Desktop Thermal Printers Service Manual 2722 2742 3742 980357-001 Rev.
FOREWARD This manual provides installation and operation information for the LP 2722, TLP 2722, LP 2742, TLP 2742 and TLP 3742 series printers, manufactured by Zebra Technologies Corporation, Camarillo, California. TECHNICAL SUPPORT If for any reason you require product technical support, please contact the Distributor where you first purchased your equipment. If they cannot help you or at their direction, contact Zebra Repair Administration.
TRADEMARKS LP 2722, TLP 2722, LP 2742, TLP 2742 and TLP 3742 are of Zebra Technologies Corporation. Windows and MS-DOS are registered trademarks of Microsoft Corp. All other marks are trademarks or registered trademarks of their respective holders. OPERATOR CAUTIONS AND WARNINGS These pages describe general safety and maintenance procedures that an operator must follow. They are referenced throughout the service manual. The manual may include other warnings and cautions not displayed here.
Media Cautions & Tips 1) Always use high quality, approved labels and tags. Approved supplies can be ordered from your dealer. For the name of a dealer in your area, call Customer Service. 2) If poor quality, adhesive backed labels are used, that DO NOT lay flat on the backing liner, the exposed edges may stick to the label guides and rollers inside the printer, causing the label to peel off from the liner and jam the printer. 3) DO NOT use non-approved transfer ribbon.
vi 980357-001 Rev.
CONTENTS INTRODUCTION 1 Models . . . . . . . . . . . . . . . . Conventions . . . . . . . . . . . . . Unpacking the Printer . . . . . . . . Preparing a Static-Safe Work Area . . Environmental and Shock Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii 980357-001 Rev.
INTRODUCTION If you are a field engineer or technician, this manual helps you with routine maintenance, troubleshooting and procedures for replacing parts for repair. Follow the parts replacement procedures as closely as possible. If you are unsure of any procedure, please contact your service representative or call the Zebra Technologies technical support group at (805) 579-1800 Zebra Technologies stocks all replacement parts for the printer.
Models There are several models of the printer, each of which look similar but have different ribbon and media handling features. LP models print using direct thermal media only. They have a flat print head carriage. TLP models print using either direct thermal or thermal transfer media. They have a carriage with ribbon spool hubs. There are models that can handle up to four-inch (10.2 cm) wide media and those that can handle up to two-inch (5.1 cm) wide media.
Conventions This manual uses the following notations to call attention to important information. ICON / SYMBOL MEANING WARNING - critical safety information. CAUTION - problem avoidance messages. STATIC SENSITIVE - follow procedures that protect against the discharge of electrostatic energy that accumulates on the surface of the human body or other objects as this discharge can damage or destroy the print head and other electronic components. HEAT - The print head becomes hot while printing.
Environmental and Shock Protection Extreme temperature and humidity fluctuations or mishandling can damage the printer and power supply. Allow 30 minutes or more before opening the printer's plastic bag. This time allows the printer to stabilize temperature especially after storage in a cool, dry location and then placement in a warmer, more humid location. Warm, humid air condenses on the cool components of the printer and this condensation may damage the components. Move the printer carefully.
CLEANING AND MAINTENANCE The printers are manufactured and tested under a strict quality management program. Zebra Technologies uses only high quality components and materials in its printers. Although only minimal routine maintenance is required, following these simple maintenance guidelines will ensure longer life with quality printing performance. General Cleaning Keep the outside your printer clean by periodically wiping it with a soft cloth dampened water.
Cleaning the Media Path Keep the inside of your printer clean as needed, by using a brush, vacuum or air blower along the media path (except the print head). If a label jams inside the printer, remove the label and any adhesive residue immediately. Adhesive may spread throughout the printer's media path if not completely removed. Many adhesive are permanent and have short "set" times.
Cleaning the Print Head Over time, the print head becomes contaminate resulting in poor print quality. After using five rolls of media or ribbon, rub the cleaning pen across the dark area of the print head. Allow the print head to dry for one minute before loading labels. Never touch the print head. Always clean the print head with a cleaning pen or a cotton swab moistened with 70% isopropyl alcohol to gently remove dirt and dust. Lubrication None of the serviceable parts require additional lubrication.
8 980357-001 Rev.
TROUBLESHOOTING GUIDE PROBLEMS SOLUTIONS Status indicator does not light when power switch is on (I) 1. Check power connections from the printer to the outlet. 2. Remove power supply and check fuse. If blown, remove the power supply and return it to the manufacturer. Install a new power supply. Printer is in dump mode but nothing prints after sending file. 1. File does not contain a form feed code that will advance sheet. Press the Feed button to print data in the printer’s buffer.
PROBLEMS Printer appears to be working with the indicator light GREEN, but nothing is printed. SOLUTIONS 1. Check the connections between the printer and the cable as well as the cable and the computer. 2. Verify that the labels are the correct type. 3. Check the roll and verify that the print surface faces up for direct thermal printing. 4. Check that the transfer ribbon is correctly routed and has the ink side down. 5. Check print head wire bundle connections in carriage at main PCBA.
PROBLEMS SOLUTIONS The printer firmware is updated by way of the parallel port. 1. Use the download utility to send firmware to the printer. Printer firmware must be updated. 980357-001 Rev. A 2. Optionally, you can download from the c:\ prompt by typing copy/b filename lpt1: from the directory holding the update file. The printer's light should start flashing green-orange, and then every few seconds will flash red a couple of seconds. Once the update is done, the light goes dark then comes on green.
Print Head Life The print head on the left is brand new. The print head in the center has been run over a million inches and has been cleaned after each media roll (and/or ribbon). The print head on the right has been run less than a million inches without cleaning and wear is evident. The print head has a limited life and is considered a consumable item. The media rubs across the print elements and wears away the surface. Media material, operational settings, and environment all affect this process.
REQUIRED TOOLS Make use of the following tools while performing replacement procedures: • • • • • • • • • • Phillips driver #0 Phillips driver #1 Phillips driver #2 Slot-head screwdriver tweezers hex nut driver 5/32 needle-nose pliers pliers for E-ring retainers pliers for axial retainers pliers for integrated chips 980357-001 Rev.
14 980357-001 Rev.
REPLACING PARTS To access some parts, you need to dissemble other parts; therefore, other procedures must be followed before and after performing a particular replacement. You can find these procedures on the repair paths chart. 980357-001 Rev.
REPAI R PATHS 202 Enclosure Latch 200 Packing Materials 204 Ribbon TakeUp Clutch 205 Ribbon Supply Clutch 290 Print Head 203 Roll Hubs 201 Rubber Feet 206 Cutter Option 207 Media Frame 209 Feed Button LED 214 Black Line Sensor Assy 208 Label Taken Sensor 210 Ribbon Out Sensor 213 Top 213 Bottom Transmissive Transmissive Gap Sensor Gap Sensor 212 Print Mechanism 215 SRAM 1MB, IE Flash, RTC 211 Battery 217 Platen Motor 218 Latch, Left Head 216 Main PCBA 219 Latch, Right Head 16 220 Plat
Packing Materials Replacement 980357-200A To ship or store the printer, make sure all components are packed as shown. 1 Foam set (two parts) 2 Master carton all-in-one 3 Poly-bag 4 Ship kit (various per printer) Extreme temperature and humidity fluctuations or mishandling can damage the printer and power supply. When unpacking the printer, allow 30 minutes or more before opening the printer's plastic bag.
Rubber Foot Replacement 980357-201A Removal Use tweezers to pull the foot 1234 free of the bottom case. Assembly Push the new foot into its receptacle ! until it pops into place. 18 980357-001 Rev.
Enclosure Latch Replacement 980357-202A Removal Use a slotted screwdriver to push or needle-nose pliers to pull the latch 12 free of the bottom case. Assembly Push the new latch into its receptacle ! until it snaps into place. 980357-001 Rev.
Ribbon Roll Hub Replacement 980357-203A Both the front and rear assemblies are on the left side of the carriage and are replaced with the same steps. Preparations Before starting the procedure, open the printer, then remove media and any ribbon from the printer. Removal 1. Use retainer pliers to remove the E-style retaining ring 1 from the outside of the hub. 2. Slide the hub 4, spring 3, and washer 2 out of the carriage side frame. Assembly 1.
Ribbon Take-Up Clutch Replacement 980357-204A Preparations Open the cover, then remove media and any ribbon from the printer. Removal 1. Remove the retaining ring 3 from the outside shaft of the hub. 2. Remove the take-up clutch assembly 2. 3. Slide the hub 1 out of the carriage side frame !. Assembly 1. Insert the hub 1 through the carriage side frame !. 2. Put the ribbon take-up clutch assembly 2 into place. 3. Secure with an exterior retaining ring 3. 980357-001 Rev.
Ribbon Supply Clutch Replacement 980357-205A Removal The compression spring 3 has considerable force. Hold the assembly as you begin to remove it. 1. Use retainer pliers to remove the retaining ring : from the outside shaft of the hub. 2. Remove the loose parts from the assembly. 3. Remove the E-style retaining ring 1 from the shaft of the hub ;. 4. Slide the hub ; out of the side frame !. Assembly 1. Insert the hub ; through the side frame ! 2. Lock the retaining ring 1 into place. 3.
Front Bezel, Cutter Replacement 980357-206A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Removal 1. Pull the bezel 1 forward and away from the bottom case !. 2. If necessary, provide outward lateral pressure on the sidewalls of the bottom case. 3. Unplug the cutter's ribbon cable 2 from where it connects to the main PCBA. Assembly 1.
Media Frame Replacement 980357-207A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the cover, and remove any media and ribbon (if necessary). Removal 1. Use a #1 Phillips driver to loosen the four screws 1 that hold the frame 2 to the bottom case !. 2. Lift the frame 2 free of the print mechanism and bottom case.
Label Taken Sensor Replacement 980357-208A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Follow the removal steps of the Media Frame Replacement procedure (980357-207). MOVIE Removal 1. Push outward the sensor door 1 until it pops out of the top cover !. 2. Pull the ribbon cable from its guide posts inside the top cover. 3.
Feed Button/LED Replacement 980357-209A Preparations Follow the removal steps of the Media Frame Replacement procedure (980357-207). MOVIE Removal 1. Use a slot-head screwdriver to pry the button cover 1 from the left support !. 2. Lift the button 2 off the assembly. 3. Detach the ribbon cable from the notches beneath the frame. 4. Lift the feed switch PCBA 3 out of the recessed supports. 5. Pull the feed switch PCBA free of the assembly. MOVIE Assembly 1.
Ribbon Out Sensor Replacement 980357-210A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. 1. Open the cover, then remove media and ribbon from the printer. 2. Follow the removal steps of the Media Frame Replacement procedure (980357-207). 3. Follow the removal steps of the Print Head Replacement procedure (980357-290). MOVIE MOVIE Removal 1.
Ribbon Out Sensor Replacement (continued) 980357-210A Installation 1. Insert the connector through the carriage from the top to the bottom. Route the ribbon cable around the print head wires. Then, plug the connector into location J4 on the main PCBA. 2. Align the wire plate into place and use a #0 Phillips driver to tighten the two screws that secure it to the bottom of the cross brace. 3.
Battery Replacement 980357-211A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. All information in the printer's memory will be lost if the battery is removed. The battery keeps printer memory active if power is switched off or disconnected. When the battery is exhausted, the printer will print "LOST INTERNAL INFO." 1.
Print Mechanism Replacement 980357-212A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Detaching the Mechanism 1. Detach the front bezel. Press outward on both sides (in front of the cover latches) until the bezel can fall forward. If this is a cutter bezel, detach its ribbon cable where it connects to main PCBA at J11. 2.
Print Mechanism Replacement (continued) 980357-212A Removing the Mechanism 1. Follow the removal steps of the Media Frame Replacement procedure (980357-207). 2. Use a #1 Phillips driver to remove the screw that secures the ground wire to the main PCBA. 3. Make note of the locations and routing of the bundles and cables. Then, detach wire bundles and ribbon cables from the following locations on the main PCBA: PCBA Location J2 J3 J8 J7 J9 J4 J10 J12 3.
Transmissive Gap Sensor Replacement 980357-213A The sensor has two parts: one above and one below the media path. Preparations 1. Do the removal steps of the Media FrameReplacement procedure (980357-207). 2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212). Removal of Top Sensor 1. Detach the carriage by flexingthe joints. MOVIE MOVIE MOVIE 2. Use a #0 Phillips driver to remove the screw 1 that holds the sensor 2 to the top of the cross brace !. 3.
Transmissive (Gap) Sensor Replacement (continued) 980357-213A Removal of Bottom Sensor 1. Use a #0 Phillips driver to remove the screw 3 that holds the sensor 4 to the bottom of the cross brace ". 2. Pull the ribbon cable from its guide posts. Assembly of Bottom Sensor 1. Align the sensor so the ribbon cable leads to the left. 2. Replace the screw that holds the sensor to the cross brace and use a #0 Phillips driver to tighten it. 3. Insert the ribbon cable into its guide posts.
Black Line Sensor Replacement 980357-214A Preparations 1. Do the removal steps of the Label FrameReplacement procedure (980357-207). 2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212). MOVIE MOVIE Removal Flex the retainer backward to release the sensor from its place. Assembly 1. Align the sensor 1 so that the wire bundle leads to the rear of the mechanism. 2. Press the sensor into the forward retainers. 3.
Upgrades to Memory and Real Time Clock Option 980357-215A These procedures outline the steps to access and replace SRAM memory, IE flash program memory, and the real-time clock option. Preparations 1. Make sure you have a back up any fonts, forms and graphics you downloaded to the printer. 2. Follow the removal steps of the Media Frame Replacement procedure (980357-207). MOVIE Replacing the Integrated Circuit Chips Protect against static discharge when following this procedure.
Upgrades to Memory and Real Time Clock Option - Continued 980357-215A Assembling the Printer Follow the assembly steps of the Media Frame Replacement procedure (980357-207). Checking the Installation Turn on the printer and run your printer's AutoSense routine to get a dump mode printout. This action tests the printer's media drive and printing capabilities. 8” UKQ1775 V3.20 Serial port : 96,N,8,1 MOVIE You can also check the printout for the upgrade or option you loaded.
Main Printed Circuit Board Assembly (PCBA) Replacement 980357-216A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. 1. Do the removal steps of the Media FrameReplacement procedure (980357-207). MOVIE 2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212). Removal 1.
Main Printed Circuit Board Assembly (PCBA) Replacement 980357-216A Assembling the Printer 1. Perform the assembly steps of the Print Mechanism Replacement procedure (980357-212). 2. Perform the assembly steps of the Media Frame Replacement procedure (980357-207). 3. Check the installation. Turn on the printer and run the AutoSense routine to get a dump mode printout. This action tests the printer's media drive and printing capabilities. 38 980357-001 Rev.
Platen Motor Replacement 980357-217A Preparations 1. Do the removal steps of the Media FrameReplacement procedure (980357-207). 2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212). MOVIE MOVIE Removal Use a #1 Phillips driver to remove the two screws 34 that secure the motor shield 2 and platen motor 1 to the left side frame !. Assembly 1.
Latch, Left Replacement 980357-218A Preparations 1. Do the removal steps of the Media FrameReplacement procedure (980357-207). 2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212). Removal MOVIE MOVIE 1. Use pliers to pull the return spring ! out of its slot. 2. Use retainer pliers to release the retaining ring 1 that holds the latch 2 to the label stripper shaft ". 3. Pull the latch off of the shaft. MOVIE 40 980357-001 Rev.
Latch, Left Replacement 980357-218A Assembly 1. Turn the shaft " so that the flat of the end faces upward. 2. Align the latch 3 so that the flat side of its mounting bearing matches the flat side of the shaft; then, press the latch onto the shaft. 3. The latch aligns with a stripper cam # that can be found between the side frame $ and roller %. 4. Use retainer pliers to place a new retaining ring 2 onto the shaft to secure the latch. 5. Use pliers to push the return spring ! into its slot. 6.
Latch, Right Replacement 980357-219A Preparations 1. Do the removal steps of the Media Frame Replacement procedure (980357-207). 2. Do the removal steps of the Print Mechanism Replacement procedure (980357-212). MOVIE MOVIE 3. Do the removal steps of the Platen Motor Replacement procedure (980357-217). Removal MOVIE 1. Use retainer pliers to remove the ring retainer ! from the platen gear "; then, pull the gear off of the shaft. 3. Use pliers to pull the return spring # out of its slot. 4.
Latch, Right Replacement 980357-219A Assembly 1. Turn the shaft $ so that the flat of the end faces upward. 2. Align the latch 2 so that the flat side of its mounting bearing matches the flat side of the shaft; then, press the latch onto the shaft. 3. The latch aligns with a stripper cam % that can be found between the side frame & and roller '. 4. Use retainer pliers to place a new retaining ring 1 onto the shaft to secure the latch. 5. Use pliers to push the return spring # into its slot. 6.
Platen Parts 980357-220A The platen is not a field replaceable item. Accessing the platen would require you to first follow the removal steps of the Media Frame Replacement, the Print Mechanism Replacement, and the Platen Motor Replacement procedures. Then, on the right side of the mechanism, use retainer pliers to remove the ring retainer ! from the platen gear ". Pull the platen gear off of the shaft.
Print Head Replacement 980357-290A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. While the two print heads from different manufacturers are functionally equivalent, each requires its own cable. See the Swapping the Cables procedure at the end of this procedure. Open the cover, and remove any media and ribbon (if necessary). Removal 1.
Print Head Replacement 980357-290A Swapping the Cables 1. 2. Follow the removal steps of the Media Frame Replacement procedure (980357-207) Detach the top carriage # from the bottom frame $. MOVIE MOVIE 3. Use a #0 Phillips driver to remove the two screws 34 that hold the wire plate 5 to the carriage. 4. Detach the cable connector 6 from its location on the main PCBA. Unwind the ribbon cable from the print head wires. Then, pull the print head cable free of the carriage. 5.
980357-001 Rev.
980357- 001 A
