Citation: Writer: Lori Elliott       Illustrator: George Wilson


Repairing the 44xx Printer
Repairing the  Click on a topic for more information. Basic Operation and Maintenance  Troubleshooting Testing and Adjusting Replacing Printer Parts Spare Parts List and Exploded Views Printer Specifications Theory of Operation PCB Parts List and Schematics For help using this online document, press F1.


To order PCB parts list and schematics, contact Intermec at:

Phone:  1.425.348.2600, extension 6685.

E-mail: records@intermec.com

E-mail from the internal Intermec network: Records - 600K Docs

Document	Document Title	Part Number

4420 Main PCB	PCB ASSY, MAIN, 4420	067835

4440 Main PCB	PCB ASSY, MAIN, 4440	067836

Cutter PCB	PCB ASSY, MAIN, CUTTER	066181

Self-strip/Batch Takeup PCB	PCB ASSY, SELF STRIP	066073


Basic Operation and Maintenance

Understanding the basic operation and maintenance of the printer includes:

Basic features

Understanding the front panel

Loading media

Loading thermal transfer ribbon

Configuring the serial port

Cleaning the printer


Basic Features

Before you proceed to repair the printer, you may want to familiarize yourself with the printer features. Click on one of the links below to see the different parts of the printer.

Front view of the printer

Rear view of the printer

Internal view of the printer


Front View of the Printer


Rear View of the Printer


Internal View of the Printer


Understanding the Front Panel

Use this information to understand the function of the front panel LEDs and the Feed/Pause button. You use the front panel LEDs to monitor the status of the printer:

Move your mouse over the picture. When the pointer changes to a hand [image], click to see the definition of the front panel feature.


Front Panel LEDs

Use the front panel LEDs to monitor the status of the printer.

LED	State	Indication
Power/Data	Off On Flashing	Power off Power on Receiving data
Alert	Off Flashing On	Printing or idle Over-temperature System fault
Empty/Pause	Off Flashing On	Printing or idle Paused Media fault
Over-temperature    If the printer overheats, the Alert LED flashes and the printer stops. Do not try to troubleshoot or adjust the printer—just allow it enough time to cool down and it will resume operation on its own. You should only encounter this problem after extended print jobs, unusual environmental conditions, or unusual label formats.

Media or system faults    If the Empty/Pause or the Alert LED remains on, your printer is experiencing a media or system fault. See Printer Operation Problems for help in correcting the problem.


Feed/Pause Button

The Feed/Pause button performs several functions depending on the mode of the printer.

Printer Mode	You Want To	What to Do
Idle	Feed out one label or a minimum specified amount of media. Continuously feed media. Take the printer offline.	Press and release the Feed/Pause button Press and hold the Feed/Pause button. When you release the button the media stops feeding. Press the Feed/Pause button twice. Press the button again to bring the printer online.
Printing	Pause the printer. Cancel the current print job.	Press and release the Feed/Pause button. Press and release the button again to resume printing. Press and hold the Feed/Pause button until the printer stops printing.
Powered on for the first time.	Print the hardware configuration test label.	Press and hold the Feed/Pause button. See Printing the Hardware Configuration Test Label for more information.


Loading Media

The default setting for the printer is direct thermal mode. If you are using thermal transfer media, you need to change the media type setting and load thermal transfer ribbon.

To load roll media

1.	Rotate the head lift lever clockwise to disengage the printhead.

2.	Turn the supply roll retainer counterclockwise to release it and then slide it to the outer end of the supply roll post.

3.	Place the media roll on the supply roll post and position it firmly against the inside of the printer.

4.	Insert the media support between the roll of media and the supply roll retainer and then secure the supply roll retainer against the media by sliding it in and turning clockwise.

5.	Unroll several inches of media and thread it through the printer. Make sure the label passes between the upper and lower media guides.

6.	Unscrew the edge guide and adjust it to position the media firmly against the inside wall of the printer.

7.	Adjust the label gap sensor position if necessary.

8.	If you are using thermal transfer media, you need to load ribbon before finishing this procedure.

9.	Rotate the head lift lever counterclockwise to lock it in position.

10.	Press the Feed/Pause button to advance several inches of media through the printer and out the front of the printer.

Note: If you are loading continuous media or mark label stock, use PrintSet, your third-party software, or the IPL command set to tell the printer what kind of media you are using.


Illustration of Loading Media


Loading Thermal Transfer Ribbon

If you plan to print in thermal transfer mode, you must install a thermal transfer ribbon after you install the thermal transfer media.

The core of your thermal transfer ribbon is either made of cardboard or plastic. You need to use the correct core-locking brackets for your ribbon core or you may experience printing problems or possible damage to the printer. The printer ships from the factory with the cardboard core-locking brackets already attached.

To load thermal transfer ribbon

1.	Make sure that you have raised the printhead. If not, turn the head lift lever clockwise to disengage the printhead.

2.	If the core of your ribbon is made of plastic, you need to replace the cardboard core-locking brackets with the plastic core-locking brackets.

3.	Place an empty ribbon core on the ribbon rewind hub.

4.	Detach the leader from the new thermal transfer ribbon roll and unwind approximately 8 inches. The edge of the ribbon should have an adhesive strip leader that you can use to guide the ribbon through the printer.

5.	Slide the roll of thermal transfer ribbon onto the ribbon supply hub. Make sure that the ribbon roll unwinds clockwise.

6.	Route the ribbon leader through the printer.

7.	Attach the adhesive strip on the leader to the empty ribbon core and turn the ribbon rewind hub clockwise until the ribbon runs smoothly through the printhead mechanism.

Note: Make sure the ribbon runs above the upper media guide. The shiny side of the ribbon must come in contact with the printhead.

8.	Rotate the head lift lever counterclockwise to lock it in position.

9.	Enable thermal transfer printing by setting DIP switch 8 on the bottom bank of switches to the on position. Refer to Configuring the Serial Port for more information.


Replacing the Ribbon Core-Locking Brackets

To replace the cardboard core-locking brackets with the plastic core-locking brackets

1.	Pull up on the middle of the cardboard core-locking bracket (P/N 065375) until the bracket is free of the ribbon hub.

2.	Slide one end of the plastic core-locking bracket (P/N 066792) into a bracket slot on the ribbon hub.

3.	Lift up on the middle of the bracket and slide the other end of the bracket into the remaining bracket slot.


Illustration of Loading Thermal Transfer Ribbon


Printing a Hardware Configuration Test Label

You can print the hardware configuration test label to make sure that the printer is operating correctly. The hardware configuration test label contains information such as the amount of memory installed and the firmware version.

To print the hardware configuration test label

1.	Turn off the printer.

2.	Press and hold the Feed/Pause button while you turn on the printer. The Alert and Empty/Pause LEDs blink during the printer self-test.

3.	Release the Feed/Pause button when the media starts to move. The printer feeds out one or two blank labels and then prints the hardware configuration test label.

4.	Turn the printer power off and then on again.

If the printer does not print a hardware configuration label, see Printer Operation Problems for help.


Illustration of a Hardware Configuration Label


Configuring the Serial Port

The DIP switches on the rear panel of the printer control communications parameters, media type configuration, and test and service functions. The printer ships from the factory with the 16 DIP switches set to the default configuration.

Note: You need to configure the printer serial port for 8 data bits if you want to print code pages or 8-bit ASCII character sets. Also, use XON/XOFF protocol for Ready/Busy buffer control.

To configure the printer serial port

1.	Set the DIP switches on or off with a small straight-slot screwdriver.

2.	Turn the printer power off and then on for the configuration changes to take effect.

Note: Make sure you set all Multi-Drop switches to off if you are not using a Multi-Drop network.

Top Bank of DIP Switches

Bottom Bank of DIP Switches


Top Bank of DIP Switches

0 = OFF
1 = ON
Red text = Default setting

DIP Switch Number	1	2	3	4	5	6	7	8
Baud Rate Selection 115,200 57,600 38,400 19,200 9,600 4,800 2,400 1,200	1 0 1 0 1 0 1 0	1 1 0 0 0 1 1 0	1 1 1 0 0 0 0 1
Parity Selection Even Odd None None				0 1 0 1	0 0 1 1
Number of Data Bits 7 bit 8 bit						0 1
Reserved							0
Batch Takeup Disabled Enabled								0 1


Bottom Bank of DIP Switches

0 = OFF
1 = ON
Red text = Default setting

DIP Switch Number	1	2	3	4	5	6	7	8
Multi-Drop Address Selection A B C D E F G H I J K L M N O P Q R S T U V W X Y Z 0 1 2 3 4 5	0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1	0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1	0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1	0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1	0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Protocol Selection XON/XOFF Industry Standard XON/XOFF Intermec Standard Intermec Auto Discriminate Intermec Multi-Drop						0 0 1 1	0 1 0 1
Media Type Direct Thermal Thermal Transfer								0 1


Cleaning the Printer
Before you clean the printer, you may want to check for these items:

•	Make sure that the printer is properly grounded.

•	Inspect the work environment. Be aware that large electric motors, welders, and switching equipment can affect printer performance.

•	Check for loose wires or poorly installed connections. Make sure you replace corroded wires.

These procedures explain how to access the printer parts and clean them without causing any harm to the printer or yourself.

	Warning Turn off the printer power and remove the power cord before cleaning any part of the printer.
Cleaning the printhead

Cleaning the rollers and the tear bar

Cleaning the media guides and the media path

Cleaning the label sensors


Tools for Cleaning the Printer

To clean the printer safely and effectively, use these items:

•	Isopropyl alcohol

•	Cotton swabs

•	Clean lint-free cloth

•	Soft bristle brush or vacuum cleaner

•	Soapy water or mild detergent


Cleaning the Printhead

To provide good print quality, the printhead needs to maintain close contact with the media. Clean the printer after every roll of media (6,000 inches or 152 m) or ribbon (18,000 inches or 457 m). Clean more often if necessary.

	Caution Do not use sharp objects such as knives or screwdrivers to scrape the printhead clean. Cleaning with sharp objects will damage the printhead. Clean with only a cotton swab, or a clean, lint-free cloth or tissue damp with isopropyl alcohol.
To clean the printhead

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, raise the printhead, and remove the media and ribbon if necessary.

3.	Use a cotton swab moistened with alcohol to remove any dirt, adhesive, or debris from the print surface on the bottom of the printhead.

4.	Wait 5 to 10 seconds for the print surface to dry.

5.	Replace the media and ribbon, lower the printhead, and replace the media cover.


Illustration of Cleaning the Printhead


Cleaning the Rollers and the Tear Bar

Clean the rollers and tear bar when necessary to preserve print quality by ensuring close contact between the media and the printhead.

To clean the rollers and the tear bar

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, raise the printhead, and remove the media and ribbon if necessary.

3.	Clean the rollers by using a lint-free cloth moistened with isopropyl alcohol. Use a side-to-side motion to make sure that you remove all debris. Make sure that you rotate the rollers to clean all areas.

4.	Clean both sides of the tear bar with the moistened cloth. Remove all traces of dust, paper, and adhesive.

5.	Replace the media and ribbon, lower the printhead, and replace the media cover.


Illustration of Cleaning the Rollers and Tear Bar


Cleaning the Media Guides and the Media Path

Clean the media guides and the media path regularly to keep debris off the media surface and printhead where irregularities can spoil print quality or damage the printhead. Cleaning the guides also prevents the media from skewing or improperly tracking as it travels through the media path, which can result in smeared images and print off the side of the label. Always clean the media guides after a label jam in the printer.

To clean the media guides and media path

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, raise the printhead, and remove the media and ribbon if necessary.

3.	Pull down on the lower media guide to open up the media path.

Note: The lower media guide is spring loaded. You must hold it open to clean.

4.	Using a lint-free cloth moistened with isopropyl alcohol, clean both the upper and lower media guides . Make sure that you remove all traces of debris.

5.	Remove all traces of dust, paper, and adhesive from the media path with a soft bristle brush or vacuum.

6.	Use the moistened cloth to clean the flat surfaces of the media path (including the edge guide). Release the lower media guide.

7.	Replace the media and ribbon, lower the printhead, and replace the media cover.


Illustration of Cleaning the Media Path and Media Guides


Cleaning the Label Sensors

These two sensors on the printer require regular cleaning:

•	Label mark sensor

•	Label gap sensor

To clean the label sensors

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, raise the printhead, and remove the media and ribbon if necessary.

3.	Clean the label mark sensor with a cotton swab moistened with isopropyl alcohol.

4.	Pull down on the lower media guide to expose the label gap sensor. Using a cleaning brush or vacuum, remove all debris and dust from the label gap sensor.

5.	Clean the label gap sensor with a cotton swab and alcohol. Release the lower media guide.

6.	Replace the media and ribbon, lower the printhead, and replace the media cover.


Illustration of Cleaning the Label Sensors


Troubleshooting

You may have printer operation, print quality, or printer communications problems at some time during the life of the printer. It is easy to fix most problems and consequently not delay operation of the printer for long periods of time.

To troubleshoot your printer

1.	First try cleaning the printer and checking all of the connections.

2.	If cleaning the printer and checking the connections does not solve the problem, use one of these links to locate the symptom. Follow the solution in the link to fix your problem.

Printer Operation Problems

Print Quality Problems

Printer Communications Problems

Environmental Problems

Preventing Data Loss


Printer Operation Problems

If your printer is not operating correctly, try locating the problem in this list:

•	No power or loss of power.

•	Labels stop feeding through the printer.

•	Printer slows down.

•	The Alert LED flashes and printing stops.

•	Media fault.

•	Hardware test configuration label does not print.

•	Printer is not communicating, not printing, or not printing properly.

•	All of the front panel LEDs remain on after you turn on the printer.

•	Continuous media fault light.


No Power or Loss of Power

Possible cause:    You have damaged or disconnected the AC power cable.

Solution:    Make sure you have plugged the power cable into both the printer and an outlet or power strip. Replace the cable if damaged.

Possible Cause:    Printer circuit breaker tripped.

Solution:    Turn off the printer and then turn it on again.


Labels Stop Feeding Through the Printer

Possible Causes:    Printer is out of media or you have loaded the media incorrectly.

Solution:    Load media or check the media path.

Possible Cause:    Label gap or label mark sensors are dirty.

Solution:    Clean the label sensors.

Possible Cause:    Printer is set for continuous label stock type.

Solution:    Use PrintSet or the Transmit Configuration Parameters IPL command to check the configuration settings. Use PrintSet or the Label Stock Type, Select IPL command to configure the printer for label gap or label mark media.

Possible Cause:    Media is sticking to the paper path.

Solution:    Clear any extraneous material from the paper path and clean the path thoroughly.


Printer Slows Down

Possible Causes:    You have incorrectly set the image bands or print speed.

Solution:    Use PrintSet or the IPL command set to change the number of image bands or the print speed setting.

Possible Causes:    The printer has aborted and reset the print speed and image bands.

Solution:    Use PrintSet or the IPL command set to change the number of image bands or the print speed setting.


The Alert LED Flashes and Printing Stops

Possible Causes:    Printhead has overheated.

Solution:    Leave the printer alone until it has time to cool down. It will resume printing on its own.


Media Fault

Possible Causes:    The printhead is up.

Solution:    Make sure the printhead is down. The head lift lever should be almost straight up and down (in the 1 o’clock position). Press the Feed/Pause button to resume printing.

Possible Causes:    Sensor type set incorrectly.

Solution:    Configure the printer for the correct sensor, either label gap or label mark sensor. Use PrintSet or the IPL command set to configure the correct sensor.

Possible Causes:    You have loaded the media incorrectly or the printer is out of media.

Solution:    Try reloading the media.

Possible Causes:    One of the sensors is located incorrectly.

Solution:    Adjust the label gap sensor or the label mark sensor to the correct location for the type of label stock that you are using.

Possible Causes:    Media type is set incorrectly.

Solution:    Make sure the DIP switch for media type is set correctly. Configure the media type for either direct thermal (default) or thermal transfer.

Possible Causes:    Printer configured for self-strip.

Solution:    Configure the printer for the correct operation.


Continuous Media Fault Light

Possible Causes:    The label mark sensor is not in the correct position.

Solution:    Adjust the label mark sensor to the correct location for the type of label stock that you are using.


Hardware Test Configuration Label Does Not Print

Possible Causes:    You have loaded the media incorrectly.

Solution:    Try reloading the media.

Possible Causes:    You have configured the printer for self-strip media.

Solution:    Set the printer to the default configuration settings.

Possible Causes:    Media fault.

Solution:    See possible media fault causes and solutions.


Printer is Not Communicating, Not Printing, or Not Printing Properly

Possible Causes:    Corrupt or incorrect information in the printer memory.

Solution:    Reset the memory to return the printer to its default configuration.


All of the front panel LEDs remain on after you turn on the printer

Possible Causes:    The printer boot sector has been lost or erased.

Solution:    Reload the printer firmware including the boot sector.


Print Quality Problems

If your labels are not printing properly, try locating your problem in this list:

•	Blotches printing on labels.

•	Printing is too light or too dark.

•	Printing is not aligned on the label.

•	Labels are not stopping at the right point for removal.

•	Print quality is poor

•	The printer skips labels randomly or sends an intermittent error.

 •	Label prints too close to front or back edge of label.


Blotches Printing on Labels

Possible Causes:    Dirty printhead.

Solution:    Clean the printhead.

Possible Causes:    Dirty media path.

Solution:    Clean the media path.

Possible Causes:    Poor quality label or ribbon stock.

Solution:    Use only Intermec label and ribbon stock to ensure superior print quality and product performance.


Printing is Too Light or Too Dark

Possible Causes:    Incorrect darkness adjust control setting.

Solution:    Adjust the print darkness to achieve the best print quality.

Possible Causes:    Incorrect media sensitivity number.

Solution:    Change the sensitivity setting to match the type of media that you are using. For help, refer to the PrintSet online help or your user's manual. If you set the sensitivity setting correctly, try adjusting the print darkness.

Possible Causes:    Poor quality label or ribbon stock.

Solution:    Use only Intermec label and ribbon stock to ensure superior print quality and product performance.

Possible Causes:    Dirty printhead.

Solution:    Clean the printhead.


Printing is Not Aligned on the Label

Possible Causes:    Printer is misfeeding media.

Solution:    Try reloading the media.

Possible Causes:    Poor printhead alignment.

Solution:    Realign the printhead.


Labels Are Not Stopping at the Right Point for Removal

Possible Causes:    The label rest point setting is incorrect.

Solution:    Adjust the label rest point. Use PrintSet or the Label Rest Point, Adjust IPL command to configure the label rest point.


Print Quality is Poor

Possible Causes:    Incorrect darkness adjust control setting.

Solution:    Adjust the print darkness to achieve the best print quality.

Possible Causes:    Incorrect media sensitivity number.

Solution:    Change the sensitivity setting to match the type of media that you are using. If you set the sensitivity setting correctly, try adjusting the print darkness.

Possible Causes:    Poor quality label or ribbon stock.

Solution:    Use only Intermec label and ribbon stock to ensure superior print quality and product performance.

Possible Causes:    Ribbon wrinkling or the ribbon is installed upside down.

Solution:    Make sure that you have loaded the ribbon correctly, including the bias adjust.

Possible Causes:    Print speed exceeds the capability of the media.

Solution:    Lower your print speed or use Intermec media recommended for your print speed.

Possible Causes:    Printhead, platen roller, or media path are dirty.

Solution:    Clean the printhead, platen roller, or media path.

Possible Causes:   Uneven print contrast (density).

Solution:   Adjust the bias adjust screw.

Possible Causes:    Direct thermal/thermal transfer DIP switch in the wrong position.

Solution:    Set the DIP switch to the correct position for the media you are using.

Possible Causes:    Media may be slipping against the platen roller causing the printing to compress.

Solution:    Switch to approved media or clean the printhead or platen roller.

Possible Causes:    You are using the wrong core-locking bracket on your ribbon hub.

Solution:    Replace the ribbon core-locking bracket with the correct bracket for your ribbon core. Use the plastic core-locking bracket for plastic ribbon cores and the cardboard core-locking bracket for cardboard ribbon cores.

Possible Causes:    The printhead is installed incorrectly.

Solution:    Perform the printhead alignment procedure.


The Printer Skips Labels Randomly or Sends an Intermittent Error

Possible Causes:    The label format extends beyond the label length.

Solution:    Edit the format to make sure that it fits on the label.

Possible Causes:    The label gap sensor is not in the correct position.

Solution:    Adjust the label gap sensor to the correct location for the type of label stock that you are using.


Label Prints Too Close to Front or Back Edge of Label

Possible Causes:    The top of form position is not adjusted properly.

Solution:    Use the top of form switch to fine-tune the top of form position or use the Top of Form IPL command.


Printer Communications Problems

If your printer is not receiving downloaded data, try locating your problem in this list:

•	Printer does not communicate with the host


Printer Does Not Communicate With the Host

Possible Causes    Serial port is configured incorrectly.

Solution    Make sure the printer’s serial port settings match those of the host. Print a software test configuration label to check the settings.

Possible Causes    Damaged or incorrect I/O cable.

Solution    Check the connections at both ends or replace the cable.


Environmental Problems

Symptoms associated with environmental problems include:

•	Printing garbage

•	Resetting

•	Total lockup

To determine if the problem is environmental, move the printer to a new location and see if the problem disappears. If the problem appears in a printer that has recently been moved from another area, it is probably an environmental problem.

Follow these steps when you are troubleshooting environmental problems:

1.	Correlate an environmental event with the failure.

2.	Check for static discharges.

3.	Check for adequate grounding.

4.	Check the AC power for proper level and purity.

5.	Check for inductive motors, relays, or other spike inducing equipment on the power line.

6.	Exercise good judgment and common sense.

When you have isolated the problem, use this list to help you find a solution:

•	Electrostatic Discharge (ESD)

•	Electromagnetic and Radio Frequency Interference (EMI and RFI)

•	Ground Loops Between Equipment

•	Inadequate Earth Ground

•	AC Power Problems (Surges, Sags, Spikes, Noise, and Outages)


Electrostatic Discharge (ESD)

ESD can cause failure or weakening of affected components. Typically, ESD occurs when a person with a large electrical potential unintentionally discharges that potential by touching the conductive surfaces of the equipment. Static charge is created through friction from:

•	people walking

•	conveyor belts

•	paper moving through a printer

•	wheelchairs

The solution is to reduce the charge by grounding and by employing prevention measures such as antistatic bags for ICs and PCBs, grounded antistatic mats, antistatic spray for carpeting, antistatic clothing (no wool), antistatic wax for tile floors, conductive floor materials, air ionizers, and antistatic cleaners for plastics. To further protect against ESD, use shielded cable for interface cables, and tie the shield to metal backshells at both ends of the cable. Do not connect the shield of the cable to chassis ground or signal ground of the interface.


Electromagnetic and Radio Frequency Interference EMI and RFI
Electromagnetic and Radio Frequency Interference (EMI and RFI)

Noise induced in interface cables can result in the printer receiving false data. This noise may cause the printer to skip printing a label or lockup. Sources of EMI and RFI are radio transmitters, ignition systems, and relays. To eliminate the effects of EMI and RFI, use low capacitance, twisted pair, shielded cables. Route cables away from sources of EMI and RFI such as large inductive motors or fluorescent lighting ballasts. Do not run cables near AC power lines. If communication cables must run near AC power lines, cross them at 90 degree angles. Eliminate ground loops; they act as receiving antennas for RFI. Limit the number of breaks (connectors) in the cable. It is possible to use a power line monitor to test for noise on the interface cable.


Ground Loops Between Equipment

Ground loops pick up RFI as well as generate their own noise in interface cables. The recommended wiring of the interface cable calls for connecting chassis ground (pin 1) between the host computer and the printer to ensure that the chassis of both devices remains at the same electrical potential in the event of a faulty ground in either device. With this wiring you would normally expect problems with ground loops, but the printer, chassis ground, and signal ground are connected to each other through a 10kΩ resistor, thus providing some ground loop immunity.

If connections in the interface cable described above are discovered to cause ground loop problems, disconnect the shield from the backshell at only the printer, and sever the chassis ground (pin 1) connection between the host computer and the printer. To ensure safety, double your efforts to guarantee that both the host computer and the printer make a solid electrical and physical connection to earth ground.


Inadequate Earth Ground

Poor grounds can cause fuses on equipment to blow and may damage components. The ground in the AC power receptacle must be a good, solid earth ground. Do not rely on conduit for ground. The ground rod should penetrate the earth at least 8 feet below the frost line. The soil should contain clay minerals; dry, sandy soil does not provide a good ground. Ensure that all ground connections from the service panel to the AC receptacle are solid and secure.


AC Power Problems (Surges, Sags, Spikes, Noise, and Outages)

Most environmental problems involve the AC power line. In the 4420 printer, 115V supply voltages can range from 90 VAC to 132 VAC. Outside the U.S., 230V supply voltages can range from 180 VAC to 264 VAC. Voltage overages or underages can result from poor utility regulation to in-plant loading of the power service. Use a power line monitor to look for power service problems. To eliminate the effects of voltage overages and underages, install an uninterruptible power supply (UPS) or install a dedicated circuit for the printer and the host computer.

Intermittent power outages can be caused by a combination of vibration and loose connections between the service panel and the AC receptacle. Check the wiring to ensure that all connections are solid and secure. Use a power line monitor to test for outages. To eliminate the effects of power outages, install a UPS.

Impulse noise on the power line can cause the printer to lockup or reset. All Intermec products, including the 4420 printer, can withstand impulses on the power line of 280V maximum. Impulses can range from 200V to 5000V and are caused by lightning, switching operations, firing of SCRs, triacs, static discharge, and arc welders. Use a power line monitor to verify the presence of impulse noise and use a spike suppressor to eliminate its effect.

Irregular sine waveforms on the AC power line can also effect printer performance. Irregular sine waveforms are caused by switching power supplies. Use a power line monitor to verify the presence of irregular sine waveforms and use a power line conditioner to eliminate their effects.

High frequency noise and hash riding on the AC waveform can affect printer performance. It is caused by transmitters and ignition systems. Use an oscilloscope to verify the presence of noise and hash. Install EMI/RFI filters to eliminate their effects.


Preventing Data Loss

There are a variety of conditions that can cause data loss or communication problems on the 4420 printer. Data loss can result in printing errors or missing field data.

The 4420 printer is a serial ASCII device that communicates with the host through an ASCII serial communication I/O port. Hardware handshaking involves the use of a hardware wire. Software handshaking involves a two-way datalink between the devices. The two devices communicate with each other without losing data through the use of handshaking. The printer sends both forms of handshaking simultaneously when the printer’s input buffer is full. Any loss of data can cause printing errors or missing data.

Hardware handshaking uses pins 11 or 20 of the RS-232 interface to control data flow. When the printer is using Intermec Standard protocol, it holds pins 11 and 20 high when it is ready to receive data. The printer holds the pins low when it is in one of these conditions:

•	Buffer full

•	Ribbon fault

•	No label stock

•	Label at strip pin

The printer uses XON/XOFF protocol for software handshaking. When the input buffer is full, the printer transmits an XOFF character. This character alerts the host to the fact that the printer buffer is full and cannot receive any more data. When the printer is ready to receive more data, it sends the XON character.

To check for communications problems

1.	Check the cabling from the printer to the host system.

2.	Check the communications interfacing of the devices connected to the printer.

3.	Check the printer for proper electrical operation of the I/O port.

4.	Ensure that the host system is not overrunning the printer input buffers.

5.	Ensure that the data string being sent to the printer contains the correct information.


Testing and Adjusting

Use the Test and Service mode, printer adjustments, and alignment procedures to return the printer to optimum performance after you have replaced a component.

Using Test and Service Mode

Adjusting the Printer

Performing Alignment Procedures

Reloading the Printer Firmware


Using Test and Service Mode

Use Test and Service mode to print test labels and provide printer hardware diagnostic information to the host. Once you enter Test and Service mode, the printer will remain in Test and Service mode until the power is turned off and the DIP switches are reset. All functions are executed as soon as they are selected. Selecting a new function terminates the current test.

•	To enter Test and Service mode

•	To exit Test and Service mode

Here are the Test and Service Mode DIP Switch Settings:

•	Test Labels

•	Data Line Print Mode


To enter Test and Service mode

1.	Turn off the printer.

2.	Press and hold the Feed/Pause button while turning on the printer.

The printer prints out a hardware configuration test label and then enters Data Line Print mode.

3.	Set the DIP Switches to the test or service function that you wish to perform.

4.	Press and hold the Feed/Pause button. The test begins immediately.

5.	If you want to perform another function, change the DIP switch settings and press the Feed/Pause button.


To exit Test and Service mode

1.	Turn off the printer.

2.	Reset the DIP switches to their original settings.

3.	Turn on the printer.


Printing Test Labels

The 4420 and 4440 printers can print a variety of test print labels that provide you with information about the printer configuration and the print quality. Use the test labels to check printhead alignment, printhead bias, dots out of specification, label tracking, and ribbon wrinkling.

Once the printer begins to print test labels, it continues to print new labels until you press and hold the Feed/Pause button. To momentarily stop printing labels, press and release the Feed/Pause button.

To print a test label

1.	Turn off the printer.

2.	Press and hold the Feed/Pause button while turning on the printer.

The printer prints out a hardware configuration test label and then enters Data Line Print mode.

3.	Set the DIP switches to print the test label you want.

4.	Hold the Feed/Pause button until the printer starts printing the test label.

5.	Exit Test and Service mode.

Use these labels to troubleshoot your printing problems:

•	Hardware Configuration Test Label

•	Software Configuration Label

•	Print Quality Label

•	Pitch Label

•	Format Label

•	Font Label

•	Page Label

•	UDC Label


Hardware Configuration Test Label

The hardware configuration test label is the first label to print when you enter Test and Service mode. This label contains information on:

•	printer memory including both storage and image RAM.

•	printer mileage including inches processed and inches burned.

•	printhead settings including width, dot size, and burn pot setting.

•	firmware checksum, program, and version number.

•	vertical lines for adjusting the printhead alignment.

To achieve the highest quality label, print the hardware configuration test label. Use the bias adjust screw to correct uneven print quality problems with narrow media.


Software Configuration Label

The software configuration label lists the current configuration parameters stored in printer memory. To change the printer configuration settings, use PrintSet or download IPL commands from the host. The software configuration label also lists defined pages, formats, graphics, fonts, and any printer options you have installed.


Print Quality Label

The print quality label contains several bar code fields that you can use to determine if you are getting the best print quality possible. If you notice problems with the print quality, align the printhead to adjust the printhead for optimal performance.


Pitch Label

The pitch label contains a gray scale that the printer produces by printing every third dot of the printhead. You can use this label to determine whether the printhead is printing evenly. The label should present a regular gray pattern with dots that line up diagonally when the label is held at an angle. Look for irregularities or chips in the dot pattern that may indicate a problem with the platen roller or the media path. You can also diagnose other problems, such as an uneven printhead or a skewed print path, by evaluating the gray scale on the pitch label.


Format Label

The format label contains a single format that you can use to evaluate the print quality of a particular format. You can set the DIP switches to print a specific format label or you can print labels for all of the formats stored in printer memory.


Font Label

The font label contains all of the characters in a single font. You can print an "all-font" test, but this test uses a lot of media. It is a better idea to test one font at a time.


Page Label

The page label tests the ability of the printer to receive and print single or multiple pages of label data that is sent from the host. To correctly evaluate the print quality of the printer, use a page format supplied by the customer when you run this test.


UDC Label

The UDC label tests the ability of the printer to receive and print single or multiple user-defined characters (bitmap graphic) that are sent from the host. To further assess the print quality of the printer, test print a UDC supplied by the customer.


Running Test and Service Mode From a Host

There are several Test and Service mode IPL commands that you can use with the printer. All commands in Test and Service mode must end with the command terminator (;), except the last command in a message.

To enter Test and Service mode from Print mode

•	Send this command from the host:  <ESC>T

To exit Test and Service mode

•	Send this command from the host:  R

Use these Test and Service commands to print test labels and transmit sensor values.


Test and Service Commands

Syntax	Command	Description
C	Print Pitch Label	Causes the printer to print the pitch label.
D	Reset Printer Configuration	Sets the printer configuration to the factory defaults.
G	Transmit Transmissive Sensor Value	Transmits the label gap output back to the host. Values range from 00 to FF.
K	Dark Adjust	This command changes the darkness of the print on your labels. It is for fine-tuning only.
L	Transmits Paper Path Open Sensor Value	Transmits the Paper Path Open switch value back to the host. A value of 0 indicates the paper path is open and a value of 1 means that it is closed.
M	Transmit Reflective Sensor Value	Transmits the label mark reflective sensor output back to the host. The values range from 00 to FF.
P	Transmit Printhead Temperature Sensor Value	Transmits the printhead temperature sensor output back to the host. Values range from 00 to FF.
Q	Print Quality Test	Causes the printer to print out the print quality program and model number label.
T	Transmit Label Taken Sensor Value	Transmits the label taken sensor output back to the host. Values range from 00 to FF.


Test and Service Mode DIP Switch Settings - Test Prints

0 = OFF
1 = ON
Red text = Default setting	Top Bank	Bottom Bank

DIP Switch Number	1	2	3	4	5	6	7	8	1	2	3	4	5	6	7	8
Test Prints Configuration Hardware Software	0	0	0	0	0	0	0 1	0 0								Q Q
Test Labels Print Quality Pitch				1	0	0	0 1	0 0								Q Q
Page Single Page All Pages				0	1	0	0	0	N 1	N 1	N 1	N 1	N 1			Q Q
Format Single Format All Formats				1	1	0	0	0	N 1	N 1	N 1	N 1	N 1			Q Q
UDC Single UDC All UDCs				0	0	1	0	0	N 1	N 1	N 1	N 1	N 1	N 1	N 1	Q Q
Font Single Font All Fonts				1	0	1	0	0	N 1	N 1	N 1	N 1	N 1	N 1
Q:  OFF = Batch of 1.  ON = Batch of 100.
N:  Page/Format/UDC/Font number. Least significant bit is Switch 8.
S:  Source Page/Format/UDC/Font number.
D:  Destination Page/Format/UDC/Font number.


Test and Service Mode DIP Switch Settings - Data Line Print Mode

0 = OFF
1 = ON
Red text = Default setting	Top Bank	Bottom Bank

DIP Switch Number	1	2	3	4	5	6	7	8	1	2	3	4	5	6	7	8
Data Line Print	1	0	0	0	0	0	0	0
Selective Transfer Receiver Send Pages Single Page All Pages	1	1	0	0 1	0 0	0 0	S 1	S 1	S 1	S 1	S 1	D 1	D 1	D 1	D 1	D 1
Send Format Single Format All Formats				0	1	0	S 1	S 1	S 1	S 1	S 1	D 1	D 1	D 1	D 1	D 1
Send UDC Single UDC All UDCs				1	1	0	S 1	S 1	S 1	S 1	S 1	S 1	S 1	S 1
Send Font Single Font All Fonts				0	0	1	S 1	S 1	S 1	S 1	S 1	D 1	D 1	D 1	D 1	D 1
Send Configuration Send Tables Send All				1 0 1	0 1 1	1 1 1
Memory Reset Page/Format UDC/Font Configuration Tables All	0	0	1	0 1 0 1 1	0 0 1 1 1	0 0 0 0 1
Q:  OFF = Batch of 1.  ON = Batch of 100.
N:  Page/Format/UDC/Font number. Least significant bit is Switch 8.
S:  Source Page/Format/UDC/Font number.
D:  Destination Page/Format/UDC/Font number.


Adjusting the Printer

Use these procedures to perform minor adjustments on the printer:

Adjusting the Label Gap Sensor

Correcting Uneven Print Quality

Fine-Tuning the Top of Form Position

Adjusting the Print Darkness

Adjusting the Label Mark Sensor

Adjusting the Printhead Adjustment Lever


Adjusting the Label Gap Sensor

If you experience problems such as the printer skipping labels or the printer stopping and the yellow LED flashing, you may need to adjust the label gap sensor. You are most likely to experience any of these problems if you are using very narrow label stock and the label gap sensor is not in the correct position. You can adjust the label gap sensor from 0 to 1.0 inch
(2.54 cm) from the inner edge of the printer.

Note:  Intermec sets the label gap sensor to 0.5 inch (1.27 cm) from the inner edge of the printer at the factory. You should be able to leave it in this position for most labels wider than 1.0 inch (2.54 cm).

Note:  The label gap sensor does not have an adjustable potentiometer.

To adjust the label gap sensor

1.	Remove the media cover.

2.	Turn the label gap sensor knob approximately ½ turn counterclockwise to free the sensor for adjustment.

3.	Slide the label gap sensor knob to the position where the label gap sensor is optimized for your label stock.

Here are some guidelines for you to follow.

4.	Turn the label gap sensor knob clockwise to secure it in the new position.

5.	Print a label to see if the printer is detecting the start of the label (top of form).

6.	If the printer still does not detect the top of form, slide the label gap sensor a little further toward the outer edge of the lower media guide.

7.	Replace the media cover.


Guidelines

•	If your labels are less than 1.0 inch (2.54 cm) wide, position the label gap sensor in the middle of the label.

•	If your labels are greater than 1.0 inch (2.54 cm) wide, position the label gap sensor over the straight edge of the label (not over the radius).

•	If your labels are round, position the label gap sensor over the middle of the radius edge.


Illustration of Adjusting the Label Gap Sensor


Correcting Uneven Print Quality

You may experience problems in print quality (ribbon wrinkling or light print on one side of your label) if the printhead is not making even contact with the label stock. This condition can happen with any size of label stock, but is most common when using narrow label stock. You need a straight-slot screwdriver to turn the bias adjust screw.

To achieve the best print quality, adjust the bias adjust screw each time you use media of a different width.

Note: You must properly adjust the bias adjust screw to prevent premature printhead failure and excessive platen wear.

To adjust the bias adjust screw

1.	Remove the media cover and locate the bias adjust screw.

2.	To compensate for uneven print quality, turn the bias adjust screw .

Adjusting the bias adjust screw causes the printhead to rest evenly on the drive roller and results in even print quality.

3.	Replace the media cover.


Locating the Bias Adjust Screw


Illustration of Correcting Uneven Print Quality


Fine-Tuning the Top of Form Position

If your label format prints too close to the front or back edge of the label, you can fine-tune the position with the top of form (TOF) switch. The TOF switch controls the position of the format forward or backward along the length of the label.

Only use the TOF switch to fine-tune your label format position. Do not use the TOF switch to design your label format. This is important because the printer returns to the default TOF setting when you:

•	cycle printer power

•	lift the printhead

Use the TOF switch to fine-tune the format position after you design the label. Use PrintSet or the IPL top of form command to control the initial TOF setting. For help on using the top of form command, see the PrintSet online help or the IPL Programming Reference Manual.

The TOF switch is a small rocker switch located on the lower outboard plate of the printer.

Note: You will see the new format position on the second label you print after pressing the TOF switch.

To move a label format backward with the TOF switch

1.	Remove the media cover.

Note: Do not raise the printhead while adjusting the TOF position.

2.	Press on the front or back part of the TOF switch. Each time you press the TOF switch, you move the label format forward or backward 0.005 inch (0.127 mm).

3.	Press the TOF switch repeatedly until your format moves forward or backward to the correct position on the label.


Illustration of Top of Form Switch


Adjusting the Print Darkness

Use the darkness adjust control in combination with the Print Darkness adjustment in PrintSet to fine-tune the darkness of print on your labels. The fine adjustments compensate for variations in the media, the printhead, or the printer.

For the best results in adjusting the print darkness (energy to the printhead), perform these procedures in order:

1.	Set the correct media sensitivity number.

2.	Adjust the manual darkness adjust control on the back of the printer.

3.	Adjust the print darkness setting with PrintSet.


To adjust the manual darkness adjust control

1.	Locate the darkness adjust control on the back of the printer.

2.	Use a small straight-slot screwdriver to adjust the print darkness:

•	To increase the print darkness, turn the control clockwise.

•	To decrease the print darkness, turn the control counterclockwise.


Adjusting the Print Darkness with PrintSet

The print darkness adjust in PrintSet is similar to the dark adjust available on a copier. An increase in print darkness increases the energy to the printhead and results in darker print. A decrease in print darkness decreases the energy to the printhead and results in lighter print.

To adjust the print darkness with PrintSet

1.	Start PrintSet on your PC.

2.	Click the Paper Type button.

3.	In the Print Quality Setup dialog box, adjust the Print Darkness slider bar until the setting that you want appears underneath it.

You can adjust the print darkness from +10 to -10.

4.	Download your change to the printer by pressing the button to send command updates to the attached printer.


Adjusting the Label Mark Sensor

The label mark sensor detects the mark on the back of continuous or butt-cut media stock. The printer uses the output to determine the start of print. The label mark sensor is behind the platen roller and near the inboard edge of the printer. You can position the label mark sensor no more than 2.5 inches (6.35 cm) from the inboard edge of the printer.

To adjust the label mark sensor

1.	Remove the media cover and locate the label mark sensor.

2.	Use your index finger to slide the label mark sensor to the correct position for your media. You can position the label mark sensor anywhere from the inboard edge of the printer to the center of the paper path.

3.	Print a few labels to make sure that the label mark sensor is detecting the black mark on the media.

4.	Replace the media cover.


Illustration of Adjusting the Label Mark Sensor


Adjusting the Printhead Adjustment Lever

Use the printhead adjustment lever to fine-tune the position of the printhead and achieve the best print quality. The lever is located at the end of the printhead pivot bracket. The printhead can move three steps forward or three steps backward from the center position. Each step is equal to 0.006 inch (.015 cm).

To adjust the position of the printhead

1.	Locate the printhead adjustment lever.

2.	Use a straight-slot screwdriver (or your fingers) and turn the printhead adjustment lever

•	clockwise to move the printhead forward.

•	counterclockwise to move the printhead backward.


Illustration of Adjusting the Printhead Adjustment Lever


Performing Alignment Procedures

You should only perform alignment procedures on the printer when you have replaced a part or when a part is out of alignment. You can perform these three alignment procedures on the printer:

Aligning the Printhead

Aligning the Printer Rollers

Aligning the TTR Supply Hub

	Caution Never remove the motor plate while replacing printer parts. The motor plate requires alignment that can only be performed at the factory.


Aligning the Printhead
Use this procedure only when necessary to properly align the printhead. This procedure may not be necessary when you replace the printhead, but may be required when you replace a roller.

To align the printhead

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, the front bezel, the tear bar, and the label taken sensor (if installed).

3.	Turn the head lift lever clockwise to raise the printhead and remove any media in the label path.

Note: The printhead must be installed in the printer.

4.	Loosen the two Allen screws located on the printhead yoke so that you can move the printhead heatsink. Make sure the printhead adjustment lever is in the neutral position (perpendicular).

5.	Fit the printhead alignment tool over the platen roller and the platen roller bushing. Press down on the printhead heatsink to fully engage the alignment tool locating pins with the heatsink.

6.	Hold the printhead alignment tool so that the left side of the tool is flush with the printer main deck plate and the locating pin arms are flush with the printhead heatsink.

7.	Use even pressure to press down on the printhead alignment tool and then alternately tighten the two printhead yoke screws until the printhead is secure.

8.	Remove the printhead alignment tool and then replace the tool to ensure that the printhead heatsink is flush with the tool.

9.	Verify that the printhead heat sink is parallel to the platen roller. If not, repeat Steps 4 to 8.

10.	Reload the media, insert the label taken sensor (if installed), attach the front bezel and tear bar, replace the media cover, and install the power cord.

11.	Turn on the printer and test the printhead alignment by printing the print quality and the pitch label.


Tools for aligning the printhead

•	Printhead alignment tool, Part No. 064251

•	9/64-inch Allen screwdriver


Illustration of Aligning the Printhead


Aligning the Printer Rollers
You should align the printer rollers every time you replace a roller.

To align the rollers

1.	Remove the media cover, the electronics cover, and the bezel cover.

2.	Turn the head lift lever clockwise to raise the printhead.

	Caution Align only one guide plate at a time (either the upper or the lower) to put the rollers back into factory alignment. If you loosen both plates, it may not be possible to align the rollers outside of the factory.
3.	Loosen the Phillips screws on the guide plate that you are aligning.

4.	Align the three holes in the roller alignment tool with the platen roller, the self-strip roller, and the TTR assist roller. The fourth hole in the roller alignment tool fits over the black plastic bushing closest to the front of the printer.

5.	When the tool fits properly on all of the rollers and the bushing, tighten the screws on the guide plate that you are aligning. The rollers are now in alignment.

6.	Lower the printhead and replace all of the printer covers.


Tools for aligning the printer rollers

•	Roller alignment tool, Part No. 064807

•	#2 Phillips screwdriver


Illustration of Aligning the Printer Rollers


Aligning the TTR Supply Hub
You should only align the TTR supply hub if you are experiencing ribbon wrinkle on full width ribbon after the rollers and printhead have been aligned.

To align the TTR supply hub

1.	Turn off the printer power.

2.	Remove the media cover and the electronics cover.

3.	Install the TTR supply hub alignment tool.

4.	Tighten the alignment tool thumbscrew so that the bushing tab is flush against the bushing on the hub adjustment plate.

5.	Loosen the two screws securing the hub adjustment plate.

6.	Turn on the printer power.

7.	Print a number of the labels that you were printing when the ribbon wrinkling problem occurred. While the labels are printing, adjust the TTR supply hub up or down (with the thumbscrew on the tool) until ribbon wrinkling is eliminated.

Note: If this adjustment does not eliminate the ribbon wrinkling problem, perform steps 3 to 5 of this procedure again and align the printhead.

8.	When you properly align the TTR supply hub and eliminate wrinkling, tighten the two screws on the hub adjustment plate.

9.	Remove the TTR supply hub alignment tool and retest for ribbon wrinkling.

10.	After the printer is correctly adjusted, turn off the power and replace the printer covers.


Tools for aligning the TTR supply hub

•	TTR supply hub alignment tool, Part No. T43149

•	#2 Phillips screwdriver


Illustration of Aligning the TTR Supply Hub


Reloading the Printer Firmware
You need to reload the printer firmware if the printer boot sector has been lost or erased.

To reload the printer firmware

1.	Turn off the printer and remove the power cord.

2.	Locate jumpers J18, J19, and J21 on the main PCB.

3.	Move the jumpers from the NORMAL position to the PROGRAM position.

4.	Insert the programming tool into the Flash SIMM board connector on the Main PCB.

5.	Plug in the power cord and turn on the printer. All three LEDs will light.

When the printer firmware is done reloading, the green Power LED will remain on. If you do not have media loaded, the yellow Empty/Pause LED will also remain on.

6.	Turn off the printer and remove the power cord.

7.	Move the jumpers from the PROGRAM position back to the NORMAL position.

8.	Remove the programming tool.

9.	Plug in the power cord and turn on the printer.

The printer boot sector and firmware are now restored. The green Power LED remains on. If you do not have media loaded, the yellow Empty/Pause LED will also remain on.

If you now want to upgrade your firmware, use PrintSet to upgrade the firmware. You can download the PrintSet Firmware upgrade from the company website at http://www.intermec.com/products/printset.htm.


Programming tools

•	4420 SIMM Board Programming Tool, Part No. 067096S

•	4440 SIMM Board Programming Tool, Part No. 067098S


Illustration of Reloading Printer Firmware


Replacing Printer Parts

Many parts of the 4420 and 4440 printers are spared to make repair of the printer as easy as possible. Instead of purchasing a complete assembly, you can order individual parts.

Before you replace any printer parts, make sure you read about protecting electronic components.

After you replace printer parts, you will want to perform any adjustment or alignment procedures necessary to ensure that the printer is performing at its optimal level.

Use these procedures to replace some of the most common failed parts:

Replacing the Printhead

Replacing the Main PCB Assembly

Replacing the Label Gap Sensor

Replacing the Label Mark Sensor

Replacing the Label Taken Sensor

Replacing the Platen Roller and Gear

Replacing the Ribbon Drive Roller


Protecting Electronic Components

As Intermec moves to surface mount technology and smaller components, our products become more vulnerable to damage from electrostatic discharge (ESD). Recently Intermec experienced spare board assembly failures in the field that were traced to improper ESD protection while handling or installing the boards. This is costly and can be easily avoided.

Intermec's Service department recommends that all field personnel follow three guidelines to prevent ESD damage:

•	Use an ESD mat and wrist strap when repairing and replacing printed circuit boards.

•	Before you open any Intermec product, place that product on an ESD mat and ground the product.

•	Follow all standard ESD procedures for your workplace.

	Follow ESD Procedures 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 guidelines to avoid damaging the equipment you are servicing.
The Everett facility uses several vendors for ESD products. One USA vendor is DESCO Industries, Inc., which you can reach either on the World Wide Web at http://www.desco.com/ or by telephone at 1.909.598.2753.


Replacing the Printhead
Printhead failure is characterized by the appearance of long white streaks on printed labels. The white streaks are caused by the loss of print bead dots on the printhead.

	Follow ESD Procedures 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 guidelines to avoid damaging the equipment you are servicing.
To replace the printhead

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, raise the printhead, and remove any media in the label path.

3.	Use a straight-slot screwdriver to loosen the printhead retaining screw. The screw is easier to loosen if you place one of your fingers underneath the printhead, between the printhead and the platen roller.

4.	Release the locks on the printhead cable by pressing in on each side of the cable connector. Remove the printhead cable and pull the printhead away from the printer.

Note: If you have any problems separating the printhead from the cable, unplug the printhead cable from the main PCB and pull some of it through the cutout in the printer frame.

5.	Replace the printhead and tighten the printhead retaining screw.

6.	Replace the media cover and install the power cord.

7.	Turn on the printer and check for proper operation of the printhead.

You may find that you need to align the printhead.


Tools for replacing the printhead

•	4.4-inch, 203 dpi printhead, Part No. 063716S-001

or

•	4.4-inch, 406 dpi printhead, Part No. 062682S-001

•	ESD grounding strap

•	Medium straight-slot screwdriver

•	ESD grounding mat


Illustration of Replacing the Printhead


Replacing the Main PCB Assembly
	Warning Always disconnect the power cord before replacing the main PCB assembly. Failure to disconnect the power cord may result in injury or death due to electric shock.
	Follow ESD Procedures 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 guidelinesto avoid damaging the equipment you are servicing.
To replace the main PCB assembly

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover and the electronics cover.

3.	Unplug all of the cables from the main PCB and remove the eight screws securing the main PCB to the printer.

Note:  Both the cable connectors and the main PCB are labeled with the cable name. This naming convention makes it easy for you to reattach cables to the new main board.

4.	Remove the main PCB. Remove the two heatsink screws and attach the heatsink to the new main PCB assembly.

5.	Replace the eight screws removed in Step 3 and reattach all of the cables.

6.	Replace the electronics cover and the media cover.

7.	Install the power cord and turn on the printer to test for proper operation of the main PCB.


Tools for replacing the main PCB

•	4420 main PCB assembly, Part No. 067835

or

•	4440 main PCB assembly, Part No. 067836

•	ESD grounding strap

•	#2 Phillips screwdriver

•	ESD grounding mat


Illustration of Replacing the Main PCB


Replacing the Label Mark Sensor
	Follow ESD Procedures 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 guidelines to avoid damaging the equipment you are servicing.
To replace the label mark sensor

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, the electronics cover, and the front bezel cover.

3.	Raise the printhead. Remove media and ribbon if necessary.

4.	Remove the four Phillips screws that secure the lower outboard plate to the printer and pull the outboard plate away from the printer. Retain the tear bar and the tear bar support that are secured by this plate.

5.	Disconnect the label mark sensor connector from the main PCB.

6.	Push the label mark sensor cable through the cutout in the printer frame and then slide the sensor out from the extrusion.

7.	Insert the new label mark sensor into the extrusion. Route the cable through the cutout in the printer frame and attach the cable to the main PCB. Attach the cable to the cable clamps.

Note: Ensure that the cable is secure and that it is not making contact with gears or belts. Do not forget to replace the tear bar and the support when reinstalling the outboard plate.

8.	Replace the lower outboard plate and replace the four Phillips screws that you removed in Step 3.

Note: During installation, perform the roller alignment procedure to ensure proper alignment of the lower outboard plate. You may need to perform the printhead alignment procedure after you perform the roller alignment procedure to attain optimum print quality.

9.	Replace the printer covers, install the power cord, and turn on the printer to test for proper operation of the label mark sensor.


Tools for replacing the label mark sensor

•	Label mark sensor cable assembly, Part No. 059729-003

•	#2 Phillips screwdriver

•	Roller alignment tool, Part No. T43150

•	ESD grounding strap

•	ESD grounding mat


Removing the Lower Outboard Plate


Illustration of Replacing the Label Mark Sensor


Replacing the Label Taken Sensor
Replacing the Label Taken Sensor (Part of the Self-Strip Option)
	Follow ESD Procedures 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 guidelines to avoid damaging the equipment you are servicing.
To replace the label taken sensor

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, the electronics cover, and the front bezel.

3.	Disconnect the label taken sensor cable from the main PCB and push it through the cutout in the printer frame.

4.	Slide the label taken sensor housing away from the printer frame.

5.	Slide the new sensor housing onto the printer frame.

6.	Route the cable through the cutout in the printer frame and attach it to connector J12 on the main PCB. Attach the cable to the cable clamps.

Note: Make sure that the cable is secure and that it is not making contact with any gears or belts.

7.	Replace the printer bezel and covers.

8.	Install the power cord and turn on the printer to test for proper operation of the label taken sensor.


Tools for replacing the label taken sensor

•	Label taken sensor cable assembly, Part No. 059496-004

•	ESD grounding strap

•	#2 Phillips screwdriver

•	ESD grounding mat


Illustration of Replacing the Label Taken Sensor


Replacing the Label Gap Sensor
	Follow ESD Procedures 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 guidelines to avoid damaging the equipment you are servicing.
To replace the label gap sensor

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover and the electronics cover.

3.	Disconnect the label gap sensor cable from the main PCB.

4.	Remove the three screws that secure the media guide assembly to the printer and lift the media guide assembly away from the printer . Be careful when pulling the label gap sensor cable through the cutout in the printer frame.

5.	Slide the upper media guide outward to separate it from the rest of the assembly.

6.	Use a small straight-slot screwdriver to lift up each of the two locking tabs that secure the label gap sensor. Slide the label gap sensor from its housing and replace it with the new label gap sensor. The label gap sensor should snap into place.

7.	Slide the upper media guide plate back together with the lower media guide plate. Make sure that the lift spring is positioned under the lower media guide.

8.	Route the label gap sensor cable through the cutout in the printer frame and reattach the media guide assembly with the three Phillips screws that you removed in Step 4.

9.	Attach the label gap sensor cable to the main PCB.

10.	Replace the printer covers.

11.	Install the power cord and turn on the printer to test for proper operation of the label gap sensor.


Tools for replacing the label gap sensor

•	Label gap sensor cable assembly, Part No. 066376-002

•	ESD grounding strip

•	Small straight-slot screwdriver

•	12-inch #2 Phillips screwdriver

•	ESD grounding mat


Illustration of Removing the Label Gap Sensor


Illustration of Replacing the Label Gap Sensor


Replacing the Platen Roller and Gear
To replace the platen roller and gear

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, the electronics cover, and the front bezel.

3.	Remove the snap ring that holds the platen roller gear in place.

4.	Remove the lower outboard plate from the printer frame. The tear bar and the tear bar support will come loose when you remove the outboard plate. Make sure that you save these items in a safe place.

5.	Loosen the motor mounting screws.

6.	Replace either the platen roller or the platen roller gear, the washer, and the E-ring and secure everything with the snap ring that you removed in Step 3.

7.	Slide the motor forward and press into the liner drive gear/pulley and the ribbon drive roller gear. Rotate the platen roller to check for gear engagement and tighten the motor mounting screws.

8.	Replace the lower outboard plate.

Note:  During installation, use the roller alignment tool to ensure proper alignment of the lower outboard plate. Do not forget to replace the tear bar and tear bar support. You may need to perform the printhead alignment procedure after you perform the roller alignment procedure to attain optimum print quality.

9.	Replace the printer covers.

10.	Install the power cord and turn on the printer to test for proper operation of the platen roller and platen roller gear.


Tools for replacing the platen roller and gear

•	Platen roller, Part No. 058996-009

•	Platen roller gear, Part No. 061557-003

•	#2 Phillips screwdriver

•	Snap ring pliers

•	ESD grounding strap

•	Roller alignment tool, Part No. T43716


Illustration of Replacing the Platen Roller and Gear


Replacing the Ribbon Drive Roller
To replace the ribbon drive roller

1.	Turn off the printer and remove the power cord.

2.	Remove the media cover, the electronics cover, and the front bezel.

3.	Remove the E-ring that holds the ribbon drive roller gear. The E-ring is located on the electronics side of the printer. Remove the drive belt from the ribbon drive roller gear.

4.	Remove the screw that secures the printhead pressure handle to the cam assembly and then remove the handle.

5.	Use the spring hook tool to remove the printhead spring from the upper outboard plate.

6.	Remove the four Phillips screws that secure the upper outboard plate and then remove the upper outboard plate.

7.	Remove the ribbon drive roller. Observe the order of the roller gear, washers, and E-rings.

8.	Insert the new ribbon drive roller with the roller gear, washers, and E-rings in the proper order.

9.	Attach the E-ring that holds the ribbon drive roller gear. Install the drive belt.

10.	Replace the upper outboard plate. All four shafts must be firmly inserted into the outboard plate before you tighten the plate to the printer.

11.	Secure the upper outboard plate to the printer with the four Phillips screws removed in Step 6.

Note:  Use the roller alignment tool to ensure proper alignment of the upper outboard plate.

12.	Connect the printhead spring to the upper outboard plate.

13.	Install the printhead pressure handle and secure the handle to the cam assembly with the screw removed in Step 4.

14.	Install the printer bezel and covers.

15.	Install the power cord and turn on the printer to test for proper operation of the ribbon drive roller.


Tools for replacing the ribbon drive roller

•	Ribbon drive roller, Part No. 058997-005

•	0.250 diameter basic retaining snap ring, Part No. 501409

•	Snap ring pliers

•	E-ring pliers

•	#2 Phillips screwdriver


Illustration of Replacing the Ribbon Drive Roller


Spare Parts List and Exploded Views

Media Side Spare Parts

Electronics Side Spare Parts

Printhead and Front Bezel Spare Parts

PCBs, Connectors, and Circuits Spare Parts

Covers Spare Parts

Cutter Option Spare Parts

Self-Strip Option Spare Parts

Miscellaneous Spare Parts


Media Side Spare Parts

Item #	Description	Part Number

1	Extrusion, Printed Span	059025-003

2	Screw, w/Cone Washer, 8-32 x .375L	505321

3	Cable Assembly, Gap Sensor, 44XX	066376-002

4	Post, Media	059117-005

5	Shaft, Paper Path	059509-002

6	Mount, Label Gap Sensor	062396-002

7	Cover, Printhead Cable	065369-004

8	Spring, Paper Path Return	061567-002

9	Lens, Acrylic, Gap Sensor	063902-003

10	Bracket, Media Path, Upper	065363-001

11	Edge Guide, Outer	059030-005

12	Bracket, Media Path, Lower	065364-001

13	Bracket, Gap Sense Detector	062645-003

14	Washer, Spr, Conl, .175 x .500 x .07H	521118-001

15	Block, Pivot	062610-001

16	Spring, Torsion, Printhead	059040-007

17	Bracket, Pivot	062611-001

18	Spring, Compression, 360 OD .44F/L .040	506827-001

19	Plate, Upper Module, Outboard	066783-001

20	Screw, Thd Roll w/Cone, 8-32 x .38	522690

21	Screw, PHP W/L Washer, 6-32 x .312	526018

22	Cap, Media Post	059120-002

23	Ring, Label Supply	059718-002

24	Handle, Liner Takeup	065082-005

25	Switch, Rocker, Top of Form	064397-001

26	Shaft, TTR Ribbon	059038-003

27	Ring, Retaining, .250 Diameter Basic	501409

28	Cam Assembly, Printhead Pressure, Spare	062613S-001

29	Plate, Lower Outboard	064939-006

30	Label, Top of Form Switch	064519-001

31	Roller, Platen	058996-009

32	Roller, Drive	058997-005

33	Cable Assembly, Top of Form Switch	064345-001

34	Ring, Retaining .250 Diameter 8610/2	501401

35	Washer, SST, .255ID x .407OD x .030T	506013

36	Extrusion, Printed Span, Op Mtg	065367-003

37	Cable Assembly, Label Mark (inc. mount)	059729-003

38	Bar, Strip Support	059029-006

39	Bar, Tear, 5.3 inch	057606


Electronics Side Spare Parts

Item #	Description	Part Number

40	Hub, Ribbon Drive	061513-003

41	Washer, Flat, SST, .327 x .500 x .080	506040-006

42	Bracket, Core-Locking, Cardboard	065375-003

43	Collet, Hub Clutch	063469-002

44	Washer, TTR Clutch	059115-005

45	Washer, Flat, SST, .327 x .500 x .030	506040-005

46	Spring, Hub Clutch	063470-001

47	Flag, Printhead Position	063115-001

48	Gear/Pulley, Cluster, L/H Lock	061563-002

49	Bracket, Motor Mount	059102-002

50	Plate, Hub Adjust	062603-001

51	Screw Assembly, PHP 6-32 x .250 LG	505335-007

52	Ring, Retaining, .310 Diameter Gripping	501410

53	Screw, PHP, w/Int. Star, 8-32 x .500	507639

54	Cable Assembly, Motor, Main Stepper	061551-003

55	Ring, Retaining, External, .395	501461-001

56	Washer, Flat, SST, .446 x .563 x .024	506040-007

57	Pulley, Ribbon Clutch	062927-001

58	Washer, Flat, SST, .817 x 1.00 x .030	506040-004

59	Spring, Compression, Clutch, .076	062962-001

60	Collet, Takeup Clutch	059687-005

61	Encoder, TTR Clutch	059114-007

62	Spring, Compression, TTR Clutch, .067	506816-004

63	Spring, TTR Return	065374-001

64	Pad, TTR Clutch	065373-002

65	O-Ring, 3.07ID x .210THK	501462-005


Printhead and Front Bezel Spare Parts

Item #	Description	Part Number

66	Button, Cap	059103-002

67	Cable Assembly, Ribbon Printhead	061548-001

68	Screw, Soc. HD. Cap, 8-32 x .375	505613

69	Gasket, EMI, C-Fold, .75 inch	590469-001

70	Screw, PHP, w/Int. Star, 6-32 x .375	526036

71	PCB Assembly, Bezel, Spare	066268S-001

72	Plate, Front Cover	064935-006

73	Bracket, Hinge	059387-003

74	Bezel, Front Cover, Spare	065358S-002

75	Screw, PHM, 8-32 x  .375	505767

76	Cap, Bias Screw	062862-002

77	Printhead, 4.4 in, 203 dpi, Spare	063716S-001

Printhead, 4.4 in, 406 dpi, Spare	062682S-001

78	Bumper, Rubber-With/Wash (Feet)	523308


PCBs, Connectors, and Circuits Spare Parts

Item #	Description	Part Number

79	Transformer Assembly, 115V	590442-002

Transformer Assembly, 230V	590442-004

80	Screw, Self-Locking, 2-56 x .312	507424

81	Washer, Lock, Split, No. 4	506111

82	Gasket, ESD, RS-232 Connect	066878-002

83	PCB Assembly, Main, 4420, Spare	067835S-001

PCB Assembly, Main, 4420, Exchange	067835E-001

PCB Assembly, Main, 4440, Spare	067836S-001

PCB Assembly, Main, 4440, Exchange	067836E-001

84	Cable Assembly, Bezel	059727-001

85	Bracket, I/O Support	065526-005

86	Jumper Assembly, .25 Term. Lugs, 4 inch	041776

87	Filter Assembly, Line AC, 3400	060246-002


Covers Spare Parts

Item #	Description	Part Number

88	Cover, Rear, Spare	064934S-001

89	Cover, Media Access, Spare	064937S-001

90	Cover, Electronics	064936-005


Miscellaneous Spare Parts

Description Part Number Bezel, Top Cover 065357-003 Cable Assembly, Printhead Position Sensor 063116-001 Clutch Assembly, Ribbon Takeup, Spare 062927S-001 Clutch Assembly, TTR Ribbon Encode, Spare 067584S-001 Circuit Breaker, Switch, 1A 220V 501273-002 Circuit Breaker, Switch, 2A 120V 501273-001 Core, Ribbon, Cardboard 048524 Cover, Cutter Port, Blank 066398-001 Cover, I/O Slot 053866 Door Assembly, Media Access 065359-004 Edge Guide Assembly, Spare 059781S--002 Fastener, Cotter Pin, .25 507717 Gasket, EMI, Fingers, BECU, .72L 590697-001 Gear, Platen, D Shaft, 96TO 061557-003 Heatsink Assembly, Printhead 065365-002 Heatsink, PCB Drivers 065527-003 Label, Encoder 059708-003 Label, International Loading Instructions 060622-001 Label, Front Bezel, 4420 065360-003 Lens, Media Inspection 059013-003 Light Pipe, Dock/Charger 058776-004 Magnet, Door Latch 059710S-001 Mount, Wire Routing, ADH Back 501394-001 Plate, Motor 065368-003 Programming Tool, SIMM Board, 4420 067096S-004 Programming Tool, SIMM Board, 4440 067098S-002 Screw, Jack, 4-40 x .312 507659-001 Support, Media (Do not Disturb sign) 063471-001 Thumbscrew Assembly, .25 LG 062912S-001 Washer, Lock, Ext. Star, No. 8 506103


Cutter Option Spare Parts

Item #	Description	Part Number

1	Cutter Cable Assembly	066195-001

2	Cutter Cover Assembly	065591-001

3	Cutter Main PCB Assembly	066181-004

Cutter Assembly, Spare	066833S-001

Cutter Assembly, Exchange	066833E-001


Self-Strip Option Spare Parts

Item #	Description	Part Number

1	Self-Strip / BTU, Guide, Batch	066151-004

2	Self-Strip / BTU Motor and Cable Assembly	063643-004

3	Self-Strip / BTU PCB Assembly	066073-004

4	Self-Strip / BTU Cable Assembly, Label Taken	059496-004

5	Self-Strip Cable Assembly 	066765-001


To order parts...

Call Intermec Technologies Corporation at:

1.425.348.2600

Or mail your order to:

Intermec Technologies Corporation
6001 36th Avenue West
P.O. Box 4280
Everett, Washington  98203-9280


Printer Specifications

Character Sets

Dimensions (no options installed)

Electrical Requirements

Environment

Fonts and Graphics

Media Specifications

Printer Memory

Printhead

Printing Method

Printing Speed

Ribbon Specifications

Factory Default Settings


Character Sets

US ASCII	Norwegian/Danish
UK ASCII	Swedish/Finnish
German	Italian
French	Spanish
Switzerland	Code Page 850


Dimensions (no options installed)

Height	16.5 inches (41.9 cm)
Width	9.75 inches (24.8 cm)
Length	17.25 inches (43.8 cm)
Weight	43 pounds (19.5 kg)


Electrical Requirements

Input Voltage	100, 115, or 230 VAC ± 10%
Frequency	47-63 Hz
Current	2 or 1A


Environment

Operating	50°F to 104°F (10°C to 40°C)
Storage	-4°F to 158°F (-20°C to 70°C)
Humidity	10% to 90% with maximum wet bulb 82°F (28°C) and
minimum dew point 36°F (2°C)


Fonts and Graphics

There are 21 resident bitmap fonts (including OCR A and B) and three outline fonts available on the 4420 and 4440 printers. You can use font ID 3 through 6 and 8 through 19 to download user-defined fonts.

Maximum UDF	4 inches square (102 mm square)

Maximum UDC	4 inches square (102 mm square)


Media Specifications

Number	Description	Minimum	Maximum
A	Label width	0.65 inch (13 mm)	4.4 inches (111.8 mm)
B	Backing width (or tag width)	0.75 inch (19 mm)	4.5 inches (114.3 mm)
C	Gap between labels	0.10 inch (2.54 mm)	1.0 inch (25.4 mm)
D	Label length - self-strip media Label length - butt cut media	1.0 inch (25.4 mm) 0.5 inch (12.7 mm)	24 inches (609.6 mm) 24 inches (609.6 mm)
E	Media thickness (including backing)	0.0059 inch (0.15 mm)	0.012 inch (0.30 mm)
F	Reflective sensor mark length	0.10 inch (2.54 mm)	0.5 inch (12.7 mm)
G	Notch diameter	0.125 inch (3.18 mm)	N/A
H	Notch height (depth)	0.25 inch (6.4 mm)	N/A
	Roll diameter		8.38 inches (213 mm)


Printer Memory

Base	Optional
1MB of DRAM	8 or 16 MB DRAM SIMM modules
128K of flash	8 to 16 MB Kanji/Katakana flash SIMM module


Printhead

Printed dot size	4420    0.00492 inch square (0.127 mm) 4440    0.00246 inch square (0.065 mm)
Width	4.4 inches maximum (112 mm)
Resolution	4420    203 dots per inch (8 dots per mm) 4440    406 dots per inch (16 dots per mm)
Number of elements	4420    896 per printhead 4440    1792 per printhead
“X” dimensions	4420    10 mil to 500 mil (0.25 mm to 12.7 mm); 5 mil (0.13 mm) in drag mode only (specified media only) 4440    5 mil to 500 mil (0.127 mm to 12.7 mm) (specified media only); 2.5 mil (0.06 mm) in drag mode only (specified media only)


Printing Method

The 4420 and 4440 printers are capable of direct thermal (DT) printing or thermal transfer (TTR) printing using a thermal transfer ribbon.


Printing Speed

Maximum	8 inches per second (203 mm per second) on specified media only
Minimum	2 inches per second (51 mm per second)

The print speed can be changed in 1 ips increments only: 2, 3, 4, 5, 6, 7 or 8.


Ribbon Specifications

Length	18,000 linear inches (450 m)
Widths	2.125 inches (54 mm)
3.0 inches (76 mm)
4.1 inches (104 mm)
4.5 inches (114 mm)
Diameter	3.2 inches maximum (81 mm)


Factory Default Settings

The following table lists the factory default settings for the 4420 and 4440 printer. Use PrintSet to set these parameters:

Configuration	Default Setting

Preamble Character	Disabled

Postamble Character	Disabled

Auto-Transmit 1	Disabled

Auto-Transmit 2	Disabled

Auto-Transmit 3	Disabled

Message Delay	0 milliseconds

Power-Up Mode	5 mil Advanced mode (4420)
2.5 mil Advanced mode (4440)

Cutter	Disabled

End-of-Print Skip Distance	100 dots (0.5 inches)

Top of Form	20 dots (0.1 inches)

Media Sensitivity	470 Direct Thermal/567 Thermal Transfer

Number of Image Bands	3

Maximum Label Length	1000 dots (5 inches)

Printer Character Set	US ASCII

Label Retract	Disabled

Label Retract Distance	0

Print Speed	3 inches per second (ips)

Label Stock Type	Die-cut

Intercharacter Delay	0 milliseconds

Storage Memory (standard)	128K flash


Theory of Operation

This theory of operation describes the operation of the electronics on the 4420 and 4440 printer. Parts referenced appear on the 4420 or 4440 main PCB.

Power Supply	A/D Converter
+5V Supply	Front Panel Interface
+40V Supply	Processor
+24V Supply	Clock Generation
Power Fail Detection/Reset Generation	Gate Array
Power On Reset	Communication Interface
Power Fail Detect	DIP Switches
Stepper Motor Drive	I/O Option Interface
Sensors	Accessory Port Interface
Label Sensors	Memory
Head Up Sensor	Flash
Ribbon Monitor	DRAM
Voltage Sensing	Memory Expansion
Printhead Temperature	Thermal Compensation
Darkness Adjust


Power Supply

The power supply for the 4420 is primarily a linear supply with a switching buck converter for the 24V printhead supply. The base mechanism is equipped with an AC input filter, a power switch, a circuit breaker, and a transformer that supplies +/- 12 VAC and +40 VAC. These unregulated voltages are used to generate +5V for the motor logic and +24V for the printhead.


+5V Supply

The +5V supply is generated from the 12 VAC inputs on connector J10. Diode bridge D12 (or alternately D24) rectifies the AC voltage and regulator VR1 regulates the resultant DC voltage to +5V, as set by resistors R60, R197, and R200. Capacitors C102-C104 are used for filtering and storing energy for holdup time at power down or brownout. VR1 is a low dropout, adjustable regulator that maintains the output voltage within tolerance over variation in line voltage and output load. VR1 is heatsinked to handle up to 2.5A of output current. The typical +5V load is approximately 1A.


+40V Supply

The +40V supply is generated from the 40 VAC inputs on connector J10. A half bridge made up of diodes D10 and D29 rectifies the AC voltage. Capacitor C111 is used as a filter to provide an unregulated DC voltage of +40V nominal. This unregulated +40V is used for the paper drive stepper motor supply voltage. The +40V supply is also “zenered down” to 5.1V with R181 and D20 to supply the motor drive control logic, which prevents excessive motor currents on power up. Another zener diode, D26, is used to generate a +15V supply that is used by the +24V buck converter.


+24V Supply

The +24V supply is generated by a switching buck converter that takes the +40V supply and steps it down to +24V for use by the printhead. Switching element Q5 is driven at approximately 100 KHz. When Q5 is on, energy is stored in inductor L1. When Q5 is off, energy is transferred to output capacitor C106. L1 and C106 make up a filter that averages the switching to produce a DC output voltage that is set by the voltage divider made up of R194, R63, and R51 along with the 5.1 volt reference made fromR18 and D19. The divided down output voltage is compared with the R18/D19 reference using U27 and the switching element is driven accordingly to maintain the +24V output.


Power Fail Detection/Reset Generation

Both the power fail detection and reset generation functions are controlled by U10, a single power supply monitor IC. U10 has two components: a power on reset circuit and a power fail detect circuit.


Power On Reset

U10 monitors the +5V supply on pin 2 and generates both an active low and an active high power on reset signal. On power up, the RESET* output is low and the RESET output is high while the voltage on pin 2 is below 4.65V. When the voltage on pin 2 exceeds 4.65 volts, the reset state is maintained for approximately 400 ms to give the microprocessor time to initialize before RESET* goes high and RESET goes low. On power down, the two reset outputs go active when the voltage on pin 2 drops below 4.65 volts.


Power Fail Detect

The power fail detect circuit monitors the 12 VAC for early detection of a pending power fail. Diodes D6 and D7 rectify the incoming 12 VAC and R161 and R162 act as a divider. D8 is a zener diode used to prevent the power fail input of U10 from exceeding +5V. When the voltage at pin 4 of U10 drops below 1.235V, the PFAIL* output goes low indicating an imminent power loss. R127 and R176 add some hysteresis to help filter out noise or brownouts. C91 and C93 are also for filtering. The holdup time of the +5V, after PFAIL* goes active, varies with line voltage and the state of the printer. The holdup time exceeds 20 ms at low line and when not printing.


Stepper Motor Drive

The motor driver/control circuit for the 4420 consists of ICs U24, U22, U20, U21 and numerous discrete devices. U24 is an integrated, dual full-bridge motor driver that provides bipolar current mode control of a two-phase stepper motor. Each winding has a direction and an inhibit input which control the current in each winding. These four inputs, M1 - M4, are controlled by a state machine on gate array U6, that provides the eight distinct states required to implement a half stepping sequence. Comparator U22 is used to maintain the desired motor winding currents by pulse width modulating the inhibit inputs. The four control inputs are combined using logic gates U20 and U21 to generate the six inputs required by U24.

M1	M2	M3	M4
1	0	0	1
1	0	1	0
1	0	1	1
0	1	1	1
1	1	1	1
1	1	0	0
1	1	0	1
0	0	0	1

Signals M2 and M3 set the direction of current flow in their respective windings. Signals M1 and M4 are used to enable each winding of the motor. If M1 or M4 is LOW, the winding is disabled. If M1 or M4 is HIGH, the winding is enabled. The table above shows the sequence used to step the motor.

A pulse width modulated output, M5, generated by U6, provides the capability to alter the motor winding current under firmware control. Firmware sets the frequency and duty cycle of the M5 signal which then drives Q3 on and off. R141, R150, R42, and C88 form a low pass filter that provides a DC voltage that is a function of the duty cycle of M5. This voltage is then used as the current reference setting for maintaining a constant winding current.

The current in each motor winding is represented by the voltage across its respective current sense resistors, R140 and R145. This current feedback is compared to the current reference setting using comparator U22. When the voltage across the current sense resistor exceeds the reference voltage, the comparator output goes high, turning the winding off. As the current in the winding drops below the reference setting, the comparator turns off causing the winding to turn on again. The winding current is maintained constant within a small range around the current setting. The winding can be disabled using the stepping sequence by setting its corresponding inhibit bit, M1 or M4, low.


Sensors

The following sensors provide information on the state of the 4420 printer: media sensors, power supply monitors, and printhead monitors.


Label Sensors

Label gap, label taken, and label mark sensors are interfaced to the 4420/4440 electronics through connectors J11, J12, and J13 respectively. The following discussion refers to the label gap sensor on J11, but the same description can be used for the label taken and label mark sensors.

Pin 1 and pin 3 of J11 form connections to the anode and cathode of an infra-red light emitting diode, that is biased by the circuit made up of Q1, U25, and numerous discrete capacitors and resistors. Pin 2 and pin 4 of J11 form the connections to the collector and emitter of a photo-transistor that is paired with the LED. The LED bias is set by feeding back the output of the photo-transistor to the comparator circuit to maintain a sensor output voltage that is always in a range that can be processed by the A/D converter, U5. If the output of the photo-transistor increases, the drive to the LED is reduced to bring the output back into range. Similarly, if the output of the photo-transistor decreases, the LED drive is increased. The sensor output (pin 2 of J11) is filtered and then input to the processor through A/D converter, U5.


Head Up Sensor

A micro-switch connected to J6 is used to monitor the position of the printhead. When the printhead is in the up position, the switch is closed and pin 1 of J6 is low indicating that the head is up. When the printhead is in the down position, the switch is open and pin 1 of J6 is pulled up to +5V indicating that the head is down. The head up signal is input to the processor on an available digital input pin of the communications controller IC, U7.


Ribbon Monitor

The ribbon monitor also uses an LED/photo-transistor pair, Q8, configured as a reflective optical sensor. The LED is biased with R136, and the gain of the phototransistor is fixed with R137. As the ribbon take-up hub turns, Q8 is alternately covered by white and black regions on an encoder wheel. The collector of Q8 alternates between low and high logic levels. Each low-to-high or high-to-low transition of this signal sets a flip-flop internal to gate array U6. Firmware reads this flip-flop and then clears it to give an indication of ribbon status. As long as Q8 collector continues to toggle, the flip-flop continues to get set, which is an indication that the ribbon hub is rotating. If the flip-flop does not get set, a ribbon problem is indicated.


Voltage Sensing

R177 and R180, connected in series from the +40V supply to ground, form a voltage divider whose output is interfaced to the processor through A/D converter U5 and is used to monitor the voltage of the +40 V supply. Similarly, R172 and R175 form a divider that can be used to monitor the printhead voltage.


Printhead Temperature

Printhead temperature is monitored using a thermistor mounted to the printhead. The thermistor forms a voltage divider with R163. As the printhead temperature changes, the thermistor resistance changes causing the voltage divider output to change. This voltage is monitored by the firmware through A/D converter, U5.


Darkness Adjust

A darkness adjust pot, R129, is monitored so the printhead strobe can be adjusted. The pot output ranges from 0V to +5V and is interfaced to the firmware through A/D converter, U5.


Top of Form Adjustment

A rocker switch assembly connected to J22 allows adjustment of the start of print relative to the leading edge of the label. The switch can be pressed in one of two directions indicating a fore or aft adjustment of the top of form. Each of the switch positions outputs a different voltage that the printer firmware can monitor through A/D converter, U5.


A/D Converter

Click a printer model to see the A/D Converter theory of operation for it:

4420

4440


4420 A/D Converter

The Motorola MC145041 A/D converter is an eleven channel, 8-bit, serial A/D converter. Eight of the eleven channels are used. The converted data is shifted serially into the gate array and stored in a 10 x 8 register file that is read by the processor. The reference for conversion is +2.56 volts.

Channel	Function
0	Label gap sensor
1	Darkness adjust
2	Printhead thermistor
3	Label mark sensor
4	Top of Form
5	Printhead voltage, +24V
6	Label taken sensor
7 8	Unused +40V

The A/D converter is continuously communicating with the gate array through the SPI interface. It receives conversion commands and channel addresses from the gate array while sending back results from the previous command. Conversion commands are clocked into the A/D converter on the falling edge of the ADCLK signal from the gate array. At the same time, the eight data bits from the previous command are clocked into the gate array on the rising edge of ADCLK. After this sequence of eight ADCLK cycles, the SPI controller on the gate array waits approximately 40 μs for the current conversion to complete before clocking in the conversion result and simultaneously clocking out the conversion command for the next channel. The clock rate for data transfer is 0.5 MHz.


4440 A/D Converter

The A/D converter U5 is an eleven channel, 8-bit, serial A/D converter. Eight of the eleven channels are used. The converted data is shifted serially into the gate array and stored in an 10 x 8 register file that is read by the processor. The reference for conversion is +2.56 volts.

Channel	Function
0	Label gap sensor
1	Darkness adjust
2	Printhead thermistor
3	Label mark sensor
4	Top of Form
5	Printhead voltage, +24V
6	Label taken sensor
7 8	Unused +40V

The A/D converter is continuously communicating with the gate array through the SPI interface. It receives conversion commands and channel addresses from the gate array while sending back results from the previous command. Conversion commands are clocked into the A/D converter on the falling edge of the ADCLK signal from the gate array. At the same time, the eight data bits from the previous command are clocked into the gate array on the rising edge of ADCLK. After this sequence of eight ADCLK cycles, the SPI controller on the gate array waits approximately 40 μs for the current conversion to complete before clocking in the conversion result and simultaneously clocking out the conversion command for the next channel. The clock rate for data transfer is 0.5 MHz.


Front Panel Interface

Connector J15 connects to a small PCB that houses the front panel controls and indicators. Inputs consist of one button (Feed/Pause) and outputs drive three LEDs (Power, Alert, and Empty/Pause). Interface to each of these controls and indicators is through the gate array, U6.


Processor

The processor, U3, used in the 4420 is an Intel i960JA running at 16 MHz. The i960JA-16 is the lowest performance member of a family of pin compatible, 32-bit, RISC-based architecture processors. The processor has a 2K two-way set associative instruction cache, a 1K direct mapped data cache, an on-chip stack frame cache, 1K of on-chip fast SRAM, a high speed interrupt controller, a variable width burst bus interface, and two 32-bit timers. The multiplexed address/data bus, along with bus control signals, are input to the gate array that controls processor accesses to external memory or I/O.

Click here to see the memory and I/O map.


Clock Generation

The Y1 oscillator provides a 16 MHz clock signal that drives the clkin pin of the processor and is also the time base for the bus control logic on the gate array. The oscillator can be disabled by pulling pin 1 of Y1 to ground.


Gate Array

U6 is the i960JX Printer Controller ASIC that is used to control much of the functionality of the 4420 electronics. U6 contains chip select generation and memory control, wait state generation, an SPI controller for interfacing to the A/D converter, a stepper motor control state machine, a two bank DRAM controller, address bus generation, thirteen general purpose output ports and two general purpose input ports to control the print engine, an Intermec accessory controller, and a buffered data bus interface. A detailed description of the ASIC is contained in the following two documents:

•	608271    i960JX Printer Controller ASIC II Data Sheet

•	608272    i960JX Printer Controller ASIC II Detailed Design Description

U16, which is normally not installed, is a configuration EPROM used to load the program into U6 if a programmable part is used in place of the ASIC.


Communication Interface

Communication on the 4420 is accomplished using a serial port or a 1284 compliant bi-directional parallel port.

The serial interface follows the Intermec Standard Data Connector model criterion. J1 is a 25-pin, D-sub connector that supports both RS-232 and RS-485 interfaces. U1 is the RS-485 driver/receiver, and U2 and U4 are the RS-232 driver and receiver, respectively. To further enhance the interface to support maximum flexibility on DTR/RTS flow control, the DTR pin and the PIN11 signal are driven independently.

A 243 ohm series resistor and a capacitor to ground are placed on all RS-232 signals to increase immunity to ESD. The RS-232 receive data signal is combined with the RS485 receive data signal in pld U33 to form a single serial data input. The two signals cannot be active simultaneously.

The serial port signals are interfaced to the processor with a UART contained on the communications controller, U7. U7 houses two full function UART channels and a 1284 peripheral interface controller. The UART contains two separate 12 byte transmit and receive FIFOs that decrease the interrupt processing required by the i960JA on interrupts from the serial interface. U7 has numerous control/status registers that are accessed using controls generated by the gate array, U6. Transmit data is written to the UART, which then serializes the data and outputs it to the RS232/485 drivers. Receive data is input from the RS232/485 receiver in serial form to the UART which then outputs the data to the processor in parallel form. A single interrupt line to the processor multiplexes all interrupt sources from the serial interface. Baud rates for the transfer are generated by the UART using a time base provided by the 16 MHz oscillator, Y1. All standard baud rates up to 115.2 Kbaud are supported.

Connector J5 is a 1284-B (Centronics compatible) connector for interfacing to the parallel port. Data, status and control signals for the parallel port are all handled by the 1284 controller on U7. U7 contains a 64-byte FIFO for receiving and transmitting parallel port data, which decreases the processing load on the i960JA processor. The 1284 controller on U7 is configured and programmed via control/status registers. A separate interrupt for the parallel port is interfaced to the i960.


DIP Switches

The 4420 has 16 DIP switches to provide configuration, and test and service operation. Reading of the DIP switches is controlled by chip select generation logic contained in the gate array, U6.


I/O Option Interface

The I/O option connector, J3, is a 40-position pin field. Eight bits of bidirectional data are available for transfer to and from the I/O option card. Two chip selects generated by the gate array, IO_OPTCS0* and IO_OPTCS1*, are used to select either the board identification number or the data port. IO_XMT and IO_RCV are outputs from the I/O option cards that generate communications interrupts.


Accessory Port Interface

U33 buffers the accessory port connector from the accessory port controller in U6. Accessory port signals consist of a bidirectional data pin, a clock pin, and an accessory interrupt pin. Control of the direction of the bidirectional data pin is by ACCOUTEN pin from U6. For more detailed information on the operation of the Intermec Accessory Interface, refer to the accessory port description contained in document 607780.


Memory

The i960JA has a separate multiplexed address/data bus. The bus is de-multiplexed in U6 which generates the memory address bus MA23-MA2. Because of the multiplexed address/data bus, bus cycles include an address cycle where address information is driven on the AD pins, a data cycle where data is transferred, and a recovery cycle to allow the bus to be cleared for the subsequent address cycle. Wait states are inserted as appropriate by U6 between the address cycle and the data cycle.


Flash

Program code and embedded fonts are contained in 2 Mbytes of Flash Ram. The Flash is configured as a single bank of 1M x 16 using a single device, U8. The chip select for the flash is generated by U6. Flash accesses have a single wait state at 16 MHz bus operation and three wait states at 25 MHz operation. In addition to code and fonts, 128 Kbytes of the Flash is allocated to non-volatile storage memory for storing user fonts, formats, graphics and configuration. This storage RAM replaces the battery backed SRAM used on previous printers. The printer operating code stored in the Flash can be updated in one of two ways. Using an appropriate utility, new code can be downloaded over the serial or parallel port. In addition, code can be updated by using a special Flash SIMM module in socket J16 and setting jumpers J18, J19, and J21 to the “program” position. If this is done, the processor will boot using code on the SIMM and then transfer the new code from the SIMM to the Flash, U8.


DRAM

The 4420 has 1MB of DRAM for main/image memory. The DRAM is configured as 256K x 32 using two 256K x 16 devices, U26 and U32. U6 contains a DRAM controller that performs all the RAS/CAS sequencing and address multiplexing for all DRAM accesses and refreshes. Two banks of DRAM are supported by the controller. RAS0 and RAS1 are the row address strobe signals for the standard base DRAM, while RAS2 and RAS3 support the expansion DRAM SIMM module. Each bank can have 1, 2, 4, 8, or 16MB of capacity, with the 2MB and 8MB banks requiring two sub-banks of 1MB or 4MB respectively. Both banks share common column address strobe lines, CAS3-CAS0, each of which is used to activate a particular byte of the access.

The base DRAM on the 4420 is set to 1MB by configuring the SIZE0 and SIZE1 pins using pullup/pulldown R92. The footprint for U26 and U32 are designed to support possible expansion of the base DRAM to 4MB capacity through the use of 1MB x 16 devices. U6 performs the address multiplexing required for interface to DRAM devices.

Prior to an active RAS signal, the high order address is placed on MA21-MA11. The low order half of the address is then placed on these pins prior to activating the CAS signals. Accesses to all DRAM banks incur one wait state.


Memory Expansion

Two SIMM sockets are available for memory expansion options. J14 is a standard 72-pin SIMM socket that will accommodate a 1, 2, 4, 8, or 16MB DRAM module configured as 32 bits wide. This optional DRAM module makes up the second bank of DRAM that is controlled by U6. The modules pull up or pull down the SIZEX0 and SIZEX1 pins to convey the module size to the DRAM controller. J16 is a JEDEC standard 80-pin SIMM socket for flash memory modules. The socket will accommodate 1, 2, 4, 8, or 16MB modules configured as 32 bits wide. Modules 8MB or less in capacity are single bank modules that use FLASH1CS* to enable accesses. The 16MB module must have two banks with FLASH1CS* controlling the lower bank and FLASH2CS* controlling the upper bank. Accesses to either SIMM module socket incurs one wait state.

Transceivers U14 and U17 buffer the main address bus to the modules. These transceivers are always enabled in the A-to-B direction. Transceivers U13 and U15 buffer the main data bus to the module. The enable and direction controls for these two transceivers are generated by the gate array.


Thermal Compensation

Click a printer model to see the Thermal Compensation theory of operation for it:

4420

4440


4420 Thermal Compensation

The 4420 uses the same Thermal Compensation ASIC used on the 3440 printer. This ASIC handles the loading of the printhead to implement Intermec’s dot-by-dot thermal management scheme. A single ASIC, U18, is used for controlling a 203 dpi printhead. Two ASICs are used to handle the increased number of dots required by a 406 dpi printhead. ASIC0, U18, controls the first 1024 dots and ASIC1, U19, controls the remaining dots. Oscillator Y2 provides a 48 MHz time base for the ASIC operation. The ASIC provides a 48 MHz clock output that is used by the gate array as the time base for the DRAM refresh and most of the print engine control functionality. For more detailed information on the operation of the Thermal Compensation ASIC, refer to 607651, 607653, and 606137.


4440 Thermal Compensation

The 4440 uses the same Thermal Compensation ASIC used on the 3440 printer. This ASIC handles the loading of the printhead to implement Intermec’s dot-by-dot thermal management scheme. ASIC0, U18, controls the first 1024 dots and ASIC1, U19, controls the remaining dots. Oscillator Y2 provides a 48 MHz time base for the ASIC operation. The ASIC provides a 48 MHz clock output that is used by the gate array as the time base for the DRAM refresh and most of the print engine control functionality. For more detailed information on the operation of the Thermal Compensation ASIC, refer to 607651, 607653, and 606137.


Memory and I/O Map

i960JA Address Range	Description	Total Capacity	Width
FFFF FFFF - FF00 0000	Memory Mapped Registers	16MB
FEFF FFFF - FEFF FF60	Reserved	160 bytes	16 bits
FEFF FF5F - FEFF FF30	Initialization Boot Record (IBR)	48 bytes
FEFF FFFF - FE00 0000	Code/Font Storage - Single Bank Flash	16MB
FDFF FFFF - E000 0000	Unused	480MB
DFFF FFFF - C100 0000	Unused	496MB	32 bits
C0FF FFFF - C000 0000	DRAM SIMM	16MB
BFFF FFFF - BFF0 0000	Base DRAM	1MB	32 bits
BFEF FFFF - A000 0000	Unused	511MB
9FFF FFFF - 8100 0000	Unused	496MB	32 bits
80FF FFFF - 8000 0000	Flash SIMM	16MB
7FFF FFFF - 6010 0000	Unused	511MB	32 bits
600F FFFF - 6000 0000	DIP Switches	1MB
5FFF FFFF - 4070 0000	Unused	505MB
40AF FFFF - 40A0 0000	A/D Converter	1MB
405F FFFF - 4050 0000	Accessory Port	1MB
404F FFFF - 4080 0000	Engine Control Registers	1MB
403F FFFF - 4030 0000	I/O Option ID Register	1MB	16 bits
402F FFFF - 4020 0000	I/O Option Port	1MB
401F FFFF - 4010 0000	Thermal Compensation ASIC	1MB
400F FFFF - 4000 0000	Unused	1MB
3FFF FFFF - 2010 0000	Unused	511MB	8 bits
200F FFFF - 2000 0000	Communication Controller	1MB
1FFF FFFF - 0000 0400	Unused	512MB
0000 03FF - 0000 0040	Internal Data Ram	960 bytes	32 bits
0000 003F - 0000 0004	Interrupt Vector Table or Internal Data RAM	60 bytes
0000 0000	NMI Vector	4 bytes


Extrusion, Printed Span

059025-003


Screw, w/Cone Washer, 8-32 x .375L

505321


Cable Assembly, Gap Sensor, 44XX

066376-002


Post, Media

059117-005


Shaft, Paper Path

059509-002


Mount, Label Gap Sensor

062396-002


Cover, Printhead Cable

065369-004


Spring, Paper Path Return

061567-002


Lens, Acrylic, Gap Sensor

063902-003


Bracket, Media Path, Lower

065364-001


Bracket, Media Path, Upper

065363-001


Edge Guide, Outer

059030-005


Bracket, Gap Sense Detector

062645-003


Washer, Spr, Conl, .175 x .500 x .07H

521118-001


Block, Pivot

062610-001


Spring, Torsion, Printhead

059040-007


Bracket, Pivot

062611-001


Spring, Compression, 360 OD .44F/L  .040

506827-001


Plate, Upper Module, Outboard

066783-001


Screw, Thd Roll w/Cone, 8-32 x .38

522690


Screw, PHP W/L Washer, 6-32 x .312

526018


Cap, Media Post

059120-002


Ring, Label Supply

059718-002


Handle, Liner Takeup

065082-005


Switch, Rocker, Top of Form

064397-001


Shaft, TTR Ribbon

059038-003


Ring, Retaining, .250 Diameter Basic

501409


Cam Assembly, Printhead Pressure, Spare

062613S-001


Plate, Lower Outboard

064939-006


Label, Top of Form Switch

064519-001


Roller, Platen

058996-009


Roller, Drive

058997-005


Cable Assembly, Top of Form Switch

064345-001


Ring, Retaining, .250 Diameter 8610/2

501401


Washer, SST, .255ID x .407OD x .030T

506013


Extrusion, Printed Span, Op Mtg

065367-003


Cable Assembly, Label Mark

059729-003


Bar, Strip Support

059029-006


Bar, Tear, 5.3 inch

057606


Hub, Ribbon Drive

061513-003


Washer, Flat, SST, .327 x .500 x .080

506040-006


Bracket, Core-Locking, Cardboard

065375-003


Collet, Hub Clutch

063469-002


Washer, TTR Clutch

059115-005


Washer, Flat, SST, .327 x .500 x .030

506040-005


Spring, Hub Clutch

063470-001


Flag, Printhead Position

063115-001


Gear/Pulley, Cluster, L/H Lock

061563-002


Bracket, Motor Mount

059102-002


Plate, Hub Adjust

062603-001


Screw Assembly, PHP 6-32 x .250 LG

505335-007


Ring, Retaining, .310 Diameter Gripping

501410


Screw, PHP w/Int. Star, 8-32 x .500

507639


Cable Assembly, Motor, Main Stepper

061551-003


Ring, Retaining, External, .395

501461-001


Washer, Flat, SST, .446 x .563 x .024

506040-007


Pulley, Ribbon Clutch

062927-001


Washer, Flat, SST, .817 x 1.00 x .030

506040-004


Spring, Compression, Clutch, .076

062962-001


Collet, Takeup Clutch

059687-005


Encoder, TTR Clutch

059114-007


Spring, Compression, TTR Clutch, .067

506816-004


Spring, TTR Return

065374-001


Pad, TTR Clutch

065373-002


O-Ring, 3.07ID x .210THK

501462-005


Button, Cap

059103-002


Cable Assembly, Ribbon Printhead

061548-001


Screw, Soc. HD. Cap, 8-32 x .375

505613


Gasket, EMI, C-Fold, .75 inch

590469-001


Screw, PHP, w/Int. Star, 6-32 x .375

526036


PCB Assembly, Bezel, Spare

066268S-001


Plate, Front Cover

064935-006


Bracket, Hinge

059387-003


Bezel, Front Cover, Spare

065358S-002


Screw, PHM, 8-32 x .375

505767


Cap, Bias Screw

062862-002


Printhead, Spare

4.4 inch, 203 dpi	063716S-001
4.4 inch, 406 dpi	062682S-001


Bumper, Rubber

523308


Transformer Assembly

115V	590442-002
230V	590442-004


Screw, Self-Locking, 2-56 x .312

507424


Washer, Lock, Split, No. 4

506111


Gasket, ESD, RS-232 Connect

066878-002


PCB Assembly, Main

4420 Spare	067835S-001
4420 Exchange	067835E-001

4440 Spare	067836S-001
4440 Exchange	067836E-001


Cable Assembly, Bezel

059727-001


Bracket, I/O Support

065526-005


Jumper Assembly, .25 Term. Lugs, 4 inch

041776


Filter Assembly, Line AC 3400

060246-002


Cover, Rear, Spare

064934S-001


Cover, Media Access, Spare

064937S-001


Cover, Electronics

064936-005


Cutter Cable Assembly

066195-001


Cutter Cover Assembly

065591-001


Cutter Main PCB Assembly

066181-004


Self-Strip/BTU, Guide, Batch

066151-004


Self-Strip/BTU Motor and Cable Assembly

063643-004


Self-Strip/BTU PCB Assembly

066073-004


Self-Strip/BTU Cable Assembly, Label Taken

059496-004


Self-Strip Cable Assembly

066765-001