PA40x/PT40x Series PORTABLE PRINTERS Maintenance Manual Revision 3 Registration Form =(%5$ 7(&+12/2*,(6 &25325$7,21 To receive maintenance manual revisions and updates, complete this form and fax or mail it to Zebra Technologies at the fax number or address shown below. COMPANY ADDRESS CITY STATE, ZIP PHONE # ( ) CONTACT: Zebra Technologies Corporation 30 Plan Way Warwick, RI 02866-1012 U.S.A. ATTN: Technical Training Department FAX NUMBER: +1.401.732.7808 505142L Rev.
127(6 505142L Rev.
7DEOH RI &RQWHQWV Table of Contents Section 1 Description of Equipment Description............................................................................................................................. 1-1 Printer Operating Modes........................................................................................................ 1-1 Printing Method ..................................................................................................................... 1-1 Specifications...............
7DEOH RI &RQWHQWV Adjust Faststrap ................................................................................................................... 2-20 Convert to a Shoulder Strap .................................................................................... 2-20 Convert to a Hand Strap .......................................................................................... 2-21 Section 3 Troubleshooting Troubleshoot ..............................................................................
7DEOH RI &RQWHQWV Section 5 Maintenance and Assembly Drawings Drawing and Parts List .......................................................................................................... 5-1 Power Supply Board Layout ..................................................................................... 5-6 Main Logic Board Layout .........................................................................................
7DEOH RI &RQWHQWV LY / 5HY
/LVW RI )LJXUHV /LVW RI )LJXUHV Figure 1-1. Adapter Cable Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 1-2.Null Modem Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 1-3.PA/PT40x Electronics System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Figure 2-1.Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .
/LVW RI )LJXUHV Figure 4-11.Locate Printhead Ground Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Figure 4-12.Locate Printhead 16-Pin Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Figure 4-13. Remove Ribbon Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Figure 4-14.Install Ribbon Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ 6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 'HVFULSWLRQ The Zebra PA40x Series is a low-cost, portable, direct thermal printer. The Zebra PT40x Seriesis a low-cost, portable, thermal transfer printer. Both can be carried by the shoulder strap, sit on a workspace, or be mounted to a specific location. The battery makes them truly portable especially in environments where AC power is not readily available.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 6SHFLILFDWLRQV 7DEOH 6SHFLILFDWLRQV 3ULQW GHQVLW\ 3ULQW ZLGWK GRWV LQ GRWV PP LQ WR LQ PP WR PP LQ VHF PP VHF RU RU 3ULQW VSHHG LQ VHF PP VHF /DEHO ZLGWK ,QFOXGLQJ OLQHU LQ WR LQ PP WR PP /DEHO OHQJWK VWDQGDUG PHPRU\ LQ WR LQ PP WR PP ,QWHUODEHO JDS LQ WR LQ PP WR PP /DEHO WKLFNQHVV LQ WR LQ PP WR PP 0D[ RXWHU GLDPHWHU LQ
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ 7DEOH 6SHFLILFDWLRQV &RQWLQXHG 5RWDWLRQ DQJOHV 520 PHPRU\ VWDQGDUG 5$0 PHPRU\ VWDQGDUG DQG 0% 3$ 37 ² 0% 3$ 37 .
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 25-Pin D-Sub to 9-Pin D-Sub Null Modem Cable DB-25P Connector to PC 2 3 4 5 6 7 8 20 DB-9S Connector to Printer TXD RXD RTS CTS DSR GND DCD DTR DCD RXD TXD DTR GND DSR RTS CTS 1 2 3 4 5 6 7 8 9-Pin D-Sub to 9-Pin D-Sub Null Modem Cable DB-9S Connector to PC 1 2 3 4 5 6 7 8 DB-9P Connector to Printer DCD RXD TXD DTR GND DSR RTS CTS DCD RXD TXD DTR GND DSR RTS CTS 1 2 3 4 5 6 7 8 Figure 1-2.
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ (OHFWURQLFV 6\VWHP %ORFN 'LDJUDP J1 Main Logic Board J2 J5 J9 J7 Serial Cable Battery Charger J12 Battery Power & Feed Membrane Switch Power Supply Board Print Mechanism Module Peel Sensor Media Sensor Head-Open Sensor Printhead Assembly Ribbon Sensor Board * * PT40x Series only 4 Wire Connector Motor Figure 1-3.
6HFWLRQ 3DJH 'HVFULSWLRQ RI (TXLSPHQW =HEUD 3$ 37 [ 6HULHV 0DLQWHQDQFH 0DQXDO / 5HY
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ 6HFWLRQ 2SHUDWLRQ 2YHUYLHZ 2SHUDWRU &RQWUROV Refer to Figure 2-1. Power Button Press to turn printer On (O). Press and hold for two seconds to turn printer Off (2). Feed Button Forces the printer to feed one blank label. Takes the printer out of a pause condition. The printer pauses from a ZPL command or an error condition. Used for printer setup and status. Power LED (Green) On during normal printer operations.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ ,QVWDOO %DWWHU\ 7KH (3$ FHUWLILHG 5%5& %DWWHU\ 5HF\FOLQJ 6HDO RQ WKH QLFNHO FDGPLXP 1L &G EDWWHU\ LQGLFDWHV =HEUD 7HFKQRORJLHV LV YROXQWDULO\ SDUWLFLSDWLQJ LQ DQ LQGXVWU\ SURJUDP WR FROOHFW DQG UHF\FOH WKHVH EDWWHULHV DW WKH HQG RI WKHLU XVHIXO OLIH ZKHQ WDNHQ RXW RI VHUYLFH LQ WKH 8QLWHG 6WDWHV RU &DQDGD 7KH 5%5& SURJUDP SURYLGHV D FRQYHQLHQW DOWHUQDWLYH WR SODFLQJ XVHG 1L &G EDWWHULHV LQWR WKH WUDVK RU WKH PXQLFLSDO ZDVWH VWUHDP ZKLFK PD\ EH LOOHJDO LQ \RXU DUHD
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ &KDUJH %DWWHU\ 1RWH &RPSOHWHO\ GLVFKDUJH WKH EDWWHU\ EHIRUH UHFKDUJLQJ :DLW XQWLO D EDWWHU\ XQGHU YROWDJH ² OHYHO LQGLFDWLRQ (UURU /(' LV RII DQG 3RZHU /(' LV IODVKLQJ H[LVWV EHIRUH UHFKDUJLQJ Refer to Figure 2-4. 9$& %DWWHU\ &KDUJHU 1. With the battery installed in the printer, insert the connector of the battery charger into the receptacle on the side of the printer. 2. Plug the transformer into an appropriate 120 VAC electrical outlet. 3.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ ([WHQGLQJ %DWWHU\ /LIH 7KH (3$ FHUWLILHG 5%5& %DWWHU\ 5HF\FOLQJ 6HDO RQ WKH QLFNHO FDGPLXP 1L &G EDWWHU\ LQGLFDWHV =HEUD 7HFKQRORJLHV LV YROXQWDULO\ SDUWLFLSDWLQJ LQ DQ LQGXVWU\ SURJUDP WR FROOHFW DQG UHF\FOH WKHVH EDWWHULHV DW WKH HQG RI WKHLU XVHIXO OLIH ZKHQ WDNHQ RXW RI VHUYLFH LQ WKH 8QLWHG 6WDWHV RU &DQDGD 7KH 5%5& SURJUDP SURYLGHV D FRQYHQLHQW DOWHUQDWLYH WR SODFLQJ XVHG 1L &G EDWWHULHV LQWR WKH WUDVK RU WKH PXQLFLSDO ZDVWH VWUHDP ZKLFK PD\ EH LOOHJDO LQ \RX
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ 3ULQWHU 2YHUYLHZ 1 2 3 14 4 5 6 7 8 9 10 13 11 12 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 Top Cover Error LED Power LED Printhead Pressure Adjuster Power Button Feed Button Printhead Platen Roller Media Guides Media Hangers Media Access Door Battery Compartment Media Compartment Strap Communications Port Battery Charging Receptacle Battery Charging LED Charging Station Connector Peel Bar 15 16 17 19 18 Figure 2-5.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ /RDG 6XSSOLHV Refer to Figure 2-5 for general printer assembly terminology and location for loading supplies. &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV WKH SULQWKHDG 'LUW DQG PRLVWXUH IURP \RX KDQGV FDQ SUHPDWXUHO\ VKRUWHQ WKH SULQWKHDG OLIH 7HDU 2II 0RGH 3DJH 1. Refer to Figure 2-6. Raise the media access door by lifting at the notch until it unhooks from the top cover. 2. Refer to Figure 2-7. Swing open the media access door to expose the media compartment. 3.
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ Top Cover Notch Media Access Door Figure 2-6. Open Media Access Door Media Compartment Printhead Media Guides Media Hangers Figure 2-7.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ Media Guides 1 in. (25 mm) beyond printhead Media Hangers Unwind this direction Media Roll Figure 2-8. Load Media Tab Protrusion Lip Figure 2-9.
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ Tear Blade Figure 2-10. Media Over Tear Blade &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV WKH SULQWKHDG 'LUW DQG PRLVWXUH IURP \RX KDQGV FDQ SUHPDWXUHO\ VKRUWHQ WKH SULQWKHDG OLIH 3HHO 2II 0RGH / 5HY 1. Refer to Figure 2-6. Raise the media access door by lifting at the notch until it unhooks from the top cover. 2. Refer to Figure 2-7. Swing open the medis access door to expose the media compartment. 3. Pivot the top cover to reveal the printhead. 4.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ Refer to Figure 2-11. The tear blade should be stored on the inside of the media access door. With the lip of the tear blade facing the inside of the door, place the notches of the tear blade over the tabs on the door. Press and slide the tear blade toward the hinged end. Lift the tab to allow the tear blade to slip past the protrusion and lock in place. 10. Close the printhead and the top cover. 11.
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ /RDG 5LEERQ 1. Lift the printhead until you feel it lock in place. 2. Hold the ribbon cartridge as shown in Figure 2-13. The placement arrows should be visible and pointing toward the rear of the printer. 3. Install the ribbon cartridge onto the printhead. The portion of the cartridge with the white gear should be placed over the printhead. 4. Refer to Figure 2-14. The ribbon cartridge automatically slides into the correct operating position. 5. Refer to Figure 2-15.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ Ribbon Cartridge Printhead Figure 2-14. Operate Position (Ribbon Cartridge) Close Printhead Ribbon Figure 2-15.
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ ,QLWLDO 3RZHU 8S 3ULQW 7HVW /DEHO Before connecting the printer to a computer or portable data terminal, ensure it is in proper working order. Print a configuration label by following the instructions in Table 2-1. A sample configuration label is shown in Figure 2-16. Figure 2-16. Sample Configuration Label Figure 2-17.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ 7DEOH )((' 0RGH &KDUW 3RZHU 2II 0RGH &RPPXQLFDWLRQV 'LDJQRVWLFV 0RGH :LWK WKH SULQWHU 2II 2 SUHVV DQG KROG )((' ZKLOH \RX WXUQ WKH SULQWHU 2Q O 5HIHU WR )LJXUH 7KH SULQWHU SULQWV RXW D OLVW RI LWV FXUUHQW FRQILJXUDWLRQ 5HIHU WR )LJXUH $IWHU SULQWLQJ WKH ODEHO WKH SULQWHU ZLOO DXWRPDWLFDOO\ HQWHU D GLDJQRVWLF PRGH DQG SULQWV RXW D OLWHUDO UHSUHVHQWDWLRQ RI DOO GDWD VXEVHTXHQWO\ UHFHLYHG 3RZHU 2Q 0RGHV :LWK WKH SULQWHU 2Q O SULQWKHDG FORVHG DQG
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ &RQQHFW &RPSXWHU &DXWLRQ 7KH 5- MDFN RQ WKH VLGH RI WKH SULQWHU LV IRU VHULDO SRUW FRPPXQLFDWLRQV RQO\ 'R QRW FRQQHFW WR D WHOHSKRQH MDFN 7KLV ZLOO GDPDJH WKH SULQWHU The PA/PT40x Series printer is configured as Data Terminal Equipment (DTE). The null modem cable used to connect the computer to the adapter cable and printer may be either: • 9-pin D-type (DB9S) computer serial port connector to a 9-pin D-type (DB9P) adapter cable connector.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ 6HW &RPPXQLFDWLRQ 3DUDPHWHUV When using the printer’s serial port to transfer data, the printer and the computer must have identical communication parameter settings. 'HIDXOW YDOXHV Press and hold FEED until the Error LED flashes once, twice, and then three times. Release FEED after the LED flashes three times. The baud rate for the printer resets to 9600 baud, 8-bit word length, no parity, 1 stop bit, and the flow control sets to XON/ XOFF.
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ $XWR &DOLEUDWLRQ 1RWH 7KH SULQWHU GRHV QRW DXWR FDOLEUDWH FRUUHFWO\ ZKHQ \RX DUH XVLQJ SUHSULQWHG ODEHOV ,I WKLV W\SH RI PHGLD LV EHLQJ XVHG VHH 0DQXDO &DOLEUDWLRQ RQ SDJH By default, this printer automatically sets the sensor levels and determines the length of the label being used. To auto-calibrate: 1. Turn the printer On (O). 2. Load the media and close the printhead. 3. Press FEED. Two labels print, completing auto-calibration.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ &DOLEUDWH 5LEERQ 6HQVRU 37 [ RQO\ Perform this ribbon sensor calibration whenever a new Ribbon Sensor Board is installed. To calibrate the ribbon sensor: 1. Turn printer Off (2). 2. Install an empty ribbon cartridge with a white core into the PT400. 3. Turn the printer On (O . 4. Press and hold FEED. 5. The Error LED begins to flash. When the LED flashes for the sixth time, continue to hold (for an additional five seconds) until the seventh flash.
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ 2SHUDWH 3ULQWHU To create a label for the Zebra PA400, you may either use a commercial label preparation system software, such as Zebra BAR-ONE, to create the label format or write one in ZPL II, which is Zebra’s programming language for creating labels. If you are using commercial label preparation software, refer to the software’s help files or users guide.
6HFWLRQ 2SHUDWLRQ 2YHUYLHZ $GMXVW )DVWVWUDS &RQYHUW WR D 6KRXOGHU 6WUDS 1. Refer to Figure 2-21. With the front of the printer facing you, unwrap the padded handle by lifting up the loose end of the handle. 2. Unlatch the buckle by squeezing both sides of the fastener. 3. Pull up the padded handle. 4. Wrap and secure the padded handle around the strap. 1 4 Handle 2 (Pull Up) Fastener Buckle 3 Figure 2-21.
2SHUDWLRQ 2YHUYLHZ 6HFWLRQ &RQYHUW WR D +DQG 6WUDS 1. Refer to Figure 2-22. With the front of the printer facing you, unwrap the padded handle by lifting up the loose end of the handle. 2. Pull the buckle to the right until the strap is taut. 3. Latch the buckle by inserting the fastener into the buckle. 4. Wrap and secure the padded handle around the strap. 2 3 Handle Fastener Buckle 2 1 Figure 2-22.
6HFWLRQ 3DJH 2SHUDWLRQ 2YHUYLHZ =HEUD 3$ 37 [ 6HULHV 0DLQWHQDQFH 0DQXDO / 5HY
7URXEOHVKRRWLQJ 6HFWLRQ 6HFWLRQ 7URXEOHVKRRWLQJ Use Table 3-1 to match your printer’s LED status to the chart. The last column of Table 3-1 gives a number to refer to in Table 3-2 on page 3-2. Table 3-3 on page 3-3 lists print quality problems that may or may not have any trouble indication from the LEDs. Tables 3-2 and 3-3 Troubleshooting Charts list the most common problems that may be encountered when operating the PA/PT40x printer.
7URXEOHVKRRWLQJ 6HFWLRQ 7DEOH /(' 7URXEOHVKRRWLQJ 5HVROXWLRQ &KDUW 'LDJQRVLV $FWLRQ 3UHVV 2Q O 3ULQWHU LV QRW UHFHLYLQJ SRZHU (QVXUH WKH EDWWHU\ LV IXOO\ FKDUJHG DQG SURSHUO\ LQVWDOOHG 7U\ DQRWKHU IXOO\ FKDUJHG EDWWHU\ 0HPEUDQH VZLWFK GHIHFWLYH 3RZHU VXSSO\ ERDUG GHIHFWLYH 0DLQ ORJLF ERDUG GHIHFWLYH 3ULQWKHDG LV RSHQ &ORVH WKH WRS FRYHU DQG PHGLD DFFHVV GRRU 0HGLD LV RXW /RDG D UROO RI PHGLD 3ULQWHU LV SDXVHG 3UHVV )((' WR UHVXPH SULQWLQJ 3ULQWKHDG LV XQGHU W
6HFWLRQ 7URXEOHVKRRWLQJ 7DEOH 3ULQW 4XDOLW\ &KDUW 'LDJQRVLV $FWLRQ (QVXUH WKDW GLUHFW WKHUPDO PHGLD LV ORDGHG LQWR WKH SULQWHU 1R SULQW RQ WKH ODEHO (QVXUH WKH PHGLD LV ORDGHG FRUUHFWO\ (QVXUH WKH SULQWHU LV EHLQJ XVHG ZLWKLQ RSHUDWLRQDO OLPLWV RI EHWZHHQ °) DQG °) °& DQG °& 3ULQW GDUNQHVV QHHGV WR EH DGMXVWHG 3ULQWKHDG LV GLUW\ &OHDQ WKH SULQWKHDG 3ULQWKHDG SUHVVXUH QHHGV WR EH DGMXVWHG 3ULQWHG LPDJH GRHV QRW ORRN 7KH PHGLD EHLQJ XVHG LV LQFRPSDWLEOH ZLWK WKH SULQWHU %H
7URXEOHVKRRWLQJ 6HFWLRQ )DFWRU\ $VVLVWDQFH Should you encounter any problem that cannot be corrected with the aid of this manual, and you have Internet access, check out ZIP Support at http://support.zebra.com. If you cannot solve your problem via ZIP Support or do not have Internet access, contact your Distributor or Zebra Technologies’ Technical Support Department to minimize or avoid printer downtime.
0DLQWHQDQFH 6HFWLRQ 6HFWLRQ 0DLQWHQDQFH 7DEOH RI &RQWHQWV Preventive Maintenance Schedule ...................................................................... 4-5 Clean ................................................................................................................... 4-5 Battery Maintenance ........................................................................................... 4-6 Lubrication ......................................................................................
0DLQWHQDQFH 6HFWLRQ (TXLSPHQW 6DIHW\ 7LSV R R After reviewing each procedure, place a check in the box. The AC power plug and IEC 320 connectors on all Zebra printers must bear the certification mark of at least one international safety organization listed below. + R R R R R / 5HY Unless indicated otherwise, turn the power Off (2) before performing any maintenance procedures to the printer.
6HFWLRQ 0DLQWHQDQFH (TXLSPHQW 6DIHW\ 7LSV &RQWLQXHG R R R R R R 3DJH To ensure optimum printhead life, observe proper electrostatic safety precautions (for example ESD wrist straps) when removing, handling, and replacing the printhead. Nickel Cadmium (Ni-Cd) must be recycled or disposed of properly. They must not be disposed of in municipal waste. For recycling information in the United States and Canada, please call 1-800-8-BATTERY.
0DLQWHQDQFH 6HFWLRQ 3HUVRQDO 6DIHW\ 7LSV R R R R R / 5HY Danger of an explosion exists if the Ni-Cd battery is discharged incorrectly. Do not wear any jewelry (rings, watches, etc.) or loose clothing when servicing the printers. Beware of pinch points on the printers. Be especially careful of: • Opening and closing covers • Printhead • Platen roller Wear protective eyewear when removing E-rings, C-clips, and springs.
0DLQWHQDQFH 6HFWLRQ 3UHYHQWLYH 0DLQWHQDQFH 6FKHGXOH &OHDQ &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 'LUW DQG PRLVWXUH IURP KDQGV FDQ SUHPDWXUHO\ VKRUWHQ SULQWKHDGV OLIH 7DEOH &OHDQ 6FKHGXOH $UHD 0HWKRG ,QWHUYDO 1RWH
6HFWLRQ 0DLQWHQDQFH %DWWHU\ 0DLQWHQDQFH Check battery contacts and keep clean of corrosion and grime. Clean contacts with 90% isopropyl alcohol and a cotton swab. Batteries should be completely discharged once per week. To discharge, run the printer until you get a battery under voltage—level 1 indication (Error LED off and Power LED flashing). Follow the procedures in Charge Battery on page 2-3 for recharging the battery.
0DLQWHQDQFH 6HFWLRQ &RUUHFWLYH 0DLQWHQDQFH 7RROV 5HTXLUHG 3KLOOLSV 6FUHZGULYHUV $QWL6WDWLF 0DW )ODW %ODGH 6FUHZGULYHU LQ $QWL6WDWLF :ULVW 6WUDS 3DUW DQG $VVHPEO\ ,GHQWLILFDWLRQ Use Figure 4-2 when identifying printer parts or assemblies for troubleshooting. Printer Front Cover Power Supply Board Rubber Bezel Print Mechanism Module Shoulder Strap Sleeve Printer Rear Cover Battery Access Door Shoulder Strap Sleeve Main Logic Board Figure 4-2.
6HFWLRQ 0DLQWHQDQFH 5HPRYH ,QVWDOO 6KRXOGHU 6WUDS 5HPRYH 6KRXOGHU 6WUDS 1. Turn the printer Off (2). Disconnect the battery charger. 2. Lay the printer on a flat surface with the back of the printer facing up. 3. Remove the two shoulder strap screws indicated in Figure 4-3. 4. Remove the shoulder strap.
0DLQWHQDQFH 6HFWLRQ 'LVDVVHPEOH $VVHPEOH 3ULQWHU &DXWLRQ 2EVHUYH SURSHU HOHFWURVWDWLF VDIHW\ SUHFDXWLRQV ZKHQ UHPRYLQJ KDQGOLQJ DQG UHSODFLQJ SULQWHG FLUFXLW ERDUGV 'LVDVVHPEOH 3ULQWHU / 5HY 1. Turn the printer Off (2). Disconnect the battery charger. 2. Slide the battery compartment door open and remove the battery. 3. Lay the printer on a flat surface with the back of the printer facing up. 4. Remove the two shoulder strap screws indicated in Figure 4-3.
6HFWLRQ 0DLQWHQDQFH J1 (Printhead) J2 (Stepper Motor) J7 (Logic Board) J12 (Membrane Switch) Front J5 (RJ45 Jack) J9 (Battery Charger Jack) Back Figure 4-4.
0DLQWHQDQFH 6HFWLRQ 5HDVVHPEOH 3ULQWHU 1. Refer to Figure 4-4. Replace J12 (membrane switch ribbon cable). 2. Ensure the contacts on the membrane switch ribbon cable face away from the edge of the main logic board, where J12 is found. Reinstall the membrane switch ribbon cable into J12. 3. Refer to Figure 4-5. Slide the power supply board and main logic board into the front cover, ensuring the rubber bezel slides into the slots in the front cover. 4. Refer to Figure 4-6.
6HFWLRQ 0DLQWHQDQFH Figure 4-6. Remove/Install Print Mechanism Module 5RXWH %DWWHU\ $FFHVV 'RRU 5HSODFH 3DJH 1. Turn the printer Off (2). Disconnect the battery charger. 2. Slide the battery compartment door open and remove the battery. 3. Lay the printer on a flat surface with the back facing up. 4. Remove the two shoulder strap screws indicated in Figure 4-3 on page 4-8. Set the shoulder strap, two shoulder strap sleeves, and two shoulder strap screws aside. 5.
0DLQWHQDQFH 6HFWLRQ Figure 4-7. Remove/Install Battery Access Door 5HSODFH 0DLQ /RJLF %RDUG &DXWLRQ 2EVHUYH SURSHU HOHFWURVWDWLF VDIHW\ SUHFDXWLRQV ZKHQ UHPRYLQJ KDQGOLQJ DQG UHSODFLQJ SULQWHG FLUFXLW ERDUGV / 5HY 1. Turn the printer Off (2). Disconnect the battery charger. 2. Slide the battery compartment door open and remove the battery. 3. Lay the printer on a flat surface with the back facing up. 4. Remove the two shoulder strap screws indicated in Figure 4-3.
6HFWLRQ 0DLQWHQDQFH 10. Refer to Figure 4-5. Reinstall the power supply board and main logic board in the front cover, ensuring the rubber bezel slides into the slots in the front cover. 11. Refer to Figure 4-8. Route all harnesses to avoid pinching and screw posts. 12. Refer top Figure 4-7. Ensure the battery access door is in the slot of the front cover with the flat side facing in. 13. Replace the cover and shoulder strap. 14. Reinstall the battery. Connect a battery charger if necessary.
0DLQWHQDQFH 6HFWLRQ 5HSODFH 3RZHU 6XSSO\ %RDUG &DXWLRQ 2EVHUYH SURSHU HOHFWURVWDWLF VDIHW\ SUHFDXWLRQV ZKHQ UHPRYLQJ KDQGOLQJ DQG UHSODFLQJ SULQWHG FLUFXLW ERDUGV / 5HY 1. Turn the printer Off (2). Disconnect the battery charger. 2. Slide the battery compartment door open and remove the battery. 3. Lay the printer on a flat surface with the back facing up. 4. Remove the two shoulder strap screws indicated in Figure 4-3.
6HFWLRQ 0DLQWHQDQFH 21. Refer to Figure 4-7. Ensure the battery access door is in the slot in the front cover with the flat side facing in. 22. Replace the cover and shoulder strap. 23. Reinstall the battery. Connect a battery charger if necessary. Figure 4-9.
0DLQWHQDQFH 6HFWLRQ 5HSODFH 3ULQWKHDG $VVHPEO\ &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 7KH SULQW HOHPHQWV PD\ EH KRW DQG ZLOO EXUQ WKH VNLQ &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 'LUW DQG PRLVWXUH IURP WKH KDQGV FDQ SUHPDWXUHO\ VKRUWHQ WKH SULQWKHDG OLIH 1RWH 7KH SULQWKHDG DVVHPEOLHV DUH IDFWRU\ DGMXVWHG 2WKHU WKDQ DGMXVWLQJ WKH SULQWKHDG SUHVVXUH IRU PHGLD GR QRW PDNH DQ\ DGMXVWPHQWV ,I WKH VFUHZV PRXQWLQJ WKH SULQWKHDG DUH DGMXVWHG LW FDQ FDXVH GD
6HFWLRQ 0DLQWHQDQFH Figure 4-10. Remove/Install Printhead Assembly Ribbon Sensor Board Head-Open Switch Wire Ground wire (second ground wire on the PT40x and replacement wiring harnesses only). Figure 4-11.
0DLQWHQDQFH 6HFWLRQ 5HSODFH 5LEERQ 6HQVRU %RDUG $VVHPEO\ &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 7KH SULQW HOHPHQWV PD\ EH KRW DQG ZLOO EXUQ WKH VNLQ &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 'LUW DQG PRLVWXUH IURP WKH KDQGV FDQ SUHPDWXUHO\ VKRUWHQ WKH SULQWKHDG OLIH &DXWLRQ 2EVHUYH SURSHU HOHFWURVWDWLF VDIHW\ SUHFDXWLRQV ZKHQ UHPRYLQJ KDQGOLQJ DQG UHSODFLQJ SULQWHG FLUFXLW ERDUGV / 5HY 1. Turn the printer Off (2).
6HFWLRQ 0DLQWHQDQFH 1. Insert screwdriver tip between plug and receptacle. Do not adjust or remove these screws. 2. Carefully twist screwdriver to pry apart. Plug Receptacle Figure 4-12.
0DLQWHQDQFH 6HFWLRQ Tab Ribbon Sensor Board 1. Slide a 1/4 in.(6.4 mm) flat-blade screwdriver under the tab (about 1/4 in.)(6.4 mm). 2. Gently lift up on the screwdriver handle until the screwdriver is perpendicular to the printhead assembly and ribbon sensor board. 3. The ribbon sensor board slides away from the printhead assembly. Figure 4-13. Remove Ribbon Sensor Board Tab Cutout Ribbon Sensor Board Figure 4-14.
6HFWLRQ 0DLQWHQDQFH 5HSODFH 3ULQW 0HFKDQLVP 0RGXOH &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 7KH SULQW HOHPHQWV PD\ EH KRW DQG ZLOO EXUQ WKH VNLQ &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 'LUW DQG PRLVWXUH IURP WKH KDQGV FDQ SUHPDWXUHO\ VKRUWHQ WKH SULQWKHDG OLIH &DXWLRQ 2EVHUYH SURSHU HOHFWURVWDWLF VDIHW\ SUHFDXWLRQV ZKHQ UHPRYLQJ KDQGOLQJ DQG UHSODFLQJ SULQWHG FLUFXLW ERDUGV 3DJH 1. Turn the printer Off (2). Disconnect the battery charger. 2.
0DLQWHQDQFH 6HFWLRQ 18. Refer to Figure 4-6 on page 4-12 and replace J2 (motor harness) and J1 (printhead harness). J2 and J1 are keyed and fit only one way. Do not force them into the connectors. 19. Refer to Figure 4-8 on page 4-14. Route all harnesses to avoid pinching and screw posts. 20. Refer to Figure 4-7 on page 4-13. Ensure the battery access door is in the slot in the front cover with the flat side facing in. 21. Replace the cover and shoulder strap. 22.
6HFWLRQ 3DJH 0DLQWHQDQFH 10. Set the printhead assembly on the antistatic mat. Close the media access door and place the printer face down. 11. Remove the two shoulder strap screws indicated in Figure 4-3 on page 4-8. Set the shoulder strap, the two shoulder strap sleeves, and the two shoulder strap screws aside. 12. Remove the cover mounting screws. 13. Lift the rear cover off and set it aside. 14. Refer to Figure 4-4 on page 4-10.
0DLQWHQDQFH 6HFWLRQ 1RWH 7KH UHSODFHPHQW ZLULQJ KDUQHVV DVVHPEO\ LV GHVLJQHG IRU XVH RQ ERWK WKH 3$ [ DQG 37 [ $Q DGGLWLRQDO JURXQG ZLUH OHDGLQJ IURP EHQHDWK WKH PHWDO VKLHOG LQVLGH WKH WRS FRYHU VKRZQ LQ )LJXUH RQ SDJH LWHP DWWDFKHV WR WKH JURXQG VFUHZ RQ WKH SULQWKHDG &RQQHFW WKH DGGLWLRQDO JURXQG ZLUH WR WKH JURXQG VFUHZ RQ WKH SULQWKHDG ZKHQ XVLQJ WKH ZLULQJ KDUQHVV RQ WKH 3$ [ DQG 37 [ VHH )LJXUH RQ SDJH 30.
6HFWLRQ 0DLQWHQDQFH 5HSODFH 0HPEUDQH 6ZLWFK $VVHPEO\ &DXWLRQ 2EVHUYH SURSHU HOHFWURVWDWLF VDIHW\ SUHFDXWLRQV ZKHQ UHPRYLQJ KDQGOLQJ DQG UHSODFLQJ SULQWHG FLUFXLW ERDUGV 3DJH 1. Turn the printer Off (2). Disconnect the battery charger. 2. Slide the battery compartment door open and remove the battery. 3. Lay the printer on a flat surface with the back of the printer facing up. 4. Remove the two shoulder strap screws indicated in Figure 4-3 on page 4-8.
0DLQWHQDQFH 6HFWLRQ 19. Refer to Figure 4-6 on page 4-12. Place the print mechanism, with the media access door facing down, into the front cover by holding it at the top near the access door. Slide in the bottom of the print mechanism first. 20. Refer to Figure 4-3 on page 4-8 and replace J2 (motor harness) and J1 (printhead harness). J2 and J1 are keyed and fit only one way. Do not force them into the connectors. 21. Refer to Figure 4-8 on page 4-14.
6HFWLRQ 0DLQWHQDQFH 5HSDLU 0HGLD *XLGH &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 7KH SULQW HOHPHQWV PD\ EH KRW DQG ZLOO EXUQ WKH VNLQ &DXWLRQ 'R QRW WRXFK WKH SULQW HOHPHQWV RQ WKH SULQWKHDG 'LUW DQG PRLVWXUH IURP WKH KDQGV FDQ SUHPDWXUHO\ VKRUWHQ WKH SULQWKHDG OLIH &DXWLRQ 2EVHUYH SURSHU HOHFWURVWDWLF VDIHW\ SUHFDXWLRQV ZKHQ UHPRYLQJ KDQGOLQJ DQG UHSODFLQJ SULQWHG FLUFXLW ERDUGV Refer to Figure 4-18. The media guides are part of the print mechanism assembly.
0DLQWHQDQFH 6HFWLRQ 13. Install a battery, load the media, and calibrate the unit. Connect a battery charger if necessary. Ensure that the horizontal portion of the media guides are parallel to the platen roller. Ensure that the vertical portion of the media guides are perpendicular to the platen roller. Figure 4-18.
6HFWLRQ 0DLQWHQDQFH ,U'$ %RDUG DQG &DEOH 5HSODFHPHQW 1. Turn the printer Off (2). Disconnect the battery charger. 2. Slide the battery compartment door open and remove the battery. 3. Lay the printer on a flat surface with the back facing up. 4. Remove the two shoulder strap screws indicated in Figure 4-3 on page 4-8. Set the shoulder strap, shoulder strap sleeves, and shoulder strap screws aside. 5. Remove the rear cover mounting screws. 6. Lift the rear cover off and set it aside. 7.
6HFWLRQ Battery Access Door 0.25 in. (6.35 mm) 3.9375 in. (100 mm) 2.75 in. (69.8 mm) 0DLQWHQDQFH Figure 4-20.
6HFWLRQ 0DLQWHQDQFH 3DJH / 5HY
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ 6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 'UDZLQJ DQG 3DUWV /LVW Use Figures 5-1 and 5-2 when identifying PA400/403 and PT400/403 printer parts, assemblies, and kits for troubleshooting and repair. For replacement parts and pricing, contact your Zebra distributor. Tables 5-1 and 5-2 list replacement parts and kits available for the PA400/403 and PT400/403 printer. Some of these are available only in kit form or as subassemblies.
Maintenance and Assembly Drawings Section 5 Table 5-1 Replacement Parts and Assemblies (See Figur e 5-1) Item Qty Part Number 1 1 505086 X X X X Tear Blade 2 1 505145M X X X X Printhead Assembly 3 1 505040M X 1 505040-02M 4 1 505014 X X 5 1 580018M X X 6 1 58008M X X 1 52700M 7 1 505073 X 8 1 505004M 9 10 1 1 562005M 81519 1 82330 1 AA6002-1 1 AA6002-2 11 1 580013M 12 1 52582M X X X X IrDA PCBAssy.
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 2 11 1 3 4 8 5 13 12 14 6 9 7 10 Figure 5-1.
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ 7DEOH 2SWLRQ DQG $FFHVVRU\ .LWV ,WHP 4W\ 3DUW 1XPEHU 'HVFULSWLRQ 9$& &KDUJHU $FFHVVRU\ &DEOH 5- '% 8QLYHUVDO &KDUJHU :LWKRXW 3RZHU &RUG 3RZHU &RUG 8. ,(& & 3RZHU &RUG $XVW ,(& & 3RZHU &RUG (XUR ,(& & 3RZHU &RUG 86 ,(& & 0 =HEUD )DVWUDS DQG +DUGZDUH .
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ 1 2 Power Cord Varies by Country 4 3 5 6 7 8 Figure 5-2.
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 3RZHU 6XSSO\ %RDUG /D\RXW J1 (Printhead) J2 (Stepper Motor) J7 (Logic Board) J12 (Membrane Switch) Front J5 (RJ45 Jack) J9 (Battery Charger Jack) Back Figure 5-3.
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ 0DLQ /RJLF %RDUG /D\RXW Figure 5-4.
6HFWLRQ 3DJH 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV / 5HY
