Zebra 3742, 2722, 2742 Service Manual

980357-001 Rev. A

©2001 Zebra Technologies Corporation

2722
2742
3742

Desktop
Thermal Printers
Service Manual

FOREWARD

This manual provides installation and operation information for the LP 2722, TLP 2722, LP 2742,
TLP 2742 and TLP 3742 series printers, manufactured by Zebra Technologies Corporation,
Camarillo, California.

TECHNICAL SUPPORT

If for any reason you require product technical support, please contact the Distributor where you first
purchased your equipment. If they cannot help you or at their direction, contact Zebra Repair
Administration.

RETURN MATERIALS AUTHORIZATION

Before returning any equipment to Zebra for in warranty or out of warranty repair, contact Repair
Administration for a Return Materials Authorization (RMA) number. Repack the equipment in the
original packing material and mark the RMA number clearly on the outside. Ship the equipment,
freight prepaid, to the address listed below:

Zebra RMA, USA

1001 Flynn Road

Camarillo, CA. 93012

Phone: [phone]

[e-mail]

Label Printers: Card Printers:

Zebra International, Europe Zebra International, Europe

Zebra House, The Valley Centre Zone Indutrielle, Rue d'Amsterdam

Gordon Road, High Wycombe 44370 Varades, France

Buckinghamshire HP13 6EQ, United Kingdom Phone: [phone]

Phone: [phone] FAX: [phone]

FAX: [phone]

COPYRIGHT NOTICE

This document contains information proprietary to Zebra Technologies Corporation. This document
and the information contained within is copyrighted by Zebra Technologies Corporation and may
not be duplicated in full or in part by any person without written approval from Zebra. While every
effort has been made to keep the information contained within current and accurate as of the date of
publication, no guarantee is given or implied that the document is error-free or that it is accurate
with regard to any specification. Zebra reserves the right to make changes, for the purpose of
product improvement, at any time.

980357-001 Rev. A iii

TRADEMARKS

LP 2722, TLP 2722, LP 2742, TLP 2742 and TLP 3742 are of Zebra Technologies Corporation.
Windows and MS-DOS are registered trademarks of Microsoft Corp. All other marks are trademarks
or registered trademarks of their respective holders.

OPERATOR CAUTIONS AND WARNINGS

These pages describe general safety and maintenance procedures that an operator must follow.
They are referenced throughout the service manual. The manual may include other warnings and
cautions not displayed here.

Warning - Shock Hazard

The printer should never be operated in a location where it can get wet.
Personal injury could result.

Warning - Static Discharge

The discharge of electrostatic energy that accumulates on the surface of
the human body or other surfaces can damage or destroy the print head or
electronic components used in this device. TAKE ANTI-STATIC
PRECAUTIONS before handling the print head or the electronic
components of the printer.

Caution - Printer Setup & Handling

1)When installing or modifying the printer setup or configuration,
ALWAYS TURN POWER OFF Before

:
A) Connecting any cables.
B) Performing any cleaning or maintenance operations.
C) Moving the printer.

2) Damage to the printer interface connector, accessories or enclosure
may result from placing the printer on it’s front bezel or backside during
unpacking or handling.

iv 980357-001 Rev. A

Media Cautions & Tips

1) Always use high quality, approved labels and tags. Approved supplies
can be ordered from your dealer. Forthe name of a dealer in your area, call
Customer Service.

2) If poor quality, adhesive backed labels are used,that DO NOT lay flat on
the backing liner, the exposed edges may stick to the label guides and
rollers inside the printer, causing the label to peel off from the liner and
jam the printer.

3) DO NOT use non-approved transfer ribbon. Permanent damage to the
print head may result if a non-approved ribbon is used. Non-approved
ribbons maybe wound incorrectly for the printer or contain chemicals that
may damage the print head.

4) IMPORTANT - If a transfer ribbon is installed incorrectly by the
operator, damage to the print head may result.

5) DO NOT use a ribbon when printing with direct thermal media.

Media Reload Tip

If you should run out of labels or ribbon while printing, DO NOT turn the
power switch OFF (0) while reloading or data loss may occur. The printer
will automatically resume printing when a new label or ribbon roll is
loaded.

Print Mode Control

The printer is reconfigured for direct thermal (or thermal transfer) printing
with the “O” command for the TLP thermal transfer printer. See the EPL2
programmer's manual for details.

Print Quality Tip

Print density (darkness) is affected by the heat energy (density setting)
applied and by the print speed. Changing both Print Speed and Density
may be required to achieve the desired results.

980357-001 Rev. A v

vi 980357-001 Rev. A

CONTENTS

INTRODUCTION 1

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparing a Static-Safe Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Environmental and Shock Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CLEANING AND MAINTENANCE 5

General Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Cleaning the Media Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Before Loading Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning the Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TROUBLESHOOTING GUIDE 9

Print Head Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

REQUIRED TOOLS 13

REPLACING PARTS 15

Packing Materials Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Rubber Foot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Enclosure Latch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ribbon Roll Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Ribbon Take-Up Clutch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Ribbon Supply Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 22

Front Bezel, Cutter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Media Frame Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Label Taken Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Feed Button/LED Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Ribbon Out Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Print Mechanism Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Transmissive Gap Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Black Line Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Upgrades to Memory and Real Time Clock Option . . . . . . . . . . . . . . . . . . . . 35

Main Printed Circuit Board Assembly (PCBA) Replacement . . . . . . . . . . . . . . . 37

Platen Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Latch, Left Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Latch, Right Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Platen Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Print Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

980357-001 Rev. A vii

viii 980357-001 Rev. A

INTRODUCTION

If you are a field engineer or technician, this manual helps you with routine maintenance,
troubleshooting and procedures for replacing parts for repair.

Follow the parts replacement procedures as closely as possible. If you are unsure of any procedure,
please contact your service representative or call the Zebra Technologies technical support group at
[phone]

Zebra Technologies stocks all replacement parts for the printer. Be sure your facility stocks sufficient
parts for the printer so that scheduled maintenance can take place in a timely manner.

980357-001 Rev. A 1

Models

There are several models of the printer, each of which look similar but have different ribbon and
media handling features.

LP models print using direct thermal media
only. They have a flat print head carriage.

TLP models print using either direct thermal
or thermal transfer media. They have a
carriage with ribbon spool hubs.

There are models that can handle up to
four-inch (10.2 cm) wide media and those
that can handle up to two-inch (5.1 cm) wide
media.

These printers also have option media
handling functions such as the dispensers to
present a single label already peeled from the
backing or cutters to present a single label
snipped from the roll.

The power supply and firmware also are
characteristics of the printer model and allow
the printer to be used in various countries.

2 980357-001 Rev. A

Conventions

This manual uses the following notations to call attention to important information.

ICON / SYMBOL MEANING

WARNING - critical safety information.

CAUTION - problem avoidance messages.

STATIC SENSITIVE - follow procedures that protect against the discharge
of electrostatic energy that accumulates on the surface of the human body
or other objects as this discharge can damage or destroy the print head
and other electronic components.

HEAT - The print head becomes hot while printing. Protect against
personal injury. DO NOT touch the print head. Use only the cleaning
pen to perform maintenance.

NOTE - important instructions and reminders.

HINT - helpful information.

MOVIE -In the Acrobat file, you can open an audio/visual clip to see a
procedure.

Unpacking the Printer

Printers are carton shipped and wrapped inside a protective electrostatic discharge (ESD) bag. Keep
all packing materials in case you need to reship the printer later or store the printer for any length of
time.

Preparing a Static-Safe Work Area

Prepare a static-safe work area before opening the printer for repair. The area must include
a properly grounded conductive cushioned mat to hold the printer and a conductive wrist
strap for the technician. ESD protective devices are available from most electronic supply
stores or by contacting 3M Corporation.

980357-001 Rev. A 3

MOVIE

MOVIE

Environmental and Shock Protection

Extreme temperature and humidity fluctuations or mishandling can damage the printer and power
supply.

Allow 30 minutes or more before opening the printer's plastic bag. This time allows the printer to
stabilize temperature especially after storage in a cool, dry location and then placement in a warmer,
more humid location. Warm, humid air condenses on the cool components of the printer and this
condensation may damage the components.

Move the printer carefully. Mechanical damage can certainly result from falls or rough handling.

4 980357-001 Rev. A

CLEANING AND MAINTENANCE

The printers are manufactured and tested under a strict quality management program. Zebra
Technologies uses only high quality components and materials in its printers. Although only
minimal routine maintenance is required, following these simple maintenance guidelines will ensure
longer life with quality printing performance.

General Cleaning

Keep the outside your printer clean by periodically wiping it with a soft cloth dampened
water. Do not use abrasive cleaners as they will damage the surfaces.

Shock Hazard - See page vi. Always turn off the printer before cleaning.

980357-001 Rev. A 5

MOVIE

Cleaning the Media Path

Keep the inside of your printer clean as needed, by using a brush, vacuum or air blower along the
media path (except the print head).

If a label jams inside the printer, remove the label and any adhesive residue immediately. Adhesive
may spread throughout the printer's media path if not completely removed. Many adhesive are
permanent and have short "set" times.

If the platen, dispenser bar, or serrated tear bear require cleaning, use 70% isopropyl alcohol
absorbed into a clean, lint-free cloth to wipe these surfaces. To turn the platen, use your finger to
advance the platen gear.

If the cutter requires cleaning, turn the printer off. Use tweezers to remove the media. Never use
solutions or solvents to clean the blade. If necessary, turn the printer on and use the C programming
command to cycle the cutter several times to perform a self cleaning operation. See the EPL2
programmer's manual.

Before Loading Media

You must remove the outside length of media (that is, one, full revolution of labels and any liner).
When you remove this part of the media, you remove the oils, dust, and adhesivers that
contaminate it. Tape or adhesive holds the loose end and the outside length of media becomes
contaminated when handled or stored.

You must avoid dragging adhesive or dirty media between the print head and
platen. such an occurance damages theprint headand is not covered under the
warranty. Using clean media prevents damage and reduces wear on the print
head and platen.

6 980357-001 Rev. A

MOVIE

Cleaning the Print Head

Over time, the print head becomes contaminate resulting in poor print quality. After using
five rolls of media or ribbon, rub the cleaning pen across the dark area of the print head.
Allow the print head to dry for one minute before loading labels.

Never touch the print head. Always clean the print headwith a cleaning penor a
cotton swab moistened with 70% isopropyl alcohol to gently remove dirt and
dust.

Lubrication

None of the serviceable parts require additional lubrication.

980357-001 Rev. A 7

8 980357-001 Rev. A

TROUBLESHOOTING GUIDE

PROBLEMS SOLUTIONS

Status indicator does
not light when power
switch is on (I)

1. Check power connections from the printer to the outlet.

2. Remove power supply and check fuse. If blown, remove the power
supply and return it to the manufacturer. Install a new power supply.

Printer is in dump
mode but nothing
prints after sending
file.

1. File does not contain a form feed code that will advance sheet. Press
the Feed button to print data in the printer’s buffer.

ASCII characters print
in place of expected
label art and bar
codes.

1. Printer may be in dump mode. Press the Feed button to reset to
normal operation.

2. Check serial port configuration using the Y command. See the EPL2
programmer’s manual.

Printing is uniformly
faded or poor quality.

1. Wipe the print head with the cleaning pen.

2. Adjust print speed/darkness in software or with programming.

3. Check the roll and verify that the media print surface is facing up.

4. Verify that the correct combination thermal transfer ribbon and
media are in use.

980357-001 Rev. A 9

PROBLEMS SOLUTIONS

Printer appears to be
working with the
indicator light
GREEN, but nothing
is printed.

1. Check the connections between the printer and the cable as well as
the cable and the computer.

2. Verify that the labels are the correct type.

3. Check the roll and verify that the print surface faces up for direct
thermal printing.

4. Check that the transfer ribbon is correctly routed and has the ink side
down.

5. Check print head wire bundle connections in carriage at main PCBA.

Printing stops and
status indicator lights
red

1. Perform the AutoSense adjustment.

2. Check that gap between labels is at least 1/16 inch (1.6mm)

3. Check for media jam.

4. Check that media is correctly routed.

5. Check printer memory configuration and correct data syntax.

6. Transmissive (gap) is dirty. Clean media path.

Status indicator
remains red.

1. Check for out-of-media condition or missing labels in the middle of a
roll.

2. Check for out-of-ribbon condition or damage or previous use of
ribbon in middle of roll.

3. Check that the ribbon and label stock or correctly routed

4. If using direct thermal printing, check that programmed mode or
printer driver is set for direct thermal printing. See the programmer’s
book for details.

5. Transmissive (gap) sensor may be dirty. Clean media path.

6. Check that the printer carriage is closed and latched.

Rubbing noise when
pressing Feed button.

1. Media is not loaded and the platen is rubbing against the print head.
Insert media (and load ribbon if necessary) between carriage and
platen.

Cutter makes
incomplete cuts or
cuts in the wrong spot.

1. Form length is set wrong. Change length through printer driver or
programming language. See the EPL2 programming manual.

Short length,
perforated media are
difficult to load when
preparing for
dispenser/peel mode.

1. Media length must be a minimum of 0.5 inch (12.7mm).

10 980357-001 Rev. A

PROBLEMS SOLUTIONS

Printer firmware must
be updated.

The printer firmware is updated by way of the parallel port.

1. Use the download utility to send firmware to the printer.

2. Optionally, you can download from the c:\ prompt by typing
copy/b filename lpt1: from the directory holding the update file.

The printer's light should start flashing green-orange, and then every few
seconds will flash red a couple of seconds. Once the update is done, the
light goes dark then comes on green.

980357-001 Rev. A 11

Print Head Life

The print head on the left is brand new. The print head in the center has been run over a million
inches and has been cleaned after each media roll (and/or ribbon). The print head on the right has
been run less than a million inches without cleaning and wear is evident.

The print head has a limited life and is considered a consumable item. The media rubs across the
print elements and wears away the surface. Media material, operational settings, and environment
all affect this process. Printing with worn elements may create illegible images. If the print quality
remains poor after cleaning, you may need to replace the print head. Damage can be caused by
improper cleaning (unapproved fluids or implements), electrostatic discharge (ESD), or touching the
print head (contaminating it with bodily, oily acids). Examples of poor print:

Weak or Damaged Print Elements Weak or Damaged Print Elements or Print Logic

(Full-On Print Pattern) (Rotating Print Element Pattern)

12 980357-001 Rev. A

REQUIRED TOOLS

Make use of the following tools while performing replacement procedures:

•

Phillips driver #0

•

Phillips driver #1

•

Phillips driver #2

•

Slot-head screwdriver

•

tweezers

•

hex nut driver 5/32

•

needle-nose pliers

•

pliers for E-ring retainers

•

pliers for axial retainers

•

pliers for integrated chips

980357-001 Rev. A 13

14 980357-001 Rev. A

REPLACING PARTS

To access some parts, you need to dissemble other parts; therefore, other procedures must be
followed before and after performing a particular replacement. You can find these procedures on
the repair paths chart.

980357-001 Rev. A 15

16 980357-001 Rev. A

200

Packing

Materials

290

Print

Head

203

Roll

Hubs

204

Ribbon Take-

Up Clutch

205

Ribbon

Supply Clutch

202

Enclosure

Latch

207

Media

Frame

201

Rubber

Feet

218

Latch,

Left Head

211

Battery

206

Cutter

Option

209

Feed Button

LED

212

Print

Mechanism

215

SRAM 1MB,

IE Flash, RTC

216

Main

PCBA

217

Platen

Motor

210

Ribbon Out

Sensor

208

Label Taken

Sensor

214

Black Line

Sensor Assy

213 Bottom

Transmissive

Gap Sensor

REPAIR PATHS

219

Latch,

Right Head

220

Platen

213 Top

Transmissive

Gap Sensor

Packing Materials Replacement 980357-200A

To ship or store the printer, make sure all components are packed as shown.

Move the printer carefully. While the printer has sturdy construction, mechanical damage can
certainly result from falls or rough handling.

980357-001 Rev. A 17

1 Foam set (two parts)

2 Master carton all-in-one

3 Poly-bag

4 Ship kit (various per printer)

Extreme temperature and humidity
fluctuations or mishandling can damage the
printer and power supply.

When unpacking the printer, allow 30 minutes
or more before opening the printer's plastic
bag. This time allows the printer to stabilize
temperature especially after storage in a cool,
dry location and then placement in a warmer,
more humid location. Warm, humid air
condenses on the cool components of the
printer and this condensation may damage
the components.

Rubber Foot Replacement 980357-201A

Removal

Use tweezers to pull the foot 1234 free of
the bottom case.

Assembly

Push the new foot into its receptacle !
until it pops into place.

18 980357-001 Rev. A

Enclosure Latch Replacement 980357-202A

Removal

Use a slotted screwdriver to push or
needle-nose pliers to pull the latch 12 free of
the bottom case.

Assembly

Push the new latch into its receptacle ! until
it snaps into place.

980357-001 Rev. A 19

Ribbon Roll Hub Replacement 980357-203A

Both the front and rear assemblies are on the left side of the carriage and are replaced with the same
steps.

Preparations

Before starting the procedure, open the printer, then remove media and any ribbon from the printer.

Removal

1. Use retainer pliers to remove the E-style
retaining ring 1 from the outside of the
hub.

2. Slide the hub 4, spring 3, and washer
2 out of the carriage side frame.

Assembly

1. Align the spring so that the larger
conical end goes against the inside of
the spoked hub.

2. Place the washer so it is between the
spring and the carriage side frame.

3. Insert the hub through the bearing in
carriage side frame

!.

4. Place the E-style retaining ring to hold
the hub shaft in place.

20 980357-001 Rev. A

MOVIE

Ribbon Take-Up Clutch Replacement 980357-204A

Preparations

Open the cover, then remove media and any ribbon from the printer.

Removal

1. Remove the retaining ring 3 from the
outside shaft of the hub.

2. Remove the take-up clutch assembly 2.

3. Slide the hub 1 out of the carriage side
frame

!.

Assembly

1. Insert the hub 1 through the carriage
side frame

!.

2. Put the ribbon take-up clutch assembly
2 into place.

3. Secure with an exterior retaining ring 3.

980357-001 Rev. A 21

MOVIE

Ribbon Supply Clutch Replacement 980357-205A

Removal

The compression spring 3 has considerable force. Hold the assembly as you begin to remove it.

1. Use retainer pliers to remove the
retaining ring : from the outside shaft
of the hub.

2. Remove the loose parts from the
assembly.

3. Remove the

E-style retaining ring 1

from the shaft of the hub ;.

4. Slide the hub ; out of the side frame

!.

Assembly

1. Insert the hub ; through the side frame

!

2. Lock the retaining ring 1 into place.

3. Place the bushing 2 on the hub shaft.

4. Place the compression spring 3 against
the bushing.

5. Place the bushing 4 against the spring

6. Mount the hole in the torsion disk 5 on
the pin on the side frame.

7. Hook the torsion spring 6 onto the tab
on the disk from beneath (the spring
must provide a counterclockwise force).

8. Hook the spring onto the mount of the
anchor disk 7. Twist the anchor disk
one-quarter clockwise revolution to put
tension on the spring.

9. Place the spacer 8 into the anchor disk.

10. Place the friction disk 9 onto the anchor disk.

11. Secure with a retaining ring :.

22 980357-001 Rev. A

MOVIE

Front Bezel, Cutter Replacement 980357-206A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

Removal

1. Pull the bezel 1 forward and away from the bottom case !.

2. If necessary, provide outward lateral pressure on the sidewalls of the bottom case.

3. Unplug the cutter's ribbon cable 2 from where it connects to the main PCBA.

Assembly

1. Plug in the cutter's ribbon cable into its
connector on the main PCBA.

2. Press the bezel onto the bottom case
until it snaps into place.

Check the Installation

Reload media and ribbon, if necessary.

Plug in the power cord, turn on the printer
and run the AutoSense routine to get a dump
mode printout. This action tests the printer's
media drive and printing capabilities.

980357-001 Rev. A 23

Media Frame Replacement 980357-207A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

Open the cover, and remove any media and ribbon (if necessary).

Removal

1. Use a #1 Phillips driver to loosen the four
screws 1 that hold the frame 2 to the
bottom case

!.

2. Lift the frame 2 free of the print mechanism
and bottom case.

Optionally, you can detach the feed switch ribbon
cable 3 from its connector on the main PCBA

".

Assembly

If necessary, plug the feed switch ribbon cable into
its connector on the main PCBA.

1. Align the frame so that the feed button/LED
are to the left; then, lower the frame onto the
bottom case and behind the print
mechanism.

2. Replace the four screws that hold the frame to the bottom case and use a #1 Phillips driver to
tighten them.

Assemble the Printer

Reload media and ribbon, if necessary.

Check the installation. Plug in the power cord, turn on the printer and run the AutoSense routine to
get a dump mode printout. This action tests the printer's media drive and printing capabilities.

24 980357-001 Rev. A

MOVIE

Label Taken Sensor Replacement 980357-208A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

Follow the removal steps of the Media Frame Replacement procedure (980357-207).

Removal

1. Push outward the sensor door 1 until it
pops out of the top cover

!.

2. Pull the ribbon cable from its guide posts
inside the top cover.

3. Carefully pull the connector from its
location J6 on the main PCBA.

4. Pull the ribbon cable and connector out
of the front of the top cover.

Assembly

1. Route the ribbon cable connector from
the front to the inside of the top cover.

1. Insert the connector into its location J6
on the main PCBA.

2. Align the sensor and sensor door so that
the ribbon cable leads to the left, then
snap them into the top cover.

3. Feed the ribbon cable along its path and insert it into the notches to secure it. You may use
tape or hot glue if necessary.

Assemble the Printer

1. Follow the assembly steps of the Media Frame Replacement procedure (980357-207).

2. Reload media and ribbon. Plug in the power cord, turn on the printer and run the AutoSense
routine to get a dump mode printout. Run the printer in dispense mode to test the sensor.

980357-001 Rev. A 25

MOVIE

MOVIE

Feed Button/LED Replacement 980357-209A

Preparations

Follow the removal steps of the Media Frame Replacement procedure (980357-207).

Removal

1. Use a slot-head screwdriver to pry the
button cover 1 from the left support

!.

2. Lift the button 2 off the assembly.

3. Detach the ribbon cable from the
notches beneath the frame.

4. Lift the feed switch PCBA 3 out of the
recessed supports.

5. Pull the feed switch PCBA free of the
assembly.

Assembly

1. Insert the connector 4 and ribbon cable through the left support from above to below the
assembly.

2. Align the feed switch PCBA so that the LED is to the front of the assembly; then, insert the
board into its recessed supports.

3. Align the button so that the rounded end is to the front of the assembly; then, lower the button
onto the board.

4. Align the button cover so it fits over the button and LED; then, snap the cover onto the left
support.

5. Feed the ribbon cable along its path and insert it into the notches to secure it.

Assemble the Printer

Follow the assembly steps of the Media Frame Replacement procedure (980357-207).

26 980357-001 Rev. A

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Ribbon Out Sensor Replacement 980357-210A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

1. Open the cover, then remove media
and ribbon from the printer.

2. Follow the removal steps of
the Media Frame Replacement
procedure (980357-207).

3. Follow the removal steps of the
Print Head Replacement pro­cedure (980357-290).

Removal

1. Use a #0 Phillips driver to remove the
screw 1 that holds the sensor 2 to the
cross brace

!.

2. Detach the carriage

" by flexing the

joints.

3. Use a #0 Phillips driver to remove the
two screws 34 that hold the wire plate

# to the carriage.

4. Detach the cable 5 connector from
location J4 on the main PCBA. Unwind
the ribbon cable from the print head
wires. Then, pull the sensor, cable and
connector free of the carriage.

980357-001 Rev. A 27

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Ribbon Out Sensor Replacement (continued) 980357-210A

Installation

1. Insert the connector through the carriage from the top to the bottom. Route the ribbon cable
around the print head wires. Then, plug the connector into location J4 on the main PCBA.

2. Align the wire plate into place and use a #0 Phillips driver to tighten the two screws that
secure it to the bottom of the cross brace.

3. Align the sensor into position and use a #0 Phillips driver to tighten the screw that secures it to
the top of the cross brace.

4. Attach the carriage by snapping the joints back into place

5. Replace the ribbon detent springs at the rear of the printing mechanism.

Assembling the Printer

1. Follow the installation steps of the Print Head Replacement procedure (980357-290).

2. Follow the removal steps of the Media Frame Replacement procedure (980357-207).

3. Reload media and ribbon. Plug in the power cord, turn on the printer and run the AutoSense
routine to get a dump mode printout.

28 980357-001 Rev. A

Battery Replacement 980357-211A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

All information in the printer's memory will be lost if the battery is removed.

The battery keeps printer memory active if power is switched off or disconnected. When the battery
is exhausted, the printer will print "LOST INTERNAL INFO."

1. Find your back up of fonts, forms and graphics you previously downloaded to the printer.

2. Follow the removal steps of the Media Frame Replacement procedure (980357-207).

Removal

1. Slip the battery 1 out from its holder.

2. Dispose of the battery according to the
manufacturer's instructions.

Assembly

Slide the battery under the print clip.

Assemble the Printer

1. Perform the installation steps of the
Media Frame Replacement procedure
(980357-207).

2. Check the installation. Turn on the
printer and run the AutoSense routine
to get a dump mode printout. This
action tests the printer's media drive
and printing capabilities

If a "LOST INTERNAL INFO" label prints, switch the power off and back on.

There is danger of explosion if the battery is incorrectly replaced. Replace
batteries with 3 Volt lithium cell only. Discard used batteries according to the
instructions supplied bythe batterymanufacturer. Do not dispose of the battery
in fire. The battery may explode causing damage or injury.

980357-001 Rev. A 29

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Print Mechanism Replacement 980357-212A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

Detaching the Mechanism

1. Detach the front bezel. Press outward
on both sides (in front of the cover
latches) until the bezel can fall forward.
If this is a cutter bezel, detach its ribbon
cable where it connects to main PCBA
at J11.

2. Use a #1 Phillips driver to remove the
screws that secure the mechanism to the
stand offs 1234 in the bottom case.
The wide printer has four screws and
the narrow printer has three screws.

With the mechanism loose but still attached,
you can do a variety of other procedures.

For example, you can simply tilt the
mechanism to work on the latches, carriage
hooks, or (if necessary) the platen and roller.

30 980357-001 Rev. A

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Print Mechanism Replacement (continued) 980357-212A

Removing the Mechanism

1. Follow the removal steps of the Media Frame Replacement procedure (980357-207).

2. Use a #1 Phillips driver to remove the screw that secures the ground wire to the main PCBA.

3. Make note of the locations and routing of the bundles and cables. Then, detach wire bundles
and ribbon cables from the following locations on the main PCBA:

PCBA Bundle/Cable

Location Connects to

J2 Print head (Rohm™)
J3 Print head (Kyocera™)
J8 Platen driver motor
J7 Transmissive gap sensor (top)
J9 Transmissive gap sensor (bottom)

J4 Ribbon out sensor
J10 Black line sensor (if present)
J12 Head-up sensor (if present)

3. Lift the mechanism up and away from the bottom case.

Assembly

1. Attach the wire bundles and ribbon cables.

2. Align the mechanism over the mounting stand-offs and lower into the bottom case

3. Install the screws that secure the mechanism and use a #1 Phillips driver to tighten them.

4. Attach the front bezel. If it is a cutter bezel, attach its ribbon cable to connector J11.

Assembling the Printer

1. Follow the assembly steps of the Media Frame Replacement procedure (98nnnn-110).

2. Check the installation. Turn on the printer and run the AutoSense routine to get a dump
mode printout. This action tests the printer's media drive and printing capabilities.

980357-001 Rev. A 31

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Transmissive Gap Sensor Replacement 980357-213A

The sensor has two parts: one above and one below the media path.

Preparations

1. Do the removal steps of the Media FrameReplacement procedure (980357-207).

2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212).

Removal of Top Sensor

1. Detach the
carriage by
flexingthe joints.

2. Use a #0 Phillips driver to remove the
screw 1 that holds the sensor 2 to the top
of the cross brace

!.

3. Pull the ribbon cable from its guide posts.

4. Carefully pull the connector through the left
side frame.

Assembly of Top Sensor

1. Align the sensor so the ribbon cable leads
to the left.

2. Replace the screw that holds the sensor to
the cross brace and use a #0 Phillips driver
to tighten it.

3. Carefully insert the connector through the
left side frame and pull the ribbon cable taut.

4. Insert the ribbon cable into its guide posts.

32 980357-001 Rev. A

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Transmissive (Gap) Sensor Replacement (continued) 980357-213A

Removal of Bottom Sensor

1. Use a #0 Phillips driver to remove the
screw 3 that holds the sensor 4 to the
bottom of the cross brace

".

2. Pull the ribbon cable from its guide
posts.

Assembly of Bottom Sensor

1. Align the sensor so the ribbon cable
leads to the left.

2. Replace the screw that holds the sensor
to the cross brace and use a #0 Phillips
driver to tighten it.

3. Insert the ribbon cable into its guide
posts.

Assemble the Printer

1. Attach the carriage to the bottom frame by snapping the joints into place.

2. Replace the ribbon detent springs at the rear of the printing mechanism

3. Follow the assembly steps of the Print Mechanism Replacement procedure (980357-212).

4. Follow the assembly steps of the Media Frame Replacement procedure (980357-207).

5. Check the installation. Turn on the printer and run the AutoSense routine to get a dump
mode printout. This action tests the printer's media drive and printing capabilities.

980357-001 Rev. A 33

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Black Line Sensor Replacement 980357-214A

Preparations

1. Do the removal steps of the Label FrameReplacement procedure (980357-207).

2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212).

Removal

Flex the retainer backward to release the
sensor from its place.

Assembly

1. Align the sensor 1 so that the wire
bundle leads to the rear of the
mechanism.

2. Press the sensor into the forward
retainers.

3. Press the sensor into the rear retainer
until it snaps into place

!.

Assembling the Printer

1. Follow the assembly steps of the Print Mechanism Replacement procedure (980357-212).

2. Follow the assembly steps of the Media Frame Replacement procedure (980357-207).

3. Check the installation. Turn on the printer and run the AutoSense routine to get a dump
mode printout. This action tests the printer's media drive and printing capabilities.

34 980357-001 Rev. A

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Upgrades to Memory and Real Time Clock Option 980357-215A

These procedures outline the steps to access and replace SRAM memory, IE flash program memory,
and the real-time clock option.

Preparations

1. Make sure you have a back up any fonts, forms and graphics you downloaded to the printer.

2. Follow the removal steps of the Media Frame Replacement procedure (980357-207).

Replacing the Integrated Circuit Chips

Protect against static discharge when following this procedure. Your work area
must be static-safe and include a properly grounded conductive cushioned mat
to hold the printer and a conductive wrist strap for yourself.

Push the wire bundles aside to see the main printed circuit board assembly in the bottom case.

To replace a chip, use the following procedure:

1. Use chip pliers to pull the chip out of its
socket on the main PCBA.

2. Carefully align each chip and insert it
into the main PCBA. Check that all pins
are in their holes.

! Flash/Firmware 1MB Upgrade -- U18 and

U4. IE Flash stores pre-designed elements
(fonts, forms and graphics) that go into a print
job plus some operation code for the printer.

" SRAM 512KB Upgrade -- U15 and U6.

SRAM provides image buffer for the printer.
A larger SRAM capacity allows for larger
images.

# Real Time Clock Option -- U22. The real

time clock option stores the time of day and
date. The chip's battery has a life of up to ten
years. See the EPL2 Programmer's Manual
for information about setting the real time
clock, and formatting the layout of the date
and time.

980357-001 Rev. A 35

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Upgrades to Memory and Real Time Clock Option - Continued 980357-215A

Assembling the Printer

Follow the assembly steps of the Media Frame Replacement procedure (980357-207).

Checking the Installation

If you replaced the IE flash and the version number on the dump mode printout is wrong, download
current firmware to the printer. Also, you will need to reload your specific fonts, forms or graphics
before you start any new print jobs.

36 980357-001 Rev. A

8” UKQ1775 V3.20
Serial port : 96,N,8,1

Image buffer size:0507K
Fmem:000.5K,060.9K avl
Gmem:024K,0045K avl
E
I8,0,001 rN
S4 D10 R064,000 ZT UN
q1600 Q1209,026
Option:
17 21 25

Date: 07-19-99
Time: 12:44:00

now in DUMP

mem:000K,0045K avl

Turn on the printer and run your printer's
AutoSense routine to get a dump mode
printout. This action tests the printer's
media drive and printing capabilities.

You can also check the printout for the upgrade
or option you loaded.

! Firmware version number
" Memory (available bytes)
# Real time clock option (if installed)

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Main Printed Circuit Board Assembly (PCBA) Replacement 980357-216A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

1. Do the removal steps of the Media FrameReplacement procedure (980357-207).

2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212).

Removal

1. Use a #1 Phillips to remove the screws
that secure the PCBA to the bottom
case. The wide printer has five screws
and the narrow printer has four screws.

2. Lift the metal bracket (with the interface
ports) to release the metal bracket; then,
work the board out of the bottom case.

Assembly

1. Lower the PCBA into place and insert
the rear metal bracket (with the interface
ports) into its slot on the bottom case.

2. Install the screws that secure the PCBA
to the bottom case and use a #1 Phillips
driver to tighten them.

980357-001 Rev. A 37

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Main Printed Circuit Board Assembly (PCBA) Replacement 980357-216A

Assembling the Printer

1. Perform the assembly steps of the Print
Mechanism Replacement procedure
(980357-212).

2. Perform the assembly steps of the
Media Frame Replacement procedure
(980357-207).

3. Check the installation. Turn on the
printer and run the AutoSense routine
to get a dump mode printout. This
action tests the printer's media drive and
printing capabilities.

38 980357-001 Rev. A

Platen Motor Replacement 980357-217A

Preparations

1. Do the removal steps of the Media FrameReplacement procedure (980357-207).

2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212).

Removal

Use a #1 Phillips driver to remove the two
screws 34 that secure the motor shield 2
and platen motor 1 to the left side frame

!.

Assembly

1. Align the motor and shield together so
that the wire bundle leads off to the rear
of the mechanism and place against the
left side frame.

2. Replace the two screws that hold the
motor and shield in place and use a #1
Phillips driver to tighten them.

Assembling the Printer

1. Follow the assembly steps of the Printer
Mechanism Replacement procedure

(980357-212).

2. Follow the assembly steps of the Media
Frame Replacement procedure
(980357-207).

3. Check the installation. Turn on the
printer and run the AutoSense routine
to get a dump mode printout. This
action tests the printer's media drive and
printing capabilities.

980357-001 Rev. A 39

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Latch, Left Replacement 980357-218A

Preparations

1. Do the removal steps of the Media FrameReplacement procedure (980357-207).

2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212).

Removal

1. Use pliers to pull the return spring ! out of its slot.

2. Use retainer pliers to release the retaining ring 1 that holds the latch 2 to the label stripper
shaft

".

3. Pull the latch off of the shaft.

40 980357-001 Rev. A

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Latch, Left Replacement 980357-218A

Assembly

1. Turn the shaft " so that the flat of the end faces upward.

2. Align the latch 3 so that the flat side of its mounting bearing matches the flat side of the shaft;
then, press the latch onto the shaft.

3. The latch aligns with a stripper cam

# that can be found between the side frame $ and

roller

%.

4. Use retainer pliers to place a new retaining ring 2 onto the shaft to secure the latch.

5. Use pliers to push the return spring

! into its slot.

6. Ensure the stripper spring

& is correctly mounted.

Assembling the Printer

1. Follow the assembly steps of the Printer Mechanism Replacement procedure (980357-212).

2. Follow the assembly steps of the Media Frame Replacement procedure (980357-207).

3. Check the installation. Turn on the printer and run the AutoSense routine to get a dump
mode printout. This action tests the printer's media drive and printing capabilities.

980357-001 Rev. A 41

Latch, Right Replacement 980357-219A

Preparations

1. Do the removal steps of the Media Frame Replacement procedure (980357-207).

2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212).

3. Do the removal steps of the Platen Motor Replacement procedure (980357-217).

Removal

1. Use retainer pliers to remove the ring retainer ! from the platen gear "; then, pull the gear
off of the shaft.

3. Use pliers to pull the return spring

# out of its slot.

4. Use retainer pliers to remove the ring retainer 1 from the label stripper shaft

$; then, pull the

latch 2 off of the shaft.

42 980357-001 Rev. A

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Latch, Right Replacement 980357-219A

Assembly

1. Turn the shaft $ so that the flat of the end faces upward.

2. Align the latch 2 so that the flat side of its mounting bearing matches the flat side of the shaft;
then, press the latch onto the shaft.

3. The latch aligns with a stripper cam

% that can be found between the side frame & and

roller

'.

4. Use retainer pliers to place a new retaining ring 1 onto the shaft to secure the latch.

5. Use pliers to push the return spring

# into its slot.

6. Ensure the stripper spring

( is correctly mounted.

7. Press the platen gear

" onto the platen shaft ).

8. Use retainer pliers to attach a new ring retainer

! to secure the platen gear.

Assembling the Printer

1. Follow the assembly steps of the Platen Motor Replacement procedure (980357-217).

2. Follow the assembly steps of the Print Mechanism Replacement procedure (980357-212).

3. Follow the assembly steps of the Media Frame Replacement procedure (980357-207).

4. Check the installation. Turn on the printer and run the AutoSense routine to get a dump
mode printout. This action tests the printer's media drive and printing capabilities.

980357-001 Rev. A 43

Platen Parts 980357-220A

The platen is not a field replaceable item.

Accessing the platen would require you to first follow the removal steps of the Media Frame
Replacement, the Print Mechanism Replacement, and the Platen Motor Replacement procedures.
Then, on the right side of the mechanism, use retainer pliers to remove the ring retainer

! from the

platen gear

". Pull the platen gear off of the shaft. On the left side of the mechanism, use retainer

pliers to remove the ring retainer

# from the platen bearing $. Pull both bearings $% out of

the side frames. Slide the platen

& to the side and lift away from the mechanism.

To assemble the platen, first slide the platen into place, long end first through the right side frame.
Then, place a platen bearing on each end of the platen shaft. Insert each platen bearing into the
keyed hole on its side frame. Align the platen gear to fit over the flat edge on the right side of the
platen; then, press onto the shaft. Use retainer pliers to installing a retaining ring on each end of the
shaft. Align the platen gear so that the flat side of its mounting bearing matches the flat side of the
platen shaft; then, press the gear onto the shaft. Use retainer pliers to place a new retaining ring
onto the platen shaft to secure the gear. To complete the process, follow the assembly steps of the
Platen Motor Replacement, the Print Mechanism Replacement, and the Media Frame Replacement
procedures. Afterward, check the installation. Turn on the printer and run the AutoSense routine to
get a dump mode printout. This action tests the printer's media drive and printing capabilities.

44 980357-001 Rev. A

Print Head Replacement 980357-290A

Preparations

Protect against static discharge. Your work area mustbe static-safe and include
a properly grounded conductive cushioned mat to hold the printer and a
conductive wrist strap for yourself.

While the two print heads from different manufacturers are functionally
equivalent, each requires its own cable. See the Swapping the Cables
procedure at the end of this procedure.

Open the cover, and remove any media and ribbon (if necessary).

Removal

1. Pull the release lever ! to unlatch the carriage; then, open the carriage " to its raised
position.

2. Use a #1 Phillips driver to remove the screw 1 that holds the print head 2 to the carriage.

3. Detach the print head from the wire bundle and pull the print head away from the printer.

Assembly

1. Align the print head 2 so that the wire
connector is on top and facing the rear
of the printer.

2. Plug the print head into the wire
bundle. Take care not to bend any of
the wires.

3. Replace the center screw 1 that holds
the print head. Use a Phillips #1 driver
to tighten it. Tighten to 2.5 ± in lb
torque.

4. Clean the print head.

Check the Installation

Reload media and ribbon, if necessary.

Plug in the power cord, turn on the printer
and run the AutoSense routine to get a dump
mode printout. This action tests the printer's
media drive and printing capabilities.

980357-001 Rev. A 45

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Print Head Replacement 980357-290A

Swapping the Cables

1. Follow the removal
steps of the Media

Frame Replacement

procedure (980357-207)

2. Detach the top
carriage

# from

the bottom frame

$.

3. Use a #0 Phillips driver to remove the
two screws 34 that hold the wire plate
5 to the carriage.

4. Detach the cable connector 6 from its
location on the main PCBA. Unwind
the ribbon cable from the print head
wires. Then, pull the print head cable
free of the carriage.

5. Attach the new cable connector to its location on the main PCBA. Wind the ribbon cable and
the print head wires.

Connector PCBA Location Bundle/Cable Connects to

White, in-line J2 Print head (Rohm™)

Black, dual-line J3 Print head (Kyocera™)

6. Attach the new cable connector to its location on the main PCBA. Wind the ribbon cable and
the print head wires.

7. Align the wire plate into place and use a #0 Phillips driver to tighten the two screws that
secure it to the bottom of the cross brace.

8. Attach the carriage by snapping the joints back into place

9. Replace the ribbon detent springs at the rear of the printing mechanism.

Assembling the Printer

1. Do the installation steps of the Print Head Replacement procedure (980357-290).

2. Do the installation steps of the Media Frame Replacement procedure (980357-207).

3. Reload media and ribbon. Plug in the power cord, turn on the printer and run the AutoSense
routine to get a dump mode printout.

46 980357-001 Rev. A

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980357-001 Rev. A 47

980357- 001 A

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