardware

Kit 171629-001 (page 202).
26 171642-001 Field Kit, Gimbal Spring/Guard Set
27 170876-001 Spacer, Gimbal (3)
28 171864-001 Retainer, Head Latch, Inboard
29 171864-002 Retainer, Head Latch, Outboard
30 175116-001 Cable, Upper Media Sensor Not part of item 1.
31 Ref Bracket, Head Mount, 8 inch Part of item 1.

Ref Bracket, Head Mount, 6 inch
32 175174-901 Printhead Cover/Upper Media Sensor Part of item 1, but can be

Assembly, 8 inch ordered separately.
175174-902 Printhead Cover/Upper Media Sensor
Assembly, 6 inch
33 203281-001 Screw, Btn Hd Soc Cap, M3x6mm (3) Part of item 1. Also available
(page 202).
176
177
13
A
14 17 From page 170.
B
15 9
13
27
22
11
23
24
7
12 7 10
26 16
13
21
23
24
B
7 25 5
28 18 13
19
22
2
6 29 3
7
20
1 8
31 4
7
32
2
33
30
Figure 29. Four Inch Printhead, Pivoting Deck, and Upper Support Assembly
For RFID models, see Figure 99 on page 340.
178
Item
No.
1 173603-001 Field Kit, Printhead Assy, 203 dpi, 4 in Includes items 31, 32, and
173606-001 Field Kit, Printhead Assy, 300 dpi, 4 in 33. Does not include item 30.
For SL5000e and T5000e SR
models, see Figure 99,
page 340, item 3.
2 203419-001 Ring, Retaining, E, .188 inch (3) Available only in Hardware

Kit 171629-001 (page 202).
3 170383-001 Dial, Head Pressure Adjustment Small knob version.
171089-001 Dial, Head Pressure Adjustment Large knob version.
4 170382-001 Indicator, Head Pressure Dial For small knob.

171088-001 Indicator, Head Pressure Dial For large knob.
5 170298-001 Knob, Lead Screw, SM, .90 in OD Small knob.

171087-001 Knob, Lead Screw, LG, 1.15 in OD Large knob. Not on -DT
models.
6 171458-001 Handle, Pressure Pad, 4 inch Not on -DT models.
Kit 171629-001 (page 202).
8 171173-001 Shaft, Head Pressure, 4 inch For small knob.

M4x10mm (3) Kit 171629-001 (page 202).
11 170193-001 Holder, Sensor
12 171277-001 Clip, Head Retainer (2) Right clip not shown.
13 203513-001 Screw, Button Head, M3x4mm (7) Available only in Hardware

Kit 171629-001 (page 202).
14 173858-001 Brush Assembly, Anti-Static, 4 inch Not on -DT models.

15 171161-001 Gimbal, Adjustable, 4 inch Not on -DT models.
Kit 171629-001 (page 202).
17 171121-001 Ground Wire, Antistatic Not on -DT models.
18 172197-001 Rack, Gimbal Pivot, 4 inch Not on -DT models.
19 171458-001 Handle, Pressure Pad, 4 inch Not on -DT models.
20 172266-001 Head Pressure Block Assy, 4 inch (2) Not on -DT models.
179
Item
No.
21 171146-001 Spring, Leaf (2) Not on -DT models.
22 171996-001 Bushing, Ribbon Guide, RH Not on -DT models.
23 171996-002 Bushing, Ribbon Guide, LH Not on -DT models.
24 171166-001 Shaft, Ribbon Guide, 4 inch Not on -DT models.
25 203431-001 Washer, Curved, .194 Available only in Hardware

Kit 171629-001 (page 202).
26 171377-001 Guard, Leaf Spring (2) Not on -DT models.
27 170876-001 Spacer, Gimbal (3) Not on -DT models.

28 171864-001 Retainer, Head Latch, Inboard
29 171864-002 Retainer, Head Latch, Outboard
30 175116-001 Cable, Upper Media Sensor Not part of item 1.
31 Ref Bracket, Head Mount, 4 inch Part of item 1.
32 175174-903 Printhead Cover/Upper Media Sensor Part of item 1, but can be

Assembly, 4 inch ordered separately.
page 340, item 3.
33 203513-001 Screw, Btn Hd Soc Cap, M3x4mm (3) Part of item 1. Also available
(page 202).
180
181
B
1
From page 170.
2, 2a 8
7
3
10
9a
5
12
11
Figure 30. Platen and Lower Support Assemblies
182
Item
No.
1 171405-001 Field Kit, Platen Assembly, 8 inch Includes: platen shaft, 8 inch
750572-001; bearing, ball,
sealed (2) 151944-001;
bearing, roller (2) 203376-
001; and spacer, platen (2)
170258-001.
171404-001 Field Kit, Platen Assembly, 6 inch Includes: platen shaft, 6 inch
750572-002; bearing, ball,
sealed (2) 151944-001;
bearing, roller (2) 203376-
001; and spacer, platen (2)
170258-001.
172261-001 Field Kit, Platen Assembly, 4 inch Includes: platen shaft, 4 inch;
bearing, ball, sealed (2)
151944-001; bearing, roller
(2) 203376-001; and spacer,
platen (2) 170258-001.
2 173623-001 Field Kit, Lower Support Assy, Dual, Includes item 9. Does not
4 inch include platen assy, peel/tear
173621-001 Field Kit, Lower Support Assy, Dual, assy, or lower media sensor
6 inch assy. Used in dual media
173622-001 Field Kit, Lower Support Assy, Dual, sensor models only.
8 inch
page 340, item 9.
2a 172270-001 Field Kit, Lower Support Assy, Single, Includes item 9a. Does not
4 in include platen assy, peel/tear
171624-001 Field Kit, Lower Support Assy, Single, assy, or lower media sensor
6 inch assy. Used in single media
171625-001 Field Kit, Lower Support Assy, Single, sensor models only.
8 inch
3 203257-001 Ring, Retaining, .875 Available only in Hardware

Kit 171629-001 (page 202).
4 171714-001 Lever, Deck Lock Includes magnet.

5 173624-001 Field Kit, Media Sensor Assy, Lower Used in dual media sensor
models only.
6 203419-001 Ring, Retaining, E, .188 inch Part of item 1, but also

171629-001 (page 202).
183
Item
No.
7 203414-001 Washer, Wavy, .870 ID Available only in Hardware

Kit 171629-001 (page 202).
Kit 171629-001 (page 202).
9 173255-001 Media Guard, PH3, 8 inch Part of item 2. Used in dual

173255-002 Media Guard, PH3, 6 inch media sensor models only.
173255-003 Media Guard, PH3, 4 inch
page 340, item 8.
9a 171484-001 Media Guard, Wide, 8 inch Part of item 2a. Used in

171484-002 Media Guard, Wide, 6 inch single media sensor models
171484-003 Media Guard, Wide, 4 inch only.
Kit 171629-001 (page 202).
11 171635-001 Field Kit, Media Sensor Assy Includes item 12. Used in
single media sensor models
only.
12 170545-001 Handle, Media Sensor Part of item 11, but can be

ordered separately. Used in
single media sensor models
only.
184
185
12
13
10
2
1
11
3
5 4
Figure 31. Frame and Base Pan Assembly, Phase I
186
Item
No.

M4x10mm (4) Kit 171629-001 (page 202).
2 750908-001 Bracket, Dashpot, 6 and 8 inch
3 750659-001 Pad, Rubber (4)

M4x10mm (11) Kit 171629-001 (page 202).
5 171939-001 Pan Assembly, 8 inch Includes item 11.

171939-002 Pan Assembly, 6 inch
6 750923-001 Button, Damping (7)
7 170219-001 Sensor, Label Taken, Front Cover Used in early models only.
Mounted Later models use a frame
mounted label taken sensor.
8 171942-001 Cover, Front, 8 inch

171942-002 Cover, Front, 6 inch
172152-001 Cover, Front, 4 inch
9 203251-001 Screw, Hx Skt Btn Hd, ZI, M3x8mm Available only in Hardware
Kit 171629-001 (page 202).
10 202721-001 Clip, Plastic Bearing Available only in Hardware

Kit 171629-001 (page 202).
11 750631-001 Magnet Part of item 5, but can also be

ordered separately.
12 750852-001 Plate, I/O, Blank
13 750892-001 Screen, Fan
187
10
8
2
3
5 4
Figure 32. Frame and Base Pan Assembly, Phase II
188
Item
No.

M4x10mm (4) Kit 171629-001 (page 202).

177508-001 Bracket, Dashpot, 4 inch
3 750659-001 Pad, Rubber (4)

M4x10mm (11) Kit 171629-001 (page 202).
5 171962-001 Pan Assembly, 8 inch

6 750923-001 Button, Damping (7) Available only in Hardware

Kit 171629-001 (page 202).
7 203682-001 Plug, .4375 inch Only on four inch printers

without the rewinder option.
Kit 171629-001 (page 202).
8 203643-001 Plug, .5 inch (4) Available only in Hardware

Kit 171629-001 (page 202).
9 750852-001 Plate, I/O, Blank
10 750892-001 Screen, Fan
189
8
2
3
5
4
Figure 33. Frame and Base Pan Assembly, Phase III
190
Item
No.

M4x10mm (4) Kit 171629-001 (page 202).

177508-001 Bracket, Dashpot, 4 inch
3 750659-001 Pad, Rubber (4)

M4x10mm (11) Kit 171629-001 (page 202).
5 171962-001 Pan Assembly, 8 inch

6 750923-001 Button, Damping (7) Available only in Hardware

Kit 171629-001 (page 202).
7 203682-001 Plug, .4375 inch (2) Used only on printers without

the rewinder option.
Kit 171629-001 (page 202).
8 203643-001 Plug, .5 inch (3) Available only in Hardware

Kit 171629-001 (page 202).
191
18
18 1
7
19
8
20
15
21
14
10
11 4
12
2, 2a
3
17
13
6
16
9
9a
Figure 34. Controller Board and I/O Assemblies
192
Item
No.
1 750906-001 Grommet, Rubber

2 175077-901 Controller PCBA, V5 Includes items 19, 20, and
21. Used in dual and single
media sensor models.
2a 171662-901 Controller PCBA, V4 Includes items 19, 20, and

21. Used in single media
sensor models only.
3 172087-001 SIMM, Flash, 4 MB

172088-001 SIMM, Flash, 10 MB
4 173024-001 Field Kit, SIMM, DRAM, 8 MB

170978-001 Field Kit, SIMM, DRAM, 16 MB
5 152439-901 Cable Assembly, Centronics I/O
6 203548-001 Clamp, Ferrite, Enclosed Radio frequency interference

suppressor.

M4x10mm (6) Kit 171629-001 (page 202).
8 203464-001 Thermal Gap Filler Pad Must be installed under the

controller PCBA, item 2.
9 170826-001 Field Kit, Internal 10/100Base-T Internal NIC assembly.
9a 171747-001 Field Kit, External 10/100Base-T External NIC assembly.

10 170397-901 Expansion-CT Subassembly Includes items 17 and 21, CT
PCBA, and bracket.
11 203516-001 Expansion Cable, 60-pin
12 203328-001 Socket Strip, 60-pin
13 140752-002 Cable Assembly, Twinax, Smart T
Kit 171629-001 (page 202).
15 Ref PAL, Security See Table 10 on page 144.
16 102559-405 Screw, w/Lockwasher, 4-40x.31 (2) Available only in Hardware

Kit 171629-001 (page 202).
17 175291-001 Plate, CT Adapter
18 202379-001 Wire Saddle Blind Hole (4) Available only in Hardware

Kit 171629-001 (page 202).
193
Item
No.
19 203326-001 Ring, Retaining, E, .156 (6) Part of items 2 and 2a, but
also available in Hardware Kit
171629-001 (page 202).
20 203711-001 Screw, Captive, Btn Hd, M4x10mm (6) Part of items 2 and 2a, but
also available in Hardware Kit
171629-001 (page 202).
21 202434-001 Kit, Screw, M/F, 4-40 (2) Part of items 2, 2a, and 10,
but also available in
Hardware Kit 171629-001
(page 202).
194
195
7
6
3
4
9
1
2
8
6a
3
5 4
Figure 35. Screen, Gears, and Ribbon Drive Motors
196
Item
No.
1 750568-001 Gear, Ribbon Drive, Intermediate Not on -DT models.

2 203419-001 Ring, Retaining, E Available only in Hardware
Kit 171629-001 (page 202).
3 171403-001 Field Kit, DC Motor Does not include item 4.

Not on -DT models.
4 204002-001 Screw, Flanged, Socket Head, Not part of item 3. Available

M4x12mm (2 per motor) only in Hardware Kit
171629-001 (page 202).
Kit 171629-001 (page 202).
6 173179-003 Plate, Rear Panel, Ventless Model
6a 173179-002 Plate, Rear Panel, Vented Model
7 175330-001 Plate, I/O, Blank, Wide Fits items 6 and 6a.

8 175286-001 Plate, Parallel, Blank Fits items 6 and 6a.

M4x10mm (6) Kit 171629-001 (page 202).
197
8
t53ipb11
Figure 36. Control Panel Assembly
198
Item
No.
1 170644-001 Control Panel Assembly Does not include overlay.

Includes item 8.
2 750561-001 Overlay, Control Panel, English

170504-001 Overlay, Control Panel, International
171731-001 Overlay, Control Panel, French
171732-001 Overlay, Control Panel, German
171733-001 Overlay, Control Panel, Italian
171734-001 Overlay, Control Panel, Spanish
171735-001 Overlay, Control Panel, Brazilian
Portuguese
3 170625-001 Lens, Control Panel
4 203475-001 Finger, Control Panel Ground
5 203513-001 Screw, Btn Hd, M3x4mm (2) Available only in Hardware

Kit 171629-001 (page 202).
6 171896-001 Sensor, Label Taken, Frame Mounted Early models use the front
cover mounted label taken
sensor instead of this sensor.
(Figure 31, page 186,
item 7.)
7 203251-001 Screw, Hx Skt Btn Hd, ZI, M3x8mm Available only in Hardware
Kit 171629-001 (page 202).
8 750547-001 Housing, Control Panel Part of item 1.
199
16
15 11 7
17
13
12
14
8
6
5
3 4
1
10
Figure 37. Cable Assemblies and Interconnections
200
Item
No.
1 152439-901 Centronics I/O Cable Assembly

2 171947-001 Field Kit, Cable Assy, Validator option Includes ferrite.
3 750695-001 Printhead/Controller Cable Assembly 6 and 8 inch printers.

171774-001 Printhead/Controller Cable Assembly 4 inch printers.
4 170070-901 Cable Assembly, Power Supply/

Controller PCBA
5 Ref Part of Power Supply Assembly
6 Ref Part of Ribbon Drive DC Motor Not on -DT models.
7 750560-001 Cable Assembly, Control Panel
8 Ref Part of Stepper Motor Field Kit
9 102512-001 Power Cord, 125 Volt, 10A, 8 feet

102512-004 Power Cord, 250 Volt, 6A Detachable
102512-007 Power Cord, 240 Volt, 6A/10A, UK
10 Ref Power Supply to Printhead cable Part of power supply.
11 171628-901 Media Sensor Used in single media sensor

models only.
12 170219-001 Sensor, Label Taken, Front Cover Used in early models.

Mounted (Figure 33, item 7.)
171896-001 Sensor, Label Taken, Frame Mounted Used in later models.
(Figure 36, item 6.)
14 Ref Cable assembly, part of Media Cutter

option
15 175174-901 Printhead Cover/Upper Media Sensor Used in dual media sensor

Assembly, 8 inch models only. Part of the
175174-902 Printhead Cover/Upper Media Sensor printhead assembly.
Assembly, 6 inch
175174-903 Printhead Cover/Upper Media Sensor
Assembly, 4 inch
16 173624-001 Lower Media Sensor Assembly Used in dual media sensor

models only.
17 175116-001 Cable, Upper Media Sensor Used in dual media sensor

models only.
201
Hardware Kit
Hardware Kit 171629-001 contains an assortment of fasteners used in the
printer. The contents of the kit are listed below.
Part No. Description Qty Notes
101480-001 Tie Wrap, 4 inch 4
102559-405 Screw, w/lock washer, 4-40x.31 2
105625-005 Screw, Set, Oval, 8-32x3/8 2 Use on aluminum pulley.
105678-003 Ring, Retaining, .3125 inch 1

140664-002 Nut, Hex, Steel, Zinc Plated, M4 2
140822-007 Screw, M4x30mm 2
173587-001 Clutch, Intermediate, Rewinder 3
202379-001 Wire Saddle Blind Hole 2
202434-001 Kit, Screw, M/F, 4-40 1
202721-001 Clip, Plastic Bearing 2
203225-001 Washer, Nylon, .25 1 For inboard front door

hinge to take up excess
clearance.
203251-001 Screw, Hx Socket Button Head, ZI, M3x8mm 5
203255-001 Screw, Set, Hex Socket Head, M4x8mm 1 Use on plastic pulley.
203257-001 Ring, Retaining, .875 1
203278-001 Ring, Retaining, E, .375 2
203281-001 Screw, Button Head, Socket Cap, M3x6mm 2
203326-001 Ring, Retaining, E, .156 2
203345-001 Washer, Wavy 1 For outboard front door

hinge to take up excess
clearance.
203414-001 Washer, Wave, .870 OD 1
203419-001 Ring, Retaining E, .188 2
203431-001 Washer, Curved, .194 ID 1
203510-001 Washer, Nylon, .750x.443x.032 2

203513-001 Screw, Button Head, Socket Cap, M3x4mm 5
203523-001 Washer, Nylon, .380x.683x.031 2
202
Hardware Kit, Cutter Options
203526-001 Washer, .390x.656x.020 2
203527-001 Clip, EMI 3
203590-001 Grommet, Hole 4 For DC and stepper

motors.
203643-001 Plug, Frame, .5 inch 2 Frame plugs.
203662-001 Nut, Locking, M10 1
203682-001 Plug, Frame, .4375 inch 2 For 4 inch rewinder hole.
203711-001 Screw, Captive, Btn Hd, M4x10mm 2 Use to fasten frame side
cover.
203824-001 Screw, Flanged, Socket Head, M4x10mm 10
204002-001 Screw, Flange, Soc Hd, Bk, M4x12mm 2
204014-001 Screw, Button, Socket Head, SS, M5x10mm 2

204527-001 Washer, Nylon, 1.125x.500x.080 inch 1
750923-001 Button, Damping 3

Hardware Kit, Cutter Options 175508-001 contains an assortment of
fasteners used in the standard and heavy duty cutters. The contents of the kit
are listed below.
140988-005 Screw, Phil Head, M2x8mm 2 Use in heavy duty cutter.

203251-001 Screw, Hex Socket Btn Head, M3x8mm, ZI 8 Use in all cutters.
203252-001 Screw, Hex Socket Head, M4x10mm, ZI 2 Use in all cutters.
203254-001 Screw, Hex Socket Head, M5x16mm, ZI 2 Use in heavy duty cutter.
203513-001 Screw, Btn Head Socket Cap, M3x4mm 6 Use in heavy duty cutter.
203715-001 Finger, Ground, Cutter 1 Use in heavy duty cutter.
204014-001 Screw, Btn Head Socket Cap, M5x10mm 2 Use in all cutters.
203
204
A ASCII Codes
Char Dec Hex Char Dec Hex Char Dec Hex Char Dec Hex
NUL 0 00 EM 25 19 2 50 32 K 75 4B
SOH 1 01 SUB 26 1A 3 51 33 L 76 4C
STX 2 02 ESC 27 1B 4 52 34 M 77 4D
EXT 3 03 FS 28 1C 5 53 35 N 78 4E
EOT 4 04 GS 29 1D 6 54 36 O 79 4F
ENQ 5 05 RS 30 1E 7 55 37 P 80 50
ACK 6 06 US 31 1F 8 56 38 Q 81 51
BEL 7 07 32 20 9 57 39 R 82 52
BS 8 08 ! 33 21 : 58 3A S 83 53
HT 9 09 + 34 22 ; 59 3B T 84 54
LF 10 0A # 35 23 < 60 3C U 85 55
VT 11 0B $ 36 24 = 61 3D V 86 56
FF 12 0C % 37 25 > 62 3E W 87 57
CR 13 0D & 38 26 ? 63 3F X 88 58
SO 14 0E + 39 27 @ 64 40 Y 89 59
SI 15 0F ( 40 28 A 65 41 Z 90 5A
DLE 16 10 ) 41 29 B 66 42 [ 91 5B
DC1 17 11 * 42 2A C 67 43 \ 92 5C
DC2 18 12 + 43 2B D 68 44 ] 93 5D
DC3 19 13 , 44 2C E 69 45 ^ 94 5E
DC4 20 14 - 45 2D F 70 46 _ 95 5F
NAK 21 15 . 46 2E G 71 47 ` 96 60
SYN 22 16 / 47 2F H 72 48 a 97 61
ETB 23 17 0 48 30 I 73 49 b 98 62
CAN 24 18 1 49 31 J 74 4A c 99 63
205
Appendix A
d 100 64 130 82 160 A0 190 BE
e 101 65 131 83 161 A1 191 BF
f 102 66 132 84 162 A2 192 C0
g 103 67 133 85 163 A3 193 C1
h 104 68 134 86 164 A4 194 C2
i 105 69 135 87 165 A5 195 C3
j 106 6A 136 88 166 A6 196 C4

k 107 6B 137 89 _ 167 A7 197 C5
l 108 6C 138 8A 168 A8 _ 198 C6
m 109 6D 139 8B 169 A9 + 199 C7

n 110 6E 140 8C 170 AA 200 C8
o 111 6F 141 8D 1/2 171 AB 201 C9
p 112 70 142 8E 1/4 172 AC 202 CA

q 113 71 143 8F 173 AD 203 CB
r 114 72 144 90 174 AE 204 CC
s 115 73 145 91 175 AF 205 CD
t 116 74 146 92 176 B0 206 CE
u 117 75 147 93 177 B1 207 CF
v 118 76 148 94 @ 178 B2 _ 208 D0
w 119 77 149 95 # 179 B3 + 209 D1
x 120 78 150 96 180 B4 + 210 D2
y 121 79 151 97 + 181 B5 + 211 D3

z 122 7A 152 98 + 182 B6 + 212 D4
{ 123 7B 153 99 + 183 B7 213 D5
| 124 7C 154 9A _ 184 B8 214 D6

} 125 7D 155 9B 1 185 B9 + 215 D7
~ 126 7E 156 9C 186 BA + 216 D8
127 7F + 157 9D 187 BB 217 D9

128 80 x 158 9E 188 BC 218 DA
129 81 _ 159 9F 189 BD 219 DB
206
220 DC + 229 E5 238 EE 247 F7
221 DD 230 E6 239 EF 248 F8
+ 222 DE 231 E7 240 F0 249 F9

223 DF _ 232 E8 _ 241 F1 I 250 FA
+ 224 E0 + 233 E9 242 F2 251 FB
_ 225 E1 _ 234 EA 3/4 243 F3 252 FC
+ 226 E2 + 235 EB 244 F4 253 FD
+ 227 E3 _ 236 EC 245 F5 254 FE
_ 228 E4 _ 237 ED _ 246 F6 255 FF
NOTE: For the hardware handshake XON/XOFF commands:

XON = Hex 11 (DC1)
XOFF = Hex 13 (DC3)
207
Appendix A
208
B Downloading Software
Flash Memory
Flash memory retains its contents when printer power is turned off. (Compare
this to RAM, which loses its contents when power is removed.) Flash memory
is contained in an 80-pin 4MB (or optional 10MB) SIMM (Single Inline Memory
Module) at location J38 on the controller board.
Printer emulation and operating system software are loaded into flash
memory at the factory, but you may need to install software in some
situations:
The IPDS or different emulation option is added after the printer is
installed
A printer software upgrade is installed
The Flash SIMM has been replaced
Emulation and operating system software are stored on a CD. You will copy
the appropriate file to your computers hard disk, then download that file to the
printer.
IMPORTANT When downloading emulation and operating system software to the

printer, all other optional fonts, customer-supplied logos, setup files,
feature files, and TIFF files will be erased. You will then need to reload
those files. Before starting a download procedure, be sure that you have
all the necessary files on hand.
You can load software through the serial, parallel, or ethernet NIC port of the
printer:
If you are going to load memory through the serial or parallel port of the
printer, see Downloading Software Through the Serial or Parallel Port
on page 210. The load commands are different, depending on the printer
port you use. These differences are explained in the note following
step 22, page 212.
If the printer has the NIC installed, see Downloading Software Through
the NIC on page 213.
209
Appendix B Flash Memory
Downloading Software Through the

Serial or Parallel Port
1. Make a printout of all saved configurations. (Installing new software
erases all saved configurations. You will use the printouts to restore the
printer configurations.)
3. If the printer is already connected to the serial or parallel port of an
IBM-compatible computer running the Microsoft Windows (95, 98, Me,
NT, 2000, or XP) operating system, go to step 9. If not, go to step 4.
4. Unplug the AC power cord from the printer.
5. Disconnect all data input cables from the printer interfaces.
6. Connect a parallel data cable to the LPT1 port or a serial data cable to the
COM1 port of an IBM-compatible computer running the Microsoft
Windows (95, 98, Me, NT, 2000, or XP) operating system.
NOTE: You can connect the cable to the LPT2 port if the LPT1 port is already
in use. The load commands are different if you use this port, as
described in the note after step 22.
7. Connect the data cable to the appropriate I/O port of the printer.
8. Plug the AC power cord into the printer.
9. On the printer control panel, press and hold down the ... and keys.
Without releasing the keys, power the printer on. Continue holding down
the ... and keys.
10. When you see TESTING HARDWARE PLEASE WAIT on the LCD,
release the ... and keys.
11. Wait until you see WAITING FOR PROGRAM DOWNLOAD on the LCD
before proceeding. This can take up to 30 seconds to appear, depending
on the emulations and interfaces installed in the printer.
12. Press the + key. SELECT DOWNLOAD PORT=CENTRONICS appears
on the LCD.
NOTE: The default port is CENTRONICS; this is the standard load through
the parallel port. If you want to use the default, continue at step 14.
13. Press + again to cycle through the download ports available in the printer:
RS232-9600 (RS-232 serial, 9600 baud)
RS232-19.2K (RS-232 serial, 19200 baud)
RS232-115K (RS-232 serial, 115000 baud)
RS422-9600 (RS-422 serial, 9600 baud)
RS422-19.2 (RS-422 serial, 19200 baud)
RS422-115K (RS-422 serial, 115000 baud)
DEBUG
210
Downloading Software Through the Serial or Parallel Port
14. When the printer download port you want to use is displayed on the LCD,
press . WAITING DOWNLOAD / PORT = <your selection> appears on
the display.
15. Using Windows Explorer, create a directory named download at the root
level of your C: hard drive.
16. Insert the printer emulation software CD into your computer.
Figure 38. Navigating to the Appropriate Emulation File on the CD

17. Using Windows Explorer, navigate to the appropriate emulation software
folder on the CD based on the printer model number and desired
emulation, e.g., T5000IGP. (Figure 38.)
18. Within the folder, make note of the emulation software file name, which is
a six digit number plus .exe, e.g., 123456.exe.
This is the file you will download into the printer.
211
Figure 39. Copying the Emulation File to the Download Directory

19. Copy the file to the download directory.
NOTE: You may need to hold Ctrl to make sure a + appears to the right of
the pointer. (Figure 39.)
20. Start a command prompt session. (The Start Menu icon is usually labeled
MS-DOS Prompt or Command Prompt.)
21. At the command prompt type:
C:<Enter>
cd \download<Enter>
22. At the command prompt on the computer type:
filename.exe -pb<Enter>
where filename.exe is the file name you noted in step 18. This command
decompresses the file on the hard drive and copies it as a binary file into
the flash memory on the printer controller board.
NOTE: If you are loading the file using the LPT2 port on the computer, enter
the following command:
filename.exe -pb2 <Enter>
The 9600 baud rate is the only selection some systems can use. The
baud rate information entered in the following commands must match
the selection you made in step 13.
If you are loading the file through the printer serial port, enter the
following commands:
mode COM1:9600,N,8,1,P<Enter>
filename.exe -pbc1<Enter>
212
Downloading Software Through the NIC
CAUTION Do not interrupt the downloading process once it has started.

Interrupting a download will damage the flash memory on the controller
board and NIC.
While the file is copied into memory, the printer LCD informs you of the
load process and status.
23. When the new program has successfully loaded into memory and the
printer has reset itself, set the printer power switch to O (Off).
25. Remove the CD from the host computer and store it with the printer.
26. Power off the computer.
27. If you had to install a data cable to the computer and printer in step 6,
disconnect it from the computer and printer.
28. If required, reconnect the data input cable(s) to the printer.
Using the configuration printout(s) you made in step 1, reconfigure the printer
and reload any optional fonts.

1. Make a printout of all saved configurations. (Installing new software
erases all saved configurations. You will use the printouts to restore the
printer configurations.)
3. On the printer control panel, press and hold down the ... and keys.
Without releasing the keys, power the printer on. Continue holding the ...
and keys down.
4. When you see TESTING HARDWARE PLEASE WAIT on the LCD,
5. Wait until you see WAITING FOR PROGRAM DOWNLOAD on the LCD
before proceeding. This can take up to 30 seconds to appear, depending
on the emulations and interfaces installed in the printer.
6. Using Windows Explorer, create a directory named download at the root
level of your C: hard drive.
7. Insert the printer emulation software CD into your computer.
213
Figure 40. Navigating to the Appropriate Emulation File on the CD

8. Using Windows Explorer, navigate to the appropriate file on the CD (using
the Unzipped directory) based on the printer model number and desired
emulation, e.g., UnzippedT5000IGP. (Figure 40.)
IMPORTANT You must use the Unzipped directory, since this contains the
uncompressed files necessary for NIC download.
9. Make note of the file name, which is a six digit number plus .prg,
e.g., 123456.prg.
This is the file you will download into the NIC.
10. Copy the file to the download directory.
C:<Enter>
cd \download<Enter>
13. Start the FTP protocol by typing:
ftp xxx.xxx.xxx.xxx<Enter>
(where xxx.xxx.xxx.xxx represents the IP Address of the printer.)
214
14. Log in to the printer by typing:

root<Enter>
You are given a password prompt.
NOTE: The default is no password. If the FTP program requires a password,
contact your system administrator.
15. At the password prompt, press <Enter>.
16. Once logged in, type the following sequence at the command prompt to
download the filename.prg file to the printer:
cd dest<Enter>
cd d1prn<Enter>
bin<Enter>
put filename.prg<Enter>
(where filename.prg is the file name you noted in step 9.)
CAUTION Do not interrupt the downloading process once it has started.

Interrupting a download will damage the flash memory on the controller
board and NIC.
17. As the file downloads, the FTP program shows the progress as a
percentage. Once the download is complete, exit out of the FTP program
by typing:
quit<Enter>
18. When the new program has successfully loaded into flash memory and
the printer has reset itself, set the printer power switch to O (Off).
20. Remove the CD from the host computer and store it with the printer.
21. Using the configuration printout(s), reconfigure the printer and reload any
optional fonts.
215
Downloading Optional Fonts to Flash Memory

Optional fonts are stored on a 3.5 inch floppy diskette that contains file names
comprised of a part number with a .dwn extension. You will insert this diskette
in your IBM-compatible computer and use either the parallel or serial port to
download the desired font(s) to the printers flash memory.
See Table 11 for a list of optional fonts and their corresponding part numbers.
Table 11. Optional Fonts
Font Name Part Number
Antique Olive 706612-001

Avante Garde 706617-001
Baskerville 706606-001
Caslon 706613-001
CG Bodoni 706610-001
CG Century 706598-001
CG Times 706597-001
CG Times International 706614-001
CG Triumvirate 706596-001
CG Triumvirate Condensed 706607-001
Chart 706601-001
Decorative 1 706611-001
Desktop 706603-001
Futura II 706605-001
Garamond 706604-001
Gill Sans 706595-001
ITC Galliard 706608-001
ITC Century 706609-001
Label #1 706599-001
Label #2 706600-001
Office 706602-001
Univers 706594-001
216
Downloading Optional Fonts to Flash Memory

2. Connect a parallel data cable to the LPT1 port or a serial cable to the
COM1 port of an IBM-compatible computer running the Microsoft
Windows (95, 98, Me, NT, 2000, or XP) operating system.
NOTE: You can connect the cable to the LPT2 port on the computer if the
LPT1 port is already in use. The load commands are different if you
use this port, as described in the notes after step 15.
3. Verify that the data cable is connected to the appropriate I/O port on the
printer and to the host computer.
4. Power on the computer and allow it to boot up.
5. On the printer control panel, press and hold down the ... and keys
while powering the printer on. Continue holding the ... and keys down.
6. When you see WAITING FOR PROGRAM DOWNLOAD on the LCD,
NOTE: The printer default port is CENTRONICS; if you want to use this port,
continue to step 15.
7. Press the + key. SELECT DOWNLOAD PORT = CENTRONICS
appears on the LCD.
8. Press the + key again to cycle through the download ports available in the
printer:
RS232-9600 (RS-232 serial, 9600 baud)
RS232-9600 (RS-232 serial, 19200 baud)
RS232-9600 (RS-232 serial, 38400 baud)
RS232-9600 (RS-232 serial, 115000 baud)
RS422-9600 (RS422 serial, 9600 baud)
RS422-9600 (RS422 serial, 19200 baud)
RS422-9600 (RS422 serial, 38400 baud)
RS422-9600 (RS422 serial, 115000 baud)
DEBUG
9. When the printer download port you want to use is displayed on the LCD,
press . WAITING DOWNLOAD / PORT = <your selection> appears on
the display.
10. Insert the optional font diskette into diskette drive A (or B) of the
computer.
12. Make the diskette drive the active drive by typing:
A:<Enter> (if the diskette is in drive B, type B:<Enter>)
13. List the contents of the diskette at the command prompt by typing the
following:
dir<Enter>
You will see a directory listing containing files with a .dwn extension, e.g.,
94021.dwn, 94022.dwn, 94023.dwn.
14. Make note of the file name with the .dwn extension of each file you want
to download to the printer.
217
NOTE: The numeric portion of the file name will match the numbers of the
font typefaces listed in Appendix E of the PGL and VGL
Programmers Reference Manuals and provide you with a description
and print sample of the typeface.
copy /b filename.dwn LPT1<Enter>
(where filename.dwn is file name you noted in step 14.)
NOTE: If you are loading the file using the LPT2 port on the computer, type
the following command:
(where filename.dwn is a file you noted in step 14.)
If you are loading the file using the serial port on the computer, type
the following commands:
mode COM1:9600,N,8,1,P<Enter>
copy /b filename.dwn COM1<Enter>
(where filename.dwn is a file you noted in step 14.)
The 9600 baud rate is the only selection some systems can use. The
baud rate information entered in the above commands must match the
selection you made in step 8.
You can download the optional fonts one at a time by entering one file
name per the copy command or you can copy multiple files in one copy
command.
To download one file at a time, enter the following at the command
prompt:
To download multiple files, enter the following at the command prompt,
for example:
copy /b filename1.dwn+filename2.dwn+...LPT1<Enter>
16. While the font file is copied into flash memory, the printer LCD informs
you of the load process and status. When the new file is successfully
loaded into memory, the printer will reset itself and go online.
17. To verify that the optional fonts have been downloaded:
a. Perform a configuration printout.
OR
b. Select PRINTER CONTROLView File List. The new file names
will appear with the same part number file name you downloaded, but
with an .sf extension.
NOTE: The optional font typefaces cannot be selected via the printer control
panel. They can only be selected via a software command from the
host.
18. Press the PAUSE key to place the printer online and return the printer to
normal operation.
218
C Wire Data
Circuit Board And Cable Pinouts

Interconnection Diagrams
Dual Media Sensor Models....................................................... page 220
Single Media Sensor Models .................................................... page 222
Cable Routing
Dual Media Sensor Models....................................................... page 221
Single Media Sensor Models .................................................... page 223
Circuit Board Pinouts
Controller Board........................................................................ page 224
IBM Coax/Twinax Expansion Board ......................................... page 230
Cable Assemblies
Centronics I/O........................................................................... page 231
Twinax Auto-Termination.......................................................... page 232
Printhead/Controller.................................................................. page 233
Power Supply Control ............................................................... page 234
Control Panel ............................................................................ page 235
Validator.................................................................................... page 236
Validator, V2 ............................................................................. page 237
Sensors
Sensor, Label Taken, Front Cover Mounted............................. page 238
Sensor, Label Taken, Frame Mounted ..................................... page 239
Sensor, Head Up ...................................................................... page 240
Media Sensor, Single Media Sensor Models............................ page 241
Media Sensor Assembly, Lower, Dual Media Sensor Models .. page 242
Media Sensor Assembly, Upper, Dual Media Sensor Models .. page 243
219
Appendix C Circuit Board And Cable Pinouts
Interconnection Diagram, Dual Media Sensor Models
Media Sensor,
Single Media Sensor
Models Only
Legend: = n wires
n in cable assy
Cutter
P2 J2 J1 P1 P301
PCBA Option
J301

4 7
8 Panel
3 3
P13 P9 P11 P18
J13 J9 J11 J18
Cutter Option
J21 P21

J2 Port J P
Flash DRAM 1 1 Upper Media
DB25 SIMM SIMM 5 5
Diagnostic Port P8, Ribbon Sensor
J16
DB9 16 Supply
Controller
Expansion Port 2 Motor
J3 J14 P14 Stepper
J4
4 Motor
TP1 +40VDC
TP2 +24VDC
P10
TP4 GND
TP3 VCC
Head Up
J10 Sensor
Ribbon
P8, Take-up
J112 J8 Label
16 Motor
P112 2 Taken
J6 J5 J17 Sensor
P6 P5 P17 4
J203
Parallel Lower Media
40
Port Sensor
Frame Ground. Power
8 8
30 & Logic Ground.
Common electrical tie P401
Expansion-CT
Option point. J401
P403 Thermal
CN403 Print
AC Power P402 Head
Line 1 J201
Ground (green/ 10
yellow wire)

Option NIC Option
220
Cable Routing, Dual Media Sensor Models
Upper Media Sensor
Printhead/ (Part of the Printhead Cover)
Power Supply
Cable Assy
Head Up Lower Media
Sensor Sensor
P18
P11
Printhead/Controller
Cable Assy
P21
P15
P13
P8,16 P14
P8,16
P22
P5 P17
P6
P112
P403
221
Interconnection Diagram, Single Media Sensor Models
Legend: = n wires
n in cable assy
Cutter
J1 P1 P301
PCBA Option
J301

4 7
8 Panel
3 3
P13 P9 P11 P18
J13 J9 J11 J18
Cutter Option

J2 Port Flash DRAM
DB25 SIMM SIMM
Diagnostic Port P8, Ribbon
J16
DB9 16 Supply
Controller
Expansion Port 2 Motor
J3 J14 P14 Stepper
J4
4 Motor
TP1 +40VDC
TP2 +24VDC
P10
TP4 GND
TP3 VCC
Head Up
J10 Sensor
Ribbon
P8, Take-up
J112 J8 Label
16 Motor
P112 2 Taken
J6 J5 J17 Sensor
P6 P5 P17 4
J203
Parallel Media
40
Port Sensor
Frame Ground. Power
8 8
30 & Logic Ground.
Common electrical tie P401
Expansion-CT
Option point. J401
P403 Thermal
CN403 Print
AC Power P402 Head
Line 1 J201
Ground (green/ 10
yellow wire)

Option NIC Option
222
Cable Routing, Single Media Sensor Models
Printhead/
Power Supply
Head Up Cable Assy Media
Sensor Sensor
P18
P11
Printhead/Controller
Cable Assy
P12
P13
P8,16
P14
P8,16
P5 P17
P6
P112
P403
223
Controller Board
VCC VCC
100 180
J20 (Not used) 0.1W 0.25W
MM LED POS
1
Media MM LED NEG
2
Motion MM SENSE COLLECTOR
Sensor 3
4 MM SENSE EMITTER
1000 PF 1000 PF .01 F
10% 10% 10%
50V 50V 50V
R OUT2A
J16 2K 2K 2K
Ribbon 0.25W 0.25W 0.25W
DC 1
Motor 2 2K 2K 2K
(Supply) 0.25W 0.25W 0.25W
R OUT2B
R OUT1A
J8 2K 2K 2K
Ribbon 0.25W 0.25W 0.25W
DC 1
Motor 2 2K 2K 2K
(Take-up) 0.25W 0.25W 0.25W
R OUT1B
224
Controller Board
VCC
Head Up
Sensor
1K
J11 0.1W VCC
1
2 HEAD UP VCC
3 1000 PF J18 4.7K
10% 0.1W
50V 1
2 PEEL
Label Taken 3
1000 PF
Serial Port Sensor 4 NC 10%
50V
5 NC
J2
1
2 HOST TXD
3 HOST RXD2
4 HOST RTS
5 HOST CTS
6 HOST DSR PHA
26 7
8 HOST DCD
J14
9 NC PHA
10 NC 1
11 NC Stepper 2
12 NC Motor 3
13 NC 4
14 NC PHB
15 DIFF RXD-
16 NC
27 17 DIFF RXD+
PHB
18 NC
19 DIFF TXD-
20 HOST DTR
21 NC
22 NC
23 NC
24 NC
25 DIFF TXD+
225
Controller Board
J38
Flash
SIMM
J33
DRAM
SIMM
Upper Media Sensor,

Media Sensor,
Dual Media Sensor Models
Single Media Sensor Models
J21
J12
1 FF RESISTOR
1 MG LED DRIVE
2 MG IRED DRIVE
2 REFL LED SINK
3 FF RESISTOR
3 MG SENSE COLLECTOR
4 MG SENSE EMITTER
Lower Media Sensor,

Dual Media Sensor Models
J15
1 MG LED DRIVE
2 REFL LED SINK
4 MG SENSE EMITTER
226
Controller Board
Diagnostic
Port
J3
1 EXT 5V
2 DB TXD
10 DB RXD
Control Panel
3
4 NC J13
5 1 N FP DATA AVAIL VCC
6 NC 2 FP CLK
11
7 NC 3
8 NC 4
NC 475 PF
9 5 N FP LED WR 10%
6 FP DATA 50V
7
Verifier 8 N FP LCD WR
Port
(Validator)
J10
1
2
VCC
3 +24V VCC
NC 4
5 1K
NC 6 0.1W
J9
1
2
Media 3
MEDIA CUT RUN
Cutter 4
5 MEDIA CUT DIR
6 CUT DONE .01 F 470 PF
7 CUT SPARE 10% 10%
50V 50V
1K
0.1W
227
Controller Board
J112 VCC Expansion-CT

Expansion Port
Parallel Port
4.7K 4.7K J4
0.1W 0.1W
2 32 EXPD6
1 31 EXPD7
EXPN ID SEL 4 34 EXPD4
NC 3 33 EXPD5
NC 12/10V 6 36 EXPD3
5 35
NDMAREQ0 8 38 EXPD1
NC 7 37 EXPD2
10 40 EXPA15
NDMAREQ1 9 39 EXPD0
EXPN INT 12 42
NC 11 41 EXPA14
EXPN WR 14 44 EXPA12
13 43 EXPA13
CAJ NACK 16 46 EXPA10
NRESET 15 45 EXPA11
18 48 EXPA9
EXPN M SEL 17 47
EXPN DS 20 50 EXPA7
19 49 EXPA8
EXPD14 22 52 EXPA5
EXPD15 21 51 EXPA6
EXPD13 24 54
23 53 EXPA4
EXPD11 26 56 EXPA2
EXPD12 25 55 EXPA3 VCC
EXPD9 28 58 EXPA0
EXPD10 27 57 EXPA1
30 60
EXPD8 29 59
228
Controller Board
J6
Thermal
Printhead Signal
VCC VCC
J22
Radio 1
1K Card 2
J5 0.1W Power
1 PRINT ENABLE BUF
2 V SELECT 1
Power 3 V SELECT 2
V SELECT 3
Supply 4
5 N OVER TEMP
Signal
6 NC
7
8
TP2 +24V +40V TP1

Testpoint Testpoint
.1 F .1 F
10% 10%
J17 50V 50V
1
2
3 NC
4
Power 5
Supply 6 NC 220 F 220 F 22K 22K
7 +24V SWITCHED 20% 20% 0.1W 0.1W
63V 63V
8 FAN NEG TP4
9 Testpoint
10
.1 F .1 F
10% 10%
50V 50V
229
Expansion-CT
J2
Twinax
Connector
1 NC
2 NC
3 NC
16 4 NC
SHIELD 1 5
6 NC
7 TWINAX PHASE B
8 NC
9 NC
17 NC
SHIELD 2 10
NC
11
12 NC
13 NC
14 TWINAX PHASE A
15 NC
J3
Coax
Connector
1 COAX SHIELD
2 COAX DATA
VCC Expansion
Port
4.7K 4.7K J4
0.1W 0.1W
2 32 EXPD6
1 31 EXPD7
EXPN ID SEL 4 34 EXPD4
NC 3 33 EXPD5
NC 12/10V 6 36 EXPD3
5 35
NDMAREQ0 8 38 EXPD1
NC 7 37 EXPD2
10 40 EXPA15
NDMAREQ1 9 39 EXPD0
EXPN INT 12 42
NC 11 41 EXPA14
EXPN WR 14 44 EXPA12
13 43 EXPA13
CAJ NACK 16 46 EXPA10
NRESET 15 45 EXPA11
18 48 EXPA9
EXPN M SEL 17 47
EXPN DS 20 50 EXPA7
19 49 EXPA8
EXPD14 22 52 EXPA5
EXPD15 21 51 EXPA6
EXPD13 24 54
23 53 EXPA4
EXPD11 26 56 EXPA2
EXPD12 25 55 EXPA3 VCC
EXPD9 28 58 EXPA0
EXPD10 27 57 EXPA1
30 60
EXPD8 29 59
230
Cable Assembly, Centronics I/O
152439-901
PIN 1
NOTE:
If you replace the I/O cable
assembly, you must install
the ferrite clamp.
See Appendix E.
PIN 1
231
Cable Assembly, Twinax, Smart-T
140752-002
Jack
1 2
White
14
Gray
7
Shield
5
Resistance Chart
Pin Pin Ohms

1 2 110
3 4 110
1, 2, 3, 4 Shield 55
5 Shield 0
14 1, 4 0
3 4 7 2, 3 0
Jack
232
Cable Assembly, Printhead/Controller
750695-001
PIN 1 PIN 1
750695
April 11, 200
233
Cable Assembly, Power Supply Control
170070-901
PIN 1
PIN 8
PIN 8
PIN 1
170070
April 11, 200
234
Cable Assembly, Control Panel
750560-001
TO
CONTROLLER
BOARD
235
Cable Assembly, Validator
171276-001
236
Cable Assembly, Validator, V2
176065-001
237
Sensor, Label Taken, Front Cover Mounted
170219-001
Wire Table
Pin Signal Wire Color
1 Vcc Red
2 Vout Blue
3 Ground Black
4 N/A
5 N/A
238
171896-001
Wire Table
1 Vcc Red
2 Vout Blue
3 Ground Black
4 N/A
5 N/A
239
Sensor, Head Up
171746-001
300.25
0.610
0.26
0.258
Attach label here

24 AWG, twisted 1 turn
Molex Mini II system connector

Terminal pins: 50212-8000
Series 51090 Housings: 51090-0300 (3 pins)
Wire Table
1 N/A N/A
2 Vout White
3 Ground White
240
Media Sensor, Single Media Sensor Models
170217-001
Wire Table
1 MG LED DRIVE Brown
2 FF RESISTOR Red
3 MG SENSE COLLECTOR Orange
4 MG SENSE EMITTER Yellow
241
Media Sensor Assembly, Lower, Dual Media Sensor Models
173625-001
174390
Wire Table
Pin Signal
1 MG LED DRIVE
2 REF LED SINK
4 MG SENSE EMITTER
242
Media Sensor Assembly, Upper, Dual Media Sensor Models
NOTE: Part of the printhead cover.

See Figure 28, page 174, or Figure 29,
page 178, item 32.
Wire Table
Pin Signal
1 Not used
2 Not used
3 Not used
4 Not used
5 Not used
6 MG IRED DRIVE
7 FF RESISTOR
243
244
D Media Cutters and Tray
Introduction
Two cutters are available as options: a standard cutter and a heavy duty
cutter.
This appendix explains how to install both cutters and the cutter tray option for
the heavy duty cutter.
Cutter Installation and Removal ...................................................... page 246
Cutter Tray Installation And Removal ............................................. page 251
Cutter Assembly Replacement........................................................ page 253
Troubleshooting .............................................................................. page 255
Maintenance.................................................................................... page 256
Spare Parts
Heavy Duty Cutter, Early Models.............................................. page 258
Heavy Duty Cutter, Later Models.............................................. page 262
Standard Cutter ........................................................................ page 266
245
Appendix D Cutter Installation and Removal
Cutter Installation and Removal

NOTE: To remove a cutter, reverse the steps of this procedure.
CAUTION To prevent electrostatic damage to electronic components, wear a

grounded static wrist strap when you handle circuit boards.
frame. Then touch the frame using your hand with the static wrist strap
attached.
4. Using a 2 mm Allen wrench, install the cutter driver PCBA with two
screws as shown in Figure 41.
5. Connect the cutter board cable to connector J9 on the controller board.
6. Route the cutter board cable and snap it into the wire saddles as shown.
Connector J9 on
Controller Board
Cable Path
Wire Saddle
Cutter Board Cable

Connector
Screw (2)
Cutter Driver PCBA
Figure 41. Installing the Cutter Driver Board
246
8. Open the peel/tear door by pulling it upward, then forward. (Figure 42.)
9. Using a 3 mm Allen wrench, remove the two M5x10mm screws securing
the peel/tear assembly to the lower support assembly. Keep the two
screws you have removed; you will use them to attach the cutter
assembly to the lower support assembly. (Figure 42.)
10. Remove the peel/tear assembly.
Peel/Tear
Assembly
Peel/Tear Door
Screw
M5x10mm (2)
Figure 42. Removing the Peel/Tear Assembly
247
11. Swing open the cutter assembly mounting bracket from the cutter
assembly. (Figure 44.)
WARNING The cutter blades are sharp. Keep your fingers away from the cutter
blades.
12. Place the cutter assembly inside the lower cutter enclosure, and secure it
using the two M5x16mm screws. (Figure 49, page 262, items 4, 12,
and 24.)
13. Secure the upper cutter enclosure to the cutter assembly using the two
captive screws. (Figure 43.)
14. Plug the RJ-11 connector from the cutter assembly into the cutter driver
board as shown in Figure 43 (heavy duty cutter) and Figure 44 (standard
cutter).
15. Position the cutter assembly as shown in Figure 43 and Figure 44 and
install the two M5x10mm screws with a 3 mm Allen wrench.
16. Heavy duty cutter only: Put the cutter in the up (closed) position. (The
printer cannot detect the presence of the heavy duty cutter unless it is in
the up [closed] position when the printer is powered on.)
17. Standard cutter only: Place the cutter assembly into the up (closed)
position and secure it by tightening the knurled thumbscrew. (Figure 44.)
RJ-11 Receptacle
RJ-11 Connector
Captive
Screw (2)
Mounting Bracket
Cutter Assembly
Screw
M5x10mm (2)
Figure 43. Heavy Duty Cutter Assembly
248
RJ-11 Receptacle
RJ-11
Connector
Mounting Bracket
Screw (2)
Cutter Assembly
Thumbscrew
(Not visible in this
view.)
Figure 44. Standard Cutter Assembly

18. Plug the AC power cord into the printer and the power source.
19. Set the printer power switch to | (On).
20. Press and at the same time to unlock the key. (This key
combination can be changed by the user. Use the customers key
combination if necessary.)
..
21. Press . until PRINTER CONTROL appears on the printer display.
22. Press until Advanced User displays.
249
23. Press + or until Enable displays.

24. Press to select the Enable option. An asterisk (*) appears next to
Enable.
..
25. Press . until MEDIA CONTROL displays
26. Press until Media Handling displays.
27. Press + or until the Cut option displays.
28. Press to select the Cut option. An asterisk (*) appears next to Cut.
29. Press until Cutter Type appears on the printer display.
30. Press + or until the type of cutter installed is displayed (Standard or
Hvy Duty).
31. Press to select the cutter displayed. An asterisk (*) appears next to the
selection.
32. Press and at the same time to lock the key.
33. Test the printer cutting operation and print quality by pressing TEST
PRINT and selecting one of the test patterns to print (page 37).
34. To save the configuration parameters, refer to the Users Manual.
35. If the validator is installed, adjust the validator beam (page 290).
250
Cutter Tray Installation And Removal
This section explains how to assemble and install the optional media cutter
tray. To remove the tray, reverse the steps of this procedure.
NOTE: The cutter tray is not used with the standard cutter.
1. Align the flanges of the cutter tray bin with the slots in the cutter tray base.
(Figure 45.)
a. For long labels, attach the bin at a lower position so the labels will not
interfere with cutter operation.
b. For short labels, attach the bin higher so labels will fall into the bin as
they are cut.
2. Push the flanges into the slots, then push the cutter tray bin downward to
secure it.
Part Number Description

Slot
172597-001 Cutter Tray Assembly, 4 inch
Cutter Tray Bin Flanges (4)
Cutter Tray Base
Figure 45. Attaching the Cutter Tray Bin to the Cutter Base
251
Appendix D Cutter Tray Installation And Removal
3. Position the output area of the printer adjacent to the edge of the
supporting table or stand. (Figure 46, a.)
4. Open the media cover and slide the lip of the media cutter tray over the lip
of the printer base pan.
5. Rotate the media cutter tray into position, with the tray resting against the
table. (Figure 46, b.)
Figure 46. Removing/Installing the Media Tray
252
Cutter Assembly Replacement
NOTE: This procedure is for replacing a defective cutter assembly.
Removal
2. Put the cutter in the down (open) position. (Figure 43, page 248.)
the cutter assembly to the lower support assembly. Keep the two screws
you have removed; you will use them to attach the new cutter assembly to
the lower support assembly.
4. Remove the cutter assembly.
5. Unscrew the two captive screws securing the upper cutter enclosure to
the cutter assembly. (Figure 47, page 254.)
6. Remove the upper cutter enclosure from the cutter assembly.
the cutter assembly to the lower cutter enclosure.
8. Angle the front of the cutter assembly (the front has the blades) and lift it
out of the lower cutter enclosure.
9. Using a 2 mm Allen wrench, remove the M3x8mm screw securing the
cutter support chain to the cutter assembly.
the cutter bracket to the cutter assembly.
11. Remove the cutter support chain and cutter bracket from the cutter
assembly. (You do not need to remove the cutter support chain from the
cutter bracket.)
Installation
NOTE: When installing the cutter assembly into the lower enclosure, angle
the right side of the cutter assembly into the lower cutter enclosure
first, then align the holes in the front lip of the lower cutter enclosure
with the holes in the cutter assembly.
253
Appendix D Cutter Assembly Replacement
Cutter Support
Chain
Screw
Screw M3x8mm M5x10mm (2)
Cutter Bracket
Screw
M5x16mm (2)
Cutter Assembly
Upper Cutter
Enclosure
Captive Screw (2)
Lower Cutter
Enclosure
Screw
M4x10mm (2)
Figure 47. Replacing the Cutter Assembly
254
Troubleshooting
If the customer reports problems with the cutter, consult Table 12.
Table 12. Troubleshooting the Cutter
Problem Solution
CUTTER FAULT 1. Clear obstructions from the cutter

Jam or Cut Fail assembly.
2. Check that the thickness of the media
does not exceed 0.01 inch (0.254 mm).
3. Wait a few minutes for the cutter circuit
breaker to automatically reset. Press
PAUSE to clear the fault message and
resume printing.
4. Make sure the cutter assembly is closed
and locked in the operating position with
the upper cutter enclosure installed.
5. Make sure the two interlock switches are
enabled and not damaged. If damaged,
replace the cutter assembly.
6. Replace the cutter driver PCBA.
OPTION NOT INSTALLED 1. Check that the cutter option is installed,

connected, and in the up position before
powering on the printer.
2. Install the cutter option or change to the
correct Media Handling selection in the
MEDIA CONTROL menu.
3. Check the cable from the cutter assembly
to the cutter PCBA. Reconnect the cable
to J1 on the cutter driver PDBA.
4. Remove the frame side cover and check
the cable from cutter PCBA to the
controller PCBA. Reconnect the cable to
J9 on the controller PCBA.
255
Appendix D Maintenance
Maintenance
The standard and heavy duty cutters require only periodic cleaning.
WARNING Keep your fingers away from the cutter blades. They are sharp.
Standard Cutter
Removing Paper Dust And Debris From The Cutter
Perform the following procedure after every three rolls of media.
2. Rotate the deck lock lever fully clockwise until the deck swings upward.
3. Place the cutter in the down (open) position by loosening the captive
thumbscrew.
4. Use a can of compressed air with a nozzle and blow air from the rear
entrance slot of the cutter out the front exit slot of the cutter.
5. Place the cutter assembly in the up (closed) position and tighten the
thumbscrew on the front of the cutter.
6. Route the media through the cutter.
7. Close the pivoting deck and rotate the deck lock lever fully
counterclockwise.
8. Set the printer power switch to I (On).
Cleaning And Sharpening The Cutter

Perform the following procedure after every 40,000 cuts.
1. Make sure the printer is powered on, the media is installed, and the
pivoting deck is closed.
2. Loosen the thumbscrew on the front of the cutter and place the cutter
assembly in the down (open) position.
NOTE: The media must be routed over the top of the cutter assembly and not
through it.
3. Press the FEED key on the printer. The cutter blade should rotate.
4. Continue to press the FEED key 20 times. This procedure will
automatically clean and sharpen both edges of the cutter blade.
5. Place the cutter assembly in the up (closed) position and tighten the
thumbscrew on the front of the cutter.
6. Route the media through the cutter.
8. Test the printer cutting operation by pressing the TEST PRINT key and
selecting one of the test patterns to print. (Refer to the Users Manual.)
256
Heavy Duty Cutter
Heavy Duty Cutter

Perform the following procedure whenever too much dust or debris is visible.
2. Rotate the deck lock lever fully clockwise until the deck swings upward.
3. Remove the cutter top cover by loosening the two captive thumbscrews.
4. Place the cutter in the down (open) position.
5. Use a vacuum or can of compressed air with a nozzle around the area of
the cutter blade to remove any dust or debris.
6. Use a cloth with a light amount of WD-40 oil to clean adhesive from the
cutter blade and upper or lower stainless steel cutter guides. Excessive
oil must be cleaned from the blade and guides with a dry cloth to prevent
dust attraction.
CAUTION Do not use isopropyl alcohol to clean the cutter blade it dissolves oils
required for lubrication.
7. Place the cutter in the up (closed) position.
8. Install the cutter top cover and tighten the two captive thumbscrews.
9. Properly route the media through the printer and cutter.
counterclockwise.
12. Test the printer cutting operation by pressing the TEST PRINT key and
selecting one of the test patterns to print. (Refer to the Users Manual.)
Specifications
The heavy duty cutter is designed to cut tags and label liner.
The standard cutter is designed to cut lightweight tags and label liner.
IMPORTANT Avoid cutting through the adhesive backed portion of any media.
Heavy Duty Cutter Standard Cutter
Typical Life > 1,000,000 cuts > 750,000 cuts
Warranty 500,000 cuts 500,000 cuts
Environment Same specifications as printer Same specifications as printer
Cutting Method Rotating single-edged blade Rotating double-edged blade
Media Thickness Range 0.0025 to 0.010 in. 0.0025 to 0.007 in.

(0.064 to 0.254 mm) (0.064 to 0.178 mm)
Media Width Range Same range as printer 0.75 to 4.5 in.
(19.1 to 114.3 mm)
Media Length Range 1.00 to 99 in. (25.4 to 2515 mm) 1.00 to 99 in. (25.4 to 2515 mm)
257
Appendix D Spare Parts
Spare Parts
This section contains drawings of the heavy duty cutter assembly, early
models (Figure 48); heavy duty cutter assembly, later models (Figure 49); and
standard cutter assembly (Figure 51). The table following each illustration lists
the spare parts and their part numbers.
Items marked Ref (reference) are not spared, are part of another assembly,
or are shown elsewhere.
8
9
8
12
10
8
11
13
3
8
8 14
7
7
Figure 48. Heavy Duty Cutter Spare Parts, Early Models
258
Heavy Duty Cutter
Item
No.
172341-001 Field Kit, Media Cutter, 4 inch Includes all items shown in
170827-001 Field Kit, Media Cutter, 6 inch Figure 48.
170828-001 Field Kit, Media Cutter, 8 inch
1 172431-001 Bracket, Cutter, 4 inch
172432-001 Bracket, Cutter, 6 inch
2 170518-003 Brush, Static, Cutter, 4 inch

170518-002 Brush, Static, Cutter, 6 inch
170518-001 Brush, Static, Cutter, 8 inch
3 750870-001 Cutter Assembly, 4 inch

750870-002 Cutter Assembly, 6 inch
750870-003 Cutter Assembly, 8 inch
4 172428-001 Enclosure, Cutter, 4 inch

172429-001 Enclosure, Cutter, 6 inch
172430-001 Enclosure, Cutter, 8 inch
5 172710-001 PCBA, Cutter Driver Requires item 14.

(Early model PCBAs had the
cable soldered to the board.)
6 203254-001 Screw, Hex Skt Hd, M5x16mm (2) Available only in Hardware
Kit, Cutter Options
175508-001 (page 203).
Kit, Cutter Options
175508-001 (page 203).
Kit, 171629-001 (page 202)
and Hardware Kit, Cutter
Options 175508-001
(page 203).
9 172529-001 Chain, Support, Cutter
Kit 171629-001 (page 202)
Options 175508-001
(page 203).
11 203715-001 Finger, Ground, Cutter Available only in Hardware
Kit, Cutter Options
175508-001 (page 203).
259
Item
No.
12 203646-001 Catch, Magnetic, Round (2) Only one is used on the

4 inch cutter.
13 172436-003 Bracket, Guide, Cutter, 4 inch

172436-002 Bracket, Guide, Cutter, 6 inch
14 172698-001 Cable, Cutter Driver
260
Heavy Duty Cutter
261
9 8
8
1
(See page 263.) 17
A 12
23 2
5
15
4
10
26
8
7
8
13
14
24
10
Figure 49. Heavy Duty Cutter Spare Parts, Later Models

Sheet 1 of 2
262
Heavy Duty Cutter
A
From page 262.
16
8
11
2
3
18 19
20
12
21
25
22
18
Figure 50. Heavy Duty Cutter Spare Parts, Later Models

Sheet 2 of 2
263
Item
No.
175261-003 Field Kit, HD Media Cutter, 4 inch Includes all items shown in
175261-002 Field Kit, HD Media Cutter, 6 inch Figure 49 and Figure 50.
175261-001 Field Kit, HD Media Cutter, 8 inch
1 172431-001 Bracket, Cutter, 4 inch
2 204395-003 Brush, Anti-Static, Cutter, 4 inch Part of items 4 and 23. Two
204395-002 Brush, Anti-Static, Cutter, 6 inch required.
204395-001 Brush, Anti-Static, Cutter, 8 inch
3 172436-003 Bracket, Guide, Cutter, 4 inch Includes warning label and
172436-002 Bracket, Guide, Cutter, 6 inch item 2. Also part of item 4.
4 175509-001 Cutter Assembly, 4 inch Includes 1 motor, 2 labels, 3
175510-001 Cutter Assembly, 6 inch switches, and items 2, 3, 8,
175511-001 Cutter Assembly, 8 inch 11, 12, 16, 18, 19, 20, and 25
(items 21 and 22).
5 174761-003 Cover, Heavy Duty Cutter, 4 inch Part of item 23.
174761-002 Cover, Heavy Duty Cutter, 6 inch
174761-001 Cover, Heavy Duty Cutter, 8 inch
6 174760-003 Housing, Heavy Duty Cutter, 4 inch Part of item 24.
174760-002 Housing, Heavy Duty Cutter, 6 inch
174760-001 Housing, Heavy Duty Cutter, 8 inch
8 203251-001 Screw, Hex Skt Hd, M3x8mm (8) Part of item 4. Also available
(page 202) and Hardware
Kit, Cutter Options 175508-
001 (page 203).
9 172529-001 Chain, Support, Cutter
10 203513-001 Screw, Btn Hd Soc Cap, M3x4mm (6) Part of items 23 and 24. Also
171629-001 (page 202) and
175508-001 (page 203).
11 203715-001 Finger, Ground, Cutter Part of item 4. Also available
in Hardware Kit, Cutter
Options 175508-001
(page 203).
264
Heavy Duty Cutter
Item
No.
12 203254-001 Screw, Hex Skt Hd, M5x16mm (2) Part of item 4. Also available
Options 175508-001
(page 203).
13 203252-001 Screw, Hex Skt Hd, M4x10mm (2) Part of item 24. Also
available in Hardware Kit,
Cutter Options 175508-001
(page 203).
14 174229-003 Guide, Lower, HD Cutter, 4 inch Part of item 24.
174229-002 Guide, Lower, HD Cutter, 6 inch
174229-001 Guide, Lower, HD Cutter, 8 inch
15 174998-003 Guide, Cover, Cutter, 4 inch Part of item 23.
174998-002 Guide, Cover, Cutter, 6 inch
174998-001 Guide, Cover, Cutter, 8 inch
16 203646-001 Catch, Magnetic, Round (2) Part of item 4. Only one is
used on the 4 inch cutter.
Kit 171629-001 (page 202)
Options 175508-001
(page 203).
18 Ref Screw, Phil Hd, M4x8mm (2) Part of item 4.
19 140988-005 Screw, Phil Hd, M2x8mm (2) Part of item 4. Also available
Options 175508-001
(page 203).
20 204387-001 Micro-Switch, Heavy Duty Cutter Part of item 4.
21 174765-001 Bracket, LH, Heavy Duty Cutter Part of items 4 and 25.
22 174762-001 Bracket, RH, Heavy Duty Cutter Part of items 4 and 25.
23 175518-001 Enclosure, HD Cutter, Upper, 4 in Includes items 2, 5, 10, and
175512-001 Enclosure, HD Cutter, Upper, 6 in 15.
175513-001 Enclosure, HD Cutter, Upper, 8 in
24 175514-001 Enclosure, HD Cutter, Lower, 4 in Includes items 6, 10, 13, and
175515-001 Enclosure, HD Cutter, Lower, 6 in 14.
175516-001 Enclosure, HD Cutter, Lower, 8 in
25 175517-001 Bracket Kit, Heavy Duty Cutter Includes items 21 and 22.
Also part of item 4.
265
13
6
2
8
8
10 9
11
7
14
5 12
15 12
Figure 51. Standard Cutter Spare Parts
266
Heavy Duty Cutter
Item
No.
174522-001 Field Kit, Cutter, Standard, 4 inch Includes all items shown in
Figure 51.
1 174337-001 Bracket, Std Duty Cutter
2 174338-001 Mounting, Std Duty Cutter
3 174621-001 Cutter, Std Duty, 4 inch
4 174339-001 Cover, Std Duty Cutter

6 203252-001 Screw, Hx Skt Hd, Z1, M4x10mm (2) Available only in Hardware
Kit, Cutter Options
175508-001 (page 203).
7 175195-001 Chain, Support
Kit 171629-001 (page 202).
9 140664-001 Nut, Hex, Steel, Zinc Plated, M3 Available only in Hardware

Kit, Cutter Options
175508-001 (page 203).
10 102049-006 Clamp, Cable
11 203513-001 Screw, Btn Hd Soc Cap, M3x4mm Available only in Hardware

Kit 171629-001 (page 202)
Options 175508-001
(page 203).
Kit 171629-001 (page 202)
Options 175508-001
(page 203).
13 204014-001 Screw, Btn Hd Soc Cap, SS, Available only in Hardware

M5x10mm (2) Kit 171629-001 (page 202)
Options 175508-001
(page 203).
15 204395-003 Brush, Anti-Static, Cutter, 4 inch
267
268
E Online Data Validator
Contents
Safety Notices ................................................................................. page 270
Overview ......................................................................................... page 271
Installation and Removal, Later Models .......................................... page 272
Installation and Removal, Early Models .......................................... page 280
Basic Setup ..................................................................................... page 288
Enabling And Disabling The Validator ...................................... page 289
Adjusting The Scanning Beam........................................................ page 290
Shifting The Scanning Beam .................................................... page 294
Calibration ....................................................................................... page 295
Bar Code Validation Demo Page.............................................. page 297
Configuring The Validator ............................................................... page 298
Bar Code Failures ........................................................................... page 298
Bad Bar Code Error Detection .................................................. page 298
Missing Bar Code Error Detection ............................................ page 298
Error Action............................................................................... page 299
Error Messages ........................................................................ page 301
Troubleshooting .............................................................................. page 304
Maintenance.................................................................................... page 306
Spare Parts, Later Models .............................................................. page 307
Spare Parts, Early Models .............................................................. page 308
269
Appendix E Safety Notices
Safety Notices
The online data validator (validator) is a Class 2 laser product. The following
notices apply at all times when the printer is powered on and the validator is
active:
WARNING Class 2 laser light. Do not stare into the laser beam or a reflected image
of the laser beam.
WARNING Using controls, making adjustments, or performing procedures other

than those specified herein may result in hazardous radiation exposure.
Note: This is the laser exit window.
Figure 52. Safety Warnings
270
Overview
The validator is an external bar code scanning device attached above the
paper exit of the printer. When activated, it scans the printed output looking
for bar codes. When it finds a bar code, it automatically determines what type
of bar code it is and monitors the bar code quality as it passes through the
scan area.
After the entire bar code has passed under the scanning beam, the validator
grades the bar code and sends a report to the printer. How the printer
responds is determined by the validator settings, explained in Configuring
The Validator in the Online Data Validator Users Manual.
Operational Parameters
The design parameters of the validator are as follows:
The validator can track the performance of up to four horizontal bar codes
at one time.
The validator requires a minimum distance of 1/2 inch or 20 times the
minimum element width (x-dimension), whichever is greater, between bar
codes.
The validator recognizes the following linear, picket fence bar codes:
Codabar
Code 39
Code 93
Code 128
Interleaved 2 of 5
UPC/EAN + add-ons.
The validator can also evaluate PDF 417 bar codes. For PDF 417
Limited, the validator works best with security level 5 or higher, using the
current default printer settings for Defects Percentage, Percent Decode,
and Decodeability. For lower security levels, lower the Defects
Percentage to 5% to enable checking for bar code damage.
Stacked, 2D, and vertical (ladder) bar codes are not supported.
Bar codes must have a minimum x-dimension of 10 mil (0.010 inch) to be
recognized by the full width of the scanning beam. The validator can
recognize bar x-dimension as narrow as 6.6 mil (0.0066 inch) for 300 dpi
printers, and 10 mil (0.010 inch) for 203 dpi printers. The validator cannot
recognize x-dimensions smaller than 6.6 mil (0.0066 inch) or larger than
40 mil (0.040 inch).
271
Appendix E Installation and Removal, Later Models
Installation and Removal, Later Models

This section explains how to install the later model validator. To remove the
validator, reverse the steps of this procedure.
Install The Ferrite

IMPORTANT If your printer has a factory installed validator, then the cable, ferrite,
wire saddle, and grommet have already been installed. Go to Install The
Brackets on page 277.
3. Remove the expansion-CT subassembly, if one is installed in the printer
(page 106).
4. Using the end of the power/data cable with the short connector, insert the
cable through the ferrite. (Figure 53.)
5. Wrap the power/data cable around the ferrite twice.
6. Adjust the position of the ferrite so that the length from the ferrite to the
long connector is 20 0.5 inches.
Power/Data Cable Ferrite

First Wrap
Long Connector
(To Validator)
20 0.5
inches
Short Connector
(To Controller Board)
Power/Data Cable
Second Wrap
Figure 53. Wrapping the Power/Data Cable Around the Ferrite
272
Install The Ferrite
Frame Boss
Wire Saddle
Figure 54. Inserting the Wire Saddle Into the Frame Boss
7. Insert the wire saddle into the frame boss. (Figure 54.)
273
Wire Saddle
Long Connector
(To Validator)
Ferrite Hole in the

Frame Wall
Figure 55. Inserting the Power/Data Cable Through the Hole in the Frame Wall
8. Raise the media cover and remove the solid grommet from the hole in the
frame wall.
9. On the electronics side of the printer, insert the long connector end of the
power/data cable through the hole in the frame wall. (Figure 55.)
10. Insert the power/data cable through the wire saddle.
274
Install The Ferrite
Grommet Inserted Grommet

Long (Media Side)
Connector
Power/Data Cable
(approximately
17 inches exposed)
Figure 56. Adding the Grommet to the Power/Data Cable

11. On the media side of the printer, slide the grommet onto the power/data
cable and insert it into the hole in the frame wall. (Figure 56.)
12. Inspect the power/data cable to ensure approximately 17 inches of cable
is exposed from the grommet to connect it to the validator.
NOTE: You will plug the power/data cable into the validator later.
275
J10
Wire Saddle
Ferrite
Upper
DC Motor
Power/Data Cable
Power Supply Cable
Figure 57. Position the Ferrite

13. On the electronics side of the printer, position the ferrite on top of the
upper DC motor. (Figure 57.)
14. Route the power/data cable through the wire saddle, then under the
power supply cable as shown in Figure 57.
15. Plug the power/data cable into the J10 receptacle on the controller board.
16. Install the expansion-CT subassembly (page 106), if you removed it in
step 3, page 272.
276
Install The Brackets
Lower
Bracket
M4x10mm
Screw (4)
Figure 58. Installing the Lower Bracket

1. Using the four M4x10mm screws, install the lower bracket as shown in
Figure 58.
277
A A
Validator
(Rear View)
Hash
Marks
4 in. 6 in. 8 in.
Printer
Lower
Bracket
Upper
Validator Bracket
(Front View)
Adjustment
Screw (2)
Figure 59. Installing the Validator/Upper Bracket Unit onto the Lower Bracket
2. Face the front of the printer while installing the validator/upper bracket
unit.
3. Loosen the two adjustment screws on the bottom of the validator.
4. Slide the validator/upper bracket unit onto the lower bracket and align the
hash marks accordingly. Refer to Figure 59, Detail A for location of the
validator hash mark for each printer model size.
NOTE: The printer model size is also inscribed on the lower bracket.
5. When the unit is positioned correctly, tighten the two adjustment screws
on the validator to lock the unit into place.
278
Attach The Power/Data Cable To The Validator

Power/Data Cable
(Long Connector)
Upper Bracket
Screw (3)
Cable
Channel
Bracket Tab
Grommet
Bracket Mounting Screw (4)
Figure 60. Attaching the Power/Data Cable

1. Loosen the three upper bracket screws and route the power/data cable
through the cable channel in the upper bracket, as shown in Figure 60.
2. Plug the long connector end of the power/data cable into the validator.
3. Route the power/data cable behind the bracket tab, as shown in
Figure 60.
NOTE: If necessary, loosen the bracket mounting screws enough to slip the
power/data cable behind the bracket tab, then retighten the bracket
mounting screws.
4. Pull the cable to minimize the slack behind the lower bracket. Push any
excess slack through the grommet.
5. Tighten the three upper bracket screws.
279
Appendix E Installation and Removal, Early Models
Installation and Removal, Early Models

NOTE: This section explains how to install the early model validator.
To remove the validator, reverse the steps of this procedure.
Install The Ferrite

IMPORTANT If your printer has a factory installed validator, then the cable, ferrite,
wire saddle, and grommet have already been installed. Go to Install The
Brackets on page 285.
3. Remove the expansion-CT subassembly, if one is installed in the printer
(page 106).
4. Using the end of the power/data cable without helical tubing, insert the
cable through the ferrite. (Figure 61.)
5. Wrap the power/data cable around the ferrite twice.
6. Adjust the position of the ferrite so that the length from the ferrite to the
helical tubing is about 6.5 inches.
Ferrite
Power/Data Cable
First Wrap
Helical Tubing
(To Validator)
About
6.5 inches
To Controller Board
Power/Data Cable
Second Wrap
280
Install The Ferrite
Figure 61. Wrapping the Power/Data Cable Around the Ferrite
Frame Boss
Wire Saddle
Figure 62. Inserting the Wire Saddle Into the Frame Boss
7. On the electronics side of the printer, insert the wire saddle into the frame
boss. (Figure 62.)
281
Wire Saddle
Helical Tubing
(To Validator)
Ferrite Hole in the

Frame Wall
Figure 63. Inserting the Power/Data Cable Through the Hole in the Frame Wall
8. Insert the helical tubing end of the power/data cable through the hole in
the frame wall. (Figure 63.)
9. Insert the power/data cable through the wire saddle.
282
Install The Ferrite
Grommet Inserted Grommet

(Media Side)
Power/Data Cable
Figure 64. Adding the Grommet to the Power/Data Cable

10. Raise the media cover and install the grommet onto the power/data cable.
(Figure 64.)
11. Slide the grommet up the power/data cable and insert it into the hole in
the frame wall.
12. Inspect the power/data cable to ensure enough length is exposed to
connect it to the validator.
NOTE: You will plug the power/data cable into the validator later.
283
J10
Wire Saddle
Ferrite
Upper
DC Motor
Power/Data Cable
Power Supply Cable
Figure 65. Position the Ferrite

13. On the electronics side of the printer, position the ferrite on top of the
upper DC motor. (Figure 65.)
14. Route the power/data cable through the wire saddle, then under the
power supply cable as shown in Figure 65.
15. Plug the power/data cable into the J10 receptacle on the controller board.
16. Install the expansion-CT subassembly (page 106), if you removed it in
step 3, page 280.
284
Lower
Bracket
M4x10mm
Screw (3)
Figure 66. Installing the Lower Bracket

1. Using the three M4x10mm screws, install the lower bracket as shown in
Figure 66.
NOTE: The screw heads can prevent complete opening of the printhead on
some models if the lower bracket is not installed as shown.
285
Validator A
(Rear View) A
Notch
Thumbscrew
4 in. 6 in. 8 in.

Printer
Lower Bracket
Upper
Bracket
Figure 67. Installing the Validator/Upper Bracket Unit onto the Lower Bracket
2. Face the front of the printer while installing the validator/upper bracket
unit.
3. Loosen the thumb screw. (Figure 67.)
4. Slide the validator/upper bracket unit onto the lower bracket and align
with the notch corresponding to the width of the printer. Refer to
Figure 67, Detail A.
5. When the unit is positioned correctly, tighten the thumb screw to lock the
unit into place.
286
Power/Data Cable
(Helical Tubing)
Cable Holder
Cable Holder
Bracket Tab
Cutout
Bracket Mounting
Screw (3)
Figure 68. Attaching the Power/Data Cable

1. Plug the helical tubing end of the power/data cable into the validator.
(Figure 68.)
2. Attach the power/data cable to the two cable holders on the side of the
validator.
3. Route the flex cable through the appropriate cutouts, as shown in
Figure 68.
NOTE: If necessary, loosen the bracket mounting screws enough to slip the
power/data cable behind the bracket tab, then retighten the bracket
mounting screws.
4. Pull the cable to minimize the slack behind the lower bracket. Push any
excess slack through the grommet.
287
Appendix E Basic Setup
Basic Setup
Unit Positioning
The validator must be positioned so that the scanning beam covers the entire
area containing the bar codes, including the area required for quiet zones.
The validator can be moved along the lower bracket and aligned with any of
the inscribed hash marks, depending on the size of the labels printed and the
positioning of the bar codes on those labels. In addition, the beam width can
be moved horizontally to the left or right. See Shifting The Scanning Beam
on page 294.
If a bar code is completely outside of the scanning area, straddles an edge, or
does not pass completely under the scanning beam, the validator interprets it
as a missing bar code and generates error conditions.
Validator Front Panel

The front panel of the validator has the following controls and indicators:
POWER: Indicates the validator is at full power.
CALIBRATION: Flashes when the validator is in calibration mode. See
page 295 for calibration instructions.
READ: Flashes when the validator is reading a bar code.
1 and 2: Used for maintenance purposes only.
RESET: This button has three functions, depending on how long you hold
the button down:
Hold down less than 2 seconds: turns on the scanning beam (has no
effect if the beam is already on)
Hold down 4 to 6 seconds: initiates calibration procedure (page 295)
Hold down more than 6 seconds: resets the validator to factory
calibration and turns off the scanning beam.
CAUTION Do not lift the printer by the validator unit or by the lower bracket.
CAUTION The validator contains sensitive electronic equipment. Do not jar or

drop the unit.
288
Enabling And Disabling The Validator

Later version software can automatically detect the validator. When the
printer is powered up with the validator installed, the VALIDATOR menu
appears and Validator Funct. is automatically set to Enable in the QUICK
SETUP and VALIDATOR menus.
NOTE: You may need to load the Factory Config. in the CONFIG CTRL
menu to allow the VALIDATOR menu to appear.
With earlier software that cannot automatically detect the validator, the default
value for Validator Funct. is Disable so that printers without validators do not
stop and wait for the validator at boot up. These printers with validators
installed need to have Validation Funct. set to Enable. This is a one-time
setting if the save configuration command is issued.
..
1. Press . to take the printer offline and place the printer in Menu mode.
2. If necessary, press and at the same time to unlock the key. (This
key combination can be changed by the user. Use the customers key
combination if necessary.)
..
3. If necessary, press . until VALIDATOR displays.
4. Press until Validator Funct. displays.
5. Press + or until the Enable displays.
6. Press to enable the validator. An asterisk (*) should appear after
Enable. Once enabled, the printer will command the validator to begin
scanning and reporting errors, and the counters will be incremented.
7. Press and at the same time to lock the key, then press PAUSE to
take the printer offline.
8. Press PAUSE again to put the printer online.
NOTE: To disable the validator once it has been enabled, repeat steps 18
and select the Disable option in step 5.
289
Appendix E Adjusting The Scanning Beam
Adjusting The Scanning Beam

NOTE: Make sure the printer is on and the scanning beam is on. If the beam
is off, press the RESET button for less than 2 seconds to turn on the
beam.
of the laser beam.

than those specified herein may result in hazardous exposure to
radiation.
When the validator is first installed, the scanning beam may need to be
aligned with the two notches on the sides of the tear bar, as shown in Detail A
of Figure 69. When the scanning beam is properly aligned it will line up with
the two notches.
A
Scanning Beam
Notch in Tear Bar
t5lsrlc2
June19, 20 0
A
Figure 69. Aligning the Scanning Beam
290
If your printer is configured for Peel-Off Media Handling mode (use of optional
internal rewinder), you may need to align the beam further behind the notches
(0.20 to 0.30 inches [5.08 mm to 7.62 mm] from the front edge of the tear bar)
so that the peeled label remains on the tear bar and the trailing edge of the
last bar code can still pass completely under the scanning beam. See
Figure 70.
0.30 inches
(7.62 mm)
Figure 70. Aligning the Scanning Beam Peel-Off Media Handling Mode
If your printer has a cutter installed, align the beam with the notches at each
side of the opening on the hinged upper lid, as shown in Detail A of Figure 71.
A
Scanning Beam
A Notch in Tear Bar/

Cutter
Figure 71. Aligning the Scanning Beam Cutter Installed
291
Top Left Screw
Bottom Left Screw
Bottom Right Screw
Figure 72. Scanning Beam Adjustment Screws

Figure 72 shows the screws used to adjust the parallelism and position of the
scanning beam. The positions of the screws assume that you are in front of
the validator unit and facing the printer. The following instructions and
illustrations show how to adjust the validator according to how the beam
appears.
1. Power the printer on and make sure the scanning beam is on. If the beam
is off, press the RESET button for less than 2 seconds to turn on the
scanning beam.
2. Use the Allen key provided to adjust the screws.
NOTE: You may have to loosen all three screws and allow the rubber
spacers to expand (relax) before making any adjustments.
292
Correct alignment of the

scanning beam. The beam lines
up with the end notches and is
parallel to the long edge of the
tear bar.
Tighten the top left screw to

move the scanning beam
downward. If the screw is
already tight, loosen both bottom
screws to lower the beam.
Tighten both bottom screws to

move the scanning beam
upward. If they are already tight,
loosen the top left screw to move
the beam upward.
Loosen the bottom right screw to

rotate the scanning beam
clockwise. If it is already loose,
tighten the bottom left screw.
Loosen the bottom left screw to

rotate the scanning beam
counterclockwise. If it is already
loose, tighten the bottom right
screw.
Summary Of Scanning Beam Adjustment
To Move Beam To Move Beam To Rotate Beam To Rotate Beam

Down Up Clockwise Counterclockwise
Tighten top left screw Tighten both bottom Loosen bottom right Loosen bottom left
screws screw screw
OR OR OR OR
Loosen both bottom Loosen top left screw Tighten bottom left Tighten bottom right
screws screw screw
293
NOTE: If the printer does not have a tear bar with notches at the ends, adjust
the scanning beam so that the center of the beam is approximately
0.06 inches (1.52 mm) from the lower edge, as shown in Figure 73.
0.06 inch
(1.52 mm)
Figure 73. Adjusting the Center of the Scanning Beam
Shifting The Scanning Beam

This option enables you to shift the scanning beam horizontally to the left or
right. The left edge of the beam should be approximately 0.13 inches
(3.3 mm) from the left edge of the tear bar. After you set this value, save it as
part of the configuration for future use.
The value range is from -99 to 99. The default is 0. Lower values will move the
beam to the left.
NOTE: You must set Admin User to Enable in the PRINTER CONTROL
menu to access the Beam Shift option. (Refer to the Users Manual.)
..
2. If necessary, press and at the same time to unlock the key.
..
4. Press until Validator Funct. displays.
5. Make sure the Enable option is selected.
6. Press until Beam Shift displays.
7. Press + or to scroll through the values: -99 to 99. The default is 0. Lower
values will move the beam to the left. Press to accept the shift value.
Keep selecting the new value until the beam width is at the desired
position. The left edge of beam should be approximately 0.13 inches
(3.3 mm) from the left edge of the tear bar.
8. Save the configuration for future use.
294
Shifting The Scanning Beam
Calibration
of the laser beam.

The validator should be calibrated when it is first installed or when the printer
displays the Calibration warning message. A special calibration bar code
card is included with the validator package.
1. Make sure the printer is on and the scanning beam is on. If the beam is
off, press the RESET button for less than 2 seconds to turn on the beam.
Table 13. Reset Button Settings
Time RESET Button Is Depressed Result
Less than 2 seconds Turns on scanning beam
More than 4 but less than 6 seconds Validator goes into calibration mode
More than 6 seconds Resets validator to factory calibration

and turns off scanning beam
2. Raise the media cover. Open the pivoting deck by rotating the deck lock
lever fully clockwise. The pivoting deck will swing upward, exposing the
bottom of the printhead assembly.
3. If the printer has the cutter option, put the cutter in the open (down)
position.
4. Remove the calibration bar code card from its protective sleeve and slide
it into the open printhead and under the scanning beam. (Figure 74.)
5. Make sure the bar code is under the scanning beam and the
CALIBRATION light is on.
6. Press and hold the RESET button on the validator until the
CALIBRATION light begins flashing.
7. The scanning beam should turn off for a few seconds then back on, and
the CALIBRATION light should turn off. This indicates a successful
calibration.
NOTE: If the scanning beam does not turn back on and/or the calibration light
is still on or flashing, the calibration has failed. In this case, refer to
Table 13 above to repeat the calibration procedure or to reset the
validator settings back to factory default.
8. Once you have a successful calibration, remove the calibration bar code
card.
counterclockwise.
295
Appendix E Calibration
11. Power the printer off, wait a few seconds, then power the printer on.
If the calibration was successful, the scanning beam is on and the
CALIBRATION light is off.
If the calibration was not successful, the scanning beam remains on and
the CALIBRATION light stays lit without flashing. Repeat the calibration
procedure. If repeated attempts fail, check the room for excessive
ambient light, including direct sunlight. You may need to move the printer
to a darker area of the room.
NOTE: In some cases the validator can detect and indicate to the printer that
calibration is required. (See Calibration warning in Table 14 on
page 301.)
CALIBRATION Light
RESET Button
Deck Lock
Calibration Bar Code Card Lever
Figure 74. Calibrating the Validator
296
Bar Code Validation Demo Page
Bar Code Validation Demo Page

The bar code validation demo page allows you to test or demonstrate the
validator operation without a host computer. This page contains some text
and two good bar code symbologies: one in Code 39, the other in Code 128.
To print and validate the bar code validation demo page:
1. Load the factory default configuration. (Refer to the Users Manual.)
2. In the VALIDATOR menu, set Validator Funct. to Enable.
3. In the CALIBRATE CTRL menu, set Gap/Mark Sensing to Gap.
4. Load media.
5. In the CALIBRATE CTRL menu, run Auto Calibrate for proper gap
sensing.
6. The printer must be offline. If the printer is in Menu mode, press the
PAUSE key to take the printer offline.
7. Press the TEST PRINT key to enter the Test Print menu. Continue to
press TEST PRINT until Barcode Demo displays.
8. Press the key to print and validate the demo page. (If the key is
locked, unlock it by pressing and at the same time.)
9. The printer will print one demo page containing two good bar codes.
NOTE: In the QUICK SETUP or MEDIA CONTROL menu, if Label Length is
set between 0.5 and 1.0 inches, only one good bar code will print.
If Label Length is less than 0.5 inches and Label Width is less than
2.0 inches, no demo page will print.
10. To demonstrate a bad bar code reading, block the scanning beam with an
opaque object while the bar code moves under the beam. When you
block the beam, the validator will generate a reading error and will
perform a default error action. The default setting for the Validator Action
in the VALIDATOR menu is Retry Form.
11. Press PAUSE to take the printer offline.
put the printer back online.
297
Appendix E Configuring The Validator
Configuring The Validator

Setting validator options is done through the VALIDATOR menu. (Refer to the
Online Data Validator Users Manual.) The validator comes equipped with a
default setting for every configuration option, and it works without having to
change any of these options. However, in some cases it is necessary to
adjust these options, which is covered in the Online Data Validator Users
Manual.
Bar Code Failures

The validator tells the printer to announce a fault condition in two situations:
if the validator detects a bad bar code
if the validator detects no bar code where it expects to find one.
How the printer reacts to these faults is determined by the printers
configuration settings, as described below.
Bad Bar Code Error Detection

The validator examines every bar code that passes under the scanning beam
and sends an analysis report to the printer. If a bar code is reported to have
failed to meet any of the acceptance criteria, an error condition is reported.
How the printer then reacts is described in Error Action on page 299.
Missing Bar Code Error Detection

A bar code may print so poorly that the validator cannot detect it, and the
printer does not receive an analysis report for the code. To catch this problem,
the printer tracks the position of the last label printed and knows when it
should have completely passed the scanning beam. It can then compare the
number of bar code analysis reports it expected to the number it received. If
the printer does not receive enough bar code reports, it enters an error
condition. How the printer then reacts is described in Error Action on
page 299.
The number of bar codes expected is determined one of two ways:
If Auto is selected for the Number of Codes parameter, and you are
using LinePrinter Plus, IGP/PGL, IGP Code V, or IPDS graphics
software, the printer compares the number of bar code commands it
receives from the software to the number of analysis reports it receives
from the validator.
You can set the number of bar codes generated by a bitmapped image
that the printer should expect per form by selecting a value in the
Number of Codes parameter.
For more information on choosing a value for the Number of Codes
parameter, see Setting Number Of Bar Codes On A Form in the Online Data
Validator Users Manual.
298
Error Action
Error Action
Whether the error stems from a bad or missing bar code, the printer response
is the same. The printer response is determined by the Validator Action
setting in the VALIDATOR menu:
..
2. If necessary, press and at the same time to unlock the key.
..
4. Press until Validator Action displays.
5. Press + or to scroll through the choices:
Stop
Overstrike
Retry Form (default)

These options are described in detail below.
6. Press to select the desired value.
take the printer offline.
8. Press PAUSE again to put the printer online.
Stop
If the system detects a bar code failure, the print job stops, the printer status
indicator lamp flashes, the alarm sounds, and the appropriate error message
displays.
The printer remains in a fault condition until you press the PAUSE key. This
clears the error message and takes the printer offline. You must correct any
condition that may have caused the fault. When ready, the printer can be put
back online and it will resume printing where it left off.
Overstrike
Use Overstrike mode when you want bad labels to be marked, but not
reprinted (i.e., when using pre-numbered labels).
If the system detects a bar code failure, the print job stops, the printer status
indicator lamp flashes, the alarm sounds, and the appropriate error message
displays.
Without pausing, the printer then automatically reverses to the top of the form
containing the failing bar code. It then prints an obliterating pattern over the
form and any other forms partially printed prior to the physical stop. By
default, the obliterating pattern is a grid of fine lines which clearly marks the
label as bad but allows you to read what was originally printed.
In the VALIDATOR menu, the Overstrike Style options are: Grid, Grey,
Checkerboard, or Error Type Msg.
NOTE: To see the error message printed on the bad label as the Overstrike
Style, select the Error Type Msg option.
299
Appendix E Bar Code Failures
After the overstrike printing, the printer clears the error message and stops
the alarm, then resumes normal printing at the point the job was stopped. The
overprinted labels are lost and a separate print command is required to
resend them from the host, if needed.
Retry Form
This mode is similar to the Overstrike mode, however, instead of resuming
printing where the printer had left off, the printer will attempt to reprint the bad
form.
NOTE: The number of times the printer will attempt to reprint the bad form is
determined by the Num Retry setting. See Num Retry in the Online
Data Validator Users Manual.
The printer will stop, indicate an error, and overstrike as described above.
Then it will skip a number of blank labels, depending on the setting for Skip
Labels (see See Setting For Skip Labels in the Online Data Validator Users
Manual). It will then slew to the next top of a blank form and reprint the entire
form that contained the bad bar code and any other forms that were perhaps
interrupted by the error.
NOTE: Because of physical differences between the location of the print
head and the laser scan line, it is likely that a second form will be
started before the first form has finished being assessed. Therefore,
the reprint operation will need to reprint more than just the form with
the error.
If the printer has to reprint the same form five times in a row, the print job
stops completely and behaves the same as in Stop mode.
300
Error Messages
Error Messages
The validator can detect a number of errors. When one of these errors occurs,
the validator alerts the printer to perform the currently selected error action
(see Error Action on page 299) and show the appropriate error message on
the printers LCD. Validator error messages are explained in Table 14.
Table 14. Validator Messages
Bar Code Improper Data validation error: the bar Fix the application so it sends
Data Format code is not properly encoded. data in the correct bar code
For example, a check sum is format.
incorrect, a required number of
characters is not met, or the
required terminator characters
are not included. This problem
is almost always caused by
incorrect form or host
application design.
Bar code quiet Data validation error: the blank 1. Fix the application.
zone too small zone(s) left or right of the bar
2. Disable Quiet Zone in the
code is not big enough to meet
VALIDATOR menu.
the minimum requirement.
Typically, this occurs in forms
where bar codes are placed too
close to other elements, the bar
code is too close to an edge of
the media, or the medias
position is shifting.
The minimum quiet zone on
each end of the bar code should
be ten times the minimum
element width or 1/4 inch,
whichever is greater. In
addition, between bar codes,
the validator requires a
minimum distance of 20 times
the minimum element width or
1/2 inch, whichever is greater.
Calibration The validator has detected that Press PAUSE to clear the
warning it needs calibration. This message. Calibrate the
message is a reminder and validator. See Calibration on
does not halt printing. page 295.
Checksum Failure The bar code data fails the Verify that the checksum digit
checksum check or is missing exists in the bar code and that it
the checksum digit. is the correct value.
301
Appendix E Bar Code Failures
Contrast too low Data validation error: the Increase Print Intensity or
Check media contrast between bars and reduce Print Speed in the
spaces is not sufficient. This QUICK SETUP menu or via
can be caused by too little heat host software, change media, or
in the thermal transfer or by use disable Symbol Contrast in the
of colored media or ribbons. VALIDATOR menu.
Poor scanning Data validation failure: 1. Adjust Print Intensity and

Check heat&head decodeability. The difference Print Speed in the QUICK
between wide and narrow SETUP menu or via host
elements is too close for the software.
validator to reliably discern. 2. Adjust the printhead
This usually indicates an pressure. (Refer to the
improperly set heat/speed/ Quick Setup Guide or
pressure combination or the Users Manual.)
loss of a printhead element.
Poor scanning Data validation failure: percent 1. Check for a wrinkled ribbon
Check media decode. The validator detected or debris on media. Roll
gross inconsistencies within the wrinkled area onto take-up
height of the bar code. These spindle.
types of failures are likely
2. Adjust the printhead
attributed to large blemishes
pressure blocks. (Refer to
within the bar code, caused by
the Quick Setup Guide or
ribbon wrinkle or debris on
Users Manual.)
media.
Poor scanning Data validation failure: 1. Check that paper and

Inspect head hardware defect. The validator ribbon are clean,
detected unexpected dark spots unwrinkled, and installed
in spaces or light spots in bars. correctly.
This usually indicates a poor
ribbon/media combination, a
dirty printhead, or a burned 3. If message reappears,
pixel. replace the printhead.
Speed Exceeds Print Speed is set above 6 IPS Change Print Speed in the
Validator Limit as the Power-Up configuration QUICK SETUP menu or via
with the validator option host software to 6 IPS or less
installed. An attempt was made when using the validator option
to set Print Speed above 6 IPS and save the new value as the
in the QUICK SETUP menu or Power-Up configuration in the
via host software. CONFIG CTRL menu.
302
Error Messages
Unscannable code Data validation error: missing 1. Check that paper and
check media bar code. An expected bar code ribbon are clean,
is missing or was printed so unwrinkled, and installed
poorly that the validator cannot correctly.
detect it. 2. Run a print job and check
that the validator beam is
not obstructed; remove
obstructions as necessary.
that the READ LED flashes
as bar codes exit the
printer. If the READ LED
does not flash, cycle power
and run the job again. If the
READ LED does not flash,
inspect the cables and the
cable connections. If the
cables are undamaged and
the connections are good,
replace the validator.
4. Press PAUSE to clear the
message.
5. In the VALIDATOR menu,
press until Clear Data
displays, then press .
Validator not The Validator Funct. = Enable in Check that the validator signal
communicating the VALIDATOR menu, but cable is securely connected to
when the printer was first the validator unit.
powered up it could not
communicate with it.
303
Appendix E Troubleshooting
Troubleshooting
If the customer reports problems with the validator, consult Table 15 for a list
of symptoms and possible solutions.
Table 15. Troubleshooting the Validator
Symptom Solution
The scanning beam does not come 1. Make sure the power/data cable is plugged into
on. the validator and the controller board on the
printer. See Installation and Removal, Later
Models on page 272 or Installation and
Removal, Early Models on page 280.
2. Make sure the validator has not been disabled in
the VALIDATOR menu. See Enabling And
Disabling The Validator on page 289.
3. Print a bar code validation demo page (page 297).
The scanning beam does not cover 1. Adjust the validator along the length of the lower
the entire width of the labels being bracket so that the scanning beam covers the
printed. complete width of labels printed. See Installation
and Removal, Later Models on page 272 or
Installation and Removal, Early Models on
page 280.
2. Use Beam Shift to move the beam horizontally to
cover the entire width of the labels. See Shifting
The Scanning Beam on page 294.
Printing 3 mil or 5 mil x-dimension The validator does not recognize x-dimensions as
width bar codes constantly causes small as 3 mil or 5 mil. If you have to print bar codes
error messages. this size, disable the validator to prevent error reports.
See Enabling And Disabling The Validator on
page 289.
The printed labels look clean, but the The validator glass may be dirty, distorting the report
validator is still reporting an error results. Power down the printer and clean the glass
message. using a household glass cleaner and a dry, lint-free
cloth.
304
Error Messages
Table 15. Troubleshooting the Validator
Symptom Solution
The printed bar codes are causing There are a number of factors which could be causing
error conditions. validation errors:
The scanning beam is not properly aligned with
the two notches on the tear bar of the printer. See
Adjusting The Scanning Beam on page 290.
Make sure the entire bar code passes completely
under the scanning beam.
The validator and printer are not properly
communicating. Test the validator operation
without using a host. See Bar Code Validation
Demo Page on page 297.
Bar code width. The validator can recognize
x-dimensions as narrow as 6.6 mil for 300 dpi
printers, and 10 mil for 203 dpi printers. The
validator cannot recognize x-dimensions smaller
than 6.6 mil or larger than 40 mil.
Bar code size. A minimum height of 1/8 inch is
required for validation.
Bar code type. The validator only recognizes the
following linear, picket fence bar codes: Codabar,
Code 39, Code 93, Code 128, Interleaved 2 of 5,
and UPC/EAN + add-ons. Stacked, 2D, and
vertical (ladder) bar codes are not supported.
Bar code spacing.The validator requires a
minimum distance of 1/2 inch or 20 times the
minimum element width, whichever is greater,
between bar codes.
Printer speed. See Print Speed Limits in the
Online Data Validator Users Manual.
Be sure the bar code is not printing on the extreme
edges of the label.
Check the number of bar codes being validated
concurrently. The validator can track the
performance of up to four bar codes at one time.
305
Appendix E Maintenance
Maintenance
of the laser beam.

The validator is a self-contained unit that requires only periodic cleaning. On
every service call, power down the printer and use a household glass cleaner
and a dry, lint-free cloth to clean the glass.
The validator is not field repairable. Replace any components that are
damaged or not operating.
306
Error Messages
Spare Parts, Later Models

Figure 75 shows the validator assembly and the table following the illustration
lists the illustrated parts and their part numbers.
4
5 7
4
6
Figure 75. Validator Spare Parts, Later Models
Item No. Part No. Description Notes
171197-001 Field Kit, Validator, T5X04/6 Includes items 1, 2, 3, 4, and 5.

1 171945-001 Field Kit, Validator & Upper Bracket Includes items 4, 5, 6, and 7.
Assembly
2 171947-001 Field Kit, Cable Assembly, Validator Includes item 8.
3 171946-001 Field Kit, Lower Bracket Assembly Includes six of item 4.
4 203824-001 Screw, Hex, M4x10mm, Flange Part of items 1 and 3, but can be
Soc Hd ordered separately in Hardware
Kit 171629-001 (page 202).
5 171423-001 Overlay, Validator, English Adheres to surface indicated in
Figure 75.
6 176992-001 Field Kit, Upper Bracket Assembly Includes five of item 4, and three
of item 7.
7 203697-001 Bushing, Upper Bracket Only available in item 6.
8 Ref Ferrite Only available in item 2.
307
Appendix E Spare Parts, Early Models
Spare Parts, Early Models

Figure 76 shows the validator assembly and the table following the illustration
lists the illustrated parts and their part numbers.
Figure 76. Validator Spare Parts, Early Models
Item No. Part No. Description Notes
1 N/A Field Kit, Validator & Upper Bracket Replace with 171197-001
Assembly (page 307).
2 171947-001 Field Kit, Cable Assembly, Validator Includes item 6.
3 N/A Field Kit, Lower Bracket Assembly Replace with 171197-001

(page 307).
4 203824-001 Screw, Hex, M4x10mm, Flange Available in Hardware Kit

Soc Hd (3) 171629-001 (page 202).
5 171423-001 Overlay, Validator, English Adheres to surface indicated in
Figure 76.
6 Ref Ferrite Only available in item 2.
308
F Dual NIC
Wireless Interface
Installation and Removal

IMPORTANT If you just need to install the radio card, protective cover, and antenna,
see page 313.
This chapter explains how to install the dual NIC wireless interface (wireless
interface, radio card, protective cover, and antenna). To remove the dual NIC
wireless interface, reverse the steps of these procedures.
309
Appendix F Installation and Removal
Install The Dual NIC Wireless Interface


4. Loosen one screw and remove the other screw that secures the blank I/O
plate to the rear of the printer frame, and set the plate aside. (Figure 35,
page 196, item 7.)
NOTE: Remove the expansion-CT subassembly, if one is installed in the
printer (page 106).
5. Loosen one screw and remove the other screw that secures the
Centronics parallel connector or current NIC to the rear of the printer
frame. (Figure 77.)
6. Unplug the Centronics parallel cable from the J112 receptacle on the
controller board.
7. Remove the Centronics parallel cable and current NIC (if installed) from
the printer.
J112 Centronics
Parallel Cable
Centronics
Parallel Connector
Screw (2)
NIC
Figure 77. Removing the Centronics Parallel Cable
310
Install The Dual NIC Wireless Interface
8. Route the radio card connector end of the RF cable through the BNC
connector hole in the wireless interface.
9. Insert the BNC connector into the BNC connector hole in the wireless
interface.
10. Slide the BNC connector washer and nut onto the RF cable and install
them onto the BNC connector.
11. Route the radio card connector end of the RF cable through the radio
card connector hole in the wireless interface.
Wireless
RF Cable Interface
BNC Connector
Hole
BNC Connector
Radio Card
Connector
BNC Connector
Washer
BNC Connector Nut
Radio Card
Connector Hole
Figure 78. Installing the RF Cable onto the Wireless Interface
311
12. Plug the wireless interface parallel cable into the J112 receptacle on the
controller board.
13. Plug the other end of the parallel cable into the wireless interface as
shown in Figure 79.
14. Plug the power cable into the J22 receptacle on the controller board.
15. Plug the other end of the power cable into the wireless interface as shown
in Figure 79.
16. Secure the parallel blank plate to the rear panel using two M3x8mm
screws.
17. Secure the wireless interface to the rear panel using two M4x12mm
screws.
Wireless Interface
Parallel Cable J22
Power Cable
M4x12mm
Screw (2)
J112
M3x8mm Wireless Interface

Screw (2)
Parallel
Blank Plate
Figure 79. Installing the Wireless Interface
312
Install The Radio Card, Protective Cover, And Antenna

NOTE: If the card you have appears different than shown in Figure 80,
installation is the same.
If your card has a protective cap covering the RF cable receptacle,
use a very small slot screwdriver to remove it.
1. Insert the radio card into the wireless interface as shown in Figure 80.
2. Install the RF cable into the top receptacle in the radio card.
3. Install the protective cover over the radio card using two M3x8mm
screws.
4. Plug the antenna onto the BNC connector.
BNC
Connector
RF Cable
Antenna
Radio Card
Top Receptacle
Protective
M3x8mm Cover
Screw (2)
Figure 80. Installing the Radio Card, Protective Cover, and Antenna
313
5. Rotate the antenna upright.

6. Remove the top two M3x8mm screws securing the rear panel.
7. Slide the antenna plate over the antenna.
8. Align the plate over the two holes in the frame, then secure the plate
using the two M3x8mm screws.
10. Refer to your printers Users Manual or the Network Interface Card
Users Manual to configure the printer for the dual NIC wireless interface.
M3x8mm
Screw (2) Antenna
Plate
Upright Antenna
Figure 81. Installing the Antenna Plate
314
Spare Parts
176290-901 Dual NIC Assy, S24, T5 Assembly includes dual NIC

176291-901 Dual NIC Assy, S24, Symbol wireless interface and
176292-901 Dual NIC Assy, Cisco/Lucent, T5 mounting hardware. Does not
include radio card, cable kit,
or antenna kit.
176293-901 Cable Kit, Dual NIC, Power and Parallel Includes power and parallel
cables for all dual NIC
assemblies.
176294-901 Antenna Kit, Dual NIC, MMCX, T5 Includes antenna, RF cable,
protective cover, and
mounting hardware for dual
NIC assemblies using an S24
or Cisco radio card.
176295-901 Antenna Kit, Dual NIC, Lucent RF Includes antenna and RF

cable for dual NIC assemblies
using a Lucent radio card
only.
315
Appendix F Spare Parts
316
G RFID Encoder and
Antenna Assemblies
Installation And Removal

This chapter describes how to install an early model RFID encoder in a
T5000e printer. To remove the RFID encoder, reverse the installation
procedures.
This document also describes how to replace a later model RFID antenna or
encoder assembly, or both, in an SL5000e (or an upgraded T5000e SR)
printer.
Prepare The Printer

1. Since you may be reloading the flash memory, make a configuration
printout of all saved configurations. (Refer to the SL5000e/T5000e Users
Manual.)
WARNING Always unplug the printer power cord from the printer or power outlet
before doing any replacement procedure. Failure to remove power could
result in injury to you and damage the equipment. You will be instructed
when to apply power.
3. Unplug the printer power cord from the printer or the AC power source.
317
Appendix G Remove The Frame Side Cover
Remove The Frame Side Cover
Captive Screw (2)
Frame Side Cover
Figure 82. Removing the Frame Side Cover

1. Use a 2.5 mm hex key to loosen the two captive screws securing the top
of the frame side cover. (Figure 82.)
2. Tilt the frame side cover back from the top and lift it until the tabs along
the lower edge disengage from the slots in the printer frame.
3. If you have an early model RFID printer (T5000e), go to page 319;
otherwise, if you have a later model RFID printer (SL5000e or upgraded
T5000e SR), go to page 326.
318
Install The RFID Encoder, Early Models
These instructions describes how to install an early model RFID encoder in a
T5000e printer.
To remove the RFID encoder, reverse the installation procedures.
Wire Saddle (3) Power Cable
Large Connector
J9
Small Connector
Hole in the Frame Wall
Figure 83. Connecting and Routing the Power Cable

1. Plug the large connector of the power cable into the J9 receptacle on the
controller board.
2. Route the power cable through the three wire saddles as shown in
Figure 83.
3. Push the small connector of the power cable through the hole in the frame
wall.
319
Appendix G Install The RFID Encoder, Early Models
Media
Cover
A
A Grommet
Hole in the
Frame Wall Power Cable
Figure 84. Adding the Grommet to the Power Cable

5. Slide the grommet onto the power cable and insert it into the hole in the
frame wall.
320
Serial Interface
Cable Port
RFID UHF Encoder
Bracket
Serial Interface Cable

Cable Channel
Figure 85. Installing the Serial Interface Cable

6. Plug the serial interface cable into the serial interface cable port in the
RFID UHF encoder. (Figure 85.)
7. Route the serial interface cable between the bracket and the RFID UHF
encoder, then through the cable channel as shown in Figure 85.
321
Cable Channel
RFID UHF Encoder
Power Cable Front Right Screw
Figure 86. Installing the RFID UHF Encoder and Power Cable
8. Slide the RFID UHF encoder into the printer as shown in Figure 86.
9. Pull the printer towards you slightly off the table.
10. Use the 2 mm hex key to install the front right screw, but do not tighten
the screw yet.
11. Lift the left side of the RFID UHF encoder, and route the power cable
through the cable channel.
322
Power Cable
Screw (3)
Power Cable
Port
Figure 87. Securing the RFID UHF Encoder

12. Route the power cable as shown in Figure 87 and plug it into the power
cable port.
13. Lift the printer, install the remaining three screws, and tighten all four
screws.
323
Serial Interface
Cable Frame
Route Cable
Here Base Pan
Cable Base Pan

Retainer (3) Screw (3)
Figure 88. Routing the Serial Interface Cable

14. Push the serial interface cable against the back edge (indicated by the
arrows in Figure 88), securing the cable with the three cable retainers and
base pan screws.
NOTE: Keep the cable flat and with no slack.
15. Route cable into the gap between the frame and base pan as indicated in
Figure 88.
324
Serial Interface
Connector
Serial Interface
Adapter
Serial Interface Cable
Figure 89. Installing the Serial Interface Connector

16. Install the serial interface adapter onto the serial interface connector.
(Figure 89.)
17. Plug the serial interface cable into the serial interface adapter.
18. Go to Finish The Installation on page 334.
325
Appendix G Replace The RFID Antenna And Encoder Assemblies, Later Models
Replace The RFID Antenna And Encoder Assemblies,

Later Models
These instructions describe how to replace an RFID antenna and encoder
assembly in an SL5000e (or an upgraded T5000e SR) printer.
Use these instructions to replace either assembly; you do not have to replace
both assemblies at the same time.
Remove the RFID Encoder Assembly
Captive
Thumb Nut
RFID Encoder
Assembly
Mounting Stud (2)
Figure 90. Removing the RFID Encoder Assembly

1. Loosen the captive thumb nut. (Figure 90.)
2. Lift the RFID encoder assembly off the two mounting studs and remove
the assembly.
326
Remove the RFID Encoder Assembly
A Alien Encoder
Antenna Cable
Antenna Cable
Connector
B
AWID Encoder
P1 Data Cable
Connector
Power Cable
Small Connector
RFID Encoder
Assembly
Interface Board
Figure 91. Disconnecting the Antenna, Power, and Data Cables
CAUTION The antenna cable connector is easily damaged. Grasp it with pliers at
the square end only and pull it straight out of the encoder without
twisting or tilting it.
1. Grasping the square end of the antenna cable connector with pliers, pull it
straight out of the RFID encoder assembly:
a. For an Alien encoder, unplug the cable from the top of the encoder.
(Figure 91, detail A.)
b. For an AWID encoder, unplug the cable from the side of the encoder.
(Figure 91, detail B.)
2. If you are replacing the RFID encoder assembly, go to step 3; otherwise,
go to step 5.
3. Unplug the P1 data cable connector and the power cable small connector
from their corresponding receptacles on the interface board.
4. Set aside the old RFID encoder assembly.
5. If you are replacing the RFID antenna assembly, go to step 1 on
page 328; otherwise, go to step 1, page 331.
327
Replace The RFID Antenna Assembly
Old
Media Guard
Front Tab
Figure 92. Removing the Old Media Guard

2. Remove media and ribbon.
3. Reaching under the old media guard, simultaneously push upward on the
front tab and downward on the back of the media guard to lift it up.
(Figure 92.)
4. Slide the old media guard away from the printer and lift it out.
328
Replace The RFID Antenna Assembly
Lower Media
Sensor
Media Guard
(Old and New)
RFID Antenna
Assembly
Front
Back
T1 Transformer
Figure 93. Removing and Installing the Lower Media Sensor
CAUTION When handling the old media guard, do not disconnect the attached
lower media sensor cable from the controller board.
5. Turn the old media guard over. (Figure 93.)
6. Remove the lower media sensor.
7. Set aside the old media guard and its attached RFID antenna assembly.
CAUTION When handling the new media guard, do not touch the T1 transformer
located on the RFID antenna assembly.
8. Using the new media guard, install the lower media sensor as shown in
Figure 93.
329
Lower Media New

Sensor Cable Media Guard
Front Edge
Rear Tab (2)
Antenna Shoulder (2)

Cable
Lower
Support
Frame Opening
Figure 94. Installing the New Media Guard

9. Turn the new media guard over, and route the antenna cable through the
frame opening as shown in Figure 94.
NOTE: Use the same frame opening that the lower media sensor cable
routes through.
10. Install the new media guard onto the lower support by hooking the left and
right rear tabs under the left and right shoulders of the lower support, then
snapping down on the left and right front edge.
11. Lower the media cover.
330
Install The RFID Encoder Assembly
Install The RFID Encoder Assembly
Antenna
Cable
A Alien Encoder
AWID Encoder
P1 Data Cable
Connector
Power Cable
Small Connector
RFID Encoder
Assembly
Interface Board
Figure 95. Connecting the Data, Power, and Antenna Cables

1. If you are replacing the RFID encoder assembly, read the IMPORTANT
notice and go to step 2; otherwise, go to step 4.
IMPORTANT Connectors on each end of the data cable are unique. Connector P1
must connect to the interface board.
2. Plug the P1 data cable connector into its corresponding receptacle on the
interface board of the new RFID encoder assembly.
3. Plug the power cable small connector into its corresponding receptacle on
the interface board.
4. Plug the antenna cable into the RFID encoder:
a. For an Alien encoder, snap in the cable on the top of the encoder, in
the receptacle closest to you. (Figure 95, detail A.)
b. For an AWID encoder, position the antenna cable vertical to the
encoder, snap in the cable, then rotate the cable horizontally along
the side of the encoder. (Figure 95, detail B.)
331
Notch
Captive
Thumb Nut
RFID Encoder
Assembly
Mounting Stud (2)
Figure 96. Installing the RFID Encoder Assembly

5. Align the captive thumb nut over the mounting stud closest to you. Align
the notch in the RFID encoder assembly over the mounting stud furthest
from you. (Figure 96.)
6. Secure the RFID encoder assembly by tightening the captive thumb nut.
332
Route The Data And Power Cables
Wire Saddle (3)

Power Cable
Power Cable
Large Connector
J9
J10
Data Cable
P10 Data Cable

Connector
Figure 97. Routing and Connecting the Power and Data Cables
7. Route the power and data cables through the three wire saddles as
shown in Figure 97.
8. Plug the power cable large connector into the J9 receptacle on the
controller board.
9. Plug the P10 data cable connector into the J10 receptacle on the
controller board.
333
Appendix G Finish The Installation
Finish The Installation

1. Engage the tabs on the bottom of the frame side cover in the slots in the
printer frame, rotate the cover into position, and tighten the two captive
screws. (Figure 82.)
IMPORTANT The printer may not recognize the RFID encoder until you download the
latest printer operating system software into the flash memory.
2. If an RFID Emulation Software CD is included in your kit, go to step 3;
otherwise, go to step 4.
3. Refer to the configuration printout you made on step 1, page 317.
Compare the Program File version number (e.g., 364519) with the version
number printed on the CD (the first six digits only, e.g., 364492).
a. If the CD number is lower than the Program File number, go to step 4.
b. If the CD number is higher, download the latest printer operating
system software into the flash memory. (Refer to the
SL5000e/T5000e Users Manual.)
4. Beginning with Loading Media And Ribbon in your smart label RFID
printer Quick Setup Guide, do the procedures up to and including Run A
Barcode Demo Test.
When you have completed the bar code demo test, installation is
complete.
334
Error Messages
The RFID encoder can detect a number of errors. When one of these errors
occurs, the RFID encoder alerts the printer to perform the currently selected
error action (see Error Handling in the Smart Label RFID Printer Quick
Setup Guide) and display the appropriate error message on the control
panels LCD (see Table 16).
Table 16. RFID Messages
RFID MAX RETRY Error Handling = Overstrike in Press PAUSE to clear the
Check System the RFID CONTROL menu, and message.
the Label Retry count has been See Troubleshooting on
exhausted. page 336.
RFID Comm Err RFID error: communication Press PAUSE to clear the
Check Cable cannot be established with the message.
RFID encoder. Reader will be See Troubleshooting on
set to Disable in the RFID page 336.
CONTROL menu and the
previous port settings restored.
RFID TAG FAILED Error Handling = Stop in the Press PAUSE to clear the
Check Media RFID CONTROL menu, and the message.
RFID encoder could not read See Troubleshooting on
the RFID tag. page 336.
335
Appendix G Troubleshooting
Troubleshooting
If you are having trouble with the RFID encoder, consult Table 17 for a list of
symptoms and possible solutions.
Table 17. Troubleshooting the RFID Encoder
Symptom Solution
No communication between the 1. Make sure the serial interface adapter and the
printer and the reader serial cable are plugged into the printer. See
Figure 89 on page 325.
2. Make sure Reader = Enable in the RFID
CONTROL menu.
3. Use the RFID Test option in the RFID CONTROL
menu (Admin User enabled) to read and display
the current RFID tag content. RFID tags usually
contain a valid entry due to the pre-test process.
See RFID Test (This Test Reads A Tag) in the
Smart Label RFID Printer Quick Setup Guide.
Tag failed 1. The label could be misaligned. Perform the Auto
Calibrate procedure to ensure the label is at top-
of-form. Refer to Running Auto Calibrate in the
Smart Label RFID Printer Quick Setup Guide.
2. Make sure the media are smart labels with RFID
tags located in the correct position.
3. The RFID tag could be defective. Try another tag.
4. Make sure the application does not send too few
or too many digits to the RFID tag.
Inconsistent results Make sure the media is loaded correctly and passes
smoothly over the antenna. Refer to Loading Media
And Ribbon in the Smart Label RFID Printer Quick
Setup Guide.
The RFID encoder works, but it does Make sure that both Error Handling and Label Retry
not meet expectations are set to desired values in the RFID CONTROL
menu.
336
Spare Parts
This section contains drawings of the early model RFID encoder (Figure 98)
and later models (Figure 99). The table following each illustration lists the
spare parts and their part numbers.
337
Appendix G Spare Parts
6 5
Figure 98. RFID Encoder, Early Models
338
Item
No.
177384-001 Option Kit, Smart Label, AWID, 4 inch Includes items 1 through 7.
1 177373-001 Encoder Assy, RFID, AWID, 4 inch Includes the RFID antenna.
2 177786-001 RS-232 Adapter Assy, RFID
3 177559-001 Cable Assy, Interface, RFID, Ph 1

4 177408-001 Clip, Cable, RFID (3)
5 203281-001 Screw, M3x6 mm, Btn Hd Soc Cap (4)
6 177788-001 Cable Assy, RFID Power
7 203534-001 Grommet, Cable Assy, Validator

M4x10mm (3) Kit 171629-001 (page 202).
339
1 2
10
4
3
10
5
9
Figure 99. RFID Encoder, Later Models
340
Item
No.
1 178406-001 Field Kit, Upper Deck Assy, 4 inch, Includes item 2 installed.
RFID
2 178168-003 Spring, Pivot Deck, 4 inch Included with item 1.
3 178403-001 Field Kit, Printhead Assy, 203 dpi,

4 inch, RFID
178404-001 Field Kit, Printhead Assy, 300 dpi,
4 inch, RFID
4 178433-001 Field Kit, Encoder Assy, RFID, AWID
5 178434-001 Field Kit, Encoder Assy, RFID, Alien
6 178155-001 Cable Assy, Interface, RFID, Ph 2
7 177788-001 Cable Assy, RFID Power
8 178472-001 Field Kit, Antenna Assy, RFID, Ph 2 Includes media guard.
178142-003 Media Guard, 4 inch, RFID For T5000 SR models (does

not include antenna).
9 178405-001 Field Kit, Lower Support Assy, 4 inch,

RFID

M4x10mm Kit 171629-001 (page 202).
341
342
Index
Numerics Belt replacement

platen, 97
06 HOST REQUEST, 39 rewind, 98
08 HOLD PRINT / TIMEOUT, 39 Block, head pressure, assembly, replacement, 110
15 COMM CHECK, 40 BUFFER OVERFLOW, 43
203 DPI Head Installed, 41 BUFFER OVERRUN, 43
22 INVALID ADDR, 40
C
27 CU TIMED OUT, 41
28 CU NOT ENAB, 41 Cables
300 DPI Head Installed, 42 interconnection diagram, 220, 222
33 HEAD OPEN / TIMEOUT, 41 routing diagram, 221, 223
48V POWER FAIL, 41 Calibration / warning, 44, 301
A CANNOT CALIBRATE / Disable Peel-Off, 44
CAUTION, definition, 14
About the Printer, 15 Checksum Failure, 44, 301
About This Manual, 13 Cleaning
ASCII Code Chart, 205 cutter, 256
Asterisk (*), meaning on messages, 38 exterior, 29
B general, 29
interior, 29
BAD VFU CHANNEL, 42
media damper, 30
Bar Code Improper / Data Format, 42, 301
media sensor, 30
Bar code quiet / zone too small, 42, 301
platen roller, 30
Bar codes, 17
printhead, 30
bad bar code error detection, 298
validator, 306
error action, 299
CLEARING PROGRAM / FROM FLASH, 44
Overstrike, 299
Communications failures, 88
Retry Form, 300
Configuration, 15
Stop, 299
Contrast too low / Check media, 44, 302
failures, 298
Control panel keys, 25
minimum width, 271
Control panel replacement, 99
missing bar code error detection, 298
Controller PCBA
types supported by validator, 271
pinouts, 224
BATT HIGH VOLT, 43
replacement, 100
BATT LOW VOLT, 43
Controls and Indicators, 23
343
Cooling fan replacement, 102 ENTER to Stop, 46
CSC, 13 ERROR
Customer Support Center, 13 DC PROGRAM / NOT VALID, 46
Cutter, 245 DRAM AT / ADDRESS XXXXXXXX, 47
maintenance, 256 FLASH / DID NOT PROGRAM, 47
spare parts, 258 IPDS needs / 300 DPI Head!, 47
specifications, 257 NO DRAM / DETECTED, 47
troubleshooting, 255 PROGRAM / NEEDS MORE DRAM, 47
CUTTER FAULT / Jam or Cut Fail, 45, 255 PROGRAM / NEEDS MORE FLASH, 48
Cutter messages PROGRAM / NOT COMPATIBLE, 48
CUTTER FAULT / Jam or Cut Fail, 255 PROGRAM / NOT VALID, 48
OPTION NOT INSTALLED, 255 SECURITY PAL / NOT DETECTED, 48
D SHORT AT / ADDRESS XXXX, 48
WRITING / TO FLASH, 49
Damper, media, replacement, 104 WRONG / CHECKSUM, 49
Dashpot replacement, 105 Error messages, clearing, 39
Data exchange, 90 Error messages, control panel
DEACTIVATING / HOST SERIAL, 45 RFID Comm Err / Check cable, 66, 335
DIAGNOSTICS PASSED, 45 RFID MAX RETRY / Check System, 66, 335
Diagrams RFID TAG FAILED / Check Media, 66, 335
cable interconnection, 220, 222 Exchange, data, 90
cable routing, 221, 223 Expansion-CT replacement, 106
controller board pinouts, 224
F
DIP switches, 10/100Base-T, 126
DIRECT THERMAL / Remove Ribbon, 45 FAN WARNING, 50
Direct Thermal Mode, 19 Fault messages, clearing, 39
Disabling the validator, 289 Features
Display indicators, 24 optional, 17
DO NOT POWER OFF, 45 standard, 17
Downloading Optional Fonts to Flash Memory, 216 FILE EXISTS / Enable Overwrite, 50
Downloading software, 209, 213 FILE SYS FULL / Add Flash, 50
DOWNLOADING TO VALIDATOR, 46 FILE SYS FULL / Delete Files, 50
DRAM SIMM, replacement, 118 FILE SYS FULL / Optimize & Reboot, 50
Dual NIC wireless interface FILE SYS INVALID / Optimize & Reboot, 51
installation/removal, 309 FILE SYS WRITE / Check Flash, 51
spare parts, 315 Flash messages
E CLEARING PROGRAM / FROM FLASH, 44
ERROR
EC SOFTWARE FAIL* / See Manual, 46 DC PROGRAM / NOT VALID, 46
Emulations, 17 DRAM AT / ADDRESS XXXXXXXX, 47
Emulations, loading, 209 FLASH / DID NOT PROGRAM, 47
E-NET INIT, 46 NO DRAM / DETECTED, 47
E-NET READY, 46 PROGRAM / NEEDS MORE DRAM, 47
E-NET RESET, 46 PROGRAM / NEEDS MORE FLASH, 48
344
PROGRAM / NOT COMPATIBLE, 48 J
PROGRAM / NOT VALID, 48
SECURITY PAL / NOT DETECTED, 48 Job In Process indicator, 23
SHORT AT / ADDRESS XXXX, 48 L
WRITING / TO FLASH, 49
LABEL MISSING / Check Paper Path, 55
WRONG / CHECKSUM, 49
LCD, 23
ERROR OCCURRED / FLUSHING
Liquid Crystal Display, 23
QUEUES*, 49
LOADING PROGRAM / FROM PORT XX%, 55
LOADING PROGRAM / FROM PORT XX%, 55
LOADING PROGRAM / INTO FLASH, 55
LOADING PROGRAM / INTO FLASH, 55
RESETTING / PLEASE WAIT, 66
M
RESTORING / BOOT CODE, 66 Maintenance
SECURITY CODE / VIOLATION, 68 cleaning the printer, 29
Flash SIMM, loading, 209 cutter, 256
Flash SIMM, replacement, 118 preparing the printer for, 93
Fonts, 17 preventive, 29
Downloading, 216 restoring the printer to operation, 94
FPGA FILE / NOT FOUND, 51 Manual conventions, 15
Frame side cover replacement, 107 Manual, other T5000 manuals, 15
FRAMING ERROR, 51 Media cover replacment, 113
G Media cutter, 245
Media damper replacement, 104
GAP NOT DETECTED / Check Media, 52, 53
Media damper, cleaning, 30
Gear, ribbon drive, final, replacement, 108
Media hanger beam replacement, 114
Gear, ribbon drive, intermediate, replacement, 109
Media sensor assembly, lower, dual media sensor
GRF CHK ERROR / PRESS PAUSE, 53
models, replacement, 115
H Media sensor assembly, single media sensor
Half Speed Mode, 53 models, replacement, 117
Handshaking Media sensor, cleaning, 30
hardware, 90 Media, types of thermal media, 19
software, 90 Memory
Hardware handshaking, 90 loading, 209
HEAD POWER FAIL / Call For Service, 54 replacement, 118
Head pressure block assembly, replacement, 110 MENU MODE / QUICK SETUP, 55
Message List (troubleshooting), 39
I
Messages
IGP/PGL ERROR, 54 06 HOST REQUEST, 39
IMPORTANT, definition, 14 08 HOLD PRINT / TIMEOUT, 39
Indicators, 10/100Base-T, 124 15 COMM CHECK, 40
Installation, 15 203 DPI Head Installed, 41
INSUFFICIENT RAM / Reboot/Add RAM, 54 22 INVALID ADDR, 40
Interconnection diagram, 220, 222 27 CU TIMED OUT, 41
Interfacing, 88 28 CU NOT ENAB, 41
345
300 DPI Head Installed, 42 FAN WARNING, 50
33 HEAD OPEN / TIMEOUT, 41 FILE EXISTS / Enable Overwrite, 50
48V POWER FAIL, 41 FILE SYS FULL / Add Flash, 50
asterisk (*), what it means, 38 FILE SYS FULL / Delete Files, 50
BAD VFU CHANNEL, 42 FILE SYS FULL / Optimize & Reboot, 50
Bar Code Improper / Data Format, 42, 301 FILE SYS INVALID / Optimize & Reboot, 51
Bar code quiet / zone too small, 42, 301 FILE SYS WRITE / Check Flash, 51
BATT HIGH VOLT, 43 FPGA FILE / NOT FOUND, 51
BATT LOW VOLT, 43 FRAMING ERROR, 51
BUFFER OVERFLOW, 43 GAP NOT DETECTED / Check Media, 52, 53
BUFFER OVERRUN, 43 GRF CHK ERROR / PRESS PAUSE, 53
Calibration / warning, 44, 301 Half Speed Mode, 53
CANNOT CALIBRATE / Disable Peel-Off, 44 HEAD POWER FAIL / Call For Service, 54
Checksum Failure, 44, 301 IGP/PGL ERROR, 54
clearing, 39 INSUFFICIENT RAM / Reboot/Add RAM, 54
CLEARING PROGRAM / FROM FLASH, 44 LABEL MISSING / Check Paper Path, 55
Contrast too low / Check media, 44, 302 LOADING PROGRAM / FROM PORT XX%, 55
CUTTER FAULT / Jam or Cut Fail, 45, 255 LOADING PROGRAM / INTO FLASH, 55
DEACTIVATING / HOST SERIAL, 45 MENU MODE / QUICK SETUP, 55
DIAGNOSTICS PASSED, 45 NON VOLATILE / MEMORY FAILED, 55
DIRECT THERMAL / Remove Ribbon, 45 OPTION NOT INSTALLED, 56, 255
DO NOT POWER OFF, 45 PAPER OUT / Load Paper, 57
DOWNLOADING TO VALIDATOR, 46 PAPER OUT / TIMEOUT, 58
EC SOFTWARE FAIL* / See Manual, 46 PARITY ERROR, 58
E-NET INIT, 46 Poor scanning / Check heat&head, 59, 302
E-NET READY, 46 Poor scanning / Check media, 59, 302
E-NET RESET, 46 Poor scanning / Inspect head, 59, 302
ENTER to Stop, 46 POWER LOSS SAVED / NON-VOLATILE
ERROR RAM, 59
DC PROGRAM / NOT VALID, 46 POWER SAVER MODE, 60
DRAM AT / ADDRESS XXXXXXXX, 47 POWER SUPPLY VOLT*, 60
FLASH / DID NOT PROGRAM, 47 PRINT HEAD COLD / See Manual, 60
IPDS needs / 300 DPI Head!, 47 PRINT HEAD HOT / See Manual, 61
NO DRAM / DETECTED, 47 PRINT HEAD UP / Close Print Head, 61
PROGRAM / NEEDS MORE DRAM, 47 PRINTER HOT / See Manual, 62
PROGRAM / NEEDS MORE FLASH, 48 PRINTER UNDER / REMOTE CONTROL, 62
PROGRAM / NOT COMPATIBLE, 48 PWR SUPPLY HOT / See Manual, 63
PROGRAM / NOT VALID, 48 RBN TAKEUP FULL / Remove Used
SECURITY PAL / NOT DETECTED, 48 Rbn, 64, 65
SHORT AT / ADDRESS XXXX, 48 REACTIVATING / HOST SERIAL, 65
WRITING / TO FLASH, 49 RECHARGE BATTERY, 65
WRONG / CHECKSUM, 49 Remove Label, 65
ERROR OCCURRED / FLUSHING RESETTING / PLEASE WAIT, 66
QUEUES*, 49 RESTORING / BOOT CODE, 66
346
RIBBON BROKEN / Reload Ribbon, 66 PAPER OUT / Load Paper, 57
RIBBON DETECTED / Remove Ribbon, 66 PAPER OUT / TIMEOUT, 58
RIBBON FAULT / TIMEOUT, 67 PARITY ERROR, 58
Ribbon Low, 67 Part numbers, replaceable parts, 157
RIBBON OUT / Load Ribbon, 67 PCBA, 100
SECURITY CODE / VIOLATION, 68 Pinouts, controller board, 224
SELECT DOWNLOAD Plate, rear panel, replacement, 127
PORT=XXXXXXXXXX, 68 Platen replacement, 128
Signal / Clipping, 68 Platen roller, cleaning, 30
SOFTWARE ERROR* / Recycle Power, 68 Poor scanning / Check heat&head, 59, 302
Speed Exceeds / Validator Limit, 69, 302 Poor scanning / Check media, 59, 302
TCP Port Busy, 69 Poor scanning / Inspect head, 59, 302
Test Page / Not Available, 70 POWER LOSS SAVED / NON-VOLATILE RAM, 59
TESTING HARDWARE / PLEASE WAIT, 70 POWER SAVER MODE, 60
Unscannable code / check media, 70, 303 Power supply replacement, 129
Validator not / communicating, 70, 303 POWER SUPPLY VOLT*, 60
WAITING FOR PROGRAM DOWNLOAD, 71 Power switch, 27
WIRELESS ADAPTER NOT COMPATIBLE, 71 Preparing the printer for maintenance, 93
Mode PRINT HEAD COLD / See Manual, 60
auto reset, 125 PRINT HEAD HOT / See Manual, 61
run, 125 PRINT HEAD UP / Close Print Head, 61
Modes of operation, 27 Print quality, 33
Motor, DC ribbon drive, replacement, 121 Printer
Motor, stepper, replacement, 122 alarms, 38
N cleaning, 29
configuration, 15
NIC replacement, 123 Dynamic Print Control, 20
NON VOLATILE / MEMORY FAILED, 55 emulations, 17
Notes and notices explained, 14 hardware options, 17
Numbers, part, replaceable parts, 157 inspection, 32
O installation, 15
model specifications, 16
Online data validator
preparing for maintenance, 93
See Validator
printing process, 19
Online Status indicator, 23
restoring to operation, 94
Operating Modes, 27
self-test, 37
OPTION NOT INSTALLED, 56, 255
thermal printing technology, 19
Optional features, 17
PRINTER HOT / See Manual, 62
P PRINTER UNDER / REMOTE CONTROL, 62
PAL, security, replacement, 144 Printhead assembly, dual media sensor models,
Paper replacement, 130
direct thermal, 19 Printhead assembly, single media sensor models,
thermal transfer, 19 replacement, 132
347
Printhead cover/upper media sensor, dual media printhead assembly, single media sensor
sensor models, replacement, 134 models, 132
Printhead, cleaning, 30 printhead cover/upper media sensor, dual
Procedures media sensor models, 134
cleaning, 29 Resistors, Terminating, 135
removal and replacement, 96 rewinder (option), 137
PWR SUPPLY HOT / See Manual, 63 security PAL, 144
R sensor, head up, 146
sensor, label taken, frame mounted, 147
RBN TAKEUP FULL / Remove Used Rbn, 64, 65 sensor, label taken, front cover mounted, 148
REACTIVATING / HOST SERIAL, 65 spindle assembly, ribbon supply or
RECHARGE BATTERY, 65 take-up, 149
Remove Lable, 65 support assembly, lower, 150
Replacement support assembly, upper, 151
belt, platen, 97 tear bar assembly, adjustable, 152
belt, rewind, 98 tensioner, rewinder belt, 155
control panel, 99 Replacement parts, 157
controller PCBA, 100 Reset mode, 125
cooling fan, 102 RESETTING / PLEASE WAIT, 66
damper, media, 104 Resistors, terminating, replacement, 135
dashpot, 105 RESTORING / BOOT CODE, 66
DRAM SIMM, 118 Restoring the printer to operation, 94
expansion-CT, 106 Rewinder (option), replacement, 137
Flash SIMM, 118 Rewinder, torque check and adjustment, V1, 138
frame side cover, 107 Rewinder, torque check and adjustment, V2, 141
gear, ribbon drive, final, 108 RFID
gear, ribbon drive, intermediate, 109 error messages, 335
head pressure block assembly, 110 installation/removal, 317
media cover, 113 spare parts, 337
media damper, 104 troubleshooting, 336
media hanger beam, 114 RFID Comm Err / Check cable, 66, 335
RFID MAX RETRY / Check System, 66, 335
media sensor assembly, lower, dual media
RFID TAG FAILED / Check Media, 66, 335
sensor models, 115
RIBBON BROKEN / Reload Ribbon, 66
media sensor assembly, single media sensor
RIBBON DETECTED / Remove Ribbon, 66
models, 117
RIBBON FAULT / TIMEOUT, 67
memory, 118
Ribbon Low, 67
motor, DC ribbon drive, 121
RIBBON OUT / Load Ribbon, 67
motor, stepper, 122
Run mode, 125
NIC, 123
plate, rear panel, 127 S
platen, 128 SECURITY CODE / VIOLATION, 68
power supply, 129 Security PAL, replacement, 144
printhead assembly, dual media sensor SELECT DOWNLOAD PORT=XXXXXXXXXX, 68
models, 130 Self Test, 10/100Base-T, 124
348
Self-test, printer, 37 U
Sensor replacement
head up, 146 Unscannable code / check media, 70, 303
label taken, frame mounted, 147 V
label taken, front cover mounted, 148
Validator
Signal / Clipping, 68
adjusting the scanning beam, 290
SOFTWARE ERROR* / Recycle Power, 68
bar code failures, 298
Software handshaking, 90
calibration, 295
Software, downloading, 213
configuration, 298
Software, loading, 209
controls, 288
Spare parts and part numbers, 157
Specifications disabling, 289
cutter, 257 error action, 299
printer model, 16 installation/removal, early models, 280
Speed Exceeds / Validator Limit, 69, 302 installation/removal, later models, 272
Spindle assembly, ribbon supply or take-up, maintenance, 306
replacement, 149 operational parameters, 271
Standard features, 17 overview, 271
Status and Display Indicators matrix, 24 safety, 270
Status indicators, 24 setup, 288
Support assembly, upper, replacement, 151 spare parts, early models, 308
Supprt assembly, lower, replacement, 150 spare parts, later models, 307
T troubleshooting, 304
TCP Port Busy, 69 Validator messages
Tear bar assembly, adjustable, replacement, 152 Bar Code Improper / Data Format, 42, 301
Technical support, 13 Bar code quiet / zone too small, 42, 301
Tensioner, rewinder belt replacement, 155 Calibration / warning, 44, 301
Terminating Resistors, replacement, 135 Checksum Failure, 44, 301
Test Page / Not Available, 70 Contrast too low / Check media, 44, 302
TESTING HARDWARE / PLEASE WAIT, 70 Poor scanning / Check heat&head, 59, 302
Tests, printer, 37 Poor scanning / Check media, 59, 302
Thermal printer series product line, 16 Poor scanning / Inspect head, 59, 302
Thermal Transfer Mode, 20 Speed Exceeds / Validator Limit, 69, 302
Torque, values for fasteners, 95 Unscannable code / check media, 70, 303
Troubleshooting Validator not / communicating, 70, 303
cutter, 255 Validator not / communicating, 70, 303
display messages, 38
W
how to, 36
message list, 39 WAITING FOR PROGRAM DOWNLOAD, 71
newly installed printer, 91 WARNING, definition, 14, 248, 256
other symptoms, 72 WIRELESS ADAPTER NOT COMPATIBLE, 71
procedures, 88 Wireless dual NIC interface
RFID encoder, 336 installation/removal, 309
start here, 35 spare parts, 315
Twinax/coax host interface, 18
349
350
For technical assistance, contact your
Distributor/VAR/Reseller for service.
For further assistance, contact the Printronix Customer Support Center.
Printronix Customer Support Center
Americas (714) 368-2686

Europe, Middle East, and Africa (31) 24 6489 410
Asia Pacific (65) 6548 4114
Web site: http://www.printronix.com/public/servicessupport/default.aspx
Printronix Supplier Center
Americas (800) 733-1900

Europe, Middle East, and Africa (33) 1 46 25 1900
Asia Pacific (65) 6548 4116 or (65) 6548 4182
Web site: http://www.printronix.com/public/supplies/default.aspx
Printronix, Inc. Printronix Schweiz Gmbh Printronix, Inc.

14600 Myford Road 42 Changi South Street 1 Nederland BV
P.O. Box 19559 Changi South Industrial P.O. Box 163 Nieuweweg 283
Irvine, CA 92623-9559 Estate Singapore 486763 NI-6600 Ad Wijchen
Phone: (714) 368-2300 Phone: (65) 6542 0110 The Netherlands
Fax: (714) 368-2600 Fax: (65) 6543 0220 Phone: (31) 24 6489 489
Fax: (31) 24 6489 499
Or visit the Printronix web site at www.printronix.com
*750931-001*
750931-001G

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Maintenance Manual

SL5000 e , T5000 e SR, T5000 e, and T5000 Thermal Printers

Das Gert erfllt die Schutzanforderungen nach EN 55022 und EN 55024

Copyright 2000, 2004, Printronix, Inc.

1 Maintenance Overview ....................................... 13

2 Preventive Maintenance ..................................... 29

Troubleshooting Display Messages..................................................... 38

Power Supply Assembly.............................................................. 129

5 Illustrated Parts Breakdown .............................. 157

A ASCII Codes ..................................................... 205

B Downloading Software ...................................... 209

C Wire Data .......................................................... 219

D Media Cutters and Tray .................................... 245

Maintenance ...................................................................................... 256

E Online Data Validator ........................................ 269

F Dual NIC Wireless Interface .............................. 309

G RFID Encoder and Antenna Assemblies .......... 317

Printronix Customer Support Center

Call the Printronix Customer Support Center at:

About This Manual

that is magnified here, on

Notes And Notices

IMPORTANT Information vital to proper operation of the printer.

The T5000 Series Label Printer

Printronix Dynamic Print Control provides exceptional print quality. A circuit

Table 1. The T5000, Smart Ready, and SmartLine Series

Max Print Printing Max Print

SL5204e MP 10 203 4.1

SL5204e C1 10 203 4.1

T5204e SR 10 203 4.1

T5204e 10 203 4.1

T5204e-DT* 10 203 4.1

T5204 10 203 4.1

T5206e 10 203 6.6

T5206 10 203 6.6

T5208e 8 203 8.5

T5208 8 203 8.5

T5304 8 300 4.1

T5304-DT* 8 300 4.1

SL5304e C1 8 300 4.1

SL5304e SR 8 300 4.1

T5306e 8 300 6.6

T5306 8 300 6.6

T5308e 6 300 8.5

T5308 6 300 8.5

NOTE: ips = inches per second

Memory Expansion (for non-IPDS printers only):

Online Data Validator: Analyzes each bar code to ensure it meets

Thermal Printer Media

Thermal Printer Technology

The Printing Process

Dynamic Print Control

Validator Option Control

P13 P9 P11 P18

Serial J38 J33 J12 P12

Ethernet NIC Wireless Dual

Figure 1. Functional Block Diagram, Dual Media Sensor Models

Validator Option Control

P13 P9 P11 P18

Serial J38 J33 J12 P12

Ethernet NIC Wireless Dual

Figure 2. Functional Block Diagram, Single Media Sensor Models

Controls And Indicators