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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.
© 2004 by 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.
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.

Intermec EasyCoder PD4—Service Manual iii


iv Intermec EasyCoder PD4—Service Manual
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
1.2
Models........................................................................................................................2
Options ......................................................................................................................3
1.3 Technical Specifications ..............................................................................................5

2 Front Panels
2.1
2.2
Front Panel (no display)........... ..................................................................................8
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
3.2
Right-Hand Door ....................................................................................................16
Left-Hand Panel .......................................................................................................17

4 Chassis
4.1
4.2
Chassis......................................................................................................................20
Rear Plate .................................................................................................................21

5 Media Supply
5.1 Media Supply Post ...................................................................................................24

6 Transfer Ribbon Mechanism


6.1
6.2
Ribbon Module........................................................................................................28
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

Intermec EasyCoder PD4—Service Manual v


Contents

7.6 Headlift Sensor ........................................................................................................41


7.7 Printhead Module ....................................................................................................42

8 Rewinder Module
8.1 Rewinder Module ....................................................................................................50

9 Strip Module9.1 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

vi Intermec EasyCoder PD4—Service Manual


Before You Begin

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.

Intermec EasyCoder PD4—Service Manual vii


Before You Begin

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.

viii Intermec EasyCoder PD4—Service Manual


Before You Begin

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.

Intermec EasyCoder PD4—Service Manual ix


Before You Begin

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).

x Intermec EasyCoder PD4—Service Manual


1 Models and Options

This chapter describes the various models of the EasyCoder PD4 printer
family, describes the option, and provides technical specifications.

Intermec EasyCoder PD4—Service Manual 1


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)

2 Intermec EasyCoder PD4—Service Manual


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

Intermec EasyCoder PD4—Service Manual 3


Chapter 1—Models and Options

EasyCoder PD4 with cutter

EasyCoder PD4 with rewinder


(right-hand door not shown)

4 Intermec EasyCoder PD4—Service Manual


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.) 8 dots/mm (203.2 dpi)
50.8 to 101.6 mm/sec. (2 to 4 in/sec.) 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) 8 dots/mm (203.2 dpi)
558.8 mm (22 in) 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
Chinese Big5 level 1 & 2 Chinese
KS X 11001:1992 Korean
JIS X0208:12977 Japanese
Built-in bar code symbologies (stan- 34
dard)
Physical Measures
Dimensions (W × L × H) 276 × 454.6 × 283.0 mm
(10.85 × 17.9 × 11.2 in)

Intermec EasyCoder PD4—Service Manual 5


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 Yes1 Date/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
1
Display Yes Graphic 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 Option1 For peel-off operation
Takeup
Cutter Option1
2MB Flash Memory Expansion Card Option1
Keyboard/Display Unit Option
EasyLAN 10 External Ethernet Option
Adapter
1
/. Models with graphic display front panel only.

6 Intermec EasyCoder PD4—Service Manual


2 Front Panels

This chapter describes the front panels for various models of the Easy-
Coder PD4 printer family.

Intermec EasyCoder PD4—Service Manual 7


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

Screw and washer (x4)

Console pcb

LEDs (green-green-red)

Control keys
(Feed-Pause-Cancel)

Label E-ring

Overlay

Dummy strip sensor

Clear window

Front panel moulding

8 Intermec EasyCoder PD4—Service Manual


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

Screw and washer (x4)

Console pcb

LEDs (green-green-red)
LCD display

Control keys
(Feed-Pause-Cancel)

Screw (x2)

Label E-ring

Dust protection

Strip sensor pcb


PUS
H (cable not shown)

Overlay
Strip sensor housing

Clear window

Front panel moulding

Intermec EasyCoder PD4—Service Manual 9


Chapter 2—Front Panels

2.3 Replacing the Front Panel


To replace the front panel, follow these steps:
1 Remove 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.
2 Disconnect the flat cable from the main board.
3 From inside the electronics compartment, remove the two screws that
hold the front panel assembly at the top front of the center section.
4 Lift the front panel assembly up/out so the panel moulding disengages
the two keyholes in the center section.
5 In 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.
6 Disconnect the flat cable from the console pcb.
7 If necessary, replace the entire assembly. Individual items, except the
strip sensor assembly, are not available as spare parts.
8 Install the front panel in reverse order.

10 Intermec EasyCoder PD4—Service Manual


Chapter 2—Front Panels

2.4 Bottom Right-Hand Panel


Description
All models have a panel fitted to the bottom plate in front of the print
mechanism. This panel is temporarily removed when loading media for
peel-off (self-strip) operation in connection with an optional rewinder (see
Chapter 8). It must be permanently removed before installing an optional
cutter, see Chapter 10. The panel is held by a knurled screw inserted from
beneath the bottom plate.

Intermec EasyCoder PD4—Service Manual 11


Chapter 2—Front Panels

2.5 Console pcb.


Components
CN1
R8 R3 R11

Q3

R36

R24
R35 R10 R22 R17 R19 R18 Q2 Q1
R6 R1 C6 R20 R2 R4
+5V R16 R5 R9
CN2 R42 Q4
D5 C15

U1
LS08
C16
C7 C8 C9 C10 C11 C12 C13 C14 C5

+5V U3
A LS32
K C17

U2
HC14 200−000103−02
C18

R39 C19 R37 VR1

D4 R40

R41
C4 R14 R13 C3 R12 C2 R15 R38

C1 VR2
R25 R7 R23
BZ1

12 Intermec EasyCoder PD4—Service Manual


VCC

VCC
D1 D2 D3
Y_LED R_LED G_LED
VCC R7

2
R4 R5 R6 R1 R2 R3 C1 + R35 R36 BZ1
Schematics

Q1 Q2 Q3 CN1

R8 LEDG 2 1 D0
4 3

1
LEDR D1
LEDY 6 5 D2 VC C
R9 8 7 D3
10 9 D4
12 11 D5 R10
CS1_ 14 13
R11 D6
CS2_ 16 15
R12 FEED D7
VCC R13 PAUSE 18 17
R14 STOP 20 19
VCC 22 21
R15 R16 R2 0 24 23
26 25 RD_
CN9

8
7
6
5
8
7
6
5
2

20 R19 R17 R18 Q4 R22

4
3
19 R4 2 R21
S1 C2VCC 18 VCC CN2
(with G9) 17 E3A_
16 1

1
2
3
4
1
2
3
4

RW_ VCC
15 2
1

Intermec EasyCoder PD4—Service Manual


R23 RESET CN3 R24
14
13 CS2A 16

1
2
W_
12 CS1A 15
EMPTY

4
3
11 14
S2 C3 10 13
(with G10) 9 12
VCC 8 11
7 10
3 6 9
5 8

1
2
R25
4 E1A_ 7
3 E2A_ 6
2 E1A_ RS 5

4
3
1 4
S3 C4 3
(with G11) 2
1
C7 C8 C9 C1 0 C1 1 C1 2 C13 C1 4
C5 C6 C15 +

1
2
R37 VCC
1

VCC

9
8
7
6
5
4
3
2
1
C16 C17 C18

14
13
12
11
10
C5-C14 EMPTY
CN4

VR1 R40 U2A


V CC VCC
CS1A 2 1
CS1_
EMPTY U2E U3 A
1
D4 R39 E1A_ 10 11 3
R3 8 2

U2 C U1C
RESET EM PTY U1B
9
RESET CIRCUIT E3A_ 6 5 8 4
C19 10 6 W_
5 RD_
R41
VR2 U2D U3B
E MPT Y
EMPTY 4
E2A_ 8 9 6
5
U2B

CS2 A 4 3 CS2_

13
Chapter 2—Front Panels
Chapter 2—Front Panels

14 Intermec EasyCoder PD4—Service Manual


3 Side Panels

This chapter describes the right-hand door assembly that covers the media
compartment and the left-hand side panel that covers the electronics com-
partment.

Intermec EasyCoder PD4—Service Manual 15


Chapter 3—Side Panels

3.1 Right-Hand Door


Description
The right-hand door covers the media compartment, which contains the
print mechanism, the transfer ribbon mechanism, the media supply, and—
optionally—the rewinder. The door is fitted to the center section using two
hinges and can be opened 180° to facilitate ribbon and media load.
The door assembly consists of a hinged door to which the top right panel
is fitted using four screws. A clear plastic inspection window is glued the
inside of the door. A media and ribbon load instructions label is fitted
inside the top part of the door.
Replacement
The door assembly is available as a complete unit. The hinges are attached
to the center section using a total of 4 screws (not included).
The top/right panel can be replaced separately and is attached to the door
using a total of four screws (not included).

Window

Label

Right-hand door

Top/right panel

16 Intermec EasyCoder PD4—Service Manual


Chapter 3—Side Panels

3.2 Left-Hand Panel


Description
The left-hand panel covers the electronics compartment. It is a one-piece
metal panel which is fitted to the center section using two screws and to
the rear plate and the bottom plate using series of leaf springs along the
edges.

Screw

Leaf-springs

Screw

Panel

Leaf-springs

Intermec EasyCoder PD4—Service Manual 17


Chapter 3—Side Panels

Removal
The electronics compartment is only to be accessed by skilled service
technicians. It contains high voltages wires and circuitry. Disconnect
the power cord to eliminate the risk of electric shock and short circuits
before removing the left-hand panel.
Never run the printer without the left-hand panel installed because of
the risk of radio interference. Approvals are only valid when the cover is
installed.
Take standard precautions against ESD (Electrostatic Discharges)
before touching any electronics components inside the electronics com-
partment.
1 Disconnect the power cord.
2 Open the right-hand door.
3 Remove the screws in front of the front hinge and to the rear of the rear
hinge.
4 Close the right-hand door.
5 Using for example a flat-tipped screwdriver, pry the panel upwards until
it comes free. Protect the paint by inserting for example a thin piece of
cardboard or similar between the plate and the screwdriver.
6 Put the panel aside on a soft piece of cloth or similar to avoid scratches.
Installation
1 Making sure that the leaf springs along the rear edge of the panel
embrace the edge of the rear plate, push down the panel. Check that the
leaf springs along the bottom edge fit the bottom plate.
2 Open the right-hand door.
3 Secure the panel using two screws inserted from the media compart-
ment.
4 Reconnect the power cord.

18 Intermec EasyCoder PD4—Service Manual


4 Chassis

This chapter describes chassis, which consists of the center section, the
bottom plate, and the rear plate.

Intermec EasyCoder PD4—Service Manual 19


Chapter 4—Chassis

4.1 Chassis
Description
The chassis is the printer’s main frame to which various modules are
attached, such as the panels and doors, the print mechanism, the transfer
ribbon mechanism, the electronics, and the media supply post. It consists
of three main parts:
• Bottom plate with four rubber feet and two dampeners for the right-
hand door
• Center section (two different; the displayless model has no hole for the
rewinder and no cover plate)
• Rear plate
Rear plate

Center section

Rewinder cover plate


(display model only)

Dampeners (x2)

Rubber feet (x4)

Bottom plate

20 Intermec EasyCoder PD4—Service Manual


Chapter 4—Chassis

4.2 Rear Plate


Description
The rear plate contains the On/Off switch and AC power cord socket
assembly, and the serial port connector. It also has slots for the parallel
interface connector and the USB connector, which are fitted on the main
board.

Serial port

USB port

Parallel port

On/Off
switch

AC power
cord socket

Label Slot for external


media supply

Intermec EasyCoder PD4—Service Manual 21


Chapter 4—Chassis

Serial port
connector
(cable not shown)

Power switch kit


(cables not shown)

22 Intermec EasyCoder PD4—Service Manual


5 Media Supply

This chapter describes the media supply post with its two types of edge
guide.

Intermec EasyCoder PD4—Service Manual 23


Chapter 5—Media Supply

5.1 Media Supply Post


Description
The media supply post is intended for media rolls loaded inside the media
compartment. The printer can also use an external supply of media, for
example fan-folded tickets, placed behind the printer and routed through
the slot in the rear plate.
The printer comes with two edge guides, one of which are fitted on the
supply post and the other packed separately. The short guide makes it easy
to fit the media roll, but does not support the entire side of the roll. The
tall edge guide supports most of a full media roll, but must be folded to a
horizontal position to allow a roll or empty core to be remove and a new
roll to be loaded. Which guide to use depends mainly on the characteristics
of the media in use (for example a slippery liner versus a course roll of tags)
and if the printer placed in a completely horizontal position or if it is tilted
to the right.
The supply post is fitted to the center section using three screws. It runs
through a square hole in the triangular guide plate, which is attached to the
center section from inside the electronics compartment using three screws.

Short edge guide


Tall edge guide
(exploded)

Screws (x3)

Hook

Washer
Spring

Post
Screws (x3)

Guide plate

Center section

24 Intermec EasyCoder PD4—Service Manual


Chapter 5—Media Supply

Switching or Replacing the Edge Guide


To remove the edge guide, follow these steps:
1 Unhook the coil spring from the hook at the bottom of the plastic edge
guide underneath the post.
2 Remove the coil spring and the washer, then pull up the edge guide and
save it away for possible later use.
Edge guide

Hook

Washer

Coil spring
Post

To install the edge guide, follow these steps:


1 Insert the edge guide into the slot in the post.
2 First fit the washer and then the coil spring from underneath the post to
the protruding part of the edge guide and engage the coil spring to the
hook.

Note: The high edge guide is hinged to allow media load. Before remov-
ing an empty core or loading a roll of media, the guide must be flipped
down to a horizontal attitude. Likewise, after loading the media it must
be flipped back so it points straight up. Like the low edge guide, it can be
adjusted along the post to fit different media widths.

Edge guide

Hook

Washer

Coil spring
Post

Be careful to flip the high edge guide straight up before closing the side
door, or the guide could be damaged.

Intermec EasyCoder PD4—Service Manual 25


Chapter 5—Media Supply

26 Intermec EasyCoder PD4—Service Manual


6 Transfer Ribbon Mechanism

This chapter describes the thermal transfer ribbon mechanism.

Intermec EasyCoder PD4—Service Manual 27


Chapter 6—Transfer Ribbon Mechanism

6.1 Ribbon Module


Description
The thermal transfer mechanism hold the supply of thermal transfer
ribbon and winds up the spent ribbon after printing. It consist of a self-
contained unit that is attached to the center section and driven by a belt
from a pulley on the platen roller shaft (also see Chapter 7). In addition
to this unit, there is also a ribbon out sensor and an ink position selector
attached to the center section. Ribbon supply unit

Bracket

Ribbon rewind unit

Screws (x6)

Belt
Replacement
The ribbon module has three replaceable parts—the belt and the bobbin
plates on the ribbon supply and rewind units. The ribbon out sensor and
the ink position knob are also replaceable.
To replace the entire ribbon module, follow these instructions:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Slip the belt that drives the platen from its pulley (also see Chapter 7.2).
3 Use a pair of narrow pliers to disconnect the spring between the ribbon
supply and the ink position knob.
4 Remove the six screws that hold the ribbon module to the center section
from the media compartment side.
5 Tilt the ribbon module so you can remove the belt from the pulley on
the platen roller shaft.
6 Do not dismantle the module any further, unless you need to replace the
belt (See Chapter 6.2). Reassemble in reverse order

28 Intermec EasyCoder PD4—Service Manual


Chapter 6—Transfer Ribbon Mechanism

6.2 Ribbon Module Belt


Replacement
To replace only the belt, follow the steps below:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Slip the belt that drives the platen from its pulley (also see Chapter 7.2).
3 Remove the E-rings and the washer from the ends of the ribbon supply
and rewind shafts.
4 Remove the four screws that hold the inner bracket to the main body of
the ribbon module and pull out the bracket.
DO NOT loosen the screws that hold the bearing and the one-way
clutch to the bracket. That will affect the factory-adjustment of the
supply and rewind units and can cause ribbon creasing problems.
5 Remove the belt from the pulley on the rewind unit. Make sure that the
spring and washer stay on the supply unit shaft.
6 Reassemble in reverse order
Screws (x4)

Bearing Spring Washer


Bracket
E-ring

One-way clutch

E-ring

Washer

Belt

Intermec EasyCoder PD4—Service Manual 29


Chapter 6—Transfer Ribbon Mechanism

6.3 Ribbon Supply and Rewind Units


Description
The ribbon supply and ribbon rewind units look exactly the same, but
differ in having internal springs with different strength. The are not avail-
able as separate spare parts and should not be dismantled with the excep-
tion that the bobbin plate is replaceable.
At the outer end of each unit is a knob for adjusting the ribbon tension, see
below.
Replacement of the Bobbin Plate
The bobbin plate is held by a single screw:
Screw

Bobbin plate

Ribbon Tension Adjustment


The knob at the outer end of each unit is engraved with numbers from 1 to
4, where 1 is maximum friction and 4 is less friction. Factory default is #1
on the supply unit and #2 on rewind unit. If the friction settings prevent
the ribbon from running with the same speed as the media, smudging may
occur.
If ribbon wrinkling occurs during printing, push the knob on the ribbon
supply hub inwards (1) and rotate it clockwise to increase the breaking
force (2).
If the printer have problems pulling the labels (especially when using a
ribbon less than 50 mm/2 in wide), push the knob on the ribbon supply
hub inwards (1) and rotate it counterclockwise to decrease the breaking
force (2).

30 Intermec EasyCoder PD4—Service Manual


Chapter 6—Transfer Ribbon Mechanism

6.4 Ribbon Out Sensor


Description
The ribbon out sensor is attached to the center section from the electronics
compartment using a single screw. The sensor is connected to connector
CN11 on the main board.
The sensor assy consists of a LED and a sensor mounted on a circuit board.
The LED emits a beam of light that is detected by the sensor. The ribbon
supply unit has a flange with slots situated so the light is intermittently
let through or interrupted as the flange rotates. If no rotation is detected
during printing, an out-of-ribbon condition is assumed. This causes error
17 “Out of ribbon” if the printer is set up for thermal transfer printing. If
the printer is set up for direct thermal printing, the ribbon out sensor is not
used.
Replacement
Before replacing the sensor, check that the malfunction is not caused by
dust or foreign objects. Also disconnect and connect the cable to the main
board a few times to remove any oxide.
To remove the ribbon out sensor, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Disconnect the cable from the CN11 at the top of the main board.
3 Remove the cable from the clip and plastic spiral binding.
4 From inside the electronics compartment, remove the single screw and
washer that holds the sensor pcb to the center section.
5 Pull out the sensor and the isolating sheet.
6 Install the replacement sensor in reverse order. Do not forget to fit the
isolating sheet between the sensor and the center section.

Cable
(connector not shown)

Screw
Washer Sensor assy.

Isolating sheet

Intermec EasyCoder PD4—Service Manual 31


Chapter 6—Transfer Ribbon Mechanism

6.5 Ink Position Knob


Description
The ink position knob is used to set the printer for thermal transfer ribbon
wound with the ink facing either outwards or inwards:

Ink outside the roll Ink inside the roll Remove knob in this
position

It is important that the knob is in either position or it may be broken


when the right-hand door is closed.

Replacement
To remove the ink position knob, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Disconnect the spring from the ink position knob inside the electronics
compartment using tweezers or a pair of narrow-tipped pliers.
3 Move the knob to the center of the slot, rotate it a quarter of a turn, and
pull it out into the media compartment.
4 Install the ink position knob in reverse order. Do not forget to move it
to either end of the slot before closing the right-hand door.

Ink position knob

Slot

Spring

32 Intermec EasyCoder PD4—Service Manual


7 Print Mechanism

This chapter describes the print mechanism and the stepper motor that
drives both the platen roller and the transfer ribbon takeup unit.

Intermec EasyCoder PD4—Service Manual 33


Chapter 7—Print Mechanism

7.1 Print Unit


Description
The print unit is not a self-contained unit, but is integrate with the center
section. The displayless model has a 203.2 dpi (8 dots/mm) printhead
whereas the display-equipped models have either a 203.2 dpi (8 dots/mm)
or a 300 dpi (11.81 dots/mm) printhead. It is not possible to switch to a
different printhead density simply by installing another printhead. The
main board, the printhead connector, the platen roll pulley, and the platen
roll belt must also be replaced, which makes such an operation uneconomi-
cal.
Never use non-approved printheads. The main board will probably get
damaged beyond repair and the warranty will be void.
To help understanding the design of the print unit, an exploded view of all
parts (except cables) are shown below. Replacement parts are marked with a
shade of gray. Other parts are not stocked.

Printhead module
203.2 or 300 dpi)

Label gap sensor module

(Pulley;
for belt to Headlift sensor
ribbon unit)

Pulley
(motor belt;
203.2 or 300 dpi)
Media guide Platen module Media guide

34 Intermec EasyCoder PD4—Service Manual


Chapter 7—Print Mechanism

7.2 Motor, Pulleys, and Belts


Description
The stepper motor drives both the platen roller and the transfer ribbon
rewind unit via a series of belt and pulleys.
The stepper motor has a single pulley in the displayless model, but a
double pulley in the models with display because these models are prepared
for an optional rewinder, see Chapter 8. Only the double-pulley motor is
available as a spare part, but can also be used in the displayless model, even
if the outer part of the pulley is not used.
There are two different belts, one for 203.2 dpi printheads and one for 300
dpi printheads. Likewise, there are two different pulleys on the platen roller
shaft. The tension of the belt is automatically adjusted by a springloaded
arm-and-wheel arrangement attached to the center section.
The stepper motor module is attached to the bottom plate using four
screws. The motor is connected by a four-wire cable harness to connector
CN7 on the main board.

Belt
Motor

Pulley

Intermec EasyCoder PD4—Service Manual 35


Chapter 7—Print Mechanism

Replacement
Stepper Motor Module
To remove the stepper motor, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Disconnect the cable from CN7 on the main board and free the cable
from the spiral bindings and the cable clip.
3 Remove the four screws that hold the stepper motor module to the
bottom plate. A screwdriver with a magnetic tip is highly recommended.
4 Disconnect the belt(s) from the motor’s pulley and pull out the motor.
5 Install the motor in reverse order. In case of a printer prepared for a
rewinder, fit the platen roller belt on the inner pulley (that is, the pulley
closest to the motor housing) and the rewinder belt to the outer pulley.
Belt
To remove the belt, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Disconnect the cable from CN7 on the main board and free the cable
from the spiral bindings and the cable clip.
3 Remove the four screws that hold the stepper motor module to the
bottom plate.
4 Disconnect the belt(s) from the motor’s pulley and pull out the motor.
5 Install belt and motor in reverse order. Make sure the belt is intended for
the type of printhead (203.2 or 300 dpi) installed in the printer. In case
of a printer prepared for a rewinder, fit the platen roller belt on the inner
pulley (that is, the pulley closest to the motor housing) and the rewinder
belt to the outer pulley.

Note: If the printer is not prepared for a rewinder, that is, it has only one
belt, you do not have to remove the motor. Just pull the belt of the platen
roller pulley and then off the motor pulley. Fit the new belt in reverse
order. Temporarily disconnecting the tension adjuster spring makes the
process easier.

Platen Roller Pulley


To remove the pulley, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Pull off the belt from the pulley.
3 Remove the E-ring that holds the pulley on the platen roller shaft.
4 Install the pulley in reverse order. Make sure the pulley is intended for
the type of printhead (203.2 or 300 dpi) installed in the printer.

36 Intermec EasyCoder PD4—Service Manual


Chapter 7—Print Mechanism

7.3 Platen Module


Description
The platen module is a rubber-coated roller and a shaft. Its purpose is to
drive the media through the print mechanism and serve as a counter-force
to the thermal printhead. The silicon rubber is subject to wear and requires
the platen roller to be replaced, usually with long intervals.
When cleaning the platen roller, only use isopropyl alcohol. Other
chemicals may make the silicon rubber crack, get hard or slippery, or
dissolve the surface. Never use sharp tools to remove stuck labels. Do not
rotate the platen roller manually until the power has been off a minute
or more, or the stepper motor may generate current that can damage
the electronics. You could also disconnect the stepper motor cable from
the main board.

E-ring Washer Bearing Bearing Washer E-ring

E-ring Pulleys Inner gable Platen roller Outer gable

Replacement
To remove the platen, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Remove the front panel as described in Chapter 2.3 (this step can be
omitted)
3 Remove the E-ring from the inner end of the platen roller shaft and
remove the motor belt and pulley.
4 Remove the ribbon rewinder belt and pulley.
5 Remove the E-rings and washers from either end of the platen roller
shaft.
6 Remove the bearings.
7 Pull out the platen roller.
8 Install the platen roller, bearings, washers, E-rings, pulleys, and front
panel in reverse order.

Intermec EasyCoder PD4—Service Manual 37


Chapter 7—Print Mechanism

7.4 Media Guides


Description
The media guides are made of green plastic and are designed to guide the
media in a straight line through the print mechanism. The inner guide
should always be fitted flush to the inner gable of the print module whereas
the outer one should be adjusted to fit the width of the media without
compressing it. It can be folded upward to facilitate media load.
Replacement
The media guides are pressed onto their respective shafts and can easily
be removed and installed by hand. Take care to fit the guides as illustrated
below, that is, the flat side should face the media.

Inner gable

Shafts

Inner media guide Outer media guide

38 Intermec EasyCoder PD4—Service Manual


Chapter 7—Print Mechanism

7.5 Label Gap Sensor Module


Description
The label gap sensor detects gaps, slots, or black marks in the media as it is
feed between the two sensor boards. The lower board contains a LED and
a light sensor, whereas the upper board only has a sensor. By comparing
the detection of light/no light with the paper type setup (black mark/gap-
paper/plain paper), the firmware can determine the position of the labels or
similar along the media path and also detect out-of-media conditions.

Adjustments
Lateral Position
The label gap sensor’s point of detection can be moved manually across
the media path from 0 to 57 mm (0 to 2.24 in) from the inner edge of the
media. The point of detection is indicated by a narrow white triangle vis-
ible from the front of the print mechanism when the printhead is open.

Sensitivity
The sensitivity of the sensor can be adjusted in the Setup Mode (printers
with display only) or using ESim commands, see the EasyCoder PD4 User’s
Guide and the Intermec ESim v5.xx, Programmer’s Reference Manual.

Intermec EasyCoder PD4—Service Manual 39


Chapter 7—Print Mechanism

Replacement
Before replacing the module, check that there is no dirt, dust, adhesive resi-
due, or stuck labels that blocks the light between the two sensors. To clean
the sensors, it may be necessary to take out the module as described below.
To remove the label gap sensor module, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
Open the right-hand door and remove the bottom right-hand panel, see
Chapter 2.4.
2 Remove the E-ring, washer, and bearing from the outer end of the platen
roller, that is, the end in the media compartment.
3 Remove six screws that hold the outer gable of the printhead.
4 Fold the outer gable aside, taking care not to damage the headlift sensor
and its cable (see Chapter 7.6).
5 Remove the single screw that holds the label gap sensor module in the
electronics compartment. It is situated immediately to the rear of the
black sensor module.
6 Disconnect the cables from CN8 (“BLACK”) and CN9 (“SEE”) on the
main board. Free the cables from the spiral bindings and the cable clip.
7 Pull out the entire label gap sensor module into the media compartment.
8 Do not dismantle the module. The entire module is available as a
replacement part.
9 Install the label gap sensor module in reverse order.

Label gap sensor module

Outer gable
Bearing
Washer
E-ring

Screw (x6)

40 Intermec EasyCoder PD4—Service Manual


Chapter 7—Print Mechanism

7.6 Headlift Sensor


Description
The headlift sensor is a microswitch fitted inside the outer gable of the
print mechanism, immediately below the platen roller bearing. The
microswitch is activated by an arm connected to the printhead lever. If
attempting to print while the headlift sensor indicates that the printhead is
open, Error 11 “Print head lifted” occurs.
The headlift sensor is connected to CN14 (“DOOR”) on the main board.
Replacement
Before replacing the headlift sensor, check the function of the microswitch
by lifting the printhead and inserting a match or similar through a hole in
the outer gable and pressing the button on the switch.
To remove the headlift sensor, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
Open the right-hand door and remove the bottom right-hand panel, see
Chapter 2.4.
2 Disconnect the cable from CN14 (“DOOR”) on the main board. Free
the cable from the spiral binding and the cable clips.
3 Remove the E-ring, washer, and bearing from the outer end of the platen
roller, that is, the end in the media compartment.
4 Remove six screws that hold the outer gable of the printhead.
5 Fold the outer gable aside, taking care not to damage the headlift sensor
and its cable.
6 Remove the single screw that holds the sensor to the L-shaped bracket.
7 Pull out the headlift sensor through the holes in the bracket and the
inner gable and into the electronics compartment.
8 Install the headlift sensor in reverse order.

Bearing
Washer
Headlift sensor E-ring

Screw (x6)
Outer gable

Intermec EasyCoder PD4—Service Manual 41


Chapter 7—Print Mechanism

7.7 Printhead Module


Description
The printing is produced by the thermal printhead, which consists of a
line of very small, closely spaced resistors on a ceramic tile fitted across the
media path. When a current is led through the resistors, commonly called
“dots,” these will be heated very quickly. When the current is shut off, the
dots cool down just as fast.
As the media is fed past the dots, the hot dots will produce a number of
black spots on heat sensitive (direct thermal) media, or on other face mate-
rials via a thermal transfer ribbon. The spots can be combined into bitmap
patterns, which make up characters, bar codes, images, lines, and boxes.
The direct thermal printing method requires special media coated with a
thin layer of heat-sensitive chemicals. As the media is fed past the dots, the
heat from the dots will make the chemicals react, producing a dark salt,
which makes up the imprint under each dot.
In the thermal transfer printing method, a special “ink”-coated transfer
ribbon is used. When the ribbon is heated by a dot on the printhead, the
“ink” melts and sticks to the receiving face material, where the ink immedi-
ately becomes solid again, producing a black spot. Transfer ribbons nor-
mally do not smear at room temperature, neither before nor after printing.
Nor do the printed labels smear, even if the printout may be smudged by
extensive rubbing if an unfortunate combination of ribbon and face mate-
rial is used. The thermal transfer method makes it possible to use a wide
range of face materials for printing, for example papers, boards, plastics,
foils, etc. However, an original transfer ribbon from Intermec should
always be used.
Information on how to switch between direct thermal and thermal transfer
printing is provided in the User’s Guide.
The EasyCoder PD4 comes with two printhead densities, 203.2 dpi (8
dots/mm) and 300 dpi (11.81 dots/mm). The 300 dpi printhead is only
available for printer models with displays.
In a 203.2 dpi printhead, each dot under standardized conditions will pro-
duce a black spot which has a diameter of 4.92 mils (0.125 mm).
In a 300 dpi printhead, each dot under standardized conditions will pro-
duce a black spot which has a diameter of 3.33 mils (0.086 mm).
Depending on dot temperature, exposure time, media and ribbon charac-
teristics, etc., the spot may actually be somewhat smaller (weak print) or
larger (black print), but that does not affect the calculation of distances,
sizes, and positions.
Note that there are different main boards, pulleys, and belts for each
printhead density.

42 Intermec EasyCoder PD4—Service Manual


Chapter 7—Print Mechanism

Adjustments
Printhead Balance
The printer is factory-adjusted for full-size media width. When using
media less than full width, it is recommended that you adjust the position
of the printhead balance boxes so the printhead gets an even pressure across
the media.
A poorly adjusted printhead pressure may be detected by a weaker printout
on either side of the media path.
To adjust the pressure, proceed as follows:
1 Open the top cover.
2 Remove the ribbon.
3 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.
4 Move the balance box on the right side (outer) outward (to the right) for
wider media and inwards (to the left) for more narrow media.
Balance box

5 Engage the printhead and load the ribbon.


6 Test and readjust if necessary. (Hint! If you use direct thermal media you
will not have to load and remove the ribbon over and over again.)
Printhead Pressure
The pressure of the thermal printhead against the platen roller is factory-
adjusted. However, if the printing is weaker on one side of the media or if
the thermal transfer ribbon starts to crease (indicated by unprinted white
streaks along the media feed direction), it may be necessary to readjust the
printhead pressure.

Note: Before readjusting the pressure, try to fix the problem by moving the
outer balance box as described earlier in this chapter.

1 Open the top cover.


2 Remove the ribbon.
3 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.

Intermec EasyCoder PD4—Service Manual 43


Chapter 7—Print Mechanism

4 Use a straight-slot screwdriver to turn the screw at the top of the balance
boxes clockwise to increase the pressure or counterclockwise to decrease
the pressure. To set the pressure to factory default value, turn the screws
down completely and then 9 turns up (counterclockwise).

Adjustment screws

5 Engage the printhead and load the ribbon.


6 Test and readjust if necessary. (Hint! If you use direct thermal media you
will not have to load and remove the ribbon over and over again.)
Printhead Dot Line Position
When using thick or stiff media, the printhead needs to be moved forward
so the dot line becomes exactly aligned with the top of the platen roller.
Obviously, the platen roller and printhead must also be completely in
parallel.
To perform this adjustment, follow all the steps below:
1 Open the top cover.
2 Remove the ribbon.
3 Important step! Use a straight-slot screwdriver to turn the two screws at
the top of the printhead bracket counterclockwise a single turn.

44 Intermec EasyCoder PD4—Service Manual


Chapter 7—Print Mechanism

4 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.
5 Turn both screws at the front of the printhead carefully clockwise a
quarter of a turn at a time (a full turn corresponds to 0.5 mm which
is a lot). The adjustment range is ±2 mm (0.08 in). Make sure to make
identical adjustments on both the screws! If you get lost, tighten both
screws by turning them counterclockwise as far as they go and start all
over again.

6 Important step! Engage the printhead and lock the printhead by tight-
ening the two screws at the top of the printhead bracket, that is, the
reverse action of step #3.
7 Load the ribbon (only in case of thermal transfer printing).
8 Test the print quality and readjust if necessary. (Hint! If you use direct
thermal media you will not have to load and remove the ribbon over and
over again.)

Intermec EasyCoder PD4—Service Manual 45


Chapter 7—Print Mechanism

Replacement
The printhead is subject to wear both from the direct thermal media (or
ribbon) and from the rapid heating and cooling process during printing.
Thus, the printhead will require periodic replacement.
Time between printhead replacements depends on the print images, the
type of direct thermal media (or ribbon) in use, the amount of energy to
the printhead, the print speed, the ambient temperature, and several other
factors.
While replacing the printhead, the power must be off. The firmware
will not detect the new printhead resistance until the printer has been
restarted.
Take precautions against electrostatic discharges by touching a
grounded object, for example the chassis of the printer (assuming the
printer is connected to a grounded wall socket).

Install a replacement printhead this way:


1 Switch off the power to the printer.
2 Open the side door.
3 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.
4 Remove any transfer ribbon.
5 Pull out the printhead straight forward.
6 Insert the replacement printhead so it engages the connectors on the
printhead bracket.
7 Reload the transfer ribbon, close the printhead, close the side door and
switch on the power.

46 Intermec EasyCoder PD4—Service Manual


Chapter 7—Print Mechanism

Precautions
Some simple measures can be taken by the user to prevent premature wear-
out:
• Clean the printhead regularly, as described in the User’s Guide. Not only
will a dirty printhead produce an inferior printout, but any residue on
the dots will prevent heat to dissipate through the media.
• Use as low density setting as possible. Too much energy to the printhead
will wear it out rapidly.
• Do not use higher speed setting than necessary.
• Low ambient temperature requires more energy to the printhead dots
than room temperatures and will therefore cause more wear to the
printhead. High print speed accelerates the wear. Thus, at low tempera-
tures, select as low a print speed as acceptable.
• Do not use a higher printhead pressure than necessary.
• Never print outside the media path. Dots that are not in contact with
the media will not be cooled properly.
• When using media with less than full width, be careful to adjust the
printhead balance so there is an even pressure across the media. Not only
will an uneven pressure impair the printout quality, but it may also pre-
vent the dots from being properly cooled. Moreover, a sharp outer media
edge in direct contact with the printhead may cause excessive mechanical
wear on some dots, which may be visible when printing on wider media
later.
• When using preprinted labels or labels with some type of varnish or
non-standard top coating for direct thermal printing, use original
Intermec labels or inks recommended by leading manufacturers of direct
thermal media. The labels must not contain any aggressive substances
such as chloride or grinding substances such as titanium dioxide.
• Only use transfer ribbons recommended by Intermec.

Intermec EasyCoder PD4—Service Manual 47


Chapter 7—Print Mechanism

48 Intermec EasyCoder PD4—Service Manual


8 Rewinder Module

This chapter describes the optional internal liner rewinder required for
peel-off (self-strip) operation. The rewinder can only be fitted on Easy-
Coder PD4 printers with a display.

Intermec EasyCoder PD4—Service Manual 49


Chapter 8—Rewinder Module

8.1 Rewinder Module


Description
The rewinder module is an optional device for EasyCoder PD4 printer
models with display. These printers are prepared with belt, pulley, and gear
train for driving the rewinder using the same stepper motor that also drives
the platen roller and transfer ribbon rewinder. They are also prepared with
wiring and a connector for the rewinder module’s takeup full sensor. A
removable plate covers the hole in the center section for the rewinder.

Cover plate

Gear

Rewinder connector
Cutter connector

Gear/pulley

Washer
E-ring

Flange Connects to outer


pulley of stepper
E-ring Belt
motor

The rewinder module consists of the following parts. Only the liner reten-
tion clip and the liner takeup full sensor are available as spare parts. The
cable from the takeup full sensor is not shown in this drawing.

Liner takeup full sensor Liner retention clip

50 Intermec EasyCoder PD4—Service Manual


Chapter 8—Rewinder Module

Installation
The rewinder module can easily be fitted by the operator following these
steps.
1 Remove the screw that holds the front cover. Remove the front cover.

Front cover

Screw

2 Open the side door and remove the rewinder option cover plate, which
is held by two screws.

Cover plate

Y
Z X

3 Remove the U-shaped clip and attach the rewinder unit to the center
section using the four screws included in the kit.

Intermec EasyCoder PD4—Service Manual 51


Chapter 8—Rewinder Module

4 Plug in the cable from the rewinder switch into the front one of the two
connectors in the center section.

Switch

Rewinder cable

5 Install the media as described in the EasyCoder PD4, User‘s Guide.

52 Intermec EasyCoder PD4—Service Manual


9 Strip Module

This chapter describes the strip module (also called “label taken sensor”)
which is a standard feature on EasyCoder PD4 printers with a display. It
cannot be fitted on printers without a display.

Intermec EasyCoder PD4—Service Manual 53


Chapter 9—Strip Module

9.1 Strip Module


Description
Strip module is a somewhat inadequate name for this sensor, which detects
if a label or similar has been removed after printing and—if not—holds
the printing of next label until the present one has been removed. It works
equally well when the media is manually torn off after printing as when
the labels are automatically separated from the liner. The latter requires an
optional rewinder module (see Chapter 8).
The strip module (also called “label taken sensor”) is a standard feature on
all EasyCoder PD4 printers that have a LCD display. It cannot be fitted on
the model without display, where it is replaced by a similar plastic mould-
ing without any sensor.
The strip module is normally folded up into the side of the front panel
(see Chapter 2.2) but can be folded down to a horizontal position after
the right hand door has been opened. In the horizontal position, it detects
labels approximately 15 mm (0.59 in) from the inner edge of the media
path and approximately 22 mm (0.86 in) in front of the printhead’s dot
line.
The strip module can not be used when a paper cutter is installed.
The strip module consists of a plastic housing which is hinged on a pin
protruding from the inside of the panel module. The housing contains a
circuit board with a light-emitting diode (LED) and a light-sensitive sensor.
The sensors are connected to CN12 (marked ”strip”) on the main board.
When the light from the LED is reflected back from the back side of a
label and hits the sensor, a label present condition is assumed. If no light is
detected, a label taken condition is assumed. Thus, the sensor is somewhat
sensitive to the ambient light conditions and to the reflection properties of
the back side of the media.

Strip module

54 Intermec EasyCoder PD4—Service Manual


Chapter 9—Strip Module

Replacement
Before replacing the strip module, check
• that the sensor is in its horizontal position,
• that nothing blocks the LED and the sensor, for example dust or stuck
labels,
• that the back side of the media is able to reflect the light,
• and that the cables of the sensor are visibly undamaged and properly
connected to CN12 on the main board.
Replace the strip module this way:
1 Remove 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.
2 Disconnect the flat cable from the main board.
3 Remove the front panel module as described in Chapter 2.3.
4 Disconnect the strip module cable from the main board and remove it
from the clips, ties, and plastic spiral binding.
5 Remove the E-ring that holds the strip module and pull it away. The
strip module is only available as a complete unit.
6 Assemble in reverse order.

E-ring

H
PUS

Strip module

Front panel

Intermec EasyCoder PD4—Service Manual 55


Chapter 9—Strip Module

56 Intermec EasyCoder PD4—Service Manual


10 Cutter

This chapter describes the cutter which is an option for EasyCoder PD4
printers with a display. It cannot be fitted on printers without a display.
Never use the cutter to cut through any kind of adhesive, which will get
stuck on the shears and render the cutter inoperable or even damage
it. If you need to cut self-adhesive labels, be careful to cut the liner
between labels.

Intermec EasyCoder PD4—Service Manual 57


Chapter 10—Cutter

10.1 Cutter
Description
The cutter cuts off portions of continuous media after printing and collects
them on a tray. It is an option for EasyCoder PD4 printers with an LCD
display, but cannot be used on printer models without a display. When a
cutter is installed, the strip module (see Chapter 9) cannot be used. The
cutter can cut non-adhesive media 64 to 118 mm (2.52 to 4.65 in) wide
and with a thickness of 60 to 250 µm (2.3 to 9.8 mils).
The cutter comes in three main parts:
• Cutter mechanism including cable
• Cutter front panel
• Tray
Control
The cutter is controlled in the Setup Mode, see the EasyCoder PD4 User’s
Guide, or using an O command, see ESim v5.xx for EasyCoder PD4, Pro-
grammer’s Reference Manual.
Replacement Parts
In addition to the complete cutter module, the following replacement parts
are available:
• Cutter pcb
• Cutter front panel
• Tray

Cutter pcb

Screws (x6)
Bracket

Cutter
mechanism
Bracket

Front Panel

Tray

58 Intermec EasyCoder PD4—Service Manual


Chapter 10—Cutter

Installation
1 Remove the screw that holds the front cover. Remove the front cover.

Front cover

Screw

2 Open the side door and remove the tear bar, which is held by two Phil-
lips screws.

Screws Tear bar

3 Attach the cutter mechanism to the printer using the two Phillips screws
and washers included in the kit.

Intermec EasyCoder PD4—Service Manual 59


Chapter 10—Cutter

4 Plug in the cable from the cutter into the rear one of the two connectors
in the center section and fasten the cable to the bottom plate using the
two cable clips included in the kit.

Cutter
connector

Cutter cable

Cable clips

5 Attach the cutter cover onto the cutter mechanism by first connecting
the hooks on the back side of the cover over the cutter mechanism and
then locking the cover with the screw at the bottom.

6 If needed, fit the tray to the front of the cutter.

60 Intermec EasyCoder PD4—Service Manual


Chapter 10—Cutter

Clearing Media Jam in Cutter


To clear a media jam inside the cutter mechanism, follow the instructions
below:
1 At media jams and cutter malfunctions, switch off the power to the
printer.
Never insert fingers or tools into the printer while the power is still on.
Risk of personal injury or damage to the cutter if the cutter starts to
run by mistake.
2 Insert a 3 mm hexagon screwdriver in the hole on the side of the cutter
(A) and turn the cutter blade clockwise.
3 After the media jam is cleared, switch on the power to the printer, and
the cutter blade will go back to its original position.

Note: It is recommended to use labels with a length of 35 mm (1.5 in) or


more.

Intermec EasyCoder PD4—Service Manual 61


Chapter 10—Cutter

62 Intermec EasyCoder PD4—Service Manual


11 Switching Power Module

This chapter describes the switching power module and its connections
from the power switch unit and to the main board.

Intermec EasyCoder PD4—Service Manual 63


Chapter 11—Switching Power Module

11.1 Switching Power Module


Description
The switching power module receives 90/260 VAC, 47 to 63 Hz from
the power switch kit via a cable harness connected to CN1 on the power
module. The power module converts the current using switching technique
and delivers +24 VDC ± 2% to the main board via a cable harness from
CN2 on the power module to CN28 on the main board.
Consumption
Stand-by: 0.15A
Normal operation: 4.5A
Peak: 10.5A
Switched power modules are generally difficult to repair. If one compo-
nent fails due to aging or overload, a number of other components will
also break as a consequence. They are hard to troubleshoot, because the
power module often is “dead” or the fuses blow immediately. It is also
impossible to guarantee the life of a repaired power module, because
components may still work but be on the verge of failing. Thus, if a fuse
blows, only replace it once. Do not attempt to repair the power module
Fuse 5A or replace the fuse a second time, but replace the entire unit.
slow

CN1
90-260
VAC In

CN2
24 VDC
to main
board

64 Intermec EasyCoder PD4—Service Manual


Chapter 11—Switching Power Module

Replacement
To replace the power module, follow these steps:
1 Remove 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.
2 Disconnect the two cable harnesses at the rear of the power module.
3 Remove the two screws at the front of the power module that hold it to
the bottom plate.
4 Push the module forward so as to disengage the tab at the rear and lift
out the entire unit.
5 Install the power module in reverse order.

Intermec EasyCoder PD4—Service Manual 65


Chapter 11—Switching Power Module

Components
MADE IN TAIWAN D3 CN4 FAN
HS2 +

R3
C10 C11

C6
L2 C15 CN3 LED
+

R4
D1
− CN2

R13
R19

R14

+V
C9
R20

R12
HS1
Q1 C12 C13
R5
R2

GND
AUTEC UPS 110−1001
L1

R18 C14
REV−B
C7
R7
R8

R17

+V
T1
SCR1
R6

R9
D2

C16
R10 VR1
R11

R15

R16
ZD1
D4
ZD2

C17
JP1
C8 CONT1
C5 C4
G
TR1 C1
N
1

C2 C3
L
LF1
BO1

R1
CN1
VDR1
F1 5A−250V
3

Schematics
CN1
+HV
F1
L LF1
+ BD1
C1 R1 VDR1 + C5
N
TR1

C2 C3 -HV
FC
C4

+HV

R4 R2 C6 R3 CN3

D1 LED
R12 C9
R14
CN2
CONT1
R7 Q1+HS1 +24V
3 D3+HS2 L2
SCR1 ZD1
1
R5 + C10 + C11 + C12 + C13 + C14
2 D2
7 6 5 4 R8 R6 R18 R19 R16
+
C8 GND
L1
C17
R9

+24V
R10

R11

VR1

66 Intermec EasyCoder PD4—Service Manual


12 Main Board

This chapter describes the three different main boards including connec-
tions, test points, component placement, and schematics.

Intermec EasyCoder PD4—Service Manual 67


Chapter 12—Main Board

12.1 Description
Models
There are three different main boards for the EasyCoder PD4 depending
on printer model:
• EasyCoder PD4 No display 203.2 dpi
• EasyCoder PD4 LCD display 203.2 dpi
• EasyCoder PD4 LCD display 300 dpi
The printer must be fitted with the correct type of main board or it will
not work.
All types of main board are based on the same circuit board but the com-
plement of circuits differ. They are all designed to work with ESim v5.xx
for EasyCoder PD4 or later versions.
The main boards are delivered as complete units. Do not attempt to repair
or modify a main board.
The main board has a 16 bit microprocessor and, as standard, a memory of
2MB flash and 2MB DRAM.
The models with an LCD display has a real-time clock and the memory
can be expanded using a 2MB flash memory module.
Block Diagram

FEED Flash
Flash (1) Flash (2) EDO Memory
EEPROM

PAUSE
Memory Memory RAM Extension
Input Console

CANCEL CPU RTC


(1M) (1M) (2M) (2M)
LCD
IO Bus

Buzzer

LEDs
System Buss
IEEE 1284
A/D line
IO Ports

RS-232 port
Virtual pot
USB Drivers
GAP sensor

BM sensor

Sensors
Stepper Motor

Rewinder unit
Printhead

Power
Power detection
TPH temp

Cutter
Ribbon End

Power Input
TPH open

Power Temp
termistor

supply
Sensor

24 VDC
Sensors

68 Intermec EasyCoder PD4—Service Manual


Chapter 12—Main Board

12.2 Replacement
To replace the main board, follow these steps:
1 Remove 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.
2 Disconnect all cables from the main board. It may be a good idea to
mark them up first.
3 In case there is a memory expansion board installed, remove it (see
Chapter 12.7.
4 Remove the five screws and washers that hold the main board. (In case
of a memory expansion board, there are four sets of screws and washers
plus one hexagonal spacer.)
5 Install the main board in reverse order.

Intermec EasyCoder PD4—Service Manual 69


Chapter 12—Main Board

12.3 Connections
EasyCoder PD4, no display, 203.2 dpi
CN23 CN11 CN14 CN8 CN9
RS-232 Ribbon out Headlift Black See
mark through
JP4
USB

CN21 CN7 CNA1 & CNB1 CN28


Centronics Motor Printhead Power

70 Intermec EasyCoder PD4—Service Manual


Chapter 12—Main Board

EasyCoder PD4, display, 203.2 dpi

CN23 CN11 CN12 CN17 CN14 CN8 CN9 CN22


RS-232 Ribbon out Strip module Rewinder full Headlift Black See LCD Panel
mark through
JP4
USB

CN21 CN3 & CN4 CN19 CN7 CNA1 & CNB1 CN28
Centronics Memory Cutter Motor Printhead Power
expansion card

Intermec EasyCoder PD4—Service Manual 71


Chapter 12—Main Board

EasyCoder PD4, display, 300 dpi

CN23 CN11 CN12 CN17 CN14 CN8 CN9 CN22


RS-232 Ribbon out Strip module Rewinder full Headlift Black See LCD Panel
mark through
JP4
USB

CN21 CN3 & CN4 CN19 CN7 CN5 CN28


Centronics Memory Cutter Motor Printhead Power
expansion card

72 Intermec EasyCoder PD4—Service Manual


CN24

CN31
CN1

CN23
UART1
L12
FB1 R181
REWIND EXTDRAM R180
L UART2 CN10 CN11 CN13 CN12 CN17 CN14 CN20 CN8 CN9
R151 R6 R7 U37A

R52
C93 R166 C152 R182 JP3 R152
CN26

SEE
JP2 R53 CN22

DOOR
U37 1

STRIP
Q1 C46

COVER
R51
JP5

BLACK
R56
R57

C59
R84
R78
R50
R147

C51
R68
R65

C52
R67
C55
R73
R72
C44

SPSTMP
C45
R55
R54
C48
R61
R59
C49
R62
R60

R165
R58
R148
C5

C140
R153
R162
R150
REWINDFUL

R85
R167 R183

RIBBONOUT
RIBBONEND

C19
C18 R69
C153

R168
C146
R164
R173 C109
Q4 R8

C112

U43 R174
C141 U3

R2 R1
U7

C134
R177 U2

C133
C17

C144 C145 C136

R172

C149
R115 U40

R171
PS2 C95 Y3 R10
R86 R91 U25 Y2 C138 Y1
12.4 Components

JP4 C94 JP1


C150
C60 C61 R5 C16

RT3 RT4
Q5 C132 U11 U9
R184 C128

C147
R170
R169

C151
R4
LCD PANNEL

R114 R142 U10 U8

C13

C14
R141 C139 R143

C154
C137
C131
R140 U6

R163

R128
R139 X1
U35 U34
R9
U27 Y2A C4 C3

R176
R28

R129
R127
R131
R132
USB L11 R3

C127
C111
CN21 R126 U4

Intermec EasyCoder PD4—Service Manual


C135
C156 U17 R154
C130 C15 C67 L10
ZD1
C2 L1 C1

R11

C11
U27A

R12
R185

C115 R175
R186

C129
C8 C79 C80 C108 U1 C110
C81 C82
CN4 CN3
R83
R82
R80

R155 C117

R26
R23
R18
R17
R144
CN29

R89 D13 C9 C143


U26 R154
R74

C114
U12
R88
C148 R92

R157
U28
R79
R187
R188

C66 R90
C64 Q7 Q6 LX1 DC-JACK
C65 R87 U24 C12 U5 R30 CN28

D42 D19 D38


R93
C63 R94 D33 U19

C57
C62
R95 R134

MEMORY CADR
C69 C7 L5
MEMORY CADR
R96 C30
C68 U39 L7
R29 C125
R75 U33

C142
1
C126

C31
R39

R33
C83 D45 R34 R35 R37 R34 R38 C124
R136

C10
C23 R106

R15
C20
R13
U20 C28
R135

U21 U18
C120

R14

C22
D3 D2 C123

C113
C121
FX1

C155 D12 R146 U15 C122


C119

C29
D16 U13
D40 POWER
L9 L8
D22 D7 CN27

R31
R32

C27
U13A
C41
C40
R44
C42

D44 C24

R47
R41
R40
C32
R36
R43
R42

R46 L6 GNDS
C38
C37
C36
C35

C78 R97 D34 R48 CN5


1 D36 C6

C43
C77 R98 C33 C86 VDD
C76 R99 RP1 D39 U16 R45 C118
C75 R100 D32 D11 GND
C74 R101 D28 R49 U22
C73 R102 5V

D41 D14 D20 D15 D21 D25 D29 D26 D30 D37 D35
R64

R71
C72 R103 D31 C87 D1
C71 R104 D27 D10 POWER
R20

C56
R24
R22
R19

C70 R105
C26
A D24 D9 R81 C58
D18 CN19 D5 D4
C157

R77
P1 D23 CUTER C39

R63
Q2 D8 ZD2
D17 R66 CN7 L4 C85 C25

C47

C53
D43
MOTOR

200-000102-03

R70
MOTOR

REV.E MIT A C50 CN15 CN30


Q3 FAN CN6 CNA1 1 CNB1 1

73
Chapter 12—Main Board
Chapter 12—Main Board

12.5 Test Points


Signal Location Note
24 VDC CN27 Pin 3 24 VDC Power in
5 VDC U3 Pin 1 5V Regulator output (VCC)
RESET U12 Pin 4 Reset
CPURST U16 Pin 3 CPU reset
WRCASL U3 Pin 31 Column address strobe, low byte
WRCASH U3 Pin 30 Column address strobe, high byte
RAS U3 Pin 14 Row address strobe
RDDW U3 Pin 13 Read/Write
PINT0 U12 Pin 8 LPT port interrupt
BUSY0 U24 Pin 5 LPT port busy
USBFXF U40 Pin 12 USB data in interrupt
PDAT CN5 Pin 19 Printhead serial data
PCLK CN5 Pin 15 Prithead serial clock
PHLTH CN5 Pin 20 Printhead data latch
HCTL U15 Pin 9 Printhead control
STB1 U18 Pin 10 Printhead strobe
BLACK U28 Pin 2 Black mark sensor
SEE U28 Pin 24 See_through sensor
THPM CN5 Pin 9 Printhead temperature sensor
STRIP CN9 Pin 2 Strip sensor
POT_CS U28 Pin 11 Potentiometer chip select
POT_RS U28 Pin 15 Potentiometer reset
POT_CK U28 Pin 14 Potentiometer serial clock
POT_DI U28 Pin 12 Potentiometer serial data in
TXD0 U27 Pin 11 RS-232 Port transmit data
RXD0 U27 Pin 12 RS-232 Port receive data

74 Intermec EasyCoder PD4—Service Manual


VCC
R142 R141 R140 R139 U35 VCC
POWERLO
U34
STRIP STB1 EMPTY
V CC VCC
COVER STB2
SOP 1 8 D0
DOOR STB3 A0 VCC D0
EEPCS 1 8 2 7 D1
CS VCC A1 WP D1
M11 2 7 3 6 D2
E_RST EEPCLK SK NC A2 SCL EEPCLK D2
R1 M10 3 6 4 5 D3
E _M D EEPDI DI PE GND SDA EEPDI D3
MPB 4 5 D4
EEPDO DO GND D4
MPA D5
D5
D6
D6
D7
STOP D7
U1 VCC
PAUSE L1
FEED VCC
R2 A[1..23]
Rewindful
1 2 A19 1 24
PHTM CLK/I0 VCC

D0
D1
D2
D3
D4
D5
D6
D7
D8
A20 2 23 D[0..15]
PWRTM I1 I/O9 FLASH0
C1 C2 A21 3 22
BLACK I2 I/O8 FLASH1
SEE A22 4 21
I3 I/O7 FLASH2

D9
D8
R3 A23

D15
D14
D13
D12
D11
D10
A19
A18
A17
A16
A15
A14
5 I4/PD I/O6 20 FLASH3
RDDW 6 19
I5 I/O5 EXTMEM0 WRCASL
WRCASL 7 18 PORTS
I6 I/O4 WRCASH
EEPDO PDAT 8 I7 I/O3 17 RD_
R4 9 16
PCLK I8 I/O2 WR_
U2 10 15

144
143
142
141
140
139
138
137
136
135
134
133
132
131
130
129
128
127
126
125
124
123
122
121
120
119
118
117
116
115
114
113
112
111
110
109
DO I9 I/O1 DI
11 14 R154
HCTL I10 I/O0 PHDI
R5 12 13

42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
GND I11 SW
U3

Vcc
Vss

Vref
AVcc
AVss
P150
P151
P152
P153
P154
P155
P156
P157
P110
P111
P112
P113
P114

P00/D0
P01/D1
P02/D2
P03/D3
P04/D4
P05/D5
P06/D6
P07/D7
P10/D8
A9
A8
A7
A6
A5
A4

NC
VCC

Vss
Vss
Vss

OE-

I/O9
I/O8

P100/AN0
P101/AN1
P102/AN2
P103/AN3
I/O15
I/O14
I/O13
I/O12
I/O11
I/O10
Y1

CASL-
R6 R7 VCC

P104/AN4/KI0
P105/AN5/KI1
P106/AN6/KI2
P107/AN7/KI3
2 1 10K 10K

Vcc
I/O0
I/O1
I/O2
I/O3
Vcc
I/O4
I/O5
I/O6
I/O7
NC
NC
WE- CASH-
RAS-
NC
NC
A0
A1
A2
A3
Vcc
RAS_
R8

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
RAS1_
JP2 RDDW
C3 C4 RAS0_ WRCASL RDDW

P97/ADtrg-/RxD4/SCL4/STxD4
WRCASH WRCASL VCC
12.6 Schematics

WRCASH RAS0_
1 108 D9
EEPDI P96/ANEX1/TxD4/SD4/SRxD4 P11/D9
2 107 D10 RDDW
EEPCLK P95/ANEX0/CLK4 P12/D10

1
2
3
D0
D1
D2
D3
D4
D5
D6
D7
A10
A11
A12
PHDI 3 P94/DA1/TB4in/CTS4/RTS4/SS4 P13/D11 106 D11 CN1 A13
4 105 D 12
LCDLIGHT P93/DA0/TB3in/CTS3/RTS3/SS3 P14/D12 D13
5 104
Processor and Memory

RS P92/TB2in/TxD3/SDA3/SRxD3 P15/D13/INT3-
PDAT 6 103 D14 A[1..23]
P91/B1in/RxD3/SCL3/STxD3 P16/D14/INT4- D15
7 P90/TB0in/CLK3 P17/D15/INT5- 102
VCC PCLK VCC D[0..15]
PHLTH 8 P146 P20/A0(/D0) 101
9 100 A1 U5
HCTL P145 P21/A1(/D1)
10 99 A2 A18 1 15
SCTL P144 P22/A2(/D2) A Y0 SRAM SRAM
R9 R10 11 98 A3 A1 9 2 14
BLACK/_EN P143 P23/A3(/D3) B Y1 RTC
12 97 A4 A20 3 13 RDDW
CUT1 P142 P24/A4(D4) C Y2 POE0
CUT2 13 96 A5 12 WRCASH W R C ASL
P141 P25/A5(D5) Y3 USBCS_
14 95 A6 11
CUT_SW P140 P26/A6(D6) Y4 LCDE0
A7

A9
A9

15 94 6 10
D7
D6
D5
D4
D3

BYTE P27/A7(D7) G1 Y5 LCDE1 VCC

A12
A16
A14
A10
A11

A16
A14
A10
A11
A12

D15
D14
D13
D12
D11
VCC
16 CNVss Vss 93 4 G2A Y6 9 RTC_ALE
XIN 17 92 A8 5 7
P87/Xcin P30/A8(MA0)(D8) G2B Y7
XOUT 18 P86/Xcout Vcc 91
JP1 19 90

32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17

CPURST RESET- P120 PBUSY0


20 Xout P121 89 PE0
21 88

W
W

Vss P122 SELECT0

S2
A8
A9
S1
S2
A8
A9
S1

OE
OE

A15
A13
A11
A10
A15
A13
A11
A10

22 87
DO8
DO7
DO6
DO5
DO4
DO8
DO7
DO6
DO5
DO4

VCC
VCC

Xin P123 PERR0

Intermec EasyCoder PD4—Service Manual


23 Vcc P124 86 AUTOLF0
24 85 A9 U6 U7
P85/NMI- P31/A9(MA1)(D9) A10
SHTD# 25 P84/INT2- P32/A10(MA2)(D10) 84
26 83 A11
USBRXF P83/INT1- P33/A11(MA3)(D11) EMPTY EMPTY
27 82 A12

NC
A16
A14
A12
A7
A6
A5
A4
A3
A2
A1
A0
DO1
DO2
DO3
GND
NC
A16
A14
A12
A7
A6
A5
A4
A3
A2
A1
A0
DO1
DO2
DO3
GND

PINT0 P82/INT0- P34/A12(MA4)(D12)


28 81 A13 SOP SOP
FAN P81/TA4in/U- P35/A13(MA5)(D13) A14 SRAM621024 SRAM621024
DCMOT 29 P80/TA4out/U P36/A14(MA6)(D14) 80

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

30 79 A15
RIBBONOUT P77/TA3in P37/A15(MA7)(D15) A16
BUZZER 31 P76/TA3out P40/A16/(MA8) 78
32 77 A17
LEDG P75/TA2in/W- P41/A17/(MA9)
LEDR 33 P74/TA2out/W Vss 76
A18
A7
A5
A4
A2
A8
A6
A4
A3
A1

A8
A6
A3
A1
A7
A5
A2

34 75
D8
D9
D0
D1
D2

LEDY P73/CTS2-RTS2-/TA1in/V- P42/A18(MA10)


A18
A15
A13
A17
A13

A17
A18
A15

D10

PS2CLOCK 35 P72/CLK2/TA1out/V Vcc 74


36 73 A19
PS2DATA P71/RxD2/SCL2/TA0in/TB5in P43/A19/(MA11) A[1..23] A[1..23]

D[0..15] D[0..15]
XIN XOUT
VCC C5
FLASH0
R143
CN3 + RDDW
Y2 EMPTY
A1 WRCASL
EMPTY A2 1 2 D0
A9
A9
D7
D6
D5
D4
D3

A18
A15
A12
A15
A14
A10
A11

3 4
A14
A10
A11
A18
A12

D15
D14
D13
D12
D11

2 1 A3 D1
A4 5 6 D2 VCC VC C
A5 7 8 D3
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17

C138 C139 A6 9 10 D4
A7 11 12 D5

P70/TxD2/SDA2/TA0out
P67/TxD1
Vcc
P66/RxD1
Vss
P65/CLK1
P64/CTS1-/RTS1-/CTS0-/CLKS1
P63/TxD0
P62/RxD0
P61/CLK0
P60/CTS0-/RTS0-
P137
P136
P135
P134
P57/RDY-
P56/ALE/RAS-
P55/HOLD-
P54/HLDA-/ALE
P133
Vss
P132
Vcc
P131
P130
P53/BCLK/ALE/CLKout
P52/RD-/DW-
P51/WRH-/BHE-/CASH-
P50/WRL-/WR-/CASL-
P127
P126
P125
P147/CS0-/A23
P46/CS1-/A22
P45/CS2-/A21
P44/CS3-/A20(M12)
13 14
A8
A9
A8
A9

D7
D6
D5
D4
D3
D7
D6
D5
D4
D3

CE
CE

NC
OE
NC
OE

EMPTY EMPTY
WE
WE

A8 D6
A14
A13
A11
A10
A14
A13
A11
A10

VCC
VCC

15 16 D7
RDDW 17 18

37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
FLASH2 19 20 WRCASL
U8 U9
FLASH3 21 22 EXTMEM0
EEPCS
23 24
NC
A16
A15
A12
A7
A6
A5
A4
A3
A2
A1
A0
D0
D1
D2
GND
NC
A16
A15
A12
A7
A6
A5
A4
A3
A2
A1
A0
D0
D1
D2
GND

TXD1
RXD1

A23
A22
A21
A20
DTR1 VCC C6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

DSR1
TXD0
RXD0 +
A7
A5
A4
A2
A8
A6
A4
A3
A1

A[1..23] CN4
A8
A6
A3
A1
A7
A5
A2

D8
D9
D0
D1
D2

A19
A16
A13
A17
A13

DSR0
A17
A19
A16

D10

A9
DTR0 A10 1 2 D8 A[1..23]
WRCASL A11 3 4 D9
REWIND 5 6
PRGRST WRCASH A12 D10 D[0..15]
R DD W A13 7 8 D11
USBTXE RAS_ A14 9 10 D12
A15 11 12 D13
POT_CS 13 14 FLASH1
A16 D14
POT_RS SELIN0 15 16 RDDW
A18 D15
POT_CK SW_ROM 17 18 WRCASL
A17
POT_DI LCDRW_ 19 20 WRCASH
A19
A9
A9
D7
D6
D5
D4
D3

TPH_ON 21 22
A18
A15
A12
A15
A14
A10
A11

A14
A10
A11
A18
A12

D15
D14
D13
D12
D11

23 24 RAS1_ VCC VCC


32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17

R11 R12
U 10 U11
A8
A9
A8
A9

D7
D6
D5
D4
D3
D7
D6
D5
D4
D3

CE
CE

VCC VCC
NC
OE
NC
OE

WE
WE

VCC
A14
A13
A11
A10
A14
A13
A11
A10

VCC
VCC

VCC VCC
VCC U12A
1

C7 C8 C9 C10 C11 C12 R144


VCC 6
NC
A16
A15
A12
A7
A6
A5
A4
A3
A2
A1
A0
D0
D1
D2
GND
NC
A16
A15
A12
A7
A6
A5
A4
A3
A2
A1
A0
D0
D1
D2
GND

Q
CL

R13 D45
CLK 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

R146 5 2
PR

SW Q D SW_ROM
D8
D9

A7
A5
A4
A2
A8
A6
A4
A3
A1

A8
A6
A3
A1
A7
A5
A2

A19
A16
A13
A17
A13

A17
A19
A16

D10

R14 D12
D0
D1
D2

VCC
EMPTY U13 A[1..23]
RESET_
2 VIN
1 U15A D[0..15]
OUT
3 GND 14 CEXT
C13 C14 C15 C16 C17 C18 C19 VCC
+ C20
C22 C23 + R1 5 U16A
C155 15
EMPTY REXT/CEXT
1
PRGRST 1 A Q 13 3 CPURST
2 B 2
3 C LR Q 4

VCC

C127 C128 C129 C130 C131 C132 C134 C133 + C141


1

75
Chapter 12—Main Board
Chapter 12—Main Board

Motor Driver

2 1
VDD1
D3 D2
1 2
V CC

C29
820pF\50V R32 1 16
56K MB E
2 T MA 15
3 VMM VMM 14
4 13 R33
GND GND 1K
5 GND GND 12
6 11 R34
VCC VR 0.5 1W
7 I1 C 10
C30 + 8 9 DIP
47uF\35V PHASE I0 C31
DIP U20 820pF\50V
TEA3718/3770
VDD1 DIP
VCC
CN6
MT4 D4
1 D5 VDD1 DIP 2 R35
2 1
MT3 DIP 0
3 MT2
4 1 2
5 MT1 VCC VR
6
DIP:2.5 C32
MOTOR 820pF\50V R36 1 16 R37
EMPTY 56K MB E [560]
2 T MA 15
3 VMM VMM 14
4 13 R38
GND GND 1K
5 GND GND 12
6 VCC VR 11
7 10 R39
I1 C 0.5 1W
8 PHASE I0 9
+ C34 DIP
C33 U21 820pF\50V
47uF\35V DIP TEA3718/3770
DIP

U22
[SLA7026M]
CN7 DI P R40

1 8 OUTA INA 6 MPA


2 300
3 1 OUTA INA 5
4
18 OUTB INB 17
MOTOR R41
DIP:2.5 11 16
OUTB INB modify position MPB
C35 C36 C37 C38
[.22uF] [.22uF] [.22uF] [.22uF] VDD1 7 2 300
EMPTY EMPTY EMPTY EMPTY VSA TDA modify position
12 VSB TDB 13
R42
RSA 9 M10
+
REFA 3
C39 300
100uF/35V 4 14
DIP GA REFB R43
15 GB RSB 10
EMPTY
EMPTY M11
300

VCC VCC

R44
C40 C41 [56K] R45
[2200pF] R46 R47 [2200pF] EMPTY 56K
EMPTY [2.4K] [2.4K] EMPTY EMPTY
R48 EMPTY EMPTY
[0.5 2W] R49
EMPTY
DIP [0.5 2W]
DIP C43
820pF\50V
C42 EMPTY
[820pF\50V]
EMPTY

76 Intermec EasyCoder PD4—Service Manual


VHH
VHH VCC
CNB1

+
Printhead

VCC + C 24
15 C85
14 CN5
VCC U23 13 U 4B
12 R19 2 1
11 4 3
10 R22 6 5
Q6 9 8 7 4 3 PHSTB2
C28 VDD2 8 10 9
VHH 7 12 11
6 14 13 U4C
R29 5 16 15
4 D1 18 17
3 20 19
2 22 21 6 5 PHSTB1
1 24 23
26 25
+ EMPTY R20
R30
PCLK
C25
DI
CNA1

R74
Q7
TPH_ON 15 PHTM

Intermec EasyCoder PD4—Service Manual


14 V CC
13
12 DI
11 PHSTB1
10 PHSTB2
9 PHSTB3
8
7 PCLK
6 PHLTH
5 DO
R24
4
3
+ C26
2
1

U18C
R176

9
8 PHSTB1
STB1 10
PHSTB2
VCC STB2 U18D
PHSTB3
STB3
12
VCC R175 11
U18B 13
U17C U16D VCC
R163

3
4 U18A
DELAY
9 + 6 12 R17
3

14 5 11 U17A 10K
8 - 13 1 LM339 7
C27 3 +
1
6 CEXT 2 6

12
VCC -
R28 R18
R31
12

10K
7 REXT/CEXT

SCTL 9 A Q 5 VCC
10 B
RESET_ 11 CLR Q 12
U 17B R 23
3

U15B LM339 10K


+ 5
2
- 4

R26
12

10K

77
Chapter 12—Main Board
78
VDD2
VCC VDD1 VCC
Power
CN27
R126
1
R127 EMPTY 2
3
R128 U17D 4
ZD1

3
11 EMPTY
+
13
Chapter 12—Main Board

POWERLO
- 10

12
R129

DC24V R131 R132


CN28

6 VDD1 L4
5
4

1
3
2 2 1 2 VDD2
1 3 4
CN29 LX1 L5

3
+ C117 FX1 + C118
FUSE 5A

R134 L6 L7
VCC
8 DC SC 1
7 IS SE 2
6 VCC TC 3
5 CI GND 4
D7 + C119 + C1 2 0 + C1 2 1 C124
U33 C122 C123
C125 +

R135 R136

VCC
+5V VCC VDD L10
1 2

L9
1 2 C126
L12 L8
1 2 1 2

Intermec EasyCoder PD4—Service Manual


Chapter 12—Main Board

Connectors

VCC VCC VCC


STRIP MODULE CN12
STRIP
R60 VC C
BLACK1 R62
R80
U28 1
2
1 AGND2 B1 24 SEE1 STRIP 3
2 23 R82
B2 A1 4
3 A2 W1 22
4 21 C49
W2 AGND1
5 AGND4 B3 20 SEN_TX0
R79 6 19 R8 3
A3 B4
W3 18 7 A4 SEN_TX1
8 W4 AGND3 17
9 16 V CC
10
11
DGND
/SHDN
/CS
VDD
/RS
CLK
15
14
POT_RS
POT_CL
HEADLIFT
12 13 R6 5
SDI SDO CN14
R68 DOOR
POT_DI
POT_CS DOOR 1
2
C51

VCC

VCC
R180
REWINDER
BLACK MARK R72

CN17
BLACK1 R73 REWINDFUL
EMPTY
SEN_TX0 Rewindful
1
R50 2
R147 CN8
C55
BLACK
R51
SEN_TX1 1
2
BLACK 3
4

Q1
BLACK/_EN
R53 C44 VCC
R52
EMPTY COVER
R78

VCC
(not used) R84
CN20
COVER
EMPTY
COVER 1
SEE THROUGH R181
R5 K C59
2

SEE1 for simple sensor board


VCC D IP

VCC CN9
R56 R148 SEE

EMPTY R57
1
SEE 2
3
VCC
R58

EMPTY
C4 6
SPSTMP
VCC
(not used) R54

CN10
CN11 R55 SPSTMP
EMPTY
R59 RIBBONOUT
VCC
RIBBON R61
1
PWRTM 1
2
2
3 C45
VCC 4
C48

U37
5 1 OUT
VDD A END
B 2
RIBBONOUT 4 Y VSS 3
V CC
CN13
RIBBONEND
R67 VCC

R69 1 VCC
2
3 REWIND
4
C52 (not used) R150 R151 R152
JP 5
R162
EMPTY CN31
REWIND
REWIND EMPTY
Q4
1
2
VDD1 3
R153

FAN & MOTOR C140

EMPTY
CN30
(not used) D8 C47 FAN

U16B
1
D10 R63 2
Q2
FAN 4
6
5
VCC
R64
CUTTER VCC VDD1
R66
VDD1
VCC R77 CN19
DELAY HEADER 5
CUTTER
+
C50 1
D9 CN15 CUT1 2
C53 DCMOTOR CUT2 3
C5 6 C57
EMPTY EMPTY CUT_SW 4
U16C 5
1 R81
D11 R70 2
Q3 C58
DCMOT 9
8
10
EMPTY

POWER TEMPERATURE SENSOR


R71

DRIVERS

Intermec EasyCoder PD4—Service Manual 79


VCC

80
C67 + Ports 1
VCC CN22
U25 D0 1 2
3 4 LEDG
R85 24 1 D1
VCC MOT 5 6 LEDR
23 2 D2
SQW X1 7 8 L EDY
22 3 D3
NC X2 9 10 RS
21 4 D0 D4
RCLR AD0 11 12 WRCASL
20 5 D1 D5
VBAT AD1 13 14 LCDE0
19 6 D2 D6
IRQ AD2 15 16 LCDE1
18 7 D3 D7
RESET_ RESET AD3 17 18 FEED
RD_ 17 DS AD4 8 D4 BUZZER 19 20 PAUSE
Chapter 12—Main Board

16 GND AD5 9 D5 LCDLIGHT 21 22 STOP


WR_ 15 R/W AD6 10 D6 23 24
AS 14 AS AD7 11 D7 RD_ 25 26 LCDRW_
13 CS GND 12
CN22

VCC
RTC
C79 U27
FB1 VCC

1 16 C80
CN23 1 16

+
+

3 3 2 2
C81 4 15
4 15

+
5 6 C82
TXD0a 5 6
+

2 1 14 T1OT T1IN 11 TXD0


DTR0a 7 10
4 3 T2OT T2IN DTR0
RXD0a 13 12
6 5 R1IN R1OT RXD0
DSR0a 8 9
8 7 R2IN R2OT DSR0
JP3
10 9
U4F U24C EMPTY
10 RTC_ALE
AS 12 13 8
9 WRCASL
SERIAL 1

D[0..7]

D0
D0
D1
D1
D2
D2
D3 CN24
D3
D4
D4 TXD1 2 1 SHTD#
D5 VCC
D5 DTR1 4 3 RXD1
VCC D6
D6 DSR1 6 5
D7
D7 8 7 E_MD
R115
10 9 E_RST
R114
12 11

SERIAL
RT3
PS2CLOCK TO USB
C93 + RT4 EMPTY
PS2DATA

C94 C95 VCC

3
1
2
4
5 6 C136 C108 C109 C110 C111 C112 C113 C114 C115
CN26
EMPTY

Intermec EasyCoder PD4—Service Manual


VCC
U39
1 1G
2 1A1 1Y1 18 SELIN0
4 1A2 1 Y2 16
6 14 AUTOLF0
PERR0 1A3 1 Y3
R87 R8 8 8 12
SELECT0
Ports 2
1A4 1Y4
VCC 19 2G
PE0 11 2A1 2Y1 9
CN21 R89 Selectin 13 7
2A2 2Y2
36 15 2A3 2Y3 5
18 R90 Autolf 17 3
2A4 2Y4
35
17 R92
34
16 R93
33
15 R94
32 Error
14 C65 C6 6 C6 2 C63 C64
31
13 Select
30 VCC
12 Paper error RP1 PR10
29 U24B 5
BUSY+ R95
11 6
28 R96 4

10
9
8
7
6
5
4
3
2
1
10 A CK-
27
9 R9 7
PBUSY0
26
8 R98

Intermec EasyCoder PD4—Service Manual


U26
25
7 R99 11 CLK
24 1 OC
6 R100
23 PD7a 18 19
D7 Q7 D7
5 R101 PD6a 17 16
D6 Q6 D6
22 PD5a 14 15
D5 Q5 D5
4 R102 PD4 a 13 12
D4 Q4 D4
21 PD3a 8 9
D3 Q3 D3
3 R103 PD2a 7 6
D2 Q2 D2
20 PD1a 4 5
D1 Q1 D1
2 R104 PD0a 3 2
D0 Q0 D0
19
1 stb

R105 U14E

C68 C69 C7 0 C71 C72 C73 C74 C7 5 C7 6 C77 C7 8 11 10 STROBE-

RESET_

PINT0
U19B
6 VCC U12B VCC
CEXT
10

C8 3
R106 9 12
Q D
PR

REXT/CEXT 7
CL K 11
5 Q A 9 POE0
10 8
CL

B Q
12 Q CLR 11
13

VCC VC C V CC VCC VCC VCC VCC V CC VCC VCC VCC VCC VCC VCC VCC VCC

D33 D13 D14 D15 D35 D19 D20 D21 D3 7 D38 D2 5 D26 D41 D42 D2 9 D30

EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY

Paper error Selectin PD0 PD2 BUSY+ Autolf PD1 PD3 ACK- Error P D4 PD6 st b Select PD5 PD7

D34 D16 D17 D18 D36 D2 2 D2 3 D24 D39 D40 D27 D28 D43 D44 D31 D32

EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY

81
Chapter 12—Main Board
VCC VCC

82
VCC R164
USB
L11

U40
R165 C152 C153
EMPTY

30
3
13
26
JP4
R166
1 7 25

VCC
VCC
VCC
USBDP D0 D0

AVCC
2
R167
3 8 USBDM D1 24 D1
4
Chapter 12—Main Board

D2 23 D2
6 3V3OUT D3 22 D3
C154

5
TO USB D4 21 D4
C144
27 XTIN D5 20 D5
VCC 19
D6 D6
Y3 18
D7 D7
C145
R168 28 U24A
XTOUT
2 USBCS_
VCC 16 3
RD#
1 RD_
31 RCCLK WR 15

C147 C146 4 14 U4D U24D


R169 RESET# TXE#
R184 12 13
RXF#
8 9 11
32 VCC 12
Q5 EECS WR_
1 EESK EEREQ# 11
USBTXE
2 EEDATA EEGNT# 10
R182
USBRXF
5 TEST
R170 R171

AGND
GND
GND
R183

29
9
17
DECOUPLING CAPS

VCC

VCC
R172 VCC

VCC
U43
1 CS VCC 8
2 SK NC 7
3 DIN NC 6
C148 C149 C150 C151 4 5
DOUT GND

R173

GND

R174

USED BY USB PID AND VID

Intermec EasyCoder PD4—Service Manual


Chapter 12—Main Board

12.7 Memory Expansion Card

Description
The memory expansion card can only be installed in EasyCoder PD4
printers with and LCD display. It provides an additional 2MB of flash
memory.

Installation
To install a memory expansion card, follow these steps:
1 Remove 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.
2 Remove the screw and washer at the center of the main board and
replace it with the hexagonal spacer delivered with the expansion card.
3 Connect the expansion card to CN3 and CN4 on the main board,
making sure that the hole at the center of the card corresponds to the
threaded hole in the spacer.
If the expansion card is fitted upside down (that is, the hole is not
aligned with the spacer), the card will blow when the power is switched
on.
4 Secure the card by fitting the screw and washer you previously removed
through the hole in the expansion card and into the spacer.
5 Put back the left side panel and connect the power cord.

Intermec EasyCoder PD4—Service Manual 83


Chapter 12—Main Board

84 Intermec EasyCoder PD4—Service Manual


13 Interfaces

This chapter describes the communication interfaces of the EasyCoder


PD4:
• RS-232 serial interface
• USB serial interface
• Centronics parallel interface

Intermec EasyCoder PD4—Service Manual 85


Chapter 13—Interfaces

13.1 RS-232 Serial Interface


Description
The RS-232 serial interface is a bidirectional communication protocol
for distances up to 10 to 15 metres (33 to 49 ft). The communication
parameters can be set in the Setup Mode (see EasyCoder PD4, User’s Guide)
or using a Y command (see ESim for EasyCoder PD4 v5.xx, Programmer’s
Reference Manual) as follows:
Baud rate 4,800 bps
9,600 bps
19,200 bps
38,400 bps
Parity No parity
Odd parity
Even parity
Data length 7 bits
8 bits
Stop bit(s) 1 bit
2 bits
Handshaking is XON/XOFF and RTS/CTS
One line contains +5 VDC, max 500mA (permanently enabled)
The connector on the printer’s rear plate is a DB-9pin socket.

Signals
Pin Signal Meaning Remark
1 External +5 VDC Max. 500mA, permanently enabled
2 TXD Transmit data
3 RXD Receive data
4 Not used
5 GND Ground
6 Not used
7 CTS Clear to send
8 RTS Request to send
9 Not used

86 Intermec EasyCoder PD4—Service Manual


Chapter 13—Interfaces

13.2 USB Serial Interface


Description
The EasyCoder PD4 printer supports USB v1.1 (also called USB 2.0 full
speed). To use the USB interface for printing from a PC, you need a special
Intermec USB printer driver installed in your PC.
The printer is a so called “self-powered device.” You can connect the
printer to a USB port on the host, either directly or via a hub. Keyboards,
mouses, or more printers can also be connected to the same hub.
Using a USB Class A/B cable, connect the Class A plug to your PC or hub
and the Class B plug to your printer.
There is no communication setup for the USB port.

USB Class A connector.


Connect to PC or hub.

USB Class B connector.


Connect to USB receptacle on the printer’s rear plate.

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Chapter 13—Interfaces

13.3 Centronics Parallel Interface


Description
The Centronics parallel interface is essentially a one-way protocol for short
distances. There is no setup for the parallel interface.
Handshake: DSTB connects to the printer, BUSY connects to the
host
Interface cable: Parallel cable compatible to IBM PC
One line contains +5 VDC, max 500 mA, permanently enabled.

Pinout Description
Pin Function Transmitter Comment
1 /Strobe host
2-9 Data 0-7 host
10 /Acknowledge printer
11 Busy printer
12 /Paper empty printer
13 /Select printer
14-16 Not connected
17 Chassis ground
18 External +5 VDC Max 500mA, permanently enabled
19-30 Signal ground
31 Not connected
32 /ERROR printer
33 Signal ground
34-36 Not connected

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14 Troubleshooting

This chapter describes how to troubleshoot the EasyCoder PD4 printer


and suggests remedies, which in most cases means identifying a faulty part
and replacing it. Do not attempt repairing the power supply or any circuit
boards.

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Chapter 14—Troubleshooting

14.1 Error Handling


When an error occurs, the Error LED goes solid or flashing red and the
beeper emits two beeps. Provided the printer is fitted with a display, two
error message are displayed alternatingly, for example:

When all errors have been cleared, the Error LED goes off, the beeper
emits a single beep, and the printer returns to the same mode as when the
error occurred, which is indicated in the display window.
The printer’s error-handler can manage the following errors:
Description/Display Message Action
01: Syntax error Press the Feed key
02: Object exceeds image buffer border Press the Feed key
03: Data length error Press the Feed key
04: Insufficient memory to store data Press the Feed key
05: Memory configuration error Press the Feed key
07: Out of media Load new supply of media
08: Form or image name duplicate Press the Feed key
09: Form or image not found Press the Feed key
11: Print head lifted Close the printhead
13: Label taken sensor waiting Remove label
15: Rewinder is full Remove wound-up liner
16: No form was retrieved before ‘?’ Press the Feed key
17: Out of ribbon Load new supply of ribbon
50: Does not fit in area specified Press the Feed key
51: Data length too long Press the Feed key
62: High print head temperature (WAIT) Wait for printhead to cool off
71: Default Setup retrieved (RESET) Switch power off/on or send ^@ cmd
72: Flashing not completed (RESET) Switch power off/on or send ^@ cmd
73: Download error (RESET) Switch power off/on or send ^@ cmd
81: Cutter jammed or not installed Clear media from cutter or disable cutter

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Chapter 14—Troubleshooting

14.2 Troubleshooting Check List


Error Suggested action Refer to
The Power control lamp does not Check the power outlet and power cord Chapter 14.3
shine and the LCD display (if any) Check the power switch and cables to power module Chapter 14.3
shows no message after the power has
been switched on Check the switching power module and the cables to the Chapter 14.3
main board
Check the main board and cable to the panel module Chapter 14.3
Check the console board Chapter 14.3
Error LED light turns solid red after Check if printer is out of media or ribbon Chapter 14.4
printing stops Check if printhead is not closed and locked Chapter 14.4
Check if media is jammed/tangled up Chapter 14.4
Check if label gap sensor is blocked by media Chapter 14.4
Check for bad software setting or ESim command errors User’s Guide and
Programmer’s Ref-
erence Manual
Check cutter, if any
Printing started, but nothing is Check if media is placed upside down or if media is not Chapter 14.5
printed on the label suitable for the application
Check if the ink-coated side of the transfer ribbon faces Chapter 14.5
the media
Select the correct printer driver Chapter 14.5
Select the correct media and print type Chapter 14.5
Check that the printhead is properly connected to the Chapter 14.5
print mechanism
Check that the printhead cables are properly connected to Chapter 14.5
the main board
Check the main board Chapter 14.5
When printing, label is jammed or Clear the media jam, and if label is stuck on thermal User’s Guide
tangled up printhead, remove it using a soft cloth soaked with iso-
propyl alcohol or a cleaning card.
When printing, part of the print Check for ribbon wrinkles and creases Chapter 14.6
image was not printed along the feed Check if thermal printhead needs cleaning Chapter 14.6
direction
Check if the printhead is damaged Chapter 14.6
Check printhead balance Chapter 14.6
Check if application program has errors
Check if power supply is correct Chapter 11
Printout not in desired position Check for bad settings in the application or ESim com- Programmer’s Ref-
mand errors erence Manual
Check if label gap sensor is disturbed by media, dust, or Chapter 14.7
erroneously loaded transfer ribbon
Check lateral position of label gap sensor Chapter 14.7
Calibrate label gap sensor in Autoadjust Mode User’s Guide
Check label gap sensor for faults or bad connection Chapter 14.7
Check the edge guide and media guides Chapters 5.1 and
7.4
Check the media Chapter 14.7
Check if the platen roller needs cleaning or replacement Chapter 7.3

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Chapter 14—Troubleshooting

When printing, page skipping occurs Check label height setting (Q command) Programmer’s Ref-
erence Manual
Check if label gap sensor is disturbed by media or dust Chapter 14.7
Weak printout Check density setting User’s Guide
Check if thermal printhead needs cleaning User’s Guide
Check printhead pressure Chapter 7.7
Check printhead dot line position Chapter 7.7
Uneven darkness across media path Check printhead balance Chapter 7.7
When using cutter, label was not cut Check if media is loaded correctly User’s Guide
straight
When using cutter, label was not cut Check if media is loaded correctly User’s Guide
successfully Check that media thickness does not exceed 250 µm (9.8
mils)
When using cutter, label could not Check if cutter is installed properly Chapter 10.1
feed or abnormal cutting occurs Check if paper feed rods are sticky. Clean if necessary
using isopropyl alcohol.
When using stripper, abnormal func- Check if stripper full sensor is working Chapter 9.1
tion occurs Check if media is loaded properly User’s Guide

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Chapter 14—Troubleshooting

14.3 No Reaction at Power Up


The electronics compartment contains high voltages wires and circuitry.
Whenever possible, disconnect the power cord to eliminate the risk of
electric shock and short circuits before removing the left-hand panel.
When is necessary to test function while the power is on, be extremely
careful to avoid electric shock and never work alone!
Description:
There is no visible reaction when the power to the printer is switched on.
• The Power LED does not light up.
• There is no text in the display window (if any).
Possible Causes and Suggested Remedies:
• No power in AC wall socket.
- Check with some other electrical device or a voltage meter.
• Power cord connectors not completely inserted in printer’s power cord
receptacle or in wall socket.
- Disconnect and firmly connect both ends of power cord. Try again.
• Faulty power cord.
- Replace and try again.
• Power switch or cables to power module defect.
- Using a voltage meter, check voltage between black and white wire in
the connector at the power module end of the cable harness.
• Defect power module.
- Check fuse F1 on power module. If blown, replace only once with a
5A slow fuse. If it blows again, replace the entire power module.
- Check 24 VDC output on CN2 on the power module between line
and ground (there are 3 red line wires and 3 black ground wires). If
there is no +24V, replace the entire power module.
• Power Supply overload.
- Too high a temperature in the power module. Leave the power on and
wait for the power supply to cool off (may take up to half an hour).
When the temperature returns to normal, the printer will automati-
cally restart. If the error persists, examine the power module.
• Cable between main board and power module not properly connected
or damaged.
- Check that the cable between CN2 on the power module and CN28
on the main board is properly connected.
- Check 24 VDC output in the socket at the main board end of the
cable (there are 3 red line wires and 3 black ground wires). If there is
no +24V, the cable is damaged.

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Chapter 14—Troubleshooting

• Main board troubles


- Check the fuse. If blown, replace with a 5A fuse. If the fuse blows
again when the power is switched on, the power supply is probably
damaged and must be replaced, see Chapter 11.1.
• Cable between main board and console board not connected or dam-
aged.
- Check that the cable is properly connected to CN22 on the main
board and CN1 on the console board and that there is no visible
damage. Replace if necessary.
• Faulty console unit.
- Try connecting the cable to a replacement console board without
actually installing it (mind the risk of electrostatic discharges). If
the trouble seems to be the console board, replace the entire panel
module.

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Chapter 14—Troubleshooting

14.4 Error During Printing


Description:
During printing, an error occurs:
• The printing stops
• The Error LED turns solid red.
• An error message appears in the display window (if any).
Possible Causes and Suggested Remedies:
• The printer is out of media or transfer ribbon (Error 07 or 17).
- Check and load a new supply if necessary.
• The printhead was not properly locked in closed position and has
lifted partly or completely (Error 11).
- Engage the printhead and make sure the printhead lever is locked.
- If the printhead actually is closed and locked, but error 11 is still
reported, the headlift sensor may be out of order. Check connection
to CN14 on the main board. Check headlift microswitch (see Chap-
ter 7.6) and replace if necessary.
• Check for jammed or entangled media or ribbon.
- If found, clear and reload. Clean parts that may have been exposed to
the media’s adhesive using isopropyl alcohol or a cleaning card.
• Check if the light path between the upper and lower parts of the label
gap sensor is obstructed by dust, adhesive, or stuck labels.
- If so, clean using isopropyl alcohol or a cleaning card.
• Check for bad settings or program command errors.
- See the User’s Guide or the ESim v5.xx for EasyCoder PD4, Program-
mer’s Reference Manual.

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Chapter 14—Troubleshooting

14.5 No Printing
Description:
Printing is started but nothing is printed.
Possible Causes and Suggested Remedies:
• Incorrectly loaded supplies.
- Check if direct thermal media is loaded with the heat-sensitive side
facing down. If so, reload the media.
- Check if the ink-coated side of the thermal transfer ribbon faces the
media. If not, reload the ribbon.
• Wrong printer driver.
- Check that the correct printer driver is specified in the host computer.
• Wrong Media Type, Paper Type, and Option setup.
- Check that the printer is set for correct media type, paper type, and
print method, either using the Setup mode or program commands
depending on whether the printer has a display or not (see User’s
Guide).
• Bad connection between printhead and main board.
- Check that the printhead is properly inserted into the print mecha-
nism, see Chapter 7.7.
- Check that the cables running from the print mechanism to the main
board are not visibly damaged and that they are properly connected to
the main board, see Chapter 12.3.
- Try installing a replacement printhead (must have the same density!).
• Faulty main board
- Use an oscilloscope to examine the printhead signals on the main
board while trying to print for example a test label (see Chapter 12.5
“Test Points”).
• Label taken sensor active and label not removed.
- Check if the label taken sensor is folded out and enabled and if there
is a label left in the outfeed slot or the ambient light disturbs the label
taken sensor.

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Chapter 14—Troubleshooting

14.6 Printing Partly Missing along the Feed Direction


Description:
Part of the print image is missing on the label along the feed direction.
Possible Causes and Suggested Remedies:
• Ribbon wrinkled.
- In case of thermal transfer printing, check the transfer ribbon for
wrinkles and creases. Reload if necessary. If the problem remains,
adjust the ribbon tension as described in Chapter 6.3.
• Printhead dirty or something is stuck on the printhead.
- Check the printhead for dirt, adhesive residue, contamination from
the back side of the transfer ribbon, stuck labels, etc. If necessary,
clean as described in the User’s Guide using isopropyl alcohol or a
cleaning card. Never use any sharp tools. As a last resort, replace the
printhead (see Chapter 7.7).
• Printhead damaged.
- One or more of the heat-sensitive resistors (“dots”) on the printhead
has been damaged or is worn out. Replace the printhead (see Chapter
7.7).
• Bad printhead balance.
- If the printing is weak or non-existing on either the inner or outer
part of the media, the printhead balance may need to be readjusted as
described in Chapter 7.7. This is most likely to occur when switching
between media of different widths.

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Chapter 14—Troubleshooting

14.7 Printout not in Desired Position


Description:
The print image is not positioned as expected on the labels or similar.
Possible Causes and Suggested Remedies:
• Bad application settings or ESim command errors
- Check the application settings or the ESim commands for possible
explanations. See the application manual or the ESim v5.xx for Easy-
Coder PD4, Programmer’s Reference Manual.
• Label gap sensor errors
- Check if the light path between the two parts of the label gap sensor
is disturbed by dust, stuck labels, or an erroneously loaded transfer
ribbon. Clear or clean.
- Check if the label gap sensor is positioned correctly across the media
path to detect black marks or punched holes. If using irregularly
shaped labels, the sensor should be aligned with the front tip of the
label.
- Calibrate the sensor as described in Chapter 11 in the User’s Guide.
- Check if the label gap sensor is properly connected to CN8 and CN9
on the main board.
- Check that the printer is set the proper paper type (Black mark/Gap
paper/Plain paper). With the power on, check signals on U28, pin
2 (Black Mark) and U28, pin 24 (See Through) on the main board
while manually pulling a media with gaps or black marks through the
two parts of the sensor. If no reaction, the sensor needs replacing as
described in Chapter 7.5.
• The media is not guided properly through the print mechanism.
- Check that the edge guide on the media supply post guides the media
so it runs flush with the guide plate (see Chapter 5.1).
- Check that the inner media guide is placed flush to the inner gable
and that the outer guide is adjusted according to the with of the
media and is folded down so it engages the lower shaft (see Chapter
7.4).
• Bad media properties.
- Check that the media characteristics match the media specifications in
the User’s Guide in regard of position and size of slots, black marks, or
punched holes.
- In case of self-adhesive labels on a liner, consider if the liner has insuf-
ficient transparency or if there is some kind of printing on the liner
that may interfere with the label gap sensor.

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Chapter 14—Troubleshooting

- In case of tickets with black marks, consider if the black marks have
sufficient blackness or if there is some kind of printing on the back of
the media that may interfere with the label gap sensor.
• Bad friction between platen roller and media.
- Check if the platen roller is slippery, worn out, or dry and hard. Clean
or replace if necessary (see Chapter 7.3).

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Chapter 14—Troubleshooting

100 Intermec EasyCoder PD4—Service Manual


A Firmware Upgrading

This appendix describes how to upgrade the printer with a new firmware
version.

Intermec EasyCoder PD4—Service Manual 101


Appendix A—Firmware Upgrading

Requirements
To upgrade the printer’s firmware via a cable connection from a PC run-
ning MS Windows, you will need the following:
• The Intermec EasyCoder PD4 Config Tool. This is a free software
running under Microsoft Windows1. It makes it possible to download
various firmware version either directly to the printer or to a memory
cartridge. It also supports font downloading and memory partitioning.
The Config Tool supports seven languages and comes with a compre-
hensive on-line help in English.
• An upgrading file (.ufz). The Intermec EasyCoder PD4 Config Tool
comes with a collection of firmware upgrading files. New files can be
downloaded from the Intermec Web site (http://www.intermec.com)
and should be located in the subfolder “Firmware.”
• A host computer running Microsoft Windows with a parallel, USB, or
RS-232 connection to the EasyCoder PD4. (Parallel or USB connec-
tions are recommended.)

Instructions
1 Install the Intermec EasyCoder PD4 Config Tool in your PC.
2 Run the PD4Conf.exe program.
3 Set up the parameters for the firmware download. Use the on-line help
for instructions.
4 Start the Firmware download wizard and follow the instructions on the
screen.

1
/. Supported versions of MS Windows: Windows 95, Windows 98, Windows Me, Win-
dows 2000, and Windows XP.

102 Intermec EasyCoder PD4—Service Manual


Intermec Technologies Corporation
Corporate Headquarters
6001 36th Avenue West
Everett, WA 98203
U.S.A.
tel +425.348.2600
fax +425.355.9551
www.intermec.com

Intermec EasyCoder PD4—Service Manual

*1-960618-00*
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