Intermec EasyCoder PC4 Service Manual
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Intermec EasyCoder PC4 Service Manual

Bar code label printer
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Summary of Contents for Intermec EasyCoder PC4

  • Page 1 Service Manual EasyCoder PC4 Bar Code Label Printer...
  • Page 2 The information contained herein is proprietary and is provided solely for the purpose of allowing customers to operate and/or service Intermec manufactured equipment and is not to be released, reproduced, or used for any other purpose without written permission of Intermec.

  • Page 3: Table Of Contents

    About This Manual ....................... v Notices and Approvals ......................vi Models and Options 1.1 Models..........................2 1.2 Options ...........................3 1.3 EasyCoder PC4 Specifications ..................4 1.4 EasyCoder PC4 Measures ....................6 Main Parts 2.1 Taking the Printer Apart ....................10 2.2 Reassembling the Printer ....................10 2.3 Exploded View ......................11...
  • Page 4 9.1 Description........................64 9.2 Memory Sizes ........................65 9.3 Schematics ........................66 Starting Up 10.1 Normal Mode ......................68 10.2 Test Mode ........................69 10.3 Dump Mode .......................70 Firmware Upgrading 11.1 Requirements ......................72 11.2 Step-by Step Instructions ....................73 Troubleshooting 12.1 Checklist........................76 Intermec EasyCoder PC4—Service Manual...

  • Page 5: About This Manual

    About This Manual This Service Manual is intended to facilitate installation, troubleshooting and repair of the Intermec EasyCoder PC4 in the version delivered at the date of publishing. Thus, all information on the ESim firmware is based on version 6.xx. The on-going product improvement can be followed in the Technical Bulletins published at the Intermec Knowledge Center.

  • Page 6: Notices And Approvals

    EU Standard EN 55022 (The European Union) WARNING This is a Class A ITE product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. Intermec EasyCoder PC4—Service Manual...

  • Page 7: Models And Options

    Models and Options This chapter provides information on the various models of the EasyCoder PC4 and contains specifications and physical measures. Intermec EasyCoder PC4—Service Manual...

  • Page 8: Models

    Chapter 1—Models and Options 1.1 Models There are two main models of the EasyCoder PC4; one dedicated direct thermal (DT) model and one dual-capable direct thermal/thermal transfer (TTR) model. Both models are based on a common double clam-shell mechanical platform and have the same type of electronics, so except from the fact that the direct thermal model has no transfer ribbon mechanism, there are very few differences.

  • Page 9: Options

    1.2 Options The available options for the EasyCoder PC4 are memory cartridges, USB, serial and parallel interface cables, a keyboard/display unit, a paper cutter, a battery unit and an assortment of power cords. Refer to the EasyCoder PC4, Spare Parts Catalog or Spare Parts List for updated information.

  • Page 10: Easycoder Pc4 Specifications

    Chapter 1—Models and Options 1.3 EasyCoder PC4 Specifications Printing Print Technique Thermal Transfer and/or Direct Thermal Printhead Resolution 203.2 dpi (8 dots/mm) or 300 dpi (11.81 dots/mm) Print Speed (selectable) 30, 40, 50, 75 or 100 mm/sec. (1.2,1.6, 2, 3 or 4 in/sec.) Print Width (max) at 203.2 dpi...
  • Page 11 Parallel Interface Cable Standard RS-232 Cable Option Memory Cartridge Option 1MB flash Keyboard/Display Unit Option Paper Cutter Option V-spring for stiff/thick media Option >150µm/5.9 mils Mobile Battery Unit Option Battery Pack Option Battery Charger Option USB cable Option Intermec EasyCoder PC4—Service Manual...

  • Page 12: Easycoder Pc4 Measures

    Chapter 1—Models and Options 1.4 EasyCoder PC4 Measures Side View 259 mm (10.20 in) 333 mm (13.11 in) Intermec EasyCoder PC4—Service Manual...

  • Page 13: Front View

    Chapter 1—Models and Options Front View 50 mm (1.97 in) 133 mm (5.24 in) Rear View Intermec EasyCoder PC4—Service Manual...

  • Page 14: Top View

    Chapter 1—Models and Options Top View Bottom View 39 mm (1.54 in) 184 mm (7.24 in) 17 mm (0.67 in) 154 mm (6.06 in) Intermec EasyCoder PC4—Service Manual...

  • Page 15: Main Parts

    Main Parts This chapter shows the printer’s main parts and explains how the printer is taken apart and reassembled. Each of the main parts is described in more detail in the chapters that follow. Intermec EasyCoder PC4—Service Manual...

  • Page 16: Taking The Printer Apart

    Chapter 2—Main Parts 2.1 Taking the Printer Apart The EasyCoder PC4 is a so called double clam-shell design, where the print frame and the top cover are hinged to a base frame. The bottom part of the base frame is enclosed by the bottom cover, which is held by four Phillips screws.

  • Page 17: Exploded View

    Chapter 2—Main Parts 2.3 Exploded View Top Cover Print Frame E-ring Bolts Base Frame E-ring Bottom Cover Intermec EasyCoder PC4—Service Manual...
  • Page 18 Chapter 2—Main Parts Intermec EasyCoder PC4—Service Manual...

  • Page 19: Top Cover

    Top Cover This chapter describes the parts of the top cover and explains how to replace the tear-off plate. Intermec EasyCoder PC4—Service Manual...

  • Page 20: Description

    Note that in case of a PC4 DT printer, the locks are cut off and you will need to insert a flat screwdriver or similar to release the locks. Top cover locks Base locks Intermec EasyCoder PC4—Service Manual...

  • Page 21: Tear-Off Plate

    Two L-shaped rails hold the plate. If you need to remove the tear-off plate with- out discarding it, be careful not to break the tabs, which are quite delicate. Intermec EasyCoder PC4—Service Manual...
  • Page 22 Chapter 3—Top Cover Intermec EasyCoder PC4—Service Manual...

  • Page 23: Print Frame

    This chapter describes the print frame which contains the thermal print- head, the transfer ribbon supply, the LED control lamp, the Feed key, and the emitter of the label gap sensor. It also provides instructions for how to replace the various parts. Intermec EasyCoder PC4—Service Manual...

  • Page 24: Description

    Short top cover locks Thermal Transfer (TTR) Model LED control lamp Label gap sensor (Emitter) Feed switch Ribbon load label Print frame moulding Printhead Ribbon end sensor Transfer ribbon mechanism Long top cover locks Intermec EasyCoder PC4—Service Manual...

  • Page 25: Led And Feed Switch

    Phillips screw and a snap lock. The Feed Switch PCB is inserted between two rails in the moulding and is cov- ered by an isolation sheet. Screw Cable cover Snap lock Isolation sheet Feed switch PCB Print frame Intermec EasyCoder PC4—Service Manual...
  • Page 26 Chapter 4—Print Frame Schematics LED1 LED1 YELLOW Intermec EasyCoder PC4—Service Manual...

  • Page 27: Top Cover Locks

    Feed Switch PCB earlier in this chap- ter. The right-side spring hook is easily accessible in the DT model whereas in the TTR model, you will need to dismantle the ribbon takeup mechanism (see Chapter 4.8). Intermec EasyCoder PC4—Service Manual...

  • Page 28: Printhead

    Some simple measures can be taken by the user to prevent premature wear- out: • Clean the printhead regularly, as described in the EasyCoder PC4 User’s Guide. Not only will a dirty printhead result in an inferior printout, but any residue on the dots will prevent heat to dissipate through the ribbon and media.
  • Page 29 • Continue to press forward so the U-shaped slots in the sides of the print- head bracket also become disengaged from the studs at the inner sides of the cavity in the print frame. V-Spring Pocket Stud Printhead assy Slot Intermec EasyCoder PC4—Service Manual...
  • Page 30 V-spring runs between the two guiding ridges on the printhead bracket. • Test that the printhead can move slightly up against the pressure force of the V-spring. Finally, check that the printhead is working properly by printing a test label as described in Chapter 10.2. Intermec EasyCoder PC4—Service Manual...

  • Page 31: Ribbon End Sensor

    • Install a replacement sensor in reverse order. Ribbon end sensor Intermec EasyCoder PC4—Service Manual...
  • Page 32 Chapter 4—Print Frame Schematics ON: ENABLE STRIPPER OFF: DISABLE RIBBON 100K Intermec EasyCoder PC4—Service Manual...

  • Page 33: Label Gap Sensor (Emitter)

    • Remove the screw that holds the circuit board and pull it straight up while carefully manipulating the cable and connector through the hinge and out through the wall of the ribbon supply cavity. • Install a replacement circuit board in reverse order. Label gap sensor Schematics Intermec EasyCoder PC4—Service Manual...

  • Page 34: Ribbon Feed Mechanism

    Ribbon supply shaft Spring StarLoc washer Ribbon return cap Spring Friction plate Wool fiber disc Fixed holder Screws (2) Intermec EasyCoder PC4—Service Manual...
  • Page 35 The shaft is held by an E-ring inside the Feed button cavity. A spring on the shaft makes it possible to snap the core in place. No adjustments are facilitated. E-ring Washer Spring Ribbon core holder Intermec EasyCoder PC4—Service Manual...
  • Page 36 E-ring and lift out the entire rewind assembly without dismantling it any further. This way, you will keep the factory adjustments. Ribbon rewind shaft One-way clutch holder Wool fiber disc Gear Friction plate Spring Screws (2) Fixed holder E-ring Intermec EasyCoder PC4—Service Manual...
  • Page 37 There are no facilities for adjustments. Bolt Spring Gears (2) E-rings (2) Intermec EasyCoder PC4—Service Manual...
  • Page 38 Chapter 4—Print Frame Intermec EasyCoder PC4—Service Manual...

  • Page 39: Base Frame

    Base Frame This chapter describes the main parts of the base frame and provides replacement instructions. Intermec EasyCoder PC4—Service Manual...

  • Page 40: Main Parts

    Thus, modifications of printing density are not intended. The optional paper cutter is normally factory-fitted, but could be field- installed by an authorized service technician (see EasyCoder PC4 Cutter, Installation Instructions). It replaces the standard peel-off mechanism. Media spindle...

  • Page 41: Main Board

    • Remove the nut at the top of the rear plate and disconnect the ground- ing cable • Install a new board in reverse order. Refer to Chapter 7.3 for a connec- tion diagram. • Download the saved files from the host to the flash memory of the new board. Intermec EasyCoder PC4—Service Manual...

  • Page 42: Platen Roller

    D-shaped hole, and that the tab on the right-side bushing fits into the corresponding slot in the base frame moulding before locking the assem- bly with the platen cover. Plastic bushing with brass insert Platen cover Platen roller Snap-lock Right-side bushing Gear Intermec EasyCoder PC4—Service Manual...

  • Page 43: Peel-Off Mechanism

    • Disengage the hinges from the inner walls of the base frame moulding and pull out the peel-off mechanism. • Install a replacement unit in reverse order. Label Taken Sensor Roller To JP8 on main board Hinges Intermec EasyCoder PC4—Service Manual...
  • Page 44 Chapter 5—Base Frame ON/OFF Switch The On/Off switch makes it possible for the operator to enable/disable the label taken sensor without having to issue an ESim command. Schematics ON: ENABLE STRIPPER OFF: DISABLE RIBBON 100K Intermec EasyCoder PC4—Service Manual...

  • Page 45: Motor Assy

    • Pull out the motor and bracket. • Install a replacement unit in reverse order. Pulley Motor, thermistor, and bracket M3 nut To JP2 on main board Gear Washer To JP1 on main board E-ring E-ring M3 nut Gear Intermec EasyCoder PC4—Service Manual...

  • Page 46: Media Guides

    5.6 Media Guides Description The EasyCoder PC4 is designed to have the media centered in relation to the printhead. It has two stoppers that keep the media roll centered on the media spindle and two guides that align the media before it is fed under the printhead.

  • Page 47: Base Locks

    Closed and locked position is assumed when both micro- switches are activated. The right-side base lock is connected to JP12 and the left-side base lock is connected to JP11 on the main board. Intermec EasyCoder PC4—Service Manual...
  • Page 48 • Remove the screws that hold the locks. • Install new base locks in reverse order. In the illustration below, the right-side base lock is exploded to better show the principles of design. Base frame Microswitch Screw Push button Holder Spring Screws (2) Intermec EasyCoder PC4—Service Manual...

  • Page 49: Label Gap/Black Mark Sensors

    • Remove the main board from the base frame moulding. • Disconnect the cable from JP13 on the main board. • Adjust med media guides for maximum media width. • Remove the screws that hold the sensor board. • Install new board in reverse order. Intermec EasyCoder PC4—Service Manual...
  • Page 50 Chapter 5—Base Frame Schematics Intermec EasyCoder PC4—Service Manual...

  • Page 51: Media Spindle

    As an alternative to using a media supply roll on the spindle, fan-folds or similar can be routed from an external supply behind the printer and into the media cavity through a slot in above the printer's rear plate. 1 inch 25.4 mm 1.5 inch 38.1 mm Intermec EasyCoder PC4—Service Manual...
  • Page 52 Chapter 5—Base Frame Intermec EasyCoder PC4—Service Manual...

  • Page 53: Bottom Cover

    Bottom Cover This chapter describes the bottom cover and explains how to remove the accessory cover. Intermec EasyCoder PC4—Service Manual...

  • Page 54: Bottom Cover

    Four rubber feet are glued to the bottom plate, which also has four screw pockets that allow the printer to be permanently attached to a table or similar. Screw pockets Bottom cover Accessory cover Rubber foot (4) Screw (4) Intermec EasyCoder PC4—Service Manual...

  • Page 55: Main Board

    Main Board This chapter describes the main board including test points, connections, memory organization, and schematics. Intermec EasyCoder PC4—Service Manual...

  • Page 56: Description

    The main board has a memory where the user can store graphics and forms. The memory can be expanded by fitting an optional memory cartridge directly to a connector on the main board. PRODUCT/REV. NO. Intermec EasyCoder PC4—Service Manual...

  • Page 57: Accessing The Main Board

    JP14 Cutter JP3 Centronics JP2 Thermistor JP13 Lower Label Gap Sensor/Black Mark Sensor JP10 Upper Label Gap Sensor JP7 Ribbon End Sensor Printhead GND JP9 Feed Switch/LED JP4 RS 232 JP15 Memory Cartridge JP11 Headlift (left) Intermec EasyCoder PC4—Service Manual...

  • Page 58: Test Points

    Chapter 7—Main Board 7.4 Test Points PRODUCT/REV. NO. TP22 TP28 TP21 TP18 TP34 TP20 TP19 TP10 TP30 TP31 TP27 TP32 TP33 TP38 TP37 TP35 TP36 TP14 TP17 TP16 TP15 TP13 TP12 TP29 Intermec EasyCoder PC4—Service Manual...
  • Page 59 Digital potentiometer control TP31 POT_CLK Digital potentiometer control TP32 POT_DI Digital potentiometer control TP33 POT_CS Digital potentiometer control TP34 CPU crystal 20MHz TP35 WRCASL DRAM Control TP36 WRCASH DRAM Control TP37 RD# Read enable TP38 RAS DRAM Control Intermec EasyCoder PC4—Service Manual...

  • Page 60: Block Diagram

    JP13: Lower label gap & black mark sensor (JP15) JP8: Label taken sensor JP7: Ribbon end sensor JP14: Cutter interface MOTOR BLOCK Polar stepper motor (JP1) External thermistor sensor (JP2) PRINTHEAD 8 or 11.81 dots/mm (CN1,CN2) Intermec EasyCoder PC4—Service Manual...

  • Page 61: Internal Memory

    Chapter 7—Main Board 7.6 Internal Memory The EasyCoder PC4 has, as a standard, a flash memory of 1024K and an RAM memory of 2048K fitted on the main board. The memory is organized as follows: Flash Memory Firmware and 5 std. bitmap fonts...

  • Page 62: Schematics

    P153 P55/HOLD- P152 P56/ALE/RAS- P151 P57/RDY- P134 P150 P135 P136 P107/AN7/KI3 P137 P106/AN6/KI2 P60/CTS0-/RTS0- P105/AN5/KI1 P61/CLK0 P104/AN4/KI0 P62/RxD0 P103/AN3 P63/TxD0 P102/AN2 P64/CTS1-/RTS1-/CTS0-/CLKS1 P101/AN1 P65/CLK1 AVss P100/AN0 P66/RxD1 Vref AVcc P67/TxD1 P97/ADtrg-/RxD4/SCL4/STxD4 P70/TxD2/SDA2/TA0out CPU, Memory, and Reset Intermec EasyCoder PC4—Service Manual...
  • Page 63 Chapter 7—Main Board Power Block Motor Block Intermec EasyCoder PC4—Service Manual...
  • Page 64 Chapter 7—Main Board Serial Port (RS-232) Parallel Port (Centronic) Intermec EasyCoder PC4—Service Manual...
  • Page 65 Chapter 7—Main Board Printhead control Intermec EasyCoder PC4—Service Manual...
  • Page 66 Chapter 7—Main Board Sensor & I/O Connect Intermec EasyCoder PC4—Service Manual...

  • Page 67: Power Supply

    Power Supply This chapter describes the separate power supply. Intermec EasyCoder PC4—Service Manual...

  • Page 68: Description

    Chapter 8—Power Supply 8.1 Description The EasyCoder PC4 has a separate power supply. The power supply is designed for an input of 100 to 240 VAC, 50 to 60 Hz, 1.9A, 100 to 200 VA and gives an output voltage of 24 VDC, 3.0A.

  • Page 69: Memory Cartridge (Option)

    Memory Cartridge (option) This chapter describes the optional memory cartridge that can be used to expand the printer’s built-in memory and for firmware upgrading. Intermec EasyCoder PC4—Service Manual...

  • Page 70: Description

    On the front short side is a switch, that is used in connection with firm- ware upgrading (see Chapter 12). Normally, the switch should be set in its lower position. Firmware download position Normal position Intermec EasyCoder PC4—Service Manual...

  • Page 71: Memory Sizes

    firmware upgrades or to store forms, graphics and fonts. Note: This external memory space is directly connected to the printer's internal memory configuration which means cartridge data is not inter- changeable between printers, except for firmware upgrades. Intermec EasyCoder PC4—Service Manual...

  • Page 72: Schematics

    Chapter 9—Memory Cartridge 9.3 Schematics RAM1 RAM1 RAM2 RAM2 RAM1 RAM1 RAM2 RAM2 Memory Cartridge Intermec EasyCoder PC4—Service Manual...

  • Page 73: Starting Up

    Starting Up This chapter describes how the printer starts up in normal mode or test mode and how the printer automatically switches from test mode to dump mode. Intermec EasyCoder PC4—Service Manual...

  • Page 74: Normal Mode

    M DE > - ed W it p s e m mo y r R d->Green P nt r P in t S art This diagram illustrates the entire startup procedure. Intermec EasyCoder PC4—Service Manual...

  • Page 75: Test Mode

    The test label shows the printer’s configuration. The test label above shows the default configuration for a 203.2 dpi (8 dots/mm) printer without a memory cartridge. When the test label has been printed, the printer auto- matically switches to Dump Mode (see Chapter 10.3). Intermec EasyCoder PC4—Service Manual...

  • Page 76: Dump Mode

    If you leave the Dump Mode by pressing the Feed key for three seconds or more, you will reset the printer to its default configuration (see the test label in Chapter 10.2). Release the Feed key. Cycle the power to reboot the printer and you can start printing labels. Intermec EasyCoder PC4—Service Manual...

  • Page 77: Firmware Upgrading

    Firmware Upgrading This chapter explains how to upgrade the printer with a later firmware version. Intermec EasyCoder PC4—Service Manual...

  • Page 78: Requirements

    To upgrade the printer’s firmware via a cable connection from a PC run- ning MS Windows, you will need the following: • The Intermec ESim Config Tool. This is a free software running under Microsoft Windows . It makes it possible to download various firmware versions either directly to the printer or to a memory cartridge.

  • Page 79: Step-By Step Instructions

    Chapter 11—Firmware Upgrading 11.2 Step-by Step Instructions Using a PC Install the Intermec ESim Config Tool in your PC. Run the ESimConf.exe program. Set up the parameters for the firmware download (select printer type etc.). Use the on-line help for instructions.
  • Page 80 Chapter 11—Firmware Upgrading Intermec EasyCoder PC4—Service Manual...

  • Page 81: Troubleshooting

    Troubleshooting This chapter list some possible error conditions and suggests remedies depending on the cause of the error. Intermec EasyCoder PC4—Service Manual...

  • Page 82: Checklist

    - Check that the heat-sensitive side faces the printhead. • Ribbon faults (TTR): - Verify that the printer is loaded with transfer ribbon and that the ink- coated sided faces the receiving face material. Intermec EasyCoder PC4—Service Manual...
  • Page 83 - Forms longer than 200 mm or forms with black marks require that the form length is set using a Q command. Check test label. • Label gap sensor out of order. - Check both emitter and receiver boards for visible damage and bad connections. Replace if necessary. Intermec EasyCoder PC4—Service Manual...
  • Page 84 Possible Cause of Problem and Suggested Measures: • Media jam in the cutter (option). - Clear the jammed media. If necessary, remove the cutter housing and rotate the screw on the side of the cutter motor casing. Intermec EasyCoder PC4—Service Manual...
  • Page 85 • Ribbon end sensor out of order. - Check for foreign objects that can block the light beam and for bad connections. Replace if necessary. Intermec EasyCoder PC4—Service Manual...
  • Page 86 Chapter 12—Troubleshooting Intermec EasyCoder PC4—Service Manual...
  • Page 88 Intermec Technologies Corporation Corporate Headquarters 6001 36th Avenue West Everett , WA 98203 U.S.A. tel +425.348.2600 fax +425.355.9551 www.intermec.com EasyCoder PC4 Service Manual *1-960643-00* *1-960643-00*...

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