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Zebra 402

Zebra 402
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980358-001 Rev. B
©2003 Zebra Technologies Corporation
402
2443
2824
2844
3842
3844
Desktop
Thermal Printers
Service Manual
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Zebra 402 Specifications

General IconGeneral
Resolution203 dpi
Maximum Print Width4.09 in./104 mm
Maximum Print Speed6 in./152 mm per second
Maximum Print Length39 in./991 mm
Media TypeContinuous, Fanfold, Roll
ConnectivityUSB

Summary

Foreword

Technical Support

Contacting distributor or Zebra Repair Administration for product support.

Return Materials Authorization

Procedures for returning equipment for repair, including RMA number and shipping address.

Copyright Notice

Information on proprietary data, copyright, and disclaimer of errors.

Trademarks

Operator Cautions and Warnings

Warning - Shock Hazard

Warning about operating the printer in wet locations to prevent injury.

Warning - Static Discharge

Caution regarding electrostatic discharge damaging components; take anti-static precautions.

Caution - Printer Setup & Handling

Procedures to always turn power off before setup/maintenance and handling precautions.

Media Cautions & Tips

Guidelines on using approved labels, ribbon, and handling media to prevent damage.

Media Reload Tip

Do not turn off the printer when out of labels/ribbon; it will resume automatically.

Print Quality Tip

Print density is affected by heat energy and print speed; adjust both for desired results.

Introduction

Models

Describes different printer models and their media handling features.

Conventions

Explains notations used in the manual (warnings, cautions, notes, hints).

Unpacking the Printer

Instructions for unpacking and storing the printer and its packing materials.

Preparing a Static-Safe Work Area

Requirements for a static-safe work area for printer repair.

Environmental and Shock Protection

Precautions regarding temperature, humidity, and careful handling to prevent damage.

Cleaning and Maintenance

General Cleaning

How to clean the printer exterior using a soft cloth.

Cleaning the Media Path

Procedures and supplies for cleaning the print head, platen roller, peel bar, and tear bar.

Print Head Considerations

How print head contamination affects quality and how to clean it.

Media Path Considerations

Using cleaning swabs/pens to remove debris from media path components.

Cleaning Card Considerations

Using cleaning cards to remove debris from the platen without damaging it.

Platen Considerations

Cleaning the platen roller, especially for linerless media printers.

Lubrication

Warning against using any lubricating agents on the printer.

Before Loading Media

How to prepare media before loading and avoid dragging debris.

Troubleshooting Guide

Status indicator does not light when power switch is on

Troubleshooting steps when the status indicator is off.

Printer is in dump mode but nothing prints after sending file

Solutions for when the printer is in dump mode but doesn't print.

ASCII characters print in place of expected label art and bar codes

Troubleshooting for incorrect character printing, potentially due to dump mode.

Printing is uniformly faded or poor quality

Steps to resolve faded or poor print quality.

Printer appears to be working with the indicator light GREEN, but nothing is printed

Troubleshooting when the indicator is green but no printing occurs.

Printing stops and status indicator lights red

Solutions for when printing stops and the status indicator turns red.

Status indicator remains red

Troubleshooting steps for a constantly red status indicator.

Rubbing noise when pressing Feed button

Addressing rubbing noise when the feed button is pressed.

Cutter makes incomplete cuts or cuts in the wrong spot

Troubleshooting issues with the cutter making incorrect cuts.

Short length, perforated media are difficult to load when preparing for dispenserpeel mode

Issues loading short or perforated media for dispenser/peel mode.

Print Head Wear

Required Tools

Parts for Wide Printers

Repair Paths

Latch Replacement - LP

Top Cover Replacement - LP

Print Head Replacement - LP

Packing Materials Replacement

Feet Replacement

Front Bezel Replacement

FrontCutter Bezel Replacement

Platen Replacement

Bottom Case (Base Housing) Replacement

Motor Replacement

Black Line and Bottom Gap Sensors Replacement

Head-Up Sensor Replacement

Main Print Circuit Board Assembly Replacement

Dispenser Bezel Replacement

Latch Replacement - TLP

Cover Support Replacement - TLP

Hinge Replacement - TLP

Upper Case (Top Cover) Replacement - TLP

Ribbon Carriage Replacement - TLP

Feed ButtonLED and Top Gap Sensor Replacement - TLP

Ribbon Motion Sensor Replacement - TLP

Real Time Clock Option

Print Head Replacement - TLP

Parts for Narrow Printers

FeedGap Sensor Cable Assembly Replacement

FeedLED PCBA Replacement

Cable Routing

Cable Routing for TLP Wide Printers

Wiring diagram for carriage and upper frame on TLP wide printers.

Cable Routing for LP Wide Printers

Wiring diagram for carriage and upper frame on LP wide printers.

Cable Routing for LP Narrow Printers

Wiring diagram for upper frame on LP narrow printers.

Cable Routing for TLP Narrow Printers

Wiring diagram for carriage and upper frame on TLP narrow printers.

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