Service Manual

EasyCoder®
PD41/PD42 Printer

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
 Service Manual

EasyCoder®
PD41/PD42 Printer

Downloaded from www.Manualslib.com manuals search engine

 Intermec Technologies Corporation
Worldwide Headquarters
6001 36th Ave.W.
Everett, WA 98203
U.S.A.
www.intermec.com
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.
Information and specifications contained in this document are subject to change without prior notice and do
not represent a commitment on the part of Intermec Technologies Corporation.
© 2007-2008 by Intermec Technologies Corporation. All rights reserved.
The word Intermec, the Intermec logo, Norand, ArciTech, Beverage Routebook, CrossBar, dcBrowser,
Duratherm, EasyADC, EasyCoder, EasySet, Fingerprint, INCA (under license), i-gistics, Intellitag, Intellitag
Gen2, JANUS, LabelShop, MobileLAN, Picolink, Ready-to-Work, RoutePower, Sabre, ScanPlus, ShopScan,
Smart Mobile Computing, SmartSystems, TE 2000, Trakker Antares, and Vista Powered are either trademarks
or registered trademarks of Intermec Technologies Corporation.
There are U.S. and foreign patents as well as U.S. and foreign patents pending.
Other trademarks or registered trademarks. For example,
Wi-Fi is a registered certification mark of the Wi-Fi Alliance.
Microsoft, Windows, and the Windows logo are registered trademarks of Microsoft Corporation in the United
States and/or other countries.
Bluetooth is a trademark of Bluetooth SIG, Inc., U.S.A.
This product includes software developed by the OpenSSL Project for use in the OpenSSL Toolkit
(www.openssl.org).
This product includes cryptographic software written by Eric Young ([email protected]).
This product uses Regex++, Index software during its operational phases. The owner of Regex++ has granted
use of the software to anyone provided such use is accompanied by the following copyright and permission
notice:
Regex++, Index. (Version 3.31, 16th Dec 2001)
Copyright © 1998-2001 Dr John Maddock
Permission to use, copy, modify, distribute and sell this software and its documentation for any purpose is
hereby granted without fee, provided that the above copyright notice appear in all copies and that both that
copyright notice and this permission notice appear in supporting documentation. Dr John Maddock makes no
representations about the suitability of this software for any purpose. It is provided "as is" without express or
implied warranty.

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 Contents

Contents
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Sicherheitsübersicht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Nicht alleine Reparaturen oder Einstellungen durchführen . . . . . . . . . . . vii
Erste Hilfe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Wiederbelebung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Stromführende Geräte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Global Services and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Web Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Service Location Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Who Should Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Other Copyright Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

1 Troubleshooting the PD41/PD42 ........................................... 1

Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

No Reaction at Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Models and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Replacing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Front Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front Panel (PD41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front Panel (PD42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bottom Right Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Console PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Right-Hand Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Left-Hand Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chassis Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Media Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Media Supply Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Transfer Ribbon Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Ribbon Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ribbon Module Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ribbon Supply and Rewind Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacing the Ribbon Core Spring Blade. . . . . . . . . . . . . . . . . . . . . . . . . 37
Adjusting Ribbon Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ribbon Out Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ink Position Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Print Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Motor, Pulleys, and Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Platen Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Media Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Label Gap Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Headlift Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Printhead Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Extending the Life of the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjusting the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Rewinder Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installing the Rewinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Label Taken Sensor (LTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Installing the Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Clearing Media Jams in Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Replacing the Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Circuits Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main Board, Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main Board, Components and Reference Points. . . . . . . . . . . . . . . . . . . . . . . . . . 72
Selected Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Upgrading Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Communication Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

RS-232 Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

USB Serial Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

USB Host Interface (PD42 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Parallel IEEE1284 Interface (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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Installing the Parallel IEEE1284 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

EasyLAN Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Installing the EasyLAN Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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 Before You Begin

Before You Begin

This section provides you with safety information, technical support
information, and sources for additional product information.

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.

Do Not Repair or Adjust Alone

Do not repair or adjust energized equipment alone under any
circumstances. Someone capable of providing first aid must always be
present for your safety.

First Aid
Always obtain first aid or medical attention immediately after an injury.
Never neglect an injury, no matter how slight it seems.

Resuscitation
Begin resuscitation immediately if someone is injured and stops breathing.
Any delay could result in death. To work on or near high voltage, you
should be familiar with approved industrial first aid methods.

Energized Equipment
Never work on energized equipment unless authorized by a responsible
authority. Energized electrical equipment is dangerous. Electrical shock
from energized equipment can cause death. If you must perform
authorized emergency work on energized equipment, be sure that you
comply strictly with approved safety regulations.

Sicherheitsübersicht
Ihre Sicherheit ist äußerst wichtig. Lesen und befolgen Sie alle Warn- und
Vorsichtshinweise in diesem Dokument, bevor Sie Intermec-Geräte
verwenden und betreiben. Falls die Sicherheitswarnungen und
Vorsichtshinweise nicht befolgt werden, kann es zu ernsthaften
Verletzungen sowie Geräteschäden und Datenverlusten kommen.

Nicht alleine Reparaturen oder Einstellungen durchführen

Reparieren oder justieren Sie niemals alleine stromführende Geräte. Aus
Sicherheitsgründen muss eine zweite Person anwesend sein, die erste Hilfe
leisten kann.

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 Before You Begin

Erste Hilfe
Nach einer Verletzung unverzüglich erste Hilfe oder medizinische
Betreuung aufsuchen. Verletzungen dürfen nicht vernachlässigt werden,
auch wenn sie noch so unbedeutend erscheinen.

Wiederbelebung
Wiederbelebungsversuche müssen unverzüglich eingeleitet werden, falls
jemand verletzt wird und die Atmung aussetzt. Verzögerungen können zum
Tod führen. Bei Arbeiten an oder in der Nähe von Hochspannung müssen
Ihnen die zugelassenen Erste-Hilfe-Methoden vertraut sein.

Stromführende Geräte
Niemals an stromführenden Geräten arbeiten, es sei denn Sie wurden von
einer verantwortlichen Stelle dazu berechtigt. Stromführende Geräte sind
gefährlich. Stromschläge durch stromführende Geräte können zu tödlichen
Verletzungen führen. Falls zugelassene Notreparaturen an stromführenden
Geräten vorgenommen werden müssen, ist darauf zu achten, dass die
genehmigten Sicherheitsvorschriften strikt eingehalten werden.

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.
This section explains how to identify and understand dangers, warnings,
cautions, and notes that are in this document. You may also see icons that
tell you when to follow ESD procedures and when to take special
precautions for handling optical parts.

A warning alerts you of an operating procedure, practice, condition, or

statement that must be strictly observed to avoid death or serious injury
to the persons working on the equipment.
Warnung: Ein Warnhinweis macht Sie auf ein Betriebsverfahren, eine
Praktik, einen Zustand oder eine Anweisung aufmerksam, die genaue-
stens befolgt werden muss, um schwere oder tödliche Verletzungen der
an den Maschinen arbeitenden Personen zu vermeiden.

A caution alerts you to an operating procedure, practice, condition, or

statement that must be strictly observed to prevent equipment damage
or destruction, or corruption or loss of data.
Vorsicht: Ein Vorsichtshinweis macht Sie auf ein Betriebsverfahren,
eine Praktik, einen Zustand oder eine Anweisung aufmerksam, die
genauestens befolgt werden muss, um Schäden oder eine Zerstörung
der Maschine bzw. die Zerstörung oder den Verlust von Daten zu ver-
meiden.

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 Before You Begin

This icon appears at the beginning of any procedure in this manual that
could cause you to touch components (such as printed circuit boards)
that are susceptible to damage from electrostatic discharge (ESD).
When you see this icon, you must follow standard ESD guidelines to
avoid damaging the equipment you are servicing.

Because finger oils can impede the performance of scanner parts and
dissolve the reflective coating of the plastic mirrors, always wear finger
cots or non-powdered latex gloves when handling optical parts.

Note: Notes either provide extra information about a topic or contain

special instructions for handling a particular condition or set of
circumstances.

Global Services and Support

Warranty Information
To understand the warranty for your Intermec product, visit the Intermec
web site at www.intermec.com and click Support > Returns and Repairs >
Warranty.
Disclaimer of warranties: The sample code included in this document is
presented for reference only. The code does not necessarily represent
complete, tested programs. The code is provided “as is with all faults.” All
warranties are expressly disclaimed, including the implied warranties of
merchantability and fitness for a particular purpose.

Web Support
Visit the Intermec web site at www.intermec.com to download our current
manuals (in PDF). To order printed versions of the Intermec manuals,
contact your local Intermec representative or distributor.
Visit the Intermec technical knowledge base (Knowledge Central) at
www.intermec.com and click Support > Knowledge Central to review
technical information or to request technical support for your Intermec
product.

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 Before You Begin

Telephone Support
In the USA and Canada
call 1-800-755-5505 and
Services Description choose this option
Order Intermec • Place an order. 1 and then choose 2
products • Ask about an existing order.
Order Intermec media Order printer labels and ribbons. 1 and then choose 1
Order spare parts Order spare parts. 1 or 2 and then choose 4
Technical Support Talk to technical support about 2 and then choose 2
your Intermec product.
Service • Get a return authorization 2 and then choose 1
number for authorized service
center repair.
• Request an on-site repair
technician.
Service contracts • Ask about an existing contract. 1 or 2 and then choose 3
• Renew a contract.
• Inquire about repair billing or
other service invoicing
questions.

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 > Repair Locations.
For technical support in South Korea, use the after service locations listed
below:
AWOO Systems
102-1304 SK Ventium
522 Dangjung-dong
Gunpo-si, Gyeonggi-do Korea, South 435-776
Contact: Mr. Sinbum Kang
Telephone: +82-31-436-1191
E-mail: [email protected]
IN Information System PTD LTD
6th Floor
Daegu Venture Center Bldg 95
Shinchun 3 Dong
Donggu, Daegu City, Korea
E-mail: [email protected] or [email protected]

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 Before You Begin

Who Should Read This Manual

This document is written for the person who is responsible for installing,
configuring, and maintaining the EasyCoder PD41/PD42 printer.
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.

Related Documents
This table contains a list of related Intermec documents and their part
numbers.
Table
Document Title Part Number
EasyCoder PD41 User’s Guide 1-960652-xx
EasyCoder PD42 User’s Guide 934-009-xxx
Intermec Fingerprint Command Reference Manual 937-005-xxx
Intermec Printer Language (IPL) Command Reference Manual 937-007-xxx
Intermec Fingerprint Developer’s Guide 934-019-xxx
Intermec Printer Language (IPL) Developer’s Guide 934-013-xxx

The Intermec web site at www.intermec.com contains our documents (as

PDF files) that you can download for free.
To download documents
1 Visit the Intermec web site at www.intermec.com.
2 Click Support > Manuals.
3 In the Select a Product field, choose the product whose documentation
you want to download.
To order printed versions of the Intermec manuals, contact your local
Intermec representative or distributor.

Other Copyright Information

Microsoft, Windows, and the Windows logo are registered trademarks of
Microsoft Corporation in the United States and/or other countries.

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 Before You Begin

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 1 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.

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 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. On the PD42, additional error
information is communicated through the display.

LEDs and the Print button

When all errors have been cleared, the Error LED is turned off, the error
message disappears from the display and the Ready-to-Work indicator is
turned back on.

Display Error Messages (Blue Ready-to-Work LED Blinks)

Error Symbol Error Message Solution
Printhead lifted Lower printhead.

Maintenance The printer is upgrading its firmware. Wait for it to complete the task.

IP link error Check if the network cable has been unplugged

Press feed not done Press Feed( ) or Testfeed( )

Test

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 Chapter 1 — Troubleshooting the PD41/PD42

Display Error Messages (Blue Ready-to-Work LED Blinks) (continued)

Error Symbol Error Message Solution
Label not taken. Printing has been halted because a label is obstructing the LTS sensor. Remove
label to resume printing.

LSS too high, LSS These errors can occur when you run a testfeed without any media installed, or if
too low. you have incorrect media settings.
Load the printer with media, restart the printer in Test mode and select the
appropriate media type.
For more information, see the EasyCoder PD42 User’s Guide (P/N 934-009-xxx)
IP Configuration The printer is trying to acquire an IP address from the network.
Error. Wait for it to complete the task.

Display Error Messages (Error LED Blinks)

Error Symbol Error Message Solution
Field out of label. You are attempting to print in an area that extends beyond the “print window.” For
more information, see the EasyCoder PD42 User’s Guide (P/N 934-009-xxx)

Out of media. Load media in printer. See the EasyCoder PD42 User’s Guide (P/N 934-009-xxx)

Ribbon empty. Load transfer ribbon. See the EasyCoder PD42 User’s Guide (P/N 934-009-xxx).
This error could also occur if you have just switched to direct thermal media, and
the printer is expecting ribbon to be loaded. If this is the case, change Paper Type
in Setup.
Label not found. The printer does not find a label gap or black mark.
• Go into Setup mode and verify that the label length parameter is correct.
• Verify that the Media type settings are correct. This error can occur if you are,
for instance, using continuous media but your media settings are set to labels
with gaps.
Printhead hot. The printhead is overheated and needs to cool down.Wait for printing to be
resumed automatically.

Testfeed not done. Press Testfeed ( ).

Test

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.

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 Chapter 1 — Troubleshooting the PD41/PD42

Other Printer Operation Problems

Problem Solution Refer to
The Power control lamp does not • Check the power outlet and power cord “No Reaction at Power Up” on
light up when the printer is started • Check the power switch and cables to page 6
and there is no response when the power module
print button is pushed. • Check the switching power module and
the cables to the main board
• Check the main board and cable to the
panel module
• Check the console board
Error LED is turned on (solid light) • Check if printer is out of media or ribbon
• Check that the printhead is closed and
locked
• Check if media is jammed/tangled up
• Check if label gap sensor is blocked by
media
“Cutter” on page 61
• Check cutter, if any
Error LED is turned on (flashing • Check for bad software setting
light)
Error LED is off, but Ready-to- • Check that the printhead is closed and
Work LED is flashing. locked
Printing started, but nothing is • Check if media is placed upside down or if
printed on the label media is not suitable for the application
• Check if the ink-coated side of the transfer
ribbons faces the media
• Select the correct media and print type
• Check that the printhead is properly
connected to the print mechanism
• Check that the printhead cables are
properly connected to the main board
• Check the main board
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.

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 Chapter 1 — Troubleshooting the PD41/PD42

Other Printer Operation Problems (continued)

Problem Solution Refer to
When printing, part of the print • Check for ribbon wrinkles and creases
image was not printed along the • Check if thermal printhead needs cleaning
feed direction. • Check if the printhead is damaged
• Check printhead balance
• Check if application program has errors
“Power Supply” on page 63
• Check if power supply is working
Printout not in desired position • Check for bad settings in the application. Fingerprint Command Reference
• Check if label gap sensor is disturbed by Manual (P/N 937-005-xxx)
media, dust, or incorrectly loaded transfer “” on page 9
ribbon
• Check lateral position of label gap sensor User’s Guide
• Calibrate label gap sensor in Autoadjust
Mode “” on page 9
• Check label gap sensor for faults or bad “Media Supply Post” on page 32
connection and “Media Guides” on page 46
• Check the edge guide and media guides
“” on page 9
• Check the media
“Platen Module” on page 44
• Check if the platen roller needs cleaning
or replacing
When printing, page skipping • Do a Test Feed or Check Media Settings User’s Guide
occurs • Check if label gap sensor is disturbed by “” on page 9
media or dust
Weak printout • Check density setting User’s Guide
• Check if thermal printhead needs cleaning User’s Guide
• Check printhead pressure
“Printhead Module” on page 49
• Check printhead dot line position
Uneven darkness across media path • Check printhead balance “Printhead Module” on page 49
When using cutter, label was not cut • Check if media is loaded correctly User’s Guide
straight
When using cutter, label was not cut • Check if media is loaded correctly User’s Guide
successfully • Check that media thickness does not
exceed 250 μm (9.8 mils)
When using cutter, label could not • Check if cutter is installed properly “Installing the Cutter” on page 62
feed or abnormal cutting occurs • Check if paper feed rods are sticky. Clean
if necessary using isopropyl alcohol.
When using Label Taken Sensor, • Check if LTS sensor is working “Label Taken Sensor (LTS)” on
abnormal function occurs • Check if media is loaded properly page 59
User’s Guide

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 Chapter 1 — Troubleshooting the PD41/PD42

No Reaction at Power Up
The electronics compartment contains wires and components with
dangerous voltage (up to 380V). Always switch off the power and
unplug the power cord before you remove the cover over the electronics
compartment!
Im Elektronikfach gibt es Kabel und Komponenten, die hohe
Spannungen (bis zu 380 V) führen. Immer die Stromversorgung
abschalten und das Netzkabel abziehen, bevor die Abdeckung des
Elektronikfachs abgenommen wird!

Printer Problems at Power Up

Problem Solution Refer to
Error during printing • Check if the printer is out of media or
transfer ribbon
• Check that the printhead lever is closed
and locked
• If the printhead is closed and locked, but “Headlift Sensor” on page 48
the problem persists, the headlift sensor
may be out of order. Check connection to
P34 on the main board. Check headlift
microswitch.
• Check if media is jammed/tangled up.
Clear the jam and reload. Clean parts that
may have been exposed to the media’s
adhesive using isopropyl alcohol or a
cleaning card.
• Check the light path between the upper
and lower parts of the label gap sensor to
see if it is obstructed by dust, adhesive, or
stuck labels. Clean using isopropyl alcohol
or a cleaning card.
• Recalibrate the sensors by running a
testfeed.
No printing due to software error • 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

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 Chapter 1 — Troubleshooting the PD41/PD42

Printer Problems at Power Up (continued)

Problem Solution Refer to
The printer is not ready • Check that the printhead is properly
locked in a closed position.
• Check that the network cable is plugged
in.
• Use the command SYSHEALTH$ to
obtain an error diagnosis. Enter the line
PRINT SYSHEALTH$ through a
terminal connection to receive the printer’s
Ready-to-Work status.
No reaction at power up • Check the power outlet and power cord
• Check the power switch and cables to power module
• Check the main board and cable to the panel module
• Check the 24 VDC output on CN1 on the power module between line and
ground (there are 3 red line wires and 3 black ground wires). If there is no +24V,
replace the entire power module.
• Verify that the same electric potential is present in the other end of the cable
(connected to socket P60 on the main board) to rule out the possibility of errors
in the cable.
• Check that the cable between CN1 on the power module and P60 on the main
board is properly connected.
• Check the status of the F1 and F2 fuses on the power module. If blown, replace
the entire module.
• Check the temperature in the power module. If it is too high, shut off the power
and wait for the power supply to cool off (may take up to half an hour). If the
error persists, examine the power module.
• Check for main board problems
• The electronics compartment contains wires and components with dangerous
voltage (up to 380V). Always switch off the power and unplug the power cord
before you remove the cover over the electronics compartment.
• Check the fuse F1 on the main board, and try to determine the source of the
error. Most likely, you will have to replace the main board.
• Check the cable between main board and console board not connected or
damaged.
• Check that the cable is properly connected to P92 on the main board and P1 on
the console board and that there is no visible damage. Replace if necessary.
• Check for a faulty console unit
• 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

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 Chapter 1 — Troubleshooting the PD41/PD42

Printer Problems at Power Up (continued)

Problem Solution Refer to
The printer is working, but nothing • Check that direct thermal media is loaded
is printing with the heat-sensitive side facing up. If
not, reload the media.
• Check if the ink-coated side of the thermal
transfer ribbon faces the media. If not,
reload the ribbon.
• Check that the printer is set for correct
media type, paper type, and print method.
• Check that the printhead is properly “Printhead Module” on page 49.
inserted into the print mechanism.
“Replacing the Main Board” on
• Check that the cables running from the
page 70.
print mechanism to the main board are
not visibly damaged and that they are
properly connected to the main board,
• Install a replacement printhead.
• Use an oscilloscope to examine the “Selected Test Points” on
printhead signals on the main board while page 73
trying to print, for example, a test label
• Check if the label taken sensor is folded
out and enabled and if there is a label left
in the feed slot or the ambient light
disturbs the label taken sensor.
Printing is missing along the feed • Check the transfer ribbon for wrinkles and “Adjusting Ribbon Tension” on
direction. creases. Reload if necessary. If the problem page 38
persists, adjust ribbon tension.
• Check the printhead for dirt, adhesive
residue, contamination from the back side
of the transfer ribbon, stuck labels, etc. If
necessary, clean using isopropyl alcohol or
a cleaning card. Never use any sharp tools.
As a last resort, replace the printhead.
• One or more of the heat-sensitive resistors “To replace the printhead” on
(“dots”) on the printhead has been page 51
damaged or is worn out. Replace the
printhead.
• If the printing is weak or non-existing on “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.

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 Chapter 1 — Troubleshooting the PD41/PD42

Printer Problems at Power Up (continued)

Problem Solution Refer to
Printout not in the desired position • Check the application settings for possible
explanations.
• Check if the light path between the two
parts of the label gap sensor is disturbed by
dust, stuck labels, or an incorrectly loaded
transfer ribbon. Clear or clean.
• Check if the label gap sensor is positioned
correctly across the media path to detect
black marks or punched holes. If using
irregularly shaped labels, the sensor should
be aligned with the front tip of the label.
• Calibrate the sensor.
• Check if the label gap sensor is properly
connected to CN8 and CN9 on the main
board.
• Check that the printer is set the proper “Label Gap Sensor Module” on
paper type (Black mark/Gap paper/Plain page 46
paper). While feeding or printing a label,
check signals on P37, pin 1 (Black Mark)
and P36, pin 3 (Gap) on the main board
while manually pulling a media with gaps
or black marks through the two parts of
the sensor. If no reaction, the sensor needs
replacing.
• Check that the edge guide on the media “Media Supply Post” on page 32
supply post guides the media so it runs
flush with the guide plate.
• Check that the inner media guide is placed “Media Guides” on page 46
flush to the inner gable and that the outer
guide is adjusted according to the width of
the media and is folded down so it engages
the lower shaft.
• Check that the media characteristics
match the media specifications in the
User’s Guide in regard of position and size
of slots, black marks, or punched holes.
• In case of self-adhesive labels on a liner,
consider if the liner has insufficient
transparency or if there is some kind of
printing on the liner that may interfere
with the label gap sensor.
• In case of tickets with black marks,
consider if the black marks have sufficient
blackness or if there is some kind of
printing on the back of the media that
may interfere with the label gap sensor.
• Check if the platen roller is slippery, worn
out, or dry and hard. Clean or replace if “Platen Module” on page 44
necessary.

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 Chapter 1 — Troubleshooting the PD41/PD42

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 2 Models and Options

This chapter contains general information about the EasyCoder PD41

and PD42 printers, including available options and technical
specifications.

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 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.
The PD42 is best described as an enhanced version of the PD41, which
comes equipped with a display, larger memory, real time clock, and a USB
host interface as a standard. The dimensions of the two printers are
identical.
All models ship with either Fingerprint or IPL firmware pre-installed.

Note: All error messages in this version of the service manual relate to
Fingerprint. IPL specific error messages are not covered in this manual.

EasyCoder PD41 printer

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 Chapter 2 — Models and Options

EasyCoder PD42 printer

Options
The following field-installable options are available for the PD41/PD42:
• Cutter kit
• Internal rewinder (for peel-off and batch takeup operation)
• EasyLAN Ethernet adapter
• Parallel 1284 interface
• Thermal printhead (200/300 dpi)
Instructions for installing these options are covered in Chapter 3.

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 Chapter 2 — Models and Options

Technical Specifications
EasyCoder PD41 Printer
Physical Dimensions
Dimensions (WxLxH) 276 x 454.4 x 283.0 mm
(10.9 x 17.9 x 11.2 in)
Weight (excl. media) 13 kg (28.7 pounds)
Power Supply
Input rating ~100-240V 2-1A 50/60 Hz
Power consumption • Stand-by: 12 W
• Normal operation/printing: 80 W
• Peak: 250 in
Printing
Print technique Direct Thermal/Thermal Transfer
Printhead resolutions 8 dots/mm (203.2 dpi) or
11.8 dots/mm (300 dpi)
Print speed
8 dots/mm (203 dpi) 50.8 to 152.4 mm/sec (2 to 6 in/sec)
11.8 dots/mm (300dpi) 50.8 to 101.6 mm/sec (2 to 4 in/sec)
Print Width Max.
8 dots/mm (203 dpi) 104 mm (4.1 in)
11.8 dots/mm (300dpi) 105.7 mm (4.2 in)
Print Length Max. Fingerprint IPL
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) Yes
Cut-off Option with cutter
Peel-off (self-strip) Option with internal
rewinder
Firmware (Fingerprint)
Operating system Fingerprint v10.x.x Includes Direct Protocol
Smooth fonts TrueType and TrueDoc fonts
Resident scalable fonts 15
Character sets • 23 single-byte character sets standard.
• UTF-8 support as standard.
Resident bar codes 61

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 Chapter 2 — Models and Options

EasyCoder PD41 Printer (continued)

Firmware (IPL)
Operating system IPL v10.x.x
Smooth fonts TrueType and TrueDoc fonts
Resident scalable fonts 13 (+21 simulated bitmap)
Character sets • 23 single-byte character sets standard
• UTF-8 support as standard
Resident bar codes 31
Environment
Operating temperature +5°C to +40°C (+41°F to 104°F)
Storage temperature -20°C to 70°C (-4°F to 122°F)
Operating humidity 20 to 80% non-condensing
Storage humidity 10 to 90% non-condensing
Media
Media width 25 to 118 mm (1 to 4.6 in)
Max 114 mm (4.5 in) with cutter
Media roll diameter 213 mm (8.4 in) max.
190 mm (7.5 in) with internal rewinder
Internal rewinder diameter Max 140 mm (5.51 in)
Media roll core diameter 38.1 to 76.2 mm (1.5 to 3 in)
Media thickness 60 μm to 250 μm (2.3 to 9.8 mils)
Transfer Ribbon
Material Wax, hybrid, or resin
Winding Ink on either inside or outside of roll
Ribbon width 30 to 110 mm (1.18 to 4.33 in)
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 Yes
media
Printhead lifted Yes
Label taken Yes
Ribbon end Yes
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.

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 Chapter 2 — Models and Options

EasyCoder PD41 Printer (continued)

Interfaces
RS-232 serial Standard
USB Standard
Ethernet Option
IEEE 1284 parallel Option
CompactFlash Standard
Accessories and Options
Internal rewinder and batch takeup
Cutter
Printhead 203/300 dpi
EasyLAN ethernet interface
Parallel IEEE 1284 interface
Real time clock

EasyCoder PD42 Printer

Physical Dimensions
Dimensions (WxLxH) 276 x 454.4 x 283.0 mm
(10.9 x 17.9 x 11.2 in)
Weight (excl. media) 13 kg (28.7 pounds)
Power Supply
Input rating ~100-240V 2-1A 50/60 Hz
Power consumption • Stand-by: 12 W
• Normal operation/printing: 80 W
• Peak: 250 inW
Printing
Print technique Direct Thermal/Thermal Transfer
Printhead resolutions 8 dots/mm (203.2 dpi) or
11.8 dots/mm (300 dpi)
Print speed
8 dots/mm (203 dpi) 50.8 to 152.4 mm/sec (2 to 6 in/sec)
11.8 dots/mm (300dpi) 50.8 to 101.6 mm/sec (2 to 4 in/sec)
Print Width Max.
8 dots/mm (203 dpi) 104 mm (4.1 in)
11.8 dots/mm (300dpi) 105.7 mm (4.2 in)
Print Length Max. Fingerprint IPL
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) Yes
Cut-off Option with cutter

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 Chapter 2 — Models and Options

EasyCoder PD42 Printer (continued)

Peel-off (self-strip) Option with internal
rewinder
Firmware (Fingerprint)
Operating system Fingerprint v10.x.x Includes Direct Protocol
Smooth fonts TrueType and TrueDoc fonts
Resident scalable fonts 15
Character sets • 23 single-byte character sets standard.
• UTF-8 support as standard.
Resident bar codes 61
Firmware (IPL)
Operating system IPL v10.x.x
Smooth fonts TrueType and TrueDoc fonts
Resident scalable fonts 13 (+21 simulated bitmap)
Character sets • 23 single-byte character sets standard
• UTF-8 support as standard
Resident bar codes 31
Environment
Operating temperature +5°C to +40°C (+41°F to 104°F)
Storage temperature -20°C to 70°C (-4°F to 122°F)
Operating humidity 20 to 80% non-condensing
Storage humidity 10 to 90% non-condensing
Media
Media width 25 to 118 mm (1 to 4.6 in)
Max 114 mm (4.5 in) with cutter
Media roll diameter 213 mm (8.4 in) max.
190 mm (7.5 in) with internal rewinder
Internal rewinder diameter Max 140 mm (5.51 in)
Media roll core diameter 38.1 to 76.2 mm (1.5 to 3 in)
Media thickness 60 μm to 250 μm (2.3 to 9.8 mils)
Transfer Ribbon
Material Wax, hybrid, or resin
Winding Ink on either inside or outside of roll
Ribbon width 30 to 110 mm (1.18 to 4.33 in)
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 Yes
media
Printhead lifted Yes
Label taken Yes
Ribbon end Yes

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 Chapter 2 — Models and Options

EasyCoder PD42 Printer (continued)

Controls
Graphical display LCD, 240*160 pixels with LED backlight
LED indicators Power, Data/Ready, Error, Ready-to-Work™
Keys 1 Print Button + 5 Soft Keys
Electronics
Microprocessor ARM 9
Standard memory 8 MB flash, 16 MB SDRAM.
Interfaces
RS-232 serial Yes
USB Yes
Ethernet Option
IEEE 1284 parallel Option
CompactFlash Yes
USB host Yes
Accessories and Options
Internal rewinder and batch takeup
Cutter
Printhead 203/300 dpi
EasyLAN ethernet interface
Parallel IEEE 1284 interface
Real time clock

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 3 Replacing Parts

This chapter explains how to replace the various parts of the EasyCoder
PD41/PD42 printer. The chapter contains the following sections:
• Front Panels
• Side Panels
• Chassis
• Media Supply
• Transfer Ribbon Mechanism
• Print Mechanism
• Rewinder Module
• Label Taken Sensor
• Cutter
• Power Supply
• Main Board
• Upgrading Firmware

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 Chapter 3 — Replacing Parts

Front Panels
This section describes the front panels for the PD41/PD42 and how to
replace them.

Front Panel (PD41)

The PD41 has a front panel molding with four colored LED control lamps
and a print button.
The control lamp LEDs are fitted on a console PCB that also contains the
switch for the print button. An overlay, covered with a transparent plastic
window, provides the icons for the LEDs. The console PCB is connected to
connector P92 (“CONSOLE”), on the main board via a separate flat cable.
The Label Taken Sensor uses a separate cable that connects to connector
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

EasyCoder PD41

Overlay Front Panel

PD41 Front Panel: Exploded View

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 Chapter 3 — Replacing Parts

Front Panel (PD42)

The EasyCoder PD42 has a front panel molding with a LCD, four colored
LED control lamps and a Print button.
The control lamp LEDs are fitted on a console PCB that also contains the
switch for the print button. An overlay, covered with a transparent plastic
window, provides the icons for the LEDs. The console PCB is connected to
connector P92 (“CONSOLE”) on the main board via a separate flat cable.
Another flat cable runs from the display to the connector P46 (“LCD”) on
the main board. The Label Taken Sensor uses a separate cable which
connects to connector 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

EasyCoder PD42

Overlay Front Panel

PD42 Front Panel: Exploded View

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 Chapter 3 — Replacing Parts

To replace the front panel

1 Remove the left-hand panel (For help, see “To remove the left-hand
panel” on page 27).
2 Disconnect the cables (Console PCB and LTS) from the main board
and release them from the clips and the spiral binding.
3 Disconnect the display flat cable (for the PD42 only).
4 From inside the electronics compartment, remove the two screws that
hold the front panel assembly at the top front of the center section.
5 Lift the front panel assembly up and out so the panel molding
disengages the two keyholes in the center section.
6 Replace the entire assembly or individual parts (the display PCB on the
PD42, the LTS sensor).
7 To install the front panel, reverse steps 1 to 6.

Bottom Right Panel

All models have a panel fitted to the bottom plate in front of the print
mechanism. This panel is temporarily removed when loading media for
peel-off (self-strip) operation when a rewinder (For help, see “Rewinder
Module” on page 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

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 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

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5V 5V 5V 5V

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D1 D2 D3 D4
RED GREEN BLUE GREEN
LED_3MM
LED_3MM LED_3MM LED_3MM

R1 R2 R3 R4

Console PCB: Schematics

220 220 560 220
5V

P1
1
2
3
4
5
6

3
4
6-PIN

SW 1

1
2
COMPONENT PLACEMENT REF.
TOP SIDE VIEW

D4
GREEN
D2
GREEN
P1
SW1
D1
RED
D3
BLUE

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Side Panels
This section describes the right-hand door assembly that covers the media
compartment and the left-hand side panel that covers the electronics
compartment.

Right-Hand Door
The right-hand door covers the media compartment, which contains the
print mechanism, the transfer ribbon mechanism, the media supply, and
the optional rewinder. The door is attached to the center section with two
hinges and can be opened 180° to facilitate ribbon and media load.
The door assembly consists of a hinged door to which the top right panel is
fitted using four screws. A clear plastic inspection window is glued to the
inside of the door. A media and ribbon load instructions label is fitted
inside the top part of the door.
The door assembly is available as a complete unit. The top/right panel can
be replaced separately and is attached to the door using a total of four
screws (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

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Left-Hand Panel
The left-hand panel covers the electronics compartment. It is a one-piece
metal panel, which is fitted to the center section using two screws and to
the rear plate and the bottom plate using a series of leaf springs along the
edges.

The electronics compartment contains wires and components with

dangerous voltage (up to 380V). Always switch off the power and
unplug the power cord before you remove the cover over the electronics
compartment!
Im Elektronikfach gibt es Kabel und Komponenten, die hohe
Spannungen (bis zu 380 V) führen. Immer die Stromversorgung
abschalten und das Netzkabel abziehen, bevor die Abdeckung des
Elektronikfachs abgenommen wird!

Never run the printer without the left-hand panel installed, as this may
cause radio interference. Approvals are only valid when the cover is
installed.
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.

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Screw

Leaf-springs

Screw

Panel

Leaf-springs

Left-Hand Panel

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.

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4 Close the right-hand door.

5 Lay the printer down on its side, with the electronics compartment
facing up.
6 Dislocate the left-hand panel by placing the tip of a slotted screwdriver
at the edge of the panel and gently pushing the handle towards the top
of the printer. 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.

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To install the left-hand panel

1 Making sure that the leaf springs along the rear edge of the panel
embrace the edge of the rear plate, push down the panel. Check that the
leaf springs along the bottom edge fit the bottom plate.
2 Open the right-hand door.
3 Secure the panel using two screws inserted from the media
compartment.
4 Reconnect the power cord.

Chassis
This section describes the chassis, which consists of the center section, the
bottom plate, and the rear plate.

Chassis Overview
The chassis is the printer’s main frame to which various modules are
attached, such as the panels and doors, the print mechanism, the transfer
ribbon mechanism, the electronics, and the media supply post. It consists of
three main parts:
• Bottom plate with four rubber feet and two dampeners for the right-
hand door
• Center section
• Rear plate

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Rear Plate

Center Section

Rewinder Cover Plate

Dampeners (x2)

Bottom Plate

Rubber Feet (x4)

Chassis Overview

Rear Plate
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.

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Intake for external

media supply

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

I
O
Power switch

AC power cord socket

Rear Connectors on the PD41

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USB host port

Ethernet RJ-45 port
USB port
MAC address label

RS-232 serial port

IEEE 1284 parallel port

CompactFlash socket

I
O
Power switch

AC power cord socket

Rear Connectors on the PD42

Media Supply
This section describes the media supply post and the two different types of
edge guides available.

Media Supply Post

The media supply post is intended for media rolls loaded inside the media
compartment. The printer can also use an external supply of media. For
example, fan-folded tickets placed behind the printer and routed through
the slot in the rear plate.
The printer comes with two edge guides: one of them is fitted on the supply
post; the other one is packed separately. The short guide makes it easy to fit
the media roll, but does not support the entire side of the roll. The tall edge
guide supports most of a full media roll, but must be folded to a horizontal
position to allow a roll or empty core to be removed and a new roll to be
loaded. Which guide to use depends mainly on the characteristics of the
media in use. For example, a “slippery” liner versus a “coarse” roll of tags. If
the printer is placed in a completely horizontal position, or if it is tilted to
the right.
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.

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Short Edge Guide

Tall Edge Guide (exploded)

Screws(x3)

Hook

Washer

Spring
Post
Screws(x3)
Guide Plate

Center Section

Media Supply Post: Exploded View

To remove the edge guide

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

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To install the edge guide

1 Insert the edge guide into the slot in the post.
2 First fit the washer and then the coil spring from underneath the post to
the protruding part of the edge guide and engage the coil spring to the
hook.

Note: The high edge guide is hinged to allow media load. Before
removing an empty core or loading a roll of media, the guide must be
lowered to a horizontal position. Similarly, after loading the media it
must be flipped back so it points straight up. Like the low edge guide, it
can be adjusted along the post to fit different media widths.

Make sure you put the high edge guide in vertical position before you
close the side door, or the guide could get damaged.
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.

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Transfer Ribbon Mechanism

This section describes the thermal transfer ribbon mechanism.

Ribbon Module
The thermal transfer mechanism holds the supply of thermal transfer
ribbon and winds up the spent ribbon after printing. It consists of a self-
contained unit that is attached to the center section and driven by a belt
from a pulley on the platen roller shaft (For help, see “Print Mechanism”
on page 41). In addition to this unit, there is also a ribbon out sensor and
an ink position selector attached to the center section.
Spring for Ink
Position Knob Ribbon Core
Spring Blade

Ribbon Supply Unit

Bracket

Ribbon Out
Sensor Location

Ribbon Rewind Unit

Screws (x6)

Belt

Ribbon Module

The ribbon module can be replaced as a unit. It also has four replaceable
parts—the belt, the ribbon core spring blades, the ribbon out sensor, and
the ink position knob.
To replace the ribbon module
1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).

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2 Slip the belt that drives the platen from its pulley (For help, see “Motor,
Pulleys, and Belts” on page 42).
3 Use a pair of narrow pliers to disconnect the spring between the ribbon
supply and the ink position knob.
4 Remove the six screws that hold the ribbon module to the center section
from the media compartment side.
5 Tilt the ribbon module so you can remove the belt from the pulley on
the platen roller shaft.
6 Do not dismantle the module any further, unless you need to replace the
belt. Reassemble in reverse order.

Ribbon Module Belt

The ribbon module belt is used to drive the ribbon rewind unit.

Screws(x4) Spring

Bearing Washer

Bracket
E-ring
One-Way Clutch

E-ring

Washer

Belt

Ribbon Module Exploded View

To replace the ribbon module belt

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Slip the belt that drives the platen from its pulley (For help, see “Motor,
Pulleys, and Belts” on page 42).
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.

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DO NOT loosen the screws that hold the bearing and the one-way
clutch to the bracket. Doing so will affect the factory-adjustment of
the supply and rewind units and can cause ribbon creasing
problems.
Die Schrauben, mit denen das Lager und die Kupplung an der
Halterung befestigt sind, NICHT lockern. Dies verändert die
Werkseinstellung der Zufuhr- und Aufwickelmodule und kann zu
Bandfaltungsproblemen führen.

5 Remove the belt from the pulley on the rewind unit. Make sure that the
spring and washer stay on the supply unit shaft.
6 Reassemble in reverse order.

Ribbon Supply and Rewind Units

The ribbon supply and ribbon rewind units look exactly the same, but
differ in having internal springs with different strength. Only the ribbon
core spring blade is replaceable as described in the next section.
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

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Adjusting Ribbon Tension

The knob at the outer end of each unit is engraved with numbers from 1 to
4, where 1 is maximum friction and 4 is minimum friction. Factory default
is #1 on the supply unit and #2 on rewind unit. If the friction settings
prevent the ribbon from running with the same speed as the media,
smudging may occur.
If ribbon wrinkling occurs during printing, push the knob on the ribbon
supply hub inwards (1) and rotate it clockwise to increase the breaking
force (2).
If the printer has problems pulling the labels (especially when using a
ribbon less than 50 mm/2 inches wide), push the knob on the ribbon
supply hub inwards (1) and rotate it counterclockwise to decrease the
breaking force (2).

Adjusting Ribbon Tension

Ribbon Out Sensor

The ribbon out sensor is attached to the center section from the electronics
compartment using a single screw. The sensor is connected to connector
P39 (RIBBON) on the main board.
The sensor assembly consists of a LED and a sensor mounted on a circuit
board. The LED emits a beam of light that is detected by the sensor. The
ribbon supply unit has a flange with slots situated, so the light is
intermittently let through or interrupted as the flange rotates. If no rotation
is detected during printing, an out-of-ribbon condition is assumed. This
causes error “Out of transfer ribbon” (Error 1027), and the red LED emits a
solid glow if the printer is set up for thermal transfer printing. If the printer
is set up for direct thermal printing, the ribbon out sensor is not used.
To replace the ribbon out sensor
Note: Before replacing the sensor, check that the malfunction is not caused
by dust or foreign objects. 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,
see “To remove the left-hand panel” on page 27).

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2 Disconnect the cable from P39 (RIBBON) at the top of the main
board.
3 Remove the cable from the clip and plastic spiral binding.
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

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Ink Position Knob

The ink position knob is used to set the printer for thermal transfer ribbon
wound with the ink facing either outwards or inwards.

Ink Position Knob

Slot

Spring

The Ink Position Knob

To remove the ink position knob

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
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.

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4 Install the new ink position knob in reverse order. Do not forget to
move it to either end of the slot before closing the right-hand door.

It is important that the knob is locked in either position or it may be

damaged when the right-hand door is closed.
Es ist wichtig, dass der Knopf in einer seiner Stellungen arretiert ist;
andernfalls kann er beim Schließen der rechten Klappe beschädigt
werden.

Print Mechanism
This section describes the print mechanism and the stepper motor that
drives both the platen roller and the transfer ribbon takeup unit.

Print Unit
The print unit is not a self-contained unit, but is integrated with the center
section. The basic printer configuration includes a 203.2 dpi (8 dots/mm)
printhead which can be upgraded to one capable of 300 dpi (11.81 dots/
mm). 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.
Nur von Intermec zugelassene Druckköpfe benutzen. Wenn ein
Druckkopf benutzt wird, der nicht für den Drucker geeignet ist, wird
dadurch die Garantie nichtig und die Hauptplatine kann so stark
beschädigt werden, dass sie nicht mehr reparierbar ist.

To help understanding the design of the print unit, an exploded view of all
parts is shown below. Cables are omitted for clarity.

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Printhead Module
(203 or 300 dpi)
Pressure Box
(Blue)

Label Gap Sensor Module

Pulley
for Belt to
Ribbon Unit

Pulley TPH Lever

(motor belt, (blue)
203 or 300 dpi) Inner Headlift
Media Outer Sensor
Guide Media
Platen Roller Guide
Print Unit Exploded View

Motor, Pulleys, and Belts

The stepper motor drives both the platen roller and the transfer ribbon
rewind unit via a series of belts and pulleys.
As a standard, the stepper motor has double pulleys to be prepared for the
installation of an optional rewinder (as described in “Rewinder Module”
on page 57). The motor and belt are available as spare parts. The tension of
the belt is automatically adjusted by a sprinkled arm-and-wheel
arrangement attached to the center section.
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.

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Belt
Motor

Pulley

Print Unit Assembly

and Printhead Module

Motor, Pulleys and Belts

To replace the stepper motor

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Disconnect the cable from P31 on the main board and free the cable
from the spiral bindings and the cable clip.
3 Remove the four screws that hold the stepper motor module to the
bottom plate. A screwdriver with a magnetic tip is highly recommended.
4 Disconnect the belt(s) from the motor’s pulley and pull out the motor.
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.

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To replace the belt

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Disconnect the cable from P31 on the main board and free the cable
from the spiral bindings and the cable clip.
3 Remove the four screws that hold the stepper motor module to the
bottom plate.
4 Disconnect the belt(s) from the motor’s pulley and pull out the motor.
5 Install belt and motor in reverse order. If the printer is equipped with a
rewinder, fit the platen roller belt on the inner pulley (that is, the pulley
closest to the motor housing) and the rewinder belt to the outer pulley.

Note: If the printer is not equipped with a rewinder, it has only one belt.
Do not remove the motor. Pull the belt off of the platen roller pulley and
then off the motor pulley. Fit the new belt in reverse order. Temporarily
disconnecting the tension adjuster spring makes the process easier.

To replace the pulley

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Pull off the belt from the pulley. Temporarily disconnecting the tension
adjuster spring makes the process easier.
3 Remove the E-ring that holds the pulley on the platen roller shaft.
4 Install the pulley in reverse order.

Platen Module
The platen module is comprised of a rubber-coated roller and a shaft. Its
purpose is to drive the media through the print mechanism and serve as a
counter-force to the thermal printhead. The silicone rubber is subject to
wear and requires the platen roller to be replaced, usually with long
intervals.

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When cleaning the platen roller, only use isopropyl alcohol. Other
chemicals may make the silicone rubber crack, get hard or slippery, or
dissolve the surface. Never use sharp tools to remove stuck labels. Do
not rotate the platen roller manually until the power has been off a
minute or more, or the stepper motor may generate current that can
damage the electronics. You could also disconnect the stepper motor
cable from the main board.
Beim Reinigen der Druckwalze nur Isopropylalkohol benutzen. Andere
Chemikalien können zur Rissbildung im Silikongummi führen, bzw.
diesen hart oder schlüpfrig machen oder die Oberfläche auflösen.
Steckende Etiketten niemals mit scharfen Werkzeugen entfernen. Die
Druckwalze nicht manuell drehen, solange die Stromversorgung nicht
mehr als eine Minute ausgeschaltet ist. Der Schrittmotor könnte
andernfalls Strom erzeugen, der die Elektronik beschädigen kann. Es
könnte auch das Schrittmotorkabel von der Hauptplatine getrennt
werden.

Washer Bearing
Bearing
E-ring Washer
E-ring

E-ring
Pulleys
Inner Gable Platen Roller
Outer Gable

Platen Module Exploded View

To replace the platen roller

1 Disconnect the power cord and remove the left-hand panel (see “To
remove the left-hand panel” on page 27).
2 Remove the front panel as described on page 22.
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.

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6 Remove the bearings.

7 Pull out the platen roller.
8 Install the platen roller, bearings, washers, E-rings, pulleys, and front
panel in reverse order.

Media Guides
The media guides are made of blue plastic and are designed to guide the
media in a straight line through the print mechanism. The inner guide
should always be fitted flush to the inner gable of the print module whereas
the outer one should be adjusted to fit the width of the media without
compressing it. It can be folded upward to facilitate media load.
The media guides are pressed onto their respective shafts and can easily be
removed and installed by hand. Take care to fit the guides as illustrated
below (the flat side should face the media).

Inner Gable

Shafts

Outer Media Guide

Inner Media Guide

Media Guides Exploded View

Label Gap Sensor Module

The label gap sensor detects gaps, slots, or black marks in the media as it is
fed between the two sensor boards. The lower board contains a LED and a
light sensor, whereas the upper board only has a sensor. 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.

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Label Gap Sensor Module: Front View

The label gap sensor’s point of detection can be moved manually across the
media path from 0 to 57 mm (0 to 2.24 in) from the inner edge of the
media. The point of detection is indicated by a narrow white triangle visible
from the front of the print mechanism when the printhead is open.

Label Gap Sensor Module: Rear View

The sensitivity of the sensor is automatically adjusted when you run a

testfeed. 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. To clean the sensors, it may be necessary to take out the module as
described below.

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Open the right-hand door and remove the bottom right-hand panel
(For help, see “Bottom Right Panel” on page 22).

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3 Remove the E-ring, washer, and bearing from the outer end of the
platen roller (the end in the media compartment).
4 Remove the six screws that hold the outer gable of the printhead.
5 Fold the outer gable aside, taking care not to damage the headlift sensor
and its cable (see “Headlift Sensor” on page 48).
6 Remove the single screw that holds the label gap sensor module in the
electronics compartment. It is situated immediately to the rear of the
black sensor module.
7 Disconnect the cables from P36 (“GAP”) and P37(“MARK”) on the
main board. Free the cables from the spiral bindings and the cable clip.
8 Pull out the entire label gap sensor module into the media
compartment.
9 Do not dismantle the module. The entire module is available as a
replacement part.
10 Install the label gap sensor module in reverse order.

Label Gap Sensor Module

Outer Gable
Bearing
Washer
E-ring

Screw (x6)

Label Gap Sensor Assembly Exploded View

Headlift Sensor
The headlift sensor is a microswitch fitted inside the outer gable of the print
mechanism, immediately below the platen roller bearing. 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.

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The headlift sensor is connected to P34 (“HEADLIFT”) on the main

board.
To replace the headlift sensor
1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Disconnect the cable from P34 (“HEADLIFT”) on the main board.
Free the cable from the spiral binding and the cable clips.
3 Remove the E-ring, washer, and bearing from the outer end of the
platen roller (the end in the media compartment).
4 Remove the six screws that hold the outer gable of the printhead.
5 Remove the screw that holds the headlift sensor and the L-shaped
bracket to the outer gable.
6 Carefully retract the headlift sensor cable from inside the electronics
compartment through the hole in the center section (you may have to
remove several cable clips inside the electronics compartment).
7 Install the new headlift sensor and bracket in reverse order.

Headlift Sensor
Bearing
Washer
E-ring

Screw
Outer Gable

Printhead Module
The printing is performed by the thermal printhead, which consists of a
line of very small, closely spaced resistors on a ceramic tile fitted across the
media path. When a current is led through the resistors, commonly called
“dots,” these will be heated very quickly. When the current is shut off, the
dots cool down just as fast.
As the media is fed past the dots, the heated dots will produce a number of
black spots on heat sensitive (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.

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 Chapter 3 — Replacing Parts

The direct thermal printing method requires special media coated with a
thin layer of heat-sensitive chemicals. As the media is fed past the dots, the
heat from the dots will make the chemicals react, producing a dark salt,
which makes up the imprint under each dot.
In the thermal transfer printing method, a special ink-coated transfer
ribbon is used. When the ribbon is heated by a dot on the printhead, the
ink melts and sticks to the receiving face material, where the ink
immediately becomes solid again, producing a black spot. Transfer ribbons
normally do not smear at room temperature, neither before nor after
printing. Nor do the printed labels smear, even if the printout may be
smudged by extensive rubbing if an unfortunate combination of ribbon
and face material is used. The thermal transfer method makes it possible to
use a wide range of face materials for printing, for example papers, boards,
plastics, foils, etc. However, an original transfer ribbon from Intermec
should always be used.
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
(0.125 mm).
• In a 300 dpi printhead (11.81 dots/mm), each dot under standardized
conditions will produce a black spot which has a diameter of 3.33 mils
(0.086 mm).
Depending on dot temperature, exposure time, media and ribbon
characteristics, etc., the spot may actually be somewhat smaller (weak print)
or larger (black print). However, that does not affect the calculation of
distances, sizes, and positions.

Note: When switching to a printhead with a different density, the

printhead PCB must also be replaced.

The printhead is subject to wear both from the direct thermal media (or
ribbon) and from the rapid heating and cooling process during printing.
Thus, the printhead will require periodic replacement.
Time between printhead replacements depends on the print images, the
type of direct thermal media (or ribbon) in use, the amount of energy to the
printhead, the print speed, the ambient temperature, and several other
factors.

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 Chapter 3 — Replacing Parts

Printhead

Note: While replacing the printhead, the power must be off. The firmware
will not detect the new printhead resistance until the printer has been
restarted.

Take precautions against electrostatic discharges by touching a

grounded object. For example, the chassis of the printer (assuming the
printer is connected to a grounded wall socket).

To replace the printhead

1 Switch off the power to the printer.
2 Open the side door.
3 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.
4 Remove any transfer ribbon.
5 Remove the old printhead by pulling it out straight forward.

Note: Steps 6-9 describe how to replace the printhead’s PCB (Printed
Circuit Board), which is required if you are switching to a printhead with a
different density (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.

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7 Use an appropriate tool, for instance a straight-slot screwdriver, to

carefully pry the printhead cable connector loose from the PCB.
8 Loosen the screws and remove the old PCB.
9 Attach the new PCB with the screws and connect the printhead cable.
Adjust the position of the balance boxes so that they do not obstruct the
procedure.
10 Connect the new printhead.
11 Reload the transfer ribbon, lower the printhead, close the side door and
switch on the power.

Extending the Life of the Printhead

Some simple measures can be taken by the user to extend the life of the
printhead:
• Clean the printhead regularly, as described in the user’s guide. Not only
will a dirty printhead produce an inferior printout, but any residue on
the dots will prevent heat to dissipate through the media.
• Use as low density setting as possible. Too much energy to the printhead
will wear it out rapidly.
• Do not use higher speed setting than necessary.
• Low ambient temperature requires more energy to the printhead dots
than room temperatures and will therefore cause more wear to the
printhead. High print speed accelerates the wear. Thus, at low
temperatures, select as low a print speed as acceptable.
• Do not use a higher printhead pressure than necessary.
• Never print outside the media path. Dots that are not in contact with
the media will not be cooled properly.
• When using media with less than full width, be careful to adjust the
printhead balance so there is an even pressure across the media. Not
only will an uneven pressure impair the printout quality, but it may also
prevent the dots from being cooled properly. Moreover, a sharp outer
media edge in direct contact with the printhead may cause excessive
mechanical wear on some dots, which may be visible when printing on
wider media later.
• 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.
• Only use transfer ribbons recommended by Intermec.

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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.
To adjust printhead balance
1 Open the side door.
2 Remove the ribbon.
3 Lift the printhead.
4 Move the balance box on the right side (outer) outward (to the right) for
wider media and inwards (to the left) for more narrow media.

5 Engage the printhead and load the ribbon.

6 Test and readjust if necessary.
The pressure of the thermal printhead against the platen roller is factory-
adjusted. However, if the printing is weaker on one side of the media or if
the thermal transfer ribbon starts to crease (indicated by unprinted white
streaks along the media feed direction), it may be necessary to readjust the
printhead pressure.
To adjust printhead pressure

Note: Before attempting to adjust the printhead pressure, try to fix the
problem by moving the outer balance box as described in the previous
section.

1 Open the side door.

2 Remove the ribbon.
3 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.
4 Use a straight-slot screwdriver to turn the screw at the top of the balance
boxes clockwise to increase the pressure or counterclockwise to decrease
the pressure. To reset the factory default setting, turn the screws down
completely and then 9 turns up (counterclockwise).

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 Chapter 3 — Replacing Parts

5 Engage the printhead and load the ribbon.

6 Test and readjust if necessary.
When using thick or stiff media, the printhead needs to be moved forward
so the dot line is precisely aligned with the top of the platen roller. The
platen roller and printhead must of course be perfectly parallel as well.
To adjust the printhead dot line position
1 Open the side door.
2 Remove the ribbon and lower the printhead.
3 Use a straight-slot screwdriver to turn the two screws at the top of the
printhead bracket counterclockwise a single turn.

4 Turn the printhead lever to raise the printhead.

5 Carefully turn both screws at the front of the printhead clockwise a
quarter of a turn at a time (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.

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 Chapter 3 — Replacing Parts

6 Engage the printhead and lock the printhead by tightening the two
screws at the top of the printhead bracket (the reverse action of Step 3).
7 Load the ribbon (only in case of thermal transfer printing).
8 Test the print quality and readjust if necessary.
To reset dot line position to factory default setting
1 Release screws A and B (half a turn is enough).

A
C
B
D

2 Tighten screws C and D (counterclockwise) as far as they will go. Be

careful not to overdo it, as it may damage the threads.
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.

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The ribbon shield mechanism is located on the thermal printhead. It has

two adjustable screws, A and B, as shown below.

B
Ribbon Shield Adjustment Screws

If labels come out looking as depicted below, you may want to try adjusting
the ribbon shield.

Test Label A Test Label B

1234567890 1234567890
Low Quality Printout: These bar codes show the results of ribbon wrinkling.

To adjust ribbon shield

1 If the label printout matches Test label A, turn screw A clockwise. If the
printout matches Test label B, turn screw B clockwise.
2 Twist the screw half a turn clockwise and perform a new test print.
3 Continue until you achieve a smooth printout quality.
Screw adjustment must not exceed two full turns or paper may not feed
smoothly. In such a case, turn the screws counterclockwise completely and
start over.
To reset ribbon shield to factory default setting
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.

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Rewinder Module
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. A removable plate covers the hole in the
center section for the rewinder.

Cover Plate

Gear

Empty Connector

Cutter Connector Gear/Pulley

Washer

E-ring

Flange
Belt Connects to outer
E-ring pulley of stepper
motor
Rewinder Module: Driving components

The rewinder module consists of the parts depicted below. Only the liner
retention clip is available as a spare part.

Linear
retention
clip
Rewinder Module: Exploded view

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Installing the Rewinder

The installation kit contains:
• One rewinder module with liner retention clip
• One liner retention guide
• Four M3x4.5 screws
To install the rewinder
1 Open the side door.
2 Remove the rewinder option cover plate, held by two phillips screws (see
previous page).
3 Remove the liner retention clip from the rewinder unit. Attach the
rewinder unit to the center section of the printer using two of the screws
included in the kit together with the two that were previously used to
hold the cover plate in place.
4 For batch takeup operation only: Remove the screw that holds the front
cover. Remove the front cover (In batch takeup operation, labels are
wound up on the internal rewinder instead of being peeled off at the
tear bar).
5 For batch takeup operation only: Attach the liner retention guide.

6 Install media as described in the printer user’s guide.

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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. The latter
requires an optional rewinder module (see “Rewinder Module” on
page 57).
The LTS is normally folded up into the side of the front panel but can be
folded down to a horizontal position after the right hand door has been
opened. In the horizontal position, it detects labels approximately 15 mm
(0.59 in) from the inner edge of the media path and approximately 22 mm
(0.86 in) in front of the printhead’s dot line.

Label Taken
Sensor

Note: If you are running a software application, the LTS must be activated
before it can be used. When you are not using the LTS, be sure to flip it
back in vertical position and de-activate it in the application. Also note that
the LTS cannot be used when a paper cutter is installed.

The LTS has a plastic housing, which is hinged on a pin protruding from
the inside of the panel module. The housing contains a circuit board with a
LED and a light-sensitive sensor. The sensors are connected to P38
(marked “LTS”) on the main board. When the light from the LED is
reflected back from the back side of a label and hits the sensor, a “label
present” condition is assumed. If no light is detected, a “label taken”
condition is assumed. Thus, the sensor is somewhat sensitive to the
ambient light conditions and to the reflection properties of the back side of
the media.

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Before replacing the LTS, troubleshoot it by checking that:

• The sensor is in its horizontal position.
• Nothing blocks the LED and the sensor, for example dust or stuck
labels.
• The back side of the media is able to reflect the light.
• The cables of the sensor are undamaged and properly connected to P38
(“LTS”) on the main board.
To replace the Label Taken Sensor

Take standard precautions against ESD (Electrostatic Discharges)

before touching any electronics components.

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Remove the front panel (For help, see “To replace the front panel” on
page 22).
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

H
PUS
Label Taken Sensor

Front Panel (PD41)

Label Taken Sensor

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Cutter
The cutter is an optional device which is used to cut off sections of
continuous media after printing. When a cutter is installed, the Label
Taken Sensor cannot be used (For help, see “Label Taken Sensor (LTS)” on
page 59). The cutter can cut non-adhesive media 64 to 114 mm (2.52 to
4.4 in) wide and with a thickness of 60 to 250 μm (2.3 to 9.8 mils).
Never use the cutter to cut through any kind of adhesive. The adhesive
will get stuck on the shears and can render the cutter inoperable or
even damage it. If you need to cut self-adhesive labels, be careful to
only cut through the liner between labels.
Mit der Schneidvorrichtung niemals klebstoffhaltiges Material
schneiden. Der Klebstoff haftet an den Scheren an und kann die
Schneidvorrichtung unwirksam machen oder beschädigen. Falls
selbstklebende Etiketten geschnitten werden müssen, darf dies nur
durch den Bogen zwischen Etiketten erfolgen.

The main parts of the cutter are:

• Cutter mechanism
• Cutter PCB
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

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Installing the Cutter

The installation kit contains all of the parts shown above, along with cables
for connection to the main board.
To install the cutter
1 Remove the screw that holds the front cover. Remove the front cover.
2 Remove the tear bar, which is held by two Phillips screws.
3 Attach the cutter mechanism to the printer using the two Phillips screws
included in the kit.
4 Plug the cutter cable into the connector in the center section. Secure the
cable to the bottom plate using the two cable clips included in the kit.
5 Hook the cutter cover onto the cutter mechanism and lock the cover
with the screw at the bottom.

Clearing Media Jams in Cutter

Never insert fingers or tools into the cutter while the power is on.
Risk of personal injury or damage to the cutter if the cutter starts to
run by mistake.
Nie Finger oder Werkzeuge in die Schneidvorrichtung stecken,
während die Stromversorgung eingeschaltet ist. Falls die
Schneidvorrichtung versehentlich aktiviert wird, besteht
Verletzungsgefahr und außerdem kann die Schneidvorrichtung
beschädigt werden.

To clear a media jam inside the cutter mechanism

1 Switch off the power to the printer.
2 Insert a 3 mm hexagon screwdriver in the hole on the side of the cutter
(A) and turn the cutter blade clockwise.

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).

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Power Supply
The power supply unit is primary-switched with a power correction factor
controller in order to comply with the CE regulations, which require a sine-
shaped load curve. It is designed for input voltages in the range of 110/240
VAC, 50 to 60 Hz directly from the socket. The power module converts the
current using switching technique and delivers +24 VDC (± 2%) to the
main board via a cable harness from CN1 on the power module to P60
(“POWER”) on the main board.
The power supply is equipped with over-temperature protection and high
voltage protection. If any of these are triggered, the module will shut down
immediately and you will have to turn the printer off and then back on
(once the cause of the error has been identified and eliminated).

Power Consumption
Stand-by: ~12W
Normal operation: ~80W
Peak: ~280W

The power supply unit contains wires and circuits with dangerous
voltages. For safety reasons, it is strictly forbidden to try to repair a
power supply unit or to replace a blown fuse. Whenever a fuse blows,
always replace the entire power supply unit.
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.

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 Chapter 3 — Replacing Parts

CN1
24VDC
to main
board

PD41/PD42 Power Supply Unit

To replace the power supply module

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Disconnect the cable harness which connects the power module to the
main board.
3 Remove the two screws that hold the power module to the bottom plate.
4 Remove the two screws that hold the power module to the back plate.
5 Lift out the entire unit.
6 Install the power module in reverse order.

Once the new power module is in place, make sure it makes proper
contact with the bottom plate as this is essential to provide adequate
cooling for the unit.
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.

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 Chapter 3 — Replacing Parts

Components

Components on PD41/PD42 Power Supply

Schematics

Schematic forPD41 only

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Main Board
The main board is a four-layer board with most of its circuits surface-
mounted. Inside the laminate is a combined VCC layer (5V/3.3V/2.5V)
and a GND layer. The front and back sides are signal routing layers. The
following list represents a selection of important components and functions
that are fitted on the main board:
• Processor core
• Thermal printhead driver
• Stepper motor control logic
• Sensor drivers
• Power connector and voltage converters
• Interfaces for external communication, including USB, serial, parallel,
and ethernet
• Interfaces for internal communication with stepper motor, accessories,
and sensors
• 4 MB (PD41) or 8 MB (PD42) flash memory for code storage, fonts,
forms and parameters
• 8 MB (PD41) or 16 MB (PD42) SDRAM for firmware execution and
temporary storage
• 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

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Timers, GPIO Stepper

driver

SPI
5V driver TPH
Timers, GPIO Str.+Latch
JTAG
Cutter
Latch
CPU
NetSilicon SDRAM LEDs
NS9360 Addr
USB D Crystals

RS232 Clock
RS232 Button(s)
driver Data
CPLD
MII Buffers/Transc
Ethernet
hdr
Option brd

1284 FLASH
IEEE1284 bus
Option brd hdr
B-Addr** CompactFlash

Sensors
B-Data
A/D
I2C
Dig. Pot.
24V 5V 3.3V
EEPROM
(Part No, Serial No,
etc) ** B-Addr is low order bits only

24-to-5V 5-to-3.3V
1.5V
5-to-1.5V

Main Board Block Diagram (PD41)

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 Chapter 3 — Replacing Parts

Replacing the Main Board

The electronic compartment contains wires and components with
dangerous voltage. Always switch off the power and unplug the power
cord before you remove the cover over the electronics compartment!
Im Elektronikfach gibt es Kabel und Komponenten, die hohe
Spannungen führen. Immer die Stromversorgung abschalten und das
Netzkabel abziehen, bevor die Abdeckung des Elektronikfachs
abgenommen wird!

Do not attempt to replace individual components on the main board.

Replace the entire board instead.
Nicht versuchen, einzelne Komponenten auf der Hauptplatine
auszutauschen. Es muss die gesamte Platine ausgetauscht werden.

Take standard precautions against ESD (Electrostatic Discharges)

before touching any electronics components.

To replace the main board

1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Disconnect all cables from the main board (it may be a good idea to
label them first).
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.

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Circuits Overview
Ext. 5V A/D Digital
RS232 CPU SDRAM EEPROM Reset Switch Converter Potentiometer
Driver

5V to 3.3V
Converter

5V to 1.5V
Converter

Printhead
voltage switch

Fuse

CPLD Flash Stepper motor 24V to 5V

converter

Main Board, Interfaces

Ethernet Real-time Ribbon LTS Headlift Blackmark
board clock sensor sensor sensor
Gap
sensor

USB
LCD (PD42 only)

Serial Console

IEEE1284
Printhead
board

CF

Power

Cutter Stepper
Motor

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 EasyCoder PD41/PD42 Printer Service Manual
FL12 FT1 P39 P38 P37 P36
P34

FT2
MH1 P48 MH4
R167

R48
JP2 R53

U37 C143
R339 R23 R75

R47
R21
2
D7 D6 C146

P45 C129
FL10

P61

C144
R115 C145 U61
P43 R338
R125
R116

R117

Q3
C
R86
R84

R192R211 R151 R88 R89 R146 B E

FL9
R92 P30
R121
R79
R80

R123
R119

K
R81

R83

R193 R98
R90
R87

R71
A A
R190 U27

R20
RD* R177 RD*
R70

K K
R72
A
R99
R122
R120
R118
R85
R82

C138 U64
R212
R124
R100

C127
R243
R242

C135
NC

U34 U44
Z1

Y1
K

P42 FL11 Q9
K

C68
A

D5
A

C69 R240
R330

R335 C130
E
K

U43
C

C175 R184 P46

C39

C38
R55

R27
C118

B
C35
C33

R173 C7 R2 C8
R332

K
R284
R148
R286
R288
FL8 A A R287

R323
U62
R333

R145
C34 D4 R60
C36

R296

1
R189 FL1 R295 C105

3
SW2

R337
R294 C106 R39

2
R334

FL2 FT4 R293 E B

R292 C107 C137 Q4 C
R271
P44 FL3 R291 U31

C140

C63
R52

C65
U40

R113 R290 C111

U66
R114 R16 R289 E B
FL6 C16 C108 Q5 C
R273
R64 C70 P92
R62 C170 R19 R54
R127 R312 U11
R183

R65 C171 C109 C112 C60 E B

R63 U10 Q6 C
Main Board, Components and Reference Points

R311 C141
U41

C30
C27
C29

C31
P40 C50 R279 C132

R22
R15
R18

R56
R69
R171

C173 R310

C67
R67
R321

C51 R281 R328 R309 R325

C174

C83 C58 FL5

C48 R278 R66 R181 R308 R58
C49 R280 R128 C110 R37
C172 C134 R195 R307 U32 R36

C113
FL7 C133 R234 C86 R73

FT5
R236R239 R232 R230R227R209R207 R180 R306
25 R202 R196 R305
1 R198 R172
R197 R210 U36
P41
2
R178
R226
R225
R224
R223
R222
R221
R179
R77

26 R208 U21 U20

R206

FL4

R103
R102
R104
R229 R213 R10
R231

C142
R235
R233

R238

R228
R153 R152R157

R101
C13 L1

C84

C44
R154

C12

C59
C85
U33
C17

R276
R26

P90

C45
R274
R275

R277
C46
JP1

C47
C115

C114
Y2

C15

R12
C122
U63
R158

C62
R51
MH3

R68
U26
C28

C61
R191 C121 R324

R322
R59 R168 L6
C32 C64 C169

R105
C125 U22

C41

R93
C126 R106

R91

R94

G
Q7
C14 C42

D
R272 U38 Q8

R265
R266
R267
R268
R269
R270
R247
R248
C
R162 C120

C23

C21

S
B E
C119

C116
P20 U25 C66
C22
C43

C40
C123
C124
R160
R161
R174 R25
P21
R163 C147 C57
R327 C149 F1

R107
R108
R109
R110
R111
R112
R155
R156

R326 R50 R24

C148 C150 L5
R164

U35
C26

C37
R49
U30

Downloaded from www.Manualslib.com manuals search engine

R205
R165

C25

C24
R46
R44

R42
P70 R40 D2

P60
L3
R159 C131 C128 R43 C55
Chapter 3 — Replacing Parts

R95 C56
R45 C52

C18
C19

C20
R34
R33

R35
R28
R29
R30
R38

U60
R32 R31 L2 R204

Q2
C160
R169 L4
C159C158

C54
C
C53

C117
R282
B E
FT3 P31
P47

R14

R97
FL13

R96
MH2 MH5

72
 Chapter 3 — Replacing Parts

Selected Test Points

All testpoints are marked with silkscreen on the bottom side of the main
board. Some of them can also be accessed from the top side, but are more
difficult to find since they are not marked out.
Test Points on Main Board
Signal Note
24VS +24V supply voltage (to stepper motor), max ±0.3V
5V Logic supply voltage, max ±0.2V
3.3V_x Logic supply voltage, max ±0.2V
1.5V Logic supply voltage, max ±0.1V
GND_x Logic ground
STRB Printhead strobe, toggles high when activated
24V_PH Printhead +24V supply, +24V when printing
STEP Stepper motor clock
RIB Ribbon sensor A/D, toggling when ribbon supply bobbin is
rotating
LTS Label taken sensor A/D, high level when label is sensed
HL Headlift sensor A/D, high level when printhead lifted
GAP Gap sensor A/D, high level in label gap
BM Blackmark sensor A/D, low level in blackmark
RESET_N System reset, high when printer is active
5VE +5V supplied to external ports, max ±0.25V
OC_N 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 73

Downloaded from www.Manualslib.com manuals search engine

 Chapter 3 — Replacing Parts

GND_5
3.3V_3
HL
GND_4

3.3V_2

CUTHOME

CUT2
CUT1

STEP
RESET_N

5VE

OC_N
LTS

GAP
BM

RIB

3.3V_1
GND_6

STRB

GND_3
1.5V

24VS
GND_2

5V

GND_1
24V_PH

Test points on Main Board

74 EasyCoder PD41/PD42 Printer Service Manual

Downloaded from www.Manualslib.com manuals search engine

 Y1 R148 OE_N
C7 C8 NOT POPULATED TO BUFFER (NEXT PAGE)
3.3V C11 R7 R41
CLKOUT1 SWE_N TO SDRAM
FL1 29.4912MHZ R149 WE_N
R2 TO BUFFER (NEXT PAGE)
C1 C4 R287 DQM0
R1 R285

TXEN
TXER
RAS_N
CAS_N
DQM1

TXD0
TXD1
TXD2
TXD3
FL2 R288 DQM2

R4
R5
R3

R283
R284
1.5V R286 DQM3
C2 C5

R6
R76
SDRAM

R201
R203
R11 CLKOUT3 SDATA(31..0)
TO CPLD
1.5V R241 R289

TXC
COL
CRS
MDC
ST_CS0_N 31 31

RXDV
RXER
RXD0
RXD1
RXD2
RXD3
MDIO
R242 64MBIT OR 128MBIT
FL3 ST_CS1_N

PLL_LPF
R290 SEE SEPARATE BOMS
3.3V 30 30
R243 3.3V 3.3V

X1_SYS
X2_SYS
ETHINT_N
ST_CS2_N
C3 C6

SYS_OSC_VDD
PRTR_RDY_N
U11

R329
R330
R244 R291

SYS_PLL_AVDD
SYS_PLL_DVDD
ST_CS3_N 29 29
1 86
0 2 VDD VSS 85 15
28 R292 28 3 DQ0 DQ15 84
1 4 VDDQ VSSQ 83 14
DQ1 DQ14

Processor and Memory

2 5 82 13
R293 DQ2 DQ13

L4
L3
L1
K1
K3
K4
K9
K10
K11
K12
L2
K2
H1
H2
H3
H4

W1
T4
V2
U3
V1
U2
T3
R4
U1
T2
R3
P4
T1
R2
P3
N4
P2
R1
P1
M4
N3
N2
N1
M3
M2
M1
J1
J2
J3
J4
F2
G3
F1
G2
G1
G4
F4
D1
E2
F3
E1
E4
B3
C1
D2
E3
D3
D4
C2
C3
B1
B2
27 27 6 81
3 7 VSSQ VDDQ 80 12
4 8 DQ3 DQ12 79 11
26
R294 26 9 DQ4 DQ11 78

MDC
OE_N
WE_N

VSS31
VSS37
VSS41

RAS_N
CAS_N
VDDQ VSSQ

CLK_IN

VDDC7

VSS32
VSS33
VSS34
VSS35
VSS36
VSS38
VSS39
VSS40
VSS42
VSS43
VSS44
VSS45
VSS46

GPIO51
GPIO57
GPIO61
5 10 77 10

VDDS11

VDDS9
VDDC6
VDDC8

TX_CLK
GPIO52
GPIO63
GPIO64
GPIO65
GPIO53
GPIO54
GPIO55
GPIO56
GPIO58
GPIO59
GPIO60
GPIO62
GPIO50
GPIO72

VDDS10
VDDS12

PLL_LPF
DQ5 DQ10

ST_CS_N0
ST_CS_N1
ST_CS_N2
ST_CS_N3
6 11 76 9

CLK_OUT3
R295

X1_SYS_OSC
X2_SYS_OSC
DQ6 DQ9

DATA_MASK0
DATA_MASK1
DATA_MASK2
DATA_MASK3
Y1 A1 25 25 12 75

SYS_PLL_AVSS
SYS_OSC_VDD

SYS_PLL_DVSS
VSS1 VSS47

SYS_PLL_AVDD
SYS_PLL_DVDD
W2 A2 7 13 VSSQ VDDQ 74 8
VSS2 VSS48 R337

BYTE_LANE_SEL_N0
BYTE_LANE_SEL_N1
BYTE_LANE_SEL_N2
BYTE_LANE_SEL_N3
V3 B4 DY_CS0_N 14 DQ7 DQ8 73
VSS3 DY_CS_N0
U4 A3 24 R296 24 15 NC NC 72
VSS4 DY_CS_N1
Y2 D5 DQM0 16 VDD VSS 71 DQM1
VSS5 DY_CS_N2
SCANEN_N Y3 C4 SWE_N 17 DQM0 DQM1 70
SCAN_EN_N DY_CS_N3
BISTEN_N V5 D6 23 R297 23 CAS_N 18 WE* NC 69
BIST_EN_N VDDS13
CPU_RTCK Y4 C5 31 RAS_N 19 CAS* NC 68 CLKOUT2
RTCK D31
RXC V4 A4 30 DY_CS0_N 20 RAS* CLK 67
RX_CLK D30 R298 CS* CKE

Downloaded from www.Manualslib.com manuals search engine

SRESET_N W3 SRESET_N D29
B5 29 22 22 11 21 66 9 R19
RESET_DONE W4 C6 28 A11 FOR 13 22 NC/A11 A9 65 8
RESET_DONE D28
RESET_N U5 D7 128MBIT 14 23 BA0 A8 64 7
RESET_N VDDS14 R16 R299
PLLTST_N U6 A7 CLKOUT2 21 21 ONLY 10 24 BA1 A7 63 6
PLL_TEST_N CLK_OUT2
SPIBTX R113 W5 A5 27 0 25 A10 A6 62 5
GPIO0 D27 TO SDRAM C16
SPIBRX V6 B6 26 1 26 A0 A5 61 4
GPIO1 D26 R300
STM_DIR Y5 C7 25 20 20 2 27 A1 A4 60 3
GPIO2 D25
U7 A6 24 DQM2 28 A2 A3 59 DQM3
NOT POPULATED

VDDS1 D24
1284ACK_N W6 D8 29 DQM2 DQM3 58
GPIO3 VSS49
R301 VDD VSS
1284BUSY
1284PERR
V7
Y6
GPIO4
GPIO5
PROCESSOR D23
D22
B7
C8
23
22
19 19
16
30
31 NC NC
57
56 31
SPIBCK R114 W7 B8 21 32 DQ16 DQ31 55
GPIO6 D21
U8 A8 20 18 R302 18 17 33 VSSQ VDDQ 54 30
VDDS2 D20
SPIBEN_N Y7 D9 18 34 DQ17 DQ30 53 29
GPIO7 VSS50
TXDA V8 C9 19 35 DQ18 DQ29 52
GPIO8 D19 R303
RXDA W8 B9 18 17 17 19 36 VDDQ VSSQ 51 28
GPIO9 D18
RTSA Y8 A9 17 20 37 DQ19 DQ28 50 27
GPIO10 D17
U9 B10 16 38 DQ20 DQ27 49
VSS6 D16 R304
CTSA V9 D10 16 16 21 39 VSSQ VDDQ 48 26
GPIO11 VDDC9
STM_STEP W9 C10 15 22 40 DQ21 DQ26 47 25

EasyCoder PD41/PD42 Printer Service Manual

GPIO12 D15
TPH_STRBL
CUTHOME
Y9
W10
GPIO13
GPIO14
NS9360 D14
D13
A10
A11
14
13 15 R305 15 23
41
42
DQ22
VDDQ
DQ23
DQ25
VSSQ
DQ24
46
45 24
U10 VDDC1 D12
C11 12 43 44
1.5V M9 J9 VDD VSS
VSS7 VSS51
M10
U10 J10 1.5V 14 R306 14
VSS8 VSS52 TSOP86
M11 VSS9 VSS53
J11
M12 VSS10 VSS54
J12
P24EN V10 B11 11 13 R307 13
GPIO15 D11
1284PFLT_N Y10 B12 10 SADDR(14..0)
GPIO16 D10
LCD_CLLP R13 TPH_LATCHL_N Y11 C12 9
GPIO17 D9 R308
LCD_CLPOWER V11 GPIO18 D8
A13 8 12 12
LCD_CLCP R176 U11 D11
VDDC2 VDDC10
W11 B13 7 14 R150 14
R17 GPIO19 D7 R309
LCD_CLFP Y12 GPIO20 D6
C13 6 11 11
W12 GPIO21 D5
A14 5
LCD_CLAC R199 V12 B14 4 13
R214 13
GPIO22 D4 R310
U12 VSS11 VSS55
D12 10 10
LTS_INST_N Y13 GPIO23 VSS56
D13
LCD_CLD0 R200 W13 A12 R331 CLKOUT1 11
R215 11
GPIO24 CLK_OUT1
V13 A15 3 9 R311 9
R74 GPIO25 D3
LCD_CLD1 Y14 C14 2 FOR FEEDBACK
GPIO26 D2 R216
U13 B15 1 LOOP ONLY 10 10
VDDS3 D1
LCD_CLD2 R210 W14 A16 0 8 R312 8
GPIO27 D0
TPH_ID0 Y15 GPIO28 VDDS15
D14
LCD_CLD3 R172 TPH_ID1 V14 D15 9 R217 9
GPIO29 VDDS16 R313
1284INST_N W15 GPIO30 CLK_OUT0
C15 7 7
U14 B16 R246 SDA
VDDS4 GPIO71
CF_CD1_N Y16 A17 8 R218 8
GPIO31 GPIO70 R245 R314
1284D0 V15 GPIO32 USB_DM
B17 SCL 6 6
1284D1 W16 GPIO33 USB_DP
A18
1284D2 Y17 D16 7
R219 7
GPIO34 VSS57 R315
1284D3 U15 GPIO35 VSS58
C16 USBCPU_D- 5 5
1284D4 V16 GPIO36 VSS59
D17 USBCPU_D+ TERMINATION ONLY ON SIGNALS
1284D5 W17 C17 6
R220 6
GPIO37 VSS60
R316 WITH LONG PCB TRACES FROM
1284D6 Y18 GPIO38 VSS61
C18 4 4 TRANSMITTING PINS
1284D7 U16 GPIO39 VSS62
B18
TXDC V17 B19 5 R221 5
GPIO40 VSS63
RXDC W18 A19 3 R317 3
GPIO41 VSS64
Y19 VSS12 VSS65
A20
4 R222 4
2
R318 2

R223

VSS13
VSS14
VSS15
VSS16
VSS17
VSS18
GPIO42
GPIO43
GPIO44
GPIO45
VSS19
GPIO46
GPIO47
GPIO48
GPIO49
NC
A0
A1
A2
A3
VDDS5
VDDS6
A4
A5
A6
A7
VSS20
VSS21
A8
A9
A10
A11
VSS22
VSS23
VSS24
VSS25
VDDC3
A12
A13
A14
A15
VDDC4
A16
A17
A18
A19
VDDC5
A20
A21
GPIO66
VSS26
TDO
TCK
TRST_N
TMS
USB_OSC_VDD
X2_USB_OSC
X1_USB_OSC
VDDS7
TDI_IN
GPIO67
GPIO68
GPIO69
VSS27
VSS28
VSS29
VSS30
VDDS8

3 3
1
R319 1

2
R224 2

L9
0 R320 0

L19
L18
L10
L11
L12
L17
L20
K20
K18
K19
K17
H20
H18
H19
H17

Y20
W19
V18
U17
W20
V19
U18
V20
U19
U20
T17
T19
R18
T20
R19
T18
P18
R20
P19
P20
R17
P17
N18
N19
N20
M18
N17
M17
M19
M20
J20
J19
J18
J17
G20
G19
G18
F20
F19
E19
E20
F18
G17
D20
E18
D19
C20
E17
D18
C19
B20
F17

DATA(31..0)
1
R225 1

1.5V
0 R226 0
IRQ_N

1
7
10
11
12
13
14
15
16
17
18
19

0
2
4
5
6
8
9
20
21
ADDR(21..0)

ISIP_GPIO1

1284SEL
1284AUTOFD_N
1284INIT_N
1284SELIN_N

USB_VP
USB_VM
GPIO45
STM_CURR
GPIO66
CPU_TDO
TCK
TRST_N
TMS
X2_USB
X1_USB
TDI

ISIP_GPIO0
ADDR22
3.3V USB_OSC_VDD
FL4 R9 L1
R8
R10 C15 R12
C9 C10

Y2

C12 C13
48MHZ

75
Chapter 3 — Replacing Parts
 76
BUS TRANSCEIVERS
AND BUFFERS
BDATA(15..0)

BSADDR(5..0)

SDATA(31..0)

Flash and CPLD

BSDATA(15..0)

ADDR(21..0)

0
R249 0

FLASH COMPACT-
1
R250 1
FLASH
2
R251 2

U20 16
BUFEN_N 19 3 R252 3
G3
Chapter 3 — Replacing Parts

3EN1[BA]
OE_N 1 32MBIT OR 64MBIT
3.3V 3.3V
3EN2[AB]
4 R253 4
AHC245
SEE SEPARATE BOMS
1
0 9 11 0 3.3V
2 R254 3.3V

Downloaded from www.Manualslib.com manuals search engine

1 8 12 1 5 5 P21
2 7 13 2 COMPACTFLASH
3 6 14 3 U25 1 26 CF_CD1_N
GND1 CD1*
4 5 15 4 6
R255 6 15 1 48 3 2 27 11
A15 A16 D3 D11
5 4 16 5 14 2 A14 BYTE_N
47 4 3 D4 D12 28 12
6 3 17 6 13 3 A13 VSS2
46 5 4 D5 D13 29 13
7 2 18 7 7
R256 7 12 4 45 15 6 5 30 14
A12 DQ15/A-1 D6 D14
11 5 A11 DQ7
44 7 7 6 D7 D15 31 15
VCC=3.3V;GND=GND1
10 6 A10 DQ14
43 14 CF_CS0_N 7 CS0* CS1* 32 CF_CS1_N
8 R257 8 9 7 42 6 8 33 VS1_N
U21 A9 DQ6 A10 VS1*
19 G3
8 8 A8 DQ13
41 13 9 ATASEL* IORD* 34 CF_RD_N
3EN1[BA]
19 9 A19 DQ5
40 5 10 A9 IOWR* 35 CF_WR_N
1 9 R258 9 20 10 39 12 11 36
3EN2[AB] A20 DQ12 A8 WE*
BWE_N 11 WE_N DQ4
38 4 12 A7 INTRQ 37 CF_INTRQ
AHC245
1
RESET_N 12 RESET_N VCC
37 13 VCC1 VCC2 38
8 9 11 8 10
R259 10 21 13 36 11 14 39
2 NC/A21 DQ11 A6 CSEL*
9 8 12 9 14 WP_N DQ3
35 3 15 A5 VS2* 40 VS2_N
10 7 13 10 15 RY/BY_N DQ10
34 10 16 A4 RESET* 41 RESET_N
11 6 14 11 11
R260 11 18 16 33 2 17 42
A18 DQ2 A3 IORDY NC
12 5 15 12 17 17 A17 DQ9
32 9 CF_ADDR2 18 A2 RFU1 43 NC
13 4 16 13 7 18 A7 DQ1
31 1 CF_ADDR1 19 A1 RFU2 44
14 3 17 14 12
R261 12 6 19 30 8 CF_ADDR0 20 45 DASP_N
A6 DQ8 A0 DASP*
15 2 18 15 5 20 A5 DQ0
29 0 0 21 D0 PDIAG* 46 PDIAG_N
R25 4 21 A4 OE_N
28 BOE_N 1 22 D1 D8 47 8
VCC=3.3V;GND=GND1 13 R262 13 3 22 27 2 23 48 9
A3 VSS1 D2 D9
2 23 A2 CE_N
26 ST_CS1_N IOCS16_N 24 IOCS16* D10 49 10
1 24 A1 A0
25 0 CF_CD2_N 25 CD2* GND2 50
14 R263 14
MTG1
MTG2

S29GL0XXM

15
R264 15

0 R265 0

1 R266 1

3.3V
2
R267 2
U27
CLK
IRQ_N
BWE_N
PB1_N

ST_CS0_N 2 R322 R268

AD_MUX2
AD_MUX1
AD_MUX0

ST_CS1_N 1 & 3 3 3
U27
HEADLIFT

LVC08
VCC=3.3V;GND=GND1
OVERCURR_N

10 CLKOUT3
R115 R269 3.3V
FBPRESSED_N

9 & 8 4 4
U27 LVC08
CPLD
VCC=3.3V;GND=GND1
U22 R26
ST_CS2_N 5 19 G3
ST_CS3_N 4 6 5 R270 5
& 3EN1[BA]
39
38
37
36
35
34

44
43
42
41
40

LVC08 1 3EN2[AB]
VCC=3.3V;GND=GND1 C17
BADDR(5..0) CPLD JTAG
AHC245
1 PROGRAMMING
0 9 11 0 PORT
IO28
IO27
IO26
IO25
IO24
IO23

2
1 8 12 1
IO_GCK2
IO_GCK1
IO_GTS1
IO_GTS2
VCCINT2

2 7 13 2
NOT POPULATED

BOE_N 3.3V
3 6 14 3 CF_ADDR0 1 IO_G C K3 IO_G S R 33 RESET_N
4 5 15 4 BOE_N 2 IO1 IO22 32 CF_ADDR1
5 4 16 5 ST_CS0_N 3 IO2 XC9536XL IO21 31 CF_ADDR2
OE_N 3 17 R247 BOE_N 4 30 CF_WR_N
GND1 IO20
WE_N 2 18 ST_CS2_N 5 IO3 IO19 29 CF_RD_N
R248 BWE_N 4 6 U26 28 CF_CS1_N P20
IO4 IO18
VCC=3.3V;GND=GND1 3 7 27 CF_CS0_N
IO5 IO17 1
2 8 IO6 VCCIO 26 2
CPLD_TDI 9 TDI GND3 25 CPLD_TCK 3
CPLD_TMS 10 TMS TDO 24 CPLD_TDO 4
BWE_N CPLD_TCK 11 TCK IO16 23 CPLD_TDI 5
CPLD_TMS 6
SIL6
3.3V NOT POPULATED
IO7
IO8
IO9
IO10
IO11
IO12
IO13
IO14
IO15

VCCINT1
GND2

12
13
14
15
16
17
18
19
20
21
22

1
0
3

7
1

6
5
4
2
0

BSDATA(15..0)

EasyCoder PD41/PD42 Printer Service Manual

 STEPPER
3.3V
3.3V 24VS

C22 C23

TPH and Sensors

C21
3.3V 3.3V

32
37
38
36

16
43
25
U35 U35
STEP
HOME_N AHC123 AHC123
PRINTHEAD

VDD
CP1
CP2
VCP
VBB
VBB
P31

VREG
14 6
C26 CEXT C37 CEXT
RESET_N 27 RESET_N OUT1A 6 OUT1A 1
42 OUT1B R49 15 R24 7
SLEEP_N 2
41 OUT2A REXT/CEXT REXT/CEXT
ENABLE_N 3
3.3V OUT1B 40 OUT2B 4 1 13 9 5
STM_HOME_N 4 HOME_N A Q A Q
20 MS1
2.5MM_XH TPH_STRBL 2 10
19 MS2 B B
R29 A3977 OUT2A 18 4 12
Q Q
STM_STEP 31 STEP RESET_N 3 11
STM_DIR 5 CLR CLR 24V_PH
DIR U30
OUT2B 28 R326 R327
R34 26 SR_N VCC=3.3V;GND=GND1 VCC=3.3V;GND=GND1 5V
14 REF
SENSE1 3 NOT POPULATED
9 PFD C25

R50

Downloaded from www.Manualslib.com manuals search engine

10 21 P90

R42
R44
R46
RC1 SENSE2

R205
15

R28
R30
C18 RC2 1
FL5 2

C
3

PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
C19 C20
R14 4
STM_CURR B Q2 5
C24

1
2
R58 6

33
34
35

11
12
13
22
23
24
44
LATCH_N TPHCLK

R33
R35
R38
R40
R43
R45
7

R204

E
8
9
3.3V TO 5V CONVERSION TPH_ID0 10
RES1206 R277 TPH_LATCH_N 11
U36 12
5V 19 13
G3
DRIVE CURRENT 2.0A <=> MAX VREF 3V R325 3EN1[BA]
R276 STRB 14
1 3EN2[AB]
TPH_CLK 15
HOLDING CURRENT 0A <=> VREF=0V AHCT245
16
1
R274 17

EasyCoder PD41/PD42 Printer Service Manual

9 2
11 TPH_STRB TPH_ID1 18
SPIBTX 8 12 R27 19
SPIBCK 7 13 TPH_TEMP 20
TPH_LATCHL_N 6 14 21
C38
5 15 22
4 16 TPHDATA 23
3 17 24
2 18 25
A/D CONVERSION VCC=5V;GND=GND1 R275 26
U34 TPH_DATA
DIL26V
ST_CS3_N 12
1
BOE_N 13 11 5V TO 3.3V CONVERSION C45 C44 C46 C47
U34 AHC32 3.3V
VCC=3.3V;GND=GND1

BWE_N 4 U33
1
SO20 19
BSADDR(5) 5 6 U32 3.3V G3

AHC32 R324 3EN1[BA] R60

VCC=3.3V;GND=GND1 1 3EN2[AB]
NOT POPULATED CONSOLE
AHC245 R59
1
SO16 R36 13 CS* D0 2 9 11 0 PB1_N 5V
2
U31 3 8 12 1 EXT CTRL REG
8 D1 C32
RD* 4 7 13 2
5V D2 RESET_N
5V HCT4051 6 WR*/RDY D3 5 6 14 3
D4 14 5 15 4
GAP 13 Y0 R37 D5 15 4 16 5 U34 P92
7 MODE U38
BLACK_MARK 14 Y1 D6 16 3 17 6 1
R338 RIBBON 15 17 2 18 7 ST_CS3_N 1 1
Y2 D7 1 RESET 2
C

LABEL_TAKEN 12 Y3 Z 3 1 AIN BWE_N 2 3 11 3

VCC=3.3V;GND=GND1 CLK
TPH_TEMP 1 Y4 OFLW* 18 AHC32 4
VCC=3.3V;GND=GND1 AHC273 R39
P30 FBUTTON 5 Y5 5V 5V 0 3 2 LED_RED B Q4 5
20 VCC D
C

AD6 2 Y6 INT* 9 1 4 5 LED_GREEN 6

1 4 Y7 2 7 6 LED_BLUE
12 REF+ R52 Q5
E

2 VCC 16 3 8 9 CUT2 B
AD7
C

6 E* 11 REF- 4 13 12 CUT1
5 14 15 BM_G_LED_EN
SIL2_UM GND 8 R54 Q6
E

AD_MUX0 11 S0 10 GND NC 19 6 17 16 LCD_BL_EN B

BDATA(15..0)
AD_MUX1 10 S1 7 18 19 1284MUX_N
NOT POPULATED AD_MUX2 9 7
S2 VEE
E

BDATA(15..0) VCC=3.3V;GND=GND1
VCC=5V;GND=GND1
R323

3.3V
DIGITAL POT SENSORS
P* BM HL R53
5V P36
1 P34
GAP R15 2 HEADLIFT R51 5V
3 GAP SENSOR 1
R18 C28 2
HEAD LIFT
BLACK_MARK 2MM_PH
C27 C29
2MM_PH R23 2MM_PH
LTS
P38
5V 1 LABEL
5V 2 TAKEN
U37 5V LABEL_TAKEN R22
R47 3
5 VDD W1
10 2.5MM_EH LTS_INST_N 4
2 1 P37 RIB R339 5V
A0 B1 C30
8 3 R48
A1 W2 1 P39
SDA 7 SDA B2
9 2 BM/GAP LED
SCL 6 4 R21
SCL GND 3 R56 1
4 BLACK MARK SENSOR RIBBON 2 RIBBON

C
AD5248 3
C31
R20 2.5MM_SPOX NC 4
BM_G_LED_EN B Q3

E
I2C ADDRESS 0X2C (7-BIT)

77
Chapter 3 — Replacing Parts
 5VE

78
3.3V
RS232
FL7

16
U40 P40
C33 VCC C35 PARTS POPULATED
1 C1+ V+
2 1 PRTR_RDY_N DEPENDING ON ASSY
3 C1- 2 SEE SEPARATE BOMS
4 6 3 3.3V
C2+ V-
C34 5 C2- C36 4 U43
R278 5
TXDA 11 T1IN T1OUT
14 6 R333 LP2980
RTSA 10 T2IN T2OUT
7 7 R332
RXDA 12 13 R280 1 5
R1OUT R1IN 8 VIN VOUT
CTSA 9 R2OUT R2IN
8 9
R279 C118
GND MTG1

C
EN
GND
NC1
R281 MTG2
USB PHY
PARTS POPULATED

3
2
4
DEPENDING ON ASSY B R334

15
FL6 9PIN DSUB SEE SEPARATE BOMS Q9
3.3V

C49
C51
E
C172
USB DEVICE

C48
C50
C
R66

Communication Interfaces
3.3V FL11 C135
VBUS
VPU
U42
1 VIF VTRM
12 R335
Chapter 3 — Replacing Parts

C175
IEEE1284 6 NC/CON VBUS
14 Z1
USB_OE_N 9 13 3.3V
OE_N NC/VPU
USB_RCV 3 RCV
USB_VP 4 11 R57
3.3V VP D+ R70
USB_VM 5 10 P42

Downloaded from www.Manualslib.com manuals search engine

VM D-
2 SPD USB
8 7 R61 D4
SUS GND
R67 1
CONFIG LOCKED FOR USBD_D- 2
C173 C174
P41 FULL SPEED DEVICE USBD_D+ 3
OPERATION 4
1 NOT POP
2 R62 MTG1
1284D0 3 D5 MTG2
1284D1 4
1284D2 R63 NOT POP
5
1284D3 6
FL8

1284D4 TYPEB
7
1284D5 8
1284D6 9
1284D7 10
11 C
1284ACK_N 12
1284BUSY 13 R64
USBCPU_D+ USBH_O_D+
1284PERR 14
1284SEL 15
1284PFLT_N 16 R65
USBCPU_D- USBH_O_D-
1284STRB_N 17
1284AUTOFD_N 18
1284INIT_N 19 C170 C171
1284SELIN_N 1206 RESISTORS
20
1284DIR 21
NC 22
1284INST_N 23
24
5V 25 NOT POPULATED R321 PARTS POPULATED
5VE 26 DEPENDING ON ASSY
SEE SEPARATE BOMS
DIL26

U41
1284MUX_N 1 A*/B

R328 15 OE*

MUX
AHC158
1284STRB_N 2 A1
Y1* 4 GPIO45
ETHERNET USB_RCV 3 B1

3.3V 5 A2
Y2* 7 USB_OE_N
1284SEL 6 B2
P45
MDIO 1 11 A3
2 Y3* 9
MDC 3 10 B3
RXD3 4 R321 OR U41+R328 POPULATED
5 14 A4 DEPENDING ON ASSY
6 Y4* 12 SEE SEPARATE BOMS
RXD2 7 13 B4
RXD1 8
RXD0 VCC=3.3V;GND=GND1
9
RXDV 10
11
12
RXC 13
14
15
16
RXER 17
TXER 18
19
20
TXC 21
22 CUT1
CUTTER 24VC
23 CUT2
24 2MM_PH
TXEN 25
TXD0 26 P47
TXD1 27
TXD2 28 R31
CUT1
29 1
30 2
TXD3 31 R32
CUT2 3
COL 32
CRS 33 4
34 5
CUTHOME
ETHINT_N 35
RESET_N 36 C158 C159 C160
SDA 37
38
SCL 39
NC 40 CUTHOME

DIL40_2.0MM
‘

EasyCoder PD41/PD42 Printer Service Manual

 TPH VOLTAGE SWITCH
24V_PH
Q8 5V TO 1.5V

Power
S D
24V_PH
R94 5V
C169

G
NOT POPULATED
L6
R93
P24EN C61 + C62
R102 R103 R104

C
R68

P24EN R91 B
Q7

C41

E
U63
R101 1 PVIN LX
10
2 9 1.5V
VIN PGND
3 BLON GND
8
4 ILIM VOUT
7
5 SHDN FB
6
24 TO 5V
C59 R105
P60 5V C64

1 L4 L5 C42 + C66
2 U60
3 F1
4 24V_PSU 24V 24V_SWITCH 8 VCC OUT
1
5 7 GND SYNC
2 R106
6 6 VREF INH
3
5 FB COMP
4 R96
6X3,96 PAD
C56
C52 + C53 + C54

2
C55

PAD
C57 + C40

Downloaded from www.Manualslib.com manuals search engine

D2
R95
R97

1
RESET
3.3V
RESET_N
STEPPER,
U62
2

EasyCoder PD41/PD42 Printer Service Manual

LCD & ISIP SUPPLY CUTTER SUPPLY
VCC
24V S 24V C 1 RESET_N
RST*
L3 L2 GND
1

3
2

SW2

NOT POPULATED
3
4

EXT 5V SWITCH I2C EEPROM 5V TO 3.3V

3.3V 3.3V 5V 3.3V
5V 5VE 24C02
U66
U61 U64 LD1117
5VE R98 R99 3 2
POWER_SWITCH VIN VOUT
1 GND OUT 8
2 IN OUT 7 1 A0 VCC 8 C58 GND C65
+ C60 C63 +
3 IN OUT 6 2 A1 WP 7
PRTR_RDY_N 4 5 OVERCURR_N 3 A2 SCL 6 SCL
1

EN_N OC_N
4 GND SDA 5 SDA

OC_N

I2C ADDRESS 0X52 (7-BIT) SCL

SDA

79
Chapter 3 — Replacing Parts
 80
PULL-UPS AND PULL-DOWNS
ETHERNET
3.3V 3.3V
IEEE1284 3.3V NS9360 CONFIGURATIONS
(SEE ALSO JP2)
BSADDR(5..0) 3.3V RESET_N R145 MDIO R79 1284D0 R202

0
R107 SRESET_N R146 MDC R80 1284D1 R206 RTCK R177
NOT POPULATED

1 R108 SRST_N R190 RXC R81 1284D2 R207

GPIO49 STM_CURR R178
NOT POPULATED
JUMPERS

Pull-ups and Debug

2 R109 PLLTST_N R147 TXER R82 1284D3 R208 1284SEL R179
GPIO44

3 R110 TCK R151 TXC R83 1284D4 R209 LCD_CLD0 R180

GPIO24
JP1
4
R111 CPLD_TDI R152 TXEN R84 1284D5 R213 LCD_CLCP R181 LCD_CLD3
GPIO20
1 DEBUG
R191 2
5
R112 CPLD_TMS R153 TXD0 R85 1284D6 R227 LCD_CLLP R182
GPIO19 NOT POPULATED SIL2

CPLD_TCK R154 TXD1 R86 1284D7 R228 TPH_LATCHL_N R183

GPIO17
Chapter 3 — Replacing Parts

BOE_N R155 TXD2 R100 1284ACK_N R229 STM_STEP R184

GPIO12 NOT POPULATED
BSDATA(15..0) 3.3V JP2
RESET_DONE
R156 R116 R230 R185

Downloaded from www.Manualslib.com manuals search engine

BWE_N TXD3 1284BUSY NOT POPULATED GPIO10 RTSA 1 SPI BOOT
0
R129 R193 2
R157 R117 R231 R186 SIL2_UM
IOCS16_N ETHINT_N 1284PFLT_N GPIO8 TXDA
1 R130
NOT POPULATED

CF_CD1_N R158 1284STRB_N R232 1284BUSY R187

R131 R118 GPIO4
2 RXD3

CF_CD2_N R159 1284AUTOFD_N R233 STM_DIR R188

R132 R119 GPIO2 NOT POPULATED
3 RXD2

CF_CS0_N R160 1284INIT_N R234 SPIBTX R189

R133 R120 GPIO0 NOT POPULATED
4 RXD1

CF_CS1_N R161 1284SELIN_N R235

5
R134 RXD0 R121

VS1_N R162 1284INST_N R236

6 R135 RXDV R122

VS2_N R163
7 R136 RXER R123

DASP_N R164 BISTEN_N R237

R137 R124 NOT POPULATED
8 COL

PDIAG_N R165 1284PERR R238

9
R138 CRS R125 JTAG
OVERCURR_N R167 1284DIR R239
10
R139 3.3V
NOT POPULATED

CUTHOME R169 TRST_N R192

11 R140 P61
R69 R173 1
TPH_ID0 SCANEN_N 2
12 R141 3.3V R211 TRST_N
USB 3
R73 R174 4
TPH_ID1 CF_INTRQ 5 TDI
13 R142 PRTR_RDY_N R126
6
7 TMS
LTS_INST_N R75 P24EN R240
R143 R127 8
14 USB_OE_N 9 TCK
R77 10 R88
STM_CURR 11 RTCK CPU_RTCK
15
R144 USB_RCV R128
12 R89
13 TDO CPU_TDO
BISTEN_N R78 U27
14
15 SRST_N 13
16 12 & 11 SRESET_N
17 LVC08
3.3V VCC=3.3V;GND=GND1
LCD 18
19 R92
20
LCD_CLPOWER R166
R87 R90 NOT
DIL20_UM POPULATED
RESET_N
LCD_BL_EN R168

R170 NOT R212

LCD_CLLP POPULATED

LCD_CLCP R171 TRST_N

NOT POPULATED

LCD_CLFP R175

R194
MISC TESTPOINTS
LCD_CLAC
3.3V
24VS 5V 1.5V
LCD_CLD0 R195 IRQ_N
NOT POPULATED
IRQ_N
ST_CS0_N
R196 ST_CS0_N
LCD_CLD1 ST_CS1_N
ST_CS1_N
ST_CS2_N
R197 ST_CS2_N 24VS 5V 3.3V_1 3.3V_2 3.3V_3 1.5V
LCD_CLD2 ST_CS3_N
ST_CS3_N
R198 GND_1 GND_2 GND_3 GND_4 GND_5 GND_6
LCD_CLD3

EasyCoder PD41/PD42 Printer Service Manual

 BYPASS/DECOUPLING CAPACITORS
PROCESSOR 1.5V PROCESSOR 3.3V

1.5V 3.3V 3. 3V 3. 3V SPARE PARTS

5V 24VS
C67 C83
C105 C132 C147
+ + U40 C140
U31 + U34

C133 9
1
C68 C84 C106 U41 C141 10 8
U32 C148 AHC32
VCC=3.3V;GND=GND1

Bypass/Decoupling
C107 C134
U42 C142 U30
C69 C85
U36
+ + C149
C108
+
C136
U44 C143
U11 C109 U37
C70 C86 (SDRAM)
C137 C150
C110 U62
C144
U61
C71 C87 C111 C138
U64

C72 C88 C112

Downloaded from www.Manualslib.com manuals search engine

C73 C89 C113

5VE
C74 C90
FIDUCIAL MARKERS
C114
C75 C91 U20 C145 GROUNDS SEPARATION
U61 TOP
C76 C92 C115 FL12
U21 NOT POPULATED
C146

P43 + CPU
C77 C93
C116 FL13
U22 NOT POPULATED
C78 C94

C119 BOTTOM

EasyCoder PD41/PD42 Printer Service Manual

C79 C95 C
U25 C120
C80 C96 (FLASH)

C81 C97 C121

C82 C98 C122

C99 C123

U26
C100 (CPLD) C124 MOUNTING HOLES
C101 C125
MH1 MH4

C102 C126

C103
C127 C MH3
U27
C104

C128 MH2 MH5

U30

C129
U33
C
C117

R282

C130 NOT POPULATED

U34

C131
U35

C43
U38

81
Chapter 3 — Replacing Parts
 Chapter 3 — Replacing Parts

Upgrading Firmware
The Intermec website at www.intermec.com contains the latest firmware
versions that you can download for free.
To download firmware updates
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.
5 Extract the zip file to a folder on your computer. Normally, three
versions of the firmware are included with the following differences and
naming convention:
• No suffix: Normal firmware upgrade.
• FD suffix: Firmware upgrade resetting Factory Default. Only
applicable when upgrading through a Compact Flash card.
• NU suffix: Boots with new firmware, yet printer returns to previous
firmware version on reboot (No Upgrade). Only applicable when
upgrading through a Compact Flash card.
To install the downloaded firmware on your printer, use any one of the
following methods:
• Use PrintSet 4 and follow the firmware upgrade procedure.
• If you have a network connection, browse to the printer’s home page
and select Maintenance. Upload the firmware file.
• Copy the firmware binary file to a CompactFlash card. Turn the printer
off, insert the card into the printer’s CompactFlash socket and switch on
the printer. The printer will be upgraded automatically.

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 4 Interfaces

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 83

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 Chapter 4 — Interfaces

Communication Interfaces
The image below shows the location of the interface connectors on the rear
plate of the printer.

USB host port (PD42 only)

Ethernet RJ-45 port

USB port

RS-232 serial port

IEEE 1284 parallel port

I
O

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.

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 Chapter 4 — Interfaces

Default Setup for Serial Communication

Baud rate 9600
Character Length 8 bits
Parity None
Stop bits 1
Handshaking XON/XOFF and RTS/CTS

MTG

9
5 GND
4 DSR in
RTS out 8
3 RXD in
CTS in 7
2 TXD out
DTR out 6
1 +5V DC

MTG

RS-232 Pinout

Signals
Pin Signal Description Comment
1 EXT5V External +5 VDC Max. 500mA, permanently
enabled
2 TxD Transmit data
3 RxD Receive data
4 Not used
5 GND Ground
6 DTR Transmit data Connected to RTS
7 CTS Clear to send
8 RTS Request to send
9 NC

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 printer is a so called “self-powered device.” You can connect the printer
to a USB port on the host, either directly or via a hub. Keyboards, mouses,
or more printers can also be connected to the same hub.

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 Chapter 4 — Interfaces

Using a USB Type A/B cable, connect the Type A plug to your PC or hub
and the Type B plug to your printer.
There is no communication setup for the USB port.

USB Type A connector. Connect to PC or Hub.

USB Type B connector. Connect to USB receptacle on the printer’s rear plate.

USB Host Interface (PD42 only)

The PD42 printer is equipped with a USB host interface, which means you
can connect various USB devices (bar code scanners and keyboards of HID
type, memory sticks, and USB hubs) for use with the printer.

USB Host port with pins 1-4

USB Host Pinout

Pin Function
1 VBUS
2 D-
3 D+
4 Gnd

Parallel IEEE1284 Interface (Option)

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

86 EasyCoder PD41/PD42 Printer Service Manual

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 Chapter 4 — Interfaces

One line contains +5 VDC, max 500 mA, permanently enabled.

Signals
Pin Function Transmitter Comment
1 /Strobe host
2-9 Data 0-7 host
10 /Acknowledge printer
11 Busy printer
12 /Paper empty printer
13 /Select printer
14-15 Not connected
16 Logic ground
17 Chassis ground
18 External +5 VDC Max 0.5A, permanently enabled.
19-30 Signal ground
31 Not connected
32 /ERROR printer
33 Signal ground
34-36 Not connected

Installing the Parallel IEEE1284 Interface

The installation kit contains:
• Parallel IEEE1284 interface board with I/O bus cable.
To install the Parallel IEEE1284 option
1 Disconnect the power cord and remove the left-hand panel (For help,
see “To remove the left-hand panel” on page 27).
2 Put the printer back in upright position.
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

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 Chapter 4 — Interfaces

5 Connect the I/O bus cable to the printer main board.

88 EasyCoder PD41/PD42 Printer Service Manual

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 Chapter 4 — Interfaces

Components

P1C

P1B

P1A

EasyCoder PD41/PD42 Printer Service Manual 89

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 EasyCoder PD41/PD42 Printer Service Manual
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 C1 C2 C3 C4 C5 C6 C7 C8
5V
FL1
3.3V 3.3V 1284B -R E C
C 22
P2
C 20 C 21 + R1 R 21 S T R OB E _N 1
DIL26R C 18 C 19 R2 R 22 19
DAT A0 2
26-P IN 20
U1 R3 R 23 DAT A1 3
P1 7 31 21
VCC1 VC C _C 1 R4 R 24
1 18 VC C 2 VC C _C 2
42 DAT A2 4
2 R5 R 25 22
3 1284D0 8 A1 B1 41 B _DAT A0 DAT A3 5
4 1284D1 9 A2 B2
40 B _DAT A1 23
1284D2 11 38 B _DAT A2 R6 R 26 DAT A4
5 A3 B3 6
6 1284D3 12 A4 B4
37 B _DAT A3 24
1284D4 13 36 B _DAT A4 R7 R 27 DAT A5
7 A5 B5 7
8 1284D5 14 A6 B6 35 B _DAT A5 25
1284D6 16 33 B _DAT A6 R8 R 28 DAT A6
9 A7 B7 8
10 1284D7 17 A8 B8 32 B _DAT A7 26
2 47 B _AC K _N R9 R 29 DAT A7
11 A9 Y9 9
12 1284AC K _N 3 A10 Y10
46 B _B US Y 27
1284B US Y 4 45 B _P E R R OR R 10 R 30 AC K _N
13 A11 Y11 10
14 1284P E R R 5 A12 Y12
44 B _S E LE C T 28
1284S E L 6 43 B _F AULT _N R 11 R 31 B US Y
15 A13 Y13 11
16 1284P F LT _N 20 A14 C14
29 B _S T R OB E _N 29
1284S T R B _N 21 28 B _AUT OF D_N R 12 R 32 P E R R OR
17 A15 C15 12
18 1284AUT OF D_N 22 A16 C16 27 B _INIT _N 30
1284INIT _N 23 26 B _S E LE C T IN_N R 13 R 33 S E LE C T
19 A17 C17 13
20 1284S E LIN_N IN IT _ N 31
1284DIR 48 R 14 R 34
21 DIR 14
22 NC 1 HD 32
R 15 R 35 AUT OF D_N
23 NC 15
24 5V 19 30 NC NC 33
P LH_IN P LH_OUT R 16 R 36
25 25 HLH_IN HLH_OUT 24 NC F AULT _N S G ND 16
26 5V E NC 34
R 19 R 38 10 GND1 G ND3
39 NC 17
2K7 2K7 15 G ND2 G ND4 34 NC 35
P LH 18
R 17 R 37 S E LE C T IN_N
74LV C 161284 36
NC MT G 1
NC MT G 2
5V E
Z9 Z10 Z 11 Z12 Z13 Z14 Z15 Z16 Z 17 C9 C 10 C 11 C 12 C 13 C 14 C 15 C 16 C 17
3.3V FL2 FL3
R 18 R 20
NOT POPULATE D
HIGH DR IVE C ONFIG

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F IDUC IAL MAR K E R S
F T1 F T2 F T3
Chapter 4 — Interfaces

Schematics

90
 Chapter 4 — Interfaces

EasyLAN Ethernet Interface

The EasyLAN interface board provides the printer with a 10/100 Mbit
Ethernet connection. The port is equipped with two LED indicators that
inform the user of the state of the connection:

EasyLAN LED Indicators

LED Indicator On Off Flashing
Green Link No Link Data Activity
Yellow 100Mbit/s 10Mbit/s N/A

This chapter only describes the physical installation of the EasyLAN

interface board; for detailed configuration and setup instructions, please
refer to the EasyLAN Software for PD41/PD42 Instructions (P/N 943-130-
xxx) and the EasyLAN User's Guide (P/N 1-960590-03).
Yellow LED
Green LED

MAC Address Label

I
O

Installing the EasyLAN Ethernet Interface

The installation kit contains:
• EasyLAN Ethernet interface board
• MAC address label
To install the EasyLan Ethernet Interface
1 Disconnect the power cord and remove the left-hand panel (For help,
see “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.

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 Chapter 4 — Interfaces

4 Connect the EasyLAN board to the connector marked “Ethernet

Option” on the main board.

5 Reattach the screw.

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
C10

C2
C8
R12
R13
R20
C5

P2
R16
R17

R11
C9 C6
C15

Y1 R15
R10
R14 U1
FL2

FL1

R9
C7 R8
R7 C3
R6
R3
C12
C11

BR1 C13
C4
C16

C1 C14 U2
R4
R1
R5
R2

A
C17 D1 K C18 R18 R19
NC

P1

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Chapter 4 — Interfaces

93
Y1
C1 C2
R14 C9
TX+ 2_5VA
3.3V
TX- R15 P2
1 TX+ 1
4
75 75
3 TXCT
2_5VPLL

5
2_5VA

2_5VA

2 TX- 2
R11
D1
RESET_N
7 RX+ 3
R16 C10
RX+ 2_5VA 7
3.3V 8 RX-
75 75
3.3V 8
39
38
48
46
45
44
43
42
40

37
47

41

RX- R17 6 RXCT 6

1000PF
R4 12 A_LED1 2KV
RST_N
VDDPLL
XI
XO
GND8
GND7
VDDTX
TX+
TX-
GND6
VDDRCV
REXT

P1 1 36 LED1
MDIO R1 2
MDIO GND5
35 11 SHIELD
1 MDC GND4
K_LED1
2 3 34 NC
MDC R5 4
RXD3/PHYAD1 FXSD/FXEN
33 9
3 A_LED2
U1
RXD2/PHYAD2 RX+
4 RXD3 5 32 LED2
R2 6
RXD1/PHYAD3 RX-
31 2_5VA 10
5 RXD0/PHYAD4 VDDRX R12
K_LED2
6
7 RXD2 R6
7
8
VDDIO1
GND1
KSZ8721BL PD_N
LED3/NWAYEN

30
29
NC FOR DEFAULT
NC FOR DEFAULT 4 NC1
8 RXD1 9 28 NC FOR DEFAULT 5 NC2
RXD0 R3 10
RXDV/PCS_LPBK LED2/DUPLEX
27
9 RXC LED1/SPD100 R13
10 RXDV 11 26 13 MTG1

CRS/RMII_BTB
TXC/REF_CLK
R7 12
RXER/ISO LED0/TEST
25
11 GND2 INT_N/PHYAD0 SHIELD PINS
12 14 MTG2

COL/RMII

VDDIO2
13 RXC
VDDC

GND3
TXER

TXEN
TXD0
TXD1
TXD2
TXD3
14
15 3.3V
16
17 RXER

13
14
15
16
17
18
19
20
22
23
24
21
18 TXER 2_5V
19 C
20 R8
21 TXC
22
23 BR1
24 MTG1 BRACKET
25 TXEN MTG2
26 TXD0

EasyCoder PD41/PD42 Printer Service Manual

27 TXD1
28 TXD2
29
30
31 TXD3 C
COL R9
32
33 CRS
R10
34
35 ETHINT_N
RESET_N R20
36
37 SDA
38
39
40
SCL
BYPASS/DECOUPLING
40-PIN

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DIL40A_2.0MM
3.3V
C17 + C18 U1 (PHY) U2 (EEPROM) FL1 FL2
3.3V 3.3V 2_5V 2_5VA 2_5VPLL
C3 C4 + C5 C6 C7 C8 + C11 C12 + C13
C14 C15 C16
R18 R19
U2
1 A0 VCC 8
2 A1 WP 7
3 A2 SCL 6
4 GND SDA 5
Schematics

I2C ADDRESS 0X54 (7BIT)

 Chapter 4 — Interfaces

94 EasyCoder PD41/PD42 Printer Service Manual

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 Corporate Headquarters
6001 36th Avenue West
Everett, Washington 98203
U.S.A.
tel 425.348.2600
fax 425.355.9551
www.intermec.com

EasyCoder PD41/PD42 Printer Service Manual

*939-010-001*
P/N 939-010-001

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