Maintain 3240 Label Printer

Maintenance
Manual
3240 Bar Code Label Printer

P/N 063016-001
Intermec Corporation
6001 36th Avenue West
P.O. Box 4280
Everett, WA 98203-9280
U.S. service and technical support: 1-800-755-5505
U.S. media supplies ordering information: 1-800-227-9947
Canadian service and technical support: 1-800-688-7043
Canadian media supplies ordering information: 1-800-268-6936
Outside U.S. and Canada: Contact your local Intermec service supplier.
The information contained herein is proprietary and is provided solely for the purpose of allowing
customers to operate and/or service Intermec manufactured equipment and is not to be released,
reproduced, or used for any other purpose without written permission of Intermec.
Information and specifications in this manual are subject to change without notice.
 1996 by Intermec Corporation
All Rights Reserved
The word Intermec, the Intermec logo, JANUS, IRL, TRAKKER, Antares, Duratherm, Precision
Print, PrintSet, Virtual Wedge, and CrossBar are either trademarks or registered trademarks of
Intermec Corporation.
Throughout this manual, trademarked names may be used. Rather than put a trademark ( or )
symbol in every occurrence of a trademarked name, we state that we are using the names only in an
editorial fashion, and to the benefit of the trademark owner, with no intention of infringement.
Contents
Contents
Before You Begin ix
Warranty Information ix
Safety Summary ix
Warnings, Cautions, and Notes x
About This Manual xi
Other Intermec Manuals xiii
Basic Operation and Maintenance

1 Getting to Know the 3240 Printer 1-3
Basic Printer Setup and Operations 1-7

Understanding the Front Panel Operation 1-7
Using the Feed/Pause Button 1-8
Configuring the Printer Serial Port 1-9
Inspecting the Printer 1-11
Cleaning the Printer 1-11
Maintenance Schedule 1-12

Cleaning the Printhead 1-14
Cleaning the Printer Covers 1-15
Cleaning the Rollers and the Tear Bar 1-16
Cleaning the Media Guides and Media Path 1-18
Cleaning the Label Sensors 1-20
Troubleshooting
2 Troubleshooting Checklist 2-3
Error Handling 2-4

Syntax Errors 2-4
Parameter Errors 2-4
Image Overrun Errors 2-4
Invalid Numeric Character Errors 2-5
Insufficient Storage RAM Errors 2-5
Error Codes 2-5
Printer Operation Problems 2-8
iii
3240 Bar Code Label Printer Maintenance Manual
Print Quality Problems 2-13
Communications Problems 2-15
Preventing Data Loss 2-16
Testing and Adjusting

3 Test and Service Mode 3-3
Using Test and Service Mode 3-3
Printing Test Labels 3-5
Hardware Configuration Label 3-6
Software Configuration Label 3-7
Print Quality Label 3-7
Pitch Label 3-8
Format Label 3-8
Font Label 3-8
Page Label 3-8
UDC Label 3-8
Running Test and Service Mode From a Host 3-9
Checking for Communications 3-10
Printer Adjustments 3-12

Correcting the Lateral Position of the Label Image 3-12
Accurately Detecting the Start of a Label 3-14
Adjusting the Label Gap Sensor Potentiometer 3-16
Correcting Uneven Print Quality 3-17
Fine-Tuning the Top of Form Position 3-19
Adjusting the Print Darkness 3-22
Adjusting the Label Mark Sensor 3-23
Adjusting the Label Mark Sensor Potentiometer 3-24
Adjusting the Printer for Self-Strip Printing 3-25
Adjusting the Label Taken Sensor Potentiometer 3-26
Aligning the Printhead 3-27
Aligning the Printer Rollers 3-29
iv
Contents
Replacing Printer Parts

4 Replacing Printer Parts 4-3
Protecting Delicate Electronic Components 4-4
Replacing the Lithium Battery 4-5
Replacing the Printhead 4-7
Replacing the Main PCB Assembly 4-9
Replacing the Label Mark Sensor 4-11
Replacing the Label Taken Sensor 4-13
Replacing the Label Gap Sensor 4-15
Replacing the TTR Drive Gear/Pulley and Drive Roller 4-18
Replacing the Upper Drive Belt and TTR Takeup Clutch Pulley 4-20
Replacing the TTR Clutch Encoder 4-22
Replacing the Lower Drive Belt 4-24
Replacing the Platen Roller and Platen Roller Gear 4-27
Replacing the Ribbon Drive Roller 4-29
Spare Parts List and Assembly Drawings

5 Ordering Replacement Parts 5-3
3240 Tools 5-3
3240 Manuals 5-3
3240 Spare Parts List 5-4
3240 Assembly Drawings 5-9
v
Specifications and Reference Material

A 3240 Printer Specifications A-3
Dimensions (no options installed) A-3
Electrical Requirements A-3
Printing Method A-3
Printing Speed A-3
Printhead A-3
Media Specifications A-4
Ribbon Specifications A-5
Environment A-5
Self-Strip Specifications A-5
Fonts and Graphics A-5
Character Sets A-5
Memory A-5
Intermec Cables A-6
Printer Options A-6
Selecting the Correct Media A-8
Configuration Parameters Upload Table A-10
Summary of IPL Commands A-11
DIP Switch Settings A-17
Full ASCII Chart A-18
Theory of Operation
B Overview B-3
Power Supply B-3
Power Fail Detection B-4
Battery B-4
Reset B-4
Motor Driver B-5
vi
Contents
Processor B-5
Chip Selects B-6
TPU B-6
QSM B-7
Interrupt Priority Levels B-7
Crystal B-7
Memory B-8
Static RAM B-8
EPROM B-8
DRAM B-8
Kanji Interface B-9
Communication Interface B-9
A/D Converter B-9
3240 Gap Sensor Interface B-10
DIP Switches B-10
ASIC and I/O Option Interface B-10

Address/Data Multiplexor B-10
Chip Select Generation B-10
I/O Option Connector B-11
FIFO B-11
Front Panel Interface B-11
Debug Interface B-11
Functional Description of the 3240 Software B-14

Band Buffering and Font Caching B-14
Image Band Buffering B-14
Font Caching B-18
Print Energy Compensation B-18
Digital Thermal Compensation B-18
Global Compensation B-18
vii
PCB Parts Lists and Schematics

C 3240 Main PCB Assembly Parts List C-3
3240 Main PCB Subassembly Parts List C-4
3240 Main PCB Assembly Schematics C-11
3240 Bezel PCB Assembly Schematics C-21
viii
Before You Begin
Before You Begin

This section introduces you to standard warranty provisions, safety
precautions, warnings and cautions, document formatting conventions, and
sources of additional product information. A documentation roadmap is also
provided to guide you in finding the appropriate information.
Warranty Information
To receive a copy of the standard warranty provision for this product, contact
your local Intermec support services organization. In the U.S. call
1-800-755-5505, and in Canada call 1-800-688-7043. Otherwise, refer to the
Worldwide Sales & Service list that ships with this manual for the address and
telephone number of your Intermec sales organization.
Safety Summary
Your safety is extremely important. Read and follow all warnings and cautions
in this book before handling and operating Intermec equipment. You can be
seriously injured, and equipment and data can be damaged if you do not
follow the safety warnings and cautions.
Do not repair or adjust alone Do not repair or adjust energized equipment alone
under any circumstances. Someone capable of providing first aid must always
be present for your safety.
First aid Always obtain first aid or medical attention immediately after an
injury. Never neglect an injury, no matter how slight it seems.
Resuscitation Begin resuscitation immediately if someone is injured and stops
breathing. Any delay could result in death. To work on or near high voltage,
you should be familiar with approved industrial first aid methods.
Energized equipment Never work on energized equipment unless authorized
by a responsible authority. Energized electrical equipment is dangerous.
Electrical shock from energized equipment can cause death. If you must
perform authorized emergency work on energized equipment, be sure that you
comply strictly with approved safety regulations.
ix
Warnings, Cautions, and Notes

The warnings and cautions in this manual use the following format.
Warning
A warning alerts you of an operating procedure, practice, condition, or
statement that must be strictly observed to avoid death or serious injury to
the persons working on the equipment.
Caution
A caution alerts you to an operating procedure, practice, condition, or
statement that must be strictly observed to prevent equipment damage or
destruction, or corruption or loss of data.
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
Follow ESD this icon, you must follow standard ESD guidelines to avoid damaging the
Procedures
equipment you are servicing.
Notes: Notes are statements that either provide extra information about a topic or
contain special instructions for handling a particular condition or set of circumstances.
x
Before You Begin
About This Manual

This manual contains all of the information necessary to troubleshoot, repair,
test, adjust, and maintain the 3240 printer.
What You Will Find in This Manual

This table summarizes the information in each chapter of this manual:
For Information On Refer To

Operation and Chapter 1, “Basic Operation and Maintenance.” Tells you
maintenance the different parts of the printer and how to maintain the
printer.
Troubleshooting Chapter 2, “Troubleshooting.” Instructs you on how to

clear error messages and troubleshoot programming or
configuration problems. It also tells you how to control
print quality.
Test and Service Chapter 3, “Testing and Adjusting.” Tells you how to use
mode functions and Test and Service mode, check test points, and adjust the
adjustments printer for optimal performance.
Replacing a printer Chapter 4, “Replacing Printer Parts.” Tells you how to

part replace the major assemblies of the 3240 printer.
Spare parts Chapter 5, “Spare Parts List and Assembly Drawings.”

Contains a complete list of spare parts and manuals you
can purchase. You will also find a complete exploded view
of the printer.
Specifications Appendix A, “Specifications and Reference Material.”

Contains operating specifications for the printer and
miscellaneous reference material such as a summary of all
IPL commands.
Theory of operation Appendix B, “Theory of Operation.” Provides a theory of
operation for the printer and supporting software.
PCB Schematics Appendix C, “PCB Parts List and Schematics.” Provides a

complete list of PCB parts and their schematics.
xi
Terms and Conventions

The following special terms and conventions are used throughout the manual.
Terms
“Printer” or “3240” refer to the 3240 bar code label printer.
“Media” is the label stock on which the printer prints labels.
“Host” refers to a personal computer or other computer that communicates
with the printer.
Conventions
The following conventions are used throughout this manual for operating
procedures and descriptions of the printer.
• Feed/Pause refers to the Feed/Pause button on the printer front panel.
• Downloaded commands appear in the order that you send them to the
printer with the following conventions:
Convention Description
<> Angle brackets < > enclose mnemonic representations of ASCII control
characters. For example, <ETX> represents the ASCII “End of Text”
control character.
data Italic text represents variable data, which you must replace with a real
value. For example, n signifies a variable for which you must designate a
constant value.
[data] Italic text within brackets represents optional data.
Ctrl Bold text represents a key on your keypad. For example, Ctrl represents
the Ctrl key.
Ctrl-Z When two keys are joined with a dash, press them simultaneously. For
example, if you see the command Ctrl-Z, press the two keys at the same
time.
E3;F3 Type all characters that appear in the Courier font by pressing an
individual key on the keypad.
xii
Before You Begin
Other Intermec Manuals

The following manuals provide additional information about your 3240 printer.
Manual Intermec Part No.

Data Communications Reference Manual 044737
The Bar Code Book 051241
3240 Bar Code Label Printer User’s Manual 063015
3240 Bar Code Label Printer Getting Started Guide 063257
xiii
1
Basic Operation and Maintenance
Getting to Know the 3240 Printer 1-3
Basic Printer Setup and Operations 1-7

Understanding the Front Panel Operation 1-7
Using the Feed/Pause Button 1-8
Configuring the Printer Serial Port 1-9
Inspecting the Printer 1-11
Cleaning the Printer 1-11
Maintenance Schedule 1-12

Cleaning the Printhead 1-14
Cleaning the Printer Covers 1-15
Cleaning the Rollers and the Tear Bar 1-16
Cleaning the Media Guides and Media Path 1-18
Cleaning the Label Sensors 1-20
Basic Operation and Maintenance 1
This chapter contains an introduction to the 3240 printer and basic operating
procedures such as loading media. It also contains cleaning procedures you must
perform on a regular basis to keep the 3240 running at its highest performance level.
It is very important to perform the maintenance procedures if you expose the printer to
dirt or debris.
Getting to Know the 3240 Printer

Features of the 3240 printer include:
• Support for both direct thermal and thermal transfer printing applications.
• An internal self-strip with integral liner takeup.
• Precision Print technology that produces high registration labels. See
Chapter 2, “Troubleshooting,” for more information.
• Support for PrintSet printer configuration software.
• Support for outline fonts and 2D symbologies.
Use the following figures to familiarize yourself with the 3240 printer.
Front View of the 3240 Printer
Media
window
Power on LED
Alert LED
Empty/Pause Po
Ale
rt
we
r
LED Em
pty
/P
au
se Media
Fe
ed
/P
cover
Feed/Pause au
se
Inte
button 32
rme
c
40
3240 Printer
Media access
3240M.002
door
1-3
Rear View of the 3240 Printer
Darkness adjust
control
DIP switches
Optional I/O
1 2 3 4 5 6 7 8
board port
1 2 3 4 5 6 7 8
Serial
communications
I
port
O
On/Off
switch
AC power cord
receptacle
Fanfold media
access slot 3240M.016
1-4
Internal Components of the 3240 Printer
TTR assist
roller
Supply roll
Po
we
r
post
Ale
rt
Em
pty
/P
au
se
Label Fe
ed
/P
Supply roll
taken
au
se
Inte
rme retainer
sensor 32
c
40
Upper media
guide
Edge guide
Lower media
guide
Label
Pinch Drive Printhead gap
roller roller sensor
Self-strip Tear bar
assist roller 3240M.007
1-5
Internal Components of the 3240 Printer (continued)

Media
Ribbon brake
supply hub
TTR
takeup
Head hub
lift lever Supply
roll roller
Po
we
r
Ale
rt
Em
pty
/P
au
se
Fe
ed
/P
au
se
Inte
rme
c
32
40
Lateral
printhead
knob
Edge guide
Rewinder
hub
Rewinder
clasp
3240M.006
1-6
Basic Printer Setup and Operations
Detailed operating instructions for the 3240 printer are contained in the user’s
manual. This section summarizes this information for you as a quick reference:
• Understanding the front panel operation
• Using the Feed/Pause button
• Configuring the printer
Understanding the Front Panel Operation

On the front panel of the 3240 printer, you will find one button and three light
emitting diodes (LEDs). You use the front panel LEDs to monitor the status of
the printer:
LED State Indication

Power Power Off Power off
Green LED On Power on
Orange LED Alert Off Printing or idle

Alert Flashing Over-temperature
On System fault
Yellow LED Empty/Pause
Off Printing or idle
Empty/Pause Flashing Paused
On Media fault
Feed/Pause
3240M.009
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.
Media or system faults If the Empty/Pause or the Alert LED remains on, the
printer is experiencing a media or system fault. See Chapter 2,
“Troubleshooting,” for information on correcting the problem.
1-7
Using the Feed/Pause Button

The Feed/Pause button, located on the front panel of the 3240 printer,
performs several functions depending on the mode of the printer.
The Printer Is You Want To What to Do
Idle Feed out one label or a Press and release the Feed/Pause
minimum specified amount button.
of media.
Continuously feed media. Press and hold the Feed/Pause
button. When you release the button,
the media stops feeding.
Take the printer offline. Press the Feed/Pause button twice.
Press the button again to bring the
printer online.
Printing Pause the printer. Press and release the Feed/Pause

button. Press and release the button
again to resume printing.
Cancel the current print job. Press and hold the Feed/Pause
button until the printer stops
printing.
Powered on for Print the hardware Press and hold the Feed/Pause
the first time configuration label. button.
1-8
Configuring the Printer Serial Port
The DIP switches on the rear panel of the printer control communications
parameters, media type configuration, and test and service functions. To
change settings, set the DIP switches on or off with a small straight-slot
screwdriver.
The printer ships from the factory with the 16 DIP switches set to the default
configuration as shown in the following illustration. When changing DIP
switch settings, you must cycle the printer power from off to on for the changes
to take affect.
Factory
Default Settings
1
2
3
1 2 3 4 5 6 7 8
DIP
4
ON OFF
1 2 3 4 5 6 7 8
switches
5
6
7
8
I
O
1
2
3
4
ON OFF
5
6
7
8
3240M.011
1-9
Use this table to set the DIP switches to the correct configuration.
DIP Switch Settings

Top Bank Switch Number Bottom Bank Switch Number
OFF OFF
O = OFF O = OFF
1 = ON ON 1 2 3 4 5 6 7 8 1 = ON ON 1 2 3 4 5 6 7 8
Baud Rate Selection Multidrop Address Selection

19,200 O O O *A O O O O O
9,600* 1 O O B 1 O O O O
4,800 O 1 O C O 1 O O O
2,400 1 1 O D 1 1 O O O
1,200 O O 1 E O O 1 O O
reserved 1 O 1 F 1 O 1 O O
reserved O 1 1 G O 1 1 O O
reserved 1 1 1 H 1 1 1 O O
I O O O 1 O
Parity Selection J 1 O O 1 O
Even* O O K O 1 O 1 O
Odd 1 O L 1 1 O 1 O
None O 1 M O O 1 1 O
None 1 1 N 1 O 1 1 O
O O 1 1 1 O
Number of Data Bits P 1 1 1 1 O
7 Bit* O Q O O O O 1
8 Bit 1 R 1 O O O 1
S O 1 O O 1
Reserved O O T 1 1 O O 1
U O O 1 O 1
Default settings are noted with an * W
V 1
O
O
1
1
1
O
O
1
1
X 1 1 1 O 1
Y O O O 1 1
Z 1 O O 1 1
0 O 1 O 1 1
1 1 1 O 1 1
2 O O 1 1 1
3 1 O 1 1 1
4 O 1 1 1 1
5 1 1 1 1 1
Protocol Selection
XON/XOFF* O
Intermec Protocols 1
XON/XOFF Selection
No Status Response* O
With Status Response 1
DT/TTR
Direct Thermal* O
Thermal Transfer 1
Default settings are noted with an * 3240M.005
1-10
Inspecting the Printer
Inspect the printer and the rest of your data collection system equipment on a
regular basis. Your inspection should include the following:
• Make sure you have properly grounded the printer.
• Inspect the work environment. Large electric motors, welders, and
switching equipment can affect printer performance.
• Keep the printer away from liquids.
• Check the data collection network regularly for loose wires or poorly
installed connections. Be sure to replace corroded wires.
Cleaning the Printer

To clean the printer safely and effectively, use the following items:
• Isopropyl alcohol
• Cotton swabs
• Clean lint-free cloth
• Vacuum cleaner
• Soapy water/mild detergent
The following procedures explain how to access and clean the printer parts
without harming the printer or yourself.
1-11
Maintenance Schedule
Clean your printer regularly to maintain the quality of your labels and extend
the life of your printer. This table contains suggestions for cleaning the printer.
Use the illustration to locate the parts you need to clean.
Warning
Switch off the printer power and remove the power cord before cleaning any
part of the printer.
Printer Component Maintenance Period
Printhead Inspect after every roll of media. Clean after every

roll (or 6,000 inches) of media or more often if
necessary.
Printer cover Clean as necessary.
Drive roller Clean after every five rolls of media. If you are using
hi-tack adhesive, you must clean these components
Thermal transfer ribbon
after every roll of media. If you are using tag stock or
(TTR) assist roller
continuous media, you may want to clean after every
Self-strip assist roller five rolls of media or as necessary. Clean more often
in environments that are harsh or dusty.
Supply roll roller
Tear bar
Media path (not shown)
Edge guide
Upper media guide
Lower media guide
Label gap sensor
Label taken sensor
Pinch roller
1-12
Locating the Printer Parts You Need to Maintain
Supply roll
TTR assist roller
roller
Po
we
r
Ale
rt
Em
pty
/P
au
se
Label Fe
ed
/P
taken
au
se
Inte
rme
sensor 32
c
40
Upper media
guide
Edge guide
Lower media
guide
Label
Pinch Drive Printhead gap
roller roller sensor
Self-strip Tear bar
assist roller 3240M.020
1-13
Cleaning the Printhead

In order for the printhead to provide good print quality, it must maintain close
contact with the media. Therefore, cleaning media debris from the printhead is
very important. You should clean the printhead after every roll (or 6,000
inches) of media or 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 the On/Off switch to the off position and remove the power cord.
2. Remove the media cover.
3. Disengage the printhead by rotating the head lift lever clockwise until the
printhead releases. This action raises the printhead so that you can clean it.
4. Remove the media and ribbon if necessary.
5. Use a cotton swab moistened with alcohol to remove any dirt, adhesive, or
debris from the print surface on the bottom of the printhead.
6. Wait 5 to 10 seconds for the print surface to dry. Replace the media and
ribbon.
7. Engage the printhead by rotating the head lift lever counterclockwise until
it locks in place.
8. If you are finished cleaning, replace the media cover.
1-14
Cleaning the Printhead
Po
we
r
Ale
rt
Em
pty
/P
au
se
Fe
ed
/P
au
se
Inte
rme
c
32
40
Head
lift lever
Printhead
3240M.008
Cleaning the Printer Covers

Clean the 3240 media cover and electronics cover with a general purpose
cleaner (soapy water/mild detergent). Do not use abrasive cleansers or
solvents. Be sure to clean the transparent panel on the media cover so that the
media supply inside the printer is visible when you close the cover.
1-15
Cleaning the Rollers and the Tear Bar

Cleaning the rollers and the tear bar preserves print quality by ensuring close
contact between the media and the printhead. You should clean the rollers and
tear bar after every five rolls of media. You may want to clean them more often
if you are using hi-tack adhesive or operating the printer in a harsh or dusty
environment.
To clean the rollers and tear bar

3. Rotate the head lift lever clockwise to release the printhead.
4. Remove media and ribbon (if necessary).
5. Clean the rollers by using a lint-free cloth moistened with isopropyl
alcohol. Move the cloth over the rollers in a side-to-side motion as shown.
Make sure to rotate the rollers so you can clean all areas.
Note: Rotate the TTR assist roller toward you to clean the entire drive roller
surface.
6. Clean both sides of the tear bar with a lint-free cloth dampened with
isopropyl alcohol. Remove all traces of dust, paper, and adhesive.
7. Open the media access door to clean both the pinch roller and the self-strip
roller.
8. Replace the media and ribbon.
9. Engage the printhead by turning the head lift lever counterclockwise until
the printhead locks.
10. If you are finished cleaning, replace the media cover.
1-16
Cleaning the Rollers and Tear Bar
Supply roll
roller
TTR assist
roller
Po
we
r
Ale
rt
Em
pty
/P
au
se
Fe
ed
/P
au
se
Inte
rme
c
32
40
Head lift
lever
Drive
Media roller
access Tear
door bar 3240M.010
1-17
Cleaning the Media Guides and Media Path

You should clean the media guides and 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 immediately after a label jam in the printer.
To clean the media guides and media path

3. Remove the media and ribbon (if necessary).
4. Pull down on the lower media guide to open up the media path.
5. Clean the lower media guide by using a lint-free cloth moistened with
isopropyl alcohol as shown in the illustration.
Note: The lower media guide is spring loaded and you must hold it open to clean.
6. Use the cloth moistened with isopropyl alcohol to clean the upper media
guide. Be sure to remove all traces of debris.
7. Remove all traces of dust, paper, and adhesive from the media path with a
soft bristle brush or vacuum.
8. Clean the flat surfaces of the media path (including the edge guide) using a
lint-free cloth moistened with isopropyl alcohol.
9. Release the lower media guide.
11. Replace the media cover.
1-18
Cleaning the Media Guides and Media Path
Po
we
r
Ale
rt
Em
pty
/P
au
se
Fe
ed
/P
au
se
Inte
rme
c
32
40 Upper media
guide
Lower media
Edge guide
guide
3240M.012
Media
path
1-19
Cleaning the Label Sensors

There are two label sensors on the 3240 printer that require regular cleaning:
the label taken sensor and the label gap sensor.
To clean the label sensors

3. Disengage the printhead by rotating the head lift lever clockwise until the
printhead releases.
4. Remove the media and ribbon (if necessary).
5. Clean the label taken sensor with a cotton swab moistened with isopropyl
alcohol.
6. 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.
Note: You may want to slide the label gap sensor toward the outboard edge of the
printer for better access. Make sure you return the label gap sensor to its original
position when you finish cleaning.
7. Clean the label gap sensor using a cotton swab moistened with isopropyl
alcohol.
9. Engage the printhead by rotating the head lift lever counterclockwise until
it locks in place.
1-20
Cleaning the Label Sensors
Label taken
Cotton sensor
swab Label mark
sensor
Drive
roller
Upper media
guide Cleaning
(underside) brush
Label gap
sensor
Lower
media guide
3240M.013
1-21
2
Troubleshooting
Troubleshooting Checklist 2-3
Error Handling 2-4

Syntax Errors 2-4
Parameter Errors 2-4
Image Overrun Errors 2-4
Invalid Numeric Character Errors 2-5
Insufficient Storage RAM Errors 2-5
Error Codes 2-5
Printer Operation Problems 2-8
Print Quality Problems 2-13
Communications Problems 2-15
Preventing Data Loss 2-16

HelvC NugFont Co d e 39 Troubleshooting 2
This chapter provides some hints for troubleshooting error messages that the printer
sends to the host and problems you may experience with the printer.
Troubleshooting Checklist
Even though Intermec designed the 3240 printer to operate under harsh
conditions, you may still encounter error messages at some time. You can
easily fix most of the errors you encounter and consequently not delay
operation of the printer for very long.
If you receive an error message or encounter a functional problem with the
printer, try the following:
1. Send a <BEL> command to the printer and see if the printer sends an error
message to the host in response.
2. If there is an error message, find it in the table under “Error Codes” in this
chapter. Follow the instructions after the error message to correct the
problem.
or
If the printer does not send an error message to the host, try to locate the
symptom in the tables under Printer Operation Problems, Print Quality
Problems, or Communications Problems in this chapter. Follow the
instructions listed after the symptom to correct the problem.
3. Clean the printer components and check all connections. See Chapter 1,
“Basic Operation and Maintenance,” for details.
If the problem persists, contact your Intermec Customer Service Representative

(1-800-755-5505) from North America. If you are an international customer,
contact your local Intermec representative.
2-3
3240 Bar Code Label Printer Maintenance Manual HelvC NugFont Co d e 39
Error Handling
This section describes how the 3240 printer handles certain error conditions it
may encounter in printer or programming commands.
Syntax Errors
The 3240 printer responds to syntax errors in the messages it receives from the
host by attempting to execute the commands. It does not ignore a command
with a syntax error. Instead, the printer produces output, even if it is
erroneous, which gives you an indication of what went wrong and what you
can do to correct the problem.
Parameter Errors
Certain commands require optional parameters. If you do not supply these
parameters, the printer substitutes default values. If a parameter is above its
maximum range limit, the printer uses the maximum value. If it falls below the
minimum range, the printer uses the minimum value. Refer to Chapter 6 of the
3240 Bar Code Label Printer User’s Manual for the range and default value of
each command.
Image Overrun Errors

Image overrun occurs when a label is too complex to image for a given print
speed. An overrun will cause the printer to abort the label being printed. This
error is most common on labels over 5 inches long.
The printer automatically attempts to correct for this error condition by
resetting to the lowest print speed and to the highest number of image bands,
and then repeats printing the label. The printer remains at this setting until you
reset it. If an image overrun still occurs, printing for that batch of labels stops
and the printer executes all of the following commands.
Installing the optional 512K memory expansion decreases image overrun
errors.
2-4
Invalid Numeric Character Errors
If you include non-numeric characters within a numeric data string in a
command, the printer disregards them and continues to process the rest of the
valid numeric characters. However, if a non-numeric character begins the
numeric data string, the printer uses a default value for the affected command.
Here are two examples of valid numeric character strings, and one example of
an invalid string:
12a valid
1a2 valid
a12 invalid
Insufficient Storage RAM Errors

Before storing new formats, graphics, or user-defined fonts in the static RAM,
the printer checks to see if it has sufficient memory to store them. If there is
insufficient memory, the printer disregards the last editing session. The printer
design preserves the integrity of the existing data in the static RAM.
Error Codes
Most of the problems you may encounter cause the 3240 printer to send an
error code to the host. When this happens, find the error code in the following
table and complete the instructions to correct the problem.
2-5
Error Codes
Error Code Problem Solution

00 No error.
01 Invalid bar code check character. Verify the bar code check character modifier used in
the bar code program command.
02 Invalid number of bar code characters Verify the number of bar code characters used in the
(Code UPC/EAN). bar code program command.
04 Bar code check character within Check the bar code program command for accuracy.
numeric field marks.
05 Supplemental delimiter within Check the bar code program command for accuracy.
numeric field marks (Code
UPC/EAN).
06 Invalid supplemental character count Check the bar code program command for accuracy.
(UPC/EAN).
07 More than one supplemental delimiter Check the bar code program command for accuracy.
(Code UPC/EAN).
08 Invalid start/stop characters Verify start and stop characters in the label format.
(Codabar).
11 Invalid bar code data. Verify data in the label format.
12 Data count exceeded. Data count should not exceed what you specify for
the field.
13 Entering data in non-data entry field. Check the field for accuracy.
21 Quantity or batch count out of range. Quantity of labels or number of batches should be
between 1 and 9999.
22 Field increment/decrement out of Quantity should be between 1 and 9999.
range.
23 Intercharacter/message delay out of Delay should be between 0 and 9999.
range.
24 Missing preamble/postamble data. Delete the setup for preamble or postamble data, or
include the data.
25 Invalid format transmission syntax. Check the format transmission syntax. The correct
syntax is <ESC>xn with n ranging from 0 to 19.
26 Invalid page transmission syntax. Check the page transmission syntax. The correct
syntax is <ESC>yn with n ranging from 0 to 9.
2-6
Error Codes (continued)
Error Code Problem Solution

27 Invalid font transmission syntax. Check the font transmission syntax. The correct
syntax is <ESC>vn with n ranging from 0 to 24.
28 Invalid UDC transmission syntax. Check the UDC transmission syntax. The correct
syntax is <ESC>un with n ranging from 0 to 99.
32 Non-immediate command or data Allow the printer to empty the buffer contents
received after buffer full. before sending commands or data.
33 Invalid field delimiters. Check for all pairs of field delimiters and make sure
both are numeric, or both are alphanumeric.
34 Invalid escape command. Correct the escape command syntax.
35 Invalid data shift command. Correct the shift command syntax.
36 Invalid or undefined format number. Verify that the format numbers are between 0 and
19.
37 Insufficient room in RAM to print Reduce the number of data fields in the format.
format.
38 Invalid or undefined field number. Verify the field number in the label format.
41 Syntax error for program commands. Check the program command for proper syntax.
42 Insufficient room in RAM to store Empty the buffer contents. If the format still does
format. not fit, delete some fields or other data from the
format. You may have to remove or reduce the
UDCs, formats, or fonts if necessary.
Note: Entering <ESC>m tells the host how much
memory you have installed and how much is available.
43 Too many fields in label format. You can use up to 200 fields in a format and each
field can use up to 250 characters. Reduce field size
or delete some fields.
46 Undefined statement. Check the statement syntax.
52 Invalid UDC/UDF bitmap cell Verify that cell heights and widths are between 1
height/width or intercharacter space. and 599, and that the intercharacter space is between
0 and 199.
53 Insufficient room in RAM to store Remove or reduce formats, fonts, or UDCs.
UDC or UDF.
54 Invalid UDC command syntax. Correct the UDC command syntax.
2-7
Printer Operation Problems

If your printer is not operating correctly, try locating the problem in the table
below:
Symptom Possible Causes Solution

No power or loss AC power cable is damaged or Make sure you have plugged the power cable
of power. disconnected. into both the printer and an outlet or power
strip. Replace the AC power cable if it is
damaged.
Printer circuit breaker tripped. Turn the printer off and then back on again.
Power supply assembly is Replace the power supply.
defective.
Labels stop Printer is out of media. Load new media. See “Loading a Roll of Media”
feeding through in Chapter 1 of the 3240 Bar Code Label Printer
the printer. User’s Manual.
You have loaded the label stock Check to make sure the media is loaded
incorrectly. correctly. See “Loading a Roll of Media” in
Chapter 1 of the 3240 Bar Code Label Printer
User’s Manual for help.
Media is sticking to the paper Clean any extraneous material from the paper
path. path and clean it thoroughly. See “Cleaning the
Media Guides and Media Path” in Chapter 1.
You have set the printer for Use the Transmit Configuration Parameters
continuous label stock. <ESC>p command to check the configuration
setting. Select the correct setting with the Label
Stock Type, Select command (<SI>T). See
Chapter 6 in the 3240 Bar Code Label Printer
User’s Manual for more information.
The label gap or label mark Clean the label sensors. See “Cleaning the Label
sensors are dirty. Sensors” in Chapter 1.
The ribbon is Printhead is out of alignment. Realign the printhead using the “Aligning the
wrinkling. Printhead” procedure in Chapter 3.
The outboard plate is out of Realign the outboard plate using the “Aligning
alignment. the Printer Rollers” procedure in Chapter 3.
Printer slows You have set the image bands or Change the image bands or print speed settings.
down. print speed incorrectly. See Chapter 6 and Chapter 7 in the 3240 Bar
Code Label Printer User’s Manual.
Printer has aborted and reset the Change the image bands or print speed settings.
print speed and image bands. See Chapter 6 and Chapter 7 in the 3240 Bar
2-8
Printer Operation Problems (continued)

The Alert LED Printhead has overheated. Leave printer alone until it has time to cool
flashes and down. It will resume printing on its own.
printing stops.
Media fault. The printhead is up. Make sure the printhead is down. The head lift
lever should be straight up and down. Press the
Feed/Pause button to resume printing.
Sensor type set incorrectly. Configure the printer for the correct sensor. For
help, see the Label Stock Type, Select command
in Chapter 6 of the 3240 Bar Code Label Printer
User’s Manual.
You have incorrectly loaded the Try reloading the media. For help, see “Loading
media. a Roll of Media” in Chapter 1 of the 3240 Bar
Labels stick to The self-strip roller is dirty or Clean the self-strip roller. See “Cleaning the
media access door the pinch roller is not contacting Rollers and Tear Bar” in Chapter 1.
or fail to strip. the strip roller.
The stepper motor You did not properly adjust the Adjust the bias adjust screw to the optimum
stalls while bias adjust screw. printing position. See “Correcting Uneven Print
printing media Quality” in Chapter 3.
that is less than 2.7
inches wide.
Test configuration You have incorrectly loaded Try reloading the media. For help, see “Loading
labels do not print. media. a Roll of Media” in Chapter 1 of the 3240 Bar
You have configured the printer Set the printer to the default configuration using
for self-strip media. the DIP switches. For help, see “Configuring the
Printer Serial Port” in Chapter 1.
Media fault. Remove media from under the label taken
sensor.
Blotches on labels. Dirty printhead. Clean the printhead. See “Cleaning the
Printhead” in Chapter 1.
Dirty media path or rollers. Clean the media path or rollers. See “Cleaning
the Media Guides and Media Path” and
“Cleaning the Rollers and Tear Bar” in
Chapter 1.
Poor quality label or ribbon Replace label or ribbon stock with Intermec
stock. recommended media.
2-9

Printing is too Darkness adjust control is set Adjust the control to achieve the best print
light or too dark. incorrectly. quality. See “Adjusting the Print Darkness” in
Chapter 3.
Poor quality label or ribbon Replace label or ribbon stock with Intermec
stock. recommended media.
The sensitivity setting is not set Change the sensitivity setting the match the type
correctly. of media you are using. If the sensitivity setting
is correct, try changing the dark adjust
command (<SI>d).
Printing is not Printer is misfeeding media. Make sure that media is installed properly along
aligned on the the entire media path. See Chapter 1 of the 3240
label. Bar Code Label Printer User’s Manual.
Labels are not Label rest point command is Adjust the label rest point with the <SI>f
stopping at the incorrectly set. command. See Chapter 6 in the 3240 Bar Code
right point to be Label Printer User’s Manual for more information.
removed.
Printer is set for continuous Set the printer to thermal transfer or direct
label stock. thermal label stock.
Print quality is Incorrect media sensitivity Change the sensitivity setting to match the type
poor. setting. of media you are using. If the sensitivity setting
is correct, try changing the dark adjust
command (<SI>d).
The darkness of label print is too Adjust the darkness adjust control. See
light or too dark. “Adjusting the Print Darkness” in Chapter 3.
Printhead, platen roller, or label Clean the printhead, platen roller, and label
path are dirty. path. See Chapter 1 in this manual.
Uneven print contrast (density). Adjust the bias adjust screw. See “Correcting
Uneven Print Quality” in Chapter 3.
Incorrect label or ribbon stock is Use only Intermec label and ribbon stock to
used to print labels. ensure superior print quality and product
performance. See Appendix A for a complete
list of Intermec media supported by the 3240
printer.
Ribbon wrinkling. Check to make sure that the ribbon is installed
correctly or adjust the bias screw.
Ribbon installed upside down. Install the ribbon with the shiny side facing the
printhead. See Chapter 2 of the 3240 Bar Code
Label Printer User’s Manual.
2-10

Print quality is Direct thermal/thermal transfer Set the switch for the type of media you are
poor. switch set in the wrong position. using. See “Configuring the Printer Serial Port”
(continued) in Chapter 1.
Media may be slipping against Switch to approved media or clean the
the platen roller causing the printhead and platen roller. See Appendix A for
printing to compress. a complete list of Intermec media supported by
the 3240 printer. See Chapter 1 for cleaning
procedures.
The printhead is installed Realign the printhead using the “Aligning the
incorrectly. Printhead” procedure in Chapter 3.
Printer does not Printhead ribbon cables are not Check printhead ribbon installation.
print. properly installed.
Cable not connected between Check cable connections at the printer and the
the printer and the host host computer.
computer.
Printer serial port receiver Perform the procedure “Checking for
circuitry malfunctioning. Communications” in Chapter 3.
Printer is not receiving data. 1. Check the configuration of the host computer
serial port.
2. Run the “Checking for Communications” test
in Chapter 3.
Hardware problem. 1. Check to see if the printer prints the
configuration test labels. See Chapter 3 for
help.
2. Check the cabling on the main PCB, the
power supply, and the printhead.
3. Check to make sure that the correct media is
being used. See Appendix A for a complete
list of media supported by the 3240 printer.
4. Verify that the printhead is clean and making
contact with the media. To clean the
printhead, see Chapter 1 in this manual.
To adjust the printhead contact with the
media, see “Correcting Uneven Print
Quality” in Chapter 3.
5. If you cannot locate the problem with any of
the solutions above, replace the components
in the following order:
a. Printhead
b. Main PCB
2-11

Printer does not Communications problem. 1. Verify that the printer configuration and
print from host. transmission parameters are set correctly.
2. Make sure that the printer to host cabling is
correct.
3. Run the “Checking for Communications” test
in Chapter 3.
4. If all of the above are correct, replace the
main PCB.
Printed bar code Media may be slipping against Try one of the following:
labels cannot be the platen roller causing the
1. Switch to approved media. See Appendix A
decoded. printing to compress.
for a complete list of media supported by the
3240 printer.
2. Clean the printhead and platen roller. See
Chapter 1 in this manual.
3. Tighten or replace the motor shaft gear.
Printhead is dirty. Clean the printhead. See Chapter 1 in this
manual.
Printhead is defective. Order and install replacement printhead.
Media is defective. Switch to media that is known to be approved
for use in the 3240 printer. See Appendix A for a
complete list of media supported by the 3240
printer.
2-12
Print Quality Problems
If your labels are not being printed properly, check the following table to locate
the symptom and correct the problem.

Blotches printing Dirty printhead. Clean the printhead. See Chapter 1 in this
on labels. manual.
Dirty media path or rollers. Clean the media path. See Chapter 1 in this
manual.
Poor quality label or ribbon Use only Intermec label and ribbon stock to
stock. ensure superior print quality and product
Printing is too You have set the darkness adjust Adjust the knob to achieve the best print
light or too dark. control incorrectly. quality. See “Adjusting the Print Darkness” in
Chapter 3.
Poor quality label or ribbon Use only Intermec label and ribbon stock to
stock. ensure superior print quality and product
Dirty printhead. Clean the printhead. See Chapter 1 in this
manual.
You set the sensitivity command Change sensitivity setting to match the type of
incorrectly. media you are using (for help, see Chapter 2 in
the 3240 Bar Code Label Printer User’s Manual). If
you set the sensitivity setting correctly, try
changing the dark adjust command.
Print speed exceeds the Lower your print speed or use Intermec media
capability of the media. recommended for your print speed.
Printing not Printer is misfeeding media. Make sure you have correctly installed the
aligned on label. media. For help, see Chapter 1 in the 3240 Bar
Label stock has moved in the Adjust the lateral printhead knob. See
media path. “Correcting the Lateral Position of the Label
Image” in Chapter 3.
2-13
Print Quality Problems (continued)

Labels are not You have not set the label rest Adjust the label rest point. See the Label Rest
stopping at the point command correctly. Point, Adjust command in Chapter 6 of the 3240
right point for Bar Code Label Printer User’s Manual.
removal.
You have set the printer for Set the printer to thermal transfer or direct
continuous label stock. thermal label stock. See Chapter 1 in the 3240
Bar Code Label Printer User’s Manual.
Print quality is Incorrect media sensitivity Change sensitivity setting to match the type of
poor. setting. media you are using. If you set the sensitivity
correctly, try changing the dark adjust
command. See Chapter 6 and Chapter 7 in the
3240 Bar Code Label Printer User’s Manual.
Print speed exceeds the Lower your print speed or use Intermec media
capability of the media. recommended for your print speed.
Printhead, platen roller, or label Clean printhead, platen roller, and label path.
path is dirty. See Chapter 1 in this manual.
Dirty media. Keep media in a bag until you need it.
The darkness of label print is too Adjust the darkness adjust control. See
light or too dark. “Adjusting the Print Darkness” in Chapter 3.
Uneven print contrast (density). Adjust the bias adjust screw. See “Correcting
Uneven Print Quality” in Chapter 3.
You are using incorrect label or Use only Intermec label and ribbon stock to
ribbon stock to print labels. ensure superior print quality and product
Ribbon wrinkling. Check to make sure that you loaded the ribbon
correctly. For help, see Chapter 2 of the 3240 Bar
Code Label Printer User’s Manual. Set the bias
adjust screw. See “Correcting Uneven Print
Quality” in chapter 3.
2-14
Print Quality Problems (continued)

Print quality is Ribbon installed upside down. For help, see Chapter 2 in the 3240 Bar Code
poor. (continued) Label Printer User’s Manual.
Direct thermal/thermal transfer Set the switch for the type of media you are
switch set in the wrong position. using. For help, see “Configuring the Printer
Serial Port” in Chapter 1.
You have severely worn the Replace the platen roller or printhead.
printhead or platen roller.
Media may be slipping against Switch to approved media or clean the
the platen roller, causing the printhead and platen roller. See Appendix A for
printing to compress. a complete list of media supported by the 3240
printer. See Chapter 1 for cleaning procedures.
The printer skips The label gap sensor is not in the Properly position the label gap sensor. For help,
labels randomly or correct position. see “Accurately Detecting the Start of a Label”
sends an in Chapter 3.
intermittent error.
The label format extends beyond Edit the format to ensure that the text fits on the
the label length. label. For help, see Chapters 5 and 6 in the 3240
Bar Code Label Printer User’s Manual.
The printer is not You have not correctly Make sure that you position the label taken
waiting until you positioned the label taken sensor sensor over the media path. See “Adjusting the
remove a label to over the media path. Printer for Self-Strip Printing” in Chapter 3.
print another.
Communications Problems
If your printer is not receiving downloaded data, try these solutions.

Printer does not You have not configured the Make sure the printer’s serial port settings
communicate with serial port correctly. match those of the host.
the host.
Damaged or incorrect I/O cable. Check the connections at both ends or replace
the cable. See Appendix A for cable information.
2-15
Preventing Data Loss

Several problems can cause data loss or communications problems on the 3240
printer. Data loss can result in printing errors or missing field data.
The 3240 printer is a serial ASCII device. It communicates with the host
through an ASCII serial communications 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 the printer is ready to receive data. The printer holds the
pins low when the printer is in one of the following conditions:
• Buffer full
• Ribbon fault
• No label stock
• Label at strip pin
The 3240 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.
2-16
3
Testing and Adjusting
Test and Service Mode 3-3

Using Test and Service Mode 3-3
Printing Test Labels 3-5
Hardware Configuration Label 3-6
Software Configuration Label 3-7
Print Quality Label 3-7
Pitch Label 3-8
Format Label 3-8
Font Label 3-8
Page Label 3-8
UDC Label 3-8
Running Test and Service Mode From a Host 3-9
Checking for Communications 3-10
Printer Adjustments 3-12

Correcting the Lateral Position of the Label Image 3-12
Accurately Detecting the Start of a Label 3-14
Adjusting the Label Gap Sensor Potentiometer 3-16
Correcting Uneven Print Quality 3-17
Fine-Tuning the Top of Form Position 3-19
Adjusting the Print Darkness 3-22
Adjusting the Label Mark Sensor 3-23
Adjusting the Label Mark Sensor Potentiometer 3-24
Adjusting the Printer for Self-Strip Printing 3-25
Adjusting the Label Taken Sensor Potentiometer 3-26
Aligning the Printhead 3-27
Aligning the Printer Rollers 3-29

HelvC NugFont Co d e 39 Testing and Adjusting 3
Use Test and Service mode and the adjustment procedures to pinpoint or correct
printer problems. Also use the test and adjustment procedures after you have
replaced a component to return the printer to optimum performance.
Test and Service Mode

Test and Service mode on the 3240 printer allows you to print test labels and
provides printer hardware diagnostic information to the host. The printer
remains in Test and Service mode until you turn the power off or reset the DIP
switches. The printer executes all functions as soon as you select them.
Selecting a new function terminates the current test.
Using Test and Service Mode

Use Test and Service mode on the 3240 printer to print test labels and provide
printer hardware diagnostic information to the host.
Note: For all Test and Service tests, pressing the Feed/Pause button pauses the current
test. Holding the Feed/Pause button aborts the current test and starts a new test.
To enter Test and Service mode

1. Turn the On/Off switch to the off position.
2. Press and hold the Feed/Pause button while turning the printer power on.
The printer prints out a hardware configuration label and then enters Data
Line Print mode.
3. Set the DIP switches to the test or service function you wish to perform. See
the following table for a list of the DIP switch settings.
4. Hold the Feed/Pause button down for 1 second. The test begins
immediately.
5. If you wish to perform another function, change the DIP switch settings
and press the Feed/Pause button.
The function the printer is currently executing terminates, and the printer
performs the new function.
To exit Test and Service mode

1. Turn the printer power off.
2. Return all DIP switches to their original settings.
3. Turn the printer power back on.
3-3
Use the information in the following table to set the DIP switches for the
appropriate Test and Service mode function you want to perform.
Test and Service Mode DIP Switch Settings
Default settings are noted with an * Top Bank Bottom Bank
O = OFF OFF
1 = ON
TESTS ON 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Test Prints O O O
Configurations O O O
Hardware* O O Q
Software 1 O Q
Test Labels 1 O O
Print Quality O O Q
Pitch 1 O Q
Page O 1 O O O
Single Page N N N N N Q
All Pages 1 1 1 1 1 Q
Format 1 1 O O O
Single Format N N N N N Q
All Formats 1 1 1 1 1 Q
UDC O O 1 O O
Single UDC N N N N N N N Q
All UDCs 1 1 1 1 1 1 1 Q
Font 1 O 1 O O
Single Font N N N N N N
All Fonts 1 1 1 1 1 1
Data Line Print *1 O O O O O O O
Cloning O 1 O
Receiver O O O O O
Sender 1 O O O O
Selective Transfer 1 1 O
Receiver O O O
Send Pages 1 O O S
Single Page 1 S S S S D D D D D
All Pages 1 1 1 1 1 1 1 1 1
Send Format O 1 O S
Single Format 1 S S S S D D D D D
All Formats 1 1 1 1 1 1 1 1 1
Send UDC 1 1 O S
Single UDC 1 S S S S S S S
All UDCs 1 1 1 1 1 1 1
Send Font O O 1 S
Single Font 1 S S S S D D D
All Fonts 1 1 1 1 1 1 1
Send Configuration 1 O 1
Send Tables O 1 1
Send All 1 1 1
Memory Reset O O 1
Page/Format O O O
UDC/Font 1 O O
Configuration O 1 O
Tables 1 1 O
All 1 1 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. Least significant bit.
D: Destination Page/Format/UDC/Font number. Least significant bit.
3240M.078
3-4
Printing Test Labels
The 3240 printer can print a variety of test print labels that provide you with
information about the printer configuration and the quality of the print. 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 the Feed/Pause button. To momentarily stop printing labels, press
and release the Feed/Pause button. To stop (exit) the Test and Service mode
function, press and hold the Feed/Pause button.
To print out a test label

1. Turn the On/Off switch to the off position.
2. Press and hold the Feed/Pause button while turning on the printer.
The printer prints out a hardware configuration label and then enters Data
Line Print mode.
3. Set the DIP switches to print out the test label of your choice:
• software
• print quality
• pitch
Refer to the Test and Service Mode DIP Switch Settings table for the correct
settings.
4. Hold the Feed/Pause button down for 1 second.
The printer begins printing out the test label immediately.
5. Exit Test and Service mode by turning the printer power off and then on.
3-5
Hardware Configuration Label

The hardware configuration label is the first label printed 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. Use the bias adjust
screw to compensate for printhead alignment problems with narrow media.
See “Correcting Uneven Print Quality” later in this chapter. Use the
“Aligning the Printhead” procedure later in this chapter to achieve
optimum print quality.
To achieve the highest quality label, including the vertical lines used to adjust
the printhead alignment, print the hardware configuration label at a speed of
3 ips (inches per second).
3240 Hardware Configuration

Memory Installed
Storage RAM : 128 kilobytes
Image RAM : 326 kilobytes
Flash RAM : none
Mileage
Inches Processed :0
Inches Burned :0
Printhead
Width : 1024 dots
Dot Size : 2.5 mil
Burn Pot Setting : 214
Hardware Options
I/O Option : none
Internal Option : none
External Option : Self Strip
Firmware Checksum
ROMO (U9): C466 ROM1 (U8): F39B
Program: 063103 Version: 1.4
3240M.070
3-6
Software Configuration Label
This label lists current configuration parameters that are set from the host
computer. It also lists defined pages, formats, graphics, fonts, and installed
options. This label is meant to be used as a reference.
INTERMEC 3240 Printer
Program Version : 1.4 PRINT SPEED - 3.0 IPS RIBBON SAVE-Disabled BUAD RATE - 9600
Pages Defined : 0 IMAGE BANDS - 3 SELF STRIP-Disabled DATA BITS - 7
Formats Defined : 0 MAX LABEL LENGTH - 4 inches CUTTER-Disabled MESSAGE LENGTH - 255
Fonts Defined : 0, 1, 2, 7, 20, 21, 22,23,24, LABEL STOCK - Inter-label gap DARK ADJUST - 0 PARITY- Even
25, 26, 28, 30, 31, 32, 33, 34,
35, 36, 37, 38, 39, 40, 41 MEDIA TYPE - Direct Thermal X FORMS ADJUST - 0 STOP BITS-1
Graphics Defined: none MEDIA LENGTH - 0 inches Y FORMS ADJUST - 0 PROTOCOL-Xon/Xoff No Status
CHARACTER SET - US ASCII LABEL REST POINT - 0 DEVICE ADDRESS - A
TRANSLATION - Disabled SEWNSITIVITY - 420 INTERNAL OPTIONS - none
EMULATION - Disabled EXTERNAL OPTIONS-Self-strip
LABEL RETRACT - Disabled
3240M.072
Print Quality Label

If you choose to print the Print Quality label, a label containing bar codes and
the model number prints. Use it to determine whether you are attaining the
best print quality possible. If you notice problems with the print quality, use
the “Aligning the Printhead” procedure later in this chapter to adjust the
printhead for optimal performance.
3240M.077
3-7
Pitch Label
If you choose the Pitch label, a gray scale that prints every third dot is printed.
You can use it to determine whether the printhead is printing evenly. The label
you see should present a regular gray pattern with dots that line up diagonally
when held at an angle. Look for irregularities or chips that may signal a
problem with the platen roller or the media path. If the printhead is uneven or
the print path is skewed, it will be reflected in the pitch label.
3240M.075
Format Label
If you choose the Format label, you can print a single format or a two label
sample containing a variety of bar codes and human readable fields. Use the
format labels to determine whether the printer is attaining the best print
quality possible with a particular format.
Font Label
Use the Font label to test a single font or all of the fonts. An all-font test uses a
lot of media. It is better to test one font at a time.
Page Label
Use the Page label to test the ability to download and correctly print single or
multiple pages of label data from the host. To make a correct assessment of
print quality, use one of the customer’s page formats when you run this test.
UDC Label
Use the UDC label to test the ability to download and correctly print single or
multiple user-defined characters (bitmap graphic) from the host. To make a
correct assessment of print quality, use one of the customers UDC’s.
3-8
Running Test and Service Mode From a Host
The following table describes the Test and Service mode IPL commands. To
enter Test and Service mode from Print mode, send <ESC>T from the host
terminal.
Note: All commands in Test and Service mode end with the command terminator (;),
except the last command in a message.
Test and Service Mode Commands
Command
Code Test Description
A Transmit Ambient Transmits the ambient temperature sensor output back to the
Temperature* host. The value ranges from 00 to FF.
B Printhead Resistance Test* Causes the printer to begin the printhead resistance test. The
printer will respond with the ASCII character string “pass” or
“fail.”
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 Transmits the label gap output back to the host. Values ranges
Value 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 Transmit Paper Path Open Transmits the Paper Path Open switch value back to the host. A
Sensor Value* value of 0 indicates the paper path is open and a value of 1
means it is closed.
M Transmit Reflective Sensor Transmits the label mark reflective sensor output back to the
Value host. The values range from 00 to FF.
P Transmit Printhead Transmits the Printhead Temperature Sensor output back to the
Temperature Sensor Value host. Values range from 00 to FF.
Q Print Quality Label Causes the printer to print out the print quality program and
model number label.
R Exit Test and Service Causes the printer to exit Test and Service mode.
* The 3240 printer ignores this command.
3-9
Test and Service Mode Commands (continued)
Command
Code Test Description
S Transmit Printhead Resistance Transmits the average, maximum, or minimum printhead dot
Values* resistance value back to the host. Each value is a numeric data
string separated by a comma.
T Transmit Label Taken Sensor Transmits the label taken sensor output back to the host. Values
Value range from 00 to FF.
U Transmit 40 Volt Supply Transmits the 12 volt supply output back to the host. The
Value* values range from 00 to FF.
V Transmit 24 Volt Supply Transmits the 24 volt supply output back to the host. Values
Value* range from 00 to FF.
* The 3240 printer ignores this command.
Checking for Communications

If there is a printing problem, you may want to check for a communications
problem with the host. If this test fails, there may be a problem with the printer
serial port receiver circuitry.
To test the host-to-printer communications

1. Turn the printer power switch to the off position.
2. Press and hold the Feed/Pause button while powering on the printer. The
printer prints out the hardware configuration test label.
3. Release the Feed/Pause button after the hardware configuration label is
printed. You are now in Data Line Print mode within the Test and Service
mode.
4. Transmit at least four characters from your system.
At this point the printer does not attempt to interpret any printer
commands, but simply prints each character and its hexadecimal equivalent
as it is received.
3-10
If you are using a PC running DOS, type the following commands at the
DOS prompt and press Enter after each line:
C:\MODE COM1: 96,E,7,1,N
C:\COPY CON COM1
ABCDEF^Z
where:
MODE COM1: 96, E, 7, 1, N configures the serial port.
COPY CON COM1 tells the PC to copy the following information to the
COM1 port.
ABCDEF are random characters entered at the host.
^Z (Ctrl-Z) sends the information to the printer.
The printer prints the following characters:
3240M.014
5. To enter normal print mode again, switch the printer power off and then on
again.
If this procedure does not work, check to make sure that the DIP switches are
set to the default configuration and that the printer cable is securely plugged
into COM1 of your PC.
Note: If you are using a different platform to communicate with your printer, please
refer to your host computer user’s manual and Chapter 6 of the 3240 Bar Code Label
Printer User’s Manual for information on downloading commands.
3-11
Printer Adjustments
The following procedures tell you how to perform minor adjustments on the
3240 printer. Adjustments include:
• correcting the lateral position of the label image
• accurately detecting the start of a label
• adjusting the label gap sensor potentiometer
• correcting uneven print quality
• fine-tuning the top of form position
• adjusting the print darkness
• adjusting the label mark sensor
• adjusting the mark sensor potentiometer
• adjusting the printer for self-strip printing
Correcting the Lateral Position of the Label Image

If your label image is no longer printing in the middle of your label, you may
need to adjust the lateral position of the printhead. Use the lateral printhead
knob to compensate for lateral movement of media in the media path or
variations in a roll of media. You can move the printhead 0.10 inch in either
direction.
Note: Do not raise the printhead before attempting to adjust the lateral position.
To adjust the lateral printhead knob

2. Gradually turn the lateral printhead knob while printing and observe how
the image is moving on the label.
• Turn the knob clockwise to move the printhead toward the inboard
edge of the media path.
• Turn the knob counterclockwise to move the printhead toward the
outer edge of the media path.
3. Adjust the lateral printhead knob until the image prints exactly where you
want it to on the label.
3-12
In the first part of the following illustration, the label image starts out
printing too close to the outside edge of the label. By turning the lateral
printhead knob clockwise, the label image moves closer to the inside edge
of the label. In the lower part of the illustration, the label image prints
exactly where you want it to, in the center of the label.
Adjusting the Lateral Printhead Knob
Front view
*NARR
Printhead
Lateral
printhead
knob
Front view
*NARR
Printhead
Lateral
printhead
knob
3240M.015
3-13
Accurately Detecting the Start of a Label

If your printer skips labels or stops printing and the yellow LED flashes, you
may need to adjust the label gap sensor. You are most likely to experience
these problems if you use 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 (0 to 25.4 mm) from the inner edge of the printer.
Note: Intermec sets the label gap sensor to 0.5 inch (12.7 mm) 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 (25.4 mm).
To adjust the label gap sensor

2. Turn the label gap sensor knob counterclockwise and slide the sensor all of
the way to the inner edge of the lower media guide.
3. Tear off one of the labels from your roll of media and line it up with the
0 (zero) on the lower media guide.
4. Slide the label gap sensor knob to the position where the label gap sensor
indicator is in the middle of the label. The label gap sensor indicator is the
part of the label gap sensor knob that is visible from the top of the lower
media guide.
Here are some guidelines for you to follow:
• If your labels are less than 1.0 inch (25.4 mm) wide, position the label
gap sensor in the middle of the label.
• If your labels are greater than 1.0 inch wide, position the label gap
sensor over the straight edge of the label.
• If your labels are round, position the label gap sensor over the middle
of the radius edge.
5. Turn the label gap sensor knob clockwise to secure it in the new position.
6. Try printing a label to see if the printer is detecting the start of the label (top
of form).
7. If the printer is still not detecting the top of form, slide the label gap sensor
a little further toward the outer edge of the lower media guide.
3-14
Adjusting the Label Gap Sensor
Label
gap Label gap
sensor sensor knob
Lower
media
guide Label
radius
Position label gap

sensor indicator
in the middle of
Label
the label
gap
sensor
Edge
Lower media guide
guide
Top view
3240M.017
3-15
Adjusting the Label Gap Sensor Potentiometer

The label gap sensor output enables the software to determine the leading edge
of a label by detecting the label gap. The label gap is the space between labels
on the backing material. This reading enables the printer to properly position
the start of print.
To adjust the label gap sensor potentiometer

1. Remove the media cover and the electronics cover.
2. Connect the positive lead of a multimeter to TP15 (GAP) and the negative
lead to TP14 (GND) on the main PCB.
TP14 R6 TP15
3240M.096
3. Turn the printer power on.

4. Insert the label backing only in the label gap sensor. Adjust R6 on the main
PCB so that the voltage at TP15 (GAP) is 1V ± 0.2V.
5. Insert both the label and the label backing in the sensor. Verify that the
voltage at TP15 (GAP) is greater than 3V.
6. Replace the electronics cover and the media cover.
7. Check the printer for proper operation.
3-16
Correcting Uneven Print Quality
If your printer wrinkles the ribbon or prints light on one side of your label, the
printhead is not making even contact with the label stock. This condition can
happen with any size label stock, but is most common when using narrow
label stock of 1 inch (25.4 mm) or less. 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.
Printhead bias
adjust screw
Po
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3240M.018
3-17
2. To compensate for uneven print quality, turn the bias adjust screw as
shown.
Adjusting the bias adjust screw causes the printhead to rest evenly on the
drive roller and results in even print quality.
If printing is light on If printing is light on

the right side of label, the left side of label, turn
turn the bias adjust screw the bias adjust screw
counterclockwise. clockwise.
*N
RO
AR
*E
OR
RA
3240M.019
3-18
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.
This feature is especially important if you are printing small labels in self-strip
mode because you can easily adjust for slight shifts in the label format without
stopping the printer or downloading software commands.
Only use the TOF switch to fine-tune your label format position. This is
important because the printer returns to your initial TOF setting when you do
one of the following:
• cycle printer power.
• lift the printhead.
Use the TOF switch to fine-tune the format position after you design the label.
Do not use the TOF switch to design your label format. Use PrintSet or the Top
of Form, Set software command <SI>F to control the initial TOF setting. For
help on using this command, see the PrintSet help or Chapter 6 of the 3240 Bar
The TOF switch is a small rocker switch located on the lower outboard plate of
the printer.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
I
O
3240M.021
3-19
To move a label format backward with the TOF switch
You notice that your format is printing toward the front part of the label.
ç Label direction from printer

#123
#123
3240M.023

Note: Do not raise the printhead while adjusting the TOF position.
2. Press on the back part of the TOF switch. Each time you press the TOF
switch, you move the label format backward .005 inch (.127 mm).
3240M.024
3. Press the TOF switch repeatedly until your format moves backward to the
correct position on the label.
#123
#123
3240M.025
3-20
To move a label format forward with the TOF switch
Note: You will see the new format position on the second label you print after pushing
the TOF switch.
You notice that your format is printing toward the back part of the label.
ç Label direction from printer
#123
#123
3240M.026
Note: Do not raise the printhead while adjusting the TOF position.
2. Press on the front part of the TOF switch. Each time you press the TOF
switch, you move the label format forward .005 inch (.127 mm).
3240M.027
3. Press the TOF switch repeatedly until your format moves forward to the
correct position on the label:
#123
#123
3240M.029
3-21
Adjusting the Print Darkness

Use the darkness adjust control in combination with the Dark Adjust, Set
command <SI>d to fine-tune the darkness of print on your labels. For help, see
Chapter 6 in your 3240 Bar Code Label Printer User’s Manual. The fine
adjustments compensate for variations in the media (“lot to lot”), the
printhead, or the printer. Set the darkness adjust control after you enter the
media sensitivity number.
To adjust the print darkness

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.
Turn the darkness Darkness

1 2 3 4 5 6 7 8
adjust control clockwise adjust control

for darker density
1 2 3 4 5 6 7 8
Turn the darkness adjust

control counterclockwise
I
for lighter density
1 2 3 4 5 6 7 8
O
1 2 3 4 5 6 7 8
Screwdriver
3240M.030
3-22
Adjusting the Label Mark Sensor
The label mark sensor detects the mark on the back of continuous media stock.
The output is then used to determine the start of print.
To adjust the label mark sensor

1. Locate the sensor under the label pathway across from the platen roller.
2. Use your index finger to reach underneath the lower guide and slide the
mark sensor to the correct position. You can position the mark sensor from
the inboard edge of the printer to the center of the media path.
Platen
Roller
Locate the label mark sensor

behind the platen roller near
the inboard edge of the printer.
Use your index finger to adjust
the label mark sensor.
Inboard edge
of printer.
The platen roller
is not shown
for clarity only.
Label mark
sensor
(The label mark sensor
can be positioned no
more than 1 in (25.4 mm)
from the inboard edge.)
3240M.032
3-23
Adjusting the Label Mark Sensor Potentiometer

The mark sensor output enables the software to detect the black mark on the
back of continuous media stock. If your printer is having trouble determining
the start of print, you may need to adjust the mark sensor potentiometer.
To adjust the label mark sensor potentiometer

3. Enable the printer for mark sensing using the <SI>T2 command.
4. Connect the positive lead of a digital volt meter to TP18 (MARK) and the
negative end to TP14 (GND) on the main PCB.
TP18 R191
TP14
3240M.097
5. Place the white portion of a label under the mark sensor.

6. Adjust R191 on the main PCB so the voltage at TP18 is 1V ± 0.2V.
7. Place the black mark portion of the label under the mark sensor.
The voltage at TP18 should now be greater than 2.5 volts.
8. Install the printer electronics cover and the media cover.
3-24
Adjusting the Printer for Self-Strip Printing
If your 3240 printer is continuing to print labels even when there is a label
waiting for removal at the tear bar, you may need to adjust the label taken
sensor. The label taken sensor detects whether there is a label present at the
tear bar. The printer uses this sensor to determine when you remove a stripped
label and when it can print the next label. You can only use this sensor with the
self-strip option.
Note: It is only necessary to adjust the label taken sensor when using very narrow
labels (less than 0.5 in (12.7 mm)).
To position the label taken sensor

1. Slide the label taken sensor up to 3/8 inch from the inboard edge of the
media path.
2. Align the label taken sensor over the straight edge of the label at the tear
bar.
For narrow label stock, you may want to position the label taken sensor in
the middle of the label. The following illustration shows how to position the
label taken sensor for narrow label stock.
Label
taken
sensor
Tear
Label bar
Backing
3240M.034
3-25
Adjusting the Label Taken Sensor Potentiometer

The label taken sensor output enables the software to determine that a label has
been taken by detecting the presence of the label.
To adjust the label taken sensor

2. Connect the positive lead of a multimeter to TP19 (TAKEN) and the
negative lead to TP14 (GND) on the main PCB.
TP14 TP19
R190
3240M.098

4. Feed one label out of the printer so that it rests under the label taken sensor
in a correct orientation.
5. Adjust R190 on the main PCB until the voltage at TP19 is 1.2V ± 0.2V.
6. Remove the label from under the label taken sensor.
The multimeter reading at TP19 should now read above 4.5V.
7. Install the printer electronics cover and the media cover.
3-26
Aligning the Printhead
To properly align the printhead, follow the steps outlined below. You should
perform this procedure only when necessary. To perform this procedure, you
need the following tools:
• Printhead Alignment tool, Intermec Part No. T43255
• 9/64 inch Allen screwdriver
To align the printhead

1. Switch off the printer power and remove the power cord.
3. Raise the head lift lever and remove any media in the label path.
4. Remove the printhead. For help, see “Replacing the Printhead” in Chapter
4.
5. Make sure the lateral printhead knob is in the center of its adjustment
range.
6. Loosen the two 9/64 inch Allen screws located on the printhead yoke in
back of the printhead heat sink.
7. Install the printhead alignment tool, T43255, and press the printhead
assembly down on the platen roller. Align the tool with the pins in the
printhead heatsink.
8. Rotate the printhead lever counterclockwise to lock the printhead
alignment tool and heatsink in place.
9. Alternately tighten the two 9/64 inch printhead yoke screws until secure.
While tightening the screws, move the printhead yoke front to back to
make sure that the printhead heatsink and pivot bracket settle flat against
each other.
10. Rotate the head lift lever clockwise to raise the heatsink.
11. Remove the printhead alignment tool.
12. Install the printhead.
13. Reload media.
14. Replace the media cover and install the power cord.
15. Switch the printer power on and test for proper printhead alignment by
printing out the print quality and pitch labels.
3-27
Aligning the Printhead
Heatsink
Place the cutouts

of the printhead
alignment tool onto Printhead Po
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the shaft of the platen alignment Em

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Head lift lever

(Rotate counter-
clockwise to secure
the printhead.)
3240M.040
3-28
Aligning the Printer Rollers
To properly align the printer rollers, follow the procedure outlined below. You
should perform this procedure every time a roller is replaced. To perform this
procedure, you need the following tools:
• Roller Alignment Tool, Intermec Part No. 064807
• #2 Phillips screwdriver
• Snap ring pliers
To align the rollers

2. Raise the printhead.
3. Remove the lateral printhead knob using the snap ring pliers.
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
CAUTION possible to align the rollers outside of the factory.
4. Loosen the Phillips screws on the guide plate that you are aligning.
5. 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 bushing for the lateral printhead knob shaft
3-29
Aligning the Rollers
Roller
alignment
tool
➤
3240M.041
6. 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
factory alignment.
7. Lower the printhead and replace all of the printer covers.
3-30
4
Replacing Printer Parts 4-3
Protecting Delicate Electronic Components 4-4
Replacing the Lithium Battery 4-5
Replacing the Printhead 4-7
Replacing the Main PCB Assembly 4-9
Replacing the Label Mark Sensor 4-11
Replacing the Label Taken Sensor 4-13
Replacing the Label Gap Sensor 4-15
Replacing the TTR Drive Gear/Pulley and Drive Roller 4-18
Replacing the Upper Drive Belt and TTR Takeup Clutch Pulley 4-20
Replacing the TTR Clutch Encoder 4-22
Replacing the Lower Drive Belt 4-24
Replacing the Platen Roller and Platen Roller Gear 4-27
Replacing the Ribbon Drive Roller 4-29

HelvC NugFont Co d e 39 Replacing Printer Parts 4
Many parts of the 3240 printer have been spared to make repair as easy as possible.
Instead of purchasing a complete assembly, you can order individual parts. See
Chapter 5 for a complete list of spare parts for the 3240 printer.

When a printer part needs replacing, use the appropriate procedure in this
chapter. See Chapter 5, “Spare Parts List and Assembly Drawings,” for a
complete list of spare parts.
After replacing a part, refer to Chapter 3 for the procedures to complete the
repair by ensuring that you leave the printer performing at its optimum level.
Prior to taking any action, review all warnings, cautions, and procedures
associated with any part you intend to remove.
When performing any of the procedures in this chapter, heed the following
warnings and cautions at all times.
Warning
Always disconnect the power cord before removing the electronics cover unless
WARNING the procedure requires the unit to be energized. Failure to disconnect the power
cord may result in injury or death due to electric shock.
Caution
The printhead and integrated circuits on printer circuit boards in this
CAUTION equipment are sensitive to damage by electrostatic discharge (ESD). Prevent
ESD by always wearing skin contact ground straps firmly attached to the
equipment metal base assembly when working inside of the equipment
housing. Failure to comply can result in damage to components or the
printhead.
Caution
Do not remove the motor plate or subplates. Changing the position of the
CAUTION motor plate can alter factory alignment and cause ribbon wrinkling or liner-
stripping problems.
4-3
Protecting Delicate 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
Follow ESD this icon, you must follow standard ESD guidelines to avoid damaging the
Procedures
equipment you are servicing.
The Everett facility uses several vendors for ESD products. One USA vendor is
DESCO Industries, Inc., which you can reach at telephone (909) 598-2753 or on
the World Wide Web at http://www.desco.com/. This table lists part numbers
from DESCO’s 1996 catalog. However, you may want to find your own sources
for ESD products.
Part Number Description

7755 Large Service Kit 22 x 24
7780 Standard Service Kit 18 x 22
7790 Pocket Kit 15 x 20
A77115 Work Table Mat 24 x 28
4-4
Replacing the Lithium Battery
To replace the lithium battery, you need the following parts and tools:
• 1.75Ah 3.6V AA lithium battery, Intermec Part No. 586229
• ESD mat and grounding strap
Warning
There is danger of explosion if the battery is incorrectly replaced. Replace
WARNING it only with the same or equivalent type battery recommended by the
manufacturer. Discard used batteries according to the manufacturer’s
instructions.
Avertissement
Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du même type ou d’un type
recommandé par le constructeur. Mettre au rébut les batteries usagées
conformément aux instructions du fabricant.
To replace the lithium battery
Note: The printer will lose data if the battery fails or is removed. Before removing the
battery, upload and save the fonts, formats, pages, graphics, and configuration settings.
1. Switch off the printer power and remove the power cord, the media cover,
and the electronics cover.
2. Remove the old battery.
3. Install the new battery, matching the (+) and (-) ends of the battery with
the (+) and (-) signs on the main PCB.
Follow ESD 4. Install the covers and power cord.
Procedures
5. Switch the printer power on and check for proper operation.
4-5
Replacing the Lithium Battery
Lithium Main PCB

battery
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3240M.043
4-6
Replacing the Printhead
Printhead failure is characterized by the appearance of long white streaks in
printed labels. The white streaks are caused by the loss of print bead dots on
the printhead. To replace the printhead you need:
• 2.52 inch, 2.5 mil printhead, Intermec Part No. 062705S-001
• Medium straight-slot screwdriver
To replace the printhead

2. Remove the media cover, raise the head lift lever, and remove any media in
the label path.
3. Use a straight-slot screwdriver to loosen the printhead retaining screw,
located in the center of the printhead heat sink. 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.
Pull the printhead away from the printer by working it out to the side. The
label taken sensor does not come out, so removing the printhead can be
difficult.
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. Switch the printer power on and check for proper operation.
4-7
Replacing the Printhead
Straight-slot
screwdriver
Cable Printhead
connector cable
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Printhead
retaining
screw
You must take the

printhead out at an
angle.
3240M.042
4-8
Replacing the Main PCB Assembly
Problems with printer-to-computer communications, motor control, or media
advance may be caused by a faulty main PCB assembly. To replace the main
PCB assembly, you need the following items:
• 3240 main PCB assembly, Intermec Part No. 064173-001
• ESD grounding strap
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.
Caution
Integrated circuits on printed circuit boards (PCBs) in this equipment are
sensitive to damage by electrostatic discharge (ESD). Prevent ESD by always
wearing skin contact ground straps firmly attached to the equipment metal
base assembly when working inside of the equipment housing. Failure to
comply may result in damage to PCB components.
To replace the main PCB assembly

2. Remove the media cover and the electronics cover. Place the printer on its
side with the electronics side facing up.
Follow ESD 3. Unplug all of the cables from the main PCB and remove the seven screws
Procedures securing the main PCB to the printer.
Note: Both the cable connectors and the main PCB are labeled with the cable name.
This makes it easy for you to reattach cables to the new main board.
4. Remove the main PCB and replace it with the new main PCB assembly.
5. Replace the seven screws removed in Step 2 and reattach all of the cables.
Set the printer back in its upright position.
6. Replace the electronics cover and the media cover.
7. Install the power cord and switch the power on to test for proper operation.
4-9
Replacing the Main PCB Assembly
Main PCB
2
1 assembly
7
5
6
Feed/Pause
Intermec
3240
Empty/Pause
Alert
Power
3240M.044
4-10
Replacing the Label Mark Sensor
If the printer is no longer registering the use of marked label stock, you may
need to replace the label mark sensor. The required parts and tools are listed
below:
• Label mark sensor cable assembly, Intermec Part No. 059729-003
To replace the label mark sensor

1. Switch off printer power and remove the power cord.
2. Remove the media cover, the electronics cover, and the front bezel cover.
3. Remove the four Phillips screws that secure the lower outboard plate to the
printer and pull it away from the printer. Retain the tear bar and the tear
bar support that are secured by this plate.
Note: It may be necessary to disconnect the top of form switch from its cable to be
able to pull the lower outboard plate away from the printer.
Removing the Lower Outboard Plate
Lower outboard
plate
Tear bar
Tear bar
support
3240M.045
4-11
Replacing the Label Mark Sensor
Label mark
sensor
3240M.048
4. Disconnect the label mark sensor connector from the main PCB.
5. Push the label mark sensor cable through the cutout in the printer frame.
Slide the sensor out from the extrusion.
6. Insert the new label mark sensor into the extrusion. Route the cable
through the cutout in the printer frame and plug it into the main PCB.
Secure the cable in place by inserting it into the two cable clips.
Note: Ensure that the cable is secured and not making contact with gears, belts,
etc.
Note: Do not forget to replace the tear bar and support when reinstalling the
outboard plate.
7. Replace the lower outboard plate and replace the four Phillips screws
removed in Step 3.
Note: Use the roller alignment tool, Intermec Part No. 064807, during reassembly
for proper alignment of the outboard plate. See “Aligning the Printer Rollers” in
Chapter 3.
8. Replace all of the printer covers.

4-12
Replacing the Label Taken Sensor
If your printer is no longer sensing when labels have been removed, it may be
time to replace the label taken sensor. To replace the label taken sensor, you
need the following items:
• Label taken sensor cable assembly, Intermec Part No. 063436-001
To replace the label taken sensor

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 from the printer frame.
5. Insert the new sensor into the printer frame.
6. Route the cable through the cutout in the printer frame and plug it into the
main PCB. Clip the cable into the cable clamps.
Note: Ensure that the cable is secured and not making contact with any gears,
belts, and so on.

4-13
Replacing the Label Taken Sensor
Printer
frame
Label taken
sensor
3240M.050
4-14
Replacing the Label Gap Sensor
If labels are not stopping at the right point to be removed, or they stop
indexing, you may need to replace the label gap sensor. Before you replace the
label gap sensor, try adjusting the label gap potentiometer (see Chapter 3). If
you still have problems, you may need to replace the label gap sensor. To
replace the label gap sensor, you need:
• Label gap sensor cable assembly, Intermec Part No. 062646-001
• Small straight-slot screwdriver
• 12-inch #2 Phillips long blade screwdriver
To replace the label gap sensor

3. Disconnect the label gap sensor cable from the main PCB.
4. Remove the three screws that hold the media guide assembly and remove
the media guide assembly from the printer. Be careful when pulling the
label gap sensor cable through the cutout in the printer frame.
Label gap
sensor cable
Label gap
sensor
Upper and lower
media guide
assembly
3240M.051
4-15
Removing the Label Gap Sensor Detector
Label gap
sensor dectector
Lower Label gap
media sensor housing
guide
3240M.101
5. Remove the label gap sensor detector from the label gap sensor housing
located on the underside of the lower media guide. The detector snaps
easily out of the housing.
6. Unthread the cabling from the assembly.
4-16
Removing the Label Gap Sensor Emitter Board
Label gap
sensor
emitter board
Label gap
sensor base
Upper media
guide
3240M.100
7. Remove the label gap sensor emitter board from the label gap sensor base
in the upper media guide. The emitter board snaps in and out of the base.
You may need to use some force to remove it.
8. Snap the new emitter board into place making sure that the board seats
correctly and the emitters are centered over the lens in the upper media
guide.
9. Thread the new detector through the assembly and snap the detector into
the gap sensor housing.
10. Route the label gap sensor cable through the cutout in the printer frame
and reattach the media guide assembly to the frame with the three Phillips
screws removed in Step 4.
11. Attach the label gap sensor cable to the main PCB.
12. Reattach all of the printer covers and install the power cord. Switch the
printer power on and test for proper operation.
13. Adjust the label gap sensor potentiometer. See Chapter 3 for the procedure.
4-17
Replacing the TTR Drive Gear/Pulley and Drive Roller

If you damage the TTR assist gear assembly, replace it by using the following
parts:
• TTR drive gear/pulley, Intermec Part No. 059044-007
• .310 diameter gripping retaining E-rings, Intermec Part No. 501401
• E-ring pliers
To replace the TTR drive gear/pulley and drive roller

3. Use the E-ring pliers to remove the ribbon drive roller gear E-ring located
on the electronics side of the printer.
Make sure that you save the washer located between the E-ring and the
TTR drive gear/pulley.
4. Remove the drive belt from the TTR drive gear/pulley assembly. Slide the
TTR drive gear/pulley assembly away from the printer and off of the TTR
drive roller shaft.
Make sure that you save the washer located between the TTR drive
gear/pulley and the printer frame.
Note: Do not remove the motor plate. Changing the position of the motor plate
destroys the factory alignment and may cause ribbon wrinkling.
5. Insert the new TTR drive gear/pulley assembly by first sliding the
gear/pulley assembly onto the TTR drive roller shaft and then reinstalling
the belt.
Note: Remember to replace the washer removed in Step 4.
6. Replace the E-ring and washer removed in Step 3.

7. Replace the printer covers.
4-18
Replacing the TTR Drive Gear/Pulley
TTR takeup
drive belt TTR drive
roller
TTR takeup
drive belt
TTR roller
shaft
TTR drive
gear/pulley
Motor plate
TTR drive Washer
gear/pulley
Motor Washer
E-ring
plate
3240M.055
4-19
Replacing the Upper Drive Belt and TTR Takeup Clutch

Pulley
If the upper drive belt wears out or you need to replace the clutch pulley on the
takeup hub, replace them by using the following parts:
• Takeup clutch assembly, Intermec Part No. 059689S-008
• 2.950 ID x .139 O-ring, Intermec Part No. 501462-002
To replace the upper drive belt and TTR takeup clutch pulley
3. Remove the TTR takeup clutch pulley snap rings and the thin washer from
the end of the takeup hub shaft.
4. Pull out on the TTR takeup hub assembly to release the clutch pulley.
5. Lift the TTR takeup clutch pulley and upper drive belt away from the
printer.
destroys factory alignment and may cause ribbon wrinkling.
6. Replace the upper drive belt or the TTR takeup clutch pulley.
Note: Now is a good time to replace the TTR takeup hub if necessary.
7. Wrap the upper drive belt around the TTR takeup clutch pulley assembly
and position it so you can insert the TTR takeup hub shaft through it.
Replace the TTR takeup hub.
8. Replace the thin washer and snap rings removed in Step 3. Reinstall the
drive belt over the TTR drive gear/pulley.
4-20
Replacing the Upper Drive Belt and TTR Takeup Clutch Pulley
TTR takeup TTR takeup

drive belt clutch pulley
TTR takeup
hub
Thin washer
Snap rings
TTR drive
gear/pulley
3240M.056
4-21
Replacing the TTR Clutch Encoder

If you need to replace the TTR clutch encoder or ribbon supply hub, use the
following parts:
• TTR encoder clutch assembly, Intermec Part No. 063556S-001
• Ribbon drive hub assembly, Intermec Part No. 062654S-001
To replace the TTR clutch encoder

2. Remove the media supply cover, the electronics cover, and the front bezel
cover.
3. Remove the snap rings and thin washer from the electronics side of the
ribbon supply hub shaft.
4. Pull the ribbon supply hub away from the printer on the media side to
release the TTR clutch encoder.
5. Replace either the clutch encoder or the ribbon supply hub.
6. Align the TTR clutch encoder with the opening in the printer frame and
slide the ribbon supply hub back through the clutch encoder and the motor
plate. Ensure that the flat side of the supply hub shaft is aligned with the
TTR clutch encoder.
7. Replace the thin washer and snap rings removed in Step 3.

4-22
Replacing the Ribbon Supply Hub or TTR Clutch Encoder
TTR clutch
encoder Ribbon
assembly supply
Thin washer
hub
Thin washer
Snap rings
TTR drive
gear/pulley
3240M.57
4-23
Replacing the Lower Drive Belt

If the lower drive belt wears out or any of the lower gears or rollers need to be
replaced, you need some or all of the following parts:
• 2.950 ID x .139 O-ring, Intermec Part No. 501462-002
• Liner drive gear/pulley assembly, Intermec Part No. 063132-002
• Take-up clutch assembly, Intermec Part No. 059689S-008
• Liner drive hub assembly, Intermec Part No. 063300-001
• Platen roller, Intermec Part No. 062624-001
• Platen roller gear, Intermec Part No. 059028-006
To replace the lower drive belt

3. Remove the snap rings and the thin washer from the rewinder hub shaft on
the electronics side of the printer.
4. Remove the rewinder hub to free the rewinder hub pulley that the lower
drive belt wraps around.
5. Slide the rewinder hub pulley forward and remove it from behind the
motor plate. Unloop the drive belt from the rewinder hub pulley and the
liner drive roller gear/pulley.
Note: At this point, you can replace the rewinder hub clutch pulley or the
rewinder hub.
4-24
Replacing the Lower Drive Belt
Thin washer
Snap rings
Liner drive
hub
Liner drive
gear/pulley
Lower
drive
belt Lower drive
belt
Spring drive
Rewinder guard
hub pulley
(Slide the pulley
forward. Remove
the pulley from
behind the motor
mount plate and
unloop the belt from Metal tab
the two gear/pulleys.)
The lower drive
belt must be reinstalled
with the front loop of the
Motor belt in front of the the metal
plate tab on the spring drive guard.
3240M.060
4-25
Note: When reassembling the belt, remember that the belt has a twist between
pulleys. The belt must be reinstalled with the front loop of the belt in front of the
metal tab on the spring drive guard. The twist in the lower belt provides for
rewinder hub rotation opposite that of the upper drive belt pulley.
6. Loop one end of the drive belt around the liner drive gear/pulley and place
the other end around the rewinder hub pulley.
7. Reinsert the rewinder hub pulley into the space behind the motor plate,
making sure that the drive belt is placed correctly around the spring drive
guard.
8. Replace the rewinder hub. Inserting the rewinder hub through the
rewinder hub pulley may take some patience because you need to maintain
tension on the liner drive gear/pulley and lower drive belt while
positioning the rewinder hub pulley in place. Use the cutout in the motor
plate to help position the clutch pulley.
9. Replace the washer and snap rings removed in Step 3.
10. Reattach all of the printer covers.
11. Install the power cord and switch the printer power on to test for proper
operation.
4-26
Replacing the Platen Roller and Platen Roller Gear
If the platen roller needs to be replaced, you need some or all of the following
parts:
• Platen roller, Intermec Part No. 062624-001
• Platen roller gear, Intermec Part No. 059028-006
To replace the platen roller and platen roller gear

3. Remove the snap ring that holds the platen roller gear in place.
4. Remove the four screws that secure the lower outboard plate to the printer
frame. Lift the plate away from the printer (you may need to disconnect the
TOF switch). The tear bar and support become loose when the outboard
plate is removed; be sure to place it in a safe place.
5. Loosen the motor mounting screws.
6. Replace either the platen roller or the platen roller gear, washer, and E-ring,
and secure with the snap ring removed in Step 3.
7. Slide the motor forward and press into the liner drive gear/pulley and the
TTR assist roller gear. Spin the platen roller to check for gear engagement
and tighten the motor mounting screws.
8. Replace the lower outboard plate and secure with the four screws removed
in Step 4.
Note: When reinstalling the lower outboard plate, do not forget to replace the tear
bar and support.
for proper alignment of the outboard plate. See the “Aligning the Printer Rollers”
in Chapter 3.
4-27

operation.
Replacing the Platen Roller
Snap
ring
Platen Washer
roller E-ring
gear Platen
roller
Lower
outboard
Tear bar
plate
Tear bar
support
3240M.062
4-28
Replacing the Ribbon Drive Roller
If you damage the ribbon assist roller, replace it by using the following parts:
• Ribbon drive roller, Intermec Part No. 062625-001
• .250 diameter basic retaining snap ring, Intermec Part No. 501409
• E-ring pliers
• Spring hook tool (optional)
To replace the ribbon drive roller

3. Use the E-ring pliers to remove the ribbon drive roller gear E-ring located
on the electronics side of the printer. Remove the drive belt from the gear.
4. Remove the snap ring that secures the head lift lever to the cam assembly
shaft. Pull the head lift lever off of the head lift shaft.
5. Remove the snap ring that secures the lateral printhead adjustment knob to
the printer. Pull the adjustment knob off of the shaft.
6. Use the spring hook tool to remove the printhead spring from the upper
outboard plate.
7. Remove the four screws that secure the upper outboard plate. Remove the
upper outboard plate.
8. Remove the ribbon drive roller while making a note of washer and gear
positions.
9. Insert the new ribbon drive roller. Ensure that the gear, washers, and
E-rings are in the proper order. Reattach the ribbon drive roller gear E-ring.
Reinstall the drive belt.
Note: The printhead spring is the most difficult part to reinstall. Put the complete
assembly together and then hook the spring around the upper plate.
10. Replace the upper outboard plate. When reinserting the upper outboard
plate, make sure that all four shafts are firmly inserted into their
corresponding cutouts in the upper outboard plate.
4-29
11. Secure the upper outboard plate to the printer with the four Phillips screws
removed in Step 7.
for proper alignment of the outboard plate. See the “Aligning the Printer Rollers”
in Chapter 3.
12. Replace the head lift lever and secure it with the snap ring removed in
Step 4.
13. Replace the lateral printhead adjustment knob with the snap ring removed
in Step 5.
operation.
Replacing the Ribbon Drive Roller
Ribbon drive
roller
E-ring Cam assembly
Washer shaft
E-ring Washer
Printhead
spring
Upper outboard
plate Head lift
lever Snap ring
3240M.64
4-30
5
Spare Parts List and Assembly Drawings
Ordering Replacement Parts 5-3
3240 Tools 5-3
3240 Manuals 5-3
3240 Spare Parts List 5-4
3240 Assembly Drawings 5-9

Spare Parts List and Assembly Drawings 5
Use this chapter to identify 3240 replacement parts that you need to order.
Ordering Replacement Parts

This chapter contains a complete list of the spare parts for the 3240 printer
along with accompanying illustrations that identify each part. To locate the
part you want to replace, find the part in one of the illustrations and locate the
corresponding ID number in the spare parts list.
To order replacement parts, contact Intermec
Intermec Corporation
6001 36th Avenue West
P.O. Box 4280
Everett, WA 98203-9280
Note: Only the listed spare parts are available for purchase.
3240 Tools
T43255 Printhead Alignment Tool
064807 Roller Alignment Tool
3240 Manuals
063015 3240 Bar Code Label Printer User’s Manual
063257 3240 Bar Code Label Printer Getting Started Guide
044737 Data Communications Reference Manual
051241 The Bar Code Book by Roger C. Palmer
5-3
3240 Spare Parts List

ID Number Part Number Description
1 063436-001 Cable Assembly, Label Taken Sensor
2 062860-001 Nut, Printhead Pivot
3 522690 Screw, Thread Roll With Cone, 8-32 x .38
4 062656-001 Shaft, TTR Ribbon
5 062622-001 Extrusion, Media Post
6 062638-002 Spring, Torsion, Paper Path
7 059718-002 Ring, Label Supply
8 059120-002 Cap, Media Supply
9 062637-003 Shaft, Paper Path Adjustment
10 062396-001 Mount, Label Gap Sensor
11 062646-001 Cable Assembly, Gap Sense Detector
12 062618-002 Bracket, Media Path, Upper
13 062644-002 Edge Guide, Outer
14 062619-004 Bracket, Media Path, Lower
15 521118-001 Washer, Spring, Conl .175 x .50
16 059781-001 Thumbscrew, Assembly
17 062645-002 Bracket, Gap Sense Detector
18 062658-001 Block, Pivot
19 501401 Retaining Ring .250 Diameter 8610/2
20 506013 Washer, SST, .255ID x .407OD
21 062653-002 Spring, Torsion, Printhead Return
22 062660-001 Shaft, Printhead Pivot
23 506827-001 Spring, Compression 360 OD .44F
24 062661-002 Bracket, Printhead Pivot
25 062707-001 Knob, Printhead Adjustment
5-4
26 501409 Ring, Retaining .250 Diameter Basic
27 059039-011 Handle, Printhead Pressure
28 062657-001 Plate, Upper Module, Outboard
29 064397-001 Switch, Rocker, Top of Form (TOF)
30 064260-001 Plate, Lower Module, Outboard
31 062624-001 Roller, Platen
32 062642S-001 Cam Assembly, Head Pressure

(includes Printhead Position Flag)
33 062626-002 Roller, Liner Drive
34 062625-001 Roller, Ribbon Drive
35 062620-001 Extrusion, Printhead Span
36 059729-003 Cable Assembly, Label Mark Sensor
37 062621-001 Bar, Strip Support
38 062623-002 Bar, Tear
39 062636-001 Clamp, Liner Hub
40 063469-002 Collet, Hub Clutch
41 059115-005 Washer, TTR Clutch
42 063470-001 Spring, Hub Clutch
43 063300-001 Hub Assembly, Liner Drive
44 506040-005 Washer, Flat SST .327 x .50 x .30
45 062655-003 Bracket, Core Locking
46 062654S-001 Hub Assembly, Ribbon Drive (includes 45)
47 501394-001 Mount, Wire Routing, Adhesive Back
48 063116-001 Cable Assembly, Printhead Position Sensor
49 060363-003 Guard, O-ring
50 060286-001 Roller, O-ring Guard
5-5
51 506000 Washer, Flat, No. 2
52 507424 Screw, Self-locking, 2-56 x .312 Ph
53 059044-007 Gear/Pulley, Cluster, L/H
54 063132-002 Gear/Pulley, Cluster, Liner Drive
55 059028-006 Gear, Platen, Drive Shaft
56 059102-002 Bracket, Motor Mount
57 059024-009 Plate, Motor
58 507639 Screw, Phillips, With Internal Star 8-3
59 059021-001 Cable Assembly, Motor Main Stepper
60 063726S-001 Clutch Assembly, TTR Takeup, 3240, Spare
61 059689S-008 Clutch Assembly, Takeup Clutch, Spare
62 063556S-001 Clutch Assembly, TTR Encoder, 3240, Spare
63 059103-002 Button, Cap
64 062616S-003 Bezel, Front Cover
65 063302-001 Cable Assembly, Ribbon Printhead
66 505613 Screw, Soc. Head Cap 8-32
67 064274-002 Brake, Media Tension
68 501462-004 O-ring, .487ID x .103THK
69 063834S-002 Wheel, Media Tension, 3240, Spare
70 526036 Screw, Phillips, With Internal Star 6-32 x .375
71 063965-003 Spring, Constant Force, .25 lb
72 064292-001 Drum, Spring, Media Tension
73 059052S-003 PCB Assembly, Bezel
74 059012-009 Plate, Front Cover
75 060317-001 Pad, Sound Dampening
5-6
76 059387-003 Bracket, Hinge
77 060315-002 Roller, Pinch
78 062635-001 Shaft, Pinch Roller
79 501445 Ring, Retaining .125 Diameter E-ring, Zinc
80 062632-002 Door Assembly, Media Access
81 505767 Screw, Phm, 8-32 x .375
82 062705S-001 Printhead, 2.52 inch, 2.5 mil
83 062627-001 Plate, Base
84 501272-001 Feet, Rubber, Adhesive Backed
85 062639-001 Heatsink Assembly, Printhead
86 506111 Washer Lock, Split, No. 4
87 507659-001 Screw, Jack, 4-40 x .312
88 060544-001 Gasket, ESD, RS-232 Connector
89 586229 Battery, Lithium 3.6V AA, 1.75Ah
90 064173-001 PCB Assembly, Main
91 063104S-005 Firmware, V1.0, 3240
92 059727-001 Cable Assembly, Bezel
93 041776 Jumper Assembly, .25 Term. Lugs, 4 inch
94 060246-001 Filter Assembly, Line AC
95 506103 Washer, Lock, External Star, No. 8
96 501273-002 Circuit Breaker, Switch, 1A
96 501273-001 Circuit Breaker, Switch, 2A
97 063501-001 Label, 400 dpi, Precision Print
98 062617-001 Bezel, Top Cover (400 dpi label not included)
99 059101-009 Cover, Electronics
100 062629S-002 Cover, Rear
5-7
101 062628S-001 Cover, Media Access (includes 98, 102, 103, 104)
102 062921-001 Label, Internal Loading Instructions
103 059710-001 Magnet, Door Latch
104 059013-002 Lens, Media Inspection
062630-001 Core, Ribbon Takeup
053866 Cover, I/O Slot
501410 Ring, Retaining .310 Diameter, Gripping
506040-006 Washer, Flat SST .327 x .500 x .080
501462-002 O-ring, 2.950 ID x .139
5-8
3240 Assembly Drawings
63 places
12
3 6 10
F
4
9 11 13
View F-F
5
2 shown assembled
1 7 14
8
15 4 places
16 2 places
F
17
18
19 6 places
20 12 places
21
38 23
32 22
37 34 24
36
35 25
28
4 places 31 29 26 7 places
33 27
30
3240.EX2
5-9 (5-10 blank)

45 2 places 51
52
46 2 places
43
2 places 56
48
47
44 4 places 53
See detail A
40 58 3 places
2 places 41
39 2 places 42 55
2 places 57
49
54
See detail B
50
59
60
53
61
Detail B
49 54
Detail A
part of assembly
50 62
60
Not all parts shown

for clarity 3240.EX3
part of assembly
61
5-11 (5-12 blank)

67
68
70 12 places
69 67
65
2 places E
64 C 66
71
(Item 41)
72
63 View E_E
Rotated 90° CCW
81
73
80
82
83
85 84 4 places
76
77
79
Not all parts show 78
for clarity 75 74
View C-C
Rotated 90° CW
C
3240.EX4
5-13 (5-14 blank)

89
90
88
91
2 Places
87
2 places
86 2 places
96
95
94
93
Not all parts shown

for clarity
92
3240.EX5
5-15 (5-16 blank)

99
98
97
100 View D-D 102
101
101
(Includes 102, 103,104)
103
D
104
Not all parts shown

for clarity
3240.EX6
5-17 (5-18 blank)

A
Specifications and Reference Material
3240 Printer Specifications A-3

Dimensions (no options installed) A-3
Electrical Requirements A-3
Printing Method A-3
Printing Speed A-3
Printhead A-3
Media Specifications A-4
Ribbon Specifications A-5
Environment A-5
Self-Strip Specifications A-5
Fonts and Graphics A-5
Character Sets A-5
Memory A-5
Intermec Cables A-6
Printer Options A-6
Selecting the Correct Media A-8
Configuration Parameters Upload Table A-10
Summary of IPL Commands A-11
DIP Switch Settings A-17
Full ASCII Chart A-18

HelvC NugFont Co d e 39 Specifications and Reference Material A
3240 Printer Specifications
This section describes the specifications and performance parameters for the
3240 printer.
Dimensions (no options installed)

Height 11 in (27.9 cm)
Width 8.25 in (21 cm)
Length 17 in (43.2 cm)
Weight 32 lbs (14.5 kg)
Electrical Requirements
Input Voltage 100, 115, or 230 VAC ± 10%
Frequency 47-63 Hz
Printing Method
The 3240 printer is capable of direct thermal (DT) printing, or thermal transfer
(TTR) printing using a thermal transfer ribbon.
Printing Speed
Maximum 4 in per second (101.6 mm per second)
Minimum 2 in per second (50.8 mm per second)
You can change the print speed in 1 ips increments only: 2, 3, or 4.
Printhead
Printed dot size 0.0025 in square (0.065 mm)
Width 2.5 in maximum (63.5 mm)
Resolution 406 dots per in (16 dots per mm)
Number of elements 1024 per printhead
“X” dimensions 5 mil to 50 mil (0.127 mm to 1.27 mm); 2.5 mil
(0.06 mm) in drag mode only (specified media only)
A-3
Media Specifications
D
F
E
G
H
A
B
3240M.003
Number Description Minimum Maximum
A Label width 0.5 in (13 mm) 2.7 in (69 mm)
B Backing width 0.5 in (13 mm) 2.8 in (71 mm)
C Gap between labels 0.10 in (2.5 mm) 1.0 in (25.4 mm) plus label
length
D
Label length - stripped media 0.25 in (6.4 mm) N/A
Label length - butt cut media 0.25 in (6.4 mm) N/A
E Media thickness 0.003 in (0.08 mm) 0.012 in (0.30 mm)
F Reflective sensor mark length 0.10 in (2.5 mm) 1.0 in (25.4 mm)
G Notch length 0.10 in (2.5 mm) 1.0 in (25.4 mm)
H Notch width 0.15 in (3.8 mm) N/A
Roll diameter 8.38 in (213 mm)
A-4
Ribbon Specifications
Roll 6,000 linear in (152 m)
Widths 1.0 in (25 mm)
2.8 in (71 mm)
Diameter 2.25 in maximum (57 mm)
Environment
Environment Fahrenheit Celsius
Operating 41° to 104° 5° to 40°
Storage -4° to 158° -20° to 70°
Humidity 10% to 90% with max. wet 10% to 90% with max. wet
bulb 82° min. dew point 36° bulb 36° min. dew point 2°
Self-Strip Specifications
The self-strip rewinder hub can take up the backing of an entire 6,000-inch roll
of media. You can self-strip labels as small as 0.50 inch by 0.50 inch.
Peel Release 10-50 grams
Fonts and Graphics

There are 21 resident bitmap scaleable fonts (including OCR A and B) and three
outline fonts available on the 3240 printer. You can use font ID 3 through 6 and
8 through 19 to download user-defined fonts or characters.
Amount of RAM Maximum UDF or UDC

128K (standard) 2.5 in x 2.5 in (64 mm x 64 mm)
512K (expanded) 2.5 in x 5 in (64 mm x 127 mm)
Character Sets
US ASCII Norwegian/Danish
UK ASCII Swedish/Finnish
German Italian
French Spanish
Switzerland Code Page 850
Memory
Base Optional
512K of DRAM 512K of SRAM expanded
128K of SRAM 2 to 8MB Kanji/Katakana memory expansion board
A-5
Intermec Cables
Use the following table to determine the correct cable for the application:
For Connecting To Use Intermec Cable Part Number

IBM PC AT 048693
IBM PC XT 048668
Terminal (DTE) 047286(5)
Modem (DCE) 043237S
Printer Options
This page describes the options you can use with the 3240 printer.
Memory Expansion The memory expansion option replaces the 128K of SRAM
with 512K of SRAM to hold more formats, fonts, or bitmap graphics. It also
increases the printer’s image buffering capabilities.
Twinax Interface Use the twinax interface to connect the printer to an IBM
twinax cable system with a twinax interface. The 3240 printer emulates an IBM
5256 Model 1 printer and can operate with an IBM System/34, System/36,
System/38, or AS/400 host computer.
Coax Interface Use the coax interface adapter to connect the printer to an IBM
3270 Type A coax cable computer systems operating in the VTAM
(CICS/IMS/TSO) or 8100 (DPPX) environments. The 3240 printer emulates an
IBM 3287 printer and you can connect it to an IBM 3174/76/99 system
controller/multiplexer.
Batch Takeup Batch takeup automatically spools labels as they are printed.
This attachment is limited to small batches with a maximum outer diameter
(OD) of 5 inches.
Kanji/Katakana This option allows the 3240 printer to print Japanese characters
in two Kanji fonts and three Katakana fonts.
A-6
Centronics Parallel Interface Intermec does not provide a cable for use with the
Centronics parallel interface. You can either buy one from a local computer
store or use the following information to make an interface cable.
Note: The maximum cable length for a parallel interface is 10 feet.
The following pin descriptions are for the printer’s parallel interface connector:
Signal Pin Return Direction Description

DATASTB 1 19 IN Negative pulse. Latches DB0-7 on
the rising edge. Eight bits in
parallel provide data input. High
is logical 1 and LOW is logical 0.
DB0 2 20 IN
DB1 3 21 IN
DB2 4 22 IN
DB3 5 23 IN
DB4 6 24 IN
DB5 7 25 IN
DB6 8 26 IN
DB7 9 27 IN
ACK 10 28 OUT Negative pulse. Data has been
received.
BUSY 11 29 OUT If HIGH, printer cannot receive
data.
PE 12 30 OUT If HIGH, out of ribbon or media.
SELECT 13 - OUT Pulled to +5V. Printer is on.
CHASSIS GND 17 - - Printer’s chassis ground isolated
from logic ground.
INIT 31 16 IN Clears I/OINT0 latch.
FAULT 32 33 OUT See printer display.
A-7
Selecting the Correct Media

Media selection is one of the most important decisions you can make
concerning print quality. The 3240 printer supports a wide selection of both
direct thermal and thermal transfer media. To achieve optimum performance
in your application, you must evaluate requirements such as print speed and
environmental conditions.
It is important that you select the proper media when printing at higher
speeds. Using good quality media reduces the occurrence of images that fade
or bleed. If you want to print quality labels at higher print speeds, you must
select media with low reaction or release imaging temperatures. Printing at
lower speeds produces the highest quality labels.
Note: You may want to bring some known good media with you when you need to
troubleshoot a print quality problem.
Use these tables to select the direct thermal or thermal transfer media that you
need. You can call 1-800-227-9947 to talk to a media specialist at Intermec
Media Products about your printing needs. You can also order the Media
Reference Guide (600K document) from Intermec for more information on
selecting the correct media. To order media, contact your local Intermec sales
office.
Direct Thermal Media Sensitivity Settings
Sensitivity
Approximate Sensitivity Ratings Setting Direct Thermal Media
700 Series High Sensitivity 720 Duratherm Lightning Plus
400 Series Medium Sensitivity 480 Duratherm Lightning IR-2

460 European IR
450 Duratherm Lightning-1
440 European Thermal
420 Duratherm Lightning-2
100 Series Low Sensitivity 170 European Tag

170 European Reinforced
160 Duratherm II Tag
140 European Top
130 Duratherm II
A-8
Thermal Transfer Media and Ribbon Sensitivity Settings
Sensitivity Thermal Transfer Media

Approximate Sensitivity Ratings Setting (Media/Ribbon Stock)
800 Series High Sensitivity (Paper) 864 European Uncoated/Standard
600 Series Medium Sensitivity (Plastic) 687 Duratran TTR Poly. (Valeron)/Premium
633 European Polyethelene/Premium
627 Duratran Kimdura/Premium
500 Series Medium Sensitivity (Paper) 567 Duratran II/Premium

527 Duratran II Tag-5 mil/Premium
527 Duratran II Tag-7 mil/Premium
513 European Board Tag/Premium
513 European Coated/Premium
300 Series Low Sensitivity (Plastic) 369 Super Premium Kimdura/Super Premium 2
369 Super Premium Poly./Super Premium 2
366 Super Premium Kimdura/ Super Premium 1
366 Super Premium Poly./Super Premium 1
200 Series Low Sensitivity (Plastic) 222 Glossy Polyimide (Kapton)/Super Premium 3
226 Glossy Polyimide (Kapton)/Super Premium 1
236 Matte Polyimide (Kapton)/Super Premium 1
238 Matte Polyimide (Kapton)/Super Premium 4
A-9
Configuration Parameters Upload Table

Upload configuration parameters to the printer in the form of configuration
commands. The commands are concatenated into one command string within a
message. Listed below is the order in which the commands are transmitted and
the number of bytes in each command.
Commands Syntax Bytes

Set Message Delay <ESC><SYN>n 6
86XX/Advanced Mode on Power-Up <SI>Cn 3
Set End-of-Print Skip Distance <SI>Dn 6
Set Darkness Adjust <SI>dn 5
Set Top of Form <SI>Fn 6
Select Media Sensitivity <SI>gn,m 7
Set Number of Image Bands <SI>In 4
Set Maximum Label Length <SI>Ln 6
Select Printer Language <SI>ln 3
Define Amount of Storage RAM <SI>Nn 5
Enable/Disable Label Retract <SI>Rn 3
Set Label Retract Distance <SI>rn 4
Set Print Speed <SI>Sn 4
Select Label Stock Type <SI>Tn 3
Set Intercharacter Delay <SYN>n 5
Set Preamble <SOH>n 2-3
Set Postamble <EOT>n 2-3
Disable Auto-Transmit 1, 2, and 3 <ESC>k 2
Enable Auto-Transmit 1* <ESC>j 2
Enable Auto-Transmit 2* <ESC>d 2
Enable Auto-Transmit 3* <ESC>e 2
Total bytes 82-84
* Only sent if enabled.
A-10
Summary of IPL Commands
This table summarizes the commands in the Intermec printer language (IPL)
command set. See the user’s manual for command definitions. The 3240 printer
does not support every IPL command. In this table, as asterisk (*) marks each
command that the 3240 printer ignores.
Summary of IPL Commands
Command Factory 8636/46 Command

Function Code Default Emulation Mode
40 Volt Supply Value, Transmit* U Yes Test/Service
86XX Emulation Mode, Enter <ESC>c 0 Yes Print
86XX or Advanced Mode on Power-Up <SI>C 3 Yes Configuration
Abort Print Job <EM> Yes Immediate
Advanced Mode, Select <ESC>C 1 Yes Print
Alphanumeric Field Separator <GS> Yes Print
Ambient Temperature, Transmit* A N/A Test/Service
Amount of Storage, Define <SI>N 60 Yes Configuration
Audible Alarm, Enable or Disable* <SI>a N/A Configuration
Auto-Transmit 1, Enable <ESC>j Yes Configuration
Auto-Transmit 2, Enable <ESC>d Yes Configuration
Auto-Transmit 3, Enable <ESC>e Yes Configuration
Auto-Transmit 1, 2, and 3, Disable <ESC>k Yes Configuration
Bar Code, Select Type c 0 Yes Program
Bar Code Field, Create or Edit B 0 Yes Program
Bar Height Magnification, Define h 50 Yes Program
Bar Width Magnification, Define w 1 Yes Program
Batch Count, Set <US> 1 Yes Print
Bitmap Cell Height for Graphic or UDF, Define y 1 Yes Program
Bitmap Cell Width for Graphic or UDF, Define x 1 Yes Program
Bitmap User-Defined Font, Clear or Define T Yes Program
Border Around Human-Readable Text, Define b 0 Yes Program
Box Field, Create or Edit W 0 Yes Program
* The 3240 printer ignores these commands.
A-11
Summary of IPL Commands (continued)

Character Bitmap Origin Offset, Define X 0 Yes Program
Character Height Magnification, Define h 2 Yes Program
Character Rotation or Bar Code Ratio, Define r 0 Yes Program
Character Width Magnification, Define w 1 Yes Program
Clear All Data <CAN> Yes Print
Clear Data From Current Field <DEL> Yes Print
Code 39 Prefix Character, Define p Yes Program
Command Tables, Load C Yes Program
Command Terminator ; Yes Test/Service
Command Terminator 1 <NUL> Yes Print
Command Terminator 2 <LF> Yes Print
Configuration Parameters, Transmit <ESC>p Yes Print
Control Panel Access Permission, Set* <SI>A 0 N/A Configuration
Current Edit Session, Save N Yes Program
Cut* <SO> N/A Print
Cutter, Enable or Disable* <SI>c 0 N/A Configuration
Dark Adjust K Yes Test/Service
Dark Adjust, Set <SI>d 0 Yes Configuration
Data Shift - International Characters <SUB> Yes Print
Data Source for Format in a Page, Define e 0 No Program
End-of-Print Skip Distance, Set <SI>D 118 Yes Configuration
Error Code, Request <BEL> Yes Immediate
Factory Defaults, Reset D Yes Test/Service
Field, Delete D 0 Yes Program
Field, Select <ESC>F 0 Yes Print
Field Data, Define Source d 0 Yes Program
Field Decrement, Set <ESC>D 1 Yes Print
A-12

Field Direction, Define f 0 Yes Program
Field Increment, Set <ESC>I 1 Yes Print
Field Origin, Define o 0,0 Yes Program
First Data Entry Field, Select <ACK> Yes Print
Font, Transmit <ESC>v Yes Print
Font Character Width, Define Z cell Yes Program
Font Type, Select c 0 Yes Program
Form Feed <FF> Yes Print
Format, Create or Edit A Yes Program
Format, Create or Edit F Yes Program
Format, Erase E Yes Program
Format, Select <ESC>E Yes Print
Format, Transmit <ESC>x 0 Yes Print
Format Direction in a Page, Define q 0 No Program
Format Offset Within a Page, Define O 0,0 No Program
Format Position in a Page, Assign M a No Program
Format Position From Page, Delete m a No Program
Graphic Type, Select c 0 Yes Program
Graphic or UDC, Define u Yes Program
Height Magnification of Bar, Box, or UDC, Define h 50,100,1 Yes Program
Human-Readable Field, Create or Edit H 0 Yes Program
IBM Language Translation, Enable or Disable <SI>i 0 Yes Configuration
Increment and Decrement, Disable <ESC>N Yes Print
Intercharacter Delay, Set <SYN> 0 Yes Configuration
Intercharacter Space for UDF, Define z 2 Yes Program
A-13

Interlabel Ribbon Save, Enable or Disable* <SI>s Yes Configuration
Interpretive Field, Edit I Yes Program
Interpretive Field, Enable or Disable i 0 Yes Program
Label and Gap Length, Transmit <ESC> L Yes Immediate
Label Path Open Sensor Value, Transmit L N/A Test/Service
Label Rest Point, Adjust <SI>f 0 Yes Configuration
Label Retract, Enable or Disable <SI>R 1 Yes Configuration
Label Retract Distance, Set <SI>r 0 Yes Configuration
Label Stock Type, Select <SI>T 1 Yes Configuration
Label Taken Sensor Value, Transmit T Yes Test/Service
Label Width, Set* <SI>W 1024 N/A Configuration
Length of Line or Box Field, Define l 100 Yes Program
Line Field, Create or Edit L 0 Yes Program
Maximum Label Length, Set <SI>L 1000 Yes Configuration
Media Sensitivity, Select <SI>g 567,420 Yes Configuration
Message Delay, Set <ESC><SYN> 0 Yes Configuration
Next Data Entry Field, Select <CR> Yes Print
Number of Image Bands, Set <SI>I 3 Yes Configuration
Numeric Field Separator <FS> Yes Print
Online or Offline on Power-Up* <SI>O 0 No Configuration
Options Selected, Transmit <ESC>O Yes Print
Outline Font, Clear or Create J Yes Program
Outline Font, Download j Yes Program
Page, Create or Edit S No Program
Page, Delete s No Program
Page, Select <ESC>G 0 No Print
A-14

Page, Transmit <ESC>y No Print
Pitch Label, Print* C Yes Test/Service
Pitch Size, Set g 12 No Program
Point Size, Set k 12 No Program
Postamble, Set <EOT> NUL Yes Configuration
Preamble, Set <SOH> NUL Yes Configuration
Print <ETB> Yes Print
Print Line Dot Count Limit, Set v Yes Program
Print Quality Label, Print Q Yes Test/Service
Print Speed, Set <SI>S 30 Yes Configuration
Printer Language, Select <SI>l 0 Yes Configuration
Printhead Parameters, Transmit <ESC>H Yes Print
Printhead Pressure, Set* <SI>H 0 N/A Configuration
Printhead Resistance Test, Begin* B N/A Test/Service
Printhead Resistance Values, Transmit* S N/A Test/Service
Printhead Temperature Sensor Value, Transmit P Yes Test/Service
Printhead Test Parameters, Set* <SI>U N/A Configuration
Printhead Volt Supply Value, Transmit* V No Test/Service
Program Mode, Enter <ESC>P Yes Print
Program Mode, Exit R Yes Program
Program Number, Transmit <ESC>M Yes Print
Quantity Count, Set <RS> 1 Yes Print
Reflective Sensor Value, Transmit M No Test/Service
Remaining Quantity and Batch Count, Transmit <ESC>Q Yes Immediate
Reset <DLE> Yes Immediate
A-15

Ribbon Save Zones, Set* <SI>Z N/A Configuration
Self-Strip, Enable or Disable <SI>t 0 Yes Configuration
Start and Stop Codes (Code 39), Print <ESC><SP> Yes Print
Status Dump <VT> Yes Immediate
Status Enquiry <ENQ> Yes Immediate
Storage Area Usage, Transmit <ESC>m Yes Print
Test and Service Mode, Enter <ESC>T Yes Print
Test and Service Mode, Exit R Yes Configuration
Top of Form, Set <SI>F 20 Yes Configuration
Transmissive Sensor Value, Transmit G Yes Test/Service
User-Defined Character, Clear or Create G Yes Program
User-Defined Character Field, Create or Edit U 0 Yes Program
User-Defined Characters, Transmit <ESC>u 0 Yes Print
User-Defined Font Character, Create t Yes Program
User-Defined Tables, Transmit <ESC>Z Yes Print
Warm Boot <BS> Yes Print
Width of Line, Box, Bar, or Character, Define w 1 Yes Program
A-16
DIP Switch Settings
If the default settings of the 3240 printer do not match those of the PC or
network controlling device, you need to correctly configure the DIP switches
on the rear panel of the printer.
Top Bank Switch Number Bottom Bank Switch Number

OFF OFF
O = OFF O = OFF
1 = ON ON 1 2 3 4 5 6 7 8 1 = ON ON 1 2 3 4 5 6 7 8
Baud Rate Selection Multi-Drop Address Selection

19,200 O O O
*
A O O O O O
9,600
4,800
* 1
O
O
1
O
O
B 1 O O O O
C O 1 O O O
2,400 1 1 O D 1 1 O O O
1,200 O O 1 E O O 1 O O
reserved 1 O 1 F 1 O 1 O O
reserved O 1 1 G O 1 1 O O
reserved 1 1 1 H 1 1 1 O O
I O O O 1 O
Parity Selection J 1 O O 1 O
Even
Odd
* O O
1 O
K O 1 O 1 O
L 1 1 O 1 O
None O 1 M O O 1 1 O
None 1 1 N 1 O 1 1 O
O O 1 1 1 O
Number of Data Bits P 1 1 1 1 O
7 Bit O Q O O O O 1
8 Bit 1 R 1 O O O 1
S O 1 O O 1
Reserved O O T 1 1 O O 1
U O O 1 O 1
V 1 O 1 O 1
Default settings are noted with an * W O 1 1 O 1
X 1 1 1 O 1
Y O O O 1 1
Z 1 O O 1 1
0 O 1 O 1 1
1 1 1 O 1 1
2 O O 1 1 1
3 1 O 1 1 1
4 O 1 1 1 1
5 1 1 1 1 1
Protocol Selection
XON/XOFF
Intermec Protocols
* O
1
XON/XOFF Selection
No Status Response
With Status Response
* O
1
DT/TTR
Direct Thermal
Thermal Transfer
* O
1
Default settings are noted with an * 3240U.008
A-17
Full ASCII Chart

FULL ASCII
Binary0 Hex1 Dec2 C393 Char4 Binary Hex Dec C39 Char Control Character Definitions5
00000000 00 00 %U NUL 01000000 40 64 %V @ NUL Null, or all zeros
00000001 01 01 $A SOH 01000001 41 65 A A SOH Start of Heading
00000010 02 02 $B STX 01000010 42 66 B B STX Start of Text
00000011 03 03 $C ETX 01000011 43 67 C C ETX End of Text
00000100 04 04 $D EOT 01000100 44 68 D D EOT End of Transmission
00000101 05 05 $E ENQ 01000101 45 69 E E ENQ Enquiry
00000110 06 06 $F ACK 01000110 46 70 F F ACK Acknowledgement
00000111 07 07 $G BEL 01000111 47 71 G G BEL Bell
00001000 08 08 $H BS 01001000 48 72 H H BS Backspace
00001001 09 09 $I HT 01001001 49 73 I I HT Horizontal Tab
00001010 0A 10 $J LF 01001010 4A 74 J J LF Line Feed
00001011 0B 11 $K VT 01001011 4B 75 K K VT Vertical Tab
00001100 0C 12 $L FF 01001100 4C 76 L L FF Form Feed
00001101 0D 13 $M CR 01001101 4D 77 M M CR Carriage Return
00001110 0E 14 $N SO 01001110 4E 78 N N SO Shift Out
00001111 0F 15 $O SI 01001111 4F 79 O O SI Shift In
00010000 10 16 $P DLE 01010000 50 80 P P DLE Data Link Escape
00010001 11 17 $Q DC1 01010001 51 81 Q Q DC1 Device Control 1 (XON)
00010010 12 18 $R DC2 01010010 52 82 R R DC2 Device Control 2
00010011 13 19 $S DC3 01010011 53 83 S S DC3 Device Control 3 (XOFF)
00010100 14 20 $T DC4 01010100 54 84 T T DC4 Device Control
00010101 15 21 $U NAK 01010101 55 85 U U NAK Negative Acknowledge
00010110 16 22 $V SYN 01010110 56 86 V V SYN Syncronous Idle
00010111 17 23 $W ETB 01010111 57 87 W W ETB End Transmission Block
00011000 18 24 $X CAN 01011000 58 88 X X CAN Cancel
00011001 19 25 $Y EM 01011001 59 89 Y Y EM End of Medium
00011010 1A 26 $Z SUB 01011010 5A 90 Z Z SUB Substitute
00011011 1B 27 %A ESC 01011011 5B 91 %K [ ESC Escape
00011100 1C 28 %B FS 01011100 5C 92 %L \ FS File Separator
00011101 1D 29 %C GS 01011101 5D 93 %M ] GS Group Separator
00011110 1E 30 %D RS 01011110 5E 94 %N ^ RS Record Separator
00011111 1F 31 %E US 01011111 5F 95 %O _ US Unit Separator
00100000 20 32 SP SP6 01100000 60 96 %W ` SP Space
00100001 21 33 /A ! 01100001 61 97 +A a DEL Delete
00100010 22 34 /B " 01100010 62 98 +B b
00100011 23 35 /C # 01100011 63 99 +C c
00100100 24 36 /D $ 01100100 64 100 +D d
00100101 25 37 /E % 01100101 65 101 +E e Notes
00100110 26 38 /F & 01100110 66 102 +F f 0 Bit positions are 76543210
00100111 27 39 /G ' 01100111 67 103 +G g 1 Hexadecimal value
00101000 28 40 /H ( 01101000 68 104 +H h
00101001 29 41 /I ) 01101001 69 105 +I i 2 Decimal value
00101010 2A 42 /J * 01101010 6A 106 +J j 3 Code 39 character(s)
00101011 2B 43 /K + 01101011 6B 107 +K k 4 ASCII character
00101100 2C 44 /L , 01101100 6C 108 +L l 5 Hold down Control key and
00101101 2D 45 /M - 01101101 6D 109 +M m press key to left of definition
00101110 2E 46 /N . 01101110 6E 110 +N n
00101111 2F 47 /O / 01101111 6F 111 +O o 6 SP is the SPACE character
00110000 30 48 /P7 0 01110000 70 112 +P p 7 The Code 39 characters
00110001 31 49 /Q 1 01110001 71 113 +Q q /P through /Y may be
00110010 32 50 /R 2 01110010 72 114 +R r interchanged with the
00110011 33 51 /S 3 01110011 73 115 +S s
numbers 0 through 9
00110100 34 52 /T 4 01110100 74 116 +T t
00110101 35 53 /U 5 01110101 75 117 +U u 8 May be interchanged with
00110110 36 54 /V 6 01110110 76 118 +V v %X or %Y or %Z
00110111 37 55 /W 7 01110111 77 119 +W w 9 is the DELETE character
00111000 38 56 /X 8 01111000 78 120 +X x
00111001 39 57 /Y 9 01111001 79 121 +Y y
00111010 3A 58 /Z : 01111010 7A 122 +Z z
00111011 3B 59 %F ; 01111011 7B 123 %P {
00111100 3C 60 %G < 01111100 7C 124 %Q |
00111101 3D 61 %H = 01111101 7D 125 %R }
00111110 3E 62 %I > 01111110 7E 126 %S ~
00111111 3F 63 %J ? 01111111 7F 127 %T8 9 ASCI6x7
A-18
C
PCB Parts Lists and Schematics
3240 Main PCB Assembly Parts List C-3
3240 Main PCB Subassembly Parts List C-4
3240 Main PCB Assembly Schematics C-11
3240 Bezel PCB Assembly Schematics C-21

PCB Parts Lists and Schematics C
This chapter contains the parts lists and schematics for the main PCB assembly.
Schematics for the bezel PCB have also been included. A parts list is not available for
the bezel PCB. You must purchase parts from an outside vendor.
3240 Main PCB Assembly Parts List

PL# 064173-001 TITLE: PCB ASSY,MAIN,MEMORY EXP,3240 PAGE 1/1
PL REV: B 12311999
RUN DATE: Oct 3 09:29:46
--------------------------------------------------------------------------------
ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B
--------------------------------------------------------------------------------
1 1 064174-001 PCB SUBASSY,MACH BUILD,064173
2 0.001 RL 046766 LBL.STK..23HX1.50L,4-HI.4MIL.
3 2 580213 CONN.2-POSN.SHORTING,.10 CTRS.
"
4 4 586250 SPACER,COMP.,.187X.063X.20
5 0 061207-001 PROC,FCTN TEST,PCB 3400B
6 3 584274 XU6 SOC,32POSN,DIP LOW PROFILE
" XU8
" XU9
7 1 565091-001 Q5 XSTR,FET,60V,30A 6.1 0.2 F
8 1 580285 J10 CONN,8-POSN,HDR,.156,FRICTION 2.9 0.9 F
9 2.420 580231 CONN,26-POSN,HDR,1-ROW,.1,.230
10 4 580359 J11 CONN.HDR.4-POSN.STRAIGHT THRO. 10.2 3.5 F
" J12 9.7 3.9 F
" J13 9.7 3.1 F
" J17 9.2 3.0 F
11 1 580434 J1 CONN.25-POSN.D/SUB W/SNAP 0.7 0.8 F
12 1 581976 J14 CONN,40-POSN,HDR,.1 DBL ROW 10.2 0.6 F
13 2 581978 J9 CONN,6-POSN,HDR,.100,FRIC LOCK 8.9 0.2 F
" J15 8.9 3.0 F
14 2 582065 SW1 SW,8-POSN.DIP,SIDE ACTUATED 0.1 3.6 F
" SW2 0.1 4.5 F
15 1 585635-001 L1 INDUCTOR,TOROID,22UH,5A 8.9 2.0 F
16 1 586298 HLDR.BATTERY,AA SIZE
17 3 505312 SCREW,PHM,PHIL 4-40X.25 LK STP
18 1 059019-011 HEATSINK,PCB DRIVERS
19 1 586142 INS.SHIM
20 1 505500 SCREW,NY.PHM 4-40 X .250
21 2 521011 RIVET,POP AL.,.094DIA X .375
22 1 550617 R98 RES.CARB 1.00W 5% .51 OHM 6.7 1.4 F
23 2 550694 R130 RES.CARB 1.00W 5% 820.0 OHM 3.5 1.1 F
" R192 7.9 2.1 F
24 1 550700 R129 RES.CARB 1.00W 5% 1.5 KOHM 3.5 1.4 F
25 2 550816 R102 RES,CARB,2W,5%,.47 OHM 8.8 0.8 F
" R117 7.5 0.8 F
26 1 555450 R125 RES.POT.SIDE ADJ.W/KNOB 10KOHM 0.3 4.8 F
43 1 561016-001 C58 CAP,AL,50 V,10000 UF 2.1 1.9 F
44 1 561302 C60 CAP.ALUM. 15V MIN 220. UF 1.4 1.1 F
45 1 561908 C53 CAP,ACITOR,ALUM,16V,R/L,4700UF 3.8 0.4 F
59 2 564133-001 D19 DIODE,SCHOTTKY,60V,3A 6.9 1.2 F
" D21 6.7 1.2 F
60 1 561807 C65 CAP.ALUMINUM,ELEC.R/L,25V 330 9.6 2.1 F
70 1 506201 NUT,HEX,SELF-LOCK 4-4OUNC2B
71 1 567024 VR1 VOLTAGE REGULATOR,5V,1A 6.8 0.2 F
72 1 574079 U24 IC,TYPE UDN2998W,MOTOR DRIVER 8.4 0.2 F
73 1 580357 J16 CONN.HDR.2-POSN.STRAIGHT THRO. 9.7 3.3 F
C-3
3240 Main PCB Subassembly Parts List

PL# 064174-001 TITLE: PCB SUBASSY,MACH BUILD,064173 PAGE 1/7
PL REV: A 12311999
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
1 1 064170-001 PCB,MAIN,MEMORY EXP
2 1 062698-001 U12 IC,ASIC,THERM COMPEN II PLCC 6.5 2.9 F
3 1 555901 R6 RES.S/M.POT TOP ADJ.100 KOHM 8.4 3.1 F
4 2 555909-001 R190 RES,S/M,POT,TOP ADJ,20 KOHM 8.4 3.4 F
" R191 8.3 2.8 F
5 1 556600 R22 RES,S/M,FILM,.12W,5%,100 OHM 0.9 0.7 F
6 18 556603 R1 RES.S/M,FILM,.12W,5% 4.7 KOHM 5.2 3.0 F
" R7 6.1 4.4 F
" R11 5.2 3.3 F
" R35 5.5 5.2 F
" R36 5.3 5.2 F
" R74 5.7 3.5 F
" R75 5.9 3.5 F
" R76 6.9 3.5 F
" R96 9.1 1.3 F
" R107 4.7 0.8 F
" R108 7.7 1.5 F
" R109 8.2 1.5 F
" R114 7.3 1.5 F
" R128 3.2 0.8 F
" R142 9.7 1.2 F
" R157 6.7 4.4 F
" R185 7.5 4.1 F
" R211 9.4 3.2 F
7 83 556604 R2 RES,S/M,FILM,.12W,5%,10 KOHM 5.4 4.8 F
" R3 4.4 4.9 F
" R5 1.3 1.2 F
" R8 6.6 4.2 F
" R9 4.4 5.0 F
" R10 1.3 1.3 F
" R12 6.1 4.2 F
" R13 4.0 3.6 F
" R14 3.3 5.1 F
" R15 6.2 5.0 F
" R16 4.5 3.3 F
" R17 1.1 3.6 F
" R19 5.2 3.1 F
" R20 4.4 4.7 F
" R23 5.2 2.7 F
" R24 5.2 2.8 F
" R25 4.4 5.1 F
" R26 4.3 2.0 F
" R27 3.9 4.5 F
" R28 3.9 4.6 F
" R29 4.4 4.8 F
" R32 1.3 1.6 F
" R33 1.3 1.5 F
" R37 3.3 5.0 F
" R38 4.6 5.1 F
" R39 0.6 2.9 F
" R40 0.6 3.0 F
C-4
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" R41 0.6 3.1 F
" R42 0.6 3.2 F
" R43 0.6 3.3 F
" R44 0.6 3.4 F
" R45 0.6 3.5 F
" R46 0.6 3.6 F
" R47 0.6 3.8 F
" R48 0.6 3.9 F
" R49 0.6 4.0 F
" R50 0.6 4.1 F
" R51 0.6 4.2 F
" R52 0.6 4.3 F
" R53 0.6 4.4 F
" R54 0.6 4.5 F
" R55 4.1 3.0 F
" R56 2.3 4.5 F
" R57 1.4 2.9 F
" R58 1.4 3.1 F
" R59 1.4 3.0 F
" R60 1.4 3.2 F
" R61 1.4 3.3 F
" R62 1.4 3.4 F
" R63 1.4 3.5 F
" R64 1.4 3.6 F
" R65 1.4 3.7 F
" R66 1.4 3.8 F
" R67 1.4 3.9 F
" R68 1.4 4.0 F
" R69 1.4 4.1 F
" R70 1.4 4.2 F
" R71 1.4 4.3 F
" R72 1.4 4.4 F
" R95 6.1 2.0 F
" R99 9.1 1.1 F
" R105 7.3 1.6 F
" R111 8.6 1.1 F
" R131 8.7 2.7 F
" R134 8.5 3.6 F
" R139 6.0 0.5 F
" R141 9.4 3.1 F
" R145 9.4 3.3 F
" R151 3.3 4.9 F
" R152 3.3 4.8 F
" R153 3.9 4.8 F
" R154 3.9 4.9 F
" R155 3.9 5.0 F
" R156 5.9 5.0 F
" R158 1.3 1.7 F
" R183 4.8 1.1 F
" R187 9.1 1.8 F
" R193 4.8 3.3 F
" R194 7.5 3.2 F
" R195 9.7 1.7 F
" R201 10.1 2.9 F
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" R208 4.7 2.8 F
" R209 4.2 3.2 F
" R110 8.2 1.4 F
" R212 9.4 3.6 F
" R103 9.1 1.5 F
" R116 9.1 3.9 F
" R118 8.2 1.3 F
" R120 8.2 1.2 F
" R140 5.8 1.1 F
" R78 7.5 5.0 F
" R79 7.5 4.7 F
" R80 7.5 4.8 F
" R81 5.9 1.7 F
" R82 7.5 4.6 F
" R83 7.5 4.5 F
" R84 5.9 1.5 F
" R85 7.5 4.4 F
" R86 5.9 1.3 F
" R87 7.5 4.3 F
" R88 5.3 1.3 F
" R89 4.3 1.2 F
" R90 5.6 1.3 F
" R91 5.9 1.4 F
" R92 5.9 1.6 F
" R93 5.7 1.9 F
" R94 3.9 4.7 F
" R112 7.7 1.6 F
" R159 4.1 4.9 F
" R160 9.7 1.8 F
" R161 7.5 5.2 F
" R162 5.8 4.8 F
" R163 6.4 5.0 F
" R164 7.5 5.1 F
" R165 7.5 3.8 F
" R166 7.5 3.7 F
" R167 7.5 4.0 F
" R168 7.5 3.9 F
" R169 5.9 1.9 F
" R170 6.4 1.9 F
" R171 6.1 4.0 F
" R172 7.5 3.1 F
" R173 7.5 3.0 F
" R174 7.5 2.9 F
" R175 7.5 2.8 F
" R176 7.5 2.7 F
" R177 7.5 2.6 F
" R178 7.5 2.5 F
" R179 7.5 3.6 F
" R180 7.5 3.5 F
" R181 7.5 3.3 F
" R182 7.5 3.4 F
C-6
PL REV: A 12311999
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" R184 6.1 4.3 F
" R197 5.2 3.2 F
" R189 8.5 2.7 F
" R198 6.2 3.5 F
" R122 8.5 3.0 F
" R202 1.3 2.0 F
" R203 0.9 2.3 F
" R204 0.9 2.5 F
" R205 1.3 2.2 F
" R206 1.2 2.4 F
" R207 1.2 2.5 F
" R115 8.9 4.0 F
" R132 9.4 4.0 F
" R143 9.4 3.4 F
" R146 6.4 1.0 F
14 7 556658 R4 RES,S/M,FILM,.12W,5%,1.0 KOHM 4.3 3.0 F
" R113 7.7 1.4 F
" R119 8.0 1.5 F
" R121 8.0 1.4 F
" R126 0.6 4.6 F
" R148 5.4 1.0 F
" R210 9.4 3.7 F
" R136 6.2 1.1 F
" R137 6.4 1.1 F
16 1 556837-112 R150 RES,S/M,FILM,1/8W,1%,1500 OHMS 5.6 0.9 F
17 1 556837-166 R149 RES,S/M,FILM,1/8W,1%,5620 9.5 1.1 F
" R21 0.9 0.6 F
" R196 8.7 2.9 F
" R104 4.7 1.0 F
25 2 556742 R31 RES,S/M,FILM,.12W,5%,9.1 MOHM 4.8 4.8 F
" R73 6.3 3.6 F
28 2 563602 C46 CAP.S/M,TANT,10V MIN+-20%,10UF 4.6 0.6 F
" C54 6.7 0.4 F
29 6 563605 C43 CAP,S/M,TANT,35V,20%,1UF 8.6 1.6 F
" C45 8.6 0.6 F
" C50 7.7 1.3 F
" C51 7.7 1.1 F
" C55 4.4 0.4 F
" C56 6.7 0.5 F
30 3 563606 C35 CAP,S/M,TANT,6VMIN,10%,68UF 6.2 5.3 F
" C81 6.4 1.7 F
" C82 0.9 2.8 F
C-7

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31 37 563700 C1 CAP,S/M,CER,50VMIN,20%,.1 UF 0.9 0.9 F
" C2 4.1 2.8 F
" C3 5.2 3.4 F
" C4 5.4 4.2 F
" C5 4.2 3.4 F
" C6 4.1 4.7 F
" C7 4.0 4.2 F
" C8 4.8 3.4 F
" C10 0.9 1.4 F
" C12 4.6 4.8 F
" C13 3.5 4.7 F
" C15 4.6 4.9 F
" C16 0.9 2.9 F
" C17 2.5 4.5 F
" C18 0.9 3.8 F
" C19 3.8 1.8 F
" C20 2.6 2.6 F
" C21 3.3 4.6 F
" C23 2.9 1.5 F
" C25 7.1 2.9 F
" C26 5.9 2.9 F
" C27 6.4 4.4 F
" C28 6.9 4.3 F
" C29 5.4 2.0 F
" C30 6.6 3.5 F
" C31 5.8 3.7 F
" C32 6.6 2.2 F
" C33 5.7 2.8 F
" C37 6.9 3.7 F
" C38 4.9 2.7 F
" C61 8.7 2.8 F
" C63 5.8 0.4 F
" C64 9.6 2.4 F
" C67 6.4 0.9 F
" C72 9.6 2.5 F
" C75 6.1 0.9 F
" C76 4.3 2.7 F
32 3 563701 C11 CAP,S/M,CER,50WVDC,5%,10 PF 4.8 4.9 F
" C22 6.5 3.7 F
" C24 6.2 3.7 F
33 7 563702 C100 CAP,S/M,CER,50WVDC,5%,100 PF 7.8 2.8 F
" C101 7.8 2.9 F
" C102 7.8 3.0 F
" C103 7.8 3.1 F
" C104 7.8 2.7 F
" C105 7.8 2.6 F
" C106 7.8 2.5 F
" C40 9.1 1.2 F
" C47 8.2 1.1 F
" C52 9.1 4.0 F
" C57 0.6 4.7 F
" C59 9.4 3.5 F
C-8
PL REV: A 12311999
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" C66 9.7 1.3 F
" C73 8.9 2.8 F
" C74 9.1 3.8 F
" C108 10.1 3.0 F
35 1 563709 C9 CAP,S/M,CER,50VMIN,5%,22 PF 5.1 4.9 F
" C49 5.0 0.8 F
" C41 9.1 1.4 F
" C48 8.2 1.6 F
" C77 5.4 3.9 F
" C78 4.0 3.8 F
" C79 4.8 4.7 F
" C80 4.5 3.4 F
" C83 2.6 2.5 F
" C84 3.3 4.5 F
" C85 2.8 4.5 F
" C86 5.7 4.3 F
" C87 6.4 4.3 F
" C88 6.9 4.4 F
" C89 5.8 3.6 F
" C90 5.7 2.9 F
" C91 6.9 3.6 F
" C92 4.9 2.8 F
" C93 6.6 2.3 F
" C94 6.6 3.6 F
" C109 1.3 1.9 F
" C110 0.9 2.4 F
" C111 0.9 2.6 F
" C112 1.3 2.1 F
" C113 1.2 2.3 F
" C114 1.2 2.6 F
39 5 563729 C39 CAP,S/M,CER,50VMIN,10%,1 UF 7.3 1.1 F
" C42 7.3 0.6 F
" C95 3.2 0.6 F
" C97 5.5 0.4 F
" C98 9.7 1.5 F
40 1 563731 C107 CAP,S/M,CERM,.001UF,200V,X7R 6.8 1.7 F
41 10 564202 D3 DIODE,S/M,TYPE BAS16 3.2 4.7 F
" D5 4.2 5.2 F
" D6 8.9 1.4 F
" D7 3.5 0.9 F
" D8 3.7 0.9 F
" D10 8.2 1.7 F
" D18 5.6 0.6 F
" D22 5.9 0.9 F
" D23 6.2 0.7 F
" D29 6.1 0.4 F
42 4 564244-001 D1 DIODE,S/M,BAS70-05,DUAL,SCHOTT 4.8 3.0 F
" D2 4.7 3.0 F
" D4 3.4 4.7 F
" D14 2.8 2.2 F
C-9

PL REV: A 12311999
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43 2 564217 D15 DIODE,S/M TYPE 5231 ZENER,5V 3.8 0.9 F
" D28 9.4 1.6 F
44 2 564219 D16 DIODE,S/M TYPE 5245 ZENER,15V 4.0 0.9 F
" D20 5.9 0.4 F
45 1 564235 D9 DIODE,S/M,TYPE 5226,ZENER,3.3V 4.7 0.9 F
46 2 564238 D26 DIODE,S/M,TYPE BAS21,200VBR 2.8 1.2 F
" D27 2.6 1.2 F
47 2 564239-002 D12 DIODE,S/M,DUAL,6A,200V 2.7 0.4 F
" D13 1.9 0.4 F
49 3 565101 Q2 XSTR,S/M,4401,NPN 3.9 5.2 F
" Q9 9.3 1.6 F
" Q10 9.4 1.8 F
50 1 565110 Q7 XSTR,S/M,TYPE 6427 DARLINGTON 6.1 0.7 F
51 2 565111 Q3 XSTR,S/M,2222A,NPN 7.5 1.6 F
" Q6 5.9 0.7 F
52 1 574090 U26 IC,416C256 DRAM 3.2 2.1 F
53 1 578020 U28 IC,S/M,74HC04,HEX INVERTER 5.7 4.6 F
54 1 578023 U5 IC,S/M,74HC32,2-QUAD POST OR 3.6 5.0 F
55 1 578025 U22 IC,S/M,LP 339,QUAD COMPARATOR 8.6 1.3 F
56 4 578081 U7 IC,S/M,OCT TRISTATE XCVR 0.9 3.2 F
" U10 0.9 4.1 F
" U14 4.4 2.4 F
" U15 5.6 2.4 F
57 1 578086 U2 IC,S/M,TYPE 14C88 CMOS DRIVER 1.0 2.0 F
58 1 578087 U4 IC,S/M,TYPE 14C89,CMOS RCVR 1.0 1.6 F
59 1 578131 U11 IC,S/M,IDT72105,FIFO 3.9 2.3 F
60 1 578132 U30 IC,S/M,MC145041,8-BIT A/D 8.5 3.9 F
61 1 578134 U1 IC,S/M,TYPE 75ALS180 1.0 1.1 F
62 1 578135 U29 IC,S/M,MC34064,OV/UNO-V PROT 4.4 2.9 F
63 1 578137 D11 IC,S/M,LM385-1.2,FXD V REF 4.4 0.9 F
64 1 578145 Y2 CRYSTAL,S/M,24MHZ 6.3 4.0 F
65 1 060693-001 U13 CONFIG GAL,16V8,DRAM CONTROL 5.7 4.0 F
66 1 062906-002 U20 CONFIG GAL,16V8,DSACK,3240 6.9 4.0 F
67 1 060692-001 U23 CONFIG GAL,16V8,ASIC STATEMACH 6.3 4.7 F
68 1 060691-001 U25 CONFIG GAL,16V8,ASIC INTFC 6.9 4.7 F
69 2 578209-001 U16 IC,S/M,74ALS257,QUAD 2TO1 DATA 5.0 2.4 F
" U18 5.7 3.1 F
70 1 578211-002 U3 IC,S/M,MICPRCS,MC68332,20MHZ 4.7 4.1 F
71 2 578245-001 U27 IC,S/M,LM293,DUAL VOLT COMPTR 6.0 1.1 F
" U31 5.0 0.9 F
72 1 556837-029 R147 RES,S/M,FILM,1/8W,1%,200 OHMS 6.2 0.5 F
73 1 582282-012 J2 CONN,S/M,PIN,.8MMX6MM,80-POSN 5.5 1.7 F
74 1 586548-001 Q8 SENSOR,S/M,REFLECTIVE 9.4 4.2 F
75 1 588000 Y1 CRYSTAL,S/M 32.768 KHZ 4.9 5.1 F
76 2 589149-001 L2 FILTER,S/M,FERRITE,0603,220 OH 8.0 3.9 F
" L3 9.1 3.6 F
78 1 551800 R123 RES,S/M,0 OHM JUMPER,1206 3.0 4.6 F
C-10
3240 Main PCB Assembly C
3240 Main PCB Assembly Schematics
C-11 (C-12 blank)

C-13 (C-14 blank)

C-15 (C-16 blank)

C-17 (C-18 blank)

C-19 (C-20 blank)

3240 Bezel PCB Assembly C
3240 Bezel PCB Assembly Schematics
C-21 (C-22 blank)

C-23 (C-24 blank)

C-25 (C-26 blank)

Maintain 3240 Label Printer

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Maintain 3240 Label Printer

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Maintenance

3240 Bar Code Label Printer

Basic Operation and Maintenance

Basic Printer Setup and Operations 1-7

Inspecting the Printer 1-11

Cleaning the Printer 1-11

Maintenance Schedule 1-12

Error Handling 2-4

Printer Operation Problems 2-8

Print Quality Problems 2-13

Communications Problems 2-15

Preventing Data Loss 2-16

Testing and Adjusting

Printer Adjustments 3-12

Aligning the Printhead 3-27

Aligning the Printer Rollers 3-29

Replacing Printer Parts

Protecting Delicate Electronic Components 4-4

Replacing the Lithium Battery 4-5

Replacing the Printhead 4-7

Replacing the Main PCB Assembly 4-9

Replacing the Label Mark Sensor 4-11

Replacing the Label Taken Sensor 4-13

Replacing the Label Gap Sensor 4-15

Replacing the TTR Drive Gear/Pulley and Drive Roller 4-18

Replacing the TTR Clutch Encoder 4-22

Replacing the Lower Drive Belt 4-24

Replacing the Platen Roller and Platen Roller Gear 4-27

Replacing the Ribbon Drive Roller 4-29

Spare Parts List and Assembly Drawings

3240 Tools 5-3

3240 Manuals 5-3

3240 Spare Parts List 5-4

3240 Assembly Drawings 5-9

Specifications and Reference Material

Printer Options A-6

Selecting the Correct Media A-8

Configuration Parameters Upload Table A-10

Summary of IPL Commands A-11

DIP Switch Settings A-17

Full ASCII Chart A-18

Power Supply B-3

Power Fail Detection B-4

Motor Driver B-5

Kanji Interface B-9

Communication Interface B-9

A/D Converter B-9

3240 Gap Sensor Interface B-10

DIP Switches B-10

ASIC and I/O Option Interface B-10

Front Panel Interface B-11

Debug Interface B-11

Functional Description of the 3240 Software B-14

PCB Parts Lists and Schematics

3240 Main PCB Subassembly Parts List C-4

3240 Main PCB Assembly Schematics C-11

3240 Bezel PCB Assembly Schematics C-21

Before You Begin

Warnings, Cautions, and Notes

Follow ESD Procedures

About This Manual

What You Will Find in This Manual

For Information On Refer To