Zebra 402, 2824, 2844, 3842, 3844 Service Manual

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: [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.

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, [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.

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 [phone]

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

Top Cover Replacement - LP 980358-214A

Preparation

Perform the removal steps of the Bottom Case (980358-105) and Main PCBA
(980358-409) replacement procedures.

MOVIE

Removal

1. Unwrap the ribbon cables and wire bundles
from the ferrite core.

2. Use a #1 Phillips to loosen the hinge
between top cover and bottom assembly.

3. Use a #1 Phillips to loosen the screws that

hold the latch frame

4. Use a #1 Phillips to loosen the screws that

hold the feed/LED PCBA

5. Detach the ribbon cable
feed/LED PCBA.

6. Pull the latch frame, feed/LED PCBA and
print head cables out of the cover.

% to the cover.

$ to the cover.

# from the

&

Assembly

1. Route the print head cables !" from the
latch frame through the cover 1. Refer to
the diagram in the Cable Routing section.

2. Attach the ribbon cable
PCBA.

3. Align the feed/LED PCBA
cover and tighten the two screws to hold it.

4. Align the latch frame
use a #1 Phillips to tighten the four screws
to hold it.

20 980358-001 Rev. B

# to the feed/LED

% in the cover and

$ in the top

Top Cover Replacement - LP 2844 (continued) 980358-214A

5. Route the left print head wires through the hinge & and the right print head wires and PCBA
ribbon cable through lower frame '.

6. Align the hinge in place and use a #1 Phillips to tighten the single screw that holds it.

Assembling the Printer

Perform the assembly steps of the Main PCBA (980358-409) and Bottom Case (980358-405)
replacement procedures.

980358-001 Rev. B 21

Print Head Replacement - LP 980358-290A

MOVIE

Preparations

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. Grasp the print head spring 7 and pull it to
the left; then, slide it free of the latch frame.

3. Gently pull the wire bundles #$ from the
print head 8.

4. Use a #1 Phillips driver to loosen the two
screws 56 and release the print head from

the latch frame ' and bracket &.

Assembly

1. Route the print head cables #$ under
latch shaft and plug into the receptacles

!" on the print head 8.

2. Hold the print head 8 against the print head
bracket & while replacing the screws 56
and washers; attach the ground wire %

using the right screw and washer. Use a #1
Phillips driver to tighten the screws.

3. Slip the left end of the print head spring 7
into the left side of the latch bracket ';

then slide the right end into the other side.
The angle of the "v" fits into the indent on
top of the print head bracket.

22 980358-001 Rev. B

Print Head, LP 2844 Replacement 980358-290A

4. Align the latch bracket up to the top case ( and ensure that the cables are not bent or pinched.

5. Replace the four screws that hold the latch bracket 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 23

Packing Materials Replacement 980358-400A

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

1 Foam set

2 Master carton all-in-one

3 Poly-bag

4 Ship kit (varies 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 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. While the printer has sturdy construction, mechanical damage
can certainly result from falls or rough handling.

24 980358-001 Rev. B

Feet Replacement 980358-401A

Preparations

Tilt the printer to access the bottom.

Removal

Pry the foot 1 off the base ! using a levering
tool if necessary.

Assembly

1. Peel the foot off of its backing.

2. Place the sticky adhesive (top of foot) into
its receptacle " on the bottom case.

25 980358-001 Rev. x1

Front Bezel Replacement 980358-402A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

Use a small slot-head screwdriver to pry either
side free and then lift the bezel away from the
printer.

Assembly

Align the tabs with the notches in the media exit
and snap the bezel into place.

26 980358-001 Rev. B

Front/Cutter Bezel Replacement 980358-403A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

1. Use a small slot-head screwdriver to pry
either side free and then lift the bezel away
from the printer.

2. Unplug the connector.

Assembly

1. Align the cutter so that the connector is to
the rear.

2. Plug the connectors together.

3. Align the tabs with the notches in the media
exit and snap the bezel into place.

980358-001 Rev. B 27

Platen Replacement 980358-404A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

1. Use the blade of a small slotted screw driver
to pry the peg ! free from its hole and

rotate the bearing forward a quarter turn.
Repeat on the other side ".

2. Pinch both tabs then lift the platen 1 free of
the printer.

Assembly

1. Align the platen so that its gear # is to the
left.

2. Pinch both tabs (pressing inward) and put
each bearing into its slot.

3. Rotate each tab backward until the peg
snaps into its hole.

Older 2443 printers have only one
tab ( ! ) securing the platen with a

bearing on the right.

28 980358-001 Rev. B

Bottom Case (Base Housing) Replacement 980358-405A

MOVIE

MOVIE

Removal

1. Tilt the printer so you can see the bottom.

2. Use a #1 Phillips driver to remove the three
screws that secure the bottom case to the
bottom frame.

3. Pull the bottom case off of the bottom
frame.

Assembly

1. Align the bottom case to the bottom frame.

2. Replace the three screws that hold the case
to the frame; then, use a #1 Phillips driver
to tighten them.

980358-001 Rev. B 29

Motor Replacement 980358-406A

Preparations

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.

Perform the removal steps of the Bottom Case Replacement procedure (980358-405).

Removal

1. Unplug the wire bundle ! from the motor

1 where it attaches to the main PCBA

" .

Note its location.

2. Use a #2 Phillips to remove the screws 2
3 that hold the motor to the left side frame
of the media frame.

Assembly

1. Align the motor so that its gear is to the left;
then, insert it through the left side frame of
the media frame.

2. Replace the two screws that hold the motor
to the side frame; then, use a #2 Phillips
driver to tighten them.

3. Twist the wires at least three times; then,
plug the wire bundle from the motor into its
connector on the main PCBA.

MOVIE

Assembling the Printer

Perform the assembly steps of the Bottom Case Replacement procedure (980358-405). 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.

30 980358-001 Rev. B

Black Line and Bottom Gap Sensors Replacement 980358-407A

MOVIE

MOVIE

Preparations

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.

Perform the removal steps of the Bottom Case Replacement procedure (980358-405).

Removal

1. Unplug the ribbon cable ! from the sensor
1 where it attaches to the main PCBA ".

Note its location.

2. Use a #1 Phillips to remove the screw 2
that holds the sensor to the bottom of the
media frame.

Assembly

1. Align the sensor in place it on the bottom of
the media frame.

2. Use a #1 Phillips driver to replace and
tighten the screw that holds the sensor to
the frame.

3. Plug the ribbon cable from the sensor into
its connector on the main PCBA.

Assembling the Printer

Perform the assembly steps of the Bottom Case Replacement procedure (980358-405). 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.

980358-001 Rev. B 31

Head-Up Sensor Replacement 980358-408A

Preparations

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.

Perform the removal steps of the Bottom Case Replacement procedure (980358-405).

Removal

MOVIE

1. Unplug the ribbon cable ! from the sensor

1 where it attaches to the main PCBA

".

Note its location.

2. Use a #1 Phillips to remove the screw 2
that holds the sensor to the bottom of the
media frame. Cut away any tie-wrap.

Assembly

1. Align the sensor so that its ribbon cable is to the left; then, place it one the bottom of the media
frame.

2. Replace the screw that holds the sensor to the frame; then, use a #1 Phillips driver to tighten it.

3. Plug the ribbon cable from the sensor into its connector on the main PCBA.

New head-up sensors include a ferrite-core and a tie-wrap and anchor to secure the ribbon cable to
the frame.

Assembling the Printer

Perform the assembly
steps of the Bottom Case
Replacement procedure
(980358-405). 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.

32 980358-001 Rev. B

Connector

Anchor

Ferrite

Core

Tie-Wrap

Head-Up

Sensor

Main PCBA

Motor

Media
Guide

Adjustment

Knob

Main Print Circuit Board Assembly Replacement 980358-409A

MOVIE

Preparation

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.

Check your work when connecting the print head cables—For 2844
models, the right bundle of wires plugs into the right connector (J17) and the left
bundle plugs into the left connector (J19) on the main PCBA. For 2443 models,
the right bundle plugs into J3 and the left bundle plugs into J2 on the main
PCBA. If connected wrong, permanent damage can result to the printer.

Perform the removal steps of the Bottom Case Replacement procedure (980358-405).

Removal

1. Use a #1 Phillips driver to remove the
screw 1 that secures the board 2 to the

lower frame !.

2. Unplug the wire bundles, ribbon cables and
ground wire from their connectors on the
board. Make note of their locations and
routes.

Assembly

1. Plug the wire bundles, ribbon cables and
ground wire into their connectors on the
board.

2. Align the protective separator " against
the bottom frame.

3. Align the board onto the standoffs #.

4. Replace the screw that hold the board to the front standoff and use a #1 Phillips driver to tighten
it.

Assembling the Printer

Perform the assembly steps of the Bottom Case Replacement procedure (980358-405). 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.

980358-001 Rev. B 33

Dispenser Bezel Replacement 980358-410A

Preparations

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.

Perform the removal steps of the Bottom Case Replacement procedure (980358-405).

Removal

1. Pry either side free and then lift the bezel 1
away from the dispenser bar 2 and bottom
frame assembly.

2. Note the location of the connector ! on
the main control board; then unplug it.

3. Pull the wires and connector through the
frame access ".

Replacing the Dispenser Switch PCB

Find the dispenser PCB 3. Slip the ribbon
cable out of the dispenser access # then snap

the PCB out of/into the dispenser bezel.

Assembly

1. Align the bezel so that the connector is to
the rear.

2. Thread the connector and wires through the
access.

3. Plug the connector into its location on the
main control board.

4. Align the tabs with the notches in the media
exit and snap the bezel into place.

Assembling the Printer

Perform the assembly steps of the Bottom Case Replacement procedure (980358-405). 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.

980381-001 Rev. B 34

Latch Replacement - TLP 980358-411A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

Unsnap the latch assembly 1 from both
bearings !" in the top case.

Assembly

1. Squeeze the latch handles #$ inward
and press into the top case.

2. Push the cross bar % into each bearing
until it snaps into place.

980358-001 Rev. B 35

Cover Support Replacement - TLP 980358-412A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

1. Use a #1 Phillips driver to remove the two
screws 2 3 holding the support 1 to the

top assembly !.

2. Lift the support away from the bottom
assembly ".

Assembly

1. Align the support so that the square brace
fits into the top assembly.

2. Insert the support into the bottom assembly.

3. Replace the two screws that hold the
support the top assembly and use a #1
Phillips driver to tighten them.

36 980358-001 Rev. B

Hinge Replacement - TLP 980358-413A

MOVIE

Preparation

Perform the removal steps of the Bottom Case
(980358-405) and Main PCBA (980358-409)
and Cover Support (980358-412) procedures.

Removal

1. Use a #1 Phillips driver to loosen and
remove the screw 1 that holds the hinge

lock 2 onto the bottom media frame !.

2. Slide the hinge off of the frame.

3. Slide the top cover assembly " and

bottom media frame apart.

Installation

1. Ensure the wires follow their correct routing.
On the side opposite the hinge, make sure

the cables go through the channel '.

2. Slide the top cover assembly and bottom
media frame together.

4. Align the hinge with the link tab # facing

right and insert into the top cover assembly.
Note: Make certain that the link tab

engages with the link $ inside the top case.

5. Fit the hinge onto the bottom media frame.

6. Replace the screw and use a #1 Phillips
driver to tighten it.

7. Ensure the hinge caps %& are inserted
properly.

Assembling the Printer

Perform the assembly steps of the Cover
Support (980358-412), Main PCBA

(980358-409) and Bottom Case (980358-405)
procedures.

980358-001 Rev. B 37

Upper Case (Top Cover) Replacement - TLP 980358-414A

MOVIE

Preparation

Perform the removal steps of these procedures: Bottom Case Replacement (980358-405),
Main PCBA Replacement (980358-409), and Hinge Replacement (980358-413).

Removal

1. Loosen the four screws 5 6 7 and 8 that
hold the upper frame 1 to the top case 2.

2. Lift the frame away from the window 3
and top case. Notice that the feed/LED

cable % leads to the button assembly
attached to the top case.

Assembly

1. Align the window so that the holes at the
rear engage on the pegs of the upper frame.
Refer to the diagram in the Cable Routing
section.

2. Check that the link 4 is in place across the
ribbon carriage and upper frame.

3. Lower the top case onto the window and
frame.

4. While holding the frame, window and top
case together, flip them over so that they
rest on the window.

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

Assembling the Printer

Perform the assembly steps of these procedures: Hinge Replacement (980358-413), Main PCBA
Replacement (980358-409), and Bottom Case Replacement (980358-405).

38 980358-001 Rev. B

Ribbon Carriage Replacement - TLP 980358-415A

MOVIE

Preparation

Perform the removal steps of these procedures: Bottom Case Replacement (980358-405), Main
PCBA Replacement (980358-409), Hinge Replacement (980358-413), and Upper Case
Replacement (980358-414).

Removal

1. Gently flex the left bearing ! to release the
left hinge 1 of the carriage.

2. Gently flex the right bearing " to release
the right hinge 2 of the carriage.

3. To free the carriage from the upper frame,
cut the rear tie wrap to free the wire
bundles and ribbon cables; then, pull them
free of the case and rear hinge of the upper
frame.

Assembly

1. Route the ribbon cables and wire bundles
along the right side of the upper frame;
then, secure them all with a tie wrap above
the cover support location. Refer to the
diagram in the Cable Routing section.

2. Snap both hinges into the bearings.

Assembling the Printer

Perform the assembly steps of these procedures: Upper Case Replacement (980358-414), Hinge
Replacement (980358-413), Main PCBA Replacement (980358-409), and Bottom Case
Replacement (980358-405).

980358-001 Rev. B 39

Feed Button/LED and Top Gap Sensor Replacement - TLP 980358-416A

MOVIE

Preparation

The feed button LED PCB and the top gap (receive) sensor are one assembly. To access
them, perform the removal steps of these procedures: Bottom Case Replacement
(980358-405), Main PCBA Replacement (980358-409), Hinge Replacement (980358-413),

Upper Case Replacement (980358-414), and Ribbon Carriage Replacement (980358-415).

Removal

1. In the top cover !, use a #1 Phillips driver
to remove the two screws "# that hold

the PCB 1, and button 2.

2. On the upper frame $, use a #0 Phillips
driver to remove the screw % that holds
the metal brace & and upper gap sensor 4

in place.

3. Lift the opaque button and clear lens away
from the top cover.

Assembly

1. With the top cover upside-down, insert the
both button into place.

2. Align the feed button/LED PCBA so that
the ribbon cable faces the closest sidewall.

3. Replace the two screws that hold the LED
PCBA and use a #1 Phillips driver to
tighten them.

4. Align the top gap sensor so that the ribbon
cable goes to the right of the upper frame.

5. Align the metal brace that holds the upper
gap sensor.

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

7. Route the sensor's wires through their guides. Refer to the diagram in the Cable Routing section.

40 980358-001 Rev. B

Feed Button/LED and Top Gap Sensor Replacement (Continued) 980358-416A

Assembling the Printer

Perform the assembly steps of these procedures: Ribbon Carriage Replacement (980358-415),
Upper Case Replacement (980358-414), Hinge Replacement (980358-413), Main PCBA
Replacement (980358-409), and Bottom Case Replacement (980358-405).

980358-001 Rev. B 41

Ribbon Motion Sensor Replacement - TLP 980358-417A

MOVIE

Preparation

Perform the removal steps of these procedures: Bottom Case Replacement (980358-405), Main
PCBA Replacement (980358-409), Hinge Replacement (980358-413), Upper Case Replacement
(980358-414), and Ribbon Carriage Replacement (980358-415).

Removal

1. On the ribbon carriage, cut the tie wrap !
that holds the wire bundles and ribbon
cables to the right side frame.

2. Use a #1 Phillips driver to loosen the screw

" that holds the sensor 1 to the outside of

the left side frame.

3. Pull the sensor away from the carriage and
pull the wires through both side frames.

Assembly

1. Insert the connector through the outside of
the left side frame.

2. Insert the connector through the inside of
the right side frame.

3. Pull the wires through, and route them through their guides.

4. Align the sensor so that the wires go to the rear of the carriage.

5. Replace the screw that holds the sensor to the left side frame and use a #1 Phillips driver to
tighten it.

6. Secure the wire bundles and ribbon cables against the carriage with a tie wrap inserted through
the right side frame.

Assembling the Printer

Perform the assembly steps of these procedures: Ribbon Carriage Replacement (980358-415),
Upper Case Replacement (980358-414), Hinge Replacement (980358-413), Main PCBA
Replacement (980358-409), and Bottom Case Replacement (980358-405).

42 980358-001 Rev. B

Real Time Clock Option 980358-418A

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

MOVIE

Preparations

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.

Perform the removal steps of the Bottom Case
(980358-405) and Main PCBA (980358-409)
replacement procedures.

Installation

The socket for the real-time clock option is
designated as U15 on 2443 printers, U24 on
both TLP and LP2844 printers.

1. Align the real time clock chip above its
location on the main PCBA 1. Make sure
the notched end of the chip is oriented
correctly to the outline on the board.

2. Lower the real time clock chip into place taking care not to bend any of the pins.

Assembling the Printer

Perform the assembly steps of the Main PCBA (980358-409) and Bottom Case (980358-405)
replacement procedures.

Checking the Installation

Turn on the printer and run your printer's AutoSense rou tine to get a dump mode
print out. This ac tion tests the printer's
me dia drive and print ing ca pa bil i ties.

You can also check the print out.

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

980358-001 Rev. B 43

Print Head Replacement - TLP 980358-490A

MOVIE

Preparations

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
any ribbon from the carriage.

Removal

1. Grasp the print head spring 4 and pull it to
the left; then, slide it free of the carriage.

2. Use the spring to pry the print head clip 3
off the right side of the carriage.

3. Pull the print head and bracket 1 forward.

4. Use a #2 Phillips driver to remove the
screw 2 that holds the ground wire.

5. Unplug both bundles #$ of print head
wires from the left and right connectors.

Assembly

1. Align the print head and bracket 1 to plug
the left ! and right " connectors into the
black # and white $ wire bundles.

2. Attach the ground wire % and secure it
with the screw 2. Use a #2 Phillips driver
to tighten it.

3. Insert the bracket pegs & into the left side
of the carriage.

4. Align the right side of the bracket and insert
the print head clip 3 through the right side
of the ribbon carriage into the bracket.

44 980358-001 Rev. B

Print Head Replacement - TLP (continued) 980358-490A

5. Slip the left end of the print head spring 4 into the left side of the ribbon carriage; then slide the
right end into the other side. The angle of the "v" fits into the indent on top of the print head

bracket '.

6. Clean the print head with the cleaning pen.

Assembling the Printer

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

980358-001 Rev. B 45

46 980358-001 Rev. B

PARTS FOR NARROW PRINTERS

This section includes procedures that are specific to the 2-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. These models print at 200 dots per inch at up to four
inches per second.

980358-001 Rev. B 47

311

Latch

(Top Cover)

304

Platen

301

Rubber

Feet

303

Cutter

Option

316

Fd-Gap Snsr

Cable Assy

310

Dispenser

Label-Taken

307

Black Line

Sensor Assy

306

Platen
Motor

318

Real-Time

Clock Option

302

Front

Bezel

305

Base Housing

(Bottom)

309

Main

PCBA

317

Feed/LED

PCBA

LP 2824

REPAIR PATHS

390

LP 2824

Print Head

314

Cover (Top)

Housing

TLP 2824

511

TLP Latch

(Top Cover)

304

Platen

301

Rubber

Feet

308

Head-Up

Sensor

303

Cutter

Option

516

Feed Button

Top Gap Snsr

310

Dispenser

Label-Taken

307

Black Line

Sensor Assy

306

Platen
Motor

318

Real-Time

Clock Option

512

Upper Cover

Support

302

Front

Bezel

305

Base Housing

(Bottom)

309

Main

PCBA

513

Hinge

514

Upper Case

Assembly

515

Ribbon

Carriage

590

TLP 2824

Print Head

517

Ribbon

Motion Snsr

308

Head-Up

Sensor

48 980358-001 Rev. B

Feet Replacement 980358-301A

Preparations

Tilt the printer to access the bottom.

Removal

Pry the foot 1 off the base ! using a levering
tool if necessary.

Assembly

1. Peel the foot off of its backing.

2. Place the sticky adhesive (top of foot) into
its receptacle " on the bottom case.

49 980358-001 Rev. x1

Front Bezel Replacement 980358-302A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

Use a small slot-head screwdriver to pry either
side free and then lift the bezel 1 away from

the printer !.

Assembly

Align the tabs with the notches in the media exit
and snap the bezel into place.

50 980358-001 Rev. B

Front/Cutter Bezel Replacement 980358-303A

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

1. Pry either side free and then lift the bezel
away from the printer.

2. Unplug the connector.

Assembly

1. Align the cutter so that the connector is to
the rear.

2. Plug the connectors together.

3. Align the tabs with the notches in the media
exit and snap the bezel into place.

980358-001 Rev. B 51

Platen Replacement 980358-304A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

1. Use the blade of a small slotted screw driver
to pry the pegs !" free from their holes

and rotate the bearing forward a quarter
turn.

2. Lift the platen 1 free of the printer.

Assembly

1. Align the platen so that its gear # is to the
left.

2. Put each bearing into its slot.

3. Rotate the tabs backward until their pegs snap
into their holes.

52 980358-001 Rev. B

Bottom Case (Lower Cover) Replacement 980358-305A

MOVIE

Removal

1. Tilt the printer so you can see the bottom.

2. Use a #1 Phillips driver to remove the
screws that secure the bottom case to the
bottom frame.

3. Pull the bottom case off of the bottom
frame.

Assembly

1. Make sure that any rear-plate adapters are
in place.

2. Align the bottom case to the bottom frame.

3. Replace the screws that hold the case to the
frame; then, use a #1 Phillips driver to
tighten them.

980358-001 Rev. B 53

Older models of the LP 2824 use a spring and arm to activate the head-up sensor.

MOVIE

Preparations

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.

Removal

1. Carefully use a small slotted driver to pry
the interface cover off of the bottom case

2. Tilt the printer so you can see the bottom.

3. Use a #1 Phillips driver to remove the
three screws 123 that secure the bottom
case to the bottom frame.

4. Pull the bottom case off of the bottom
frame. Take care when moving the
interface connector past the rear access.

Assembly

1. Hold the printer upside down.

2. Place the head-up sensor plunger into its
notched hole on the lower frame.

3. Place the spring " onto the plunger !.

4. Tilt the printer so that the plunger and
spring lean into place on the main PCBA.
The flag on the plunger must fit into the
head-up sensor on the main PCBA.

5. Align the bottom case to the lower frame.
Carefully insert the interface connectors
through the rear access. Carefully insert the
plunger into the notched hole inside the
bottom case.

6. Hold the printer onto the bottom case. Check the action of the head-up sensor plunger.

7. Replace the three screws that hold the case to the frame; then, use a #1 Phillips driver to tighten
them.

8. Snap the interface cover # over the interface connectors.

54 980358-001 Rev. B

Motor Replacement 980358-306A

MOVIE

Preparations

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.

Perform the removal steps of the Bottom Case Replacement procedure (980358-305).

Removal

1. Unplug the wire bundle ! from the motor
1 where it attaches to the main PCBA " .

Note its location.

2. Use a #2 Phillips to remove the screws 2
3 that hold the motor to the left side frame
of the lower frame.

Assembly

1. Align the motor so that its gear is to the left;
then, insert it through the left side of the
lower frame.

2. Replace the two screws that hold the motor
to the side frame; then, use a #2 Phillips
driver to tighten them.

3. Twist the wires at least three times; then,
plug the wire bundle from the motor into its
connector on the main PCBA.

Assembling the Printer

Perform the assembly steps of the Bottom Case
Replacement procedure (980358-305). Check

the installation. Turn on the printer and run the

AutoSense routine to get a dump mode

printout. This action test the printer's media
drive and printing capabilities.

980358-001 Rev. B 55

Black Line and Bottom Gap Sensors Replacement 980358-307A

MOVIE

Preparations

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.

Perform the removal steps of the Bottom Case Replacement procedure (980358-305).

Removal

1. If necessary, move the main PCBA aside.

2. Unplug the ribbon cable ! from the sensor
1 where it attaches to the main PCBA.
Note its location.

3. Carefully loosen the ribbon cable retainer
on the right side of the lower frame.

4. Use a #1 Phillips to remove the screw 2
that holds the sensor to the bottom of the
lower frame.

Assembly

1. Align the sensor so that its ribbon cable is to the rear; then, place it on the bottom of the lower
frame.

2. Replace the screw that holds the sensor to the frame; then, use a #1 Phillips driver to tighten it.

3. Align the ribbon cable into the cable retainer on carefully close the retainer.

4. Plug the ribbon cable from the sensor into its connector on the main PCBA.

Assembling the Printer

Perform the assembly steps of the Bottom Case Replacement procedure (980358-305). Check the
installation. Turn on the printer and run the AutoSense routine to get a dump mode printout. This
action test the printer's media drive and printing capabilities.

56 980358-001 Rev. B

Head-Up Sensor Replacement 980358-308A

MOVIE

Preparations

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.

Perform the removal steps of the Bottom Case Replacement procedure (980358-305).

Removal

1. Unplug the ribbon cable ! from the sensor
1 where it attaches to the main PCBA ".

Note its location.

2. Use a #1 Phillips to remove the screw 2
that holds the sensor to the bottom of the
media frame.

Assembly

1. Align the sensor so that its ribbon cable is to
the left; then, place it one the bottom of the
media frame.

2. Replace the screw that holds the sensor to
the frame; then, use a #1 Phillips driver to
tighten it.

3. Plug the ribbon cable from the sensor into
its connector on the main PCBA.

Assembling the Printer

Perform the assembly steps of the Bottom Case
Replacement procedure (980358-305). 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.

980358-001 Rev. B 57

Main Printed Circuit Board Assembly (PCBA) Replacement 980358-309A

MOVIE

MOVIE

Preparations

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.

Check your work when con nect ing the print head ca bles—If con nected
wrong, per ma nent dam age can re sult to the printer.

Perform the removal steps of the Bot tom Case

Re place ment (980358-305) pro ce dure.

Removal

1. If present, snip the tie-wrap that holds the
loop of wire bundles and ribbon cables.

2. If present, use a small, slotted screwdriver
to remove the ferrite core.

3. On TLP models, use a #1 Phillips driver to
loosen and remove the screw that holds the
main PCBA.

On LP models, loosen the main PCBA 1
from its post ! and stand offs " on the

lower frame.

4. Note the locations of the cable connectors
then carefully unplug the ribbon cables and
wire bundles from their locations.

58 980358-001 Rev. B

Assembly

1. Plug the wire bundles, ribbon cables and
ground wire into their connectors on the
board.

2. Align the protective separator # ("fish
paper") against the bottom frame.

3. Align the board onto its post ! and
standoffs ".

4. On TLP models, replace the screw that
holds the board and use a #1 Phillips
driver to tighten it.

5. Replace the ferrite core around the print
head wire bundles.

6. Provide a loop in the wire bundles and
ribbon cables and secure to the bottom
frame with a tie wrap. Cut off the excess.

Assembling the Printer

Perform the assembly steps of the Bottom Case Replacement (980358-305) procedure.

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

980358-001 Rev. B 59

Dispenser Bezel Replacement 980358-310A

Preparations

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.

Perform the removal steps of the Bot tom Case Re place ment pro ce dure (980358-305).

Removal

1. Pry either side free and then lift the bezel 1
away from the dis penser bar 2 and bot tom
frame as sem bly.

2. Note the location of the connector ! on
the main con trol board; then un plug it.

3. Pull the wires and connector through the
frame access ".

Assembly

1. Align the bezel so that the connector is to
the rear.

2. Thread the connector and wires through the
access in the bottom case " and the
pro tec tive sep a ra tor ("fish pa per") #.

3. Plug the connector into its location on the
main control board.

4. Align the tabs with the notches in the media
exit and snap the bezel into place.

Assembling the Printer

Perform the assembly steps of the Bot tom Case
Re place ment pro ce dure (980358-305). Check

the in stal la tion. Turn on the printer and run the

AutoSense rou tine to get a dump mode

print out. This ac tion test the printer's me dia
drive and print ing ca pa bil i ties.

60 980358-001 Rev. B

Latch Replacement 980358-311A

MOVIE

Preparations

Perform the removal steps of the Upper Case Replacement procedure (980358-314).

Open the printer by pulling the release latches forward, then lifting the top frame.

Removal

Lift both sides of the latch to 1 unsnap it from
the upper frame.

Assembly

1. Align the latch spring 2 so that is extends to
the rear of the latch.

2. Align the latch so that the spring faces the
rear of the printer.

3. Lower the latch into its notches !" while
the spring provides tension against the
upper frame's front cross brace.

Assembling the Printer

Perform the assembly steps of the Upper Case
Replacement procedure (980358-314).

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

980358-001 Rev. B 61

Upper Case (Top Cover) Replacement 980358-314A

MOVIE

Preparations

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. Unsnap the bracket ! .

2. Free the print head " .

3. Slide the print head spring to one side to
release the opposite end.

4. Use a #1 Phillips driver to remove the
screws 1234 that hold the case to the

upper frame #.

5. Lift the top case and window away.

Assembly

1. Align the window so that the holes fit onto
the pegs on the upper frame.

2. Align the case to hold the window in place.

4. Replace the four screws and use a #1 Phillips driver to tighten them.

5. Align the print head to plug the left and right connectors into the wire bundles.

6. Slide the print head into one side and jog it into the other side.

7. Align the pivots of the bracket onto the posts; then, snap the bracket into place.

8. Clean the print head with the cleaning pen.

Assembling the Printer

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

62 980358-001 Rev. B

Feed/Gap Sensor Cable Assembly Replacement 980358-316A

MOVIE

Preparations

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.

Perform the removal steps of the Upper Case (980358-314) and Bottom Case (980358-305A).

Removal

1. Detach the cable connector
1 from where it plugs into
the feed/LED PCBA.

2. Detach the bracket 2 from
the upper case.

3. Carefully open the cable
retainers !" on the left

side of the upper frame.

4. Detach the main PCBA
connector and slip it through

the left hinge # of the frame
assemblies.

5. Remove the cables and
bracket from the upper frame.

Assembly

1. Slip the connector for the main PCBA through the upper frame and align the bracket into place.

2. Route the wires through the cable retainers on the left side of the upper frame.

3. Slip the connector through the left hinge of the frame assembly.

4. Plug the wire bundle into its receptacle on the main PCBA.

5. Plug the cable connector into its receptacle on the feed/LED PCBA.

Assembling the Printer

Perform the assembly steps of the Bottom Case (980358-305) and Upper Case (980358-314).
Reload media. Plug in the power cord, turn on the printer, load media, and run the AutoSense
routine to get a dump mode printout.

980358-001 Rev. B 63

Feed/LED PCBA Replacement 980358-317A

MOVIE

Preparations

Perform the removal steps of the Upper Case Replacement procedure (980358-314).

Removal

1. Lift the feed/LED PCBA 1 to unsnap it
from the upper frame.

2. Detach the cable connector ! from where
it plugs into the feed/LED PCBA.

Assembly

1. Plug the cable connector into the feed/LED
PCBA.

2. Lower the feed/LED PCBA onto its tab on
the upper frame.

Assembling the Printer

Perform the assembly steps of the Upper Case
Replacement procedure (980358-314).

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

64 980358-001 Rev. B

Real Time Clock Option 980358-318A

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

MOVIE

Preparations

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.

Perform the removal steps of the Bottom Case

Replacement (980358-305) and Main PCBA
Replacement (980358-309) procedures.

Installation

1. Align the real time clock chip above its
location U22 on the main PCBA 1. Make
sure the notched end of the chip is towards
the notched end of the outline printed on
the board.

2. Lower the real time clock chip into place
taking care not to bend any of the pins.

Assembling the Printer

Perform the assembly steps of the Main PCBA
Replacement (980358-309) and Bottom Case
Replacement (980358-305) procedures.

Checking the Installation

Turn on the printer and run your printer's

AutoSense rou tine to get a dump mode

print out. This ac tion tests the printer's
me dia drive and print ing ca pa bil i ties.

You can also check the print out.

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

980358-001 Rev. B 65

Print Head Replacement - LP 980358-390A

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. Unsnap the bracket 2 from the lid.

2. Slide the print head 1 to one side until it is
free of the lid.

3. Use a #1 Phillips driver to loosen the screw
that holds the ground wire to the bracket;
pull the wire away from the bracket.

4. Unplug both bundles of print head wires
from the left and right connectors.

The head spring remains in the lid. The spring
slides to one side to release the other end.

Assembly

1. Align the print head 1 to plug the left and
right connectors into the wire bundles

!" .

2. Slip the ground wire under the right screw
and use a #1 Phillips driver tighten to it.

3. Slide the print head into one side and jog it
into the other side.

4. Align the pivots #$ of the bracket 2
onto the posts %&; then, snap the

bracket into place.

4. Clean the print head with the cleaning pen.

Assembling the Printer

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

66 980358-001 Rev. B

Latch Replacement - TLP 980358-511A

MOVIE

Preparations

Open the printer by pulling the release latches forward, then lifting the top cover.

Removal

Unsnap the latch assembly 1 from both bearings

!" in the top case.

If you need to remove the springs 2, compress the
spring and then twist clockwise.

Assembly

1. Squeeze the latch handles #$ inward and
press into the top case.

2. Push the cross bar % into each bearing until it
snaps into place.

3. Make sure the springs are in place on both
sides.

980358-001 Rev. B 67

Cover Support Replacement - TLP 980358-512A

MOVIE

Preparations

Open the printer; pull the release latches forward, then lift the top cover.

Removal

1. Use a #1 Phillips driver to remove the two
screws 2 3 holding the support 1 to the

top assembly !.

2. Lift the support away from the bottom
assembly ".

Assembly

1. Align the support so that the square brace
fits into the top assembly.

2. Insert the support into the bottom assembly.

3. Replace the two screws that hold the
support the top assembly and use a #1
Phillips driver to tighten them.

980358-001 Rev. B 69

Hinge Replacement - TLP 980358-513A

MOVIE

Preparation

Perform the removal steps of the Bottom Case (980358-305) and Main PCBA (980358-309) and
Cover Support (980358-512) procedures.

Removal

1. Use a #1 Phillips driver to loosen and
remove the screw that holds the hinge lock
onto the bottom media frame.

2. Slide the hinge off of the frame.

3. Slide the top cover assembly and bottom
media frame apart.

Installation

1. Ensure the wires follow their correct routing.
On the side opposite the hinge, make sure
the cables go through the channe.

2. Slide the top cover assembly and bottom
media frame together.

4. Align the hinge with the link tab facing right
and insert into the top cover assembly.

5. Fit the hinge onto the bottom media frame.

6. Replace the screw and use a #1 Phillips
driver to tighten it.

7. Ensure the hinge caps are inserted properly.

Assembling the Printer

Perform the assembly steps of the Cover
Support (980358-412), Main PCBA

(980358-409) and Bottom Case (980358-405)
procedures.

980358-001 Rev. B 71

Upper Case (Top Cover) Replacement - TLP 980358-514A

MOVIE

Preparation

Perform the removal steps of the Bottom Case (980358-305), Main PCBA (980358-309), and
Hinge (980358-513) procedures.

Removal

1. Use a #1 Phillips driver to loosen the
screws ! that hold the upper frame 1 to

the top case 2.

2. Lift the frame away from the window 3
and top case. Notice that the feed/LED

cable " leads to the button assembly
attached to the top case.

Assembly

1. Align the window so that the holes at the
rear engage on the pegs of the upper
frame.

2. Check that the link 4 is in place across the
ribbon carriage and upper frame.

3. Lower the top case onto the window and
frame.

4. While holding the frame, window and top
case together, flip them over so that they
rest on the window.

5. Replace the screws that hold the frame to
the top case and use a #1 Phillips driver to
tighten them.

Assembling the Printer

Perform the assembly steps of these procedures:

Hinge Replacement (980358-413), Main PCBA
Replacement (980358-409), and Bottom Case
Replacement (980358-405).

980358-001 Rev. B 73

Ribbon Carriage Replacement - TLP 980358-515A

MOVIE

Preparation

Perform the removal steps of these procedures: Bottom Case Replacement (980358-305), Main
PCBA Replacement (980358-309), Hinge Replacement (980358-513), and Upper Case
Replacement (980358-514).

Removal

1. Gently flex the left bearing ! to release the
left hinge 1 of the carriage.

2. Gently flex the right bearing " to release
the right hinge 2 of the carriage.

3. To free the carriage from the upper frame,
cut the rear tie wrap to free the wire
bundles and ribbon cables; then, pull them
free of the case and rear hinge of the upper
frame.

Assembly

1. Route the ribbon cables and wire bundles
along the right side of the upper frame;
then, secure them all with a tie wrap above
the cover support location. Refer to the
diagram in the Cable Routing section.

2. Snap both hinges into the bearings.

Assembling the Printer

Perform the assembly steps of these procedures: Upper Case Replacement (980358-514), Hinge
Replacement (980358-513), Main PCBA Replacement (980358-309), and Bottom Case
Replacement (980358-305).

980358-001 Rev. B 75

Feed Button/LED and Top Gap Sensor Replacement - TLP 980358-516A

MOVIE

Preparation

The feed button LED PCB and the top gap (receive) sensor are one assembly. To access them,
perform the removal steps of the Bottom Case (980358-405), Main PCBA (980358-409), Hinge
(980358-413), Upper Case (980358-414), and Ribbon Carriage (980358-415) procedures.

Removal

1. In the top cover !, use a #1 Phillips driver
to remove the two screws "# that hold

the PCB 1, and button 2.

2. On the upper frame $, use a #0 Phillips
driver to remove the screw % that holds
the metal brace & and upper gap sensor 4

in place.

3. Lift the opaque button and clear lens away
from the top cover.

Assembly

1. With the top cover upside-down, insert the
both button into place.

2. Align the feed button/LED PCBA so that the
ribbon cable faces the closest sidewall.

3. Replace the two screws that hold the LED
PCBA and use a #1 Phillips driver to
tighten them.

4. Align the top gap sensor so that the ribbon
cable goes to the right of the upper frame.

5. Align the metal brace that holds the upper gap sensor.

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

7. Route the sensor's wires through their guides. Refer to the diagram in the Cable Routing section.

980358-001 Rev. B 77

Feed Button/LED and Top Gap Sensor Replacement (Continued) 980358-516A

8. Make sure the sensor's wires are secured
against the top frame using tape.

9. Make sure the LED/Feed Button's ribbon
cable is secured against the top case using
tape.

Assembling the Printer

Perform the assembly steps of the

Ribbon Carriage (980358-415),
Upper Case (980358-414),
Hinge (980358-413),
Main PCBA (980358-409), and
Bottom Case (980358-405)

procedures.

78 980358-001 Rev. B

Ribbon Motion Sensor Replacement - TLP 980358-517A

MOVIE

Preparation

Perform the removal steps of the Bottom Case (980358-305), Main PCBA (980358-309), Hinge
(980358-513), Upper Case (980358-514), and Ribbon Carriage (980358-515) procedures.

Removal

1. On the ribbon carriage, cut the tie wrap !
that holds the wire bundles and ribbon
cables to the right side frame.

2. Use a #1 Phillips driver to loosen the screw

" that holds the sensor 1 to the outside of

the left side frame.

3. Pull the sensor away from the carriage and
pull the wires through both side frames.

Assembly

1. Insert the connector through the outside of
the left side frame.

2. Insert the connector through the inside of
the right side frame.

3. Pull the wires through, and route them
through their guides.

4. Align the sensor so that the wires go to the
rear of the carriage.

5. Replace the screw that holds the sensor to
the left side frame and use a #1 Phillips
driver to tighten it.

6. Secure the wire bundles and ribbon cables
against the carriage with a tie wrap inserted
through the right side frame.

Assembling the Printer

Perform the assembly steps of the Ribbon Carriage (980358-515), Upper Case (980358-514),
Hinge (980358-513), Main PCBA (980358-309), and Bottom Case (980358-305) procedures.

980358-001 Rev. B 79

Print Head Replacement - TLP 980358-590A

MOVIE

Preparations

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
any ribbon from the carriage.

Removal

1. Grasp the print head spring 4 and pull it to
the left; then, slide it free of the carriage.

2. Use the spring to pry the print head clip 3
off the right side of the carriage.

3. Pull the print head and bracket 1 forward.

4. Use a #2 Phillips driver to remove the
screw 2 that holds the ground wire.

5. Unplug both bundles #$ of print head

wires from the left and right connectors.

Assembly

1. Detach the wire cover (.

2. Detach the ribbon take-up hub ).

3. Align the print head and bracket 1 to plug the left ! and right " connectors into the black #
and white $ wire bundles.

4. Attach the ground wire % and secure it with the screw 2. Use a #2 Phillips driver to tighten it.

5. Insert the bracket pegs & into the left side of the carriage.

6. Align the right side of the bracket and insert the print head clip 3 through the right side of the
ribbon carriage into the bracket.

980358-001 Rev. B 81

Print Head Replacement - TLP (continued) 980358-590A

7. Slip the left end of the print head spring 4 into the left side of the ribbon carriage; then slide the
right end into the other side. The angle of the "v" fits into the indent on top of the print head

bracket '.

8. Attach the ribbon take-up hub.

9. Attach the wire cover.

10. Clean the print head with the cleaning pen.

Assembling the Printer

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

82 980358-001 Rev. B

CABLE ROUTING

The following simplified charts show routing for the printer's electronic components.

980358-001 Rev. B 83

Cable Routing for TLP Wide Printers

tie wrap

tie wrap

PRINT HEAD (WHITE)

GROUND WIRE

RIBBON MOTION SENSOR

PRINT HEAD (BLACK)

RIGHT SIDE

TOP

SIMPLIFIED WIRING DIAGRAM
Carriage & Upper Frame

FEED / RECEIVE GAP

exit

guide

guide

Leave slack so carriage can
fully deploy to lowered position

84 980358-001 Rev. B

Cable Routing for LP Wide Printers

PRINT HEAD (RIGHT)

PRINT HEAD (LEFT)

RIGHT SIDE

TOP

SIMPLIFIED WIRING DIAGRAM
Carriage & Upper Frame

FEED

Top case and inner frame are
welded together.

980358-001 Rev. B 85

Cable Routing for LP Narrow Printers

SIMPLIFIED WIRING DIAGRAM
Upper Frame

RIGHT SIDE

TOP

tie wrap

tie wrap

tie wrap

tie wrap

tie wrap

guide

PRINT HEAD (WHITE)

GROUND WIRE

PRINT HEAD (BLACK)
FEED / RECEIVE GAP

tie wrap

86 980358-001 Rev. B

Cable Routing for TLP Narrow Printers

tie wrap

tie wrap

RIGHT SIDE

TOP

SIMPLIFIED WIRING DIAGRAM
Carriage & Upper Frame

exit

Leave slack so carriage can
fully deploy to lowered position

tie wrap

tie wrap

RIGHT SIDE

exit

Leave slack so carriage can
fully deploy to lowered position

980358-001 Rev. B 87

980358- 001 A