Desktop
402
2443
2824
2844
3842
3844
Thermal Printers
Service Manual
980358-001 Rev. B
©2003 Zebra Technologies Corporation
FOREWARD
This manual provides spares replacement and service information for the 402, 2443, 2842, 2844,
3824, and 3844 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: +1 (805) 579-1800
repair@zebra.com
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: +33 (0) 240 097 070
Phone: +44 (0) 1494 472872 FAX: +33 (0) 240 834 745
FAX: +44 (0) 1494 450103
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.
980358-001 Rev. B iii
TRADEMARKS
The following desktop label and receipt bar code printers are service marks of Zebra Technologies
Corporation. The printers are designated by:
MAXIMUM PRINT WIDTH
RESOLUTION THERMAL
Two-Inch Four-Inch
LP 2844™
200 dots per
inch
Direct
Direct and
Transfer
(Ribbon)
LP 2824™
TLP 2824™ TLP 2844™
LP 2844-Z™
LP 2443™ Orion®
DA402™
TLP 2844-Z™
300 dots per
inch
Direct and
Transfer
(Ribbon)
TLP 3842™
TLP 3844-Z™
Windows and MS-DOS are registered trademarks of Microsoft Corp. All other marks are trademarks
or registered trademarks of their respective holders.
iv 980358-001 Rev. B
OPERATOR CAUTIONS AND WARNINGS
These pages de scribe gen eral safety and main te nance procedures that an operator must follow.
They are ref er enced through out the service man ual. The man ual may in clude other warn ings and
cau tions not dis played here.
Warning - Shock Hazard
The printer should never be op er ated in a lo ca tion where it can get wet.
Per sonal in jury could re sult.
Warning - Static Discharge
The dis charge of elec tro static en ergy that ac cu mu lates on the sur face of
the hu man body or other sur faces can dam age or de stroy the print head or
elec tronic com po nents used in this de vice. TAKE ANTI-STATIC
PRECAUTIONS before handling the print head or the elec tronic
com po nents un der the print head as sem bly.
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.
Media Cautions & Tips
1) Always use high quality approved labels and tags. Approved supplies
can be ordered from your dealer.
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.
980358-001 Rev. B v
Media Reload Tip
Print Quality 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 den sity (darkness) is af fected by the heat energy (density setting)
applied and by the print speed. Chang ing both Print Speed and Den sity
may be re quired to achieve the de sired re sults.
vi 980358-001 Rev. B
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
Print Head Considerations .................................7
Media Path Considerations .................................7
Cleaning Card Considerations ...............................8
Platen Considerations ...................................8
Lubrication .........................................8
Before Loading Media ...................................9
TROUBLESHOOTING GUIDE 11
Print Head Wear .....................................14
REQUIRED TOOLS 15
PARTS FOR WIDE PRINTERS 17
Latch Replacement - LP..................................19
Top Cover Replacement - LP ...............................20
Print Head Replacement - LP ...............................22
Packing Materials Replacement ..............................24
Feet Replacement ....................................25
Front Bezel Replacement .................................26
Front/Cutter Bezel Replacement ..............................27
Platen Replacement ....................................28
Bottom Case (Base Housing) Replacement ........................29
Motor Replacement ....................................30
Black Line and Bottom Gap Sensors Replacement ....................31
Head-Up Sensor Replacement ..............................32
Main Print Circuit Board Assembly Replacement .....................33
Dispenser Bezel Replacement ...............................34
Latch Replacement - TLP .................................35
Cover Support Replacement - TLP ............................36
Hinge Replacement - TLP ................................37
Upper Case (Top Cover) Replacement - TLP ......................38
Ribbon Carriage Replacement - TLP ...........................39
Feed Button/LED and Top Gap Sensor Replacement - TLP ...............40
Ribbon Motion Sensor Replacement - TLP ........................42
980358-001 Rev. B vii
Real Time Clock Option..................................43
Print Head Replacement - TLP ..............................44
PARTS FOR NARROW PRINTERS 47
Feet Replacement .....................................49
Front Bezel Replacement .................................50
Front/Cutter Bezel Replacement ..............................51
Platen Replacement ....................................52
Bottom Case (Lower Cover) Replacement ........................53
Motor Replacement ....................................55
Black Line and Bottom Gap Sensors Replacement ....................56
Head-Up Sensor Replacement ..............................57
Main Printed Circuit Board Assembly (PCBA) Replacement................58
Dispenser Bezel Replacement ...............................60
Latch Replacement ....................................61
Upper Case (Top Cover) Replacement ..........................62
Feed/Gap Sensor Cable Assembly Replacement .....................63
Feed/LED PCBA Replacement ..............................64
Real Time Clock Option..................................65
Print Head Replacement - LP ...............................66
Latch Replacement - TLP .................................67
Cover Support Replacement - TLP ............................69
Hinge Replacement - TLP ................................71
Upper Case (Top Cover) Replacement - TLP ......................73
Ribbon Carriage Replacement - TLP ...........................75
Feed Button/LED and Top Gap Sensor Replacement - TLP ...............77
Ribbon Motion Sensor Replacement - TLP ........................79
Print Head Replacement - TLP ..............................81
CABLE ROUTING 83
Cable Routing for TLP Wide Printers ...........................84
Cable Routing for LP Wide Printers ............................85
Cable Routing for LP Narrow Printers ...........................86
Cable Routing for TLP Narrow Printers ..........................87
viii 980358-001 Rev. B
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 products technical support group at Zebra
Technologies Corporation, (805) 579-1800.
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.
980358-001 Rev. B 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. The top case is flat.
TLP models print using either direct thermal or
thermal transfer media. The top case flares at
the front to enclose the carriage and ribbon
spool hubs.
There are models that can handle up to
four-inch (102 mm) wide media and those that
can handle up to two-inch (51 mm) wide
media.
All printers also have optional 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 980358-001 Rev. B
Conventions
MOVIE
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.
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 at (800) 328-1368
980358-001 Rev. B 3
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 980358-001 Rev. B
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 with water.
Do not use abrasive cleaners as they will damage the surfaces.
Shock Hazard - See page iv. Always turn off the printer before cleaning.
980358-001 Rev. B 5
Cleaning the Media Path
When you clean the printer, use one or more of the following supplies that best suits your needs:
DESCRIPTION SPARE NUMBER
Cleaning pens (12) 105950-035
Cleaning swabs (25) 105909-057
Cleaning cards, 4-in wide (25) 105950-034
Save-a-Print Head film, 4-in wide (3) 105950-047
The cleaning process takes just a couple of minutes using the steps outlined below.
Printer
Part
Method Interval
Print head Let the print head to cool for one minute, then use a new
cleaning pen to swab the print elements (the thin gray line
on the print head) from end to end. NOTE: You do not
have to turn off the printer to do this.
If print quality remains poor after cleaning, try the
Save-a-Print Head cleaning film to remove buildup without
damaging the print head. Call your authorized reseller for
more information.
Platen roller Manually rotate the platen roller. Clean it thoroughly with
70% isopropyl alcohol and a cleaning swab, cleaning card,
or lint-free cloth.
Peel bar Clean it thoroughly with 70% isopropyl alcohol and a cotton
swab.
Tear bar Clean it thoroughly with 70% isopropyl alcohol and a
cotton swab.
As necessary or
after every five
rolls of media
As needed
Exterior Water-dampened cloth
Interior Brush or air blow
Cutter Use tweezers to remove scraps
6 980358-001 Rev. B
Adhesives and coatings of media can over time transfer onto the printer components along the
MOVIE
media path including the platen and print head. This build-up can accumulate dust and debris.
Failure to clean the print head, media path and platen roller could result in inadvertent loss of labels,
label jams and possible damage to the printer.
Print Head Considerations
When handled during installation, and over time, the print head may become contaminated
resulting in poor print quality. After installing a new print head or after using a roll 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.
Always use a new cleaning pen on the print head (an old pen carries contaminants
from its previous uses that may damage the print head).
Avoid touching the print head whenever possible. To remove dirt or dust,
always gently clean the print head with a cleaning pen or a cotton swab
moistened with 70% isopropyl alcohol.
Media Path Considerations
Use a cleaning swab or pen to remove debris, dust or crust that has built-up on the holders, guides
and media path surfaces.
1. Use the alcohol in the cleaning swab or pen to soak the debris so that it breaks up.
2. Wipe the area with the cleaning swab or pen to remove the debris.
3. Discard the cleaning swab or pen after use.
980358-001 Rev. B 7
Cleaning Card Considerations
Use a cleaning card to remove debris that has built-up on the platen. Avoid scrubbing or vigorously
rubbing the platen; otherwise, the surface could be damaged.
1. Open the printer and remove labels.
2. Place the cleaning card into the label path so that it is under the guides and it extends between
the print head and platen roller.
3. Close and latch the printer.
4. With the power switch on, press the feed switch to move the cleaning card through the printer.
5. Discard the card after use.
Platen Considerations
The standard platen (drive roller) normally does not require cleaning. Paper and liner dust can
accumulate without effecting print operations. Contaminates on the platen roller can damage the
print head or cause the media to slip when printing. Adhesive, dirt, general dust, oils and other
contaminates should be cleaned immediately off the platen.
However, the non-stick platen roller on linerless media printers requires frequent cleaning to keep
adhesive buildup from occurring and transferring to the print head and the media path. Keep a new
platen available as a spare and install it whenever the printer has significantly poorer performance,
print quality or media handling. If sticking or jamming continues even after cleaning, you must
replace the platen.
The platen can be cleaned with a fiber-free swab (such as a Texpad swab) or a lint free, clean, damp
cloth very lightly moistened with medical grade alcohol (70% pure or better).
1. Open the media door and remove the media.
2. Clean the platen surface with the alcohol moistened swab. Rotate the platen while swabbing.
Repeat this process two to three times with a new swab to remove residual contaminates.
Adhesives and oils, for example, may be thinned by the initial cleaning but not completely
removed.
3. Discard the cleaning swab or pen after use.
Allow the printer to dry for one minute before loading labels.
Lubrication
No lubricating agents of any kind should be used on this printer! Some commercially available
lubricants, if used, will damage the finish and the mechanical parts inside the printer.
8 980358-001 Rev. B
Before Loading Media
MOVIE
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 adhesives 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 occurrence damages the print head and is not covered under
the warranty. Using clean media prevents damage and reduces wear on the
print head and platen.
980358-001 Rev. B 9
10 980358-001 Rev. B
TROUBLESHOOTING GUIDE
PROBLEMS SOLUTIONS
Status indicator does
not light when power
switch is on (I)
Printer is in dump
mode but nothing
prints after sending
file.
ASCII characters print
in place of expected
label art and bar
codes.
Printing is uniformly
faded or poor quality.
1. Check power connections from the printer to the outlet.
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.
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.
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.
980358-001 Rev. B 11
PROBLEMS SOLUTIONS
1. Check the connections between the printer and the cable as well as
the cable and the computer.
Printer appears to be
working with the
indicator light
GREEN, but nothing
is printed.
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.
1. Perform the AutoSense adjustment.
2. Check that gap between labels is at least 1/16 inch (1.6mm)
Printing stops and
3. Check for media jam.
status indicator lights
red
4. Check that media is correctly routed.
5. Check printer memory configuration and correct data syntax.
6. Transmissive (gap) is dirty. Clean media path.
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.
Status indicator
remains red.
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
1. Media is not loaded and the platen is rubbing against the print head.
pressing Feed button.
Cutter makes
incomplete cuts or
1. Form length is set wrong. Change length through printer driver or
cuts in the wrong spot.
Short length,
perforated media are
difficult to load when
1. Media length must be a minimum of 0.5 inch (12.7mm).
preparing for
dispenser/peel mode.
12 980358-001 Rev. B
Insert media (and load ribbon if necessary) between carriage and
platen.
programming language. See the EPL2 programming manual.
PROBLEMS SOLUTIONS
The printer firmware is updated by way of the parallel port.
1. Use the download utility to send firmware to the printer.
Printer firmware must
be updated.
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.
980358-001 Rev. B 13
Print Head Wear
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)
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.
14 980358-001 Rev. B
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
• needle-nose pliers
• cutters
• pliers for integrated chips
980358-001 Rev. B 15
16 980358-001 Rev. B
PARTS FOR WIDE PRINTERS
This section includes procedures that are specific to the 4-inch-wide printers.
Both the LP and TLP models can print on direct thermal media. The TLP model can also print
using ribbons and thermal transfer media. Most models print at 200 dots per inch at up to four
inches per second; the 3842 model prints at 300 dots per inch at up to two inches per second.
980358-001 Rev. B 17
REPAIR PATHS
405
Base Housing
(Bottom)
409
Main
PCBA
214
Top
Cover
290
LP2844
Print Head
408
Head-Up
Sensor
211
LP Latch
(Top Cover)
407
Black Line
Sensor Assy
402
Front
Bezel
406
Platen
Motor
401
Rubber
Feet
410
Dispenser
Label-Taken
Clock Option
LP 2443 Orion™
LP 2844
LP 2844-Z
402
DA
404
Platen
418
Real-Time
403
Cutter
Option
405
Base Housing
(Bottom)
409
Main
PCBA
413
Hinge
412
Upper Cover
Support
490
TLP2844
Print Head
408
Head-Up
Sensor
Upper Case
Assembly
414
411
TLP Latch
(Top Cover)
407
Black Line
Sensor Assy
402
Front
Bezel
406
Platen
Motor
415
Ribbon
Carriage
416
Feed Button
Top Gap Snsr
401
Rubber
Feet
410
Dispenser
Label-Taken
417
Ribbon
Motion Snsr
TLP 2844
TLP 2844-Z
TLP 3842
TLP 3844-Z
R402
404
Platen
418
Real-Time
Clock Option
403
Cutter
Option
18 980358-001 Rev. B
Latch Replacement - LP 980358-211A
MOVIE
Protect against static discharge. 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.
Open the printer by pulling the release latches forward, then lifting the top cover. Remove media.
Removal
1. Use a #1 Phillips driver to loosen the four
screws 1234 that hold the latch frame !
to the top case ".
2. Detach the springs on both sides from
where they engage the latch frame #$.
3. Unsnap the latch shaft 5 from its bearings
in the frame.
Assembly
1. Make sure the springs are engaged on the
latch handles %&.
2. Align the latch assembly so that the hooks
face the rear. Snap the latch shaft into its
bearings on the frame.
3. Engage both springs into the top hole on the latch frame.
4. Align the latch frame up to the top case and
ensure that the cables are not bent or
pinched.
5. Replace the four screws that hold the latch
frame to the top case and use a #1 Phillips
driver to tighten them.
6. Clean the print head with the cleaning pen.
Assembling the Printer
Reload media. Plug in the power cord, turn on
the printer and run the AutoSense routine to get
a dump mode printout.
980358-001 Rev. B 19
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