Resolution:
CAUSE 1: 4410/4440- wrong ribbon.

SOLUTION 1: The 4410/4440 should use ribbons without the weld sensor hole- 44A507014-G06 and G10. The 4410/4440 do not have the ribbon weld sensor that is in the 4410XT/4440XT. Ribbons 44A507014-G08, G09, and G10 with the weld sensor hole will be damaged when the 4410/4440 prints over the weld sensor hole.

CAUSE 2: Damaged ribbon shield

SOLUTION 2: Inspect the shield, and repair or replace as necessary.

- 4410, 4440, 4470, 4490, 4500 series: Remove the print modules- refer to the instructions in the user's manual.

- 4800 and 4900 series: Following the instructions in the user's manual for changing the print modules, remove the ribbon deck, but do not remove the modules.

- The ribbon shield is the thin metal shield that goes between the ribbon and the paper.

CAUTION- the ribbon shield is very thin and sharp- it will cut very easily.

- Inspect the ribbon shield. The shield should have a number of holes for the print wires to pass through. Any damage will cause ribbon problems. Inspect the edges of the shield for burrs or damage. If the shield is damaged, it should be replaced.

- The shield on the 4410, 4440, 4510, 4520, 4530, and 4540 is held by three small screws. The shield on the 4470, 4490, 4570, 4590, 4800 series, and 4900 series is held by plastic guide on the left and right. The 4800 and 4900 series has a green handled hex wrench stored in the foam padding in the top of the printer.

CAUSE 2: Damaged print wires.

SOLUTION 2: Remove and inspect the print modules. If any print wires are over-extended or bent, replace the module.

CAUSE 3: (except 4410 and 4440 standard) Faulty ribbon weld sense circuit.

The ribbon consists of 65 yards of fabric ultrasonically welded together at the ends to make a continuous loop. Printing over the weld causes print quality issues, since the weld does not pick up ink. To avoid this, an oblong hole is located just before the weld. The ribbon weld sensor is an optical sensor that detects the weld. When the weld is detected, the printer suspends printing long enough for the weld to skip across the print line. When the printer goes into suspend mode, the display shows SUS (4410XT, 4440XT) or ONLINE: SUSPEND (4470, 4490, 4470XT, 4490XT). The ribbon weld timer is also reset when the printer detects the ribbon weld.

If a fault occurs in the ribbon weld sensor, the typical symptom is a display of rJ (4410XT, 4440XT) or FAULT: RIBBON WELD (4470, 4490, 4470XT, 4490XT). The weld sensor can be disabled by setting B13 (45) to 1 (4410XT, 4440XT) or by setting printer control strap B38 to IN (4470XT, 4490XT).

If the sensor is disabled, and there is a a fault in the ribbon weld sensor circuit, the printer will print over the weld sensor hole, and can cause the ribbon to tear and jam.

SOLUTION 3: IF the sensor is disabled, enable it. If the rJ or FAULT: RIBBON WELD displays are shown, troubleshoot and repair the ribbon weld circuit.