RW Series Mobile Printer Maintenance Manual for RW 420 Printer and RW 220 Printer; RW 420 Vehicle Cradle RMAN-RWS-001 rev.
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation and its subsidiaries (“Zebra Technologies”). It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such propriety information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies.
Contents Section 1: RW Series Introduction.................................1-5 Description..................................................................................................... 1-5 Operating Modes........................................................................................... 1-5 Printing Technology....................................................................................... 1-5 Communications................................................................................
Replacement Kit RK17393-023- RW Series Corner Attachment Kit.... 2-53 Replacement Kit RK17393-024 RW Series Connector Door.................2-55 Replacement Kit RK18243-1 RW 420 Vehicle Cradle PCB.....................2-57 Replacement Kit RK17393-026 RW 420 Vehicle Cradle Housing Assembly........................................... 2-60 Replacement Kit RK17949-001- RW 220 Media Cover......................... 2-63 Replacement Kit RK17949-002- RW 220 Platen/Gear...........................
Section 1: RW Series Introduction Description The Zebra RW Mobile Printer series are low-cost, portable, direct thermal printers. They can be carried by the operator using a shoulder strap or belt clip, sit at a work space, or be mounted in a vehicle using an optonal Docking Cradle. Each model is powered by a Li-ion battery pack which makes it particularly useful in environments where AC power is not readily available.
802.11b Compact Flash Module USB I/O J13 Magcard J4 USB Cable Bluetooth Module- U8 J1 Smartcard J J2 J3 2.
1 2 13 12 3 11 4 10 5 6 8 7 9 8 14 1. 2. 3. 4. 5. 6 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
1 2 11 3 4 10 9 5 6 7 8 7 12 1.Platen Roller 2. Bar Sensor 3. Media Support Disks 4. Printhead 5. Latch Release Button 6. Magnetic Stripe Reader (MSR) Slot 7. “D” Rings 8. Control Panel 9. Smart Card Slot 10. Gap Sensor 11. Media Cover 12. Communications Port Door 13. Communications Port 14. Belt Clip 15. Battery 16. Battery Charging Receptacle 14 15 16 Figure 3 - RW 220 Overview RMAN-RWS-001 rev.
Diagnostic Tools This section of the Printer Repair Manual contains instructions for using the various diagnostic tools available from Zebra and instructions on contacting technical support services offered by Zebra. Following sections contains explanations on the products configuration structure, troubleshooting guide for isolating common printer problems, illustrated parts breakdowns for specific models and specialized component replacement procedures.
Printing a Diagnostic Label Creating a Configuration Label 1. Turn the printer off. Load the media compartment with journal media (media with no black bars printed on the back) 2. Press and hold the Feed Button. 3. Press and release the Power button and keep the Feed button pressed. When printing starts, release the Feed button.
Information on any installed 802.11b/g wireless devices. In this example, an 802.11b WLAN card has been detected. List of peripherals installed. In this example the printer has the Mag Card and Smartcard reader option, and the wireless expansion module has an 802.11b and Bluetooth wireless module1. List of power mangement settings. Also includes a count of the number of times the unit has been powered on. Figure 4a: Configuration L abel Example (continued) • 1-11 • Introduction •RMAN-RWS-001 rev.
Flash Memory Size RAM Size Maximum Label Size Resident Fonts Installed Resident Pre-scaled Font Installed (my 2010.CPF) Pre-scaled fonts (.cpf) listed separately myfont .FNT myfont2 .FNT myfont3 .FNT my_2010 .CPF my_2020 .CPF Files Loaded in Printer Memory (will include Pre-scaled or Scalable Fonts) Amount of Memory Available End of Configuration Report Figure 4b: Configuration L abel Example (continued) RMAN-RWS-001 rev.
Introduction to Label Vista™ Label Vista is a program running under the Windows™ environment that allows users to design labels which can be printed on the full range of Zebra mobile printers. Label Vista also provides a powerful set of diagnostics tools which use familiar Windows “point and click” routines. These tools can be reached under the Printer selection on the Label Vista menu bar.
RW Series Unit Test & Calibration Equipment Required 1. A computer with the following minimum configuration: • Pentium CPU • 256 MB RAM • 1.44 MB Floppy Drive • 1 GB Hard Drive • CD-ROM drive • SVGA 14 in.monitor and SVGA card • 2 Serial Ports • USB Port • Windows 95/9, NT or 2000 • Unit Test Software version 3.3 or higher installed with the “euro” configuration. 2. A bar code scanner, using either RS232 (serial) keyboard “wedge” or USB communications. (Example: Symbol Model LS1908 series) 3.
Section 2: Replacement Procedures Tools and Supplies Make use of the following tools and supplies for maintaining the printer and installing the repair kits: Hand Tools • #0 or #1 Phillips Head Screw Driver • 3/32” hex driver Supplies • Cleaning Pen (10 pack), p/n AN11209-1 • Isopropyl alcohol • SuperLube™ lubricant p/n 82325 SL • Spares Kit AN16753-029, consisting of: • Eye Sensor Calibration Swatch p/n AA15417-1 • Gap Sensor Calibration Swatch p/n AA15417-2 • Media, Batteries, and Chargers for RW
Replacement Kit RK17393-001- RW 420 Media Cover Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-001 Media Cover Kit in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
4. Remove the two screws securing the CPU Board to the Lower Housing. 5. Unlock the connector J2 and remove the Bar Sense Cable from the CPU Board. 6. Remove the Printer Frame from the Lower Housing. (Refer to the procedure for RK17393-007 for more details.) Carefully pivot the printer frame out of the Lower Housing and lift the Media Cover clear of the Lower Housing . Avoid putting excess strain on the remaining cables connected to the CPU Board. Peel the old Bar Sense Cable away from the printer Frame.
9. Remove the Media Cover. Using a 3/32” hex driver, push the Hinge Pin out of the Printer Frame, and then lift the Media Cover from the Printer Frame. Installing the Media Cover 1. Insert the Double Torsion Spring into the Lower Cover. 2. Feed the Bar Sense Cable through the slot in the Printer Frame as shown. 3 Align the Media Cover with the Printer Frame and slide the Hinge Pin through the Media Cover, the Double Torsion Spring and Printer Frame. Center the pin.
4. Ensure that the hinge pin is behind the Bar Sense Cable. 5. Peel the backing off the bar sensor cable and adhere it in the groove on the bottom of the Printer Frame. Peel the adhesive backing off the Sensor cable and apply the Bar Sense Cable into the groove in the bottom of the Printer Frame. 6. Install the Printer Frame in the Lower Housing, again referring to procedure for RK17393-007 if necessary. Avoid putting excess strain on the remaining cables connected to the CPU Board. 7.
Accessory Kits AK17393-002 & AK17393-028 RW 420 Platen/Gear Installation Instruction This kit includes the parts and documentation necessary to install the AK17393-002 Platen/Gear Kit or AK17393-028 Linerless Platen/Gear Kit in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. Caution • The operator must wear a properly grounded ESD strap to perform the following repair procedure.
2 1 Assy, Gear and Platen p/n AC16703-1M (-002) or p/n AC16703-2M (-028). Holder, Platen Avoid pulling on Sensor Cable Replace Screws holding Holder, Platen in place. continued on next page • 2-21 • RMAN-RWS-001 rev.
Replacement Kit RK17393-003; RK18471-01 RW 420 Media Guide Assembly Installation Instructions This kit includes the parts and documentation necessary to install the RK17393003 or RK18471-01 Media Guide Kit in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Installing the Media Assembly 1. RK17393-003 only: Apply a sparing amount of SuperLube to the two pins on the Media Assembly where the Gears are assembled. Install the (2) Gears on the Media Guide Assembly. Assy, Media Guide, Spares RW 420 p/n CC17410-1. Apply SuperLube to pin. Apply SuperLube to pin. Gear- 48P 14T (2) p/n BA17066-1. All Repair Kits: Slide the Media Guide Assembly into the Printer Frame as shown at “1” below.
4. Secure the Media Assembly to the Printer Frame with (2) Screws. Screw, #4-40 x 1/4” Pan Hd. Phillip Nylon (2) p/n TH-SJ0803N 5. Reinstall the Printer Frame to the Lower Housing. Refer to procedure RK17393-007 for more details. 6. Plug in the Printhead, Bar Sensor and the Gap Sensor Cable to the CPU Board per the table below. If you unplugged the Motor cable, plug it into J6 at this time.
Replacement Kit RK17393-005- RW 420 Printhead Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-005 Printhead Kit in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Removing the Printhead Note: Use care when handling the Printhead Assembly. The edges of the tear bar are sharp! 1 Remove the Bar, Spring from the Printer Frame. Remove and retain the (2) Screws securing the Bar, Spring, and Flex the sides of the Printer Frame enough to allow the Bar, Spring to be removed. 2. Remove the (2) Printhead Springs. 3. Remove the Printhead out of the Printer Frame. Flex one side of the Printer frame, and then pull the pivot point of the printhead out from the Printer Frame.
Installing the Printhead Note: Use care when handing the Printhead Assembly. The edges of the tear bar are sharp! Avoid getting your fingers on the glass surface of the printhead. Always clean the printhead after installation to remove any oils or debris that may have accumulated during installation. 1. Install the Printhead Assembly. Insert one pivot point of the printhead into the slot on the Printer Frame Assembly as shown at “1” below.
4 Plug in the Printhead, Bar Sensor and the Gap Sensor Cable to the CPU Board per the table below. If you unplugged the Motor cable, plug it into J6 at this time. Replacement Printhead Springs (2) p/n BA17087-1 (Included with RK17393-005) Bar, Spring CPU CONNECTIONS CABLE CPU CONNECTOR MOTOR CABLE J6 BAR SENSOR FLEX CABLE J2 GAP SENSOR FLEX CABLE J10 PRINTHEAD CABLE J5 5. Re-secure the CPU Board. Refer to Procedure RK17393-020 for more details. 6. Install the Upper Housing Assembly.
Replacement Kit RK17393-006- RW 420 Motor Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-006 Motor Kit, RW 420 in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Removing the Motor 1. Remove the Printer Frame and Media Cover Assembly from the Lower Housing. 2. Unplug the Motor connector (J6) from the CPU Board 3. Remove the Motor from the Printer Frame by removing its mounting Screw and twisting the motor mounting ears away from the frame as shown. Screw #4-40 x 1/4” Pan Hd. Phillip Nyl. p/n TH-SJ0803N (Included with RK17393-006) Motor p/n BT16073-1 (Included with RK17393-006) Installing the Replacement Motor 1.
4. Using the Procedure RK17393-020 and the table below as a guide, plug in the cables from the Printer to the CPU Board. Ensure all ZIF connectors for the flat flex cables are locked. CPU CONNECTIONS CABLE CPU CONNECTOR MOTOR CABLE J6 BAR SENSOR FLEX CABLE J2 GAP SENSOR FLEX CABLE J10 PRINTHEAD CABLE J5 5. Re-secure the CPU Board. Refer to Procedure RK17393-020 for more details. 6. Assemble the Upper Housing to the Printer, and secure it with the retained hardware.
Replacement Kit RK17393-007- RW 420 Printer Frame Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-007 Printer Frame Kit, RW 420 in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
3. Install the Printhead Assembly: Follow the procedure for installing the Printhead Assembly in RK17393-005. Note that a new Bar, Spring is included as part of the Printer Frame Replacement Kit. 4. Install the Printer Frame and Media Cover assembly into the Lower Cover. Ensure that the Motor Cable and Bar Sense Cable will not be pinched between the Printer Frame and the Lower Cover.
6. Re-secure the CPU Board. Refer to Procedure RK17393-020 for more details. 7. Reassemble the Upper Cover and Module Housing: Re-install the Upper Housing per RK17393-008. When re-installing the Upper Housing ensure that the proper Corner Attachment Kit (ref. RK17393-023) is also re-installed. 8. Install the Battery and turn the unit on. Verify that all indicator lights turn on properly. 9. Verify proper operation of the printer by performing a two-key reset.
Replacement Kits RK17393-008 & RK18280-1 RW 420 Keypad and Housing Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-008 & RK18280-1 Keypad and Housing Kits, RW 420 in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Unplug LCD and Keypad flex circuits from the CPU board 3. Pivot the Keypad and Housing forward. 4. Unplug the Keypad and LCD flex cables from the CPU board. 5. If your printer has a Bluetooth radio, detach the antenna card from the lower housing. RMAN-RWS-001 rev.
Separate the Assemblies Remove and retain radio assembly (shown) or Bracket Radios and attaching hardware. Unplug cables from Card Reader Assembly. 1. Remove and retain the Bracket, Radios by removing the (3) screws securing the Bracket, Radios to the Card Reader Assembly. Retain the Screws. Note that some printers will have radio and interface PCBs assembled to the bracket, and some printers will not, depending on the printer’s configuration.
Remove and retain Card Reader Assembly and attaching hardware. Installing the New Upper Housing 1. If you removed a Card Reader from the printer, re-install it in the new Keypad and Housing. Arrange the Keypad and LCD flex circuits so they are between the back of the Card reader assembly and the LCD assembly. Secure the Card Reader with (4) screws. 2. If your printer has a Card Reader option, plug the two cables from the card reader into the Legacy PCB on the retained radio assembly. 3.
Plug LCD Flex Circuit into J9. Plug Keypad Flex Circuit into J7. Rotate reassembled Keypad and Housing Assy. into place on lower housing. 4. Plug the Keypad flex circuit from the Keypad and Housing into J7 on the CPU board. Plug the LCD flex circuit from the Keypad and Housing into J6 on the CPU board. Ensure both connector’s locking tabs are secured. 5. Rotate the Keypad and Housing assembly onto the lower housing of the printer.
Replacement Kit RK18241-1 RW 420 Card Reader Installation Instructions This kit includes the parts and documentation necessary to install the RK1739311 Card Reader Kit, RW 420 in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
J4 J2 Remove the Card Reader 1. Remove the (2) screws holding the Legacy Board in place. Slide it forward and pivot it upwards to gain access to the connectors for the Card Reader 2. Unplug the two cables from the Card Reader Assembly to J2 and J4 on the Legacy PCB and remove the Legacy PCB 3. Remove the (4) screws holding the Card Reader Assembly in place and remove the Card Reader assembly. continued on next page • 2-41 • RMAN-RWS-001 rev.
Screw, Self Tap M3 x 10mm Phillips Head (4) p/n TH-PTA023010-5 Assembly, Card Reader RW 420 Spares p/n CC17178-E3 Install the Card Reader 1. Install the new Card Reader Assembly in the Keypad and Housing. Arrange the Keypad and LCD flex circuits so they are between the back of the Card reader assembly and the LCD assembly. Secure the Card Reader with (4) screws. 2. Plug the two cables from the card reader into J2 and J4 on the Legacy PCB 3.
J7 J9 Rotate reassembled Keypad and Housing Assy. into place on lower housing. Re-install the Keypad and Housing 1. If necessary, plug the keypad and LCD flex cables into J7 and J9 on the CPU board. 2. Rotate the Keypad and Housing assembly onto the lower housing of the printer. Ensure that you tuck the LCD and Keypad Flex circuits behind the edge of the CPU Board before securing the two housings. Align the two housings and press the Keypad and Housing firmly into place.
Replacement Kit RK17393-012- RW 420 Docking Plug Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-012 Docking Plug Kit, RW 420 in the RW 420 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
RW 420 Radio Replacement Kits Installation Instructions This kit includes the parts and documentation necessary to install the following Replacement Kits in the RW 420 model printer. Kit p/n RK18242-1 RK17393-015 RK17393-019 RK17393-029 Description Radio, 802.11b (Compact Flash) Radio 802.11b (Zebra Value Radio) Radio, Bluetooth Kit Radio 802.11g Kit The installation procedure for all of these kits is substantially the same.
Remove the Radio Assembly 1. If your printer has a Bluetooth radio (RK17393-019), detach the antenna card from the lower housing. 2. Remove the Radio Assembly by removing the (3) screws securing the Bracket, Radios to the Card Reader Assembly.
2. Install the Radio Assembly into the Keypad and Housing. Secure it in place with (3) screws. If the Radio assembly has an external antenna card (RK17393-019), insert the antenna card into the upper housing. Plug LCD Flex Circuit into J9. Plug Keypad Flex Circuit into J7. Rotate reassembled Keypad and Housing Assy. into place on lower housing. Refer to the procedure for RK17393-008 & RK18280-1 for more details on the following steps. 4.
Replacement Kit RK17393-020 RW 420 4MB Controller Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-020 Controller Kit, 4M Kit in the RW 420 model printer. Read these instructions thoroughly before attempting to install these kits. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Installing the Replacement Controller Board J10 J6 Press Latch release button while removing Controller Board J5 J2 PC Assy RW Controller 4M. p/n CQ16910-G4 (RK17393-020) 1. Slide the replacement Controller Board into place on the Lower Housing, while pressing and holding the Latch release button. Damage could occur if the Latch release button is not pressed in while installing the Controller Board 2. Insert the Printhead cable into J5 on the Controller Board, and lock the connector.
J6 Press Latch release button while installing Controller Board J10 J2 J5 NOTES: The connector for the motor cable is polarized. It will only fit in one direction. Do not try to force the connector in place. Flex cables install in zero insertion force (ZIF) connectors. Pull the connector open, insert the cable, and close the connector to retain the flex cable. Dress the motor cable away from mounting bosses so they won’t get pinched during the next assembly steps. 3.
Accessory Kit AK17393-022- RW Series Belt Clip Installation Instructions This kit includes the parts and documentation necessary to install the AK17393-022 RW Series Belt Clip Kit in the RW 420 and RW 220 model printers. Read these instructions thoroughly before attempting to install these kits. RW 420 is illustrated.
Replace the Belt Clip 1. Press the ball end of the Belt Clip into the recess at the front of the battery well until it slips into place. 2. Rotate the Belt Clip to allow access to the Battery compartment. 3. Insert the battery into the printer. Note that the tabs on the Battery pack fit into corresponding slots on the lower cover. 4. Rock the Battery into the printer until it locks in place with an audible click. RMAN-RWS-001 rev.
Replacement Kit RK17393-023- RW Series Corner Attachment Kit Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-023 Corner Attachment Kit, in an RW series printer. Read these instructions thoroughly before attempting to install these kits. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Removing the “D” Rings 1. Remove the (2) Screws securing the upper and lower covers of the printer. 2. Slide the (2) “D” rings out from the Printer. Installing the “D” Rings 1. Slide the (2) “D” rings into the Printer. 2. Install the (2) Screws supplied with the kit. Ensure the “D” rings can pivot freely after installation. RMAN-RWS-001 rev.
Replacement Kit RK17393-024 RW Series Connector Door Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-024 RW Series Connector Door Kit in the RW 420 and RW 220 model printers. Read these instructions thoroughly before attempting to install this kit. RW 420 is illustrated. Procedure is the same for RW 220 Printers The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Remove the Connector Door 1. Pull the Connector Door away from the lower housing Install the Connector Door 1. Press the Connector Door into place on the lower housing. Ensure that the top flap of the Connector Door sits properly on the lower housing as shown. Re-assemble the Keypad and Housing Assembly 1. Re-assemble the Keypad and Housing Assembly to the Printer, referring to the procedure for RK1793-008/RK18280-1 as needed for more details. Door, Rubber, RW 420 p/n BA17089-1 RMAN-RWS-001 rev.
Replacement Kit RK18243-1 RW 420 Vehicle Cradle PCB Installation Instructions This kit includes the parts and documentation necessary to install the RK18243-1 Docking Station PCB Kit, RW 420 in the RW 420 Vehicle Cradle. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Docking Station PCB Upper Housing Power Cable B B B Remove and retain screw and hex nut securing the ground strap to the PCB Ground Strap B B Remove display pad flex circuit from J2 on PCB A A A A A A A RMAN-RWS-001 rev.
Unplug the Communications Cable 1. If you have a communications cable plugged into the RS232 port on the Vehicle Cradle, un-plug it. Remove the Cradle from the RAM Mount 1. If the Vehicle Cradle is attached to the optional RAM Mount, remove it and retain the mounting hardware. Remove the Bottom Plate 1. Remove and retain the (7) screws from the Plate, RW4 Cradle RAM Mount. (Marked “A” on illustration.) 2. Lower the Plate away from the PCB. Note that it is still attached to the PCB by the ground strap.
Replacement Kit RK17393-026- RW 420 Vehicle Cradle Housing Assembly Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-026 Docking Station Housing Assembly Kit, RW 420 in the RW 420 Vehicle Cradle. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Assy, Spares, Cradle Upper p/n CC17545-1 Docking Station PCB Power Cable B B B Ground Strap B Remove display pad flex circuit from J2 on PCB A B A A A A Remove and retain bottom plate and attaching hardware A A continued on next page • 2-61 • RMAN-RWS-001 rev.
4. Remove the PCB and the Lower Plate from the Upper housing assembly. Install the PCB in the replacement Housing 1. Plug the Flex Circuit from the Upper Housing into the PCB. 2. Secure the PCB to the Upper Housing of the Vehicle Cradle with (5) Screws retained in the previous step.. 3. Plug the Flex Circuit from the Upper Housing into the PCB. 4. Plug the power cable into the PCB Install the Base Plate 1.
Replacement Kit RK17949-001- RW 220 Media Cover Installation Instructions This kit includes the parts and documentation necessary to install the RK17949-001 Media Cover Kit in the RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
6. Remove the Printer Frame from the Lower Housing. (Refer to the procedure for RK17974-007 for more details.) Carefully pivot the printer frame out of the Lower Housing and lift the Media Cover clear of the Lower Housing . Avoid putting excess strain on the remaining cables connected to the CPU Board. 7. Remove the Platen and Gear from the Media Cover Assembly. (Refer to the procedure for RK17974-002 for more details) Peel the old Bar Sense Cable away from the printer Frame. 8.
Installing the Media Cover 1. Insert the Torsion Spring into the Lower Cover. 2. Feed the Bar Sense Cable through the slot in the Printer Frame as shown. 3 Align the Media Cover with the Printer Frame and slide the Hinge Pin through the Media Cover, the Torsion Spring and Printer Frame. Center the pin and ensure that the hinge pin is behind the Bar Sense Cable.
Peel the adhesive backing off the Sensor cable and apply the Bar Sense Cable into the groove in the bottom of the Printer Frame. 4. Peel the backing off the bar sensor cable and adhere it in the groove on the bottom of the Printer Frame. 5. Install the Printer Frame in the Lower Housing, again referring to procedure for RK17974-007 if necessary. Avoid putting excess strain on the remaining cables connected to the CPU Board. 6.
Replacement Kit RK17949-002- RW 220 Platen/Gear Installation Instruction This kit includes the parts and documentation necessary to install the RK17974-002 Platen/Gear Kit in the RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. Caution • The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Assy, Spares Platen/ Gear RW 220 p/n AN17949-002 2 1 Holder, Platen Avoid pulling on Sensor Cable Replace Screws holding Holder, Platen in place. RMAN-RWS-001 rev.
Replacement Kit RK17479-003- RW 220 Media Guide Installation Instructions This kit includes the parts and documentation necessary to install the RK17479-003 Media Guide Kit in the RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
8. Remove the Media Assembly: Use care when working around the Printhead. The edges of the tear bar are very sharp! Rock the Media Assembly towards the back of the printer and then lift it up and away from the Printer Frame. Installing the Media Assembly 1. Slide the Media Guide Assembly into the Printer Frame as shown at “1” below. Dress the Gap Sensor flex cable through the Printer Frame 2. Rock the Media Guide Assembly back towards the Printer Frame as shown at “2” until it snaps in place.
3. Secure the Media Assembly to the Printer Frame with (2) Screws. Screw, #4-40 x 1/4” Pan Hd. Phillip Nylon (2) p/n TH-SJ0803N 4. Reinstall the Printer Frame to the Lower Housing. Refer to procedure RK17479-007 for more details. 6. Plug the Gap Sensor Cable to the CPU Board Use the the table below for reference. If you unplugged the Motor cable, plug it into J6 at this time.
Replacement Kit RK17393-004- RW Series Media Disk Installation Instructions This kit includes the parts and documentation necessary to install the RK17393-004 Kit Repair RW Series Media Disk in RW series printers. Read these instructions thoroughly before attempting to install this kit. Reference Materials UMAN-RWS RW Series Users’ Guide Tools Required #0 or #1 Phillips Head Screw Driver Cautions Caution • This installation must be performed only by a qualified service technician.
Changing the Media Core Size The printer is adjusted at the factory for media with a 3/4” core. If you need to use media with a 1 3/8” core, do the following: 1. Remove and retain the Screw and Washer from a Media Support as described above. Flip the Media Disk end-for-end, and reassemble to the Media Support with the retained hardware. 2. Repeat this procedure for the other Media Support.
Replacement Kit RK17949-005- RW 220 Printhead Installation Instructions This kit includes the parts and documentation necessary to install the RK17949-005 Printhead Kit in the RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Removing the Printhead Note: Use care when handling the Printhead Assembly. The edges of the tear bar are sharp! 1 Remove the Bar, Spring from the Printer Frame. Remove and retain the (2) Screws securing the Bar, Spring. Flex the sides of the Printer Frame enough to allow the Bar, Spring to be removed. 2. Remove the (2) Printhead Springs. 3. Remove the Printhead out of the Printer Frame. Flex one side of the Printer frame, and then pull the pivot point of the printhead out from the Printer Frame.
Installing the Printhead Note: Use care when handing the Printhead Assembly. The edges of the tear bar are sharp! Avoid getting your fingers on the glass surface of the printhead. Always clean the printhead after installation to remove any oils or debris that may have accumulated during installation. 1. Install the Printhead Assembly. Insert one pivot point of the printhead into the slot on the Printer Frame Assembly as shown at “1” below.
2. Install the (2) Springs, Printhead supplied with the repair kit to the Bar, Spring. 3. Re-assemble the Bar, Spring to the Printer Frame. Ensure that the Printhead Springs are seated over the heads of the screws securing the tear bar to the printhead Replacement Printhead Springs (2) p/n BA17932-1 (Included with RK17949-005) Bar, Spring 4 Plug in the Printhead, Bar Sensor and the Gap Sensor Cable to the CPU Board per the table below. If you unplugged the Motor cable, plug it into J6 at this time.
Replacement Kit RK17949-006- RW 220 Motor Installation Instructions This kit includes the parts and documentation necessary to install the RK17949-006 Motor Kit, RW 220 in the RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Removing the Motor 1. Remove the Printer Frame and Media Cover Assembly from the Lower Housing. 2. Unplug the Motor connector (J6) from the bottom side of the CPU Board 3. Remove the Motor from the Printer Frame by removing its mounting Screw and twisting the motor away from the frame. Screw Self-Tap M3 x 6 p/n TH-PTA023008-5 (Included with RK17949-006) Motor p/n BT16601-2 (Included with RK17949-006) Installing the Replacement Motor 1. Insert the Motor’s pinion gear through the hole in the Printer Frame.
4. Using the Table below as a guide, plug in the cables from the Printer to the CPU Board. Ensure all ZIF connectors for the flat flex cables are locked. CPU CONNECTIONS CABLE CPU CONNECTOR MOTOR CABLE J6 BAR SENSOR FLEX CABLE J2 GAP SENSOR FLEX CABLE J10 PRINTHEAD CABLE J5 5. Re-secure the CPU Board. Refer to Procedure RK17949-020 for more details. 6. Assemble the Upper Housing to the Printer, and secure it with the retained hardware.
Replacement Kit RK17949-007- RW 220 Printer Frame Installation Instructions This kit includes the parts and documentation necessary to install the RK17947-007 Printer Frame Kit, RW 220. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
3. Install the Printhead Assembly: Follow the procedure for installing the Printhead Assembly in RK17947-005. Note that a new Bar, Spring is included as part of the Printer Frame Replacement Kit.
4. Using the Table below as a guide, plug in the cables from the Printer to the CPU Board. Ensure all ZIF connectors for the flat flex cables are locked. CPU CONNECTIONS CABLE CPU CONNECTOR MOTOR CABLE J6 BAR SENSOR FLEX CABLE J2 GAP SENSOR FLEX CABLE J10 PRINTHEAD CABLE J5 5. Press the latch release button inward and carefully move the CPU board in towards the printhead as far as it will go. Release the Latc relaeae button. The CPU board should be retained from moving. 5.
Housing ensure that the proper Corner Attachment Kit (ref. RK17947-018) is also re-installed. 9. Install the Battery and turn the unit on. Verify that all indicator lights turn on properly. If you have also replaced the Media Guide Assembly and/or the Printhead Assembly during this procedure you must perform a complete unit test to calibrate the new sensors included with these assemblies. 9 Verify proper operation of the printer by performing a two-key reset.
Replacement Kits RK17949-008 & -009- RW 220 Keypad and Housing Kits Installation Instructions This kit includes the parts and documentation necessary to install the RK17949-008 & RK17949-009 Keypad and Housing Kits, RW 220 in an RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Remove Screws reataining the Radio PCB from the Printer. Store the Radio PCB in a static proof bag or container J7 (LCD) J9 (Keypad) 3. Open the Media Cover 4.. Pivot the Keypad and Housing forward. 5. Unplug the Keypad and LCD flex cables from the CPU board. Separate the Assemblies 1. Remove and retain the Radio PCB by removing the (2) screws securing it to the Bracket, Radio. Retain the Screws. Unplug the radio from its antenna.
Installing the New Upper Housing 1. For RK17949-009 only: Re-install the Card Reader in the new Keypad and Housing. Arrange the Keypad and LCD flex circuits so they are between the back of the Card reader assembly and the LCD assembly. Secure the Card Reader with (4) screws. 2. For RK17949-009 only: Plug the two cables from the card reader into the retained radio PCB. 3. Install the radio assembly, or the Bracket Radios into the Keypad and Housing.
Radio PCB Assembly J7 J9 5. Reassemble the radio PCB assembly to the Bracket, Radio. 6. Plug the Keypad flex circuit from the Keypad and Housing into J7 on the CPU board. Plug the LCD flex circuit from the Keypad and Housing into J9 on the CPU board. Ensure both connector’s locking tabs are secured. 7. Rotate the Keypad and Housing assembly onto the lower housing of the printer. Ensure that you tuck the LCD and Keypad Flex circuits behind the edge of the CPU Board before securing the two housings.
Replacement Kit RK17949-010 - RW 220 Card Reader Installation Instructions This kit includes the parts and documentation necessary to install the RK17949-010 Card Reader Kit, RW 220 in the RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
Radio PCB Assembly If unit has an external antenna, unplug it from the Radio PCB Assembly. Pivot the Upper Housing Assembly forward Remove the Card Reader 1. Remove the (2) screws holding the Radio Board in place, retaining the hardware. If the unit has an external antenna, unplug the antenna lead from the Radio Board. 2. Remove the (4) screws holding the Card Reader Assembly in place and remove the Card Reader assembly. 3.
Card Reader Spares Assembly p/n CC18142-1 Dress the antenna lead through the opening in the Bracket, radio. External Antenna (802.11x type shown.) Install the Card Reader 1. If the unit has an external antenna for an 802.11x type radio, slide the Antenna PCB into the well on the top of the Radio Bracket. Dress the antenna lead through the opening in the Radio Bracket. 2. Secure the Card Reader Spares assembly to the Upper Housing with (4) screws. continued on next page • 2-91 • RMAN-RWS-001 rev.
Radio PCB Assembly J7 J9 3. Plug the antenna lead into the Radio PCB Assembly, and re-secure it with (2) screws. Re-install the Keypad and Housing 1. If necessary, plug the keypad and LCD flex cables into J7 and J9 on the CPU board. 2. Rotate the Keypad and Housing assembly onto the lower housing of the printer. Ensure that you tuck the LCD and Keypad Flex circuits behind the edge of the CPU Board before securing the two housings.
RW 220 Radio Replacement Kits Installation Instructions This kit includes the parts and documentation necessary to install the following Replacement Kits in the RW 220 model printer. Kit p/n RK17949-011 RK17949-012 RK17949-013 RK17949-015 RK17949-016 Description Radio, 802.11b, ZLAN Radio, 802.11b (Compact Flash) Radio, Bluetooth Kit Radio, 802.11g (non-card) Radio, 802.11g (with card) The installation procedure for all of these kits is substantially the same.
Radio Assembly. (Retain mounting screws) If a MCR/SmartCard is installed, un-plug the two cables into J2 and J4 on the Radio Assembly. J4 J2 Remove the Radio Assembly You must replace the Radio Assembly you have removed with one of the same type in order for the printer’s regulatory markings to remain in conformance. 1. Remove the Radio PCB from the Radio Bracket by removing and retaining (2) screws.
Radio Bracket (MCR/SmartCard version shown.) RW2 2.4GHz Monopole Antenna p/n CQ17593-G1 (supplied with RK17949-011 & -012 Bluetooth Antenna p/n CQ17715-G1 (supplied with RK17949-013 Installing the Replacement Radio Assembly 1. (RK17949-013 only) Peel the adhesive backing of the Bluetooth Antenna card and secure it to the top housing. Ensure the attachment area has been thoroughly cleaned with isopropyl alcohol to remove any adhesive residue from the antenna remove in the previous steps. 2.
Install the Upper Housing Refer to the procedure for RK17949-008 & -009 for more details on the following steps. 1. Plug the Keypad flex circuit from the Keypad and Housing into J7 on the CPU board. Plug the LCD flex circuit from the Keypad and Housing into J9 on the CPU board. Ensure both connector’s locking tabs are secured. 2. Rotate the Keypad and Housing Assembly onto the lower housing of the printer.
Replacement Kit RK17949-014 RW 220 4MB Controller Installation Instructions This kit includes the parts and documentation necessary to install the RK17949014 4 MB Controller Kit in the RW 220 model printer. Read these instructions thoroughly before attempting to install this kit. The operator must wear a properly grounded ESD strap to perform the following repair procedure.
A A A A J5 J10 J6 PC Assy RW2 Controller 4MB p/n CQ17279-G4 J2 Removing the Controller Board 1. Remove the Top Cover. Refer to the procedure for RK17949-008 and -009 for more details. 2. Remove and retain the (4) screws reatining the Printer Frame Assembly to the Lower Housing, marked “A”. 3. Unplug the all cables from the Controller Board.
Press Latch release button while removing Controller Board J5 J6 J10 J2 5. Lift the Printer Frame Assembly partially out of the Lower Housing to allow the RS 232 connector to clear the battery compartment in the Lower Housing. Push in the media cover latch release button and pull the Controller Board out from the printer. Damage could occur if the Latch release button is not pressed in while removing the Controller Board continued on next page • 2-99 • RMAN-RWS-001 rev.
A A A A Press Latch release button while installing Controller Board J5 J10 Support, Bd-to-Bd Connector p/n BA17464-1 J3 J2 Installing the Replacement Controller Board 1. Slide the replacement Controller Board into place on the Lower Housing, while pressing and holding the Latch release button. Damage could occur if the Latch release button is not pressed in while installing the Controller Board 2. Insert the Printhead cable into J5 on the Controller Board, and lock the connector.
NOTES: The connector for the motor cable is polarized. It will only fit in one direction. Do not try to force the connector in place. Flex cables install in zero insertion force (ZIF) connectors. Pull the connector open, insert the cable, and close the connector to retain the flex cable. Dress the motor cable away from mounting bosses so they won’t get pinched during the next assembly steps. 3. Ensure that the latch release button moves in and out freely. Secure the CPU Board.
Section 3: RW Series Configurator and Repair Kits Using The Product Configuration Code Each RW series Printer has a Product Configuration Code (PCC). When ordering replacement parts, use the PCC code to determine the features installed on your printer. Then use the exploded views to determine which kit to order. Contact Customer Service if you are unsure of the correct part or assembly number. Refer to “Factory Repair & Parts Ordering Procedure” for further information on ordering parts.
Factory Repair And Parts Ordering Procedure If you need to return a printer to the factory for repair or upgrade, a Return Material Authorization (RMA) must be issued from Repair Services prior to returning any assemblies, PC boards, printers, cables, etc. for repair or replacement. The name, address, contact and phone number of the company that equipment is to be returned to must also be provided. A problem description is also necessary.
RW Series Accessories ORDER NUMBER DESCRIPTION AN11209-1 CLeaNinG PENS,BOX OF 12 AC18177-6 QUAD CHARGER, Americas AC18177-1 QUAD CHARGER, UK AC18177-2 QUAD CHARGER, EUROPE AC18177-3 QUAD CHARGER, AUSTRALIA AC18177-4 QUAD CHARGER, CHINA AC18177-7 QUAD CHARGER, Japan AT17696-1 CHARGER WALL LI-ION US/JAP AT17696-2 CHARGER WALL LI-ION UK AT17696-3 CHARGER WALL LI-ION EURO AT17696-4 CHARGER WALL LI-ION AUST AT17696-17 CHARGER WALL LI-ION ARGENTINA AT17010-1 USB A to USB Mini B Cable
RW Series Product Configuration Code (PCC) R 2 _ - 0 _ _ _ 0 _ 0 _ - _ _ R 4 _ - 0 _ _ _ 0 _ 0 _ - _ _ RW 220 Printer RW 420 Printer A - 0 _ _ _ 0 _ 0 _ - _ _ RAM/FLASH 8M/4M _ - 0 U _ _ 0 _ 0 _ - _ _ _ - 0 D _ _ 0 _ 0 _ - _ _ _ - 0 F _ _ 0 _ 0 _ - _ _ _ - 0 G _ _ 0 _ 0 _ - _ _ _ - 0 H _ _ 0 _ 0 _ - _ _ _ - 0 I _ _ 0 _ 0 _ - _ _ CHARACTER SET US/Canadian English/Latin 9 Chinese 16x16 Japanese 16 x 16 Japanese 24 x 24 Chinese 16x16 (simplified) Chinese 24x24 (simplified) _ - 0 _ 0 _ 0 _
Each RW series Mobile Printer has its Product Configuration Code (PCC) printed on the bottom of the unit. Use this chart to determine the features installed on your printer, then use the Illustrated Parts List on the following pages to determine which replacement kits must be ordered.
RW 420 Replacement Kits ITEM PART # Description 1 RK17393-001 MEDIA COVER KIT, RW 420 2 AK17393-002 PLATEN/GEAR KIT, LINERED RW 420 AK17393-028 KIT RPR RW4 LNRS PLATEN RLR RK17393-003 KIT RPR RW4 MEDIA GUIDE RK18471-01 KIT RPR RW4 MEDIA GUIDE W/BELT 4 RK17393-004 MEDIA DISK KIT RW SERIES 5 RK17393-005 PRINTHEAD KIT, RW 420 3 6 RK17393-006 MOTOR KIT, RW 420 7 RK17393-007 PRINTER FRAME KIT, RW 420 8 RK17393-008 KEYPAD/HSG and LCD (NON CARD) KIT, RW 420 RK18280-1 KIT RPR RW4 KYP
RW 420 Replacement Kits- Unit Exploded View 1 3 8 5 2 1 4 7 continued RMAN-RWS-001 rev.
RW 420 Replacement Kits- Unit Exploded View 2 9 5 11 12 6 14 13 Replacement battery AK17463-005 10 • 3-95 • 15 RW 4 Replacement Kits • RMAN-RWS-001 rev.
RW 420 Vehicle Cradle Replacement Kits 17 16 ITEM PART # Description 16 RK18243-1 KIT RPR RW4 VEHICLE CRADLE PCB 17 RK17393-026 DOCKING STATION HOUSING ASSY KIT, RW 420 RMAN-RWS-001 rev.
RW 220 Accessory Kits Part Number Description AK18026-001 SOFT CASE KIT, RW 220 AK17463-018 RAM MOUNT KIT, RW 220 AK17463-019 KIT ACC RW2 VEH CRADLE AK17463-008 MOD PLUG TO 9-PIN DB PC CABLE AK17463-010 RW TO SYMBOL 8000 CABLE AK17463-011 TWIST LOCK 10 P MOD CABLE AK17463-013 RW TO CX TERMINAL CABLE AK17463-014 TWIST LOCK 10 P MOD CABLE AK17463-015 MOLD TWIST LOCK DNLD SHIELD CABLE • 3-97 • RW 2 Replacement Kits • RMAN-RWS-001 rev.
RW 220 Replacement Kits ITEM PART # Description 1 RK17949-001 KIT RPR RW2 MEDIA COVER 2 RK17949-002 KIT RPR RW2 PLATEN/GEAR LNR 3 RK17949-003 KIT RPR RW2 MEDIA GUIDE 4 RK17393-004 KIT RPR RW SERIES MEDIA DISK 5 RK17949-005 KIT RPR RW2 PRINTHEAD 6 RK17949-006 KIT RPR RW2 MOTOR 7 RK17949-007 KIT RPR RW2 PRINTER FRAME 8 RK17949-008 KIT RPR RW2 KYPD HSG LCD RK17949-009 KIT RPR RW2 KYPD HSG LCD W/CRD 9 RK17949-010 KIT RPR RW2 CARD READER 10 RK17949-011 KIT RPR RW2 802.
RW 220 Replacement Kits- Unit Exploded View 1 2 1 4 3 5 7 • 3-99 • 10 14 8 11 RW 2 Replacement Kits • RMAN-RWS-001 rev.
RW 220 Replacement Kits- Unit Exploded View 2 9 12 15 8 13 RMAN-RWS-001 rev.
