Intermec EasyCoder PD4 User manual

Service Manual
EasyCoder PD4
Bar Code Label
Printer

Intermec Technologies Corporation
Corporate Headquarters
6001 36th Ave. W.
Everett, WA 98203
U.S.A.
www.intermec.com
The information contained herein is proprietary and is provided solely for the purpose of allowing
customers to operate and service Intermec-manufactured equipment and is not to be released, repro-
duced, or used for any other purpose without written permission of Intermec.
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.
© 2004by Intermec Technologies Corporation. All rights reserved.
The word Intermec, the Intermec logo, Norand, ArciTech, CrossBar, Data Collection Browser,
dcBrowser, Duratherm, EasyCoder, EasyLAN, Enterprise Wireless LAN, EZBuilder, Fingerprint,
i-gistics, INCA (under license), InterDriver, Intermec Printer Network Manager, IRL, JANUS,
LabelShop, Mobile Framework, MobileLAN, Nor*Ware, Pen*Key, Precision Print, PrintSet, Route-
Power, TE 2000, Trakker Antares, UAP, Universal Access Point, and Virtual Wedge are either trade-
marks or registered trademarks of Intermec Technologies Corporation.
Throughout this manual, trademarked names may be used. Rather than put a trademark (™ or ®)
symbol in every occurrence of a trademarked name, we state that we are using the names only in an
editorial fashion, and to the benefit of the trademark owner, with no intention of infringement.
There are U.S. and foreign patents pending.
The name Centronics is wholly owned by GENICOM Corporation.
Windows is a trademark of Microsoft Corporation.

Intermec EasyCoder PD4—Service Manual iii
FCC Notice (United States of America)
WARNING
This equipment generates, uses, and can radiate radio frequency energy and if not installed and used
in accordance with the instructions manual, may cause interference to radio communications. It has
been tested and found to comply with the limits for a Class A computing device pursuant to Subpart
J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such inter-
ference when operated in a commercial environment. Operation of this equipment in a residential
area is likely to cause interference in which case the user at his own expense will be required to take
whatever measures may be required to correct the interference.
EMS and EMI Compliance Statement
This equipment has been tested and passed with the requirements relating to electromagnetic com-
patibility based on the standards EN50081-1 (EN55022 CLASS A) and EN61000-4-2/-3/-4/-5/-
6/-8/-11 (IEC Teil 2,3,4). The equipment also tested and passed in accordance with the European
Standard EN55022 for the both Radiated and Conducted emissions limits.

iv Intermec EasyCoder PD4—Service Manual

Intermec EasyCoder PD4—Service Manual v
Contents
Contents
Before You Begin.................................................................................................................vii
Safety Summary................................................................................................. vii
Safety Icons ......................................................................................................viii
Global Services and Support ................................................................................................ ix
Warranty Information.........................................................................................ix
Web Support ......................................................................................................ix
Telephone Support .............................................................................................ix
Related Documents..............................................................................................................ix
About this Manual................................................................................................................x
1 Models and Options
1.1 Models........................................................................................................................2
1.2 Options......................................................................................................................3
1.3 Technical Specifications..............................................................................................5
2 Front Panels
2.1 Front Panel (no display)........... ..................................................................................8
2.2 Front Panel (with display) .........................................................................................9
2.3 Replacing the Front Panel ........................................................................................10
2.4 Bottom Right-Hand Panel .......................................................................................11
2.4 Console pcb. ............................................................................................................12
3 Side Panels
3.1 Right-Hand Door ....................................................................................................16
3.2 Left-Hand Panel.......................................................................................................17
4 Chassis
4.1 Chassis......................................................................................................................20
4.2 Rear Plate.................................................................................................................21
5 Media Supply
5.1 Media Supply Post ...................................................................................................24
6 Transfer Ribbon Mechanism
6.1 Ribbon Module........................................................................................................28
6.2 Ribbon Module Belt ................................................................................................29
6.3 Ribbon Supply and Rewind Units............................................................................30
6.4 Ribbon Out Sensor ..................................................................................................31
6.5 Ink Position Knob....................................................................................................32
7 Print Mechanism
7.1 Print Unit ................................................................................................................34
7.2 Motor, Pulleys, and Belts..........................................................................................35
7.3 Platen Module..........................................................................................................37
7.4 Media Guides...........................................................................................................38
7.5 Label Gap Sensor Module ........................................................................................39

vi Intermec EasyCoder PD4—Service Manual
Contents
7.6 Headlift Sensor ........................................................................................................41
7.7 Printhead Module ....................................................................................................42
8 Rewinder Module
8.1 Rewinder Module ....................................................................................................50
9 Strip Module
9.1 Strip Module............................................................................................................54
10 Cutter
10.1 Cutter.......................................................................................................................58
11 Switching Power Module
11.1 Switching Power Module..........................................................................................64
12 Main Board
12.1 Description...............................................................................................................68
12.2 Replacement ............................................................................................................69
12.3 Connections.............................................................................................................70
12.4 Components ............................................................................................................73
12.5 Test Points................................................................................................................74
12.6 Schematics ...............................................................................................................75
12.7 Memory Expansion Card .........................................................................................83
13 Interfaces
13.1 RS-232 Serial Interface.............................................................................................86
13.2 USB Serial Interface .................................................................................................87
13.3 Centronics Parallel Interface.....................................................................................88
14 Troubleshooting
14.1 Error Handling .......................................................................................................90
14.2 Troubleshooting Check List .................................................................................... 91
14.3 No Reaction at Power Up........................................................................................93
14.4 Error During Printing .............................................................................................95
14.5 No Printing............................................................................................................. 96
14.6 Printing Partly Missing along the Feed Direction .................................................... 97
14.7 Printout not in Desired Position..............................................................................98
A Firmware Upgrading
Requirements.....................................................................................................................102
Instructions.......................................................................................................................102

Before You Begin
Intermec EasyCoder PD4—Service Manual vii
Before You Begin
This section provides you with safety information, technical support infor-
mation, and sources for additional product information.
Safety Summary
Your safety is extremely important. Read and follow all warnings and cau-
tions 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 circum-
stances. 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 breath-
ing. 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 autho-
rized emergency work on energized equipment, be sure that you comply
strictly with approved safety regulations.

Before You Begin
viii Intermec EasyCoder PD4—Service Manual
Safety Icons
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.
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.
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.
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 guide-
lines to avoid damaging the equipment you are servicing.
Note: Notes either provide extra information about a topic or contain spe-
cial instructions for handling a particular condition or set of circumstances.

Before You Begin
Intermec EasyCoder PD4—Service Manual ix
Global Services and Support
Warranty Information
To understand the warranty for your Intermec product, visit the Intermec
web site at http://www.intermec.com and click Service & Support. The
Intermec Global Sales & Service page appears. From the Service & Support
menu, move your pointer over Support, and then click Warranty.
Web Support
Visit the Intermec web site at http://www.intermec.com to download
our current documents in PDF format. To order printed versions of the
Intermec manuals, contact your local Intermec representative or distribu-
tor.
Visit the Intermec technical knowledge base (Knowledge Central) at
http://intermec.custhelp.com to review technical information or to request
technical support for your Intermec product.
Telephone Support
Contact your local Intermec representative. To search for your local repre-
sentative, from the Intermec web site, click Contact.
Related Documents
This table contains a list of related Intermec documents and their part
numbers.
Document Title Part Number
EasyCoder PD4 User´s Guide 1-960614-00
Intermec ESim v5.00 Programmer´s Reference Manual 1-960615-00
EasyCoder PD4 Spare Parts Catalog 1-960617-00
The Intermec web site at http://www.intermec.com contains our current
documents that you can download in PDF format. To order printed ver-
sions of the Intermec manuals, contact your local Intermec representative
or distributor.

Before You Begin
x Intermec EasyCoder PD4—Service Manual
About This Manual
This Service Manual is intended to facilitate installation, troubleshooting
and repair of the Intermec EasyCoder PD4 printers in the versions deliv-
ered at the date of publishing. Thus, all information on the Intermec ESim
firmware is based on version 5.00. The on-going product improvement can
be followed in the Printer Technical Bulletins from Intermec.
Please note that the operations described in this manual only should be car-
ried out by skilled and authorized personnel with proper training and full
understanding of written English. The printers contain wires and circuits
with high voltage, which implies the risk of electrical shock. Moving parts
may also cause harm, if incorrectly manipulated.
It is assumed that the reader possesses reasonable skills in mechanics and
electronics and is familiar with the Intermec ESim protocol. It is also
assumed that the reader has access to the standard tools of an electronics
workshop.
All screws are Phillips type (PH1 or PH2).

Intermec EasyCoder PD4—Service Manual 1
1 Models and Options
This chapter describes the various models of the EasyCoder PD4 printer
family, describes the option, and provides technical specifications.

2 Intermec EasyCoder PD4—Service Manual
Chapter 1—Models and Options
1.1 Models
The EasyCoder PD4 comes in three main models:
• Printer without display and 200 dpi printhead density
• Printer with display and 200 dpi printhead density
• Printer with display and 300 dpi printhead density
EasyCoder PD4 without display (200 dpi)
EasyCoder PD4 with display (200 or 300 dpi)

Intermec EasyCoder PD4—Service Manual 3
Chapter 1—Models and Options
1.2 Options
The options for the EasyCoder PD4 depend on the printer model:
• External Keyboard/Display Unit (all models)
• EasyLAN 10 External Ethernet Adapter (all models)
• Memory Expansion Board 2MB (display models only)
• Cutter (display models only)
• Rewinder (display models only)
Keyboard/Display Unit
2MB Memory Expansion Card

4 Intermec EasyCoder PD4—Service Manual
Chapter 1—Models and Options
EasyCoder PD4 with cutter
EasyCoder PD4 with rewinder
(right-hand door not shown)

Intermec EasyCoder PD4—Service Manual 5
Chapter 1—Models and Options
1.3 Technical Specifications
Printing
Print Technique Direct Thermal/Thermal Transfer
Printhead Resolutions 8 dots/mm (203.2 dpi) or
11.81 dots/mm (300 dpi)1
Print Speed (variable) 50.8 to 152.4 mm/sec. (2 to 6 in/sec.)
50.8 to 101.6 mm/sec. (2 to 4 in/sec.)
8 dots/mm (203.2 dpi)
11.81 dots/mm (300 dpi)
Print Width 25 to 104 mm (1 to 4.09 in)
25 to 106 mm (1 to 4.17 in) 8 dots/mm 11.81 dots/mm
Print Length (max) 1,270 mm (50 in)
558.8 mm (22 in)
8 dots/mm (203.2 dpi)
11.81 dots/mm (300 dpi)
Print Directions 4
Media
Media Width 25 to 118.0 mm (1 to 4.65 inches)
Media Roll Diameter (max) 212 mm (8.35 inches)
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
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 (1,471 ft) of
ribbon at ribbon thickness 8 µm
Inner Core Diameter 25.2 to 25.6 mm (1.00 inches)
Modes of Operation
Tear-Off (Straight-through) Yes
Peel-Off (Self-strip) Optional
Cut-Off Optional
Firmware
Operating System ESim v5.xx
Latin Fonts 5 resident alphanumeric fonts.
Windows bitmap fonts can be down-
loaded.
Asian Fonts Asian fonts can be downloaded:
GB 2312-80
Chinese Big5 level 1 & 2
KS X 11001:1992
JIS X0208:12977
Chinese
Chinese
Korean
Japanese
Built-in bar code symbologies (stan-
dard)
34
Physical Measures
Dimensions (W ×L ×H) 276 ×454.6 ×283.0 mm
(10.85 ×17.9 ×11.2 in)

6 Intermec EasyCoder PD4—Service Manual
Chapter 1—Models and Options
Weight (excluding media and options) ≈13 kg (28.7 pounds)
Environment
Operating Temperature +5°C to +40°C (+41°F to +104°F)
Storage Temperature -20°C to +50°C (-40°F to +122°F)
Operating Humidity 30 to 85% non-condensing. Free air
Storage Humidity 10 to 90% non-condensing. Free air
Electronics
Microprocessor 16 bit
Standard Memory 2MB flash + 2MB DRAM
Real-time Clock Yes1Date/time stamp
Power Supply
AC Voltage 100/240 VAC, 50 to 60 Hz
Power Consumption (approx.) Stand-by 5W; Peak 140W
Sensors
Label Gap/Black Mark/Out of Media Yes Moveable, left-aligned
Printhead Lifted Yes
Ribbon End Yes
Label taken Yes1
Controls
Control Lamps 3; Power, Ready, and Error Bi-color
Display Yes1Graphic LCD with background light
Control Keys 3; Feed, Pause, and Cancel
Beeper Yes
Data Interfaces
Serial 1 x RS-232 + 1 x USB
Parallel Yes
Accessories and Options
Integral Self-strip Unit with Liner
Takeup
Option1For peel-off operation
Cutter Option1
2MB Flash Memory Expansion Card Option1
Keyboard/Display Unit Option
EasyLAN 10 External Ethernet
Adapter
Option
1/. Models with graphic display front panel only.

Intermec EasyCoder PD4—Service Manual 7
2 Front Panels
This chapter describes the front panels for various models of the Easy-
Coder PD4 printer family.

8 Intermec EasyCoder PD4—Service Manual
Chapter 2—Front Panels
2.1 Front Panel (no display)
Description
The displayless model of the EasyCoder PD4 has a front panel moulding
with three colored LED control lamps and three control keys.
The control lamp LEDs are fitted on a console pcb which also contains the
switches for the control keys and a buzzer. An overlay provides the desig-
nations for the LEDs and keys. The overlay is covered with a transparent
plastic window. The console pcb is connected to CN22 on the main board
via a separate flat cable.
Refer to Chapter 2.3 for replacement instructions.
Flat cable
Console pcb
Dummy strip sensor
E-ring
Screw and washer (x4)
Front panel moulding
Label
Overlay
Clear window
LEDs (green-green-red)
Control keys
(Feed-Pause-Cancel)

PUSH
LCD display
Intermec EasyCoder PD4—Service Manual 9
Chapter 2—Front Panels
2.2 Front Panel (with display)
Description
The display-equipped models of the EasyCoder PD4 have a front panel
moulding with three colored LED control lamps, three control keys, and a
large graphic LCD display.
The control lamp LEDs are fitted on a console pcb which also contains
the LCD display, the switches for the control keys and a buzzer. An overlay
provides the designations for the LEDs and keys. The overlay is covered
with a transparent plastic window. The console pcb is connected to CN22
on the main board via a separate flat cable.
Refer to Chapter 2.3 for replacement instructions.
As opposed to the displayless model, there is a working strip sensor, that
can detect whether labels have been removed from the outfeed slot or not.
The strip sensor is further described in Chapter 9.
Flat cable
Console pcb
Strip sensor housing
E-ring
Screw and washer (x4)
Front panel moulding
Label
Overlay
Clear window
LEDs (green-green-red)
Control keys
(Feed-Pause-Cancel)
Strip sensor pcb
(cable not shown)
Screw (x2)
Dust protection

10 Intermec EasyCoder PD4—Service Manual
Chapter 2—Front Panels
2.3 Replacing the Front Panel
To replace the front panel, follow these steps:
1Remove the left side panel (see Chapter 3.2).
The electronics compartment contains high voltages wires and circuitry.
Disconnect the power cord to eliminate the risk of electric shock and
short circuits.
Take standard precautions against ESD (Electrostatic Discharges)
before touching any electronics components.
2Disconnect the flat cable from the main board.
3From inside the electronics compartment, remove the two screws that
hold the front panel assembly at the top front of the center section.
4Lift the front panel assembly up/out so the panel moulding disengages
the two keyholes in the center section.
5In case of a EasyCoder PD4 with display, disconnect the strip module
cable from CN12 on the main board and remove it from the clips, ties,
and plastic spiral binding.
6Disconnect the flat cable from the console pcb.
7If necessary, replace the entire assembly. Individual items, except the
strip sensor assembly, are not available as spare parts.
8Install the front panel in reverse order.