SL5000r T5000r Service

Maintenance Manual
SL5000 r and T5000 r

TM TM
RFID Smart Label and Thermal Printers

SL5000 r and T5000 r
RFID Smart Label and Thermal Printers
Maintenance Manual
Communication Notices
This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference in a
residential installation. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off
and on, the user is encouraged to try to correct the interference by one or
more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
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 user’s
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.
Any change or modification to this product voids the user’s authority to
operate it per FCC Part 15 Subpart A Section 15.21 regulations.
CAUTION: This product should be positioned so that personnel in the area for
prolonged periods may safely remain at least 23 cm (9 in) from the readers
antenna surface in an uncontrolled environment. See FCC OET Bulletin 56
“Hazards of radio frequency and electromagnetic fields.”
This product contains an intentional radiator with the following parameters:
Operating Frequency: 902 to 928 MHz
Typical RF Power: 25 to 100 milliwatts (SL5x04 MP) or 25 to 205 milliwatts
(SL5x04 C1)
Maximum RF Power: 1 Watt under abnormal conditions
Printronix SL5000r and T5000r
Tested To Comply
With FCC Standards
FOR HOME OR OFFICE USE

Canada
This Class B digital apparatus complies with Canadian ICES-003 and RSS
210.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du
Canada.
CE Notice (European Union)
Marking by the CE symbol indicates compliance of this Printronix system to
the EMC Directive and the Low Voltage Directive of the European Union.
Such marking is indicative that this Printronix system meets the following
technical standards:
• EN 300 220-1 (2000), Electromagnetic Compatibility and Radio Spectrum
Matters; Short Range Devices; Radio equipment to be used in the 25
MHz to 1000 MHz frequency range with power levels ranging up to 500
mW.
• EN 55022 — “Limits and Methods of Measurement of Radio Interference
Characteristics of Information Technology Equipment.”
• EN 50082-1: 1992 — “Electromagnetic compatibility—Generic immunity
standard Part 1: Residential, commercial, and light industry.”
• EN 60950 — “Safety of Information Technology Equipment.”
This printer is a Class B product for use in a typical Class B domestic
environment.
CE Symbol
Declaration Of Conformity
Manufacturer: Printronix, Inc.
14600 Myford Rd.
Irvine, CA 92623 U.S.A.
declares that the product:
Product Type: Information Technology Equipment, Printer
Equipment Class: Commercial and Light Industrial
Model Numbers: T5204r, T5304r, SL5204r, SL5304r, 5504-R40 with
optional suffixes
Configuration: serial, parallel, coax, twinax, external LAN, Ethernet,
Wireless Ethernet, RFID
conforms to the following standards:
Safety: EN 60950-1: 2001, First Edition
EMC: ETSI EN 301 489-1
ETSI EN 301 489-3
ETSI EN300 220 V1.3.1 Sec. 8.1, 8.2, 8.6, 8.7, 8.9
EN 55022: 1998 +A1 Class B
EN 55024: 1998
EN 61000-4-2
EN 61000-4-3
EN 61000-4-4
EN 61000-4-5
EN 61000-4-6
EN 61000-4-8
EN 61000-4-11
EN 61000-3-2: 2000
EN 61000-3-3: 1995 +A1
and complies with:
The Low Voltage Directive 73/23/EEC and the EMC Directive 89/336/EEC.
Taiwan
Lithium Battery Warning

The controller PCBA contains a lithium battery sealed inside the real-time
clock chip. Do not disassemble the chip to replace the battery. Do not dispose
of the chip by incineration. Failure to comply may cause the battery to
explode. Contact your local waste agency for the correct disposal procedure.
Printronix makes no representations or warranties of any kind regarding this

material, including, but not limited to, implied warranties of merchantability
and fitness for a particular purpose. Printronix shall not be held responsible
for errors contained herein or any omissions from this material or for any
damages, whether direct, indirect, incidental or consequential, in connection
with the furnishing, distribution, performance or use of this material. The
information in this manual is subject to change without notice.
This document contains proprietary information protected by copyright. No
part of this document may be reproduced, copied, translated or incorporated
in any other material in any form or by any means, whether manual, graphic,
electronic, mechanical or otherwise, without the prior written consent of
Printronix.
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.
Intermec is a registered trademark of Intermec Technologies Corporation.
IPDS is a trademark of International Business Machines Corporation.
J2SE, Java, and Solaris are trademarks of Sun Microsystems, Inc.
LaserJet is a registered trademark of Hewlett-Packard Company.
Linux is a registered trademark of Linus Torvalds.
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.
SL5000r, T5000r, IGL, STGL, TGL, and ZGL 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.
SATO is a registered trademark of SATO America, Inc.
TEC is a registered trademark of the Toshiba TEC Corporation.
UNIX is a registered trademark of Unix System Laboratories, Inc.
Zebra is a registered trademark of Zebra Technologies Corporation.
COPYRIGHT © 2005 PRINTRONIX, INC. All rights reserved.

Chapter
Table Of Contents
1 Maintenance Overview ....................................... 15

Printronix Customer Support Center.................................................... 15
About This Manual............................................................................... 15
To Replace Parts .......................................................................... 15
To Order Parts .............................................................................. 16
Notes And Notices ........................................................................ 16
Manual Conventions ..................................................................... 17
Related Manuals ........................................................................... 17
The SL5000r/T5000r Series RFID/Label Printer.................................. 18
Standard Features ........................................................................ 19
Optional Features.......................................................................... 20
Thermal Printer Media................................................................... 21
Ribbons ......................................................................................... 21
Thermal Printer Technology .......................................................... 22
Controls And Indicators ....................................................................... 25
Control Panel ................................................................................ 25
Plugging In The Printer ................................................................. 29
Power Switch ................................................................................ 29
Operating Modes........................................................................... 29
2 Preventive Maintenance ..................................... 31

Cleaning The Printer............................................................................ 31
Exterior .......................................................................................... 31
Interior ........................................................................................... 31
General Cleaning .......................................................................... 31
Cleaning The Printhead, Platen Roller And Media Sensors.......... 32
Printer Inspection................................................................................. 34
3 Troubleshooting .................................................. 35
Introduction .......................................................................................... 35
What You Should Know About Print Quality ................................. 35
How To Maximize Printhead Life................................................... 35
Troubleshooting At A Glance ........................................................ 36
Start Here ............................................................................................ 37
How To Troubleshoot .......................................................................... 38
Printer Self-Tests And How To Verify Printer Operation ............... 39
9
Table of Contents
Troubleshooting Display Messages..................................................... 40

List Of Messages .......................................................................... 41
Troubleshooting Other Symptoms ....................................................... 75
General Symptom List................................................................... 75
Communications Failures .................................................................... 91
Troubleshooting A New Installation ..................................................... 94
Printer Configuration ..................................................................... 94
GAP NOT DETECTED.................................................................. 94
PRINT HEAD UP .......................................................................... 94
Ribbon ........................................................................................... 94
Documentation .............................................................................. 94
4 Replacing Parts................................................... 95
About This Chapter.............................................................................. 95
Preparing The Printer For Maintenance ........................................ 95
Restoring The Printer To Operation .............................................. 96
Tools And Materials ...................................................................... 97
Torque Requirements ................................................................... 97
Removal And Replacement Procedures.............................................. 98
Belt, Platen .................................................................................... 99
Belt, Rewinder ............................................................................. 100
Coax/Twinax ............................................................................... 101
Control Panel Assembly .............................................................. 102
Controller PCBA (Printed Circuit Board Assembly)..................... 103
Cooling Fan, Power Supply......................................................... 106
Damper, Media............................................................................ 107
Frame Side Cover ....................................................................... 108
Gear, Ribbon Drive, Final............................................................ 109
Gear, Ribbon Drive, Intermediate ............................................... 110
Head Pressure Block Assembly .................................................. 111
Media Cover ................................................................................ 114
Media Hanger Beam ................................................................... 115
Media Sensor Assembly, Lower.................................................. 116
Memory Module, Flash SIMM ..................................................... 117
Memory Module, NVRAM And Real-Time Clock ........................ 119
Motor, DC Ribbon Drive .............................................................. 120
Motor, Stepper ............................................................................ 121
NIC, External............................................................................... 122
NIC, Internal, 10/100Base-T ....................................................... 125
NIC Configuration........................................................................ 126
Plate, Rear Panel ........................................................................ 127
Platen .......................................................................................... 128
Power Supply Assembly ............................................................. 129
Printhead Assembly .................................................................... 130
10
Table of Contents
Printhead Cover/Upper Media Sensor ........................................ 132

Resistors, Terminating ................................................................ 133
Rewinder (Option) ....................................................................... 135
Rewinder, Torque Check and Adjustment................................... 136
Security Key ................................................................................ 139
Security Key, Reprogramming .................................................... 140
Sensor, Head Up......................................................................... 142
Sensor, Label Taken ................................................................... 143
Spindle Assembly, Ribbon Supply Or Take-Up........................... 144
Support Assembly, Lower ........................................................... 145
Support Assembly, Upper ........................................................... 146
Tear Off Assembly ...................................................................... 147
Peel/Tear Assembly .................................................................... 148
Tear Bar Assembly, Adjustable ................................................... 149
Tensioner, Rewinder Belt ............................................................ 151
5 Illustrated Parts Breakdown .............................. 153

Organization Of This Chapter ............................................................ 153
Illustrated Parts Breakdown............................................................... 153
Hardware Kit ............................................................................... 196
Hardware Kit, Cutter Options ...................................................... 197
A ASCII Codes ..................................................... 199
B Downloading Software ...................................... 203

Loading Flash Memory ...................................................................... 203
Loading Software With The Firmware Download Utility .............. 204
Loading Through The Parallel Or Serial Port Using DOS ........... 205
Loading Software If Flash Contains Only Boot Code .................. 207
Loading Software Through The NIC............................................ 208
Downloading Optional Fonts to Flash Memory ........................... 210
C Wire Data .......................................................... 213

Circuit Board And Cable Pinouts ....................................................... 213
D Media Cutters and Tray .................................... 237

Introduction ........................................................................................ 237
Cutter Installation and Removal......................................................... 238
Cutter Tray Installation And Removal ................................................ 242
Cutter Assembly Replacement .......................................................... 244
Troubleshooting ................................................................................. 246
Maintenance ...................................................................................... 247
Specifications..................................................................................... 247
Spare Parts........................................................................................ 248
11
Table of Contents
E Online Data Validator ........................................ 253

Contents ............................................................................................ 253
Safety Notices.................................................................................... 254
Overview............................................................................................ 255
Installation and Removal ................................................................... 256
Install The Ferrite ........................................................................ 257
Install The Brackets..................................................................... 262
Attach The Power/Data Cable To The Validator ......................... 264
Basic Setup........................................................................................ 265
Enabling And Disabling The Validator......................................... 266
Resetting Validator Data ............................................................. 266
Adjusting The Scanning Beam .......................................................... 267
Shifting The Scanning Beam....................................................... 271
Calibration.......................................................................................... 272
Bar Code Validation Demo Page ................................................ 274
Configuring The Validator .................................................................. 275
Bar Code Failures.............................................................................. 275
Bad Bar Code Error Detection .................................................... 275
Missing Bar Code Error Detection............................................... 275
Error Action ................................................................................. 276
Error Messages ........................................................................... 280
Maintenance ...................................................................................... 286
Spare Parts........................................................................................ 287
F Wireless Interface ............................................. 289

Installation and Removal ................................................................... 289
Install The RF Antenna Cable Assembly .................................... 290
Install The Wireless Interface Card ............................................. 293
Install The Radio Card, Protective Cover, And Antenna ............. 294
Spare Parts........................................................................................ 296
G RFID Encoder and Antenna Assemblies........... 297

Installation And Removal ................................................................... 297
Prepare The Printer ........................................................................... 297
Remove The Frame Side Cover ........................................................ 298
Replace The RFID Encoder Assembly .............................................. 299
Remove The RFID Encoder Assembly ....................................... 299
Replace The RFID Antenna Assembly ....................................... 301
Install The RFID Encoder Assembly ........................................... 304
Route The Data Cable ................................................................ 307
Finish The Installation........................................................................ 308
Error Messages ................................................................................. 309
12
Table of Contents

Spare Parts........................................................................................ 311
H General Purpose Input/Output (GPIO).............. 315

Installation And Removal ................................................................... 315
Prepare The Printer ........................................................................... 315
Remove The Frame Side Cover ........................................................ 316
Install The GPIO Subassembly.......................................................... 317
Spare Parts........................................................................................ 319
13
Table of Contents
14
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 SL5000r/T5000r series RFID
and 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 95.
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 16.
4. Gather the tools you will need.
5. Do the procedure.
15
Chapter 1 About This Manual
To Order Parts
Go to the Illustrated Parts Breakdown (IPB) on page 153, 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.
16
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.
• 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:
• SL5000r/T5000r Thermal Printer User’s Manual
• SL5000r/T5000r Quick Setup Guide
• SL5000r/T5000r RFID Labeling Reference Manual
• Network Interface Card User’s Manual
• Online Data Validator User’s Manual
• IGP®/PGL Emulation Programmer’s Reference Manual
• IGP®/VGL Emulation Programmer’s Reference Manual
• IPDS™ Programmer’s Reference Manual
• LinePrinter Plus® Emulation Programmer’s Reference Manual
• Printer Protocol Interpreter (PPI) ZGL™ Programmer’s Reference Manual
• Printer Protocol Interpreter (PPI) TGL™ Programmer’s Reference Manual
• Printer Protocol Interpreter (PPI) IGL™ Programmer’s Reference Manual
• Printer Protocol Interpreter (PPI) STGL™ Programmer’s Reference
Manual
17
Chapter 1 The SL5000r/T5000r Series RFID/Label Printer
The SL5000r/T5000r Series RFID/Label Printer

NOTE: As used in this manual, the terms “T5000r” and “printer” refer to all
models within the series. “SL” refers to all SmartLine RFID models.
The T5000r series is a family of high quality, direct thermal and thermal
transfer printers specifically designed to print labels and tags from any
MS-DOS®, Windows®, ASCII, or EBCDIC (with the Coax/Twinax option)
based compatible computer.
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,
USB 2.0 Universal Serial Bus, 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 T5000r, Smart Ready, and SmartLine series are comprised of the
products detailed in Table 1.
NOTE: All 4 and 6 inch models are Smart Ready.
Table 1. The T5000r, Smart Ready, and SmartLine Series
Max Print Printing Max Print

Model
Speed (ips) Density (dpi) Width (inches)
T5204r 10 203 4.1
T5204r DT* 10 203 4.1
SL5204r MP 10 203 4.1
T5304r 8 300 4.1
T5304r DT* 8 300 4.1
SL5304r MP 8 300 4.1

T5206r 10 203 6.6
T5306r 8 300 6.6
T5208r 8 203 8.5
T5308r 6 300 8.5
* DT = Direct Thermal only 4 inch models (no ribbon transfer support)
18
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 4 inch DT models, which print only in direct thermal mode)
• Standard Interfaces:
• Serial: RS-232
• USB 2.0 Universal Serial Bus
• Parallel: Centronics-compatible parallel, IEEE 1284 compliant parallel
NOTE: The interface cable needed to connect the printer to the host device is
supplied by the user.
• Bar Codes: Support for over 20 types of bar codes
• Download: Fonts, forms, and graphics into printer memory
• Resident Fonts: Letter Gothic Bold (#93779), Courier Bold (#93952), CG
Triumvirate Bold Condensed (#92250), OCR-A (#90993), OCR-B
(#91409), CG Triumverate (#92244), CG Triumverate Bold (#92248), and
CG Times (#92500)
• 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 the 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
• 32MB DRAM memory (fixed)
• 8MB Flash memory (SIMM)
• 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
• ZGL, TGL, IGL, and STGL Interpreters: PPI/ZGL (Zebra®), PPI/TGL
(TEC®), PPI/IGL (Intermec®), and PPI/STGL (SATO®) interpreters are
powerful integration tools that allows the SL5000r/T5000r to function in
virtually all legacy ZPL, TEC, IPL, and SATO application environments
without requiring modification to host data stream.
19
Optional Features
The following options are also available for SL5000r/T5000r printers:
• 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 9 on page 210 for a list of optional fonts.
• Memory Expansion: 16MB Flash SIMM replaces standard 8MB Flash
SIMM to provide additional memory for fonts, forms, and logos.
• 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.
• Media Cutter Tray: Used with the media cutter option to catch and collect
the cut media in a bin.
• 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.
• 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.
• Coax/Twinax Host Interface: Provides connection to a host computer
system using a coaxial or twinaxial interface.
• NIC (10/100BaseT) Internal or External: The NIC (Network Interface
Card) 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, and 300 dpi printhead installed to support this field-
installed option.
NOTE: IPDS is not supported by SL/RFID models.
• 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 coax/twinax emulation to be
printed through the NIC.
NOTE: TN5250/TN3270 is not supported by SL/RFID models.
20
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.
• RS-422: Serial interface option.
• GPIO (General Purpose Input/Output): This option enables a T5000r
printer to interface with an external device such as a label applicator
system. GPIO is available as a factory option or field installable kit that
also includes a mating connector for field interface, installation
instructions, and operation manual.
• Wireless NIC: This card provides wireless 802.11b connectivity without
expensive cabling and reconfigurations required from a wired network.
• 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 T5000r 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.
NOTE: Thermal transfer is not supported on 4 inch DT model printers.
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.
21
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.
• 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.
22
Thermal Printer Technology
RFID Encoder Antenna Board
Cutter
P2 J2 J1 P1 P301
PCBA Option
J301
Validator Option Control

Panel
P13 P9 P11 P18

J13 J9 J11 J18
P12 Cutter Option
J7 RS422 J12 J21 P21
J31
RJ11 PCI Expansion Ports
Flash J P
J3 Diagnostic J25 SIMM
Port 1 1 Upper Media
5 5 Sensor
J16 P16 Ribbon
J24 Supply
Serial Controller
J2 Port Motor
DB9 J14 P14 Stepper
Motor
P10
Real Time Head Up
J10 U9 Clock/ Sensor
J4 Ribbon
NVRAM
J112 J8 P8 Take-up Label
P112 Motor Taken
J6 J5 J17 Sensor
USB
J203 P6 P5 P17
Parallel Lower Media
Port Sensor
P401
PCI Bus Expansion
Connector 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

Option Option
Figure 1. Functional Block Diagram, SL5000r
23
Cutter
P2 J2 J1 P1 P301
PCBA Option
J301

Panel
P13 P9 P11 P18

J13 J9 J11 J18
P12 Cutter Option
J7 RS422 J12 J21 P21
J31
Flash J P
5 5 Sensor
J16 P16 Ribbon
J24 Supply
Serial Controller
J2 Port Motor
DB9 J14 P14 Stepper
Motor
P10
Real Time Head Up
J4 Ribbon
NVRAM
P112 Motor Taken
J6 J5 J17 Sensor
USB
J203 P6 P5 P17
Port Sensor
P401
PCI Bus Expansion
Connector J401
P403 Thermal
CN403 Print
AC Power P402 Head
Line 1 J201
Ground (green/
yellow wire)

Option Option
Figure 2. Functional Block Diagram, T5000r
24
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
25
26
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.
27
Control Panel
28
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, set 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, set 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.
29
Chapter 1 Controls And Indicators
30
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.
31
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 24, page 166) 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.
32
Cleaning The Printhead, Platen Roller And Media Sensors
Printhead Pivoting
Heating Deck
Elements
Peel/Tear Door
Platen Roller
Lower Media
Sensor
(with visible Deck Lock
red LED) Lever
Printhead Cover/
Upper Media Sensor
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.
33
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 108).
2. Inspect the EMI clips on the frame side cover for damage. Replace any
clip that is damaged or missing. (Figure 20, page 154.)
3. Inspect the platen belt and the rewinder belt for cracks, cuts, fraying, and
wear. (Figure 22, page 160.) Replace any damaged or worn belt.
4. Inspect the ribbon drive gears and intermediate gears for cracks, chipped
or missing teeth. (Figure 23 on page 164 and Figure 33 on page 190.)
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. Open and close the media cover, checking that the cover closes
completely. Adjust as required. (Figure 20, page 154.)
9. Check that the media hanger guide assembly operates correctly and the
spring is not broken. Replace if damaged. (Figure 20, page 154.)
10. Inspect the ribbon spindles, rewinder, and media damper for damage and
smooth operation. (Figure 23, page 164.) Replace a damaged spindle or
bail.
11. Inspect the printhead and platen assemblies for obvious damage.
(Figure 25, page 168.) Replace damaged assemblies.
12. Inspect the media sensor assemblies for paper dust, sufficient horizontal
travel, smooth horizontal movement, and damaged or frayed ribbon
cable.
13. Restore the printer to operation (page 96).
34
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 User’s 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 User’s 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 32).
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 User’s Guide.
35
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 User’s Guide.
Troubleshooting At A Glance
Start Here.......................................................................................... page 37
How To Troubleshoot........................................................................ page 38
Troubleshooting Display Messages .................................................. page 40
Troubleshooting Other Symptoms .................................................... page 75
Troubleshooting A New Installation................................................... page 94
36
Troubleshooting At A Glance
Start Here
Are you here because of an Go to Troubleshooting

error message? YES Display Messages,
NO page 40.
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
user’s configuration. Make a configuration Is this a newly
Did steps 1 through 4 occur? YES printout. (Refer to YES installed printer? YES
the User’s 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 76.
and the printer
appears to be Go to
working, but nothing Troubleshooting
is printed, page 78. A New
Installation,
page 94.
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 79.
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 79. 2. Replace control panel
and cable.
3. Troubleshoot using Half-
Split Method outlined on
page 38.
37
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 41 or
Table 3 on page 76. 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.
38
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 User’s 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.
39
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
CONTROL menu. Press PAUSE to silence the alarm.
• The control panel LCD displays a fault message.
40
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.”
41
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 coax/twinax 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 Ω
Pin 3 - 4 = 110 Ω
Pin 1, 2, 3, 4 - Shield = 55 Ω
Pin 5 - Shield = 0 Ω
Pin 14 - 1, 4 = 0 Ω
Pin 7 - 2, 3 = 0 Ω
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 coax/twinax
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.
42
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 PCBA.
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.
43
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 fails This message appears when at 1. Press PAUSE to clear the
Job has errors least one label in a batch of message.
labels has a data validation
error. 2. Manually scan all the bar
codes in the label batch,
NOTE: then reprint the bad labels.
This message appears only
when Validator Action is set to
Grade&Report.
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 media’s
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.
44
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 power cart ICP 2. If High Volt Alert = 16.0
(Intelligent Control Panel) Volts and fault message
option is connected to the remains, call your
printer serial port and Battery authorized service center.
Monitor = 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 power cart ICP fails to clear the fault,
(Intelligent Control Panel) replace the battery or
option is connected to the batteries.
printer serial port and Battery
Monitor = Enable in the NOTE: Follow the battery
BATTERY CONTROL menu. manufacturer’s 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 91.
45
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 272.
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.
46
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.
47
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.
download the emulation. If
3. 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
running. to 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 PCBA.
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.
48
List Of Messages
ERROR: DRAM AT The printer found a defective 1. Cycle power: power down
ADDRESS XXXXXXXX memory location. the printer, wait 15
seconds, then power the
printer on.
ERROR: FLASH The printer encountered an 1. Download the emulation
DID NOT PROGRAMì 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 1. Cycle power: power down
DETECTED DRAM. the printer, wait 15
printer on.
ERROR: PROGRAM The program exceeds the Download a smaller program.

NEEDS MORE DRAM memory limitations of the
printer.
49
ERROR: PROGRAM The printer requires more flash 1. Install a 16MB Flash SIMM
NEEDS MORE FLASH memory in order to run the at J31.
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: SHORT AT Hardware failure in DRAM on 1. Cycle power: power down

ADDRESS XXXX main PCBA controller circuitry. the printer, wait 15
printer on.
ERROR: WRITING Hardware or software fault in 1. Download the emulation

TO FLASH flash memory. software again.
50
List Of Messages
ERROR: WRONG The printer received the 1. Download the program

CHECKSUM complete program but the using a new software CD.
checksum did not match. The If the message reappears,
data were corrupted during replace the Flash SIMM.
download. 2. Download the emulation. If
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.)
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
prints.
NOTE: This is a warning
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.
HOT, PRINTER HOT,
or PRINT HEAD HOT, 4. Replace the power supply
based on the source. fan.
5. Replace the power supply.
6. Replace the controller
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 User’s
Manual.)
51
FILE SYS FULL There is not enough flash Install a 16MB 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 User’s
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
User’s Manual.)
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 User’s
Manual.)
FILE SYS WRITE Problem writing to flash 1. Reseat Flash SIMM at J31.
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.
52
List Of Messages
GAP NOT DETECTED The printer is set for Mark, Gap, 1. If the customer is not using
Check Media Advanced Gap, or Advanced die-cut labels, set the
Notch sensing, but a mark, gap Gap/Mark Sensor to
or notch is not being detected. Disable in the QUICK
This can occur if: SETUP or CALIBRATE
1. Media with no gap or black CTRL menu.
mark is installed, and Gap 2. Inspect the horizontal
or Mark is selected in the position of the media
CALIBRATE CTRL menu. sensor. Check the paper
2. The media sensor is not path. Clean the sensor
horizontally positioned assembly.
relative to the gap, notch, 3. Position the upper sensor
hole, or black mark on the directly over the lower
media, or the media width sensor if the customer is
guide is not set correctly, using either Advanced Gap
causing the media to be or Advanced Notch.
misaligned.
4.
3. If Advanced Gap or a. Do the Auto Calibrate
Advanced Notch is selected procedure. (Refer to the
in the CALIBRATE CTRL User’s Manual.) This
menu, the upper media procedure improves the
sensor may not be ability of the sensor to
positioned over the lower detect the type of
media sensor. media in use. Save
your calibration after
4. An Auto Calibrate was not
you calibrate.
performed using the
installed media. There is b. Run a Profile Printout
not enough contrast from the CALIBRATE
between the label and liner. 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 User’s Manual.)
53
GAP NOT DETECTED d. Make sure the media

Check Media sensor cables have
good connections to
J15 and J21 on the
controller PCBA.
e. Verify that the media is
within the specification
of the printer. Refer to
the User’s 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.
54
List Of Messages
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 PCBA 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 PCBA. 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.
INCOMPATIBLE WITH Tear-Off or Peel-Off Media 1. Select a different Media

CUTTER Handling selection (in the Handling mode.
MEDIA CONTROL menu) was
2. Power off the printer and
attempted with the cutter option
remove the cutter option,
installed. These modes require
install the front door
that the front door assembly be
assembly, power on the
installed to use the label taken
printer and select Tear-Off
sensor.
or Peel-Off mode.
55
INSUFFICIENT RAM There is not enough RAM 1. Cycle power: power down
Reboot/Add RAM available for certain printer the printer, wait 15
functions or emulations. seconds, then power the
printer on.
increase the Glob Mem
Adjust size in the PRINTER
CONTROL menu and
reboot the printer.
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.
56
List Of Messages
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-RFID DATA A job was printed that had no Press PAUSE to clear the
On Rfid Tag RFID commands on at least message.
one form of the job while RFID Set Non-RFID Warning to
tags were installed in the printer Disable, print a job with RFID
and the Non-RFID Warning commands on every form, or
menu item is set to Enable. install non-RFID labels in the
printer.
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.)
57
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.
PØØ ERROR: An interrupt occurred due to a 1. Cycle power: power down

SYSTEM FAULT software or hardware problem. the printer, wait 15
printer on.
clean the gold connectors
on the internal PCI NIC.
download the latest level of
software.
58
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 User’s 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. 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.
5. 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 User’s
Manual.).
6. If the printer detected a
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
7. Make sure the media
sensor cables have good
connections to J15 and J21
on the controller PCBA.
8. Replace the media
sensor(s).
59
PAPER OUT In the CT emulation with a coax 1. Load media and print a
TIMEOUT interface, a time-out message is diagnostic test pattern
sent to the host if paper is not (page 39).
loaded within 10 minutes after 2. If the message reappears,
PAUSE was pressed to clear a replace the controller
paper out fault. PCBA. Write down the
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.
reappears, replace the
serial data cable.
reappears, go to
Communications
Failures, page 91.
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
User’s Manual.)
loss of a printhead element.
60
List Of Messages
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 User’s 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,
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.
61
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
2. The environment is too cold printhead and J6 on the
for the printhead to sustain controller PCBA.
operating temperature. 2. Move the printer to a
warmer location.
62
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 User’s
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.
63
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 is unobstructed.
powering the printer off, waiting
a few minutes, and then 2. Inspect the printer
powering the printer back on. 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.
3. Clean the printhead.
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.
64
List Of Messages
PWR SUPPLY HOT The power supply is operating 1. Make sure the fan works
See Manual at higher than normal and is unobstructed.
temperatures. This fault causes 2. Verify that the tab on the
the printer to stop printing. panel is not interfering with
NOTE: The power supply fan the fan on the power
will operate during any supply. If it is, order a power
media motion (feeding, supply.
slewing, or printing) and
3. Make sure the fan is
for a short period during connected to JP401 on the
printer power up. 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.
65
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 90.
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.
66
List Of Messages
RBN TAKEUP FULL f. Verify that the ribbon

Remove Used Rbn take-up motor is
connected to J8 on the
controller PCBA.
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 power 2. If recharging the battery
cart ICP (Intelligent Control fails to clear the fault,
Panel) option is connected to replace the battery or
the printer serial port and batteries.
Battery 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
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.
67
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 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 310.
CONTROL menu and the
previous port settings restored.
RFID FW ERR: The RFID encoder firmware Press PAUSE to clear the
Version Mismatch version is not capable of message.
operating with the printer Redownload the program file to
software. the printer.
RFID LOCK CMD: The lock command for Press PAUSE to clear the
Not supported EPC-119 type tags is not message.
supported, but a lock command Remove the lock command
was encountered. from the application.
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 310.
RFID TAG ERR: A write was attempted on a Press PAUSE to clear the
Read-Only Tag read-only tag. message.
Change media to writable tags
or remove the write command
from the application.
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 310.
68
List Of Messages
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).
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 39). 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.
69
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.
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.
SECURITY CODE The software running or being Install the correct security key at
VIOLATION downloaded does not match the J29 or use the correct
security key code. emulation program. (Security
key and program must match.)
SECURITY The security key is not present 1. Check the security key at
VIOLATION or has failed. J29 on the controller PCBA.
If the key is absent, install
correct key. If the correct
security key is present,
replace the security key.
70
List Of Messages
SELECT DOWNLOAD Normal message when the 1. Complete the downloading

PORT=XXXXXXXXXX printer is being setup for software procedure. See
downloading software using the “Loading Through The
serial or parallel port. PORT= Parallel Or Serial Port
displays selected serial port and Using DOS” on page 205.
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
reappears, replace the
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.
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.
71
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 39) and
verify the IP Address,
Netmask, Gateway, and
TCP Port settings.
Test Page An attempt was made to print Replace the NIC.
Not Available an E-Net test page. The NIC
may be defective.
72
List Of Messages
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 coax/twinax
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.
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.
73
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 203.
download software to the 2. Exit this procedure by
printer. cycling printer power.
74
General Symptom List
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.

Table 3, beginning on page 76, 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.
75
Chapter 3 Troubleshooting Other Symptoms
Table 3. General Symptom List
Symptom Solution
COMMUNICATIONS FAILURES
Printer hangs during print job. 1. Redownload the latest level of software (page 203).
2. Refer to Table 4 on page 92.
Fails to print from host. See Table 4 on page 92.
Prints incorrect characters. See Table 4 on page 92.
Prints extra characters. See Table 4 on page 92.
Drops characters. See Table 4 on page 92.
Data loss. See Table 4 on page 92.
Cannot ping (NIC). See Table 4 on page 92.
Cannot print (NIC). See Table 4 on page 92.

Host cannot communicate Refer to the Network Interface Card User’s 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 72.
76
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.
77
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 203).
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.
78
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 PCBA. 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 J31 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 PCBA. 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.
79
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 User’s Manual.
b. Decrease Gap Threshold value by 2 or 3 increments.
Refer to “Gap/Mark Thresh” in the User’s Manual.
c. Set Clip Page to Disable. Set Label Length to correct
physical length value. Refer to “Clip Page” in the
User’s Manual.
Short printhead life. See “How To Maximize Printhead Life” on page 35.
Media moves, but no image 1. Print a checkerboard diagnostic test pattern (page 39). 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 39).
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 User’s Manual.
80
Symptom Solution
Media and ribbon move, but 1. Print a checkerboard diagnostic test pattern (page 39) 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 User’s 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 21.
81
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 User’s 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 92.
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 peel/tear door is not fully closed, the label taken
sensor cannot detect labels. Close the door and do step 1.
4. The mirror and label taken sensor are misaligned on the
peel/tear door. 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
PCBA.
82
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 User’s 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.
83
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 39).
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 User’s Manual.)
9. Make sure the head pressure adjustment dial is set
correctly for the thickness of the media being used. (Refer
to the User’s 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 User’s
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 User’s 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 User’s Manual.)
84
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
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.
85
Symptom Solution
PRINTER OPERATION
“*** 053 Insufficient memory 1. Cycle power: power down the printer, wait 15 seconds,
to create the LOGO” printed then power the printer on.
on the media. 2. If the message reappears, replace the controller PCBA.
“*** 055 LOGO call not 1. Cycle power: power down the printer, wait 15 seconds,
previously defined” printed on then power the printer on.
the media.
2. If the message reappears, replace the controller PCBA.
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 User’s Manual.)
possible PAPER OUT errors.
Advances several labels 1. Check that labels are loaded correctly. (Refer to the User’s
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 User’s
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 User’s
Manual.)
5. Adjust the media sensor horizontally to detect the gap,
holes, notches, or narrow width black stripe. (Refer to the
User’s Manual.)
6. If problem persists, replace the media sensor.
86
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 User’s 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 this—this 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.
87
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
Programmer’s Reference Manual or the Ethernet Interface
User’s Manual for instruction on correctly creating a
different device profile that can utilize IGP or Code V
datastreams.
Clacking sound in Peel Off or The media rewind belt is jumping or skipping teeth.
Batch Rewind mode. Check and adjust the rewinder torque. See page 136.
The media or backing fails to The media rewind belt is jumping or skipping teeth.
consistently rewind onto the Check and adjust the rewinder torque. See page 136.
spindle when using the
rewinder.
88
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 PCBA.
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.
89
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 PCBA.
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.
90
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 User’s Manual.
91
Chapter 3 Communications Failures
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
-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 User’s Manual.
USB - Interface cable defective
-or- - Host/Printer/Network configuration
- Printer logic
Data loss - Incorrect printer configuration. Refer customer to
twinax - Interface cable defective
- Host-Printer definition
- Controller/Network configuration
- Printer logic
coax - Interface cable defective
- Controller/Network configuration
- Printer logic
ethernet - Interface cable defective
- Host/Printer/Network configuration
- Printer logic
- Incorrect ethernet configuration. Refer customer
to the Network Interface Card User’s Manual.
- See also “NIC, Internal, 10/100Base-T” on
page 125 for a description of the NIC dip switch
settings.
92
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
93
Chapter 3 Troubleshooting A New Installation
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 customer’s 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 printer’s
configuration. (Refer to the User’s Manual.)
GAP NOT DETECTED

1. Do the Run Calibrate procedure. (Refer to the User’s 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 customer’s 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.
94
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 153.
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.
95
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 108).
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 PCBA or the Flash SIMM, or installed the
IPDS or coax/twinax 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 User’s Manual.)
10. Use the customer’s configuration printout(s) to reset and save the printer
configuration(s). (Refer to the User’s Manual.)
NOTE: If you replaced the controller PCBA, Flash SIMM, media sensors, or
downloaded new software, do the Auto Calibrate procedure and save
the configuration. (Refer to the User’s Manual.)
11. Test printer operation and check print quality by printing a diagnostic test
pattern (page 39).
12. Select the emulation. (Refer to the User’s Manual.)
96
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
• 3/16 inch nut driver
• 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
• Chip installer/puller
• Static wrist strap
For rewinder (option):
• Torque Watch Tool: range 0 to 12 inch-pounds (0 to 200 inch-ounces)
Must accept a ¼ inch male hex adapter
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
97
Chapter 4 Removal And Replacement Procedures
Removal And Replacement Procedures

Belt, Platen........................................................................................ page 99
Belt, Rewinder................................................................................. page 100
Coax/Twinax ................................................................................... page 101
Control Panel Assembly.................................................................. page 102
Controller PCBA (Printed Circuit Board Assembly)......................... page 103
Cooling Fan, Power Supply............................................................. page 106
Damper, Media................................................................................ page 107
Frame Side Cover ........................................................................... page 108
Gear, Ribbon Drive, Final................................................................ page 109
Gear, Ribbon Drive, Intermediate ................................................... page 110
Head Pressure Block Assembly...................................................... page 111
Media Cover.................................................................................... page 114
Media Hanger Beam ....................................................................... page 115
Media Sensor Assembly, Lower...................................................... page 116
Memory Module, Flash SIMM ......................................................... page 117
Memory Module, NVRAM And Real-Time Clock ............................ page 119
Motor, DC Ribbon Drive .................................................................. page 120
Motor, Stepper ................................................................................ page 121
NIC, External................................................................................... page 122
NIC, Internal, 10/100Base-T ........................................................... page 125
NIC Configuration............................................................................ page 126
Plate, Rear Panel ............................................................................ page 127
Platen .............................................................................................. page 128
Power Supply Assembly ................................................................. page 129
Printhead Assembly ........................................................................ page 130
Printhead Cover/Upper Media Sensor................................................ page 132
Resistors, Terminating .................................................................... page 133
Rewinder (Option) ........................................................................... page 135
Rewinder, Torque Check and Adjustment ...................................... page 136
Security Key .................................................................................... page 139
Security Key, Reprogramming ........................................................ page 140
Sensor, Head Up............................................................................. page 142
Sensor, Label Taken ....................................................................... page 143
Spindle Assembly, Ribbon Supply Or Take-Up .............................. page 144
Support Assembly, Lower ............................................................... page 145
Support Assembly, Upper ............................................................... page 146
Tear Off Assembly .......................................................................... page 147
Peel/Tear Assembly ........................................................................ page 148
Tear Bar Assembly, Adjustable....................................................... page 149
Tensioner, Rewinder Belt................................................................ page 151
98
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 95).
3. Remove the stepper motor (page 121).
4. Slip the platen belt off the larger (outermost) cluster pulley. (Figure 22,
page 160, 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 22,
2. Install the stepper motor (page 121).
99
Belt, Rewinder
Removal
3. Remove the power supply assembly (page 129).
4. Remove the stepper motor (page 121).
5. Slip the platen belt off the larger (outermost) cluster pulley. (Figure 22,
6. Remove the retaining E-ring securing the rewinder pulley to the shaft of
the rewinder spindle assembly. (Figure 22, page 160, 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 22, page 160, 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 23, page 164, item 4.)
3. Slide the nylon washer onto the rewinder spindle shaft. (Figure 22,
page 160, 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 22, page 160, item 16.)
6. Slip the platen belt over the larger (outermost) cluster pulley.
7. Install the stepper motor (page 121).
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 108).
100
Coax/Twinax
Coax/Twinax
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. Remove the two screws that secure the coax/twinax PCI card to the rear
of the printer frame. (Figure 31, page 186, item 7.)
5. Carefully unplug the coax/twinax PCI card from the controller PCBA, and
remove it from the frame cutout.
Installation
2. Carefully plug the coax/twinax PCI card into port J24 or J25 on the
controller PCBA. (Figure 31, page 186, item 11.)
3. Position the coax/twinax subassembly in the frame cutout.
4. Install and tighten both screws securing the coax/twinax interface plate to
the rear of the printer frame.
101
Control Panel Assembly

Removal

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 34, page 192, 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 34, page 192, 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.)
102
Controller PCBA (Printed Circuit Board Assembly)

Removal

4. Remove the coax/twinax board, if one is installed in the printer
(page 101).
5. Remove the NIC assembly, if one is installed in the printer (page 125).
6. Remove the wireless interface, if one is installed in the printer (page 289.)
7. Unplug the cutter board cable, if a cutter is installed in the printer.
(Figure 36, page 238.)
8. Unplug the validator power/data cable, if a validator is installed on the
printer. (Figure 49, page 261.)
9. Unplug the RFID encoder cable, if an encoder is installed in the printer.
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 PCBA.
12. Unplug all cable assemblies from the controller PCBA. (See the Cable
Routing diagram on page 216.)
13. Remove the J15 (page 116) and J21 (page 105) connectors.
14. Remove the two standoff screws on both sides of the 9 pin RS-232
connector that attach the controller PCBA to the rear panel. (Figure 31,
page 186, item 12.)
15. Loosen (do not remove) the eight screws that secure the rear panel to the
frame. (Figure 33, page 190, item 5.)
16. Loosen (do not remove) the two screws that secure the ferrite bracket to
the frame, and pull the bracket 1/4 inch away from the frame. (Figure 31,
17. Loosen the six captive screws enough to release the controller PCBA
from the printer frame. (Figure 32, page 188, items 1 and 3.)
103
CAUTION In the next step, failure to completely remove the old thermal pad and
install the new thermal pad will damage the controller PCBA.
18. Remove the old controller PCBA and thermal pad from the printer frame.
(Figure 31, page 186, item 8.) Install the new thermal pad on the frame.
19. 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 117).
20. Remove the security key (Figure 8, page 118) at location J29 from the old
controller PCBA and install it on the new controller PCBA.
Installation
2. Reverse the steps of the removal procedure.
104
Media Label Taken

Cutter Head Up Sensor
J9 Sensor J18 Upper Media
Control J11 Sensor
Panel Lower Media J21
J13 Sensor
J15
J16
Online Data Ribbon
Validator Supply
J10 Motor
Centronics
Parallel Port
J112
J14
RFID Port Stepper
J12 Motor
Serial J8
RS422 Ribbon
Port Take-up
J7 Motor
Diagnostic
Port
J3
Serial J17
RS232 Power
Port Supply
J2
J25 U9
J24 PCI NVRAM
USB Port Connections
J4
Figure 4. Controller PCBA Connectors
105
Cooling Fan, Power Supply

Removal
4. Disconnect the fan cable connector from connector JP401 on the power
supply board.
5. Remove the fan bracket (Figure 22, page 160, item 4) by removing the
two countersunk Phillips head screws from the bottom of the power
supply assembly.
6. Unlock the reusable plastic fasteners by pushing in the center post with a
small mm hex key.
Installation
3. If the plastic fasteners are lost or broken, use the M4x30mm screw and
nut (Figure 22, page 160, items 3 and 14) available in Hardware Kit
171629-001 (page 196).
106
Damper, Media
Damper, Media
Removal
3. Remove the retaining E-ring securing the damper shaft to the printer
frame. (Figure 23, page 164, item 3.) Remove the two washers.
4. Lift the lower arm of the media damper spring (Figure 23, page 164,
item 5) from the media damper and place it on the media damper stop on
the frame (Figure 23, page 164, item 16).
NOTE: The spring should remain on the frame.
5. Slide the media damper out of the frame. (Figure 23, page 164, 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 5).
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 5.)
2. Install one nylon washer (Figure 23, page 164, 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 23, page 164, 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 23, page 164, 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 5. Removing the Media Damper
107
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
108
Gear, Ribbon Drive, Final
Gear, Ribbon Drive, Final

Removal
3. Remove the appropriate retaining E-ring securing the final ribbon drive
gear to the spindle shaft. (Figure 23, page 164, items 2 and 3.)
4. Remove the final ribbon drive gear from the spindle shaft.
Installation
109
Gear, Ribbon Drive, Intermediate

Removal
3. Remove the appropriate final ribbon drive gear (page 109).
4. Remove the appropriate DC ribbon drive motor (page 120).
5. Remove the retaining E-ring securing the intermediate ribbon drive gear
to the shaft. (Figure 33, page 190, 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.
110
Head Pressure Block Assembly

NOTE: This procedure applies only to eight and six inch printers. To replace
the head pressure blocks on a four inch printer, replace the upper
support assembly (page 146).
Removal
2. Remove the printhead assembly (page 130).
3. Rotate the lead screw knob until the outboard head pressure block is
exactly one inch from the inboard head pressure block. (Figure 26,
page 172, item 5.)
4. Remove the retaining E-ring and the lead screw knob. (Figure 26,
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 26, page 172, 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 26, page 172, items
2 and 8.)
7. Remove the pressure block handle from the inboard head pressure block.
8. Remove the pressure block pointer from the outboard head pressure
block. (Figure 26, page 172, 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 26, page 172, items 8 and
26.)
10. Remove the gimbal pivot rack from the outboard head pressure block.
111
Installation
1. Install the gimbal pivot rack on the outboard head pressure block.
(Figure 26, page 172 or Figure 27, page 176, 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 26, page 172 or Figure 27, page 176, 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 26, page 172 or Figure 27, page 176, 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 26, page 172 or
Figure 27, page 176, item 6.)
7. Install the pressure block handle on the inboard head pressure block.
(Figure 26, page 172 or Figure 27, page 176, item 19.)
8. Install the lead screw knob and retaining E-ring. (Figure 26, page 172 or
Figure 27, page 176, items 2 and 5.)
IMPORTANT Do not rotate the lead screw until the knob has been installed.
112
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 printer’s 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 39). 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 6. The T5x04 Head Pressure Blocks
113
Media Cover
Removal
3. Hold the cover securely and loosen the screws securing the media cover
hinges to the printer frame. (Figure 20, page 154, items 3, 4, and 16.)
Installation
114
Media Hanger Beam
Media Hanger Beam

Removal
4. Remove the controller PCBA (page 103).
5. Remove both media hanger beam screws and the media hangar beam.
Installation
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 20, page 154, items 6 and 7.)
2. Install the controller PCBA (page 103).
115
Media Sensor Assembly, Lower

Removal
4 Pin Lower Media

J15 Sensor Cable
Figure 7. Removing the 4 Pin Lower Media Sensor Cable

from the J15 Connector
3. Unplug the 4 pin lower media sensor cable from J15 on the controller
PCBA (Figure 4, page 105).
4. Remove the sensor cable from the wire saddles. Note the cable routing.
5. Open the pivoting deck by rotating the deck lock lever fully clockwise.
6. Use the lower media sensor handle and slide the sensor to the center of
the media guard.
7. Remove the two screws that secure the media guard to the lower support
assembly. Use a 2 mm hex key.
8. 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.
9. Remove the media guard from the printer.
10. Carefully pull the sensor cable out from under the tie wraps on the lower
support and remove the media sensor from the printer.
Installation
1. Reverse the steps of the remove procedure.
116
Memory Module, Flash SIMM
Memory Module, Flash SIMM

Printer flash memory is held in a Flash SIMM (Single In-line Memory Module).
The Flash SIMM plugs into socket J31 on the controller PCBA. (Figure 8,
page 118.)
Before 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.
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 203.)
Removal
1. Make a configuration printout of all saved configurations. (Refer to the
User’s Manual.)

5. Gently pry the side locks open, angle the SIMM to the left, and remove
the SIMM from the controller PCBA. (Figure 8, page 118.)
Installation
2. Insert the new SIMM into the socket with the notched end downward.
(Figure 8.) 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. 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 203.)
5. Select and run the OFFLINE/CONFIG. CONTROLPrint Config./
Current* menu. (Refer to the User’s Manual.) Make sure the new
memory is noted on the printout.
117
Controller
PCBA
J31
Flash
SIMM
Security Key
J29
U9
NVRAM and
Real-Time Clock
Notch
Figure 8. Replacing the Flash SIMM, NVRAM, Real-Time Clock, and Security Key
118
Memory Module, NVRAM And Real-Time Clock
Memory Module, NVRAM And Real-Time Clock

Removal
User’s Manual.)
4. Using a chip puller, remove the NVRAM module (Figure 8, page 118).
Installation
WARNING The NVRAM contains a lithium battery that can explode if replaced
incorrectly. You must position the Pin 1 circle on the NVRAM module
adjacent to the Pin 1 circle etched on the controller PCBA next to the
NVRAM position. As you face the controller PCBA, Pin 1 should be in
the upper left corner of the NVRAM position.
1. Position the NVRAM module on the controller PCBA with the Pin 1 circle
in the upper left corner.
2. Using a chip installer, seat the NVRAM module fully (Figure 8, page 118).
4. Download the desired emulation and operating system software, setup
files, feature files, TIFF files, and any optional font or logo files. (See
“Downloading Software” on page 203.)
5. Use the customer’s configuration printouts to reset and save the printer
configuration(s). (Refer to the User’s Manual.)
6. Do the Auto Calibrate procedure and save the configuration. (Refer to the
User’s Manual.)
119
Motor, DC Ribbon Drive

Removal
3. Disconnect the appropriate DC ribbon drive motor cable assembly from
the controller PCBA:
a. Disconnect the upper (ribbon take-up) DC ribbon drive motor cable
from connector J8 on the lower right edge of the controller PCBA.
b. Disconnect the lower (ribbon supply) DC ribbon drive motor cable
from connector J16 on the upper right edge of the controller PCBA.
(Figure 4.)
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 33, page 190, items 3 and 4.)
Installation
120
Motor, Stepper
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
PCBA. (Figure 4, page 105.)
5. Remove the top and bottom screws securing the stepper motor mount
plate to the printer frame. (Figure 22, page 160, 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 22, page 160, 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 22, page 160, 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.
121
NIC, External
NOTE: The NIC LAN option is an external 10/100Base-T ethernet interface
that connects to the parallel port.
If a NIC is connected to 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
User’s Manual.)
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 9. 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.
122
NIC, External
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.
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
123
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.
124
NIC, Internal, 10/100Base-T
NIC, Internal, 10/100Base-T

NOTE: The NIC LAN option is a 10/100Base-T ethernet interface available
either factory installed or as a field kit.
If a 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
User’s Manual.)
Removal

4. Remove both screws that secure the NIC to the cutout at the rear of the
printer frame. (Figure 31, page 186, item 7.)
5. Unplug the NIC from the PCI slot, slide it out of the cutout, and lift it out of
the printer. (Figure 31, page 186, item 9.)
Installation
125
NIC Configuration
1. Using the front panel, navigate to the IP Address and Netmask (Subnet
Mask) menu options and enter appropriate values. Do not enter the
Gateway Address at this point. You must press the ↵ key after inputting
each segment of the IP Address and Netmask.
2. Put the printer online and wait for the ETHERNET IS READY message to
display on the front panel. Placing the printer online starts the PrintNet IP
Address and Netmask update process. This process will take several
minutes.
NOTE: If you do not put the printer online, the setting you just entered will not
take effect. Do not turn the printer off until ETHERNET IS READY
displays. If you turn the printer off before the new values are written to
memory in the PrintNet adapter, you will need to repower the printer
and repeat step 1 and step 2 above immediately.
3. Once the ETHERNET IS READY message displays, enter the Gateway
Address by repeating step 1 and step 2 above. This will ensure the
correct Netmask becomes associated with the Gateway value you enter.
NIC Verification
Before performing the verification, you must connect the NIC to the network.
1. Print an ETHERNET test page to verify the settings you made.
2. Verify the Netmask is correct in two locations on the ETHERNET test
page:
• NETWORK INTERFACES
• TCP/IP ROUTING TABLE
The Netmask must be the same in both locations. For example, if the
Netmask is listed as 255.255.255.0 in NETWORK INTERFACES and is
listed as 255.255.255.255 in the TCP/IP ROUTING TABLE, they do not
match and you must correct it for the Gateway.
Also, if a Gateway Address was entered, verify that “xxx.xxx.xxx.xxx is
alive” is printed under the Default Gateway Ping Test, where
xxx.xxx.xxx.xxx is the Gateway Address. If a Gateway Address was not
entered, the Default Gateway Ping test is not required and will not display
on the page.
If the Netmask does not match, complete the following steps:
a. Take the printer offline.
b. Using the front panel, modify the Gateway value to 0.0.0.0.
(non-configured).
c. Place the printer online and wait for the ETHERNET IS READY
message to display.
d. Take the printer offline and enter the Gateway Address you desire.
e. Place the printer online and wait for the ETHERNET IS READY
message. This saves the new Gateway Address.
Your NIC is now configured and connected to your network. Refer to the
Network Interface Card User’s Manual for instructions on how to enable
printing from a host computer.
126
Plate, Rear Panel
Plate, Rear Panel

Removal
3. Remove the two hex standoffs (3/16 inch nuts) on both sides of the 9 pin
RS-232 connector. (Figure 31, page 186, item 12.) These attach the rear
panel to the controller PCBA.
4. Remove all screws securing any blank plates. (Figure 33, page 190,
items 7, 8, and 9.)
5. Remove all screws securing any I/O assemblies. (Figure 31, page 186,
items 7 and 13.)
6. Remove two screws near the AC power receptacle and power switch.
7. Remove eight screws securing the rear panel plate. (Figure 33, page 190,
items 5 and 6.)
8. Remove the rear panel plate. (Figure 33, page 190, item 6.)
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 25, page 168, items 5 and 6.)
8. Remove the retaining ring and wavy washer from the right side of the
lower support assembly. (Figure 28, page 180, 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 28, page 180, items 3 and 7.)
3. Position the peel/tear assembly on the lower support assembly and install
two M5x10mm screws. (Figure 25, page 168, 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 22, page 160, 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 25, page 168,
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 22, page 160.)
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 PCBA.
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 25, page 168, 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
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.
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.)
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 10), and the right side on 8 inch models.
Installation
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.
1. Touch an unpainted part of the printer frame before touching the
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 10.)
NOTE: You may need to gently pull the lower tabs of the retainer clips
upward to install the printhead assembly.
130
Printhead Assembly
Pivoting Deck
Printhead
Retainer
Clip (2)
Lower Tab (2)
Printhead
Assembly Pull-Tab
Printhead
Cover
Printhead Controller
Release Cable Assembly
Tab
Release Upper Media Sensor

Power Supply Tab Cable Assembly
Cable Assembly
Figure 10. Replacing 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 Cover/Upper Media Sensor

NOTE: The printhead cover/upper media sensor is not available for RFID
printheads. An entire printhead assembly must be replaced.
Removal
Printhead Cover/
Upper Media Sensor
Figure 11. 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 11.)
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
132
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 PCBA. These are suitable for most applications. (See Figure 12
on page 134.)
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 12, page 134.)
4. Using a chip puller, remove the packs.
Installation
1. Using a chip installation tool, install the resistor packs in the correct
socket. (Figure 12, page 134.)
133
RP1 RP2
Default: 1K Ohm Default: 470 Ohm
Alt 1: 330 Ohm Alt 1: 220 Ohm
Alt 2: None Alt 2: 1K Ohm
Figure 12. This figure shows the size and location of the terminating resistors on the
controller PCBA.
134
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 22, page 160, 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 23, page 164, 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 22,
page 160, items 5 and 6, and Figure 23, page 164, 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 23,
page 164, 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 23, page 164,
item 4.)
3. Spread a small dab of bearing grease around the back 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 22,
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 22, page 160, 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 22, page 160,
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).
135
Rewinder, Torque Check and Adjustment

The optional 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
Pivoting Deck
Optional Rewinder
Dial Indicator
Rewinder
Release Lever
Platen Roller
¼ Inch
Hex Shaft
Torque Watch
Deck Lock Lever Tool
(shown open)
Figure 13. Checking the Torque of the Optional Rewinder

1. Raise the media cover and open the pivoting deck by rotating the deck
lock lever fully clockwise. (Figure 13.)
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.
136
Rewinder, Torque Check and Adjustment
4. Hold the torque watch tool in your right hand and insert the end onto the
¼ 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 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.)
6 Inch 6 in.-lb. ± 1 in.-lb. (100 in.-oz. ± 16 in.-oz.)
8 Inch 7.5 in.-lb. ± 1 in.-lb. (120 in.-oz. ± 16 in.-oz.)
137
Adjust Rewinder Torque
Small, Flat Blade

Screwdriver
Slotted Opening
Rewinder
Spindle
Notched
Adjustment Wheel
Figure 14. Adjusting Rewinder Torque

1. Rotate the rewinder spindle by hand until the slotted opening is at the top.
(Figure 14.)
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 136. The rewinder torque is correct when six
consecutive readings of the rewinder torque show values that fall within
the ranges listed in Table 8.
138
Security Key
Security Key
Every emulation includes a security key, which is programmed for that
protocol. Security keys are programmed by using the SPX (page 140). If a
security key is damaged, install a blank one (P/N 176028-001) and program it
using the SPX (page 140).
Removal

4. Remove the old security key from location J29 on the controller PCBA.
Installation
2. Install the new security key at location J29 on the controller PCBA.
139
Security Key, Reprogramming

The security key on the controller PCBA can be reprogrammed with a
Software Program Exchange (SPX) module.
The SPX is an intelligent module that plugs into the debug port on the back of
the printer. The SPX is used only once; it automatically overwrites itself after
successfully reprogramming a security key. This allows the end user or a
service technician to enable features such as new emulations without having
to remove covers and install a new security key on the controller PCBA.
The SPX is used at power-up only and is not left in the printer during normal
operation. Because it is a single-use disposable item the user is not required
to return it to the vendor or manufacturer.
How To Reprogram The Security Key

1. Power off the printer.
2. Insert the SPX into the debug port, as shown in Figure 15.
Debug Port
SPX
Figure 15. SPX Module
140
Security Key, Reprogramming
3. Power on the printer. The printer will begin its boot-up sequence.
4. When the printer detects a valid SPX, the control panel displays:
NEW SPX DETECTED
PRESS ENTER
NOTE: If an error message displays, find the message in the Message List in
Chapter 3 and follow the troubleshooting instructions.
5. Press the ENTER key to activate the reprogramming sequence. The
display will read:
DO NOT POWER OFF
Upgrading...
6. When the security key is reprogrammed, the display will read:
REMOVE USED SPX
THEN PRESS ENTER
7. Remove the SPX from the debug port at the rear of the printer.
8. Press the ENTER key. The printer will reboot itself and you may resume
normal printing.
9. You may need to download the emulation if the emulation supported by
the SPX is not in the current printer firmware.
10. You may need to set additional menu parameters for any new features
that have been added or enabled. (Refer to the User’s Manual.)
141
Sensor, Head Up
Removal
3. Disconnect the head up sensor cable from connector J11 on the
controller PCBA. (Figure 4, page 105.)
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 216.)
5. Remove the screw securing the sensor holder to the pivoting deck.
(Figure 26, page 172 or Figure 27, page 176, items 11 and 13).
6. Remove the head up sensor from the sensor holder. (Figure 26, page 172
or Figure 27, page 176, items 10 and 11).
Installation
1. Install the head up sensor in the sensor holder. (Figure 26, page 172 or
Figure 27, page 176, items 10 and 11).
2. Install the screw securing the sensor holder to the pivoting deck.
(Figure 26, page 172 or Figure 27, page 176, items 11 and 13).
3. 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 216.)
4. Connect the head up sensor cable to connector J11 on the controller
7. 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.
9. Close and latch the pivoting deck. The audible alarm should stop.
142
Sensor, Label Taken
Sensor, Label Taken

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. Loosen the clamping screw on the cluster pulley and slide the pulley
about 1/4 inch along the platen shaft to gain access to the label taken
sensor. (Figure 22, page 160, items 8 and 13.)
7. Disconnect the label taken cable assembly from connector J18 on the
upper right corner of the controller PCBA and remove the cable assembly
from the wire saddles in the printer frame. (Figure 4, page 105.)
8. Remove the screw securing the label taken sensor to the printer frame
and remove the sensor and cable assembly from the printer. (Figure 34,
Installation
1. Position the label taken sensor assembly in the printer frame and install
the mounting screw. (Figure 34, page 192, 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 PCBA. (Figure 4, page 105.)
3. Slide the cluster pulley onto the platen shaft.
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 clamping screw 25 in.-lb. to the flat sections of
the platen shaft.
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.
143
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 23, page 164, 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 23, page 164, 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 23, page 164, item 2.)
3. Install the retaining E-ring securing the final ribbon drive gear to the
spindle shaft. (Figure 23, page 164, item 3).
144
Support Assembly, Lower
Support Assembly, Lower

Removal
2. Remove the platen (page 128).
3. Remove the media sensor assembly (page 116).
4. Remove two screws and the peel/tear assembly. (Figure 25, page 168,
items 5 and 6.)
5. Remove three screws (Figure 25, page 168, item 4) and the lower
support assembly (Figure 28, page 180, item 2).
Installation
NOTE: Before tightening the three screws, rotate and bias the lower support
clockwise.
145
Support Assembly, Upper

Removal
4. Remove the head up sensor (page 142).
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 25, page 168, 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 31, page 186, item 1.)
Make sure the upper support assembly is tightened against the frame
before installing the grommet.
146
Tear Off Assembly
Tear Off Assembly

Removal
2. Open the tear off door by pulling it forward and down. (Figure 16.)
3. Remove the two thumbscrews securing the tear off assembly to the lower
support assembly.
4. Remove the tear off assembly.
Tear Off
Assembly
Thumbscrew (2)
Lower Support
Assembly
Tear Off Door
Figure 16. Removing the Tear Off Door
Installation
147
Peel/Tear Assembly
Removal
2. Open the peel/tear door by pulling it upward, then forward. (Figure 17.)
3. Using a 3 mm hex key, remove the two screws securing the peel/tear
assembly to the lower support assembly.
4. Remove the peel/tear assembly.
Peel/Tear
Assembly
M5x10mm
Screw (2)
Lower Support
Assembly
Peel/Tear Door
Figure 17. Removing the Peel/Tear Door
Installation
IMPORTANT Do not use thumbscrews.
148
Tear Bar Assembly, Adjustable
Tear Bar Assembly, Adjustable

NOTE: The adjustable tear bar assembly supports the Tear-Off Strip and
Continuous Media Handling modes only. It does not support the
Tear-Off Media Handling mode.
Removal
2. Remove the two thumbscrews securing the adjustable tear bar assembly
to the lower support assembly.
NOTE: Keep the two thumbscrews you have removed; you will use them if
you need to reinstall the adjustable tear bar assembly.
3. Remove the adjustable tear bar assembly.
Adjustable
Tear Bar
Assembly
Tear Bar
Bracket
Thumbscrew (2)
Lower Support
Assembly
Figure 18. Removing the Adjustable Tear Bar Assembly
Installation
Mount the adjustable tear bar assembly to the lower support assembly using
the two thumbscrews. Verify the thumbscrews draw the tear bar bracket firmly
against the lower support assembly.
NOTE: 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.
149
Adjust The Tear Bar Blade
Platen Roller
Feeler Gauge
(0.0015 inch)
Adjustable
Tear Bar Blade
Tear Bar
Bracket
Screw (3)
Figure 19. Positioning the Adjustable Tear Bar Blade

1. 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!
2. Place a 0.0015 inch feeler gauge, or use the label liner (backing) from the
customer’s 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.
3. 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.
4. 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.
5. 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.
6. Repeat step 1 through step 5 until the gap between the platen and the
tear bar blade is correct.
8. In the QUICK SETUP menu, set Paper Feed Shift to -0.05 inches.
150
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 22, page 160, 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 22, page 160, item
15.)
2. Place the bottom portion of rewinder belt over the top of the belt
tensioner.
151
152
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 20. Covers and Media Hanger ................................................................................ page 154
Figure 21. Media Cover Window ........................................................................................ page 158
Figure 22. Power Supply, Belts, and Stepper Motor ..........................................................page 160
Figure 23. Shafts and Spindles .......................................................................................... page 164
Figure 24. Media Damper ................................................................................................... page 166
Figure 25. Upper and Lower Support Assemblies .............................................................. page 168
Figure 26. Six and Eight Inch Printhead, Pivoting Deck, and Upper Support Assy ............ page 172
Figure 27. Four Inch Printhead, Pivoting Deck, and Upper Support Assy..........................page 176
Figure 28. Six and Eight Inch Platen and Lower Support Assemblies ............................... page 180
Figure 29. Four Inch Platen and Lower Support Assemblies ............................................. page 182
Figure 30. Frame and Base Pan Assembly ........................................................................ page 184
Figure 31. Controller PCBA and I/O Assemblies ................................................................ page 186
Figure 32. Controller PCBA ................................................................................................ page 188
Figure 33. Screen, Gears, and Ribbon Drive Motors ......................................................... page 190
Figure 34. Control Panel Assembly ....................................................................................page 192
Figure 35. Cable Assemblies and Interconnections ........................................................... page 194
Hardware Kit....................................................................................................................... page 196
Hardware Kit, Cutter Options.............................................................................................. page 197
153
Chapter 5 Illustrated Parts Breakdown
See window detail

on page 158.
11 2
14
15
4
12
1
9
3
10
16 4 5
13
19
18
17
7
Figure 20. Covers and Media Hanger
154
Item
Part No. Description Notes
No.
1 173108-001 Cover, Side, Frame

2 178106-001 Media Cover Assy, 8 inch
178106-002 Media Cover Assy, 6 inch
178106-003 Media Cover Assy, 4 inch
3 203824-001 Screw, Socket Flange Head Cap, 8 inch printers use 2 more
M4x10mm (4) screws for the center hinge.
Available only in Hardware
Kit 171629-001 (page 196).
4 178338-001 Hinge, Friction, LH Also used as the center

hinge on 8 inch printers.
5 178338-002 Hinge, Friction, RH
6 204014-001 Screw, Socket Button Head Cap, Shown exploded in

M5x10mm (2) Figure 20, but remain behind
controller PCBA. Available in
Hardware Kit 171629-001
(page 196).
7 178496-901 Beam Assy, Media Hanger, 8 inch Includes items 18, 19, and
178496-902 Beam Assy, Media Hanger, 6 inch 20.
178496-903 Beam Assy, Media Hanger, 4 inch
8 750474-901 Guide Assy, Media Hanger
9 203527-001 Clip, EMI (6) In Hardware Kit 171629-001

(page 196), but can also be
ordered separately.
10 170437-001 Label, Media Loading Not part of item 2.
11 Ref Label, Customer Support Center Not part of item 2.

12 Ref Label, Media/Ribbon Source Not part of item 2.
13 750923-001 Button, Damping (7) In Hardware Kit 171629-001

(page 196), but can also be
ordered separately.
14 203326-001 Ring, Retaining, E, .156 Available only in Hardware

Kit 171629-001 (page 196).
15 203711-001 Screw, Captive, Socket Button Head Available only in Hardware
Cap, M4x10mm (2) Kit 171629-001 (page 196).
16 203252-002 Screw, Soc Head Cap, M4x14mm (4) 8 inch printers use 2 more
screws for the center hinge.
Available in Hardware Kit
171629-001 (page 196).
155
Item
No.
17 203254-001 Screw, Socket Button Head Cap, Part of item 7. Also available
M5x16mm in Hardware Kit, Cutter
Options (page 197).
18 Ref Cap, Plastic, Media Hanger Part of item 7.
19 Ref Beam, Media Hanger (4, 6, and 8 inch) Part of item 7.
156
(Parts lists continue on the next page.)
157
A
From page 154.
Figure 21. Media Cover Window
158
Item
No.
1 177222-001 Window, Media Cover

178453-001 Window, Media Cover, Shielded For RFID models.
2 177221-001 Clip, Window, Media Cover Available only in Hardware

Kit 171629-001 (page 196).
3 204891-001 Screw, Hex Head, M4x6mm Available only in Hardware

Kit 171629-001 (page 196).
159
19
15
8
10
5
6
12
16
11
2 13
7 9
21
20
22
18
14
3 4
1
17
Figure 22. Power Supply, Belts, and Stepper Motor
160
Item
No.
1 178207-001 Power Supply Assembly Includes items 3, 4, 14, 17,

18, 20, and 21.
2 203824-001 Screw, Socket Flange Head Cap, Available only in Hardware

M4x10mm (2) Kit 171629-001 (page 196).
3 140822-007 Screw, M4x30mm (4) Part of items 1 and 1a. Also

available in Hardware Kit
171629-001 (page 196).
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 196).
Optional.
6 174494-001 Pulley/Clutch Assy, Rewinder Use with the rewinder option

only. Ref.: Figure 23, 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, Socket Flange Head Cap, Not part of item 12. Available
M4x10mm (2) only in Hardware Kit
171629-001 (page 196).
12 172133-901 Field Kit, Stepper Motor Includes pulley and bracket,

but does not include items 10
and 11.
13 203252-002 Screw, Socket Head Cap, M4x14mm Available in Hardware Kit

171629-001 (page 196).
14 140664-002 Nut, M4 (4) Part of item 1. Also available

in Hardware Kit 171629-001
(page 196).
15 750599-001 Tensioner, Belt Use with the rewinder option

only.
16 105678-003 Ring, Retaining, E, .3125 Available only in Hardware

Kit 171629-001 (page 196).
17 171736-001 Fan Assembly, Power Supply Part of item 1, but can also
be ordered separately.
18 Ref Power Supply Part of item 1.
161
Item
No.
19 750695-001 Cable Assy, Printhead Controller 6 and 8 inch printers only.

171774-001 Cable Assy, Printhead Controller 4 inch printers only.
20 Ref Cable Assembly, Power Supply, Part of item 1.

Controller PCBA
21 Ref Cable Assembly, Power Supply, Part of item 1.

Printhead
22 205041-001 Ferrite Core, Clamp Type Not part of item 1.
162
163
12
2 3
7
13
1 3
2
15 3
9
8
14
6
10 11
1 7
8
5
7
A
See page 166.
Figure 23. Shafts and Spindles
164
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
(page 196).
4 178614-001 Spares Kit, Rewinder, 8 inch Includes items 7, 10, 11, and
178614-002 Spares Kit, Rewinder, 6 inch 14. Rewinder option.
178614-003 Spares Kit, Rewinder, 4 inch
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
171629-001 (page 196).
8 203523-001 Washer, Nylon, .380x.683x.031 Available only in Hardware
Kit 171629-001 (page 196).
9 203526-001 Washer, .390x.656x.020 Available only in Hardware
Kit 171629-001 (page 196).
10 204527-001 Washer, Nylon, 1.125x.500x.080 inch Part of item 4. Also available
(page 196).
11 174494-001 Pulley Assy, Rewinder Part of item 4. Use with the
rewinder option only.
12 203513-001 Screw, Socket Button Head Cap, Part of item 1. Available only
M3x4mm (2) in Hardware Kit 171629-001
(page 196).
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 196).
15 Ref Media Damper Stop
165
A
From page 164.
3a
Figure 24. Media Damper
166
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
3 177719-001 Guide, Media Width
3a 175756-001 Guide, Media Width, Ext. Used with optional rewinder

or validator only.
167
13
10
14
A See page 172

and page 176.
5
6 B See page 180
and page 182.
11
7
12
Figure 25. Upper and Lower Support Assemblies
168
Item
No.
1 750695-001 Cable Assembly, Printhead/Controller 6 and 8 inch printers only.

See item 20, page 160.
171774-001 Cable Assembly, Printhead/Controller 4 inch printers only. See item
20, page 160.
2 178624-901 Field Kit, Upper Support Assy, 4 inch Does not include printhead
179269-901 Field Kit, Upper Support Assy, 6 inch assembly.
171598-001 Field Kit, Upper Support Assy, 8 inch

M4x10mm (4) Kit 171629-001 (page 196).

M4x10mm (3) Kit 171629-001 (page 196).
5 172474-001 Peel/Tear Assembly, 8 inch Includes item 7. Used only on
172474-002 Peel/Tear Assembly, 6 inch models with internal rewinder
172474-003 Peel/Tear Assembly, 4 inch option.
6 204014-001 Screw, Socket Button Head Cap, Available only in Hardware

M5x10mm (2) Kit 171629-001 (page 196).
7 171892-001 Door, Peel/Tear, 8 inch

171892-002 Door, Peel/Tear, 6 inch
171892-003 Door, Peel/Tear, 4 inch
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 160.
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 196).
169
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.
See “Tear Bar Assembly,
Adjustable” on page 149.
14 177995-001 Assembly, Tear Off, 8 inch Does not support any paper
177995-002 Assembly, Tear Off, 6 inch path assy.
177995-003 Assembly, Tear Off, 4 inch Includes thumbscrews.
170
171
14
A
17
B
From page 168.
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 26. Eight and Six Inch Printhead, Pivoting Deck, and Upper Support Assembly
172
Item
No.
1 173615-001 Field Kit, Printhead Assy, 203 dpi, 8 in Includes items 31, 32, and
173617-001 Field Kit, Printhead Assy, 300 dpi, 8 in 33. Does not include item 30.
173609-001 Field Kit, Printhead Assy, 203 dpi, 6 in
173612-001 Field Kit, Printhead Assy, 300 dpi, 6 in
2 203419-001 Ring, Retaining, E, .188 inch (3) Available only in Hardware
Kit 171629-001 (page 196).
3 171089-001 Dial, Head Pressure Adjustment
4 171088-001 Indicator, Head Pressure Dial
5 171087-001 Knob, Lead Screw, LG, 1.15 in OD

6 170880-001 Pointer, Pressure Block

M3x6mm (7) Kit 171629-001 (page 196).
8 171086-001 Shaft, Head Pressure, 8 inch

171086-002 Shaft, Head Pressure, 6 inch

M4x10mm (3) Kit 171629-001 (page 196).
10 171746-001 Sensor, Head Up
11 170193-001 Holder, Sensor
12 171277-001 Clip, Head Retainer (2) Right clip not shown.

M3x4mm (7) Kit 171629-001 (page 196).
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

M3x8mm (2) Kit 171629-001 (page 196).
17 171121-001 Ground Wire, Antistatic

18 172196-001 Rack, Gimbal Pivot, 8 and 6 inch
19 171730-001 Handle, Pressure Pad, 8 and 6 inch
20 171592-001 Field Kit, Head Pressure Block, 8 in. (2)

171591-001 Field Kit, Head Pressure Block, 6 in. (2)
21 171642-001 Field Kit, Gimbal Spring/Guard Set
173
Item
No.
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 196).
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
(page 196).
174
175
13
A
14 17 From page 168.
B
9
15
13
27
22
11
23
24
7
12 10
7
16
26
13
21
23
2
24
B
25 5
7 18 13
28 22
2
6 29 3
19 7
20
1 8
31 4
7
32
2
33
30
Figure 27. Four Inch Printhead, Pivoting Deck, and Upper Support Assembly
176
Item
No.
1 178403-001 Field Kit, Printhead Assy, 203 dpi Includes items 31, 32, and
178404-001 Field Kit, Printhead Assy, 300 dpi 33. Does not include item 30.
2 203419-001 Ring, Retaining, E, .188 inch (4) Available only in Hardware

Kit 171629-001 (page 196).
3 176762-001 Dial, Hex, Head Pressure Adjustment
4 171088-001 Indicator, Head Pressure Dial
5 171087-001 Knob, Lead Screw, LG, 1.15 in OD

6 172313-001 Handle, Pressure Pad

M3x6mm (7) Kit 171629-001 (page 196).
8 176761-001 Shaft, Hex, Head Pressure

M4x10mm (3) Kit 171629-001 (page 196).
11 170193-001 Holder, Sensor

12 171277-001 Clip, Head Retainer (2) Right clip not shown.

M3x4mm (7) Kit 171629-001 (page 196).
14 173858-001 Brush Assembly, Anti-Static Not on -DT models.
15 171161-001 Gimbal, Adjustable Not on -DT models.

M3x8mm (2) Kit 171629-001 (page 196).
17 171121-001 Ground Wire, Antistatic Not on -DT models.
18 172197-001 Rack, Gimbal Pivot Not on -DT models.
19 172313-001 Handle, Pressure Pad
20 Ref Pressure Block Assy, Hex (2) Part of P/N 178624-901

(Figure 25, page 168, item 2).
21 171642-001 Field Kit, Gimbal Spring/Guard Set 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 Not on -DT models.
177
Item
No.
25 203431-001 Washer, Curved, .194 Available only in Hardware

Kit 171629-001 (page 196).
26 171642-001 Field Kit, Gimbal Spring/Guard Set 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 Part of item 1.
32 178695-901 Printhead Cover/Upper Media Sensor Part of item 1, but can be

Assembly ordered separately.
(page 196).
178
179
B
From page 168.
2 8
7
3
Figure 28. Eight and Six Inch Platen and Lower Support Assemblies
180
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.
2 173622-001 Field Kit, Lower Support Assy, 8 inch Includes item 9. Does not
179270-901 Field Kit, Lower Support Assy, 6 inch include platen assy, peel/tear
assy, or lower media sensor
assy.
3 203257-001 Ring, Retaining, .875 Available only in Hardware
Kit 171629-001 (page 196).
4 171714-001 Lever, Deck Lock Includes magnet.
5 173624-001 Field Kit, Media Sensor Assy, Lower

6 203419-001 Ring, Retaining, E, .188 inch Part of item 1, but also
171629-001 (page 196).
7 203414-001 Washer, Wave, .870 ID Available only in Hardware

Kit 171629-001 (page 196).

M3x4mm (2) Kit 171629-001 (page 196).
9 173255-001 Media Guard, PH3, 8 inch Part of item 2.
173255-002 Media Guard, PH3, 6 inch
181
B
From page 168.
1
8
7
Figure 29. Four Inch Platen and Lower Support Assemblies

For RFID models, see Figure 77 on page 312.
182
Item
No.
1 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 178405-001 Field Kit, Lower Support Assy, 4 inch Includes item 8. Does not
include platen assy, peel/tear
assy, or lower media sensor
assy.
3 203257-001 Ring, Retaining, .875 Available only in Hardware

Kit 171629-001 (page 196).
4 171714-001 Lever, Deck Lock Includes magnet.
5 173624-001 Field Kit, Media Sensor Assy, Lower
6 203419-001 Ring, Retaining, E, .188 inch Part of item 1, but also

171629-001 (page 196).
7 203414-001 Washer, Wave, .870 ID Available only in Hardware

Kit 171629-001 (page 196).
8 178426-003 Media Guard, Wide, 4 inch Part of item 2.

For RFID models, see
Figure 77, page 312, item 6.
183
3
2
Figure 30. Frame and Base Pan Assembly
184
Item
No.
1 750659-001 Pad, Rubber (4)

M4x10mm (11) Kit 171629-001 (page 196).
3 178105-001 Pan Assembly, 8 inch

178105-002 Pan Assembly, 6 inch
178105-003 Pan Assembly, 4 inch
4 750923-001 Button, Damping (7) Available only in Hardware

Kit 171629-001 (page 196).
5 203682-001 Plug, .4375 inch (2) Used only on printers without

the rewinder option.
Available only in Hardware
Kit 171629-001 (page 196).
6 203643-001 Plug, .5 inch (3) Available only in Hardware

Kit 171629-001 (page 196).
185
13
12 7 5
2
A See page 188.
3
9a
10
11
Figure 31. Controller PCBA and I/O Assemblies
186
Item
No.
1 750906-001 Grommet, Rubber

M4x10mm (2) Kit 171629-001 (page 196).
3 178722-001 Bracket, Ferrite
4 202379-001 Wire Saddle Blind Hole (4) Available only in Hardware

Kit 171629-001 (page 196).
5 152439-901 Cable Assembly, Centronics I/O

6 203548-001 Clamp, Ferrite, Enclosed Radio frequency interference
suppressor.

M3x6mm (4) Kit 171629-001 (page 196).
8 203464-001 Thermal Gap Filler Pad Must be installed under the

controller PCBA, item 2.
9 179406-901 Field Kit, Internal 10/100Base-T Internal PCI NIC assembly.
9a 171747-001 Field Kit, External 10/100Base-T External NIC assembly.
10 177929-901 PCI Coax/Twinax Card Includes coax/twinax PCBA.
11 140752-002 Cable Assembly, Twinax, Smart T
12 202434-001 Standoff Kit, Screw, M/F, 4-40x.19 (2) Available only in Hardware
Kit 171629-001 (page 196).
13 102559-405 Screw, Phillips, w/lock washer, Available only in Hardware

4-40x.31 (2) Kit 171629-001 (page 196).
187
A
From page 186. 2
1
3
6, 6a
Figure 32. Controller PCBA
188
Item
No.
1 178272-901 Controller PCBA, PPC Includes items 19, 20, and

21.
2 203326-001 Ring, Retaining, E, .156 (6) Part of item 1, but also

171629-001 (page 196).
3 203711-001 Screw, Captive, Socket Button Head Part of item 1, but also
Cap, M4x10mm (6) available in Hardware Kit
171629-001 (page 196).
4 204480-902 SIMM, Flash, 8MB Both SIMMs contain boot

204480-903 SIMM, Flash, 16MB code only.
5 176028-001 Key, Security, Blank Security keys are

programmed by using the
SPX (page 140).
6 204550-001 NVRAM
6a 178886-901 NVRAM with Real Time Clock
189
5
9 3
8 4
1
Figure 33. Screen, Gears, and Ribbon Drive Motors
190
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 196).
3 171403-001 Field Kit, DC Motor Does not include item 4.

Not on -DT models.
4 204002-001 Screw, Socket Flange Head Cap, Not part of item 3. Available
M4x12mm (2 per motor) only in Hardware Kit
171629-001 (page 196).

M3x6mm (14) Kit 171629-001 (page 196).
6 178821-001 Panel, Rear Panel
7 177855-001 Plate, Blank, GPIO
8 177856-001 Plate, Cover, Angled (2)

9 177857-001 Plate, Cover, Small
191
Figure 34. Control Panel Assembly
192
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

M3x4mm (2) Kit 171629-001 (page 196).
6 171896-001 Sensor, Label Taken

M3x8mm Kit 171629-001 (page 196).
8 750547-001 Housing, Control Panel Part of item 1.
193
16
15 7
11
13
12
14
8
6
3 4
1
10
Figure 35. Cable Assemblies and Interconnections
194
Item
No.
1 152439-901 Centronics I/O Cable Assembly

2 178108-001 Field Kit, Cable Assy, Validator option
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 175116-001 Cable, Upper Media Sensor

12 171896-001 Sensor, Label Taken Figure 34, item 6.
14 Ref Cable assembly, part of Media Cutter

option
15 175174-901 Printhead Cover/Upper Media Sensor Part of the printhead

Assembly, 8 inch assembly.
175174-902 Printhead Cover/Upper Media Sensor For RFID models, see
Assembly, 6 inch Figure 77, page 312, item 3.
175174-903 Printhead Cover/Upper Media Sensor
Assembly, 4 inch
16 173624-001 Lower Media Sensor Assembly
195
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, Phillips, w/lock washer, 4-40x5/16 2
105625-005 Screw, Set, Oval, 8-32x.375 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 Washer, 1x.5x.05 (rewinder intermediate 3

clutch)
177221-001 Clip, Window, Media Cover 2
202379-001 Wire Saddle Blind Hole 2
202434-001 Standoff Kit, Screw, M/F, 4-40x3/16 1
202721-001 Bearing, Plastic Clip, .25 ID 2
203225-001 Washer, Nylon, .25 1 For inboard front door

hinge to take up excess
clearance.
203251-001 Screw, Socket Button Head Cap, M3x8mm 5
203252-002 Screw, Socket Head Cap, M4x14mm 1

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

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
196
Hardware Kit, Cutter Options
203523-001 Washer, Nylon, .380x.683x.031 2
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, Socket Button Head Cap, 2 Use to fasten frame side
M4x10mm cover.
203824-001 Screw, Socket Flange Head Cap, M4x10mm 10
204002-001 Screw, Socket Flange Head Cap, M4x12mm 2
204527-001 Washer, Nylon, 1.125x.500x.080 inch 1
204891-001 Screw, Hex Head, M4x6mm 2
750923-001 Button, Damping 3

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


203715-001 Finger, Ground, Cutter 1
197
198
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
199
Appendix A
d 100 64 é 130 82 á 160 A0 ¥ 190 BE
e 101 65 â 131 83 í 161 A1 191 BF
f 102 66 ä 132 84 ó 162 A2 192 C0
g 103 67 à 133 85 ú 163 A3 193 C1
h 104 68 å 134 86 ñ 164 A4 194 C2
i 105 69 ç 135 87 Ñ 165 A5 195 C3
j 106 6A ê 136 88 ª 166 A6 196 C4

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

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

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

z 122 7A ÿ 152 98 + 182 B6 + 212 D4
{ 123 7B Ö 153 99 + 183 B7 213 D5
| 124 7C Ü 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

Ç 128 80 x 158 9E 188 BC 218 DA
ü 129 81 _ 159 9F ¢ 189 BD 219 DB
200
220 DC + 229 E5 238 EE 247 F7
221 DD 230 E6 239 EF º 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)
201
Appendix A
202
B Downloading Software
Loading Flash Memory

Flash memory is contained in a SIMM (single in-line memory module) located
on the controller PCBA. Printer control languages (the “emulations”) and
printer operating system software are loaded into flash memory at the factory,
but there are occasions when you may have to load this software:
• You have replaced the controller PCBA
• You have replaced flash memory
• The customer needs to upgrade printer software
• The customer needs different emulation software
• The customer buys the PGL or VGL graphics language, the
CT option, the IPDS option, or the ethernet NIC (network interface card)
option after the printer is installed
Emulation and operating system software are included as files on a CD-ROM
that comes with the printer. You will copy the appropriate file from the CD-
ROM to a computer’s hard disk, then download the file from the computer into
printer memory.
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 port of the
printer, and you can do it three ways:
• If your computer can run Java™ programs, you can load software through
any printer port by using the Firmware Download Utility included on the
CD that comes with the printer. (See below.)
• You can use DOS commands to load software through the parallel port or
serial port. (See page 205.)
• If the printer has the ethernet NIC (network interface card) installed, you
can load software through the ethernet port. (See page 208.)
203
Appendix B Loading Flash Memory
Loading Software With The Firmware Download Utility

The Firmware Download Utility (FDU) allows you to load program files into the
printer with an easy to use graphical interface. The FDU is a utility program
included on the CD that comes with the printer. It can be used on computers
running the Windows or UNIX® (such as Linux® or Solaris™) operating
systems. With the FDU, you can choose the printer port through which to load
software (all are supported), configure the port, and initiate the download.
The FDU is a Java-based program, so you need the Java 2 Platform,
Standard Edition (J2SE™) Java Runtime Environment (JRE) installed on your
computer. The Windows version of the J2SE JRE is included on the CD that
comes with the printer in the form of an executable file:
j2re-1_4_2_08-windows-i586-p.exe. Copy this file to your computer and
double-click it; it will self-extract and install the J2SE JRE on your computer.
NOTE: If you have a Linux or Solaris system, you can download the J2SE
JRE for your system from http://java.sun.com/j2se.
If you have another UNIX system, see your system administrator.
Conditions for use of the included Java Software are set forth in the Sun
Microsystems Binary Code License Agreement
(http://java.com/en/download/license.jsp). In the event of any conflicting
terms, the Binary Code License Agreement controls.
User’s Manual.)
3. Disconnect the data (signal) cable(s) from the printer interface
connectors.
4. Connect a printer data cable to the parallel, serial, or ethernet port of the
computer you will use to download the software.
5. Connect the printer data cable to the appropriate I/O port of the printer.
6. On the printer control panel, press and hold down the ... and ↓ keys.
Without releasing the keys, power the printer on. When you see
“B01: STATUS” on the on the LCD, release the keys.
7. Wait until you see “PROGRAM DOWNLOAD” on the LCD before doing
the next step. This can take about a minute to appear, depending on the
emulations and interfaces installed in the printer.
8. On your computer, create a directory named download at the root level
of the hard drive (e.g., C:\download on a Windows computer).
9. Insert the printer emulation software CD into your computer’s CD-ROM
drive.
10. Copy the FDU.jar file from the CD-ROM to your computer.
204
Loading Through The Parallel Or Serial Port Using DOS
11. Open the readme.txt file on the CD-ROM. There are two emulation sets
with corresponding part number files from which to choose:
CT / IPDS / IGP / ZGL / TGL / IGL / STGL
TN / IGP / ZGL / TGL / IGL / STGL
Both emulations include the LP+ emulation. They are offered in two file
formats: .exe and .prg. You can use either format with the FDU.
12. Identify which emulation set you want to load into the printer and note the
filename that corresponds to that emulation. The filename is a six digit
number plus .exe or .prg. For example: 123456.exe or 123456.prg
This is the file you will download into the printer.
13. Copy the file to the download directory you created in step 8.
14. Double-click the FDU.jar file (for command line prompt users, type
java -jar fdu.jar<Enter>). It will launch in its own window. Use the
FDU to enter the emulation part number, to select the I/O connection and
its corresponding settings, and to initiate the download.
IMPORTANT Do not interrupt the downloading process once it has started.

Interrupting a download will leave the flash memory on the controller
PCBA incompletely loaded, and the printer may not boot up.
15. When the new software has successfully loaded into flash memory and
the printer has reset itself, set the printer power switch to O (Off).
16. Remove the CD-ROM from your computer and store it with the printer.
17. If required, reconnect the data input cable(s) to the printer.
19. Using the configuration printout(s) you made in step 1, page 204, restore
the printer configurations. (Refer to the printer User’s Manual.)
Loading Through The Parallel Or Serial Port Using DOS

User’s Manual.)
connectors.
4. Connect a parallel data printer cable to the LPT1 port or a serial data
printer cable to the COM1 port of an IBM-compatible computer running
the 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 in use.
The load command is different if you use this port, so make sure you
use the LPT2 commands in step 15.
Software loads at 9600 baud if you load through the serial port with a
DOS command. This can take a long time. Software loads much
faster through the parallel port.
5. Connect the data cable to the appropriate I/O port of the printer.
205
Without releasing the keys, power the printer on. When you see
“B01: STATUS” on the on the LCD, release the keys.
7. Wait until you see “PROGRAM DOWNLOAD” on the LCD before doing
the next step. This can take about a minute to appear, depending on the
8. Using Windows Explorer, create a directory named download at the root
level of your C: hard drive (C:\download).
9. Insert the printer emulation software CD-ROM into your computer’s CD-
ROM drive.
formats: .exe and .prg. Use .exe files to download through the parallel
or serial port.
number plus .exe. For example: 123456.exe
13. Start a command prompt session. (The Start Menu icon is usually labeled
MS-DOS® Prompt or Command Prompt.)
14. At the command prompt type:
C:<Enter>
cd \download<Enter>
15. To load the file through the LPT1 parallel port on the computer, type the
following at the command prompt on the computer:
filename.exe -pb<Enter>
where filename.exe is the file name you noted in step 11. 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.
To load the file through the LPT2 parallel port on the computer, enter the
following command:
filename.exe -pb2 <Enter>
To load the file through the serial port, enter the following commands:
mode COM1:9600,N,8,1,P<Enter>
filename.exe -pbc1<Enter>
NOTE: Software loads at 9600 baud if you load through the serial port with a
DOS command. This can take a long time. Software loads much
faster through the parallel port.
When you power up in download mode (step 6) the printer is ready to
accept data from all ports. When the printer receives data from one of
the ports (based on the load command you give) the other ports shut
down.
206
Loading Software If Flash Contains Only Boot Code

PCBA incompletely loaded, and the printer may not boot up.
While the file is copied into memory, the printer LCD informs you of the
load process and status.
17. Remove the CD-ROM from the host computer and store it with the printer.
20. Using the configuration printout(s) you made in step 1 on page 205,
restore the printer configurations. (Refer to the printer User’s Manual.)
Loading Software If Flash Contains Only Boot Code

If the flash memory contains only boot code (e.g., if it is new), or if a download
was interrupted (e.g., by a power outage), you must download software
through the printer’s parallel port using the three-key initialization sequence
covered in this section.
1. Make sure the printer’s parallel port is available. In some configurations,
you may have to re-install the Centronics® I/O cable and connector in
order to load basic software into the printer.
connectors.
4. Connect a parallel data printer cable to the LPT1 port or LPT2 port of an
IBM-compatible computer running the Windows (95, 98, Me, NT, 2000, or
XP) operating system.
5. Connect the data cable to the Centronics port of the printer.
6. On the printer control panel, press and hold down the ... , ↓, and ↵ keys.
Without releasing the keys, power the printer on. When you see “B20:
STATUS 00% / DOWNLOAD MODE” on the LCD, release the keys.
level of your C: hard drive. (C:\download)
ROM drive.
formats: .exe and .prg. Use .exe files to download through the parallel
port.
207
number plus .exe. For example: 123456.exe

MS-DOS Prompt or Command Prompt.)
C:<Enter>
cd \download<Enter>
14. To load the file through the LPT1 parallel port on the computer, type the
following at the command prompt on the computer:
filename.exe -pb<Enter>
where filename.exe is the file name you noted in step 11. 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.
To load the file through the LPT2 parallel port on the computer, enter the
following command:
filename.exe -pb2 <Enter>
15. When the software has successfully loaded into flash memory and the
printer has reset itself, set the printer power switch to O (Off).
16. Starting at step 6, page 206, repeat the “Loading Through The Parallel Or
Serial Port Using DOS” procedure. (In other words, use the two-key
method to load software again.) This ensures that all necessary code is
loaded into printer memory.
Loading Software Through The NIC

IMPORTANT To load software through the NIC, you need the IP Address of the printer
and the flash memory must contain basic printer code. If the flash
memory was replaced, or if a download was interrupted (e.g., by a power
outage), you must load software through the parallel port. (See
“Loading Software If Flash Contains Only Boot Code” on page 207.)
User’s Manual.)
3. Connect the ethernet cable to the printer interface.
Without releasing the keys, power the printer on. When you see “B01:
STATUS” on the on the LCD, release the keys.
5. Wait until you see “WAITING FOR DOWNLOAD” on the LCD before
proceeding. This can take about a minute to appear, depending on the
level of your C: hard drive. (C:\download)
ROM drive.
208
Loading Software Through The NIC
formats: .exe and .prg. Use .prg files to download through the NIC.
number plus .prg. For example: 123456.prg
This is the file you will download into the NIC.
11. Start a command prompt session in Windows. (The Start Menu icon is
usually labeled MS-DOS Prompt or Command Prompt.)
C:<Enter>
cd \download<Enter>
13. Start the FTP (file transfer protocol) program by typing:
ftp xxx.xxx.xxx.xxx<Enter>
(where xxx.xxx.xxx.xxx is the IP Address of the printer.)
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 the 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)

PCBA and NIC incompletely loaded, and the printer may not boot up.
17. When the download is complete, exit the FTP program by typing:
quit<Enter>
19. Remove the CD-ROM from the host computer and store it with the printer.
22. Using the configuration printout(s) you made in step 1, page 208, restore
the printer configurations. (Refer to the printer User’s Manual.)
209
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 printer’s flash memory.
See Table 9 for a list of optional fonts and their corresponding part numbers.
Table 9. 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
210
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 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 13.
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.
Without releasing the keys, power the printer on. Continue holding down
the ... and ↓ keys.
..
6. When you see “B01 STATUS” on the LCD, release the . and ↓ keys.
7. Wait until you see “PROGRAM DOWNLOAD” on the LCD before
proceeding. This can take about a minute to appear, depending on the
8. Insert the optional font diskette into diskette drive A (or B) of the
computer.
MS-DOS Prompt or Command Prompt.)
10. Make the diskette drive the active drive by typing:
A:<Enter> (if the diskette is in drive B, type B:<Enter>)
11. 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.
12. Make note of the file name with the .dwn extension of each file you want
to download to the printer.
NOTE: The numeric portion of the file name will match the numbers of the
font typefaces listed in Appendix F of the PGL Programmer’s
Reference Manual 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 12.)
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 12.)
If you are loading the file using the serial port on the computer, type
the following commands:
211
mode COM1:9600,N,8,1,P<Enter>
copy /b filename.dwn COM1<Enter>
(where filename.dwn is a file you noted in step 12.)
The 9600 baud rate is the only selection some systems can use. The
baud rate information entered in the above commands must match the
Baud Rate setting (in the SERIAL PORT menu) saved in the Power-Up
Config.
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>
14. 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.
15. To verify that the optional fonts have been downloaded:
NOTE: Admin User must be set to Enable in the PRINTER CONTROL menu.
See the User’s Manual.
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.
16. Press the PAUSE key to place the printer online and return the printer to
normal operation.
212
C Wire Data
Circuit Board And Cable Pinouts

Interconnection Diagrams
SL5000r .................................................................................... page 214
T5000r ...................................................................................... page 215
Cable Routing ................................................................................. page 216
Circuit Board Pinouts
Controller PCBA ....................................................................... page 217
Coax/Twinax PCBA .................................................................. page 226
Cable Assemblies
Centronics I/O........................................................................... page 227
Twinax Auto-Termination.......................................................... page 228
Printhead/Controller.................................................................. page 229
Power Supply Control ............................................................... page 230
Control Panel ............................................................................ page 231
Validator.................................................................................... page 232
Sensors
Sensor, Label Taken................................................................. page 233
Sensor, Head Up ...................................................................... page 234
Media Sensor Assembly, Lower ............................................... page 235
Media Sensor Assembly, Upper ............................................... page 236
213
Appendix C Circuit Board And Cable Pinouts
Interconnection Diagram, SL5000r

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
P12 Cutter Option
J7 RS422 J12 J21 P21
J31
Flash J P
5 5 Sensor
J16 P16 Ribbon
J24 Supply
Serial Controller
J2 Port 2 Motor
DB9 J14 P14 Stepper
4 Motor
P10
Real Time Head Up
J4 Ribbon
NVRAM
P112 2 Motor Taken
J6 J5 J17 Sensor
USB
P6 P5 P17 4
J203
40
Port Sensor
Frame Ground. Power
8 8
30 & Logic Ground.
Common electrical tie P401
PCI Bus Expansion
Connector point. J401
P403 Thermal
CN403 Print
AC Power P402 Head
Line 1 J201
Ground (green/ 10
yellow wire)

Option Option
214
Interconnection Diagram, T5000r
Legend: = n wires
n in cable assy

Option
Cutter
P2 J2 J1 P1 P301
PCBA Option
J301

4 7
8 Panel
3 3
P13 P9 P11 P18
J13 J9 J11 J18
P12 Cutter Option
J7 RS422 J12 J21 P21
J31
Flash J P
5 5 Sensor
J16 P16 Ribbon
J24 Supply
Serial Controller
J2 Port 2 Motor
DB9 J14 P14 Stepper
4 Motor
P10
Real Time Head Up
J4 Ribbon
NVRAM
P112 2 Motor Taken
J6 J5 J17 Sensor
USB
P6 P5 P17 4
J203
40
Port Sensor
Frame Ground. Power
8 8
30 & Logic Ground.
Common electrical tie P401
PCI Bus Expansion
Connector point. J401
P403 Thermal
CN403 Print
AC Power P402 Head
Line 1 J201
Ground (green/ 10
yellow wire)

Option Option
215
Cable Routing
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
P112 P21
P15
P13
P16 P14
P8
P17
P5
P6
P403
216
Controller PCBA
R OUT2A
J16
Ribbon
DC 1
J33 Motor 2
1 (Supply)
2 R OUT2B
3 SCL
4 EXT 5V
I2C 5 F 24V
Interface 6
Connector 7
8 SDA R OUT1A
9
10 J8
Ribbon
DC 1
Motor 2
(Take-up)
R OUT1B
J19 (Not used)

1 MM LED POS
Media
2 MM LED NEG
Motion
3 MM SENSE COLLECTOR
Sensor
4 MM SENSE EMITTER
217
Controller PCBA
Head Up
Sensor
J11
1
2 HEAD UP
3 VCC
J18
1
2 PEEL
Serial RS232 Port Label Taken 3
Sensor 4 NC
J2
5 NC
1 DCD
2 RXD
10 3 TXD
4 DTR
5
11 6 DSR
7 RTS
8 CTS
9 NC
J14
1 PHA
Stepper 2 PHA
Serial RS422 Port Motor 3 PHB
J7 4 PHB
1
2 NC
3 NC
4 DIFF TXD+
5 DIFF TXD–
6 NC
7 NC
8 DIFF RXD+
9 DIFF RXD–
10 NC
218
Controller PCBA
J31
Flash
SIMM
SDRAM NVRAM and Lower Media Sensor

(permanently mounted to Real Time Clock J15
controller PCBA) 1 MG LED DRIVE
2 REFL LED SINK
3 MG SENSE COLLECTOR
Upper Media Sensor 4 MG SENSE EMITTER
J21
1
2 MG IRED DRIVE
3 FF RESISTOR
COP Port VDD
J1
1 2
COP TDO NC
3 4
COP TDI COP NTRST
5 6
7 8
COP TCLK NC
9 10
COP TMS NC
11 12
SDMR
13 14
COP NHRST NC
15 16
COP NSRST
219
Controller PCBA
Diagnostic
Port
J3
1 NC Control Panel
7 2 J13
NC 3 DB TXD
1 N FP DATA AVAIL
8 4
NC DB RXD 2 FP CLK
5
3
6 NC
VCC
4
5 N FP LED WR
6 FP DATA
7 VCC
8 N FP LCD WR
Online Verifier VCC

(Validator)
J10 J9
1 PEEL 1 +24V
2 V TXD C 2
3 V RXD C
PAGE SYNC
Media 3 VCC
4 Cutter 4 MEDIA CUT RUN
5 LINE SYNC 5 MEDIA CUT DIR
6 MARK SYNC 6 CUT DONE
7 7 NCUT ENA BUF
8 EXT 5V
9 OLF EXT 5V
10 +24V
11
12
13
14
220
Controller PCBA
Centronics Parallel Port

J112
1 N STROBE
2 Aux. Supply Port
3 P1 J32
4 1
5 P2
2
6 3
7 P3
4 F 24V
8 5
9 P4
6 EXT 5V
10
11 P5
12
13 P6
14
15 P7
16
17 P8
18
N ACK VCC
19
20 J30
21 BUSY CPLD
22 1 LC TCK
PRGM 2
23 PAPER EMPTY Port
24 3 LC TD1
25 SELECT 4
26 N INIT 5 LC TMS
27 N AUTOFEED 6 NC
28 N FAULT 7 NC
29 PI 8 NC
30 9 LC TDO
31 10
32 NC VCC1
33
34 NDPSEL
35 EXT 5V
36 N SELECT IN
37 HOST LOGIC H
38 NDPEN
39
40
CHASSIS GND
221
Controller PCBA
VCC
RFID Port VCC (Not used)
J12 J5 J36
1 1 PRINTENABLE BUF 1
2 2 V SEL BUF1 2
Power
3 R RXD 3 V SEL BUF2
R TXD Supply V SEL BUF3
4 4
Signal N OVER TEMP
5 5
Connector
6 F 24V 6 NC
7
8
TP39 +24V +40V TP37
VDD
J29 J17
Software 1 1
Security 2 SOFT ID 2
Device 3 3 NC
4
Power 5
Supply 6 NC
7 +24V SWITCHED
8 FAN NEG TP36
9
10
222
Controller PCBA
VCC
J6
Printhead Connector
1
2
J25 3
(see page 225)
4
CONFIG DONE BUF 5
J24 HD NLATCH BUF 6
(see page 224) HD NSTROBE BUF 7
HEAD CLK BUF 8
HDSERIAL1 BUF 9
HDSERIAL2 BUF 10
HDSERIAL3 BUF 11
HDSERIAL4 BUF 12
USB Port HDSERIAL5 BUF 13
VCC
HDSERIAL6 BUF 14
J4 HDSERIAL7 BUF 15
1 VBUS HDSERIAL8 BUF 16
2 D– HDSERIAL9 BUF 17
3 D+ HDSERIAL10 BUF 18
4 19
5 20
6 21
22
23
24
25
26
27
28
29
30
T6
T5
T4
T3
T2
T1
THERMISTOR 1
223
Controller PCBA – J24 PCI Connector
J24
VDD PCI Connection VDD
VCC1 VCC1
B1 RSV RSV A1
B2 RSV RSV A2
B3 GND RSV A3
B4 RSV RSV A4
B5 5V 5V A5
B6 5V NINTA A6 NIRQ1
NINTB B7 NINTB NINTC A7 NINTC
NINTD B8 NINTD 5V A8
NPRSNT2 B9 NPRSNT1 RSV A9
B10 RSV 3.3V A10
B12 KEY KEY A12
B13 KEY KEY A13
B14 RSV 3.3VAUX A14
B15 GND NRST A15 PCI_NRST
CLK1 B16 CLK 3.3V A16
B17 GND NGNT A17 NGNT1
NREQ1 B18 NREQ GND A18
B19 3.3V NPME A19
AD31 B20 AD31 AD30 A20 AD30
AD29 B21 AD29 3.3V A21
B22 GND AD28 A22 AD28
AD27 B23 AD27 AD26 A23 AD26
AD25 B24 AD25 GND A24
B25 3.3V AD24 A25 AD24
NC_BE3 B26 NC/BE3 IDSEL A26 IDSEL1
AD23 B27 AD23 3.3V A27
AD21 B29 AD21 AD20 A29 AD20
B31 3.3V AD18 A31 AD18
AD17 B32 AD17 AD16 A32 AD16
NC_BE2 B33 NC/BE2 3.3V A33
B34 GND NFRAME A34 NFRAME
NIRDY B35 NIRDY GND A35
B36 3.3V NTRDY A36 NTRDY
NDEVSEL B37 NDEVSEL GND A37
B38 GND NSTOP A38 NSTOP
B39 NLOCK 3.3V A39
NPERR B40 NPERR RSV A40
B41 3.3V RSV A41
NSERR B42 NSERR GND A42
B43 3.3V PAR A43 PAR
NC_BE1 B44 NC/BE1 AD15 A44 AD15
AD14 B45 AD14 3.3V A45
AD12 B47 AD12 AD11 A47 AD11
B49 M66EN AD9 A49 AD9
B50 GND GND A50
B51 GND GND A51
AD8 B52 AD8 NC/BE0 A52 NC_BE0
AD7 B53 AD7 3.3V A53
B54 3.3V AD6 A54 AD6
AD5 B55 AD5 AD4 A55 AD4
AD3 B56 AD3 GND A56
B57 GND AD2 A57 AD2
B59 3.3V 3.3V A59
B60 I2CDATA I2CCLK A60
B61 5V 5V A61
B62 5V 5V A62
Slot 1
SDA SCL
224
Controller PCBA – J25 PCI Connector
J25
VDD PCI Connection VDD
VCC1 VCC1
B1 RSV RSV A1
B2 RSV RSV A2
B3 GND RSV A3
B4 RSV RSV A4
B5 5V 5V A5
B6 5V NINTA A6 NIRQ2
NINTB B7 NINTB NINTC A7 NINTC
NINTD B8 NINTD 5V A8
B10 RSV 3.3V A10
B12 KEY KEY A12
B13 KEY KEY A13
B14 RSV 3.3VAUX A14
B15 GND NRST A15 PCI_NRST
CLK2 B16 CLK 3.3V A16
B17 GND NGNT A17 NGNT2
NREQ2 B18 NREQ GND A18
B19 3.3V NPME A19
AD31 B20 AD31 AD30 A20 AD30
AD29 B21 AD29 3.3V A21
AD27 B23 AD27 AD26 A23 AD26
B25 3.3V AD24 A25 AD24
NC_BE3 B26 NC/BE3 IDSEL A26 IDSEL2
AD23 B27 AD23 3.3V A27
AD21 B29 AD21 AD20 A29 AD20
B31 3.3V AD18 A31 AD18
AD17 B32 AD17 AD16 A32 AD16
NC_BE2 B33 NC/BE2 3.3V A33
B34 GND NFRAME A34 NFRAME
NIRDY B35 NIRDY GND A35
B36 3.3V NTRDY A36 NTRDY
NDEVSEL B37 NDEVSEL GND A37
B38 GND NSTOP A38 NSTOP
B39 NLOCK 3.3V A39
NPERR B40 NPERR RSV A40
B41 3.3V RSV A41
NSERR B42 NSERR GND A42
B43 3.3V PAR A43 PAR
NC_BE1 B44 NC/BE1 AD15 A44 AD15
AD14 B45 AD14 3.3V A45
AD12 B47 AD12 AD11 A47 AD11
B49 M66EN AD9 A49 AD9
B50 GND GND A50
B51 GND GND A51
AD8 B52 AD8 NC/BE0 A52 NC_BE0
AD7 B53 AD7 3.3V A53
B54 3.3V AD6 A54 AD6
AD3 B56 AD3 GND A56
B57 GND AD2 A57 AD2
B59 3.3V 3.3V A59
B60 I2CDATA I2CCLK A60
B61 5V 5V A61
B62 5V 5V A62
Slot 2
SDA SCL
225
Coax/Twinax PCBA
Twinax Connection
J2
1 NC
2 NC
3 NC
4 NC
16
5
6 NC
7 TWINAX PHASE A
8 NC
17 9 NC
10 NC
11 NC
12 NC
13 NC
14 TWINAX PHASE B
15 NC
Coax Connection
J3
1
COAX DATA 2
9400 pF, 1500 V Built-in
COAX SHIELD capacitor coax shield to
frame ground
.01 µ F
10%
500V
226
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
227
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
228
Cable Assembly, Printhead/Controller
750695-001
PIN 1 PIN 1
750695
April 11, 200
229
Cable Assembly, Power Supply Control
170070-901
PIN 1
PIN 8
PIN 8
PIN 1
170070
April 11, 200
230
Cable Assembly, Control Panel
750560-001
TO
CONTROLLER
PCBA
231
Cable Assembly, Validator
178108-001
232
Sensor, Label Taken
171896-001
Wire Table
Pin Signal Wire Color
1 Vcc Red
2 Vout Blue
3 Ground Black
4 N/A
5 N/A
233
Sensor, Head Up
171746-001
30±0.25”
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
Pin Signal Wire Color
1 N/A N/A
2 Vout White
3 Ground White
234
Media Sensor Assembly, Lower
173625-001
174390
Wire Table
Pin Signal
1 MG LED DRIVE
2 REF LED SINK
3 MG SENSE COLLECTOR
4 MG SENSE EMITTER
235
Media Sensor Assembly, Upper
NOTE: Part of the printhead cover.

See Figure 26, page 172, or Figure 27,
page 176, 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
236
D Media Cutters and Tray
Introduction
This appendix explains how to install a heavy duty cutter and the cutter tray
option.
Cutter Installation and Removal ...................................................... page 238
Cutter Tray Installation And Removal ............................................. page 242
Cutter Assembly Replacement........................................................ page 244
Troubleshooting .............................................................................. page 246
Maintenance.................................................................................... page 247
Spare Parts ..................................................................................... page 248
237
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 hex key, install the cutter driver PCBA with two screws as
shown in Figure 36.
5. Connect the cutter board cable to connector J9 on the controller PCBA.
6. Route the cutter board cable and snap it into the wire saddles as shown.
J9
Cable Path
Wire Saddle
Cutter Board
Cable Connector
Screw (2)
Cutter Driver PCBA
Figure 36. Installing the Cutter Driver Board
238
8. Open the tear off door by pulling it forward. (Figure 37.)
9. Remove the two thumbscrews securing the tear off assembly to the lower
support assembly. Keep the two thumbscrews you have removed; you
will use them if you need to reinstall the tear off assembly.
10. Remove the tear off assembly.
Tear Off
Assembly
Thumbscrew (2)
Lower Support
Assembly
Tear Off Door
Figure 37. Removing the Tear Off Assembly
239
Appendix D Cutter Installation and Removal
11. Swing open the cutter assembly mounting bracket from the cutter
assembly. (Figure 38.)
WARNING The cutter blade is sharp. Keep your fingers away from the cutter blade.
12. Place the cutter assembly inside the lower cutter enclosure, and secure it
using the two M5x16mm screws. (Figure 42, page 248, items 4, 12,
and 24.)
13. Secure the upper cutter enclosure to the cutter assembly using the two
captive screws. (Figure 38.)
14. Plug the RJ-11 connector from the cutter assembly into the cutter driver
board as shown in Figure 38.
15. Position the cutter assembly as shown in Figure 38 and install the two
M5x10mm screws with a 3 mm hex key.
16. 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.)
RJ-11 Receptacle
RJ-11 Connector
Captive
Screw (2) Lower Support
Assembly
Mounting Bracket
Cutter Assembly
Screw
M5x10mm (2)
Figure 38. Heavy Duty Cutter Assembly

17. Plug the AC power cord into the printer and the power source.
240
19. Press ↓ and ↵ at the same time to unlock the ↵ key. (This key
combination can be changed by the user. Use the customer’s key
combination if necessary.)
..
20. Press . until QUICK SETUP displays on the LCD.
21. Press ↓ until Media Handling displays.
22. Press + or – until Cut displays.
23. Press ↵ to select Cut. An asterisk (*) appears next to Cut.
24. Press ↓ and ↵ at the same time to lock the ↵ key.
25. Test the printer cutting operation and print quality by pressing TEST
PRINT and selecting one of the test patterns to print (page 39).
26. To save the configuration parameters, refer to the User’s Manual.
27. If the validator is installed, adjust the validator beam (page 267).
241
Appendix D Cutter Tray Installation And Removal
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 39.)
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
172597-001 Cutter Tray Assembly, 4 inch

Slot
Cutter Tray Bin Flanges (4)
Cutter Tray Base
Figure 39. Attaching the Cutter Tray Bin to the Cutter Base
242
3. Position the output area of the printer adjacent to the edge of the
supporting table or stand. (Figure 40, 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 40, b.)
Figure 40. Removing/Installing the Media Tray
243
Appendix D Cutter Assembly Replacement
Cutter Assembly Replacement

NOTE: This procedure is for replacing a defective cutter assembly from
within the cutter enclosure.
Removal
2. Put the cutter in the down (open) position. (Figure 38, page 240.)
3. Using a 3 mm hex key, remove the two M5x10mm screws securing 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 41, page 245.)
6. Remove the upper cutter enclosure from the cutter assembly.
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 hex key, remove the M3x8mm screw securing the cutter
support chain to the cutter assembly.
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.
244
Cutter Support
Chain
Cutter Bracket
Screw M3x8mm
Screw
M5x10mm (2)
Screw
M5x16mm (2)
Cutter Assembly
Upper Cutter
Enclosure
Captive Screw (2)
Screw
Lower Cutter M4x10mm (2)
Enclosure
Figure 41. Replacing the Cutter Assembly
245
Appendix D Troubleshooting
Troubleshooting
If the customer reports problems with the cutter, consult Table 10.
Table 10. 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
QUICK SETUP or 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.
246
Maintenance
The heavy duty cutter requires only periodic cleaning.
WARNING Keep your fingers away from the cutter blades. They are sharp.
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.
10. Close the pivoting deck and rotate the deck lock lever fully
counterclockwise.
11. Set the printer power switch to I (On).
12. Test the printer cutting operation by pressing the TEST PRINT key and
selecting one of the test patterns to print. (Refer to the User’s Manual.)
Specifications
The heavy duty cutter is designed to cut tags and label liner.
IMPORTANT Avoid cutting through the adhesive backed portion of any media.
Table 11. Heavy Duty Cutter Specifications
Typical Life > 1,000,000 cuts

Warranty 500,000 cuts
Environment Same specifications as printer
Cutting Method Rotating single-edged blade
Media Thickness Range 0.0025 to 0.010 in. (0.064 to 0.254 mm)
Media Width Range Same range as printer
Media Length Range 1.00 to 99 in. (25.4 to 2515 mm)
247
Appendix D Spare Parts
Spare Parts
8
9
8 1
17
(See page 249.) 12
23 2
A
5 4
15
10
26
13
7 6
8
14
24
10
Figure 42. Heavy Duty Cutter Spare Parts

Sheet 1 of 2
248
A
From page 248.
16 8
11
3
2
18 19
20
21
25
22
18
Figure 43. Heavy Duty Cutter Spare Parts

Sheet 2 of 2
249
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 42 and Figure 43.
175261-001 Field Kit, HD Media Cutter, 8 inch
1 172431-001 Bracket, Cutter, 4 inch
172432-001 Bracket, Cutter, 6 inch
172433-001 Bracket, Cutter, 8 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.
172436-001 Bracket, Guide, Cutter, 8 inch
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
7 172710-001 PCBA, Cutter Driver Requires item 26.
(Early model PCBAs had the
cable soldered to the board.)
(page 196) and Hardware
Kit, Cutter Options 175508-
001 (page 197).
9 172529-001 Chain, Support, Cutter
10 203513-001 Screw, Socket Button Head Cap, Part of items 23 and 24. Also
M3x4mm (6) available in Hardware Kit
171629-001 (page 196) and
175508-001 (page 197).
11 203715-001 Finger, Ground, Cutter Part of item 4. Also available
in Hardware Kit, Cutter
Options 175508-001
(page 197).
250
Item
No.
M5x16mm (2) in Hardware Kit, Cutter
Options 175508-001
(page 197).
13 203252-001 Screw, Soc Head Cap, M4x10mm (2) Part of item 24. Also
available in Hardware Kit,
Cutter Options 175508-001
(page 197).
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.
M5x10mm (2) Kit 171629-001 (page 196)
and Hardware Kit, Cutter
Options 175508-001
(page 197).
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
in Hardware Kit, Cutter
Options 175508-001
(page 197).
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.
26 172698-001 Cable, Cutter Driver
251
252
E Online Data Validator
Contents
Safety Notices ................................................................................. page 254
Overview ......................................................................................... page 255
Installation and Removal ................................................................. page 256
Basic Setup ..................................................................................... page 265
Enabling And Disabling The Validator ...................................... page 266
Adjusting The Scanning Beam........................................................ page 267
Shifting The Scanning Beam .................................................... page 271
Calibration ....................................................................................... page 272
Bar Code Validation Demo Page.............................................. page 274
Configuring The Validator ............................................................... page 275
Bar Code Failures ........................................................................... page 275
Bad Bar Code Error Detection .................................................. page 275
Missing Bar Code Error Detection ............................................ page 275
Error Action............................................................................... page 276
Error Messages ........................................................................ page 280
Troubleshooting .............................................................................. page 284
Maintenance.................................................................................... page 286
Spare Parts ..................................................................................... page 287
253
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 44. Safety Warnings
254
Overview
The online data validator (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 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 User’s 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, and
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).
Refer to Table 12 for the minimum x-dimension requirements for each printer
size of a 300 dpi printer.
Table 12: Minimum X-Dimension and Beam Width for

a 300 dpi Printer
Minimum
Printer Size Beam Width
X-Dimension
4 inch 4.5 inches 6.6 mil

6 inch 6.5 inches 10 mil
8 inch 8.5 inches 13 mil
255
Appendix E Installation and Removal
Installation and Removal

This section explains how to install the later model validator. To remove the
validator, reverse the steps of this procedure.
Factory Installation
If your printer has a factory installed validator, the ferrite, cable, wire saddle,
and grommet have already been installed. Go to “Install The Brackets” on
page 262.
Field Installation
If you are doing a field installation, you must install the ferrite, cable, wire
saddle, and grommet. Go to “Install The Ferrite” on page 257.
256
Install The Ferrite
Install The Ferrite

1. Using the RJ-11 connector end of the power/data cable, insert the cable
through the ferrite. (Figure 45.)
2. Wrap the power/data cable around the ferrite twice.
3. Adjust the position of the ferrite so that the length from the ferrite to the
RJ-11 connector is 20 ± 0.5 inches.
Power/Data Cable Ferrite

Second Wrap
RJ-11 Connector
(to validator)
20 ± 0.5
inches
Wide P10 Connector

(to controller PCBA)
Power/Data Cable
First Wrap
Figure 45. Wrapping the Power/Data Cable Around the Ferrite
257
Frame Boss
Wire Saddle
Figure 46. Inserting the Wire Saddle Into the Frame Boss
4. Insert the wire saddle into the frame boss. (Figure 46.)
258
Install The Ferrite
Wire Saddle
RJ-11 Connector
(to validator)
Ferrite Frame
Opening
Figure 47. Inserting the Power/Data Cable Through the Hole in the Frame Wall
5. Raise the media cover and remove the solid grommet from the frame
opening.
6. On the electronics side of the printer, push the RJ-11 connector end of
the power/data cable through the frame opening. (Figure 47.)
7. Route the power/data cable through the wire saddle.
259
Split
Grommet
RJ-11
Connector
Inserted Split
Grommet
(media side)
Power/Data Cable
(approximately
17 inches exposed)
Figure 48. Adding the Grommet to the Power/Data Cable

8. On the media side of the printer, slide the grommet onto the power/data
cable and insert it into the frame opening. (Figure 48.)
9. 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.
260
Install The Ferrite
J10
Power/Data Cable
Wire Saddle
Ferrite
Upper
DC Motor
Figure 49. Position the Ferrite

10. On the electronics side of the printer, position the ferrite on top of the
upper DC motor. (Figure 49.)
11. Route the power/data cable through the wire saddle as shown in
Figure 49.
12. Plug the wide P10 connector end of the power/data cable into the J10
receptacle on the controller PCBA.
261
Install The Brackets
Lower
Bracket
M4x10mm
Screw (4)
Figure 50. Installing the Lower Bracket

1. Using the four M4x10mm screws, install the lower bracket as shown in
Figure 50.
262
Install The Brackets
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 51. 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 51, 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.
263
Attach The Power/Data Cable To The Validator

Power/Data Cable
(RJ-11 connector)
Upper Bracket
Screw (3)
Cable
Channel
Bracket Tab
Grommet
Bracket Mounting Screw (4)
Figure 52. 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 52.
2. Plug the RJ-11 connector end of the power/data cable into the validator.
3. Route the power/data cable behind the bracket tab, as shown in
Figure 52.
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.
264
Attach The Power/Data Cable To The Validator
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 271.
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 272 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. See Table 13.
Table 13. RESET Button Settings
Time RESET Button Is Depressed Result
Less than 2 seconds Turns on scanning beam (has no

effect if the beam is already on)
More than 4 but less than 6 seconds Initiates calibration procedure

(page 272)
More than 6 seconds Resets validator to factory calibration

and turns off 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.
265
Appendix E Basic Setup
Enabling And Disabling The Validator

Software can automatically detect an installed validator when the printer is
powered up. If the printer is powered up with Power-Up Config. set to Factory,
the VALIDATOR menu appears and Validator Funct. is set to Enable in the
QUICK SETUP and VALIDATOR menus.
If Power-Up Config. is not set to Factory, the VALIDATOR menu appears, but
Validator Funct. is set to Disable. Enable Validator Funct. by completing the
following steps. (This is a one-time setting once you save the configuration.)
IMPORTANT Do not enable or disable the validator with data in the buffer.
See “Resetting Validator Data” below.
..
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.
..
3. If necessary, press . until VALIDATOR displays.
4. Press ↓ until Validator Funct. displays.
5. Press + or – until 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. Save the modified configuration for further use under the CONFIG.
CONTROL menu. (Refer to the User’s Manual.)
8. Press ↓ and ↵ at the same time to lock the ↵ key, then press PAUSE to
take the printer offline.
9. Press PAUSE again to put the printer online.
NOTE: To disable the validator once it has been enabled, repeat the steps
and select Disable in step 5.
Resetting Validator Data

The validator reports on all bar codes it detects since the last data reset. For
example, you print a large batch of labels with bar codes and then print a
validator report. Then you print another batch of labels with bar codes and
print another report. The report will contain information on both batch jobs.
However, if you reset the validator data between batch jobs, the second
report will only contain information on the second batch job.
To reset validator data:
..
..
4. Press ↓ until Clear Data displays.
5. Press ↵ to clear validator data.
266
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 53. 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
Figure 53. Aligning the Scanning Beam
267
Appendix E Adjusting The Scanning Beam
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 54.
0.30 inches
(7.62 mm)
Figure 54. 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 55.
Scanning Beam A
A
Notch in Tear Bar/
Cutter
Figure 55. Aligning the Scanning Beam – Cutter Installed
268
Top Left Screw
Bottom Left Screw
Bottom Right Screw
Figure 56. Scanning Beam Adjustment Screws

Figure 56 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 hex 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.
269
Appendix E Adjusting The Scanning Beam
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
270
Shifting The Scanning Beam
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 57.
0.06 inch
(1.52 mm)
Figure 57. Adjusting the Center of 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 User’s Manual.)
..
..
4. Press ↓ until Validator Funct. displays.
5. Make sure Enable 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.
271
Appendix E Calibration
Calibration
of the laser beam.

The validator should be calibrated when it is first installed or when the printer
displays Calibration warning. 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 14. RESET Button Settings
Time RESET Button Is Depressed Result
Less than 2 seconds Turns on scanning beam (has no

effect if the beam is already on)
More than 4 but less than 6 seconds Initiates calibration procedure

(page 272)
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 58.)
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 14 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.
9. Close the pivoting deck and rotate the deck lock lever fully
counterclockwise.
272

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 16 on
page 280.)
CALIBRATION Light
RESET Button
Deck Lock
Lever
Calibration Bar Code Card
Figure 58. Calibrating the Validator
273
Appendix E Calibration
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 User’s 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.
274
Bad Bar Code Error Detection
Configuring The Validator

Setting validator options is done through the VALIDATOR menu. (Refer to the
Online Data Validator User’s Manual.) The validator comes equipped with a
default setting for each 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 User’s
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 printer’s
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 276.
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 276.
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 User’s Manual.
275
Appendix E Bar Code Failures
Error Action
The printer response is the same whether the error stems from a bad or
missing bar. It is determined by the Validator Action setting in the
VALIDATOR menu:
..
..
4. Press ↓ until Validator Action displays.
5. Press + or – to scroll through the choices:
• Retry Form (default)
• Stop & Retry
• Grade&Report
• Rescan Form
• Stop
• Overstrike
These options are described in detail starting on page 277.
6. Press ↵ to select the desired value.
276
Error Action
Forms Printed After an Error Detection

Because of physical differences between the location of the print head and
the scanning beam, one or more forms may print after a bad form (a form with
a bar code error that the validator detected).
The number of forms printed after a bad form depends on the Label Length,
Print Speed, and Slew Speed settings in the MEDIA CONTROL menu.
Shorter forms and faster speeds tend to increase the number of forms printed
before the validator has a chance to detect an error. Also, the validator may
not detect an error on forms that have bar codes near the bottom of the form
until the next form has already started printing.
Forms that print after a bad form are treated differently, depending upon the
error action mode selected (see Table 15). Modes that require a reprint
operation may need to reprint more than just the bad form.
Table 15. Actions Done to Forms That Print After A Bad Form
Error Action Mode Action
Stop Tagged as failed, even though it was never scanned.
Overstrike Overstruck and reprinted.
Retry Form Reprinted.

Stop & Retry Overstruck and reprinted.
Grade&Report Not applicable (all forms are scanned once).
Rescan Form Scanned. If error persists, it will be overstruck and

reprinted.
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 with the form immediately following the
bad form and any other forms printed prior to the physical stop (see “Forms
Printed After an Error Detection” above).
277
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 bad
form. It then prints an obliterating pattern over the bad form and any other
forms printed prior to the physical stop (see “Forms Printed After an Error
Detection” on page 277). 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: Select Error Type Message to see the error message printed on the
bad form as the Overstrike Style.
IMPORTANT If you are using an RFID encoder, set the validator Overstrike Style
different than the RFID Overstrike Style (in the RFID CONTROL menu).
This will help you differentiate between a validator error and an RFID
error.
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. If
more than one form is overstruck, only the first overstruck form is lost (the one
with the missing or bad bar code), and a separate print command is required
to resend it from the host, if needed. The rest of the overstruck forms are
automatically resent.
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 User’s 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 “Setting For Skip Labels” in the Online Data Validator User’s
Manual). It will then slew to the next top of a blank form and reprint the bad
form and any other overstruck forms (see “Forms Printed After an Error
Detection” on page 277).
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.
278
Error Action
Stop & Retry

This mode is similar to the Stop mode: the printer will stop printing and display
the error message. It will then skip a number of blank labels, depending on
the setting for Skip Labels (see “Setting For Skip Labels” in the Online Data
Validator User’s Manual). Then it will slew to the next top of a blank form and
reprint the bad form and any other forms printed prior to the physical stop (see
“Forms Printed After an Error Detection” on page 277).
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 User’s Manual.
Grade&Report
In this mode, the entire print job will print uninterrupted. If one or more errors
is detected, the printer status indicator lamp flashes, the alarm sounds, and
the error message “Bar code fails / Job has errors” displays.
IMPORTANT The error message lets you know that at least one bad form printed. To
determine which form(s) are bad, you must manually scan all of them.
The printer remains in a fault condition until you press the PAUSE key. This
clears the error message and takes the printer offline. Correct any condition
that may have caused the fault, then press PAUSE to place the printer back
online.
Rescan Form
This mode is similar to the Retry mode, however, instead of backing up and
overstriking the form, the printer will back up and rescan the bad form and any
other forms that have already printed (see “Forms Printed After an Error
Detection” on page 277).
NOTE: The number of times the printer will attempt to rescan the bad form
and following forms is determined by the Num Retry setting.
See “Num Retry” in the Online Data Validator User’s Manual.
If the printer scans these forms correctly on any of the rescans, it will continue
printing with the next form.
If the printer fails to scan these forms correctly on all of the rescans, it will
overstrike the forms, stop, and indicate an error similar to the Stop mode.
When the error has been cleared, the printer will skip a number of blank
labels, depending on the setting for Skip Labels (see “Setting For Skip Labels”
in the Online Data Validator User’s Manual). It will then slew to the next top of
a blank form and reprint the bad form and any other overstruck forms (see
“Forms Printed After an Error Detection” on page 277).
279
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 276) and show the appropriate error message on
the printer display. Validator error messages are explained in Table 16.
Table 16. Validator Messages
Bar code fails This message appears when at 1. Press PAUSE to clear the
Job has errors least one label in a batch of message.
labels has a data validation
error. 2. Manually scan all the bar
codes in the label batch,
NOTE: then reprint the bad labels.
This message appears only
when Validator Action is set to
Grade&Report.
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 media’s
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.
280
Error Messages
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 272.
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.
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
User’s 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 User’s 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.
281
Speed Exceeds Print Speed is set above 6 IPS This message only appears
Validator Limit as the Power-Up configuration briefly, and the speed is
with the validator option automatically reduced. No
installed. An attempt was made action is necessary.
to set Print Speed above 6 IPS
in the QUICK SETUP menu or
via host software.
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. If using bitmapped bar
codes, set Number of
Codes to the number of
codes per form (not Auto).
See “Setting Number Of
Bar Codes On A Form” in
the Online Data Validator
User’s Manual.
5. Press PAUSE to clear the
message.
6. In the VALIDATOR menu,
press ↓ until Clear Data
displays, then press ↵.
282
Error Messages
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.
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.
283
Appendix E Troubleshooting
Troubleshooting
If the customer reports problems with the validator, consult Table 17 for a list
of symptoms and possible solutions.
Table 17. 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 PCBA on the
printer. See “Installation and Removal” on
page 256.
2. Make sure the validator has not been disabled in
the VALIDATOR menu. See “Enabling And
Disabling The Validator” on page 266.
3. Print a bar code validation demo page (page 274).
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” on page 256.
2. Use Beam Shift to move the beam horizontally to
cover the entire width of the labels. See “Shifting
The Scanning Beam” on page 271.
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 266.
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.
284
Error Messages
Table 17. 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 267.
• 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 274.
• 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 User’s 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.
285
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.
286
Error Messages
Spare Parts
4
5 7
4
6
Figure 59. Validator Spare Parts, Later Models
Item No. Part No. Description Notes
179464-001 Field Kit, Validator, T5000r Includes all shown items.

1 171945-001 Field Kit, Validator & Upper Bracket Includes items 4, 5, 6, and 7.
Assembly
2 178108-001 Cable Assembly, Validator
3 171946-001 Field Kit, Lower Bracket Assembly Includes six of item 4.
4 203824-001 Screw, Socket Flange Head Cap, Part of items 1 and 3, but can be
M4x10mm ordered separately in Hardware
Kit 171629-001 (page 196).
5 171423-001 Overlay, Validator, English Adheres to surface indicated in
Figure 59.
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 141445-001 Ferrite
287
Appendix E Spare Parts
288
F Wireless Interface
Installation and Removal

IMPORTANT If you just need to install the radio card, protective cover, and antenna,
see page 294.
This chapter explains how to install the wireless interface (RF antenna cable
assembly, wireless interface card, radio card, protective cover, and antenna).
To remove the wireless interface, reverse the steps of these procedures.
NOTE: It is the responsibility of the customer to supply the radio card.
289
Appendix F Installation and Removal
Install The RF Antenna Cable Assembly


4. Loosen one screw and remove the other screw that secures the small
cover plate to the rear of the printer frame, and set the plate aside.
(Figure 60.)
5. Remove both screws that secure the upper angled cover plate to the rear
of the printer frame, and set the plate aside.
Small Cover Plate
Upper Angled
Cover Plate
Screw (2)
Screw (2)
Figure 60. Removing the Cover Plates
290
Install The RF Antenna Cable Assembly
BNC Connector
RF Antenna
Cable
Small Antenna
Plate
Captive Nut (other
side of plate; not
visible from this angle)
Lock Washer
Nut
Figure 61. The RF Antenna Cable Assembly

6. Remove the RF antenna cable from its packaging and remove the lock
washer and nut from the back of the BNC connector. (Figure 61.)
7. Remove the small antenna plate from its packaging and route the RF
cable through the opening.
8. Secure the RF cable to the plate using the lock washer and nut. The lock
washer and nut must be located on the same side of the plate as the two
captive nuts.
291
Small Cutout
RF Antenna
Cable Assembly
BNC Connector
Screw (2)
Small Antenna
Plate
Figure 62. Installing the RF Antenna Cable Assembly

9. Insert the BNC connector end of the RF antenna cable assembly into the
small cutout, and secure the small antenna plate using the two screws as
shown in Figure 62.
292
Install The Wireless Interface Card
Install The Wireless Interface Card

1. Plug the wireless interface card into the upper PCI (Peripheral
Component Interconnect) expansion slot (J25). (Figure 63.)
2. Route the RF antenna cable around the wireless interface card and
through the RF antenna cable slot and upper expansion cutout.
J25
Wireless
RF Antenna Interface Card
Cable
RF Antenna
Cable Slot
Upper Expansion
Cutout
Figure 63. Installing the Wireless Interface Card
293
Install The Radio Card, Protective Cover, And Antenna

1. Insert the radio card into the wireless interface card. (Figure 64.)
2. Plug the RF cable into the receptacle as shown in Figure 64.
3. Install the protective cover over the radio card using the two screws.
4. Plug the antenna onto the BNC connector.
BNC
Connector
RF Cable
Antenna
Radio Card
(supplied by customer)
RF Cable
Receptacle
Wireless
Interface Card
Screw (2) Protective
Cover
Figure 64. Installing the Radio Card, Protective Cover, and Antenna
294
Install The Radio Card, Protective Cover, And Antenna
5. Rotate the antenna upright.

6. Remove the top two M3x8mm screws securing the rear panel.
7. Slide the antenna bracket over the antenna.
8. Align the bracket over the two holes in the frame, then secure the bracket
using the two M3x8mm screws.
10. Refer to your printer’s User’s Manual or the Network Interface Card
User’s Manual to configure the printer for the wireless interface.
M3x8mm Antenna
Screw (2) Bracket
Upright Antenna
Figure 65. Installing the Antenna Bracket
295
Appendix F Spare Parts
Spare Parts
5
6
1
Figure 66. Wireless Interface Spare Parts
178819-001 Antenna Kit, PCI Wireless Assy Includes items 3, 4, 5, 6, and 7.

For use with a Cisco, Lucent, or
Symbol radio card.
Does not include item 1 or 2.
1 179412-901 PCI Wireless Assy Does not include item 2 or an
antenna kit.
2 Ref Radio Card Supplied by customer.
3 Ref Protective Cover
4 Ref Antenna Bracket
5 Ref Antenna
6 Ref RF Antenna Cable
7 Ref Small Antenna Plate
296
G RFID Encoder and
Antenna Assemblies
Installation And Removal

This chapter describes how to replace an RFID antenna or encoder
assembly, or both, in an SL5000r (or an RFID upgraded T5000r) printer.
Prepare The Printer

1. Since you may be reloading the flash memory, make a configuration
printout of all saved configurations. (Refer to the SL5000r/T5000r User’s
Manual.)
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.
297
Appendix G Remove The Frame Side Cover
Remove The Frame Side Cover
Captive Screw (2)
Frame Side Cover
Figure 67. 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 67.)
298
Remove The RFID Encoder Assembly
Replace The RFID Encoder Assembly

These instructions describe how to replace an RFID antenna and encoder
assembly in an SL5000r (or an RFID upgraded T5000r) 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
Thumb Nut
RFID Encoder
Assembly
Mounting Stud (2)
Figure 68. Removing the RFID Encoder Assembly

1. Loosen the thumb nut. (Figure 68.)
2. Lift the RFID encoder assembly off the two mounting studs and remove
the assembly.
299
Appendix G Replace The RFID Encoder Assembly
Antenna Cable
Connector
AWID
RFID Encoder
Data Cable
Connector
Data Cable
Port
RFID Encoder
Assembly
Figure 69. Disconnecting the Antenna and Data Cables

1. Cut and remove any tie wrap that may be installed around the AWID
RFID encoder.
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.
2. On the side of the encoder, grasp the square end of the antenna cable
connector with pliers and pull it straight out of the encoder. (Figure 69.)
3. If you are replacing the RFID encoder assembly, go to step 4; otherwise,
go to step 6.
4. Unplug the data cable connector from data cable port.
5. Set aside the old RFID encoder assembly.
6. If you are replacing the RFID antenna assembly, go to step 1 on
page 301; otherwise, go to step 1 on page 304.
300
Replace The RFID Antenna Assembly
Old
Media Guard
Front Tab
Figure 70. Removing the Old Media Guard

1. Raise the media cover.
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 70.)
4. Slide the old media guard away from the printer and lift it out.
301
Lower Media
Sensor
Media Guard
(Old and New)
RFID Antenna
Assembly
Transformer
Figure 71. 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 PCBA.
5. Turn the old media guard over. (Figure 71.)
6. Remove the lower media sensor.
7. Set aside the old media guard (with its attached RFID antenna assembly).
CAUTION When handling the new media guard, do not touch the transformer
located on the RFID antenna assembly.
8. Using the new media guard (with its attached RFID antenna assembly),
install the lower media sensor as shown in Figure 71.
302
Lower Media New

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

Cable
Lower
Support
Frame Opening
Figure 72. 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 72.
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.
303
Install The RFID Encoder Assembly
Antenna
Cable
AWID
RFID Encoder
Data Cable
Connector
Data Cable
Port
RFID Encoder
Assembly
Figure 73. Connecting the Data and Antenna Cables

1. If you are replacing the RFID encoder assembly, go to step 2; otherwise,
go to step 3.
2. Plug the data cable connector into the data cable port on the new RFID
encoder assembly. (Figure 73.)
3. Plug the antenna cable into the AWID RFID 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 73.)
304
Install The RFID Encoder Assembly
Antenna Cable Antenna Cable

Connector
Tie Wrap
AWID
RFID Encoder
RFID Encoder
Assembly
Figure 74. Installing the Tie Wrap

4. Install the tie wrap around the antenna cable (near the connector), AWID
RFID encoder, and RFID encoder assembly, as shown in Figure 74.
305
Notch
Thumb Nut
RFID Encoder
Assembly
Mounting Stud (2)
Figure 75. Installing the RFID Encoder Assembly

5. Align the 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 75.)
6. Secure the RFID encoder assembly by tightening the thumb nut.
306
Route The Data Cable
Wire Saddle (3)
Data Cable
Data Cable
Connector
J12
Figure 76. Routing and Connecting the Data Cable

7. Route the data cable through the three wire saddles as shown in
Figure 76.
8. Plug the data cable connector into the J12 receptacle on the controller
PCBA.
307
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 67.)
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 297.
Compare the Program File version number (e.g., 365472) 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. (See “Downloading Software”
on page 203.)
4. Beginning with “Loading Media And Ribbon” in the SL5000r/T5000r 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.
308
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
panel’s LCD (see Table 18).
Table 18. RFID Control Panel Error Messages
Error Message Explanation Solution
NON-RFID DATA A job was printed that had no Press PAUSE to clear the
On Rfid Tag RFID commands on at least message.
one form of the job while Set Non-RFID Warning to
RFID tags were installed in Disable, print a job with
the printer and the Non-RFID RFID commands on every
Warning menu item is set to form, or install non-RFID
Enable. labels in the printer.
RFID Comm Err RFID error: communication Press PAUSE to clear the
Check Cable cannot be established with message.
the RFID encoder. Reader See “Troubleshooting” on
will be set to Disable in the page 310.
RFID CONTROL menu and
the previous port settings
restored.
RFID FW ERR: The RFID encoder firmware Press PAUSE to clear the
Version Mismatch version is not capable of message.
operating with the printer Redownload the program
software. file to the printer.
RFID LOCK CMD: The lock command for Press PAUSE to clear the
Not supported EPC-119 type tags is not message.
supported, but a lock Remove the lock command
command was encountered. from the application.
RFID MAX RETRY Error Handling = Overstrike in Press PAUSE to clear the
Check System the RFID CONTROL menu, message.
and the Label Retry count has See “Troubleshooting” on
been exhausted. page 310.
RFID TAG ERR: A write was attempted on a Press PAUSE to clear the
Read-Only Tag read-only tag. message.
Change media to writable
tags or remove the write
command from the
application.
RFID TAG FAILED Error Handling = Stop in the Press PAUSE to clear the
Check Media RFID CONTROL menu, and message.
the RFID encoder could not See “Troubleshooting” on
read the RFID tag. page 310.
309
Appendix G Troubleshooting
Troubleshooting
If you are having trouble with the RFID encoder, consult Table 19 for a list of
symptoms and possible solutions.
Table 19. Troubleshooting the RFID Encoder
Symptom Solution
No communication between the 1. Make sure Reader = Enable in the RFID

printer and the reader CONTROL menu.
2. Use the RFID Test option in the RFID CONTROL
menu (Admin User enabled) to read and display
the current RFID tag content. Class1 RFID tags
usually contain a valid entry due to the pre-test
process. Refer to “RFID Test (This Test Reads A
Tag)” in the RFID Labeling Reference Manual.
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
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. Refer to

“Loading Media And Ribbon” in the 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.
310
Spare Parts
This section contains a drawing of the RFID encoder (Figure 77). The table
following the illustration lists the spare parts and their part numbers.
311
Appendix G Spare Parts
1 2
11
7
4
9
3 5
11
10
Figure 77. Four Inch RFID Encoder
312
Item
No.
1 178624-901 Field Kit, Upper Support Assy, 4 inch Includes item 2 installed.
2 178168-003 Spring, Pivot Deck, 4 inch Included in item 1.
3 178403-001 Field Kit, Printhead Assy, 203 dpi, 4 inch Includes items 4, 5, and 6.
178404-001 Field Kit, Printhead Assy, 300 dpi, 4 inch
4 Ref Printhead Assy, 203 dpi, 4 inch Included in item 3.

Ref Printhead Assy, 300 dpi, 4 inch Included in item 3.
5 178695-901 Printhead Cover/Upper Media Sensor Included in item 3, but can be

Assy, 4 inch ordered separately.
6 203513-001 Screw, Socket Button Head Cap, Included in item 3. Also

M3x4mm (3) available in Hardware Kit
171629-001 (page 196).
7 178433-001 Field Kit, RFID Encoder Assy, AWID 915

179067-001 Field Kit, RFID Encoder Assy, AWID 869
8 177559-001 Cable Assy, Interface/Power, RFID
9 178472-001 Field Kit, RFID Antenna Assy, 915 Includes media guard.
179068-001 Field Kit, RFID Antenna Assy, 869 Includes media guard.
178142-003 Media Guard, RFID, 915, 4 inch Does not include antenna.
10 178405-001 Field Kit, Lower Support Assy, 4 inch

M4x12mm Kit 171629-001 (page 196).
313
Appendix G Spare Parts
314
H General Purpose
Input/Output (GPIO)
Installation And Removal

This chapter explains how to install the GPIO subassembly. To remove the
GPIO subassembly, reverse the steps of these procedures.
Prepare The Printer

before doing any installation procedure. Failure to remove power could
result in injury to you and damage the equipment. You will be instructed
when to apply power.
315
Appendix H Remove The Frame Side Cover
Remove The Frame Side Cover
Captive Screw (2)
Frame Side Cover
Figure 78. 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 78.)
316
Install The GPIO Subassembly
2. If you have the expansion-CT option, and if it is located in the J24 lower
PCI (Peripheral Component Interconnect) expansion slot (Figure 80), go
to step 3. Otherwise, go to step 8, page 318.
3. Remove both screws that secure the upper angled cover plate to the rear
of the printer frame, and set the plate aside. (Figure 79.)
4. Remove both screws that secure the expansion-CT subassembly to the
rear of the printer frame.
5. Carefully remove the expansion-CT subassembly from the J24 lower PCI
expansion slot (J24), and plug it in the J25 upper PCI expansion slot.
(Figure 80.)
6. Secure the expansion-CT subassembly to the rear of the printer frame
using the two screws. (Figure 79.)
7. Secure the lower angled cover plate to the rear panel using the two
screws.
Upper Angled
Cover Plate
Screw (2) (shown in place)
Lower Angled
Cover Plate
Flat
Cover Plate
Screw (2)
Screw (2)
Figure 79. Cover Plates
317
Appendix H Install The GPIO Subassembly
8. Plug the 7-pin power cable connector into the J9 receptacle on the
controller PCBA.
9. Plug the 2-pin power cable connector into the GPIO subassembly as
shown in Figure 80.
10. Plug the dual data cable connectors into the GPIO subassembly as
shown in Figure 80.
11. Loosen one screw and remove the other screw that secures the flat cover
plate to the rear of the printer frame, and set the plate aside. (Figure 79.)
12. Using the lower angled cover plate as a guide, plug the GPIO
subassembly into the J24 lower PCI expansion slot. (Figure 80.)
13. Insert the GPIO connector into the GPIO cutout, and secure it using the
two 3/16 inch standoff screws. (Figure 80.)
14. Restore the printer to operation. (page 96.)
J24
J25
7-pin Power
Cable Connector
Lower Angled J9
Cover Plate
GPIO
Cutout
Screw (2)
GPIO
Subassembly
Power Cable
2-Pin Power
Cable Connector
Dual Data Cable
Connectors
Data Cable
GPIO
Connector
Figure 80. GPIO Subassembly and Cables
318
Spare Parts
3
4
Figure 81. PCI GPIO Spare Parts
179321-001 Field Kit, GPIO Includes all shown items.

179863-001 Field Kit, GPIO Cables Includes items 2, 3, and 4.
1 Ref PCBA, GPIO, PCI
2 Ref Cable Assy, GPIO, 24V Power
3 Ref Cable Assy, GPIO, Data
4 202434-001 Standoff Kit, Screw, M/F, 4-40x.19 Also available in Hardware Kit
171629-001 (page 196).
5 Ref DB50 Male Connector Shown assembled.
319
Appendix H Spare Parts
320
Index
Numerics BATT HIGH VOLT, 45

BATT LOW VOLT, 45
06 HOST REQUEST, 41 Belt replacement
08 HOLD PRINT / TIMEOUT, 41 platen, 99
15 COMM CHECK, 42 rewind, 100
203 DPI Head Installed, 43 Block, head pressure, assembly, replacement, 111
22 INVALID ADDR, 42 BUFFER OVERFLOW, 45
27 CU TIMED OUT, 43 BUFFER OVERRUN, 45
28 CU NOT ENAB, 43
C
300 DPI Head Installed, 44
33 HEAD OPEN / TIMEOUT, 43 Cables
48V POWER FAIL, 43 interconnection diagram, 214, 215
A routing diagram, 216
Calibration / warning, 46, 281
About the Printer, 18 CANNOT CALIBRATE / Disable Peel-Off, 46
About This Manual, 15 CAUTION, definition, 16
ASCII Code Chart, 199 Checksum Failure, 46, 281
Asterisk (*), meaning on messages, 40 Cleaning
B cutter, 247
exterior, 31
BAD VFU CHANNEL, 44
general, 31
Bar code fails / Job has errors, 44, 280
interior, 31
Bar Code Improper / Data Format, 44, 280
media damper, 32
Bar code quiet / zone too small, 44, 280
media sensor, 32
Bar codes, 19
platen roller, 32
bad bar code error detection, 275
printhead, 32
error action, 276
validator, 286
Grade&Report, 279
Clear Data, 266
Overstrike, 278
Clear validator data, 266
Retry Form, 278
Clearing messages, 41
Stop, 277
CLEARING PROGRAM / FROM FLASH, 46
Stop & Retry, 279
Coax/twinax
failures, 275
host interface, 20
minimum width, 255
replacement, 101
missing bar code error detection, 275
Communications failures, 91
types supported by validator, 255
321
Configuration, 17 Enabling validator, 266
Contrast too low / Check media, 46, 281 E-NET INIT, 48
Control panel error messages, 309 E-NET READY, 48
Control panel keys, 27 E-NET RESET, 48
Control panel replacement, 102 ENTER to Stop, 48
Controller PCBA Error messages
pinouts, 217 See Messages
replacement, 103 Exchange, data, 93
Controls and Indicators, 25 F
Cooling fan, power supply, replacement, 106
CSC, 15 FAN WARNING, 51
Customer Support Center, 15 Fault messages
Cutter, 237 See Messages
maintenance, 247 Features
spare parts, 248 optional, 20
specifications, 247 standard, 19
troubleshooting, 246 FILE EXISTS / Enable Overwrite, 51
CUTTER FAULT / Jam or Cut Fail, 47, 246 FILE SYS FULL / Add Flash, 52
Cutter messages FILE SYS FULL / Delete Files, 52
CUTTER FAULT / Jam or Cut Fail, 246 FILE SYS FULL / Optimize & Reboot, 52
OPTION NOT INSTALLED, 246 FILE SYS INVALID / Optimize & Reboot, 52
FILE SYS WRITE / Check Flash, 52
D
Flash messages
Damper, media, replacement, 107 CLEARING PROGRAM / FROM FLASH, 46
Data exchange, 93 ERROR OCCURRED / FLUSHING QUEUES*,
DEACTIVATING / HOST SERIAL, 47 51
DIAGNOSTICS PASSED, 47 ERROR: DC PROGRAM / NOT VALID, 48
Diagrams ERROR: DRAM AT / ADDRESS XXXXXXXX,
cable interconnection, 214, 215 49
cable routing, 216 ERROR: FLASH / DID NOT PROGRAM, 49
controller PCBA pinouts, 217 ERROR: NO DRAM / DETECTED, 49
DIP switches, 10/100Base-T, 124 ERROR: PROGRAM / NEEDS MORE DRAM,
DIRECT THERMAL / Remove Ribbon, 47 49
Direct Thermal Mode, 22 ERROR: PROGRAM / NEEDS MORE FLASH,
Display indicators, 26 50
DO NOT POWER OFF, 47 ERROR: PROGRAM / NOT COMPATIBLE, 50
Downloading Optional Fonts to Flash Memory, 210 ERROR: PROGRAM / NOT VALID, 50
Downloading software, 203 ERROR: SHORT AT / ADDRESS XXXX, 50
DOWNLOADING TO VALIDATOR, 48 ERROR: WRITING / TO FLASH, 50
E ERROR: WRONG / CHECKSUM, 51
LOADING PROGRAM / FROM PORT XX%, 56
EC SOFTWARE FAIL* / See Manual, 48 LOADING PROGRAM / INTO FLASH, 56
Emulations, 19 RESETTING / PLEASE WAIT, 68
Emulations, loading, 203 RESTORING / BOOT CODE, 68
322
SECURITY CODE / VIOLATION, 70 M
Flash SIMM, loading, 203
Flash SIMM, replacement, 117 Maintenance
Fonts, 19, 20 cleaning the printer, 31
Downloading, 210 cutter, 247
FPGA FILE / NOT FOUND, 52 preparing the printer for, 95
Frame side cover replacement, 108 preventive, 31
FRAMING ERROR, 52 restoring the printer to operation, 96
Manual conventions, 17
G
Manual, other T5000 manuals, 17
GAP NOT DETECTED / Check Media, 53, 54 Media cover replacment, 114
Gear, ribbon drive, final, replacement, 109 Media cutter, 237
Gear, ribbon drive, intermediate, replacement, 110 Media damper replacement, 107
General Purpose Input/Output (GPIO), 315 Media damper, cleaning, 32
GRF CHK ERROR / PRESS PAUSE, 54 Media hanger beam replacement, 115
H Media sensor assembly, lower, replacement, 116
Media sensor, cleaning, 32
Half Speed Mode, 54 Media, types of thermal media, 21
Handshaking, hardware and software, 93 Memory, Flash SIMM, replacement, 117
HEAD POWER FAIL / Call For Service, 55 Memory, loading, 203
Head pressure block assembly, replacement, 111 Memory, NVRAM, replacement, 119
I MENU MODE / QUICK SETUP, 57
Message List (troubleshooting), 41
IGP/PGL ERROR, 55
Messages
IMPORTANT, definition, 16
06 HOST REQUEST, 41
INCOMPATIBLE WITH / CUTTER, 55
08 HOLD PRINT / TIMEOUT, 41
Indicators, 10/100Base-T, 122
15 COMM CHECK, 42
Installation, 17
203 DPI Head Installed, 43
INSUFFICIENT RAM / Reboot/Add RAM, 56
22 INVALID ADDR, 42
Interconnection diagram, 214, 215
27 CU TIMED OUT, 43
Interfacing, 91
28 CU NOT ENAB, 43
J 300 DPI Head Installed, 44
Job In Process indicator, 25 33 HEAD OPEN / TIMEOUT, 43
48V POWER FAIL, 43
K
asterisk (*), what it means, 40
Key, security, replacement, 139 BAD VFU CHANNEL, 44
L Bar code fails / Job has errors, 44, 280
Bar Code Improper / Data Format, 44, 280
LABEL MISSING / Check Paper Path, 56
Bar code quiet / zone too small, 44, 280
LCD, 25
BATT HIGH VOLT, 45
Liquid Crystal Display, 25
BATT LOW VOLT, 45
LOADING PROGRAM / FROM PORT XX%, 56
BUFFER OVERFLOW, 45
LOADING PROGRAM / INTO FLASH, 56
BUFFER OVERRUN, 45
Calibration / warning, 46, 281
323
CANNOT CALIBRATE / Disable Peel-Off, 46 Half Speed Mode, 54
Checksum Failure, 46, 281 HEAD POWER FAIL / Call For Service, 55
clearing, 41 IGP/PGL ERROR, 55
CLEARING PROGRAM / FROM FLASH, 46 INCOMPATIBLE WITH / CUTTER, 55
Contrast too low / Check media, 46, 281 INSUFFICIENT RAM / Reboot/Add RAM, 56
CUTTER FAULT / Jam or Cut Fail, 47, 246 LABEL MISSING / Check Paper Path, 56
DEACTIVATING / HOST SERIAL, 47 LOADING PROGRAM / FROM PORT XX%, 56
DIAGNOSTICS PASSED, 47 LOADING PROGRAM / INTO FLASH, 56
DIRECT THERMAL / Remove Ribbon, 47 MENU MODE / QUICK SETUP, 57
DO NOT POWER OFF, 47 NON VOLATILE / MEMORY FAILED, 57
DOWNLOADING TO VALIDATOR, 48 NON-RFID DATA / On Rfid Tag, 57, 309
EC SOFTWARE FAIL* / See Manual, 48 OPTION NOT / INSTALLED, 58
E-NET INIT, 48 OPTION NOT INSTALLED, 246
E-NET READY, 48 PAPER OUT / Load Paper, 59
E-NET RESET, 48 PAPER OUT / TIMEOUT, 60
ENTER to Stop, 48 PARITY ERROR, 60
ERROR OCCURRED / FLUSHING QUEUES*, PØØ ERROR: / SYSTEM FAULT, 58
51 Poor scanning / Check heat&head, 60, 281
ERROR: DC PROGRAM / NOT VALID, 48 Poor scanning / Check media, 61, 281
ERROR: DRAM AT / ADDRESS XXXXXXXX, Poor scanning / Inspect head, 61, 281
49 POWER LOSS SAVED / NON-VOLATILE
ERROR: FLASH / DID NOT PROGRAM, 49 RAM, 61
ERROR: IPDS needs / 300 DPI Head!, 49 POWER SAVER MODE, 61
ERROR: NO DRAM / DETECTED, 49 POWER SUPPLY VOLT*, 62
ERROR: PROGRAM / NEEDS MORE DRAM, PRINT HEAD COLD / See Manual, 62
49 PRINT HEAD HOT / See Manual, 63
ERROR: PROGRAM / NEEDS MORE FLASH, PRINT HEAD UP / Close Print Head, 63
50 PRINTER HOT / See Manual, 64
ERROR: PROGRAM / NOT COMPATIBLE, 50 PRINTER UNDER / REMOTE CONTROL, 64
ERROR: PROGRAM / NOT VALID, 50 PWR SUPPLY HOT / See Manual, 65
ERROR: SHORT AT / ADDRESS XXXX, 50 RBN TAKEUP FULL / Remove Used Rbn, 66,
ERROR: WRITING / TO FLASH, 50 67
ERROR: WRONG / CHECKSUM, 51 REACTIVATING / HOST SERIAL, 67
FAN WARNING, 51 RECHARGE BATTERY, 67
FILE EXISTS / Enable Overwrite, 51 Remove Label, 67
FILE SYS FULL / Add Flash, 52 RESETTING / PLEASE WAIT, 68
FILE SYS FULL / Delete Files, 52 RESTORING / BOOT CODE, 68
FILE SYS FULL / Optimize & Reboot, 52 RFID Comm Err / Check cable, 68, 309
FILE SYS INVALID / Optimize & Reboot, 52 RFID FW ERR: / Version Mismatch, 68, 309
FILE SYS WRITE / Check Flash, 52 RFID LOCK CMD: / Not supported, 68, 309
FPGA FILE / NOT FOUND, 52 RFID MAX RETRY / Check System, 68, 309
FRAMING ERROR, 52 RFID TAG ERR: / Read-Only Tag, 68, 309
GAP NOT DETECTED / Check Media, 53, 54 RFID TAG FAILED / Check Media, 68, 309
GRF CHK ERROR / PRESS PAUSE, 54 RIBBON BROKEN / Reload Ribbon, 69
324
RIBBON DETECTED / Remove Ribbon, 69 P
RIBBON FAULT / TIMEOUT, 69
Ribbon Low, 69 PAPER OUT / Load Paper, 59
RIBBON OUT / Load Ribbon, 70 PAPER OUT / TIMEOUT, 60
SECURITY / VIOLATION, 70 Paper, direct thermal and thermal transfer, 21
SECURITY CODE / VIOLATION, 70 PARITY ERROR, 60
SELECT DOWNLOAD PORT=XXXXXXXXXX, Part numbers, replaceable parts, 153
71 PCBA, 103
Signal / Clipping, 71 Peel/tear assembly, replacement, 148
SOFTWARE ERROR* / Recycle Power, 71 Pinouts, controller PCBA, 217
Speed Exceeds / Validator Limit, 71, 282 Plate, rear panel, replacement, 127
TCP Port Busy, 72 Platen replacement, 128
Test Page / Not Available, 72 Platen roller, cleaning, 32
TESTING HARDWARE / PLEASE WAIT, 73 PØØ ERROR: / SYSTEM FAULT, 58
Unscannable code / check media, 73, 282 Poor scanning / Check heat&head, 60, 281
Validator not / communicating, 73, 283 Poor scanning / Check media, 61, 281
WAITING FOR PROGRAM DOWNLOAD, 74 Poor scanning / Inspect head, 61, 281
Mode POWER LOSS SAVED / NON-VOLATILE RAM, 61
auto reset, 123 POWER SAVER MODE, 61
run, 123 Power supply replacement, 129
Modes of operation, 29 POWER SUPPLY VOLT*, 62
Motor, DC ribbon drive, replacement, 120 Power switch, 29
Motor, stepper, replacement, 121 PPI, 19
Preparing the printer for maintenance, 95
N
PRINT HEAD COLD / See Manual, 62
NIC PRINT HEAD HOT / See Manual, 63
configuration, 126 PRINT HEAD UP / Close Print Head, 63
external, 122 Print quality, 35
internal, 10/100Base-T, 125 Printer
internal, wireless, 289 alarms, 40
NON VOLATILE / MEMORY FAILED, 57 cleaning, 31
Notes and notices explained, 16 configuration, 17
Numbers, part, replaceable parts, 153 Dynamic Print Control, 22
NVRAM, replacement, 119 emulations, 19
O hardware options, 20
inspection, 34
Online data validator installation, 17
See Validator model specifications, 18
Online Status indicator, 25 preparing for maintenance, 95
Operating Modes, 29 printing process, 22
OPTION NOT / INSTALLED, 58 restoring to operation, 96
OPTION NOT INSTALLED, 246 self-test, 39
Optional features, 20 thermal printing technology, 22
PRINTER HOT / See Manual, 64
325
PRINTER UNDER / REMOTE CONTROL, 64 printhead assembly, 130
Printhead assembly, replacement, 130 printhead cover/upper media sensor, 132
Printhead cover/upper media sensor, replacement, real-time clock, 119
132 resistors, terminating, 133
Printhead, cleaning, 32 rewinder (option), 135
Procedures security key, 139
cleaning, 31 sensor, head up, 142
removal and replacement, 98 sensor, label taken, 143
PWR SUPPLY HOT / See Manual, 65 spindle assembly, ribbon supply or take-up,
R 144
support assembly, lower, 145
RBN TAKEUP FULL / Remove Used Rbn, 66, 67 support assembly, upper, 146
REACTIVATING / HOST SERIAL, 67 tear bar assembly, adjustable, 149
Real-time clock, replacement, 119 tear off assembly, 147
RECHARGE BATTERY, 67 tensioner, rewinder belt, 151
Remove Lable, 67 Replacement parts, 153
Replacement Reports, resetting data, 266
belt, platen, 99 Reset mode, 123
belt, rewind, 100 RESETTING / PLEASE WAIT, 68
coax/twinax, 101 Resetting data, 266
control panel, 102 Resistors, terminating, replacement, 133
controller PCBA, 103 RESTORING / BOOT CODE, 68
cooling fan, power supply, 106 Restoring the printer to operation, 96
damper, media, 107 Rewinder (option), replacement, 135
Flash SIMM, 117 Rewinder, torque check and adjustment, 136
frame side cover, 108 RFID
gear, ribbon drive, final, 109 installation/removal, 297
gear, ribbon drive, intermediate, 110 spare parts, 311
head pressure block assembly, 111 troubleshooting, 310
media cover, 114 RFID messages
media damper, 107 NON-RFID DATA / On Rfid Tag, 57, 309
media hanger beam, 115 RFID Comm Err / Check cable, 68, 309
media sensor assembly, lower, 116 RFID FW ERR: / Version Mismatch, 68, 309
memory, Flash SIMM, 117 RFID LOCK CMD: / Not supported, 68, 309
memory, NVRAM, 119 RFID MAX RETRY / Check System, 68, 309
motor, DC ribbon drive, 120 RFID TAG ERR: / Read-Only Tag, 68, 309
motor, stepper, 121 RFID TAG FAILED / Check Media, 68, 309
NIC, internal, 10/100Base-T, 125 RIBBON BROKEN / Reload Ribbon, 69
NIC, internal, wireless, 289 RIBBON DETECTED / Remove Ribbon, 69
NVRAM, 119 RIBBON FAULT / TIMEOUT, 69
peel/tear assembly, 148 Ribbon Low, 69
plate, rear panel, 127 RIBBON OUT / Load Ribbon, 70
platen, 128 Run mode, 123
power supply, 129
326
S how to, 38
message list, 41
SECURITY / VIOLATION, 70 newly installed printer, 94
SECURITY CODE / VIOLATION, 70 other symptoms, 75
Security key, replacement, 139 procedures, 91
SELECT DOWNLOAD PORT=XXXXXXXXXX, 71 RFID encoder, 310
Self Test, 10/100Base-T, 122 start here, 37
Self-test, printer, 39 validator, 284
Sensor replacement
U
head up, 142
label taken, 143 Unscannable code / check media, 73, 282
Signal / Clipping, 71 V
SOFTWARE ERROR* / Recycle Power, 71
Software handshaking, 93 Validator
Software, loading, 203 adjusting the scanning beam, 267
Spare parts and part numbers, 153 bar code failures, 275
Specifications calibration, 272
cutter, 247 configuration, 275
printer model, 18 controls, 265
Speed Exceeds / Validator Limit, 71, 282 enabling, 266
Spindle assembly, ribbon supply or take-up, error action, 276
replacement, 144 installation/removal, 256
Standard features, 19 maintenance, 286
Status and Display Indicators matrix, 26 operational parameters, 255
Status indicators, 26 overview, 255
Support assembly, upper, replacement, 146 safety, 254
Supprt assembly, lower, replacement, 145 setup, 265
spare parts, 287
T
troubleshooting, 284
TCP Port Busy, 72 Validator messages
Tear bar assembly, adjustable, replacement, 149 Bar code fails / Job has errors, 44, 280
Tear off assembly, replacement, 147 Bar Code Improper / Data Format, 44, 280
Technical support, 15 Bar code quiet / zone too small, 44, 280
Tensioner, rewinder belt replacement, 151 Calibration / warning, 46, 281
Terminating resistors, replacement, 133 Checksum Failure, 46, 281
Test Page / Not Available, 72 Contrast too low / Check media, 46, 281
TESTING HARDWARE / PLEASE WAIT, 73 Poor scanning / Check heat&head, 60, 281
Tests, printer, 39 Poor scanning / Check media, 61, 281
Thermal printer series product line, 18 Poor scanning / Inspect head, 61, 281
Thermal Transfer Mode, 22 Speed Exceeds / Validator Limit, 71, 282
Torque, values for fasteners, 97 Unscannable code / check media, 73, 282
Troubleshooting Validator not / communicating, 73, 283
cutter, 246
display messages, 40
327
W
WAITING FOR PROGRAM DOWNLOAD, 74
WARNING, definition, 16, 240, 247
Wireless interface
installation/removal, 289, 315
spare parts, 296, 319
328
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
*179280-001*
179280-001A

SL5000r T5000r Service

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Maintenance Manual

SL5000 r and T5000 r

RFID Smart Label and Thermal Printers

Printronix SL5000r and T5000r

FOR HOME OR OFFICE USE

Lithium Battery Warning

Printronix makes no representations or warranties of any kind regarding this

COPYRIGHT © 2005 PRINTRONIX, INC. All rights reserved.

1 Maintenance Overview ....................................... 15

2 Preventive Maintenance ..................................... 31

Troubleshooting Display Messages..................................................... 40

Printhead Cover/Upper Media Sensor ........................................ 132

5 Illustrated Parts Breakdown .............................. 153

A ASCII Codes ..................................................... 199

B Downloading Software ...................................... 203

C Wire Data .......................................................... 213

D Media Cutters and Tray .................................... 237

E Online Data Validator ........................................ 253

F Wireless Interface ............................................. 289

G RFID Encoder and Antenna Assemblies........... 297

Troubleshooting ................................................................................. 310

H General Purpose Input/Output (GPIO).............. 315

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 SL5000r/T5000r Series RFID/Label Printer

Table 1. The T5000r, Smart Ready, and SmartLine Series

Max Print Printing Max Print

T5204r 10 203 4.1

T5204r DT* 10 203 4.1

SL5204r MP 10 203 4.1

T5304r 8 300 4.1

T5304r DT* 8 300 4.1

SL5304r MP 8 300 4.1

T5306r 8 300 6.6

T5208r 8 203 8.5

T5308r 6 300 8.5

* DT = Direct Thermal only 4 inch models (no ribbon transfer support)

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

Thermal Printer Media

Thermal Printer Technology

The Printing Process

Dynamic Print Control

RFID Encoder Antenna Board

Validator Option Control

P13 P9 P11 P18

Ethernet NIC Wireless

Figure 1. Functional Block Diagram, SL5000r

RFID Encoder Antenna Board

Validator Option Control

P13 P9 P11 P18

Ethernet NIC Wireless

Figure 2. Functional Block Diagram, T5000r

Controls And Indicators

Figure 3. Control Panel

Flashes during a fault Flashes during a fault Flashes during a fault

action. action. action.

Off when no data is Off when no data is

JOB SELECT Key None Selects a pre-stored Scrolls left through

DECREMENT Key in Decrements option