revision history rev ecn number description updated ......pm42 service repair manual pm42...

TITLE Model DOCUMENT NO. PAGE

PM42 Service Repair Manual PM42 L3-GLBL-RPR-3872 (Rev A)

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L3-GLBL-RPR-3872 (Rev A)

Revision History

Rev ECN Number Description Updated Pages Change Type Released by A 336577 First release Te Chhang



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Disclaimer

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

HII shall not be liable for technical or editorial errors or omissions contained herein: nor for incidental or consequential damages resulting from the furnishing, performance, or use of this manual.

This document contains propriety information that is protected by copyright. All rights reserved. No part of this document may be photocopied, reproduced, or translated into another language without the prior written consent of HII.

© 2008 – 2011 Honeywell International Inc. All rights reserved.

Web Address: www.honeywellaidc.com

Trademarks

Metrologic, MetroSelect, MetroSet2, Master Diagnostics and TotalFreedom are trademarks or registered trademarks of Metrologic Instruments, Inc. or Honeywell International Inc.

Microsoft, Windows, and Windows 95 are trademarks or registered trademarks of Microsoft Corporation. Other product names mentioned in this manual may be trademarks or registered trademarks of their respective companies and are the property of their respective owners.



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Table of Contents Disclaimer ..................................................................................................................................................................................... 2 Trademarks ................................................................................................................................................................................... 2

Compliance and Safety .................................................................................................................................................... 5

General Precautions ..................................................................................................................................................................... 6 Safety Training .......................................................................................................................................................................... 6 Quality Training ........................................................................................................................................................................ 6 Product ESD Information ......................................................................................................................................................... 6

High Level Recommended Repair Process ...................................................................................................................... 7

Cautions & Notes ............................................................................................................................................................. 8

Cover - Media Door Assembly ......................................................................................................................................... 9

Cover - Electronic Cover ................................................................................................................................................ 10

Front Panel Assembly .................................................................................................................................................... 11

Platen Roller .................................................................................................................................................................. 13

Printhead ....................................................................................................................................................................... 14

Print Unit Components .................................................................................................................................................. 15

Printhead Lift Handle and Pressure Adjust Mechanism ................................................................................................ 18

Printhead Lift Sensor Assembly ..................................................................................................................................... 20

Printhead Lift Assembly ................................................................................................................................................. 21

Media Guide Top Dancer Assembly .............................................................................................................................. 22

Media Sensor Bottom Assembly ................................................................................................................................... 24

Front Media Access Door .............................................................................................................................................. 26

Ribbon Adjust Sub Assembly ......................................................................................................................................... 27

Ribbon Wrinkle Adjustment .......................................................................................................................................... 28

Tear Bar ......................................................................................................................................................................... 29

Media Hanger and Edge Guides .................................................................................................................................... 30

Ribbon Supply Assembly ............................................................................................................................................... 31

Media Hanger and Edge Guides .................................................................................................................................... 33

Base Assembly ............................................................................................................................................................... 34

Spine .............................................................................................................................................................................. 35

Back Plate ...................................................................................................................................................................... 36

LCD Touch Panel and Display Assembly ........................................................................................................................ 37

Main Logic Board Assembly........................................................................................................................................... 38



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Power Supply Assembly ................................................................................................................................................ 39

Stepper Motor and Gear Drive Assembly ..................................................................................................................... 41

Example Screws & Torque Settings ............................................................................................................................... 47



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Compliance and Safety Compliance This equipment has been tested and found to comply with limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. Any unauthorized changes or modifications to this equipment could void the users authority to operate this device. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference.

2. This device must accept any interference received, including interference that may cause undesired operation.

Notice This Class A digital apparatus complies with Canadian ICES-003.

Remarque Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

Caution Only trained personal should open and service the scanner as use of controls or adjustments or performance of procedures other than those specified herein may result in dangerous laser light exposure. Never attempt to look at the laser beam, even if the scanner appears to be nonfunctional. Doing so could result in hazardous laser light exposure. The use of optical instruments with the laser equipment will increase eye hazard.

Standard Europeo Warning This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. Funkstöreigenschaften nach EN55022:1998 Warnung!

Dies ist eine Einrichtung der Klasse A. Diese Einrichtung kann im Wohnbereich Funkstörungen verursachen. In diesem Fall kann vom Betreiber verlangt werden, angemessene Massnahmen durchzuführen. Attenzione

Questo e’ un prodotto di classe A. Se usato in vicinanza di residenze private potrebbe causare interferenze radio che potrebbero richiedere all’utilizzatore opportune misure.

Attention

Ce produit est de classe “A”. Dans un environnement domestique, ce produit peut être la cause d’interférences radio. Dans ce cas l’utiliseteur peut être amené à predre les mesures adéquates.



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General Precautions

This symbol within the document represents an important HSE Safety requirement/alert.

This symbol within the document represents an important quality step.

Safety Training Consult the local HSE Cell Risk assessment to become familiar with any potential hazards while working with the PM42 printer. HSE training for this Scanner should include;

• Hand and Portable Tools • Hazardous Chemical Management • Laser Safety • Lead Safety • PPE • Safety Awareness

Safety glasses must be worn.

Quality Training Training per the local Honeywell site for Technicians/Repair personal should include;

• Soldering Verification

Product ESD Information This product contains ESD sensitive components or ElectroStatic Discharge sensitive electronic parts. The Electrostatic discharge is defined as the transfer of charge between bodies at different electrical potentials. An ESD event has the ability to modify the electrical characteristics of a semiconductor device, possibly degrading or even destroying it. ESD also may upset the normal operation of an electronic system, causing equipment malfunction or failure. ESD PREVENTION STEPS MUST BE USED DURING ANY REPAIRS OR MODIFICATIONS TO THIS UNIT. PERFORM ALL WORK AT A CERITFIED ESD WORK STATION.



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OPERATION: High Level Recommended Repair Process

Step Process Reference Document Location Comments

1 Repair Unit SRD, SSP and STS Service Eng Team Room

High level repair information is referenece in the Service

Engineering Team Room and Service Portal page (CSSP).

2 Check for hardware /

software updates Service Procedures / Technical Bulletins

SAP

Applicable Service Procedures / Technical Bulletins are listed on Service Engineering team site and the Service Portal page

(CSSP).

3 Functional Test SPP Test Eng Team

Room

SPP’s are listed on Test Engineering team site and the

Service Portal page (CSSP).



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OPERATION: Cautions & Notes

• PM42 supports USB, serial, parallel, and Ethernet only. • The functionalilty of the PM42 printers will be backward compatible with PM43 printers except the

following:

PM43 PM42 Backward compatibility

Touch panel Support Not support no

LCD 3.5(QVGA 320 x 240 pixels) 2.36 (480 (RGB) x 234) no

Print Mech Cast metal Print mech Sheet metal Print mech no

UI button 19(Number, F1~F5, …) 8 (Menu/Home, Enter/OK) no

BT, WiFi, RFID, Touchless, RTC, Speaker

Support Not support no



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OPERATION: Cover - Media Door Assembly The media door assembly come as a complete assembly including the clear plastic window and 4 torx screws. The clear plastic window is also available as a spare part. Tools Required

Description Torx Driver T20

Parts Required

Item Part Number Description Qty 1 50124891-001FRE FRE, ASSY, MEDIA DOOR, PM42 (include 4 – 50125239-001) 1 2 50125239-001FRE FRE, SCREW MRT M4X8, Ф7, 100-Pack (16±0.8kgf/cm) 4 3 50124875-001FRE FRE, Window, Media Door, PM42 1

Media Door Assembly Replacement 1. Lift the media door cover and remove the Torx screws securing the media door assembly.

Media Door Assembly T20 Torx Screw Media Window

1

2

3



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OPERATION: Cover - Electronic Cover Tools Required


Parts Required

Item Part Number Description Qty 1 50124890-001FRE FRE, Cover, EE, PM42 1 2 814-055-008FRE Screw MRT M4X8 Black, 100-Pack (6±0.3kgf/cm) 4

Electronic Cover Replacement 1. Remove the torx screws (2 on media side and 2 on electronic side) that secure the electronic cover. 2. Lift the electronic cover up and away from the printer spine (main deck).

Electronic Cover Torx Screw

1

2

1

2



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OPERATION: Front Panel Assembly The front panel assembly is available as a complete assembly and individual replacement assemblies. Tools Required

Description Torx Driver T10 Torx Driver T20

Parts Required

Item Part Number Description Qty 1 51024892-001FRE FRE, Assy, Front Panel, w/o PCBA, PM42 1 2 50124882-001FRE FRE, BUTTON FEED 1 3 50124625-032FRE FRE, PCBA, UI Feed Button, PM42 1 4 50125473-001FRE FRE, KEYPAD MEMBRANE 1 5 TBA FRE, LABEL, EMBOSSED OVERLAY, PM42 1 6 50125130-001FRE FRE, LCD, TFT, 2.36 INCH,480(RGB)*234 1 7 50124880-001FRE FRE, LCD Window, PM42 1 8 50124625-002FRE FRE, PCB S/A, PM42 – LCD 1

Front Panel Assembly Part Replacement 1. Remove the media cover door assembly and electronic cover assembly. 2. Remove the torx screws securing the front panel assembly from the electronic side and the torx screw next to the meda access door. 3. Disconnect the ground (GND) wire and the interface cable from the main logic board (MLB). 4. Release the two locking taps on the front panel assembly and pull the front panel assembly away from the spine (main deck).



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1 2 3

4

5 6

7



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OPERATION: Platen Roller Tools Required

Description Torx T20

Parts Required

Item Part Number Description Qty 1 50124891-001FRE FRE, ASSY, MEDIA DOOR, PM42 1

Platen Roller Assembly Replacement 1. Raise or open the Printhead 2. Rotate the platen roller latch clockwise to detach the platen roller assembly from the printer and pull the platen roller away from the printer. 3. Insert the replacement platen roller into the printer and secure it by turning the latch counterclockwise.

Platen Roller Assembly

Cleaning Platen Rollers Recommended that the installed platen rollers be cleaned. To clean the platen roller, the following are needed:

• Silicone cleaning fluid • Lint-free cleaning cloth • Thermal printhead cleaning swab, wipe, or pen

1



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OPERATION: Printhead The handstrap is attached to the bottom housing. It can be removed and installed without opening the unit. Tools Required

Description Isopropyl alcohol solution

Parts Required

Item Part Number Description Qty 1 50126706-001FRE FRE, ASSY, PRINTHEAD, 203DPI, PM42 1 2 50126707-001FRE FRE, ASSY, PRINTHEAD, 300DPI, PM42 1 3 50126708-001FRE FRE, ASSY, PRINTHEAD, 406DPI, PM42 1

Printhead Assembly Replacement 1. Turn the printhead lift lever counterclockwise to raise the printhead 2. Detach the magnetic pressure arm from the printhead bracket and disconnect the two cables from the printhead as you remove it from the printer. 3. Connect the two printhead cables to the new printhead 4. As you insert the new printhead bracket into the printer, make sure the metal arms on the printhead go around the magnetic pressure arm. Attach the magnetic pressure arm to the printhead.

Thermal Printhead

Cleaning Printhead Recommended that the installed printhead be cleaned. To clean the printhead, the following are needed:

• Silicone cleaning fluid • Lint-free cleaning cloth • Thermal printhead cleaning swab, wipe, or pen

1

Printhead Cables Magnetic Pressure Arm



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OPERATION: Print Unit Components This section covers the replacement and installation of the print unit assembly that has several components. This section addresses the bottom base print mechanism and the printhead adjustment assembly. The spare bottom base print mechanism does not include the media guide assembly and sensor. Tools Required


Parts Required

Item Part Number Description Qty 1 644-052-001FRE FRE, Bar Connecting 1 2 50126032-001FRE FRE, Bottom Assembly 1 3 50125236-001FRE FRE, SCREW MRT M4X12 Ф12, 50-Pack (16±0.8kgf/cm) 1 4 1-994059-012 FRE, SCREW MRT M4X12 ZP (16±0.8kgf/cm) 1

Bottom Base Print Mechanism Replacement 1. Turn the printhead lift lever counterclockwise to raise the printhead. 2. Remove the platen roller assembly. 3. Remove the drive pulley to access the torx screw underneat. 4. Remove the 4 torx screws securing the bottom base print mechanism assembly IMPORTANT!!: Make note of the guide posts and position of media guide assembly adjustment lever as you pull the print mechanism away from the spine (main deck). See Figure 2. 5. Remove the tear bar and reverse the procedure for installation of new print mechanism assembly

Location of torx securing the print mechanism assembly

3



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Printhead Pressure Adjust Assembly Replacement 1. Turn the printhead lift lever counterclockwise to raise the printhead. 2. Remove the 5 torx screws securing the printhead pressure adjust assembly. 3. Prior to removing the printhead pressure adjust assembly, it is IMPORTANT to note the position of the crank lever and guide posts. 4. Reverse the procedure for installing the replacement printhead pressure adjust assembly.

Printhead Pressure Adjust Assembly include torque pattern

Media Gap Guide Adjustment lever

2

3

4 1 4

x5

Crank Lever Position



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1 2



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OPERATION: Printhead Lift Handle and Pressure Adjust Mechanism This section cover the replacement of printhead lift handle and pressure adjust assembly. The printhead lift handle is used to release the media (label) and ribbon for replacement. The pressure adjust assembly is part of the printhead adjust assembly to adjust the printhead pressure against the platen roller for different media thickness. The printhead pressure adjust assembly has to be removed first prior to removing the printhead lift handle and pressure adjust assembly. Tools Required


Parts Required

Item Part Number Description Qty 1 50125896-001FRE FRE, Assy, Pressure Adjust Sub, PM42 1 2 50125631-001FRE FRE, Pressure Adjust 1 3 50125623-001FRE FRE, Head Lift Lever, PM42 (include 800-619-008) 1 4 1-994059-012 FRE, SCREW MRT M4X12 ZP, T20 (16±0.8kgf/cm) 2 5 800-619-008 SCREW MRT 3X8 FBZ NYLON PATCH, T10 (6±0.3 kgf.cm) 1

Printhead Lift Handle 1. Remove the printhead pressure assembly. 2. Remove the torx securing the printhead lift handle with a Torx driver T10 as shown on Figure 1 and remove the printhead Lift handle away from the printhead pressure adjust assembly. It is important to make note on how the printhead lift handle is attached to the pressure adjust assembly.

Pressure Adjust Assembly Replacement 1. Remove the printhead pressure assembly 2. Remove the 2 torx screws securing the pressure adjust holder against pressure adjust assembly and lift the pressure adjust holder away to remove the pressure adjust assembly for replacement. It is important to note the fittings. 3. Reverse the procedure for installing replacement of pressure adjust assembly.

5



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Pressure Adjust Holder

1

4

2 3

X2



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OPERATION: Printhead Lift Sensor Assembly Printhead lift sensor senses when the printhead lifted. Tools Required


Parts Required

Item Part Number Description Qty 1 236-261-001FRE FRE, Printhead Lift Sensor Assembly, PM42 1

Printhead Lift Sensor Assembly Replacement 1. Remove the 2 torx screws securing the headlift sensor assembly. 2. Unplug the sensor cable assembly from the MLB and lift the headlift sensor away 3. Reverse the procedure to install replacement headlift sensor assembly

Headlift Sensor Assembly

2

1



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OPERATION: Printhead Lift Assembly This section cover the replacement of printhead lift mechanism assembly replacement. Replacing the assembly require removing the print motor assembly first and possible driver gears to gain access to the torx screws securing the printhead lift mechanism on the electronic side. The print unit components would also need to remove. Tools Required


Parts Required

Item Part Number Description Qty 1 50125897-001FRE FRE, ASSY,TPH SUB ASSY ASM 1 2 TBA FRE, TBA 1 3 1-994058-010 Screw MRT 3X10 FBZ, T10 (6±0.3 kgf.cm) 1

Printhead Lift Mechanism Assembly Replacement 1. Remove the print mechanism stepper motor prior to removing the printhead lift mechanism assembly. 2. Remove the print unit components. 3. Remove the torx screw securing the headlift sensor reflector. 4. Remove the torx screw securing the headlift compression spring and slide the printhead lift mechanism assembly away from the spine (main deck)

Printhead Lift Sub Assembly

3

1 2



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OPERATION: Media Guide Top Dancer Assembly This section cover the replacement of top media guide dancer assembly and the dancer assembly. Tools Required

Description Torx T20 Torx T10

Parts Required

Item Part Number Description Qty 1 50125904-001FRE FRE, Assy, Media Guide, Top, PM42 (complete

assembly include upper LSS sensor) 1

2 50125906-001FRE FRE, Assy, Dancer 1 3 50124625-002FRE FRE, Sensor Assembly, PM42 – Upper LSS 1 4 1-994059-012 FRE, SCREW MRT M4X12 ZP, T20 (16±0.8kgf/cm) 1

Media Guide Top Dancer Assembly Replacement 1. Remove the torx screw securing the top media guide dancer assembly from the electronic side. 2. Disconnect the media sensor assembly from connector P20 on the main logic board (MLB) and slide the top media guide dancer assembly away from the spine (main deck). It is IMPORTANT to note the spring position behind the spine (main deck) guide post, guide posts, and guide pin. 3. For Item #1 LSS upper assembly, the assembly can be removed without having to perform Step #1. LSS upper assembly can be removed by detaching the assembly away from the guide pin. 4. For Item #2 Dancer Assembly, the assembly can be removed by removing the c-clip and slide the assembly outward.

Screw securing media guide dancer assembly Guide posts

4 Spring



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Removing LSS Upper Assembly Removing Dancer Assembly

Top Media Guide Assembly (Complete) Dancer Assembly

Upper LSS Sensor Replacement 1. Pushing the locking tab downward and slide the sensor out of the top guide assembly.

LSS Sensor Assembly

1

2

3

Push tab down



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OPERATION: Media Sensor Bottom Assembly The bottom media assembly include the media guide sensor for printing on different media (label) width. The assembly is secured by the bottom base print mechanism and it secure by the guide posts (2 each side of the bottom guide) against the spine (main deck) and the inside of the bottom base print mechanism. Tools Required


Parts Required

Item Part Number Description Qty 1 5012907-001FRE FRE, Assy, Media Guide Bottom (complete assembly) 1 2 50125908-001FRE FRE, Assy, LSS, Adjust, PM42 1 3 50125909-001FRE FRE, LSS EE Bottom (need to be setup) 1 4 650-798-002 Cover, Frame Print Mech 1 5 1-994058-010 Screw MRT 3X10 FBZ, T10 (6±0.3 kgf.cm) 3 6 800-593-006 Screw, Plastite, M3x6, PH, Torx, T10 (6±0.3kgf.cm) 3

Bottom Media Sensor Assembly Replacement 1. Remove the cover frame print mechanism assembly. 2. Disconnect the media guide sensor cable P34 from main logic board (MLB) and cut the tie cable securing the cable. 3. Detach the bottom media guide assembly from the spine (main deck). It is IMPORTANT to make note of the guide posts. 4. Reverse the procedure for installing replacement bottom media guide assembly.

Figure 1 – Cover Frame Removal Figure 2 – Slide

3

1

2

Guide Post

4

5



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LSS Adjust Assembly Replacement 1. Remove the three torx screws securing the LSS adjust assembly. See Figure 3. 2. Lift the LSS adjust assembly and release the belt from the gap sensor assembly.

Figure 3 – Media Sensor Assembly

LSS Adjust Assembly Replacement 1. Remove the lower LSS assembly from the bottom media guide assembly. 2. Lift the LSS adjust assembly and release the belt from the gap sensor assembly.

2

1

3



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OPERATION: Front Media Access Door The door is a customer replaceable part. Tools Required


Parts Required

Item Part Number Description Qty 1 50125621-001FRE FRE, Door, Access 1 2

Access Door Replacement 1. Open the access door and carefully lift the one corner of the access door with a plastic tool. 2. Replacement access door should snap onto the guide

Door, Access

Area

1



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OPERATION: Ribbon Adjust Sub Assembly The purpose of the ribbon adjust assembly is to adjust the ribbon alignment for ribbon wrinkle for printers with thermal transfer ribbon option. Direct thermal printer will not have the ribbon adjust sub-assembly. Tools Required


Parts Required

Item Part Number Description Qty 1 50125922-001FRE FRE, Assy, Ribbon Adjust Sub, PM42 (include screws, washer, rod, and

plate) 1

2 3

Ribbon Adjust Assembly Replacement 1. Remove the torx screw securing the ribbon adjust assembly. 2. Slide the ribbon adjust assembly toward the electronics and gears side to remove from the spine (main deck). 3. Reverse the instructions for re-installation.

Ribbon Adjust Sub Assembly, Spare

Torx screw

1



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OPERATION: Ribbon Wrinkle Adjustment This section covers the instruction on how to adjust the ribbon wrinkle for printers with thermal transfer ribbon option. Direct thermal printer will not have the ribbon wrinkle adjustment mechanism. Tools Required


Parts Required

Item Part Number Description Qty 1 None 1

Ribbon Wrinkle Adjustment 1. See Steps for instructions on how to adjust the ribbon wrinkle. Step 1 Step 2

Step 3 Step 4



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OPERATION: Tear Bar This is a customer replaceable part; no tooling is required for this operation. Tools Required


Parts Required

Item Part Number Description Qty 1 650-799-001FRE FRE, Tear Bar 1

Tear Bar Replacement 1. Remove the 3 torx screws securing the tear bar against the bottom print mechanism assembly and remove the tear bar. 2. Reverse the procedure for re-installation.

Figure 1

Tear Bar, Spare



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OPERATION: Media Hanger and Edge Guides The media hanger and edge guides (large and small edge guide) come as a complet service kit. Tools Required

Description Phillips

Parts Required

Item Part Number Description Qty 1 50125626-001FRE Guide, Edge, Small 1 2 655-314-001FRE FRE, Hanger Media 1

Media Hanger Replacement 1. Remove the Phillips screw securing the media hanger against the spine (main deck). 2. Detach the media hanger away from the spine (main deck) 3. Reverse the procedure for re-installation.

Edge Guides Replacement 1. Lower the edge guide and insert a flat head screw to release the edge guide from the media hanger. 2. To install the new edge guide, expand the edge guide and snap the edge guide onto the media hanger.

Production unit will use Phillips M6x16mm screw

1 2



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OPERATION: Ribbon Supply Assembly The ribbon supply assembly has reflective material that senses ribbon low. Ribbon low sensor assembly located behind the ribbon supply assembly senses the reflective material and signal to the main logic board. Tools Required


Parts Required

Item Part Number Description Qty 1 1 2 50125990-001FRE FRE, Assy, Ribbon Sensor, PM42 1 3

Ribbon Supply Assembly Replacement 1. Remove the torx screw securing the ribbon supply assembly module to the ribbon supply rod. 2. Pull the ribbon supply assembly module away from the ribbon supply rod. It is IMPORTANT to note the position of the ribbon supply assembly guide pin attached to the spine (main deck). 3. Reverse the instructions for re-installation.

Figure 1

Ribbon Supply Assembly Module

1



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Ribbon Low Cable Sensor Assembly Replacement 1. Remove the electronic cover 2. Disconnect the ribbon low cable P25 on the main logic board (MLB) 3. Detach the ribbon sensor holder and pull the ribbon low sensor assembly through the spine (main deck).

Ribbon Low Cable Sensor Assembly

2



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OPERATION: Media Hanger and Edge Guides This section covers the replacement of ribbon take-up mechanism. Make note of the guide pins when removing the mechanism on the electronics side. Tools Required

Description Torx Driver T20 Allen Driver, 1.5mm-2.0mm

Parts Required

Item Part Number Description Qty 1 1 2 3

Ribbon Take-up Replacement 1. Remove the torx screws securing the ribbon rewind assembly module. 2. Remove the Allen set screw to remove the ribbon hub. 3. Remove the C-clips and slide the ribbon rewind assembly toward the electronics side. 4. Reverse the procedure for re-installation.

Figure 1 Figure 2

Ribbon Rewind Assembly Module Spring Plate, 1 Inch Core

1 2

3 Location of Allen set

screw



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OPERATION: Base Assembly This is NOT a customer replaceable assembly. Replacement of base assembly is rare. Stock base assembly on need a basis. Rubber foot are not included in the spare base assembly. Tools Required


Parts Required

Item Part Number Description Qty 1 50124887-001FRE FRE, Base Assy, PM42 1 2 813-172-001 Foot,Rubber PM43 4 3 1-994059-012 FRE, SCREW MRT M4X12 ZP (16±0.8kgf/cm) 4

Base Assembly Replacement 1. Remove the torx screws (x4) on electronics side and x2 on media side) securing the base assembly to the spine (main deck). 2. Lift the base assembly away from the spine. 3. Reverse the procedure for re-installation.

Base Assembly

1

3

3 3

3

3

3



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OPERATION: Spine This is a NOT customer replaceable part. The spine (main deck) will rarely need replacement unless major damage require doing so. Replacement of the spine require removing all install components, which is a complete disassembly of the printers. Stock inventory of spine assembly on a need basis. Tools Required


Parts Required

Item Part Number Description Qty 1 50124886-001FRE FRE, Spine Assy, PM42 (include bearing) 1

Spine Replacement 1. Remove all attached mechanical and electrical parts. 2. Remove the torx screws securing the spine against the base assembly.

Spine Assembly

1



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OPERATION: Back Plate Tools Required


Parts Required


Back Plate Replacement 1. Procedure - TBA 2. Procedure - TBA I/O Cover Replacement 1. Procedure - TBA 2. Procedure - TBA

1 2



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OPERATION: LCD Touch Panel and Display Assembly This section covers the replacement of LCD display assembly and LCD touch panel. Tools Required


Parts Required


LCD Display Assembly Replacement 1. Remove the front panel to access the LCD display for replacement. 2. Remove user interface PCB assembly. 3. Remove the overlay. 4. Remove the torx screwing the touch panel under the overlay. 5. Remove the 5 torx screws securing the user interface PCB support bracket. has 3 torx screws securing the user interace PCB support bracket. 6. Reverse the procedure for re-installation.

Front Panel Assembly

LCD Touch Panel Replacement 1. Remove the front panel to access the LCD display for replacement. 2. Remove user interface PCB assembly. 3. Remove the overlay. 4. Remove the torx screwing the touch panel under the overlay. 5. Remove the 5 torx screws securing the user interface PCB support bracket.

5 3.0 lbf.in/3.5 kgf.cm



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has 3 torx screws securing the user interace PCB support bracket. 5. Reverse the procedure for re-installation. It is important to note the touch panel ribbon cable routing.

OPERATION: Main Logic Board Assembly Tools Required

Description Torx Driver T20 Nut Driver 5mm or 3/16

Parts Required

Item Part Number Description Qty 1 50124649-003FRE FRE, PCBA, MLB(MAIN LOGIC BOARD) 1 2 3

Main Logic Board (MLB) Replacement 1. Remove 5 Torx screws that secure the MLB. For printer with installed option, there will be 4 Torx screws and a Standoff. 2. Remove standoff for printer with installed options.

Main Logic Board

3. Disconnect all attached cablings and carefully remove MLB away from the power supply back plate. 4. Remove the grounding plate and hex standoffs from the defective MLB and install onto replacement MLB. (Note: This procedure is necessary for initial built of spare MLB that did not include grounding plate and standoff)

MLB Grounding Plate & Hex Standoff

Standardoff

1



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OPERATION: Power Supply Assembly The power supply unit attaches to the spine (main deck) assembly with five torx screws and 2 torx screws on the exterior backplane. When removing the power supply unit, note the cable routing and tie wrapping to ensure proper re-installation. Tools Required


Parts Required

Item Part Number Description Qty 1 234-050S-003 Power Supply Unit (PSU), Assy, PM43, Spare (include PSU, PSU Bracket, and

Torx screws) 1

2 3

Power Supply Unit Replacement 1. Remove the 5 torx screws with Torx driver T20 that secure the PSU onto the spine (main deck) assembly. for location of the torx screws. 2. Remove the 2 torx screws with Torx driver T20 that secure the PSU on the back plate. 3. Cutoff the tie wrap that secure the power supply unit and ribbon sensor cable. 4. Reverse the procedure for re-installation.

2 2



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Power Supply Unit Spare Power Cable, MLB-PSU

1

3

4



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OPERATION: Stepper Motor Assembly and Drive Gear Assembly (Need to update with PM42 contents)

Tools Required


Parts Required


Print Mechanism Motor Tension Roller Assembly Belt, Pulley, Timing Motor Replacement

1. For easy access to the motor hardware, first remove the front panel per the instructions in the Front Panel replacement section, page 10

2. Unplug the motor cable connector from the MLB marked P33 Step 1, see Figure 1 3. Loosen the belt tension screw No. 1, and remove all four motor corner mounting screws , see figure 2 4. Remove the service pulley cover (guard) as shown in Figure 3 and slip the timing belt off with an upward motion, see

Figure 4 5. Tilt and pull the motor up as noted by the red arrows in Figure 5 6. To replace the motor reverse these steps, keeping in mind the drive belts are positioned as shown in Figure 5.

Figure 1 Figure 2 Figure 3

1

2

4 3

5

6



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Figure 4 Figure 5

Drive Belt Replacement

1. Remove the motor as per the motor replacement instructions 2. Remove the center ribbon drive gear by removing the mounting screw, see Figure 6 3. Slip the center gear off and lift each drive belt off, see Figures 7 and 8, note relative P/Ns of drive belts as shown in

Figure 8 , lower belt P/N 655-321-001(189mm) and upper ribbon take up drive is P/N 655-323-001 (162mm) 4. For installation reverse these steps

Figure 6 Figure 7 Figure 8

Roller Tension Replacement

1. Remove the motor as per the motor replacement instructions. 2. Remove the 3 mounting screws as shown in red circles. See Figure7. 3. Lift and remove the Roller Tension assembly as shown in Figure 9, loosen the belt tension screw for this step.

Figure 9 Pulley, Drive Kit, Spare



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OPERATION: Labeling (Need to update with PM42 contents) The PM42 contains a variety of labels on its bottom housing. These labels consist of both pre-printed labels that are ready to apply off the shelf and print on demand labels that have specific content that must be printed to match the particular unit being serviced. Anytime a bottom housing assembly is replaced, it will need new labels installed. See the Service Repair Information web site for software and format files needed to reproduce the print on demand label set. Tools Required

Description Isopropyl alcohol solution

Parts Required

Item Part Number Description Qty 1 1 2

Certification Label

1. Refer to Print-On-Demand Label Printing System to print the certification label. 2. Refer to Figure 1 for location of the certification label.

Sample Sample

Figure 1 – Family Certification Label



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Serial Number Label 1. Refer to Print-On-Demand Label Printing System to print the serial number label 2. Refer to Figure 2 for location of the serial number label on the back plate.

Figure 2 – Serial Number Label



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OPERATION: Print-On-Demand Label Printing System The PM42 print-on-demand label printing system to print the configuration number, serial number, and corresponding certification label. The print-on-demand label printing system utilities front-end software T45765 and the format files design to support different printer models and configurations. Print-On-Demand Label Printing System

1. Print-on-Demand procedure can be found on the Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only.

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

3. Print-on-demand front-end software T45765 can be found on the Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only.

4. Print-on-demand front-end software T45944 can be found on the Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only.



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OPERATION: Testing The PM42 will use the same service test software and fixture as manufacturing functional test software and fixture. It is require running the printer through the service test especially when replacing new main logic board (MLB) and touchless configuration unit assembly to program printer information to the new board. Testing Instructions

1. The test procedure is OTPPMx2-000. 2. The software PM42 be found on the Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only. 3. The test fixture bill of material can be found Intermec New Products Test Engineering SharePoint site. Access to this site is available to Intermec Team Members only. 5. The test will require test media and ribbon material. See below.

Model Used

Consumables Media/Ribbon Type P/N

PM42 DT Labels BL 4.0X6.0 W/THERM LTNG HI-TCK E06144 PM42 TTR Labels

Ribbon LBL 4.0X6.0 TTRII PERM RIBBON,TTR PREM 4420.4.1X18000

E06175 12064118



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OPERATION: Example Screws & Torque Settings

50125239-001FRE FRE, SCREW MRT M4X8, Ф7 Secure media door assembly onto main deck Comes in a pack of 100 screws

16±0.8kgf/cm Torx T20

50125236-001FRE FRE, SCREW MRT M4X12 Ф12 Secure head lift sensor assembly Comes in pack of 50 screws


814-055-008FRE Screw MRT M4X8 Black Secure electronic cover


800-619-008 SCREW MRT 3X8 FBZ NYLON PATCH 6±0.3 kgf.cm Torx T10

1-994059-012 FRE, SCREW MRT M4X12 ZP 16±0.8kgf/cm Torx T20

1-994058-010 Screw MRT 3X10 FBZ 6±0.3 kgf.cm Torx T10

800-593-006 Screw, Plastite, M3x6, PH, Torx 6±0.3kgf.cm Torx T10



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Honeywell Scanning & Mobility

9680 Old Bailes Road Fort Mill, SC 29707 www.honeywellaidc.com

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