Zebra 2844 Printer Service Manual

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980358-001 Rev. A

2443

2824

2844

Desktop

Thermal Printers

Service Manual

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Summary of 2844 Printer

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Ii 980358-001 rev. A.
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Foreward this manual provides spares replacement and service information for the lp 2443, lp 2824, tlp 2824, lp 2844, and tlp2844 series printers, manufactured by zebra technologies corporation, camarillo, california. Technical support if for any reason you require product technical support, please ...
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Trademarks lp 2824, tlp 2824, lp 2844, tlp 2844 and 2443 are service marks of zebra technologies corporation. Windows and ms-dos are registered trademarks of microsoft corp. All other marks are trademarks or registered trademarks of their respective holders. Operator cautions and warnings these page...
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Media cautions & tips 1) always use high quality approved labels and tags. Approved supplies can be ordered from your dealer. 2) if poor quality, adhesive backed labels are used, that do not lay flat on the backing liner, the exposed edges may stick to the label guides and rollers inside the printer...
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Vi 980358-001 rev. A.
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Contents introduction 1 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 unpacking the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
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2824 parts 45 feet replacement - 2824 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 front bezel replacement - 2824 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 front/cutter bezel replacement - 2824 . . . . . . . . . . . . . . . . . . . . . . . . . . 49 platen r...
Page 9: Introduction
Introduction if you are a field engineer or technician, this manual helps you with routine maintenance, troubleshooting and procedures for replacing parts for repair. Follow the parts replacement procedures as closely as possible. If you are unsure of any procedure, please contact your service repre...
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Models there are several models of the printer, each of which look similar but have different ribbon and media handling features. Lp models print using direct thermal media only. The top case is flat. Tlp models print using either direct thermal or thermal transfer media. The top case flares at the ...
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Conventions this manual uses the following notations to call attention to important information. Icon / symbol meaning warning - critical safety information. Caution - problem avoidance messages. Static sensitive - follow procedures that protect against the discharge of electrostatic energy that acc...
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Environmental and shock protection extreme temperature and humidity fluctuations or mishandling can damage the printer and power supply. Allow 30 minutes or more before opening the printer's plastic bag. This time allows the printer to stabilize temperature especially after storage in a cool, dry lo...
Page 13: Cleaning and Maintenance
Cleaning and maintenance the printers are manufactured and tested under a strict quality management program. Zebra technologies uses only high quality components and materials in its printers. Although only minimal routine maintenance is required, following these simple maintenance guidelines will e...
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Cleaning the media path keep the inside of your printer clean as needed, by using a brush, vacuum or air blower along the media path (except the print head). If a label jams inside the printer, remove the label and any adhesive residue immediately. Adhesive may spread throughout the printer's media ...
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Cleaning the print head when handled during installation, and over time, the print head may become contaminated resulting in poor print quality. After installing a new print head or after using a roll of media or ribbon, rub the cleaning pen across the dark area of the print head. Allow the print he...
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8 980358-001 rev. A.
Page 17: Troubleshooting Guide
Troubleshooting guide problems solutions status indicator does not light when power switch is on (i) 1. Check power connections from the printer to the outlet. Printer is in dump mode but nothing prints after sending file. 1. File does not contain a form feed code that will advance sheet. Press the ...
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Problems solutions printer appears to be working with the indicator light green, but nothing is printed. 1. Check the connections between the printer and the cable as well as the cable and the computer. 2. Verify that the labels are the correct type. 3. Check the roll and verify that the print surfa...
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980358-001 rev. A 11 problems solutions printer firmware must be updated. The printer firmware is updated by way of the parallel port. 1. Use the download utility to send firmware to the printer. 2. Optionally, you can download from the c:\ prompt by typing copy/b filename lpt1: from the directory h...
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Print head wear the print head has a limited life and is considered a consumable item. The media rubs across the print elements and wears away the surface. Media material, operational settings, and environment all affect this process. Printing with worn elements may create illegible images. If the p...
Page 21: Required Tools
Required tools make use of the following tools while performing replacement procedures: • phillips driver #0 • phillips driver #1 • phillips driver #2 • slot-head screwdriver • tweezers • needle-nose pliers • pliers for integrated chips 980358-001 rev. A 13.
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14 980358-001 rev. A.
Page 23: 2844 and 2443 Parts
2844 and 2443 parts the 2844 printers have a four-inch print width. Both the lp and tlp models can print on direct thermal media. The tlp model can also print using ribbons and thermal transfer media. This section includes procedures that are specific to the 2844 printers. The 2443 printer is simila...
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16 980358-001 rev. A 211 lp latch (top cover) 404 platen 401 rubber feet 408 head-up sensor 403 cutter option 410 dispenser label-taken 407 black line sensor assy 406 platen motor 418 real-time clock option 402 front bezel 405 base housing (bottom) 409 main pcba tlp 2844 repair paths 290 lp2844 prin...
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Latch, lp 2844 replacement 980358-211a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release latches forward, th...
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Top cover replacement - lp 2844 980358-214a preparation perform the removal steps of the bottom case (980358-405) and main pcba (980358-409) replacement procedures. Removal 1. Unwrap the ribbon cables and wire bundles from the ferrite core. 2. Use a #1 phillips to loosen the hinge & between top cove...
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Top cover replacement - lp 2844 (continued) 980358-214a 5. Align the hinge in place and use a #1 phillips to tighten the single screw that holds it. Assembling the printer perform the assembly steps of the main pcba (980358-409) and bottom case (980358-405) replacement procedures. 980358-001 rev. A ...
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Print head, lp 2844 replacement 980358-290a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release latches forwar...
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Print head, lp 2844 replacement 980358-290a 5. Replace the four screws that hold the latch bracket to the top case and use a #1 phillips driver to tighten them. 6. Clean the print head with the cleaning pen. Assembling the printer reload media. Plug in the power cord, turn on the printer and run the...
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Packing materials replacement - 2844 980358-400a to ship or store the printer, make sure all components are packed as shown. Move the printer carefully. While the printer has sturdy construction, mechanical damage can certainly result from falls or rough handling. 22 980358-001 rev. A 1 foam set 2 m...
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Feet replacement - 2844 980358-401a preparations tilt the printer to access the bottom. Removal pry the foot 1 off the base ! Using a levering tool if necessary. Assembly 1. Peel the foot off of its backing. 2. Place the sticky adhesive (top of foot) into its receptacle " on the bottom case. 23 9803...
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Front bezel replacement - 2844 980358-402a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal use a small slot-head screwdriver to pry either side free and then lift the bezel away from the printer. Assembly align the tabs with the notches in th...
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Front/cutter bezel replacement - 2844 980358-403a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Use a small slot-head screwdriver to pry either side free and then lift the bezel away from the printer. 2. Unplug the connector. Assembly 1....
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Platen replacement - 2844 980358-404a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Use the blade of a small slotted screw driver to pry the peg ! Free from its hole and rotate the bearing forward a quarter turn. Repeat on the other side...
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Bottom case (base housing) replacement - 2844 980358-405a removal 1. Tilt the printer so you can see the bottom. 2. Use a #1 phillips driver to remove the three screws that secure the bottom case to the bottom frame. 3. Pull the bottom case off of the bottom frame. Assembly 1. Align the bottom case ...
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Motor replacement - 2844 980358-406a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the bottom case replacement proc...
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Black line and bottom gap sensors replacement - 2844 980358-407a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the ...
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Head-up sensor replacement - 2844 980358-408a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the bottom case replace...
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980358-001 rev. A 31 main print circuit board assembly replacement - 2844 980358-409a preparation protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Check your wo...
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Dispenser bezel replacement - 2844 980358-410a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the bottom case replac...
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Latch replacement - tlp 2844 980358-411a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal unsnap the latch assembly 1 from both bearings !" in the top case. Assembly 1. Squeeze the latch handles #$ inward and press into the top case. 2. Push t...
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Cover support replacement - tlp 2844 980358-412a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Use a #1 phillips driver to remove the two screws 2 3 holding the support 1 to the top assembly ! . 2. Lift the support away from the bottom a...
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Hinge replacement - tlp 2844 980358-413a preparation perform the removal steps of the bottom case (980358-405) and main pcba (980358-409) and cover support (980358-412) procedures. Removal 1. Use a #1 phillips driver to loosen and remove the screw 1 that holds the hinge lock 2 onto the bottom media ...
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Upper case (top cover) replacement - tlp 2844 980358-414a preparation perform the removal steps of these procedures: bottom case replacement (980358-405), main pcba replacement (980358-409), and hinge replacement (980358-413). Removal 1. Loosen the four screws 5 6 7 and 8 that hold the upper frame 1...
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Ribbon carriage replacement - tlp 2844 980358-415a preparation perform the removal steps of these procedures: bottom case replacement (980358-405), main pcba replacement (980358-409), hinge replacement (980358-413), and upper case replacement (980358-414). Removal 1. Gently flex the left bearing ! T...
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Feed button/led and top gap sensor replacement - tlp 2844 980358-416a preparation the feed button led pcb and the top gap (receive) sensor are one assembly. To access them, perform the removal steps of these procedures: bottom case replacement (980358-405), main pcba replacement (980358-409), hinge ...
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Feed button/led and top gap sensor replacement (continued) 980358-416a assembling the printer perform the assembly steps of these procedures: ribbon carriage replacement (980358-415), upper case replacement (980358-414), hinge replacement (980358-413), main pcba replacement (980358-409), and bottom ...
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Ribbon motion sensor replacement - tlp 2844 980358-417a preparation perform the removal steps of these procedures: bottom case replacement (980358-405), main pcba replacement (980358-409), hinge replacement (980358-413), upper case replacement (980358-414), and ribbon carriage replacement (980358-41...
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Real time clock option - 2844 980358-418a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the bottom case (980358-405...
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Print head replacement - tlp 2844 980358-490a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release latches forw...
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Tlp2844 print head replacement (continued) 980358-490a 5. Slip the left end of the print head spring 4 into the left side of the ribbon carriage; then slide the right end into the other side. The angle of the "v" fits into the indent on top of the print head bracket ' . 6. Clean the print head with ...
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44 980358-001 rev. A.
Page 53: 2824 Parts
2824 parts the 2824 printers have a two-inch print width. Both the lp and tlp models can print on direct thermal media. The tlp model can also print using ribbons and thermal transfer media. This section includes procedures that are specific to the 2824 printers. 980358-001 rev. A 45.
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46 980358-001 rev. A 311 latch (top cover) 304 platen 301 rubber feet 303 cutter option 316 fd-gap snsr cable assy 310 dispenser label-taken 307 black line sensor assy 306 platen motor 318 real-time clock option 302 front bezel 305 base housing (bottom) 309 main pcba 317 feed/led pcba lp 2824 repair...
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Feet replacement - 2824 980358-301a preparations tilt the printer to access the bottom. Removal pry the foot 1 off the base ! Using a levering tool if necessary. Assembly 1. Peel the foot off of its backing. 2. Place the sticky adhesive (top of foot) into its receptacle " on the bottom case. 47 9803...
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Front bezel replacement - 2824 980358-302a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal use a small slot-head screwdriver to pry either side free and then lift the bezel 1 away from the printer ! . Assembly align the tabs with the notches ...
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Front/cutter bezel replacement - 2824 980358-303a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Pry either side free and then lift the bezel away from the printer. 2. Unplug the connector. Assembly 1. Align the cutter so that the connect...
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Platen replacement - 2824 980358-304a preparations open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Use the blade of a small slotted screw driver to pry the pegs !" free from their holes and rotate the bearing forward a quarter turn. 2. Lift the platen ...
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Bottom case (lower cover) replacement - 2824 980358-305a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Removal 1. Carefully used a small slotted...
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Motor replacement - 2824 980358-306a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the bottom case replacement proc...
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Black line and bottom gap sensors replacement - 2824 980358-307a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the ...
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Main printed circuit board assembly (pcba) replacement - 2824 980358-309a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Check your work when con...
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Dispenser bezel replacement - 2824 980358-310a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the bottom case replac...
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Latch replacement - lp 2824 980358-311a preparations perform the removal steps of the upper case replacement procedure (980358-314). Open the printer by pulling the release latches forward, then lifting the top frame. Removal lift both sides of the latch to 1 unsnap it from the upper frame. Assembly...
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Upper case (top cover) replacement - lp 2824 980358-314a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release l...
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Feed/gap sensor cable assembly replacement - lp 2824 980358-316a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the ...
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Feed/led pcba replacement - lp 2824 980358-317a preparations perform the removal steps of the upper case replacement procedure (980358-314). Removal 1. Lift the feed/led pcba 1 to unsnap it from the upper frame. 2. Detach the cable connector ! From where it plugs into the feed/led pcba. Assembly 1. ...
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Real time clock option - 2824 980358-318a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the bottom case replacement...
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Print head, lp 2824 replacement 980358-390a preparations protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release latches forwar...
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62 980358-001 rev. A.
Page 71: Cable Routing
Cable routing the following simplified charts show routing for the printer's electronic components. 980358-001 rev. A 63.
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Tlp 2844 cable routing 64 980358-001 rev. A tie wrap tie wrap print head (white) ground wire ribbon motion sensor print head (black) right side top simplified wiring diagram - tlp 2844 carriage & upper frame feed / receive gap exit guide guide leave slack so carriage can fully deploy to lowered posi...
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Lp 2844 and lp 2443 cable routing 980358-001 rev. A 65 print head (right) print head (left) right side top simplified wiring diagram - lp 2844 carriage & upper frame feed top case and inner frame are welded together..
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Lp 2824 cable routing 66 980358-001 rev. A simplified wiring diagram - lp 2824 upper frame right side top tie wrap tie wrap tie wrap tie wrap tie wrap guide print head (white) ground wire print head (black) feed / receive gap tie wrap.
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980358-001 rev. A 67.
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980358- 001 a.