Printronix T4204 User manual

Maintenance Manual
®
T4204 Label Printer

750513-001B
Maintenance Manual
T4204 Label Printer
®

Communication Notices
Communication Notices
Federal Communications Commission (FCC) Statement: This equipment
has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provided 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.
Properly shielded and grounded cables and connectors must be used in order
to meet FCC emission limits. Printronix is not responsible for any radio or
television interference caused by using other than recommended cables and
connectors or by any unauthorized changes or modifications to this
equipment. Unauthorized changes or modifications could void the user’s
authority to operate the equipment.
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, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
Canadian Department of Communications Compliance Statement: This
Class A digital apparatus complies with Canadian ICES-003.
Avis de conformite aux normes du ministere des Communcations du
Canada: Cet appareil numerique de la classe A est conform á norme NMB-
003 du Canada.
European Community (EC) Conformity Statement:
This product is in conformity with the protection requirements of EC Council
Directive 89/336/EEC on the approximation of the laws of the Member States
relating to electromagnetic compatibility. Printronix cannot accept
responsibility for any failure to satisfy the protection requirements resulting
from a non-recommended modification of the product, including the fitting of
non-Printronix option cards.
German Conformity Statement:
Zulassungsbescheinigung Gesetz über die elektromagnetische
Verträglichkeit von Geraten (EMVG) vom 30. August 1995
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen das EG-
Konformitätszelchen - CE - zu führen.
Der Außteller der Konformitätserklärung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gerät erfüllt die Schutzanforderungen nach EN 50082-1 und
EN 55022 Klasse A.

Communication Notices
EN 55022 Klasse A Geräte bedürfen folgender Hinweise:
Nach dem EMVG: “Geräte dürfen an Orten, für die sie nicht asreichend
entstört sind, nur mit besonderer Genehmigung des Bundesminesters für
Post und Telekommunikation oder des Bundesamtes für Post und
Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn
keine elektromagnetischen Störungen zu erwarten sind.” (Auszug aus dem
EMVG, Paragraph 3, Abs. 4) Dieses Genehmigungsverfahren ist nach
Paragraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung
(Amtsblatt 14/93) kostenpflichtig.
Nach der EN 55022: “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 und dafür aufzkommen.”
Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte,
wie in den Handbüchern angegeben, zu installieren und zu betreiben.
This product has been tested and found to comply with the limits for Class A
Information Technology Equipment according to European Standard EN
55022. The limits for Class A equipment were derived for commercial and
industrial environments to provide reasonable protection against interference
with licensed communication equipment.
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.
Warning

Warranty Information
Warranty Information
Printer Warranty
Printronix warrants to purchaser that under normal use and service, this
printer (excluding the thermal printhead) purchased hereunder shall be free
from defects in material and workmanship for a period of ninety (90) days
from the date of shipment from Printronix.
Consumable items such as media and ribbons are not covered under this
warranty. This warranty does not cover equipment or parts that have been
misused, altered, or used for purposes other than those for which they were
manufactured. This warranty also does not cover loss, shipping damage,
damage resulting from accident or damages resulting from unauthorized
service.
Thermal Printhead
Printronix warrants the printhead for a period of ninety (90) days, or 1,000,000
linear inches (Thermal Transfer/Direct Thermal) of use, whichever comes
first. The warranty does not cover printheads that have been misused,
damaged due to improper cleaning, or damaged due to use of improper
ribbons or media.
Supplies
For the number of the nearest Printronix full-service distributor that carries
Printronix genuine supplies, please call 1-800-733-1900 or fax
1-714-368-2354. Supplies design, specification, and selection are critical and
integral to the development of any computer imaging system. Printronix’s
extensive manufacturing and research capabilities and its years of experience
in the design of printers and their applications assure that the customer will
receive the materials necessary to maximize the performance of a Printronix
printer. Obtain further information by calling the Printronix ThermaLine Help
Desk at [phone] or from the Printronix Web Page at
www.printronix.com.

Trademark Acknowledgements
On-site Maintenance Service
Printronix offers on-site support services in the United States. Please contact
the Printronix Maintenance Contracts Group at [phone], for service
agreement information.
Trademark Acknowledgements
ANSI is a registered trademark of American National Standards Institute, Inc.
Centronics is a registered trademark of Genicom Corporation
Code V is a trademark of QMS, Inc.
CSA is a registered certification mark of the Canadian Standards Association.
EIA is a registered service mark of the Electronic Industries Association.
Ethernet is a trademark of Xerox Corporation.
HP is a registered trademark of Hewlett-Packard Company.
IBM is a registered trademark of International Business Machines Corp.
IEEE is a registered service mark of the Institute of Electrical and Electronic
Engineers, Inc.
Loctite is a registered trademark of Loctite Corporation.
MS-DOS and Windows are registered trademarks of Microsoft Corporation.
Mylar and Tyvek are registered trademarks of E.I. DuPont De Nemours and
Company.
PC-DOS is a trademark of International Business Machines Corp.
PCL is a registered trademark of Hewlett-Packard Company.
PKZIP is a registered trademark of PKWARE, Inc.
Printronix, IGP, IGP/Auto Label Mapping, LinePrinter Plus, and PGL are
registered trademarks of Printronix, Inc.
PrintNet and ThermaLine are trademarks of Printronix.
QMS is a registered trademark of Quality Micro Systems, Inc.
UL is a registered certification mark of Underwriters Laboratories, Inc.
Valeron is registered trademark of Van Leer’s Vatenfabriken N.V.
COPYRIGHT November 2000, Printronix, Inc. All rights reserved.

Trademark Acknowledgements

Table of Contents
1 Maintenance Overview...................................... 13
About This Manual...............................................................................13
Replacing Parts.............................................................................13
Ordering Parts...............................................................................13
Printronix ThermaLine Help Desk ................................................. 14
Notes And Notices ........................................................................ 14
Related Manuals And Packaging Components.............................15
About The Printer................................................................................. 15
Thermal Printer Technology..........................................................15
Thermal Printer Media...................................................................16
Ribbons.........................................................................................17
Emulations And Languages .......................................................... 17
Fonts And Bar Codes .......................................................................... 17
Controls And Indicators ....................................................................... 18
The POWER Switch And Indicator................................................ 19
Powering On The Printer...............................................................19
Operating Modes........................................................................... 20
Primary Control Panel Keys..........................................................20
Secondary Control Panel Keys .....................................................20
2 Preventive Maintenance..................................... 23
Cleaning The Printer............................................................................ 23
Clean The Outside Surfaces......................................................... 23
Clean The Thermal Printhead....................................................... 24
Printer Inspection................................................................................. 25
Inspect Drive Belts ........................................................................ 25
Inspect Cables And Cords ............................................................ 25
3 Diagnostics and Troubleshooting....................... 27
Introduction.......................................................................................... 27
A Word About Print Quality ...........................................................27
How To Troubleshoot .......................................................................... 28
Printer Self-Test And Verifying Printer Operation.......................... 28
Troubleshooting Display Messages..................................................... 29
How To Clear LCD Messages....................................................... 29
Troubleshooting Other Symptoms....................................................... 38

Table of Contents
Communications Failures.................................................................... 43
Ribbon Wrinkle Adjustment ................................................................. 45
4 Replacing Printer Components...........................49
Removal Procedures ........................................................................... 49
Required Tools.............................................................................. 49
Torque Requirements ................................................................... 50
List Of Removal And Replacement Procedures............................50
Top Cover Assembly..................................................................... 52
Printhead....................................................................................... 54
Power Supply................................................................................ 56
Converting Power Supply Voltage ................................................ 58
Power Supply Fuse....................................................................... 60
AC Power Switch .......................................................................... 61
Controller PCBA............................................................................ 62
Label Guide And Sensor Assembly .............................................. 64
Control Panel Assembly................................................................ 66
Front Door Assembly .................................................................... 68
Motor Assembly ............................................................................ 70
Printhead Data/Power Cable Assembly........................................ 72
Flash SIMM And DRAM SIMM...................................................... 74
Ribbon Drive Belt (324 Tooth)....................................................... 76
Platen Drive Belt (120 Tooth)........................................................ 78
Platen............................................................................................80
Platen Bearing, Flanged................................................................ 82
Clutch Pulley ................................................................................. 82
Label Rewind Pulley...................................................................... 84
Ribbon Take-Up Pulley ................................................................. 86
Printhead Carriage Assembly ....................................................... 88
Label And Ribbon Tube Assemblies............................................. 90
Shaft Support Housings ................................................................ 92
Media Support Assembly .............................................................. 93
Checking And Adjusting Cable Clearances .................................. 94
Sensor And Printhead Data/Power Cable Clamp ......................... 96
Terminating Resistors ................................................................... 98
5 Illustrated Parts Breakdown................................99
Organization Of This Chapter.............................................................. 99
Illustrated Parts Breakdown................................................................. 99
A Specifications ................................................... 117
Printer Specifications......................................................................... 117
Printing Specifications ....................................................................... 119

Table of Contents
B Printer Supplies................................................ 121
Printronix Supplies Work Best ........................................................... 121
Supplies............................................................................................. 121
Genuine Printronix Thermal Transfer Ribbons............................ 121
Genuine Printronix Media............................................................ 122
C ASCII Codes.................................................... 125
D Downloading Software..................................... 129
Flash Memory.................................................................................... 129
Loading Flash Memory...................................................................... 129

Table of Contents

13
1Maintenance Overview
About This Manual
This field service maintenance manual is designed so that you can locate
maintenance information quickly in the Table of Contents or Index.
Replacing Parts
1. Go to Chapter 4, page 49.
2. Find the removal procedure for the part.
3. Read the entire procedure before you do it, and make sure you
understand all notes and notices (defined on page 14).
4. Gather the tools you will need.
5. Do the procedure.
Ordering Parts
Go to the Illustrated Parts Breakdown, page 99, which contains drawings of
all printer assemblies. Opposite each illustration is a list of the illustrated parts
and their part numbers. When locating parts, note the following:
•You can order any part that has a part number. Part numbers are not
listed for common fasteners. Parts marked “Ref” (reference) are not
spared or are part of another assembly.
•In illustrations, an arrow and small locator letter refer you to a magnified
detail shown by the larger letter:
$
$
This points to an area . .
.that is magnified here (on
the same or a subsequent
page).

14
Chapter 1 About This Manual
•Assemblies that can be ordered as kits are shown in the following
notation:
Printronix ThermaLine Help Desk
The PrintronixThermaLineHelp Desk offers technical support in many
areas of printer operation:
•Installation
•Configuration and Setup
•Operation and Supplies Loading
•Specifying the proper media and ribbon
•Post sales service support questions
Call the Printronix ThermaLine Help Desk at [phone] or visit the
Printronix Web Page at http://www.printronix.com.
Notes And Notices
For your safety and to protect valuable equipment, it is very important that you
read and comply with all information highlighted under special headings:
WARNING Conditions that could harm you as well as damage the equipment.
CAUTION Conditions that could damage the printer or related equipment.
IMPORTANT Information vital to proper operation of the printer.
NOTE: Information and helpful tips about printer operation.
Printing Conventions In This Manual
Keys and key settings or positions are printed in UPPERCASE type.
Messages displayed on the LCD (liquid-crystal display) are shown in the
following format:
90
85
80
87
OFFLINE
PRINTER CONTROL

Related Manuals And Packaging Components
15
Related Manuals And Packaging Components
This manual does not explain how to install, operate, or configure the printer.
This manual does not explain how to program application software for
operation with the printer. For operational and programming information,
consult the appropriate reference manual:
About The Printer
The T4204 is a low cost, direct thermal and thermal transfer printer designed
to print labels and tags with or without bar codes from any MS-DOS®,
Windows®, or ASCII-based computer. The printer includes the following
features:
•High speed thermal transfer and direct thermal printing
•Supports more than 20 bar code symbologies
•Download forms, fonts, and graphics to printer memory
•A high resolution printhead for sharp graphics and text
•Built-in label rewinder for batch processing or label peel-off operation
Printronix Dynamic Print Control provides exceptional print quality. For
maximum performance, a circuit monitors the data to be printed and
automatically adjusts the energy applied to the thermal printhead.
The printer communicates with the host computer via RS-232 and RS-422
serial, Centronics®-compatible parallel, or optional coax/twinax host interface
connections. The interface cable needed to connect the printer to the host
device is supplied by the user.
Thermal Printer Technology
Unlike a dot matrix printer or a laser printer, a thermal printer uses a printhead
containing heating elements and special paper or a ribbon designed to be
used with the printhead. The T4204 printer uses an inline thermal printhead,
which produces high resolution output quickly and quietly.
Description Part Number
T4204 User’s Manual 750514-001
T4204 Quick Reference Manual 171278-001
LP+ Programmer’s Reference Manual 750515-001
IGP/PGL Programmer’s Reference Manual 750516-001
IGP/VGL Programmer’s Reference Manual 750557-001
T4204 PrintNet User’s Manual 750517-001
Coax/Twinax Programmer’s Reference Manual 164300-001
Printer Shipaway Kit (Packing) 136696-033

16
Chapter 1 About The Printer
The Printing Process
The thermal printhead allows two modes of operation:
•Direct Thermal Mode—The thermal printhead selectively heats small,
rectangular
dots. When the heated dots contact specially coated thermal
paper, the dyes and developers in the coating react to the heat and
develop an image. This mode of printing is often used for short-term
labeling applications.
•Thermal Transfer Mode—The heated dots contact a thermal ribbon; the
heat reacts with the ribbon and bonds the image to the paper. This
method is used especially for abrasive, long-storage applications and for
specialized applications, such as in extreme environmental conditions or
where tamper-proofing is required.
Dynamic Print Control
Print quality in thermal printers depends on how well the thermal ribbon and
thermal transfer paper respond to the heat of the thermal printhead. The
thermal printhead must reach a set temperature to print, then cool down in the
shortest possible time after printing. Print quality is therefore dependent on
precise control of the energy supplied to the thermal dots. If uneven print
density occurs, it is usually caused by the stored heat from previous dots.
The T4204 printer uses Dynamic Print Control technology to ensure even
print density. Dynamic Print Control is printer software that tracks and adjusts
printhead temperatures. Based on stored results of previously printed dots,
the printer predicts the amount of heat required to print subsequent dots and
regulates the electrical energy applied to the printhead. This prevents uneven
print density and permits the printing of narrow-ladder bar codes and vertical
grid lines that are absolutely straight.
Thermal Printer Media
Because there are two modes of operation, there are two kinds of thermal
printer paper:
•Direct thermal paper—paper coated with chemicals which act as
accelerators, acceptor dyes, and ink binders. In direct thermal mode, the
heat from the thermal printhead contacts the paper and causes a
chemical reaction to take place.
•Thermal transfer paper—films or synthetic paper substitutes that
transfer images well and other papers designed to resist scratching. Most
of these papers can be die-cut for easy label applications. Printronix
offers a wide selection of thermal transfer paper sizes and face stocks,
which ensures high print quality and long life when used with Printronix
ribbons.

Ribbons
17
Ribbons
Printronix Genuine Thermal Ribbons work best in the printer. These ribbons
are engineered to enhance thermal printing capabilities and to prevent
premature wear of the printhead.
Emulations And Languages
The printer comes with the Printronix LP+ and IGP®/VGL emulations and the
Printronix IGP/PGL® programming language.
The Printronix LP+ emulation provides complete compatibility with Printronix
P-Series and P5000 series printers.
The IGP/VGL emulation and Printronix IGP/PGL language are graphics
languages which simplify the job of creating forms, logos, expanded
characters and other graphic images.
Fonts And Bar Codes
The printer supports all popular bar codes and a selection of OCR-A and
OCR-B fonts, in both portrait and landscape orientations. Additional fonts can
be loaded from the host computer into printer memory. Once loaded, these
fonts are accessed in the same way as the resident fonts.
Labels can be designed and printed using the Printronix LP+ emulation, the
Printronix IGP/PGL graphics language, or IGP/VGL graphics language.

18
Chapter 1 Controls And Indicators
Controls And Indicators
Except for the power switch, printer controls and indicators are located on the
front panel of the printer, on either the Primary Control Panel or the
Secondary Control Panel. (See Figure 1.)
Legend:
1) Primary Control Panel
2) Secondary Control Panel
3) PAUSE Key
4) FEED Key
5) CANCEL Key
6) TEST Key
7) ONLINE Status Indicator
8) Directional “Arrow” Keys (Four)
9) CLEAR Key
10) PRT CONFIG Key
11) JOB SELECT Key
12) ENTER Key
Figure 1. Controls and Indicators
The Primary Control Panel is located on the front panel at the upper left
corner of the printer. This control panel has an LCD (Liquid-Crystal Display),
an ONLINE status indicator, and PAUSE, FEED, CANCEL, and TEST keys.
The Secondary Control Panel is below the Primary Control Panel behind the
front door assembly. It consists of UP, DOWN, PREV, and NEXT arrow keys,
used to navigate through the printer configuration menus, and CLEAR, PRT
CONFIG, JOB SELECT, and ENTER keys, used to perform specific functions
within the printer configuration menus.
3
4
5
6
7
9
10
11
12
1
28
$
$

The POWER Switch And Indicator
19
The POWER Switch And Indicator
The power switch is on the rear panel of the printer, in the bottom left corner
just above the connector for the AC power cord. (See Figure 2.) A back-lit
LCD or any message on the LCD panel indicates that printer power is ON.
Legend:
1) Power OFF position
2) Power ON position
Figure 2. Printer Power Switch
Powering On The Printer
When you power on the printer, it automatically executes a self-test. The
default power-up state is online. When the printer has successfully initialized,
the ONLINE status indicator light will go on, and the LCD indicates the
communication interface selected and the type of emulation installed. The
interface is indicated by PARL for parallel and SERL for serial.
If there is a fault during the self-test, the ONLINE status indicator flashes, and
a fault message appears on the display. The alarm may also sound, if it was
configured to do so.
1
2
$
$

20
Chapter 1 Controls And Indicators
Operating Modes
Online - In online mode, the printer can receive and print data sent from the
host. Pressing the PAUSE key toggles the printer between the online and
offline mode. The ONLINE status indicator is lit in online mode.
Offline - In offline mode, you may perform operator functions, such as loading
media, or navigating through the printer configuration menu to make changes
or verify option settings. Pressing the PAUSE key toggles the printer from
offline to online mode. The ONLINE status indicator is not illuminated in offline
mode.
Fault - In fault mode, a fault condition exists that must be cleared before
printing can continue. The ONLINE status indicator flashes, the alarm beeps,
if configured to do so, and a descriptive fault message displays.
The current operating mode can be selected through the control panel keys,
or may result from routine operations such as powering on the printer.
Primary Control Panel Keys
For the location of these keys, see Figure 1 on page 18.
PAUSE - Toggles the printer between online and offline modes.
FEED - Advances the media one forms length (active in online or offline
modes).
CANCEL - Cancels all data in the printer (active in online or offline modes).
TEST - Selects the self-test menu (offline mode only). Pressing the ENTER
key when a Diagnostic Test is displayed starts a test. Pressing the ENTER
key again stops the test.
Secondary Control Panel Keys
For the location of these keys, see Figure 1 on page 18.
CLEAR - If a fault condition exists, pressing the CLEAR key clears the fault
message and returns the printer to offline mode.
NOTE: If a fault condition has not been corrected before pressing CLEAR,
the fault message appears again when attempting to place the printer
to online status.
PRT CONFIG - Prints the current printer configuration menu settings.
JOB SELECT - Selects a specific printer configuration menu (offline mode
only).
ENTER - Selects the current value within the printer configuration menu
(offline mode only) and displays an asterisk (*) next to the value. If the ENTER
key is locked, the value will not be selected and an “ENTER SWITCH
LOCKED” message displays for one second, followed by a display of the
previously selected value. Pressing the UP and DOWN keys at the same time
unlocks the ENTER key and permits value selection.
UP (=) - Navigates the printer menu one level up (offline mode only).
DOWN (>) - Navigates the printer menu one level down (offline mode only).