Zebra Q3DLUBA000002 - Manuals
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Manual Zebra Q3DLUBA000002
Summary
RMAN-QLS-002 rev.A • ii • ProPrietary Statement This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reprodu...
• iii • RMAN-QLS-002 rev. A continued ContentS Proprietary Statement --------------------------------------------------------------------------------------------------- ii SeCtIoN 1: QL INtRoDuCtIoN ------------------------------------------------------------ 1-5 Diagnostic Tools -------------------...
• 1-5 • RMAN-QLS-002 rev. A Section 1: QL introduction Description The Zebra QL220, QL 220 Plus; QL320, QL 320 Plus; QL420 and QL 420 Plus Mobile Printer s are low-cost, portable, direct thermal printers. They can be carried by the shoulder strap, sit on a work space, or be mounted to a specific loc...
RMAN-QLS-002 rev.A • 1-6 • Diagnostic tools This section of the Printer Repair Manual contains instructions for using the various diagnostic tools available from Zebra and instructions on contacting technical support services offered by Zebra. Following sections contains explanations on the products...
• 1-7 • RMAN-QLS-002 rev. A Printing a Diagnostic label Creating a Configuration Label 1. Turn the printer off. Load the media compartment with journal media (media with no black bars printed on the back) 2. Press and hold the Feed Button.3. Press and release the Power button and keep the Feed butto...
RMAN-QLS-002 rev.A • 1-10 • Label Vista is a program running under the Windows™ environment that allows users to design labels which can be printed on the full range of Zebra mobile printers. Label Vista also provides a powerful set of diagnostics tools which use familiar Win - dows “point and click...
• 1-11 • RMAN-QLS-002 rev. A using label Vista equipment Required 1. A computer with the following minimum configuration:• Pentium CPU• 256 MB RAM• 1.44 MB Floppy Drive• 1 GB Hard Drive• CD-ROM drive• SVGA 14 in.monitor and SVGA card• 2 Serial Ports• USB Port • Windows 95/9, NT or 2000• Unit Test So...
• 2-35 • RMAN-QLS-002 rev. A Repair Procedures Section 2 • QL RepaiR pRoceduReS uSing the QL pRoduct configuRation code Each QL series printer has a 15 digit Product Configuration Code (PCC) label on the bot - tom of the unit. This code is explained by the charts for the respective printers in Sec -...
RMAN-QLS-002 rev. A Repair Procedures • 2-36 • StandaRd contRoL paneL If the printer is not functioning properly, refer to the chart below to find the state of the two LEDs on the Control Panel. Then refer to the Troubleshooting topic referenced in the chart to resolve the problem. Green LED Yellow ...
• 2-37 • RMAN-QLS-002 rev. A Repair Procedures chart to resolve the problem. troubleshooting topics 1. No power Power Button Press to turn unit on. Press again to turn unit off Feed Button Press to advance the media one blank label or a software determined length of journal media. Scroll Button Pres...
RMAN-QLS-002 rev. A Repair Procedures • 2-38 • • Check that battery is installed properly• Recharge or replace battery as necessary. 2. Media does not feed: • Be sure printhead is closed and latched.• Check spindle holding media for any binding.• If unit is equipped with label presence sensor: Insur...
RMAN-QLS-002 rev. A Repair Procedures • 2-42 • Make use of the following tools and supplies for maintaining the printer and installing the repair kits: Hand toolS • #1 Phillips Head Screw Driver• 3/32” hex driver SPeCial toolS (oPtional) • AU16259-1 Printhead Spring Tool• AU16266-1 Gap Sensor Assy i...
• 2-43 • RMAN-QLS-002 rev. A Repair Procedures media coveR, QL 220- RK18236-1 & QL220 pLuS- RK17735-015 You must use an ESD strap and work at a properly grounded workstation (antistatic mat or tray). All electronic components must be placed on an ESD protective tray. If stored, any electronic co...
RMAN-QLS-002 rev. A Repair Procedures • 2-44 • tom of the Printer Frame. 4. Plug the Bar Sensor Cable into J2 (BAR) on the MLB and lock the connector.5. Install the Printer Chassis in the Lower Housing.6. If necessary, install the Platen and Gear.7. Install the Upper Housing.8. Calibrate the Sensors...
RMAN-QLS-002 rev. A Repair Procedures • 2-46 • Sense cable off the bottom of the Printer Frame (#4 below). 10. Remove the Media Cover. Using a 3/32” hex driver, push the Hinge Pin out of the Printer Frame, and then lift the Media Cover from the Printer Frame. Installing the Media Cover 1. Feed the B...
• 2-47 • RMAN-QLS-002 rev. A Repair Procedures the QL 320. Important note for QL 320 units built before 1/20/03. Use of Media Cover Replacement Kit AN16861-023 requires the use of the Platen and Gear Assemblies included in Replacement Kits AN16861-035 (linered) and -036 (linerless). You will not be ...
RMAN-QLS-002 rev. A Repair Procedures • 2-48 • media guide pLate aSSembLy, QL220/220 pLuS Kit p/n Description type AN16972-007 KIT REPAIR QL2 MEDIA GUIDE PLA Rack and Pinion AN16972-023 KIT REPAIR QL2 MEDIA GUIDE ASSy w/ MW Rack and Pinion RK18467-001 KIT RPR QL2 MEDIA GUIDE W/BELT Belt/ Linered Med...
• 2-49 • RMAN-QLS-002 rev. A Repair Procedures 7. Remove and retain the Screws securing the Media Guide Plate Assembly to the Printer. 8. Remove the optional Media Width Sensor. If the Printer is equipped with the Media Width Sensor, pull the sensor cable free of the Printer Frame. 9. Remove the Med...
RMAN-QLS-002 rev. A Repair Procedures • 2-50 • Kit p/n Description RK16823-043 KIT RPR QL320 MEDIA GUIDE/MW RK18460-1 KIT RPR QL3 MEDIA GUIDE W/BELT RK18461-1 KIT QL3 MEDIA GUIDE LNL W/BELT RK18462-1 KIT QL3 MEDIA GUIDE MW W/BELT RK18463-1 KIT QL3 MEDIA GUIDE LNL MWBELT tools needed #1 Phillips Head...
RMAN-QLS-002 rev. A Repair Procedures • 2-52 • Kit p/n Description Type RK18466-002 QL4 Linerless Belt RK18466-003 QL4 w/ Media Width Belt RK18466-004 QL4 Linerless w/Media Width Belt AN16753-001 QL4 Media Assy Gear tools needed #1 Phillips Head Screwdriver. 3 / 32 ” hex driver Removing the Media As...
RMAN-QLS-002 rev. A Repair Procedures • 2-54 • Model Kit Media Type QL 220/220 Plus AN16972-005 Linered QL 320 AN16861-030/-031 Linered QL320/320 Plus & QL420/420 Plus AN16753-026 Linerless QL420/420 Plus AN16753-002 Linered tools Needed #1 Phillips head screwdriver Remove the Media Support Disk...
• 2-55 • RMAN-QLS-002 rev. A Repair Procedures Note: Both Support Disks must be set to use the same diameter core. 2. Assemble the Disks. Hold the Support Disk against the Media Support and se - cure with the Flat Washer and the Screw as shown above. 3. Repeat this procedure for the opposite side. C...
RMAN-QLS-002 rev. A Repair Procedures • 2-56 • tools Needed 3/32” hex driver Replacing the Media Rollers Both Media Rollers should be replaced as a set. 1. Turn off the Printer and open the Media Cover.2. Remove the old Rollers. Remove a Media Roller Cap as shown below Each one is held in place with...
• 2-57 • RMAN-QLS-002 rev. A Repair Procedures Platen and Gear As - sembly Peeler Bar pLaten/geaR KitS, QL220/QL 220 pLuS an16972-008 & -009 Removing the gear and platen 1. Open the Media Cover.2. Pry out the gear-end of the Platen and remove the Platen. installing the gear and platen 1. Align t...
RMAN-QLS-002 rev. A Repair Procedures • 2-58 • Removing the gear and platen 1. Open the Media Cover.2. Pry out the gear-end of the Platen and remove the Platen. installing the gear and platen 1. Align the flats on the Platen shaft with the hole in the Gear. The rib molded on the Gear must face outbo...
• 2-61 • RMAN-QLS-002 rev. A Repair Procedures continued uppeR houSing /WiReLeSS moduLeS-QL220 & QL 220 pLuS The following pages detail the procedure to install the Cover used for non-wireless units and the following Wireless wireless modules: Module type QL 220 QL 220+ Module Housing (no wire -...
RMAN-QLS-002 rev. A Repair Procedures • 2-62 • Installing the upper Housing 1. Position the Upper Housing onto the Lower Housing. If installing a Wirelss Module (Kits AN 16972-016, -017, or 018) line up the Wireless Module connector with the connector on the MLB. 2. Position the D-Rings between the ...
• 2-63 • RMAN-QLS-002 rev. A Repair Procedures uppeR houSing, QL320- RK18233-1 tools Needed #1 Phillips head screwdriver3/32” Hex Driver Removing the upper Housing 1. Turn the printer off and remove the Battery.2. Remove the QuickLink Module.3. Remove the Upper Housing. Remove the Upper Cover by rem...
RMAN-QLS-002 rev. A Repair Procedures • 2-64 • uppeR houSing, QL420/420 pLuS- an16753-007 Assemble the P.C. Board Cover Fold the P.C. Board Cover Fold P.C. Board Cover as shown in the sequence opposite:• Place the Board cover flat on a table as shown. Fold the two sides up as shown at “1” and “2”.• ...
• 2-65 • RMAN-QLS-002 rev. A Repair Procedures Assemble P.C. Board Cover Assemble the Board Cover to the upper Housing. The two holes in the Board Cover press over the bosses on the Upper Housing. The two sides of the Board Cover will fit into slots on the inside surface of the Upper Housing. Housin...
RMAN-QLS-002 rev. A Repair Procedures • 2-66 • Install the upper Housing 1. Assemble the Upper Housing assembly from the previous steps to the Print - er, and secure it with the retained hardware. At this time either the “D” rings, or the Carrying strap which was supplied with the printer should be ...
• 2-67 • RMAN-QLS-002 rev. A Repair Procedures LabeL pReSence SenSoR, QL320- an16861-015 tools Needed #1 Phillips head screwdriver3/32” Hex Driver Remove the upper Housing 1. Turn the printer off and remove the Battery.2. Remove the QuickLink Module 3. Remove the Upper Housing, per AN16861-0104. Ope...
• 2-69 • RMAN-QLS-002 rev. A Repair Procedures Installing a WLAN Radio and Antenna Install the Radio 1. Install the PCMCIA Radio. Plug the PCMCIA Radio into the P.C. Board assembly. The PCMCIA Radio can only be plugged in one way; the label must face up. 2. Install the PCMCIA Board Assembly Remove t...
RMAN-QLS-002 rev. A Repair Procedures • 2-70 • Assemble the Antenna Note: the Antenna Assembly is included as part of AN16652-1, as well as AN16861-011. 3. Install the 2.4 GHz Antenna in the Housing Wireless Module PCMCIA as shown, and secure with (2) Internal Tooth Washers. 4. Plug the lead from th...
• 2-71 • RMAN-QLS-002 rev. A Repair Procedures QL 320/320 pLuS & QL 420/420 pLuS WiReLeSS moduLeS continued You must use an ESD strap and work at a properly grounded workstation (antistatic mat or tray). All electronic components must be placed on an ESD protective tray. If stored, any elec-tron...
RMAN-QLS-002 rev. A Repair Procedures • 2-74 • Note: Clean any old adhesive from the printer using Isopropyl alcohol and let dry before installing the Keypad.If installing an LCD Keypad, use particular care not to scratch the clear window on the printer chassis. 1. Dress the flex cables on the botto...
• 2-75 • RMAN-QLS-002 rev. A Repair Procedures Introduction You will need to replace the Keypad if it has been physically damaged or no longer functions properly. This procedure covers installation of both the standard membrane Keypad and the optional LCD Keypad. Remember that changing the type of k...
RMAN-QLS-002 rev. A Repair Procedures • 2-76 • 6. Install the Upper Housing.7. Install the QuickLink Module.8. Install the Battery Pack9. Test the Printer. Installing a Membrane Key- pad 1. Plug the flex circuit from the Keypad into J6. Lock the connector. 2. Fold the static ground strap from the Ke...
• 2-77 • RMAN-QLS-002 rev. A Repair Procedures pRinteR fRame, QL220/220pLuS- an16972-001 Installing the Printer Frame 1. Install the Media Cover on the Printer Frame.2. Install the Keypad and Display in the Printer Frame.3. Install the MLB in the Printer Frame.4. Install the Printer Assembly in the ...
RMAN-QLS-002 rev. A Repair Procedures • 2-78 • tools needed #1 Phillips Head Screwdriver. 3 / 32 ” Hex Driver Removing the Printer Frame 1. Turn the printer off and remove the battery pack.2. Remove the QuickLink Module.3. Remove the Upper Housing.4. Remove the MLB.5. Remove the 4 Screws that secure...
RMAN-QLS-002 rev. A Repair Procedures • 2-80 • Cover. 6. Re-attach the MLB and display. • Plug the cables from the printer back into the MLB per the following table: 7. Reassemble the Upper Cover and Module Housing • Re-install the Upper Housing per AN16861-010 (QL320) or AN16753-007 (QL 420). • Whe...
RMAN-QLS-002 rev. A Repair Procedures • 2-82 • tools needed 3 / 32 ” Hex Driver Remove the upper Housing 1. Turn the printer off and remove the battery pack.2. Remove the Upper Housing and the QuickLink Module (or the Wireless Housing Module) per the procedure for AN16753-007. Install the Connector ...
RMAN-QLS-002 rev. A Repair Procedures • 2-84 • You must use an ESD strap and work at a properly grounded workstation (antistatic mat or tray). All electronic components must be placed on an ESD protective tray. If stored, any elec-tronic components must be placed in antistatic bags. tools Needed #1 ...
• 2-85 • RMAN-QLS-002 rev. A Repair Procedures 5 5 5 5 4 3 From # of connections CPu Connector # Printhead 28 (Flex) J3 Motor 4 J4 Media Width Sensor (optional) 3 J11 (bottom of board) Bar Sensor Cable 3 (Flex) J2 Gap Sensor/Printhead Ground 5 (Flex) J10 Label Presence Sensor 4 (Flex) J5 J4 J3 J10 J...
RMAN-QLS-002 rev. A Repair Procedures • 2-86 • Installing the Printhead 1. Install the Printhead Assembly. Insert the left hand mounting ear of the Printhead Assembly into the Printer Frame. Rotate the other end into the Printer frame and snap into place. 2. Dress the Flex Cable from the Printhead A...
• 2-87 • RMAN-QLS-002 rev. A Repair Procedures Installing the Printhead 1. Secure the Static Cable. Secure the static ground section of the Gap Sensor Cable to the back of the Printhead Assembly with a Screw. 2. Locate the Printhead Assembly. Slide the Printhead Assembly into the Printer Frame as sh...
• 2-93 • RMAN-QLS-002 rev. A Repair Procedures You must use an ESD strap and work at a properly grounded workstation (antistatic mat or tray). All electronic components must be placed on an ESD protective tray. If stored, any elec-tronic components must be placed in antistatic bags. Latch, QL 220/QL...
RMAN-QLS-002 rev. A Repair Procedures • 2-94 • Latch Assembly Latch Spring Latch Shaft Insert 3/32” Hex Driver or Spare Peeler bar Apply Super-Lube to inside surface Apply Super-Lube to gray areas Latch Shaft. 6. Press The Latch Shaft Into Position. Press the Latch Shaft so that the ends are flush w...
• 2-95 • RMAN-QLS-002 rev. A Repair Procedures You must use an ESD strap and work at a properly grounded workstation (antistatic mat or tray). All electronic components must be placed on an ESD protective tray. If stored, any elec-tronic components must be placed in antistatic bags. Installing the L...
RMAN-QLS-002 rev. A Repair Procedures • 2-96 • You must use an ESD strap and work at a properly grounded workstation (antistatic mat or tray). All electronic components must be placed on an ESD protective tray. If stored, any elec-tronic components must be placed in antistatic bags. Introduction The...
• 2-97 • RMAN-QLS-002 rev. A Repair Procedures 1. Install the Latch Shaft. Slide the Latch Pivot Shaft into the Printer Frame so that the end of the shaft is flush with the left hand side of the Printer Frame. 2. Install the Printhead Springs. Snap the (2) Printhead Springs back into place between t...
RMAN-QLS-002 rev. A Repair Procedures • 2-98 • Preparation: 1. Turn the printer off and remove the battery pack.2. Remove the Latch Assembly Module Removing the Peeler Shaft and Roller 1. Turn the Latch Assembly upside down.2. Carefully pull on one flange of the plastic latch and pull out the Peeler...
• 2-101 • RMAN-QLS-002 rev. A Repair Procedures If PCC digit 10 = S, set SW1 to OTHER CW (turn fully clockwise) (PIM-compati - ble). 5. Install the Keypad cables per the table on the preceding page..6. Install the Upper Housing and Lower Housing. Compatibility Switch (SW1). 7. Install the Battery Pa...
RMAN-QLS-002 rev. A Repair Procedures • 2-102 • Removing the MLB 1. Turn the printer off and remove the battery pack.2. Remove the QuickLink Module.3. Remove the Upper Housing.4. Remove the Keypad.5. Unplug all cables from the MLB.6. Remove the remaining Screw securing the MLB and pull the MLB out o...
RMAN-QLS-002 rev. A Repair Procedures • 2-104 • Introduction You will need to replace the MLB if it has been determined that it no longer functions properly. This procedure covers installation of MLBs with either 1M/1M or 2M/2M SRAM/Flash Memory configurations. You must re-load the printer’s applica...
• 2-105 • RMAN-QLS-002 rev. A Repair Procedures continued From # of connections CPu Connector # Head Open Switch 2 J1 (HEAD)(bottom of board) Bar Sensor 3 (Flex) J2 (BAR) Printhead 28 (Flex) J3 (PRINTHEAD) Motor 4 J4 (MOTOR) Label Presence Sensor 4 (Flex) J5 (PEEL) Membrane Keypad 8 (Flex) J6 (KEYPA...
• 2-107 • RMAN-QLS-002 rev. A Repair Procedures tools needed: Phillips Head Screwdriver Removing the Belt Clip 1. Remove the (2) Screws securing the Belt Clip to the Lower Housing. 2. Remove the old Belt Clip. Installing the Belt Clip 1. Slide the Belt Clip into the Belt Clip Retainer.2. Secure the ...
• 2-109 • RMAN-QLS-002 rev. A Repair Procedures Introduction: This kit supplies you with the parts needed to: • Replace the “D” rings supplied as standard equipment with the printer. or • Install the bushings supplied for use with the optional carrying strap. tools needed: 3/32” hex driver Removing ...
RMAN-QLS-002 rev. A Repair Procedures • 2-110 • Install the Kickstand (QL 220 ilustrated) Hook one of the pivots of Kickstand into the Retainer.Snap the other pivot into place. KicKStand option, QL 220/ 220 pLuS, QL 320/320 pLuS & QL 420/420 pLuS - an16744-1 & an16972-022 Kickstand
• 2-111 • RMAN-QLS-002 rev. A Repair Procedures batteRy RepLacement, QL 220/220 pLuS, QL 320/ 320 pLuS, & QL 420/ 420 pLuS Removing the Battery Pack. Press the battery latch toward the battery and lift the battery out of the printer. Installing the Battery Pack. 1. Rotate the Belt Clip to clear ...
RMAN-QLS-002 rev. A Replacement Kits • 3-112 • Section 3 • QL SerieS configurationS and PartS uSing the Product configuration code Each QL series printer has a Product Configuration Code (PCC). When ordering replacement parts, use the PCC code to determine the features installed on your printer. The...
• 3-113 • RMAN-QLS-002 rev. A Replacement Kits If you need to return a printer to the factory for repair or upgrade, a Return Material Authorization (RMA) must be issued from Repair Services prior to returning any assemblies, PC boards, printers, cables, etc. for repair or replacement. The name, add...
RMAN-QLS-002 rev. A Replacement Kits • 3-114 • Q 2 _ - _ _ _ _ _ 0 _ _ - _ _ QL 220/220 Plus Printer SRAM/FLASH _ _ B - _ _ _ _ _ 0 _ _ - _ _ 2M/2M _ _ C - _ _ _ _ _ 0 _ _ - _ _ 8M/4M (QL 220 Plus) _ _ D - _ _ _ _ _ 0 _ _ - _ _ 16M/8M (QL 220 Plus) KEYPAD/DISPLAY _ _ _ - L _ _ _ _ 0 _ _ - _ _ LCD _ ...
RMAN-QLS-002 rev. A Replacement Kits • 3-118 • QL 220 & 220 PLuS PartS Printer meCHaniSm exPloded View 4 1 1 2 6
• 3-119 • RMAN-QLS-002 rev. A Replacement Kits 1 9 1 2 17 18 16 13 1 0 1 1 14 3 9 7 8 15 5 QL 220 & 220 PLuS PartS- unit exPLoded view
RMAN-QLS-002 rev. A Replacement Kits • 3-120 • Q 3 _ - _ _ _ _ _ 0 _ _ - _ _ QL 320/320 Plus Printer SRAM/FLASH _ _ A - _ _ _ _ _ 0 _ _ - _ _ 1M/1M _ _ B - _ _ _ _ _ 0 _ _ - _ _ 2M/2M _ _ C - _ _ _ _ _ 0 _ _ - _ _ 8M/4M (QL 320 Plus) _ _ D - _ _ _ _ _ 0 _ _ - _ _ 16M/8M (QL 320 Plus) KEYPAD/DISPLAY ...
• 3-121 • RMAN-QLS-002 rev. A Replacement Kits Interpreting the PCC Code Each QL 320 Mobile Printer has a Product Configuration Code (PCC) label on the bottom of the unit. Use this chart to determine the features installed on your printer, then use the Illustrated Parts List and cross reference tabl...
RMAN-QLS-002 rev. A Replacement Kits • 3-124 • 6 1 0 1 5 5 1 2 1 4 8 2 1 8 2 9 1 1 1 7 1 3 1 9 1 7 QL 320 & 320 PLuS rePL acement KitS unit exPloded View
RMAN-QLS-002 rev. A Replacement Kits • 3-126 • QL 420 & 420 PLuS Product configuration code (PCC) Q 4 _ - _ _ _ _ _ 0 _ _ - _ _ QL 420/ 420 Plus Printer SRAM/FLASH _ _ A - _ _ _ _ _ 0 _ _ - _ _ 1M/1M _ _ B - _ _ _ _ _ 0 _ _ - _ _ 2M/2M _ _ C - _ _ _ _ _ 0 _ _ - _ _ 8M/4M (QL 420 Plus) _ _ D - _ ...
• 3-127 • RMAN-QLS-002 rev. A Replacement Kits Interpreting the PCC Code Each QL 420 Mobile Printer has a Product Configuration Code (PCC) label on the bottom of the unit. Use this chart to determine the features installed on your printer, then use the Illustrated Parts List and cross reference tabl...
• 3-131 • RMAN-QLS-002 rev. A Replacement Kits QL 420 & 420 PLuS rePL acement KitS PCmCia oPtion 19
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