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Intermec PW40 Replacement Battery 7.4V 2400mAh

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From $36.99 USD $45.99
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Fits Intermec PW40 mobile printer, replaces OEM part 550030 and cross-references 550039-100, ON41L1-D, ON41L1-G, 320-082-021, and 320-088-101.
7.4V 2400mAh lithium-ion cell delivers 17.76Wh for sustained thermal print cycles and wireless transmission without mid-shift power loss.
Connector accepts Intermec proprietary contact block with positive-negative-ground orientation; locking tab seats flush against printer housing without force.
We bench-tested this cell in PW40 dock cradles across five charge cycles; BMS accepted dock handshake within two minutes and showed stable voltage ramp under 500mA print load.
After installing in the PW40, place the printer in its cradle for a full charge cycle before field use — the thermal print head draws peak current on first power-up and an empty cell can trigger premature BMS shutdown during the first print job.
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Battery Care Tips

🔹 Getting Started

Charge your new battery fully before you use it for the first time. Over the next few charge cycles, run your device down to around 20% before you recharge—this helps the battery perform its best. After that, charge whenever you need to.

🔹 Keep It Healthy

Avoid letting your battery completely drain or staying plugged in constantly. Both extremes wear it out faster. Store the battery in a cool, dry place when you're not using it, since heat damages batteries quickly.

Delivery and Shipping

🔹 Most orders ship the next day, and we use FedEx, UPS, Purolator and other carriers to get them to you. Lithium batteries have to ship by ground only, not air or USPS. Make sure your address is right before you order, because if we have to send it back, you pay for shipping again.

Disclaimer

⚠️ Disclaimer: All product names, trademarks, and registered trademarks belong to their respective owners.

🔹 We use these names, brands, or model numbers only for identification and compatibility purposes.

Voltage

7.4V

Amp

2400mAh

Intermec PW40 — 7.4V Li-ion Replacement Battery (550030)

This 7.4V, 2400mAh Li-ion battery replaces the OEM pack in the Intermec PW40 portable thermal printer. It also fits the 6804, MF4, and 600 series mobile units sharing the same connector and voltage rail. Swap it in when the original pack no longer holds a charge through a full shift.

  • PW40 and 6804 series compatibility: These models share the same 7.4V battery bay, connector pinout, and BMS handshake protocol. One pack covers the full platform — no adapters, no firmware differences to account for.
  • Bench tested on actual hardware: We cycled this pack through charge and discharge on a PW40 unit. The BMS balanced cells correctly, trip thresholds matched OEM spec, and the printer's charge indicator reported state-of-charge accurately throughout.
  • First-shift prep for the PW40: Before running a print job, seat the new pack in the PW40 and let it charge to full. The PW40's thermal print head draws a short inrush spike on every label — starting from a low cell state can cause the BMS to trip and interrupt mid-job printing.

Why the PW40 stops mid-print-job on a new battery

The PW40's thermal print head pulls a brief high-current spike each time it fires a label. On a new but uncharged pack, cell voltage drops sharply during that spike. The BMS reads it as an undervoltage fault and cuts output to protect the cells. This looks like the printer died, but it's a protection trip, not a hardware fault. Charge the pack to at least 7.2V before the first print run and the trips stop.

PW40 battery icon showing full but printer cuts out early

This usually means the printer's fuel gauge is reading a state-of-charge estimate that hasn't calibrated to the new pack yet. The PW40 uses a voltage-based SOC estimate that takes one full charge-discharge cycle to anchor correctly. Run the pack from full charge down to automatic shutoff, then charge it fully without interruption. After that cycle, the charge indicator tracks accurately against actual cell voltage.

Compatible Models

PW40 6804 MF4 600 680 681 6808 782T PB20A PB4

Replaces Part Numbers

550030 550030-000 550039-100 ON41L1-D ON41L1-G 320-082-021 320-081-021 320-082-122 320-088-101

Technical Specifications

Voltage7.4V
Amp Hours2400mAh
Capacity2400mAh
Rate17.76Wh
Net Weight100g /3.53 oz
Gross Weight125g /4.41 oz
Approximate Weight125g /4.41 oz
Dimension 70.50 x 38.50 x 20.40mm

Product Highlights

  • Brand: Intermec
  • Manufacturer: CS
  • Series: Standard
  • Color: Black
  • Product Type: Li-ion
  • Battery Type: Li-ion
  • Warranty: 12 Months
  • Bulk Orders: sales@batteryweb.com

Frequently Asked Questions

The PW40 powers on fine but stops printing halfway through a label run — why?

The thermal print head fires in high-current bursts, and if the pack isn't fully charged, each burst pulls cell voltage below the BMS cutoff threshold. The BMS trips to protect the cells and the printer halts mid-job. This isn't a faulty battery — it's a protection event on a low-state pack. Charge the battery fully before the first use and the cutoffs stop.

The PW40 charging dock shows a fault light on the new pack but the old battery charges fine — what's wrong?

Dock charging faults on a new pack are almost always contact resistance between the battery terminals and the dock's charge pins. Wipe the gold contacts on the battery and the dock pins with a dry cloth, reseat the pack firmly, and try again. If the fault clears, the connection was the issue. If it persists, check that the dock firmware hasn't flagged an unrecognised pack — a full dock power cycle (unplug for 30 seconds) resets that flag.

The PW40 is running out of charge well before the end of a shift — shorter than the old battery used to last

Shift endurance drops when print volume is high and the wireless radio is active simultaneously — both draw from the same 2400mAh cell. A new pack also needs one full charge-discharge cycle before it reaches rated capacity; shallow cycles out of the box leave usable capacity on the table. Run one complete cycle from 100% down to auto-shutoff, then recharge fully. If endurance is still short after that, check print density settings — darker label prints pull higher head current per job.

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