Honeywell PC42d Operating instructions

L3-GLBL-RPR-4260 (Rev A)
Revision History
Rev
ECN Number
Description
Updated Pages
Change Type
Released by
A
First Release
Te Chhang
Te Chhang
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
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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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
Table of Contents
Disclaimer.....................................................................................................................................................................................2
Trademarks.................................................................................................................................................................................... 2
Compliance and Safety....................................................................................................................................................4
General Precautions..................................................................................................................................................................... 5
Safety Training..........................................................................................................................................................................5
Quality Training........................................................................................................................................................................ 5
Product ESD Information..........................................................................................................................................................5
High Level Recommended Repair Process.......................................................................................................................6
Cautions & Notes.............................................................................................................................................................7
Top/Bottom Cover Assembly...........................................................................................................................................8
Printhead Assembly .......................................................................................................................................................11
Platen Roller Assembly ..................................................................................................................................................12
Main Logic Board Assembly...........................................................................................................................................13
Black Mark Sensor Assembly .........................................................................................................................................15
Gap Sensor Assembly.....................................................................................................................................................16
Head Lift Sensor Assembly.............................................................................................................................................17
User Interface ................................................................................................................................................................18
Stepper Motor Assembly ...............................................................................................................................................19
Drive Gears
............................................................................................................................................................................ 20
Upper Chassis Assembly ................................................................................................................................................21
Lower Chassis Assembly ................................................................................................................................................22
Example Screws & Torque Settings ...............................................................................................................................23
Print-On-Demand ..........................................................................................................................................................24
Testing ...........................................................................................................................................................................25
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
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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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
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
XXXX scanner.
HSE training for this Scanner should include;
• Hand and Portable Tools
• HazardousChemical Management
• Laser Safety
• Lead Safety
• PPE
• SafetyAwareness
Safety glasses must be worn.
Quality Training
Training per the local Honeywell site for Technicians/Repair personal should include;
•Soldering Verification (add any additional training that would be required)
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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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
OPERATION:
High Level Recommended Repair Process
Step
Process
Reference Document
Location
Comments
1 Repair Unit
L3-GLBL-RPR-4260
PC42d Repair Manual
Service Eng
Team
Room/SAP
High level repair information is
referenece in the Service Engineering
Team Room and the Service Repair
Information (SRI) Site
2
Check for hardware
/ software updates
Service Procedures /
Technical Bulletins
Service
Engineering
Team Room/SRI
Site
Applicable Service Procedures /
Technical Bulletins are listed on
Service Engineering team site and the
Service Repair Information (SRI) Site
3 Functional Test OTPPC42d-000 Test Eng Team
Room
SPP’s are listed on Test Engineering
team site and the Service Repair
Information (SRI) Site
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
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L3-GLBL-RPR-4260 (Rev A)
•All of the fasteners removed during service can be reused. Refer to the screw part number details when
you need to replace a lost or damaged fastener.
•Take care to keep all cables, wires, and flexible components routed around potential pinch points during
reassembly. Ensure PCB’s and other (electrostatic discharge sensitive) components are properly protected
from ESD.
•Part/parts replacement process should be kept at a minimum of 15minutes. Depending on the labor rate
for a particular region, it is recommended to replace the whole printer.
OPERATION:
Cautions & Notes
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
The top enclosure will require the bottom enclosure to be removed for ease of removal. Blue gray enclosures are
available for BCC only.
Tools Required
Description
Torx Driver T10
Phillips Driver
Parts Required
Item
Part Number
Description
Qty
1
50128684-001FRE
FRE, Window, Media
1
2
50131400-001FRE
FRE, Assy, Top Cover, Black (
1
50121857-003FRE
FRE, Assy, Top Cover, White
1
3
50128692-001FRE
FRE, Cover Bottom, Black
1
50128692-002FRE
FRE, Cover Bottom, White
1
4
50130680-001FRE
FRE, Cover Bottom Peel Off, Black
1
50130680-002FRE
FRE, Cover Bottom Peel Off, White
1
5
50130021-001FRE?
Screw, M3 - 1.27X 10L, 100-Pack (torque value 9±0.45kgf/cm)
6
Bottom Enclosure Removal
1. Remove the 4 mounting screws. See Figure 1.
2. Remove the 2 mounting screws on the bottom of the printer. See Figure 2.
3. Remove the bottom enclosure
Figure 2 – Mounting Screws Bottom Enclusure
3
5
OPERATION:
Top/Bottom Cover Assembly
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5
Figure 1 – Mounting Screws

L3-GLBL-RPR-4260 (Rev A)
Top Enclosure Removal
1. Remove the 4 mounting screws. See Figure 1.
2. Remove the two side screws holding the top enclosure onto the top chasis. See Figure 3.
3. Slide the top enclosure away from the chasis bracket. See Figure 2.
Top Enclosure Window Removal
1. Carefully push the window tabs to release the window away from the top enclosure. See Figure 4.
Figure 4 – Window Removal Window
Bottom Cover Peel Off Removal
1. Carefully unlatch the peel off assembly from enclosure.
Figure 5 – Bottom Cover Peel Off Removal
1
Tabs
2
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
Tools Required
Description
Torx Driver T10
Phillips Driver
Parts Required
Item
Part Number
Description
Qty
1
50128695-001FRE
FRE, Bracket, Media, Left, Black
1
50128695-002FRE
FRE, Bracket, Media, Left, Gray
1
2
50128696-001FRE
FRE, Bracket, Media, Right, Black
1
50128696-002FRE
FRE, Bracket, Media, Right, Gray
1
3
50120023-001FRe
FRE, Bush Media Bracket
1
4
50128698-001FRE
FRE, Latch Auto Center
1
5
50128697-001FRE
FRE, Rack Assembly
1
6
50128679-001FRE
FRE, Mylar Auto Center, 20-Pack
Media Guide Assembly
4. Remove the 4 mounting screws. See Figure 1.
5. Remove the 2 mounting screws on the bottom of the printer. See Figure 2.
6. Remove the bottom enclosure
6
5
4
3
2
1
OPERATION:
Media Guide Assembly
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
Carefully pull the latching tabs holding the printhead to the chassis assembly and grounding screw.
Tools Required
Description
Phillips Screw Driver
Parts Required
Item
Part Number
Description
Qty
1
50131325-001FRE
FRE, Assy, TPH Module, PC42d
1
2
50130017-001FRE
FRE, Spring, TPH, 50-Pack
3
50130720-001FRE
FRE, Cable, TPH and Ground
1
Printhead Assembly Removal
1. Remove the printhead by releasing the printhead latches on both side. See Figure 5.
2. Remove the printhead ground screw securing the printhead assembly to chasis ground. See Figure 6.
Figure 5 – Printhead Removal Figure 6 – Printhead Ground Screw
Printhead Assembly Printhead Spring Printhead Cable
Printhead Assembly Installation
1. Install in reverse order
2. Tighten printhead grounding screw to grounding scew to 6±0.3kfg/cm.
3
2
1
OPERATION:
Printhead Assembly
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L3-GLBL-RPR-4260 (Rev A)
Tools Required
Description
Parts Required
Item
Part Number
Description
Qty
1
50131328-001FRE
FRE, Assy, Platen Roller Module, Black
1
50131328-002FRE
FRE, Assy, Platen Roller Module, Gray
1
Platen Roller Removal
1. Carefully lift the platen roller assembly with a soft plastic tool away from the upper chasis assembly. See
Figure 7.
Figure 7– Platen Roller Removal Platen Roller Assembly
1
Location to lift
OPERATION:
Platen Roller Assembly
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
PC42d has 3 different MLBs for BCC printers are sold into Chinese markets only. The differences are with the the
different communication ports supported for each MLB. Each supported communication ports supported by the
MLBs require different bottom enclosure to match the communication ports offered.
Tools Required
Description
Torx Driver
Phillips Driver
Parts Required
Item
Part Number
Description
Qty
1
50128570-024FRE
FRE, BCC, PCBA, MLB, USB Only, PC42d
1
50128570-015FRE
FRE, BCC, PCBA, MLB, USB+RS232, PC42d
1
50128570-004FRE
FRE, BCC, PCBA, MLB, USB+Ethernet, PC42d
1
50128570-034FRE
FRE, BCC, PCBA, MLB, USB+Etherent+RS232, PC42d (not release for usage)
1
2
50130020-001FRE
FRE, SCREW CROSS HEAD WASHER M3*8, 50-PACK (torque 6±0.3kgf.cm)
1
Main Logic Board Assembly Removal
1. Flip printer over and remove the 4 mounting screws. See Figure 1.
2. Remove the bottom Enclosure
3. Remove single mounting screw and disconnect all cables. Note cable locations and routing. See Figure 8.
Figure 8
Sample MLB
1
OPERATION:
Main Logic Board Assembly
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
Page 13 of 25

L3-GLBL-RPR-4260 (Rev A)
CPU
PWR Switch DC Input RS232 Option Ethernet Option
TPH PWR GND UI BM
Motor
TPH Data GAP LSS
Logic
Translator
Stepper
Motor
Driver IC
Flash
SDRAM
MLB Layout
USB Dev
USB Host
LSS
Headlift
Sensor
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(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
Tools Required
Description
Parts Required
Item
Part Number
Description
Qty
1
50131331-001FRE
FRE, Assy, Black Mark Sensor
1
Black Mark Sensor Removal
1. Remove top and bottom enclosure. Refer to Top/Bottom Enclosure Assembly Section
2. Disconnect black mark sensor cable from MLB. See Figure 9.
3. Push the latching tab and slide the black mark sensor assembly toward the right of the chasis
4. Pull the black mark sensor assembly through the opening. See Figure 10.
Figure 9 – Black Mark Sensor Connector
Figure 11 – Black Mark Sensor Assembly Removal Black Mark Sensor Assembly
1
Opening
Slide
Direction
Latching
Tab
OPERATION:
Black Mark Sensor Assembly
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
It is recommended that the Mylar be replaced when replacing gap sensor assembly
Tools Required
Description
Phillips Driver
Parts Required
Item
Part Number
Description
Qty
1
50129058-004FRE
FRE, PCBA, Gap Sensor Board
1
2
50121888-001FRE
FRE, Plastite Screw, 100-Pack ( torgue value 2±0.1kgf/cm)
1
Gap Sensor Assembly Removal
1. Remove top and bottom enclosure. Refer to Top/Bottom Enclosure Assembly Section
2. Disconnect black mark sensor cable from MLB. See Figure 11.
3. Remove the sensor mounting screw. See Figure 12.
Figure 11 – Gap Sensor Assembly Connector
Figure 12 Gap Sensor
1
Removing
sensor
assembly
OPERATION:
Gap Sensor Assembly
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
Tools Required
Description
Parts Required
Item
Part Number
Description
Qty
1
TBA
FRE, Headlift Switch
1
Head Lift Sensor Assembly Removal
1. Flip printer over and remove the 4 mounting screws. See Figure 1.
2. Disconnect head lift sensory assembly cable from the MLB. See Figure 14.
Figure 14 – Head Lift Sensor Assembly Connector
Head Lift Sensor Assembly
1
OPERATION:
Head Lift Sensor Assembly
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
Page 17 of 25

L3-GLBL-RPR-4260 (Rev A)
Tools Required
Description
Torx Driver
Phillips Driver
Parts Required
Item
Part Number
Description
Qty
1
50129058-024FRE
FRE, PCBA, UI Board
1
User Interface PCBA Assembly Removal
1. Flip printer over and remove the 4 mounting screws. See Figure 1.
2. Disconnect user interface cable from the MLB. See Figure 17.
3. Remove the 4 screws securing the chassis assembly
Figure 17 – User Interface PCBA Connector
UI Board
1
OPERATION:
User Interface
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
Page 18 of 25

L3-GLBL-RPR-4260 (Rev A)
Tools Required
Description
Torx Driver
Phillips Driver
Parts Required
Item
Part Number
Description
Qty
1
50130724-001FRE
FRE, Stepper Motor, PC42d
1
2
50110527-001FRE?
FRE, Screw, M3 - 1.27X 10L, 100-Pack (torque value 9±0.45kgf/cm)
?
Stepper Motor Assembly Removal
1. Flip printer over and remove the 4 mounting screws. See Figure 1.
2. Disconnect stepper motor assembly cable from the MLB. See Figure 18.
3. Remove stepper motor assembly mounting screws. See Figure 19.
Figure 18 – Stepper Motor Assembly Connector
Figure 19 – Stepper Motor Assembly Mounting Screws Stepper Motor Assembly
1
OPERATION:
Stepper Motor Assembly
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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L3-GLBL-RPR-4260 (Rev A)
Tools Required
Description
Torx Driver
Phillips Driver
Parts Required
Item
Part Number
Description
Qty
1
50128675-001FRE
FRE, Gear 72-20
1
2
50128676-001FRE
FRE, Gear 30
1
3
50121884-001FRE?
Flange Plastite Screw 3x10, 100-Pack (torque value 9±0.45kgf/cm)
?
Drive Gears Removal
1. Remove bottom cover assembly. See Top/Bottom Cover Assembly Section.
2. Remove the screw securing the drive gears. See Figure 20.
Figure 20 – Drive Gears Removal Drive Gears
2
1
OPERATION:
Drive Gears
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PC42d Service Repair Manual PC42d L3-GLBL-RPR-4260
(Rev A)
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