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TITLE
PM42 Service Repair Manual
Revision History
Rev
ECN Number
A
336577
Model
PM42
Description
First release
DOCUMENT NO.
L3-GLBL-RPR-3872
(Rev A)
Updated Pages
PAGE
Page 1 of 48
Change Type
Released by
Te Chhang
L3-GLBL-RPR-3872 (Rev A)

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  • Page 1

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 Page 1 of 48 PM42 Service Repair Manual PM42 (Rev A) Revision History ECN Number Description Updated Pages Change Type Released by 336577 First release Te Chhang L3-GLBL-RPR-3872 (Rev A)

  • Page 2: Disclaimer

    (Rev A) Disclaimer Honeywell International Inc. (“HII”) reserves the right to make changes in specifications and other information contained in this document without prior notice, and the reader should in all cases consult HII to determine whether any such changes have been made. The information in this publication does not represent a commitment on the part of HII.

  • Page 3: Table Of Contents

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 3 of 48 (Rev A) Table of Contents Disclaimer ..................................... 2 Trademarks ....................................2 Compliance and Safety ..............................5 General Precautions ..................................6 Safety Training ..................................6 Quality Training ..................................6 Product ESD Information .................................

  • Page 4

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 4 of 48 (Rev A) Power Supply Assembly ..............................39 Stepper Motor and Gear Drive Assembly ........................41 Example Screws & Torque Settings ..........................47 L3-GLBL-RPR-3872 (Rev A)

  • Page 5: Compliance And Safety

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 5 of 48 (Rev A) Compliance and Safety Compliance This equipment has been tested and found to comply with limits for a Class A digital device, pursuant to Part 15 of the FCC Rules.

  • Page 6: General Precautions

    • Safety Awareness Safety glasses must be worn. Quality Training Training per the local Honeywell site for Technicians/Repair personal should include; • Soldering Verification Product ESD Information This product contains ESD sensitive components or ElectroStatic Discharge sensitive electronic parts. The Electrostatic discharge is defined as the transfer of charge between bodies at different electrical potentials.

  • Page 7: High Level Recommended Repair Process

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 7 of 48 (Rev A) High Level Recommended Repair Process OPERATION: Step Process Reference Document Location Comments High level repair information is Service Eng referenece in the Service...

  • Page 8: Cautions & Notes

    Page 8 of 48 (Rev A) Cautions & Notes OPERATION: PM42 supports USB, serial, parallel, and Ethernet only. • • The functionalilty of the PM42 printers will be backward compatible with PM43 printers except the following: PM43 PM42 Backward compatibility Touch panel Support Not support 3.5(QVGA 320 x 240 pixels)

  • Page 9: Cover - Media Door Assembly

    Description Torx Driver T20 Parts Required Item Part Number Description 50124891-001FRE FRE, ASSY, MEDIA DOOR, PM42 (include 4 – 50125239-001) 50125239-001FRE FRE, SCREW MRT M4X8, Ф7, 100-Pack (16±0.8kgf/cm) 50124875-001FRE FRE, Window, Media Door, PM42 Media Door Assembly Replacement 1. Lift the media door cover and remove the Torx screws securing the media door assembly.

  • Page 10: Cover - Electronic Cover

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 10 of 48 (Rev A) Cover - Electronic Cover OPERATION: Tools Required Description Torx Driver T20 Parts Required Item Part Number Description 50124890-001FRE FRE, Cover, EE, PM42 814-055-008FRE Screw MRT M4X8 Black, 100-Pack (6±0.3kgf/cm)

  • Page 11: Front Panel Assembly

    Description Torx Driver T10 Torx Driver T20 Parts Required Item Part Number Description 51024892-001FRE FRE, Assy, Front Panel, w/o PCBA, PM42 50124882-001FRE FRE, BUTTON FEED 50124625-032FRE FRE, PCBA, UI Feed Button, PM42 50125473-001FRE FRE, KEYPAD MEMBRANE FRE, LABEL, EMBOSSED OVERLAY, PM42 50125130-001FRE FRE, LCD, TFT, 2.36 INCH,480(RGB)*234...

  • Page 12

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 12 of 48 (Rev A) L3-GLBL-RPR-3872 (Rev A)

  • Page 13: Platen Roller

    Item Part Number Description 50124891-001FRE FRE, ASSY, MEDIA DOOR, PM42 Platen Roller Assembly Replacement 1. Raise or open the Printhead 2. Rotate the platen roller latch clockwise to detach the platen roller assembly from the printer and pull the platen roller away from the printer.

  • Page 14: Printhead

    Description Isopropyl alcohol solution Parts Required Item Part Number Description 50126706-001FRE FRE, ASSY, PRINTHEAD, 203DPI, PM42 50126707-001FRE FRE, ASSY, PRINTHEAD, 300DPI, PM42 50126708-001FRE FRE, ASSY, PRINTHEAD, 406DPI, PM42 Printhead Assembly Replacement 1. Turn the printhead lift lever counterclockwise to raise the printhead 2.

  • Page 15: Print Unit Components

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 15 of 48 (Rev A) Print Unit Components OPERATION: This section covers the replacement and installation of the print unit assembly that has several components. This section addresses the bottom base print mechanism and the printhead adjustment assembly. The spare bottom base print mechanism does not include the media guide assembly and sensor.

  • Page 16

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 16 of 48 (Rev A) Media Gap Guide Adjustment lever Printhead Pressure Adjust Assembly Replacement 1. Turn the printhead lift lever counterclockwise to raise the printhead. 2. Remove the 5 torx screws securing the printhead pressure adjust assembly.

  • Page 17

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 17 of 48 (Rev A) L3-GLBL-RPR-3872 (Rev A)

  • Page 18: Printhead Lift Handle And Pressure Adjust Mechanism

    50125896-001FRE FRE, Assy, Pressure Adjust Sub, PM42 50125631-001FRE FRE, Pressure Adjust 50125623-001FRE FRE, Head Lift Lever, PM42 (include 800-619-008) 1-994059-012 FRE, SCREW MRT M4X12 ZP, T20 (16±0.8kgf/cm) 800-619-008 SCREW MRT 3X8 FBZ NYLON PATCH, T10 (6±0.3 kgf.cm) Printhead Lift Handle 1.

  • Page 19

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 19 of 48 (Rev A) Pressure Adjust Holder L3-GLBL-RPR-3872 (Rev A)

  • Page 20: Printhead Lift Sensor Assembly

    Item Part Number Description 236-261-001FRE FRE, Printhead Lift Sensor Assembly, PM42 Printhead Lift Sensor Assembly Replacement 1. Remove the 2 torx screws securing the headlift sensor assembly. 2. Unplug the sensor cable assembly from the MLB and lift the headlift sensor away 3.

  • Page 21: Printhead Lift Assembly

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 21 of 48 (Rev A) Printhead Lift Assembly OPERATION: This section cover the replacement of printhead lift mechanism assembly replacement. Replacing the assembly require removing the print motor assembly first and possible driver gears to gain access to the torx screws securing the printhead lift mechanism on the electronic side.

  • Page 22: Media Guide Top Dancer Assembly

    Description Torx T20 Torx T10 Parts Required Item Part Number Description 50125904-001FRE FRE, Assy, Media Guide, Top, PM42 (complete assembly include upper LSS sensor) 50125906-001FRE FRE, Assy, Dancer 50124625-002FRE FRE, Sensor Assembly, PM42 – Upper LSS 1-994059-012 FRE, SCREW MRT M4X12 ZP, T20 (16±0.8kgf/cm) Media Guide Top Dancer Assembly Replacement 1.

  • Page 23

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 23 of 48 (Rev A) Removing LSS Upper Assembly Removing Dancer Assembly Top Media Guide Assembly (Complete) Dancer Assembly Upper LSS Sensor Replacement 1. Pushing the locking tab downward and slide the sensor out of the top guide assembly.

  • Page 24: Media Sensor Bottom Assembly

    Parts Required Item Part Number Description 5012907-001FRE FRE, Assy, Media Guide Bottom (complete assembly) 50125908-001FRE FRE, Assy, LSS, Adjust, PM42 50125909-001FRE FRE, LSS EE Bottom (need to be setup) 650-798-002 Cover, Frame Print Mech 1-994058-010 Screw MRT 3X10 FBZ, T10 (6±0.3 kgf.cm) 800-593-006 Screw, Plastite, M3x6, PH, Torx, T10 (6±0.3kgf.cm)

  • Page 25

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 25 of 48 (Rev A) LSS Adjust Assembly Replacement 1. Remove the three torx screws securing the LSS adjust assembly. See Figure 3. 2. Lift the LSS adjust assembly and release the belt from the gap sensor assembly.

  • Page 26: Front Media Access Door

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 26 of 48 (Rev A) Front Media Access Door OPERATION: The door is a customer replaceable part. Tools Required Description Torx Driver T20 Parts Required Item Part Number...

  • Page 27: Ribbon Adjust Sub Assembly

    Parts Required Item Part Number Description 50125922-001FRE FRE, Assy, Ribbon Adjust Sub, PM42 (include screws, washer, rod, and plate) Ribbon Adjust Assembly Replacement 1. Remove the torx screw securing the ribbon adjust assembly. 2. Slide the ribbon adjust assembly toward the electronics and gears side to remove from the spine (main deck).

  • Page 28: Ribbon Wrinkle Adjustment

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 28 of 48 (Rev A) Ribbon Wrinkle Adjustment OPERATION: This section covers the instruction on how to adjust the ribbon wrinkle for printers with thermal transfer ribbon option. Direct thermal printer will not have the ribbon wrinkle adjustment mechanism.

  • Page 29: Tear Bar

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 29 of 48 (Rev A) Tear Bar OPERATION: This is a customer replaceable part; no tooling is required for this operation. Tools Required Description Torx Driver T20 Parts Required...

  • Page 30: Media Hanger And Edge Guides

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 30 of 48 (Rev A) Media Hanger and Edge Guides OPERATION: The media hanger and edge guides (large and small edge guide) come as a complet service kit.

  • Page 31: Ribbon Supply Assembly

    Item Part Number Description 50125990-001FRE FRE, Assy, Ribbon Sensor, PM42 Ribbon Supply Assembly Replacement 1. Remove the torx screw securing the ribbon supply assembly module to the ribbon supply rod. 2. Pull the ribbon supply assembly module away from the ribbon supply rod. It is IMPORTANT to note the position of the ribbon supply assembly guide pin attached to the spine (main deck).

  • Page 32

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 32 of 48 (Rev A) Ribbon Low Cable Sensor Assembly Replacement 1. Remove the electronic cover 2. Disconnect the ribbon low cable P25 on the main logic board (MLB) 3.

  • Page 33: Media Hanger And Edge Guides

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 33 of 48 (Rev A) Media Hanger and Edge Guides OPERATION: This section covers the replacement of ribbon take-up mechanism. Make note of the guide pins when removing the mechanism on the electronics side.

  • Page 34: Base Assembly

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 34 of 48 (Rev A) Base Assembly OPERATION: This is NOT a customer replaceable assembly. Replacement of base assembly is rare. Stock base assembly on need a basis. Rubber foot are not included in the spare base assembly.

  • Page 35: Spine

    Torx Driver T20 Parts Required Item Part Number Description 50124886-001FRE FRE, Spine Assy, PM42 (include bearing) Spine Replacement 1. Remove all attached mechanical and electrical parts. 2. Remove the torx screws securing the spine against the base assembly. Spine Assembly...

  • Page 36: Back Plate

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 36 of 48 (Rev A) Back Plate OPERATION: Tools Required Description Torx Driver T20 Parts Required Item Part Number Description Back Plate Replacement 1. Procedure - TBA 2. Procedure - TBA I/O Cover Replacement 1.

  • Page 37: Lcd Touch Panel And Display Assembly

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 37 of 48 (Rev A) LCD Touch Panel and Display Assembly OPERATION: This section covers the replacement of LCD display assembly and LCD touch panel. Tools Required Description...

  • Page 38: Main Logic Board Assembly

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 38 of 48 (Rev A) has 3 torx screws securing the user interace PCB support bracket. 5. Reverse the procedure for re-installation. It is important to note the touch panel ribbon cable routing.

  • Page 39: Power Supply Assembly

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 39 of 48 (Rev A) Power Supply Assembly OPERATION: The power supply unit attaches to the spine (main deck) assembly with five torx screws and 2 torx screws on the exterior backplane.

  • Page 40

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 40 of 48 (Rev A) Power Supply Unit Spare Power Cable, MLB-PSU L3-GLBL-RPR-3872 (Rev A)

  • Page 41

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 41 of 48 (Rev A) Stepper Motor Assembly and Drive Gear Assembly (Need to OPERATION: update with PM42 contents) Tools Required Description Torx Driver T20 Parts Required Item Part Number...

  • Page 42

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 42 of 48 (Rev A) Figure 4 Figure 5 Drive Belt Replacement 1. Remove the motor as per the motor replacement instructions 2. Remove the center ribbon drive gear by removing the mounting screw, see Figure 6 3.

  • Page 43

    OPERATION: The PM42 contains a variety of labels on its bottom housing. These labels consist of both pre-printed labels that are ready to apply off the shelf and print on demand labels that have specific content that must be printed to match the particular unit being serviced.

  • Page 44

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 44 of 48 (Rev A) Serial Number Label 1. Refer to Print-On-Demand Label Printing System to print the serial number label 2. Refer to Figure 2 for location of the serial number label on the back plate.

  • Page 45

    Access to this site is available to Intermec Team Members only. 2. The format files for PM42 can be found on the Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only.

  • Page 46

    Testing Instructions 1. The test procedure is OTPPMx2-000. 2. The software PM42 be found on the Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only. 3. The test fixture bill of material can be found Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only.

  • Page 47: Example Screws & Torque Settings

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 47 of 48 (Rev A) Example Screws & Torque Settings OPERATION: 50125239-001FRE FRE, SCREW MRT M4X8, Ф7 16±0.8kgf/cm Secure media door assembly onto main deck Torx T20 Comes in a pack of 100 screws 50125236-001FRE FRE, SCREW MRT M4X12 Ф12...

  • Page 48

    TITLE Model DOCUMENT NO. PAGE L3-GLBL-RPR-3872 PM42 Service Repair Manual PM42 Page 48 of 48 (Rev A) Honeywell Scanning & Mobility 9680 Old Bailes Road Fort Mill, SC 29707 www.honeywellaidc.com L3-GLBL-RPR-3872 (Rev A)

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