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Service Manual EasyCoder® PD41/PD42 Printer...
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Service Manual EasyCoder® PD41/PD42 Printer...
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The information contained herein is provided solely for the purpose of allowing customers to operate and service Intermec-manufactured equipment and is not to be released, reproduced, or used for any other purpose without written permission of Intermec Technologies Corporation.
Safety Summary Your safety is extremely important. Read and follow all warnings and cautions in this document before handling and operating Intermec equipment. You can be seriously injured, and equipment and data can be damaged if you do not follow the safety warnings and cautions.
Safety Information Your safety is extremely important. Read and follow all warnings and cautions in this document before handling and operating Intermec equipment. You can be seriously injured, and equipment and data can be damaged if you do not follow the safety warnings and cautions.
Global Services and Support Warranty Information To understand the warranty for your Intermec product, visit the Intermec web site at www.intermec.com click Support > Returns and Repairs > Warranty.
Outside the U.S.A. and Canada, contact your local Intermec representative. To search for your local representative, from the Intermec web site, click About Us > Contact Us. Service Location Support For the most current listing of service locations, click Support > Returns and Repairs >...
This document provides you with information about the features of the EasyCoder PD41/PD42 printer, and how to install, configure, operate, maintain, and troubleshoot it. Before you work with the EasyCoder PD41/PD42 printer, you should be familiar with your network and general networking terms, such as IP address.
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Before You Begin EasyCoder PD41/PD42 Printer Service Manual...
Troubleshooting the PD41/ PD42 This chapter describes how to troubleshoot the EasyCoder PD41/PD42 printer and how to identify and replace faulty parts. Do not attempt to repair the power supply or any circuit boards. EasyCoder PD41/PD42 Printer Service Manual...
Chapter 1 — Troubleshooting the PD41/PD42 Error Handling The EasyCoder PD41/PD42 printer communicates errors to the user via the red Error LED and the blue Ready-to-Work LED on the front panel. When an error condition occurs, these two will be turned on or flash depending on the cause of the error.
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Press Testfeed ( Cutter not found. A cut-command has been sent but the printer cannot find the cutter. Check that the cutter is installed properly. Cutter not Check that the cutter is installed properly. responding. EasyCoder PD41/PD42 Printer Service Manual...
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When printing, label is jammed or • Clear the media jam, and if label is stuck User’s Guide tangled up on thermal printhead, remove it using a soft cloth soaked with isopropyl alcohol or a cleaning card. EasyCoder PD41/PD42 Printer Service Manual...
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When using Label Taken Sensor, • Check if LTS sensor is working “Label Taken Sensor (LTS)” on abnormal function occurs page 59 • Check if media is loaded properly User’s Guide EasyCoder PD41/PD42 Printer Service Manual...
• Check to see if a bad command was sent Fingerprint Command Reference to the printer via Fingerprint or direct Manual (P/N 937-005-xxx protocol • Check the Fingerprint application or the last issued instruction in Direct Protocol EasyCoder PD41/PD42 Printer Service Manual...
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• Connect the cable to a replacement console board without actually installing it (mind the risk of electrostatic discharges). If the trouble seems to be the console board, replace the entire panel module. • Check the console board • Check with some other electrical device EasyCoder PD41/PD42 Printer Service Manual...
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“To adjust printhead balance” on either the inner or outer part of the media, page 53 the printhead balance may need to be readjusted. This is most likely to occur when switching between media of different widths. EasyCoder PD41/PD42 Printer Service Manual...
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• Check if the platen roller is slippery, worn out, or dry and hard. Clean or replace if “Platen Module” on page 44 necessary. EasyCoder PD41/PD42 Printer Service Manual...
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Chapter 1 — Troubleshooting the PD41/PD42 EasyCoder PD41/PD42 Printer Service Manual...
Models and Options This chapter contains general information about the EasyCoder PD41 and PD42 printers, including available options and technical specifications. EasyCoder PD41/PD42 Printer Service Manual...
Chapter 2 — Models and Options Models The EasyCoder PD41/PD42 printer is available with a 200 or 300 dpi printhead. The label taken sensor is installed into all printers. The Real Time Clock module is in the PD42 only and is supported by the Fingerprint firmware.
Firmware (Fingerprint) Operating system Fingerprint v10.x.x Includes Direct Protocol Smooth fonts TrueType and TrueDoc fonts Resident scalable fonts Character sets • 23 single-byte character sets standard. • UTF-8 support as standard. Resident bar codes EasyCoder PD41/PD42 Printer Service Manual...
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Label gap/black mark/out of media Printhead lifted Label taken Ribbon end Controls LED indicators Power, Data/Ready, Error, Ready-to-Work™ Keys 1 Print Button + 5 Soft Keys Electronics Microprocessor ARM 9 Standard memory 4 MB flash, 8 MB SDRAM. EasyCoder PD41/PD42 Printer Service Manual...
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Print Length Max. Fingerprint 8 dots/mm (203 dpi) 1270 mm (50 in) 600 mm (23 in) 11.8 dots/mm (300dpi) 558.2 mm (22 in) 406.4 mm (16 in) Modes of Operation Tear-off (straight-through) Cut-off Option with cutter EasyCoder PD41/PD42 Printer Service Manual...
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Ribbon roll diameter (outer) 76 mm (2.99 in) equivalent to 450 m (1471 ft) of ribbon. Inner core diameter 25.2 to 25.6 mm (1 in) Sensors Label gap/black mark/out of media Printhead lifted Label taken Ribbon end EasyCoder PD41/PD42 Printer Service Manual...
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8 MB flash, 16 MB SDRAM. Interfaces RS-232 serial Ethernet Option IEEE 1284 parallel Option CompactFlash USB host Accessories and Options Internal rewinder and batch takeup Cutter Printhead 203/300 dpi EasyLAN ethernet interface Parallel IEEE 1284 interface Real time clock EasyCoder PD41/PD42 Printer Service Manual...
P38 (“LTS”), also on the main board. Console PCB Screw (4 places) Screw Flat cable to (2 places) main board Print button switch LEDs (green-green-red-blue) Print button Light guide E-ring Label Taken Sensor Front Panel Overlay PD41 Front Panel: Exploded View EasyCoder PD41/PD42 Printer Service Manual...
P38 (“LTS”), also on the main board. Console PCB Screw (4 places) Screw Flat cable to (4 places) main board Print button switch LEDs (green-green-red-blue) Print button Light guide E-ring Label Taken Sensor Front Panel Overlay PD42 Front Panel: Exploded View EasyCoder PD41/PD42 Printer Service Manual...
57) is installed. It must be permanently removed before installing an optional cutter (For help, see “Cutter” on page 61). The panel is held in place by a knurled screw inserted beneath the bottom plate. Bottom Right Panel With Thumbscrew EasyCoder PD41/PD42 Printer Service Manual...
Chapter 3 — Replacing Parts Console PCB The same console PCB is used on both the PD41 and PD42 printers. It has four LEDS and a Print button. Console PCB: Components EasyCoder PD41/PD42 Printer Service Manual...
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Chapter 3 — Replacing Parts Console PCB: Schematics EasyCoder PD41/PD42 Printer Service Manual...
(not included). To remove the right-hand door Remove the four screws that attach the hinges to the center section. Window Right-hand Top/Right Panel Door Right-Hand Door EasyCoder PD41/PD42 Printer Service Manual...
Niemals den Drucker ohne angebrachte linke Seitenwand betreiben, da dies zu RF-Störungen führen kann. Zulassungen sind nur bei angebrachter Abdeckung gültig. Take standard precautions against ESD (Electrostatic Discharges) before touching any electronics components inside the electronics compartment. EasyCoder PD41/PD42 Printer Service Manual...
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To remove the left-hand panel 1 Disconnect the power cord. 2 Open the right-hand door. 3 Remove the screw located on the left side of the front hinge and the screw on the right side of the rear hinge. EasyCoder PD41/PD42 Printer Service Manual...
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DO NOT attempt to pry it loose. Protect the paint by inserting a thin piece of cardboard or similar between the plate and the screwdriver. 7 Remove the panel from the printer. EasyCoder PD41/PD42 Printer Service Manual...
It consists of three main parts: • Bottom plate with four rubber feet and two dampeners for the right- hand door • Center section • Rear plate EasyCoder PD41/PD42 Printer Service Manual...
The rear plate contains the On/Off switch, the AC power cord socket assembly, the serial and USB port connectors, and the CompactFlash card slot. It also has slots for the optional parallel interface and Ethernet connectors, which are fitted on the main board. EasyCoder PD41/PD42 Printer Service Manual...
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Machine labels Rear View of the PD41/PD42 Ethernet RJ-45 port USB port MAC address label RS-232 serial port IEEE 1284 parallel port CompactFlash socket Power switch AC power cord socket Rear Connectors on the PD41 EasyCoder PD41/PD42 Printer Service Manual...
The supply post is fitted to the center section using three screws. It runs through a square hole in the triangular guide plate, which is attached to the center section from inside the electronics compartment using three screws. EasyCoder PD41/PD42 Printer Service Manual...
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1 Unhook the coil spring from the hook at the bottom of the plastic edge guide underneath the post. 2 Remove the coil spring and the washer, then pull up the edge guide and save it for possible later use. Edge Guide Hook Washer Coil Spring Post EasyCoder PD41/PD42 Printer Service Manual...
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Sicherstellen, dass die Führung mit der hohen Kante in die vertikale Stellung gebracht wird, bevor die Seitenklappe geschlossen wird. Andernfalls könnte die Führung beschädigt werden. EasyCoder PD41/PD42 Printer Service Manual...
To replace the ribbon module 1 Disconnect the power cord and remove the left-hand panel (For help, “To remove the left-hand panel” on page 27). EasyCoder PD41/PD42 Printer Service Manual...
3 Remove the E-rings and the washer from the ends of the ribbon supply and rewind shafts. 4 Remove the four screws that hold the inner bracket to the main body of the ribbon module and pull out the bracket. EasyCoder PD41/PD42 Printer Service Manual...
At the outer end of each unit is a knob for adjusting the ribbon tension, see below. Replacing the Ribbon Core Spring Blade The ribbon core spring blade is held by a single screw. Screw Ribbon core spring blade Ribbon Core Spring Blade EasyCoder PD41/PD42 Printer Service Manual...
Also disconnect and connect the cable to the main board a few times to remove any oxide. 1 Disconnect the power cord and remove the left-hand panel (For help, “To remove the left-hand panel” on page 27). EasyCoder PD41/PD42 Printer Service Manual...
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4 From inside the electronics compartment, remove the single screw and washer that holds the sensor PCB to the center section. 5 Pull out the sensor and the isolating sheet. Cable Screw Washer Sensor Assembly Isolating sheet Ribbon Out Sensor Exploded View EasyCoder PD41/PD42 Printer Service Manual...
2 Disconnect the spring from the ink position knob inside the electronics compartment using tweezers or a pair of narrow-tipped pliers. 3 Move the knob to the center of the slot, rotate it a quarter of a turn, and pull it out into the media compartment. EasyCoder PD41/PD42 Printer Service Manual...
However, this requires that the printhead PCB is also exchanged. When ordering the Print Unit Assembly, the Printhead module is not included. Use Intermec-approved printheads only. Using a printhead that is incompatible with the printer will void the warranty and is likely to damage the main board beyond repair.
The stepper motor module is attached to the bottom plate using four screws. The motor is connected by a four-wire cable harness to connector P31(“MOTOR”) on the main board. EasyCoder PD41/PD42 Printer Service Manual...
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5 Install the motor in reverse order. If the printer is equipped with a rewinder, fit the platen roller belt on the inner pulley (the pulley closest to the motor housing) and the rewinder belt to the outer pulley. EasyCoder PD41/PD42 Printer Service Manual...
The silicone rubber is subject to wear and requires the platen roller to be replaced, usually with long intervals. EasyCoder PD41/PD42 Printer Service Manual...
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3 Remove the E-ring from the inner end of the platen roller shaft and remove the motor belt and pulley. 4 Remove the ribbon rewinder belt and pulley. 5 Remove the E-rings and washers from either end of the platen roller shaft. EasyCoder PD41/PD42 Printer Service Manual...
By comparing the detection of light/no light with the paper type setup (black mark/gap paper/plain paper), the firmware can determine the position of the labels or similar along the media path and also detect out-of-media conditions. EasyCoder PD41/PD42 Printer Service Manual...
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For more information, see the printer user’s guide. You can also adjust the sensor with Fingerprint commands. For help, see the Intermec Fingerprint Command Reference Manual (937-005-xxx). To replace the label gap sensor module Note: Before replacing the module, check that there is no dirt, dust, adhesive residue, or stuck labels that blocks the light between the two sensors.
The microswitch is activated by an arm connected to the printhead lever. If attempting to print while the headlift sensor indicates that the printhead is open, Error 11 “printhead lifted” occurs. EasyCoder PD41/PD42 Printer Service Manual...
(direct thermal) media, or on other face materials via a thermal transfer ribbon. The spots can be combined into bitmap patterns, which make up characters, bar codes, images, lines, and boxes. EasyCoder PD41/PD42 Printer Service Manual...
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Information on how to switch between direct thermal and thermal transfer printing is provided in the user’s guide of each respective printer. The EasyCoder PD41/PD42 printer can be fitted with two printheads with different densities: • In a 203.2 dpi printhead (8 dots/mm), each dot under standardized conditions will produce a black spot which has a diameter of 4.92 mils...
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(for instance, going from 203 dpi to 300 dpi). If you are just replacing a worn-out printhead, proceed to step 10. 203 dpi Printhead PCB (left) and 300 dpi Printhead PCB (right) 6 To facilitate the removal of the PCB, center the balance boxes. EasyCoder PD41/PD42 Printer Service Manual...
• When using preprinted labels or labels with some type of varnish or non-standard top coating for direct thermal printing, use original Intermec labels or inks recommended by leading manufacturers of direct thermal media. The labels must not contain any aggressive substances such as chloride or grinding substances such as titanium dioxide.
Adjusting the Printhead The printer is factory-adjusted for full-size media width. When using media less than full width, Intermec recommends that you adjust the position of the printhead balance boxes so an even pressure is applied across the media. A poorly adjusted printhead pressure may be detected by a weaker printout on either side of the media path.
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(a full turn corresponds to 0.55 mm, which is a lot). Be sure to make identical adjustments on both screws! If you are unsure, tighten both screws by turning them counterclockwise as far as they go and start over. EasyCoder PD41/PD42 Printer Service Manual...
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3 Unscrew screws C and D 5 full turns (200 dpi printhead) or 1 ½ turns (300 dpi printhead). 4 Tighten screws A and B. EasyCoder PD41/PD42 Printer Service Manual...
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1 Tighten screws A and B (see above) so that the springs are fully compressed. Be careful not to overdo it, as it may damage the threads. 2 Unscrew screws A and B 4 ½ turns. EasyCoder PD41/PD42 Printer Service Manual...
This section describes the optional internal rewinder required for peel-off (self-strip) and batch takeup operation. The rewinder module is an optional device for the EasyCoder PD41/PD42 printer. The printer is prepared with belt, pulley, and gear train for driving the rewinder using the same stepper motor that also drives the platen roller and transfer ribbon rewinder.
5 For batch takeup operation only: Attach the liner retention guide. 6 Install media as described in the printer user’s guide. EasyCoder PD41/PD42 Printer Service Manual...
Label Taken Sensor (LTS) This section describes the Label Taken Sensor, which is a standard feature on the EasyCoder PD41/PD42 printer. The purpose of the Label Taken Sensor is to detect if a label has been removed after printing and—if not—hold the printing of the next label. It works equally well when the media is manually torn off after printing as when the labels are automatically separated from the liner.
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3 Remove the E-ring that holds the LTS and pull it away. The LTS is only available as a complete unit. 4 Assemble in reverse order. E-ring Label Taken Sensor Front Panel (PD41) Label Taken Sensor EasyCoder PD41/PD42 Printer Service Manual...
The cutter is controlled from the software application, such as Fingerprint, InterDriver, or LabelShop). For more information, see the printer user’s guide. Screws (x6) Cutter PCB Screws, Plastic (x2) Bracket Cutter Spring Cutter Mechanism Front Cover EasyCoder PD41/PD42 Printer Service Manual...
3 After the media jam is cleared, switch on the power to the printer, and the cutter blade will go back to its original position. Note: It is recommended to use labels with a minimum length of 30 mm (1.2 in). EasyCoder PD41/PD42 Printer Service Manual...
Das Netzteilmodul enthält Kabel und Schaltkreise, die gefährliche Spannungen führen. Aus Sicherheitsgründen ist es streng untersagt, ein Netzteilmodul zu reparieren oder eine durchgebrannte Sicherung auszutauschen. Falls eine Sicherung durchbrennt, muss das gesamte Netzteilmodul ausgetauscht werden. EasyCoder PD41/PD42 Printer Service Manual...
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Nachdem das neue Antriebsmodul eingesetzt ist, muss sichergestellt werden, dass es korrekten Kontakt mit der unteren Platte hat, da nur so die ausreichende Kühlung der Einheit gewährleistet werden kann. EasyCoder PD41/PD42 Printer Service Manual...
Chapter 3 — Replacing Parts Components Components on PD41/PD42 Power Supply Schematics Schematic forPD41 only EasyCoder PD41/PD42 Printer Service Manual...
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Chapter 3 — Replacing Parts EasyCoder PD41/PD42 Printer Service Manual...
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Chapter 3 — Replacing Parts EasyCoder PD41/PD42 Printer Service Manual...
• 2 kbits serial EEPROM for part and serial numbers and identification • A/D converter for sensor adjustment • Compact flash memory card expansion (up to 2 GB) • CompactFlash Type II (5.0 mm thickness) cannot be used • CF+ cards may not work EasyCoder PD41/PD42 Printer Service Manual...
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Option brd 1284 FLASH IEEE1284 Option brd CompactFlash B-Addr** Sensors B-Data Dig. Pot. 3.3V EEPROM (Part No, Serial No, ** B-Addr is low order bits only etc) 24-to-5V 5-to-3.3V 1.5V 5-to-1.5V Main Board Block Diagram (PD41) EasyCoder PD41/PD42 Printer Service Manual...
3 Remove any CompactFlash memory card. 4 Remove any Ethernet and parallel interface option boards. 5 Remove the five screws and washers that hold the main board. 6 Lift out the main board and install in reverse order. EasyCoder PD41/PD42 Printer Service Manual...
Overcurrent on 5VE, low when short circuit on 5VE CUT1, CUT2 Cutter control, Outputs ({CUT1;CUT2}): {0;1} – Forward {1;0} – Reverse {1;1} – Brake {0;0} – Stop (high impedance) CUTHOME Cutter status, high level in home position EasyCoder PD41/PD42 Printer Service Manual...
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Chapter 3 — Replacing Parts Test points on Main Board EasyCoder PD41/PD42 Printer Service Manual...
1 Go to www.intermec.com. 2 Click Support > Downloads. 3 In the Select a Product field, choose EasyCoder PD41 or PD42. The Downloads page appears with a list of available firmware. 4 Download the latest firmware version to your computer.
This chapter describes the communication interfaces of the EasyCoder PD41/PD42, and contains the following sections: • Communication Interfaces • RS-232 Serial Interface • USB Serial Interface • USB Host Interface (PD42 only) • Parallel IEEE1284 Interface (Option) • EasyLAN Ethernet Interface (Option) EasyCoder PD41/PD42 Printer Service Manual...
Interface Connectors RS-232 Serial Interface As a standard, the EasyCoder PD41/PD42 printer is equipped with an RS- 232 communication port. The circuitry is fitted on the CPU board and has a fixed set of signals in a DB-9pin socket, which protrudes through a slot in the printer’s rear plate.
Clear to send Request to send USB Serial Interface The EasyCoder PD41/PD42 printer supports USB v1.1 (also called USB 2.0 full speed). To use the USB interface for printing from a PC, the Intermec InterDriver needs to be installed on the PC.
The Centronics parallel interface is essentially a one-way protocol for short distances. There is no setup for the parallel interface. Handshake: DSTB connects to the printer, BUSY connects to the host Interface cable: Parallel cable compatible to PC EasyCoder PD41/PD42 Printer Service Manual...
3 Remove the small plate that covers the slot for the Parallel board on the back of the printer. Keep the screws. 4 Use the screws that were removed in Step 3 to secure the Parallel board in the slot. Parallel IEEE 1284 interface board EasyCoder PD41/PD42 Printer Service Manual...
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Chapter 4 — Interfaces 5 Connect the I/O bus cable to the printer main board. EasyCoder PD41/PD42 Printer Service Manual...
“To remove the left-hand panel” on page 27). 2 Put the printer back in upright position. 3 Locate the screw in the upper left corner of the electronics compartment that holds the main board in place. Remove the screw. EasyCoder PD41/PD42 Printer Service Manual...
6 Reattach the left-hand panel. 7 Attach the MAC address label just below the EasyLAN port on the rear plate of the printer. When you turn on the printer, it automatically recognizes the EasyLAN board. Components EasyCoder PD41/PD42 Printer Service Manual...