Zebra 2746e Service Manual

980428-001 Rev. A©2003 ZIH Corp.2746eCommercialThermal PrintersService Manual

PROBLEMS SOLUTIONSPrinting has streaks,white (non printing)lines, uneven printing(a side or sides), orfaded print areas.1. Wipe the printhead with the

PROBLEMS SOLUTIONSPrinting stops andstatus indicator lightsred1. Align the transmissive (gap) sensor near the narrowest gap betweenlabels.2. Perform t

Identifying printhead ProblemsThe printhead wears with printer use. If the print quality does not improve after cleaning, theprinthead may require rep

REQUIRED TOOLSMake use of the following tools while performing replacement procedures:Torque wrench with 1/4" hex receptacle)Phillips driver #1 (

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REPLACING PARTSTo access some parts, you need to dissemble other parts; therefore, other procedures must befollowed before and after performing a part

Exterior CoverPreparationsThe printer's exterior cover needs to be removed to perform most ofthe disassembly and replacement procedures for the p

980428-101 Rev. 1 Prelim. 132. Lift the cover straight up about 3-5 inches.Detach the label taken sensor’s cable fromthe center panel. The cable is at

14 980428-101 Rev. 1 Prelim.AnchorsInstallation1. Ensure that the label taken sensor’s cable issecured in the two cable anchors under theleft side cov

Protect against static discharge when handling the printer with thecover removed. Your work area must be static-safe and shouldinclude a properly grou

FOREWORDThis manual provides maintenance, diagnosis, service and repair information for the 2746e printermodels manufactured by Zebra Technologies Cor

PrintheadPreparationsBefore starting the procedure, open the printer, then remove any media from the printer.Tools:3mm Allen wrench hex key or driver1

Power Supply Access and ReplacementPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Tools:#2 Philips screw driver980428

18 980428-103 Rev. 1 Prelim.Add CableAnchor TiesInstallation1. Reverse the power supply removal andaccess processes.-- If replacing the power supply,

Set AC VoltagePreparationsThe exterior cover must be removed prior to proceeding. (980428-101)The power supply must be detached from the bottom panel

DC Power Verification & AdjustmentPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)The power supply must be detache

AC Power Inlet & SwitchPreparationsThe exterior cover must be removed prior to proceeding. (Procedure 980428-101)The power supply must be unscrewe

DC Power CablePreparationsThe exterior cover must be removed prior to proceeding. (980428-101)The power supply must be detached from the bottom panel

AC Power CablePreparationsThe exterior cover must be removed prior to proceeding. (980428-101)For best results, the detach the power supply from the p

Securing the Wire HarnessThe printer was designed to meet or exceed all regulatory agency (CE, FCC, UL, CSA, etc.) safetyand electro-magnetic require

Cable Clearance Check ProcedureThe printer cables and connectors must not interfere (touch) with anymoving components (belts, gears or springs).Placem

CONTENTSINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1TROUBLESHOOTING GUIDE .

26 980428-109 Rev. 1 Prelim.5. Pull the DC power cable through powersupply’s front cable anchor tie until no morethan 2 inches and no less than 1 inch

980428-109 Rev. 1 Prelim. 27RearAnchor TieRear Power Supply Cable Tie Point1. Pull the control panel, label sensor andhead-up cables exiting the front

Main PCBAPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)If needed, load the Printer Information Software Utility into

Label Roll Support Assembly (Roll Holder)PreparationsBefore starting the procedure, open the printer, then remove any media from the printer.The exter

RTC InstallationPreparationsThe exterior cover must be removed prior to proceeding. (Procedure 980428-101)Tools:No additional tools neededInstallation

Motor CablePreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Note the main cable harness routing and cable tie positions

32 980428-115 Rev. 1 Prelim.3. Disconnect the motor cable from the motor.The motor connector can be pried off with alarge bladed screw driver. Pull th

Printhead CablePreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Tools:3mm Allen wrench hex key or driver980428-116 Rev.

34 980428-116 Rev. 1 Prelim.5. Align the printhead with the two bracketalignment pins.6. Secure printhead to printhead bracket bytightening the printh

Label Guide & SensorPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Note the main cable harness routing and cable

Warning - Shock HazardThe printer should never be operated in a location where it can get wet.Personal injury could result.Warnung - Stromschlaggefahr

36 980428-117 Rev. 1 Prelim.3. From the user’s access area (right side ofprinter), open the printhead with theprinthead's release latch.Adjust th

980428-117 Rev. 1 Prelim. 37Installation1. Slide the sensor guide's four (4) cablesthrough the sensor slide’s hole.2. Insert and hook the label g

Label Sensor PCBAsPreparationsThe exterior cover must be removed prior to proceeding. (Procedure 980428-101)Note the main cable harness routing and ca

980428-118 Rev. 1 Prelim. 395. Remove the adhesive securing the cables atthe end of the slide. Caution - Do notdamage the slide or good cables orgood

40 980428-118 Rev. 1 Prelim.6. Finish sliding the two housings together.Gently rock the lower housing while slowlypushing the lower housing into the u

Control PanelPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Note the main cable harness routing and cable tie positio

42 980428-119 Rev. 1 Prelim.4. Remove the four (4) screws holding thecontrol panel assembly to the front panel.5. Pull the control panel assembly stra

Head-up SensorPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Note the main cable harness routing and cable tie positi

44 980428-121 Rev. 1 Prelim.Installation1. Insert the head-up sensor PCBA onto thestand-offs with the cable facing into thecenter of the printer.2. Pl

Label Taken SensorPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)980428-123 Rev. 1 Prelim. 45Tools:No additional tool

INTRODUCTIONThis service manual is intended for the field service engineer or technician. It’s scope covers routinemaintenance, troubleshooting and re

46 980428-123 Rev. 1 Prelim.4. Pull the label taken sensor PCBA out of thesensor gate’s sensor shroud. Gently pull theshroud body away from the gate t

Peel MechanismTools:#1 Philips screw driverRemoval1. Remove the two (2) screws holding the peeler mechanism to the lower print mechanism. Thepeeler sp

Label Guide Tab48 980428-126 Rev. 1 Prelim.STEPPERMOTORInstallation1. Slide the guide tab on the slide.2. Insert the tab stop pin until it is flush wi

MotorPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Tools:4mm Allen hex key socket driverRemoval1. Remove the four (4

Ribbon Pulley (60 tooth)PreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Tools:11/32 Allen driver50 980428-131 Rev. 1 P

Ribbon Drive BeltPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)980428-132 Rev. 1 Prelim. 51Removal1. Cut the tie-wra

Platen Belt (120 tooth)PreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Tools:TORX tool with #T25 tip or 4mm allen head

Ribbon Collar & SpringPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)980023-138 Rev. 1 Prelim. 53Tools:Pliers for

Ribbon Tubes & Shaft SupportPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Take-Up Ribbon Tube Or Shaft Support H

Rewind Pulley, Tube & Shaft SupportPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)The power supply must be loosen

ModelsMany of the earlier model Zebra printers are similar in appearance to the Zebra 2746e thermalprinter. The printer features that identify the 274

56 980428-140 Rev. 1 Prelim.4. Rewind Tube Assembly Only (to here) -Slide the rewind tube assembly out of theshaft support housing.5. Shaft Housing -

980428-140 Rev. 1 Prelim. 57Installation1. Shaft Housing - Insert the two (2) nylonbearings into each end of the shaft housing.No lubrication is neede

Platen Bearing & Replacement KitPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)The power supply must be moved to

Installation1. Slide the long shaft end of the platen roller into the printer's center panel.2. With the platen roller's shaft perpendicular

Lower Print MechanismPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)The peel mechanism must be removed prior to proce

5. Remove the lower print mechanisms extrusion bracket that the peel mechanism and labelrewind plate were mounted to.6. Slide the latch assembly out o

Printhead CarriagePreparationsBefore starting the procedure, open the printer, then remove media from the printer.The exterior cover must be removed p

Installation1. Slide the printhead cable through the printhead carriage assembly.2. Place the printhead carriage's pivot shaft into the pivot hol

Cutter CablePreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Note the main cable harness routing and cable tie position

980428-147 Rev. 1 Prelim. 65Note - See the user's manual or cuttermounting instruction to mount and use thecutter.Cutter CableExits HereInstalla

ConventionsThis manual uses the following notations to call attention to important information.ICON / SYMBOL MEANINGWARNING - critical safety informat

FeetPreparationsBefore starting the procedure, open the printer, then remove media from the printer.Tools:#1 Philips screwdriver66 980428-149 Rev. 1

Printer Configuration CheckChecking the Installation1. Turn on the printer and run your printer's AutoSense routine to get a dump mode printout.I

Platen Belt and Motor AdjustmentPreparationsThe exterior cover must be removed prior to proceeding. (980428-101)Tools:4mm Allen hex key socket driverA

Tube Tension - Verify & AdjustPreparationsBefore starting the procedure, open the printer, then any remove media from the printer.The exterior cov

Tension Adjustment1. Hold the appropriate tube's pulley or collar and rotate the outside of the tube until the slot onthe end of the tube aligns

Ribbon Path AdjustmentPreparationsLoad 4 inch wide ribbon and media in the printer.980428-156 Rev. 1 Prelim. 71Presetting1. Loosen the three (3) horiz

72 980428-156 Rev. 1 Prelim.4. Loosen the vertical adjustment screw andadjust the ribbon adjustment shaft to correctstress lines in ribbon behind prin

Printer Information UtilityThe Printer Information utility is a proprietary service program intended for Zebra authorizedcustomers and service organiz

Resetting the printhead1. After replacing the printhead, select the Reset Head Odometer in the Printer menu.Only do this procedure once per printhead!

Packaging for ShipmentTo ship or store the printer, make sure all components are packed as shown in the figure below.980428-160 Rev. 1 Prelim. 75Print

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Unpacking Instructions76 980428-160 Rev. 1 Prelim.5. Place the power cord, cables, software, etc.in the bubble pack plastic bag andcompletely seal it

CLEANING AND MAINTENANCEThe printers are manufactured and tested under a strict quality management program. ZebraTechnologies uses only high quality

Preventive MaintenanceFor optimum performance, clean the printhead regularly after every roll of direct thermal labels.To start, only use the cleaning

Cleaning the Media PathUse a brush or vacuum to clean the media path (except the printhead).If a label jams inside the printer, remove the label and a

Save-a-Printhead Cleaning Film - Kit P/N 44902What is Save-a-Printhead cleaning film?A specially coated film that removes contamination buildup withou

RECOMMENDED SERVICETo maximize service life (before maintenance is required), the total service life, and eliminatepotential problems that are harder

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TROUBLESHOOTING GUIDEPROBLEMS SOLUTIONSWith the STATUSindicator light GREEN,the printer appears tobe working, but nothingis printed.1. Verify the labe