Zebra S4M Industrial/Commercial Printer Maintenance Manual
The S4M is an industrial/commercial printer designed for high-volume label printing. It features a variety of media handling capabilities, including tear-off and peel-off options, making it suitable for a wide range of applications. The printer is also equipped with various communication interfaces, including serial, parallel, USB, and Ethernet, providing flexibility in integration with different systems.
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S4M™
Industrial/Commercial Printer
Maintenance Manual
© 2005 ZIH Corp.
The copyrights in this manual and the label printer described therein are owned by
Zebra Technologies Corporation. Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.
This product may contain ZPL
®
, ZPL II
®
, and ZebraLink™ programs; Element
Energy Equalizer
®
Circuit; E
3 ®
; and AGFA fonts. Software © ZIH Corp. All rights reserved worldwide.
ZebraLink and all product names and numbers are trademarks, and Zebra, the
Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E
3
Circuit are registered trademarks of ZIH Corp. All rights reserved worldwide.
All other brand names, product names, or trademarks belong to their respective holders.
Part Number: 13291L-001 Rev. A
Contents
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iv Contents
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Contents v
13 • Preventive and Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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Contents vii
Ribbon/Printhead Open Sensor Assembly Maintenance Kit . . . . . . . . . . . . . . . . . . . . . 330
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viii Contents
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List of Tables
10/27/05
Table 3 • Operating Temperature and Humidity ...................................................11
Table 5 • Font Matrix for 8 dot/mm (203 dpi) Printheads .....................................28
Table 6 • Font Matrix for 12 dot/mm (300 dpi) Printheads ...................................29
Table 9 • Right Arrow Used to Reach
ADVANCED SETUP
Prompt.......................48
Table 10 • Left Arrow Used to Reach
ADVANCED SETUP
Prompt .......................48
Table 11 • Printer Parameters, Password Levels 1 and 2 ......................................54
Table 12 • Printer Parameters, Password Level 3 ..................................................59
Table 14 • Printer Parameters, Password Level 4 ..................................................71
Table 15 • Printer Parameters, Manufacturing Menu ............................................75
Table 24 • Recommended Cleaning Schedule .....................................................112
Table A • Media Side Main Printer Assemblies .................................................316
Table B • Electronics Side Main Printer Assemblies .........................................318
Table C • Print Mechanism/Printhead Assembly ...............................................320
Table E • Printhead Cable Maintenance Kit .......................................................323
Table G • Latch Assembly Maintenance Kit ......................................................326
S4M Maintenance Manual 13291L-001 Rev. A
x List of Tables
Table I • (Reflective) Media Sensor Assembly Maintenance Kit .......................329
Table J • Ribbon/Printhead Open Sensor Assembly Maintenance Kit ...............330
Table K • Transmissive Sensor Assembly Maintenance Kit ..............................331
Table L • Dancer Assembly Maintenance Kit ....................................................332
Table M • Ribbon Supply Spindle Maintenance Kit ..........................................333
Table O • Ribbon Take-up Spindle Maintenance Kit .........................................335
Table P • Media Hanger Maintenance Kit ..........................................................336
Table S • Peel Assembly Maintenance Kit .........................................................339
Table U • Electronics Cover Maintenance Kit ....................................................341
Table V • Control Panel and Take-Label Maintenance Kits ..............................342
Table W • Stepper Motor Maintenance Kit ........................................................343
Table X • Main Logic Board Maintenance Kit ...................................................344
Table Y • Real Time Clock (RTC) Maintenance/Option Kit .............................345
Table AA • Power Supply Maintenance Kit .......................................................347
Table AB • Ribbon Take-up Spindle Clutch Maintenance Kit ...........................348
Table AC • Gears and Pulley Maintenance Kit ..................................................349
Table AD • Wireless PCMCIA Board Maintenance/Option Kit ........................350
Table AE • 10/100 and Parallel Port Maintenance/Option Kits .........................351
Table AF • Hardware View 1 (Media Compartment) .........................................352
Table AG • Hardware View 2 (Printer Rear) ......................................................354
Table AH • Hardware View 3 (Printer Front) .....................................................355
Table AI • Hardware View 4 (Electronics Side) .................................................356
Table A-1 • Serial Connector Pin Configuration .................................................361
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List of Figures
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Figure 3 • Location of Control Panel Buttons and Lights .......................................3
Figure 4 • Example of Active Control Panel Buttons .............................................4
Figure 8 • International Safety Organization Certifications .................................13
Figure 10 • Communicating Using a Serial Data Port ..........................................15
Figure 11 • Communicating Using a Parallel Port ................................................16
Figure 12 • Communicating Using a USB Port ....................................................17
Figure 13 • Non-Continuous Web Media .............................................................18
Figure 16 • Ribbon Coated on Outside or Inside ..................................................20
Figure 19 • Ribbon Spindle—Normal and Low Tension .....................................37
Figure 22 • Printhead Pressure Adjustment Dials .................................................44
Figure 27 • Ribbon-Out Threshold Too High .......................................................95
Figure 31 • Bar Code Darkness Comparison ......................................................101
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xii List of Figures
13291L-001 Rev. A
Figure 32 • Communications Diagnostics Test Label ........................................103
Figure 33 • Cleaning the Printhead and Platen Roller ........................................113
Figure 35 • Remove the Mounting Screw ...........................................................122
Figure 38 • Printhead Assembly Mounting and Connections .............................128
Figure 39 • Locate the Printhead Pressure Dials .................................................131
Figure 40 • Printhead Removal and Installation .................................................132
Figure 42 • Remove the Main Logic Board Connections ...................................134
Figure 43 • Remove the Main Logic Board ........................................................135
Figure 44 • Remove the Compound Gear ...........................................................136
Figure 45 • Select the Compound Gear Position ................................................136
Figure 47 • Turn the Compound Pulley Around .................................................138
Figure 49 • Configuration Label (200 dpi or 300 dpi) ........................................140
Figure 51 • Locate the Printhead Pressure Dials .................................................142
Figure 52 • Disconnect the Print Mechanism .....................................................143
Figure 53 • Printhead Housing Mounting Screws ..............................................144
Figure 58 • Ribbon/Printhead Open Sensor ........................................................149
Figure 59 • PAUSE and CANCEL Test Label ...................................................150
Figure 60 • Locate the Printhead Pressure Knobs ...............................................152
Figure 61 • Disconnect the Print Mechanism .....................................................153
Figure 62 • Printhead Housing Mounting Screws ..............................................154
Figure 63 • Remove the Printhead Fork Assembly .............................................155
Figure 68 • Ribbon/Printhead Open Sensor ........................................................160
Figure 70 • Media Door and Latch Location (S4M) ...........................................163
Figure 71 • Remove the Latch Assembly ...........................................................164
Figure 74 • Print Mechanism Mounting Screws .................................................167
Figure 75 • Locate the Printhead Pressure Dials .................................................170
Figure 76 • Remove the Printhead and Cable Connections ................................171
Figure 77 • Set the Printer on the Electronics Cover Side (S4M) .......................172
Figure 78 • Remove the Pressure Bracket and Roller .........................................173
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List of Figures xiii
Figure 81 • Locate Drive System Components ...................................................179
Figure 82 • Remove the Transmissive Sensor ....................................................180
Figure 83 • Disconnect the Ribbon/Head Open Sensor (S4M) ..........................183
Figure 84 • Ribbon Sensor Removal and Installation .........................................184
Figure 85 • Gap Measurement between Print Mechanism and Sensor ...............185
Figure 86 • Media Sensor Connection to MLB ..................................................188
Figure 88 • Remove and Install the Control Panel ..............................................192
Figure 89 • Remove and Install the Take-Label Sensor .....................................193
Figure 90 • Install the Take-Label Sensor Board ................................................194
Figure 91 • Install the Take-Label Sensor Board on the Mounting Posts ...........195
Figure 93 • Remove the Main Logic Board Connections ...................................201
Figure 94 • Remove the Main Logic Board ........................................................202
Figure 97 • Ribbon Take-Up Spindle Assembly/Disassembly ...........................205
Figure 98 • Remove the Main Logic Board Connections ...................................208
Figure 99 • Remove the Main Logic Board ........................................................209
Figure 101 • Move the Mounting Bracket ..........................................................211
Figure 102 • Ribbon Take-Up Spindle Assembly/Disassembly .........................212
Figure 103 • Ribbon Take-Up Spindle Assembly/Disassembly .........................213
Figure 105 • Stepper Motor Removal and Installation .......................................217
Figure 106 • Remove the Ribbon Supply Spindle Mounting Screw ..................218
Figure 111 • Disconnect the Main Logic Board Connections ............................224
Figure 112 • Remove the Main Logic Board ......................................................225
Figure 113 • Remove/Install the Hanger Assembly ............................................226
Figure 114 • Locate Drive System Components .................................................228
Figure 115 • Remove the Main Logic Board Cables ..........................................231
Figure 116 • Remove the Main Logic Board ......................................................232
Figure 117 • Locate Drive System Components .................................................233
Figure 118 • Select the Orientation of the Compound Pulley and Set Screws ...234
Figure 120 • Select the Proper Compound Gear Position ...................................236
Figure 121 • Remove the Latch and Front Covers ..............................................238
Figure 122 • Remove and Install the Peel-Off/Tear-Off Bar ..............................239
Figure 123 • Remove the Latch and Front Covers ..............................................241
Figure 125 • Remove Old Peel Assembly ..........................................................243
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xiv List of Figures
13291L-001 Rev. A
Figure 127 • Rear View of Peel Assembly .........................................................245
Figure 129 • Remove and Install the Static Brush Assembly (S4M) ..................249
Figure 132 • Remove the Old Outer Media Guide .............................................254
Figure 133 • Install the New Outer Media Guide ...............................................255
Figure 134 • Stepper Motor Pivot Screw and Locking Screw ............................259
Figure 135 • Remove Old Peel Assembly ..........................................................260
Figure 136 • Remove the Lower Front Cover ....................................................261
Figure 137 • Remove the Tear Bar and Latch Cover ..........................................262
Figure 139 • Remove the Platen Roller and Bearings ........................................264
Figure 140 • Select the Orientation of the Compound Pulley .............................266
Figure 143 • Rear View of Peel Assembly .........................................................268
Figure 144 • Removing and Installing E-rings and Bearings .............................270
Figure 145 • Installing the Pinch Roller Assembly .............................................271
Figure 146 • Remove and Install the Control Panel ............................................275
Figure 147 • Remove and Install the Take-Label Sensor Board .........................276
Figure 148 • Install the Take-Label Sensor Board ..............................................277
Figure 149 • Install the Take-Label Sensor Board on the Mounting Posts .........278
Figure 150 • Install the Control Panel in the Base ..............................................279
Figure 151 • Remove the Main Logic Board Connections .................................282
Figure 152 • Remove the Main Logic Board ......................................................283
Figure 153 • Locate and Remove the MLB Fuse ................................................285
Figure 154 • Locate the RTC Option Board .......................................................287
Figure 155 • Remove and Install the Spacers and Standoffs ..............................288
Figure 161 • Remove/Install the Power Supply ..................................................296
Figure 162 • Remove the Main Logic Board Connections .................................299
Figure 163 • Remove the Main Logic Board ......................................................300
Figure 165 • Install/Remove the Wireless Print Server Board ...........................302
Figure 167 • Install the Bracket for the No Communications Option ................304
Figure 168 • Remove the Mounting Screw .........................................................309
Figure A • Media Side Main Printer Assemblies ................................................317
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List of Figures xv
Figure B • Electronics Side Main Printer Assemblies ........................................319
Figure C • Print Mechanism/Printhead Assembly ..............................................321
Figure E • Printhead Cable Maintenance Kit ......................................................323
Figure G • Latch Assembly Maintenance Kit .....................................................327
Figure I • (Reflective) Media Sensor Assembly Maintenance Kit .....................329
Figure J • Ribbon/Printhead Open Sensor Assembly Maintenance Kit ..............330
Figure K • Transmissive Sensor Assembly Maintenance Kit .............................331
Figure M • Ribbon Supply Spindle Maintenance Kit .........................................333
Figure O • Ribbon Take-up Spindle Maintenance Kit ........................................335
Figure P • Media Hanger Maintenance Kit .........................................................336
Figure S • Peel Assembly Maintenance Kit ........................................................339
Figure U • Electronics Cover Maintenance Kit ..................................................341
Figure V • Control Panel and Take-Label Maintenance Kits .............................342
Figure W • Stepper Motor Maintenance Kit .......................................................343
Figure X • Main Logic Board Maintenance Kit .................................................344
Figure Y • Real Time Clock (RTC) Option/Maintenance Kit ............................345
Figure Z • Booster Board Maintenance Kit ........................................................346
Figure AA • Power Supply Maintenance Kit ......................................................347
Figure AB • Ribbon Take-up Clutch Maintenance Kit .......................................348
Figure AC • Gears and Pulley Maintenance Kit .................................................349
Figure AD • Wireless PCMCIA Board Maintenance/Option Kit .......................350
Figure AE • 10/100 and Parallel Port Maintenance/Option Kits ........................351
Figure AF • Hardware View 1 (Media Compartment) .......................................353
Figure AG • Hardware View 2 (Printer Rear) ....................................................354
Figure AH • Hardware View 3 (Printer Front) ...................................................355
Figure AI • Hardware View 4 (Electronics Side) ...............................................357
Figure A-1 • RS-232 DB9 MLB Connections ....................................................362
Figure A-2 • RS-232 to DCE Cable Connectors .................................................362
Figure A-3 • DB-9 to DB-25 Cable Connections ...............................................363
S4M Maintenance Manual 13291L-001 Rev. A
xvi List of Figures
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13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Proprietary Statement
This manual contains proprietary information of Zebra Technologies Corporation and its subsidiaries (“Zebra Technologies”). It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
Product Improvements
Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and designs are subject to change without notice.
Liability Disclaimer
Zebra Technologies Corporation takes steps to ensure that its published Engineering specifications and manuals are correct; however, errors do occur. Zebra Technologies
Corporation reserves the right to correct any such errors and disclaims liability resulting therefrom.
Limitation of Liability
In no event shall Zebra Technologies Corporation or anyone else involved in the creation, production, or delivery of the accompanying product (including hardware and software) be liable for any damages whatsoever (including, without limitation, consequential damages including loss of business profits, business interruption, or loss of business information) arising out of the use of, the results of use of, or inability to use such product, even if Zebra
Technologies Corporation has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
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13291L-001 Rev. A S4M Maintenance Manual 10/27/05
About This Document
This section provides you with contact information, document structure and organization, and additional reference documents.
Contents
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
xx About This Document
Who Should Use This Document
Who Should Use This Document
This Maintenance Manual is intended for use by system technicians and repair personnel.
How This Document Is Organized
The Maintenance Manual is set up as follows:
Section
Maintenance and Drawings on page 313
Description
This section provides an overview of the printer.
This section provides various levels of printer maintenance required for optimum performance.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
About This Document
Contacts xxi
Contacts
You can contact Zebra Technologies Corporation at the following.
Web Site http://www.zebra.com
Technical Support via the Internet is available 24 hours per day, 365 days per year. Go to http://www.zebra.com/support .
The Americas
Regional Headquarters
Zebra Technologies International,
LLC
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061.3109
U.S.A
T: +1 847 793 2600
Toll-free +1 800 423 0422
F: +1 847 913 8766
Technical Support
T: +1 847 913 2259
F: +1 847 913 2578
Hardware: [email protected]
Software: [email protected]
Customer Service Dept.
For printers, parts, media, and ribbon, please call your distributor, or contact us.
T: +1 866 230 9494
Europe, Africa, Middle East, and India
Regional Headquarters
Zebra Technologies Europe Limited
Zebra House
The Valley Centre, Gordon Road
High Wycombe
Buckinghamshire HP13 6EQ, UK
T: +44 (0)1494 472872
F: +44 (0) 1494 450103
Technical Support
T: +44 (0) 1494 768298
F: +44 (0) 1494 768210
Germany: [email protected]
France: [email protected]
Spain/Portugal: [email protected]
All other areas: [email protected]
Internal Sales Dept.
For printers, parts, media, and ribbon, please call your distributor, or contact us.
T: +44 (0) 1494 768316
F: +44 (0) 1494 768244
Asia Pacific
Regional Headquarters
Zebra Technologies Asia Pacific, LLC
16 New Industrial Road
#05-03 Hudson TechnoCentre
Singapore 536204
T: +65 6858 0722
F: +65 6885 0838
Technical Support
T: +65 6858 0722
F: +65 6885 0838
Customer Service
For printers, parts, media, and ribbon, please call your distributor, or contact us.
T: +65 6858 0722
F: +65 6885 0837
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xxii About This Document
Document Conventions
Document Conventions
The following conventions are used throughout this document to convey certain information.
Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference
( blue text ) to jump directly to its location.
LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in
Bubbledot ICG
font.
Command Line Examples Command line examples appear in Courier New font. For example, type ZTools to get to the Post-Install scripts in the bin directory.
Files and Directories File names and directories appear in Courier New font. For example, the Zebra<version number>.tar
file and the /root directory.
Icons Used
Caution • Warns you of the potential for electrostatic discharge.
Caution • Warns you of a potential electric shock situation.
Caution • Warns you of a situation where excessive heat could cause a burn.
Caution • Advises you that failure to take or avoid a specific action could result in physical harm to you.
Caution • (No icon) Advises you that failure to take or avoid a specific action could result in physical harm to the hardware.
Important • Advises you of information that is essential to complete a task.
Note • Indicates neutral or positive information that emphasizes or supplements important points of the main text.
Example • Provides an example, often a scenario, to better clarify a section of text.
Tools • Tells you what tools you need to complete a given task.
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About This Document
Document Conventions xxiii
Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the
graphic. Figure 1 provides an example.
Figure 1 • Sample Figure with Callouts
POWER ALERT
1
2
MENU
CANCEL
PAUSE
FEED
ENTER
1
2
FEED button
CANCEL button
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xxiv About This Document
Document Conventions
Notes • ___________________________________________________________________
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13291L-001 Rev. A S4M Maintenance Manual 10/27/05
1
System Description
10/27/05
This section provides an overview of the printer. Included are specifications of the printer and a brief explanation of each component and its function.
Contents
S4M Maintenance Manual 13291L-001 Rev. A
2 System Description
External View
External View
Figure 2 shows the outside of the printer.
Figure 2 • Exterior of Printer
Front
1
2
Rear
3
4
5
3
4
1
2
5
Control panel
Media door
Electronics cover
Power switch ( O = Off, I = On)
AC power connector
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System Description
Control Panel
3
Control Panel
All controls and indicators for the printer are located on the control panel ( Figure 3
).
• The control panel Liquid Crystal Display (LCD) shows the operating status and printer parameters.
• The control panel buttons are used to control the printer operations and to set parameters.
• The control panel lights (LEDs) show the printer’s operating status or indicate which control panel buttons are active.
Figure 3 • Location of Control Panel Buttons and Lights
2 1
POWER ALERT
3
4
5
6
7
8
9
MENU
CANCEL
PAUSE
FEED
7
8
5
6
9
3
4
1
2
ALERT light
POWER light
LCD
ENTER button
MENU button
Up arrow button
CANCEL or Left Arrow button
FEED or Right Arrow button
PAUSE or Down Arrow button
ENTER
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4 System Description
Control Panel
Control Panel LCD
The control panel LCD functions differently in different printer modes.
• In Operating mode, the LCD displays the printer’s status, sometimes in conjunction with a control panel light (see
Control Panel Lights on page 6
). When the printer is receiving data, the control panel shows the word
DATA
and cycles through a series of dots and spaces.
• In Pause mode, the printer stops printing temporarily.
• In Setup mode, you can use the control panel LCD to view or modify printer parameters
(see Control Panel LCD Display on page 54 ).
• In Error mode, the LCD may display an alert or error message (see LCD Error Messages on page 86 ).
Control Panel Buttons
The printer has six basic control buttons on the control panel. Some of these buttons also function as navigational keys when the printer is in Setup mode. The current function of a particular button is determined by which light is illuminated next to it (
Figure 4 • Example of Active Control Panel Buttons
1
FEED FEED
2
1
2
FEED active
Right arrow active
Table 1 describes the function of each button. The
MENU , PAUSE , and FEED buttons are active when the printer is in normal operating mode.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
System Description
Control Panel
5
Button
MENU
ENTER
CANCEL
FEED
PAUSE
Left Arrow
Right Arrow
Up Arrow
Table 1 • Control Panel Buttons
Appearance Function/Description
MENU
Enters and exits Setup mode.
ENTER
CANCEL
FEED
PAUSE
If a parameter or option in Setup mode needs to be selected, pressing
ENTER selects the item. This button is active only when necessary.
CANCEL functions only in Pause mode. Pressing CANCEL once has these effects:
• Cancels the label format that is currently printing.
• If no label format is printing, the next one to be printed is canceled.
• If no label formats are waiting to be printed, CANCEL is ignored.
To clear the printer’s entire label format memory, press and hold
CANCEL .
Advances a blank label.
• If the printer is idle or paused, the label is fed immediately.
• If the printer is printing, the label is fed after printing finishes.
Stops and restarts the printing process or removes error messages and clears the LCD. When the printer is paused, the PAUSE light blinks.
• If the printer is idle, it enters Pause mode immediately.
• If the printer is printing, the label is completed before the printer pauses.
When in Setup mode, scrolls the LCD to the previous parameter.
When in Setup mode, scrolls the LCD to the next parameter.
When in Setup mode, increases values or scrolls to the next option.
Down Arrow When in Setup mode, decreases values or scrolls to the previous option.
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6 System Description
Control Panel
Control Panel Lights
Table 2 describes lights on the control panel that indicate different printer conditions.
Light
POWER
ALERT
PAUSE (part of the
PAUSE button)
Table 2 • Control Panel Lights
Appearance Function/Description
Indicates that the printer is on.
POWER
ALERT
PAUSE
In an error or alert situation, the ALERT light operates as follows:
• Remains on (solid) when the printer requires operator attention, such as when the print mechanism is open.
• Flashes when the ribbon or media is out.
Flashes when the printer is in Pause mode unless the printer enters
Setup mode and the down arrow becomes active.
FEED (part of the
FEED button)
CANCEL (part of the CANCEL button)
FEED
CANCEL
On during normal printer operation, indicating that the printer can feed a blank label.
On when canceling a label format is a valid option.
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System Description
Printer Media Compartment
7
Printer Media Compartment
Figure 5 shows a simplified view of the media compartment of your printer. Depending on
installed options, your printer may look slightly different.
Figure 5 • Media Compartment
1
2
3
4
5
6
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11 10 9 8 7
7
8
5
6
3
4
1
2
9
10
11
Printhead assembly
Ribbon supply spindle*
Ribbon take-up spindle*
Media supply hanger
Media supply guide
Fanfold media slot
Dancer assembly
Media guide
Printhead release latch
Peel release lever**
Peel assembly**
* Present only on printers that have the Thermal Transfer option installed.
** Present only on printers that have the Peel option installed.
S4M Maintenance Manual 13291L-001 Rev. A
8 System Description
Printer Language Modes
Printer Language Modes
Depending on how your printer was ordered, it came from the factory with firmware that operates in or allows you to use certain commands for one of the following printer languages:
• Zebra Programming Language (ZPL)
• Eltron Programming Language (EPL)
• Datamax Programming Language (APL-D)
• Intermec Printer Language (APL-I)
Firmware Downloads
You may download S4M firmware to the printer at any time to change from one printer language to another. For the latest firmware versions and instructions for downloading them, go to http://www.zebra.com/firmware .
Note • When the printer changes from one printer language to another, error messages may appear on the LCD, and some control panel lights may activate in error mode. You may ignore these error messages and lights. When the firmware download is complete, reboot the printer and load printer defaults to return the printer to Operating mode.
Additional Printer Language Information
The following manuals contain specific information about the different printer language modes. Copies of these manuals are on the CD that came with your printer and at http://www.zebra.com/manuals .
• ZPL II Programming Guide, volumes 1 and 2
• EPL2 Programming Guide
• APL-D Reference Guide
• APL-I Reference Guide
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Operations
Before You Begin
9
Before You Begin
Review this checklist, and resolve any issues before you set up or use your printer.
‰ Unpack and Inspect the Printer Have you unpacked the printer and inspected it for damage? If you have not, see
Unpack and Inspect the Printer on page 10
.
‰ Select a Site Have you selected an appropriate location for the printer? If you have not, see
Select a Site for the Printer on page 11 .
‰ Attach a Power Cord Do you have the correct power cord for your printer? If you are unsure, see
‰ Connect to a Data Source Have you determined how the printer will connect to a data source (usually a computer)? For more information, see
‰ Select Media Do you have the correct media for your application? If you are unsure, see
‰ Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if needed? If you are unsure, see
.
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10 Operations
Handling the Printer
Handling the Printer
This section describes how to handle your printer.
Unpack and Inspect the Printer
When you receive the printer, immediately unpack it and inspect for shipping damage.
• Save all packing materials.
• Check all exterior surfaces for damage.
• Raise the media door, and inspect the media compartment for damage to components.
If you discover shipping damage upon inspection:
• Immediately notify the shipping company and file a damage report.
• Keep all packaging material for shipping company inspection.
• Notify.
Important • Zebra Technologies Corporation is not responsible for any damage incurred during the shipment of the equipment and will not repair this damage under warranty.
Store the Printer
If you are not placing the printer into immediate operation, repackage it using the original packing materials. You may store the printer under the following conditions:
• Temperature: –40°F to 140°F (–40°C to 60°C)
• Relative humidity: 5% to 85%, non-condensing
Ship the Printer
If you must ship the printer:
• Remove any media or ribbon from the printer to avoid damaging the printer.
• Carefully pack the printer into the original container or a suitable alternate container to avoid damage during transit. A shipping container can be purchased from Zebra if the original packaging has been lost or destroyed.
Recycle the Printer
This printer is recyclable. If you must dispose of the printer, do not do so in unsorted municipal waste. Please recycle according to your local standards. For more information, see http://www.zebra.com/recycle .
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Operations
Select a Site for the Printer
11
Select a Site for the Printer
Consider the following when selecting an appropriate location for your printer.
Select a Surface
Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary. The choices include a table, countertop, desk, or cart.
Provide Proper Operating Conditions
This printer is designed to function in a wide range of environmental and electrical conditions, including a warehouse or factory floor. For more information on the required conditions, see
General Specifications on page 22 .
Table 3 shows the temperature and relative humidity requirements for the printer when it is
operating.
Mode
Thermal Transfer
Direct Thermal
Table 3 • Operating Temperature and Humidity
Temperature
40° to 104°F (5° to 40°C)
32° to 104°F (0° to 40°C)
Relative Humidity
20 to 85% non-condensing
20 to 85% non-condensing
Allow Proper Space
The printer should have enough space around it for you to be able to open the media door. To allow for proper ventilation and cooling, leave open space on all sides of the printer.
Caution • Do not place any padding or cushioning material behind or under the printer because this restricts air flow and could cause the printer to overheat.
Provide a Data Source
If the printer will be located away from the data source, the selected site must provide the appropriate connections to that data source. For more information on the types of
communication interfaces, see Select a Communication Interface on page 14 .
Provide a Power Source
Place the printer within a short distance of a power outlet that is easily accessible.
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12 Operations
Connect the Printer to a Power Source
Connect the Printer to a Power Source
The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with
your printer, refer to Power Cord Specifications on page 12 .
Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific three-conductor grounded plug configuration.
To connect the printer to a power source, complete these steps:
1.
Turn the printer power switch to the Off ( O ) position.
2.
Refer to Figure 6 . Plug the power cord into the AC power connector on the rear of the
printer.
3.
Plug the other end of the power cord into a power outlet near the printer.
Figure 6 • Power Connection
1
2
1
2
Power switch
AC power connector
Power Cord Specifications
Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration.
13291L-001 Rev. A
Depending on how your printer was ordered, a power cord may or may not be included. If one is not included or if the one included is not suitable for your requirements, refer to the following guidelines:
S4M Maintenance Manual 10/27/05
Operations
Connect the Printer to a Power Source
13
• The overall cord length must be less than 9.8 ft. (3.0 m).
• The cord must be rated for at least 10 A, 250 V.
• The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic interference. The third wire in the power cord grounds the connection (
1
Figure 7 • Power Cord Specifications
2 3
4
2
3
1
4
AC power plug for your country—This should bear the certification mark of at least one of the known
international safety organizations ( Figure 8 ).
3-conductor HAR cable or other cable approved for your country.
IEC 320 connector—This should bear the certification mark of at least one of the known
international safety organizations ( Figure 8 ).
Length
≤ 9.8 ft. (3 m). Rating 10 Amp, 250 VAC.
Figure 8 • International Safety Organization Certifications
+
R
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14 Operations
Select a Communication Interface
Select a Communication Interface
The way that you connect your printer to a data source depends on the communication options installed in the printer. You may use any available connection to send commands and label formats from a host computer to the printer.
Caution • Connecting a data communications cable while the power is ON may damage the printer.
Note • You must supply all interface cables for your application. Refer to
for specific cable requirements.
Connector Locations
Refer to
Figure 9 . The printer comes standard with an Electronics Industries Association (EIA)
RS-232 serial interface (DB-9 connector), an IEEE 1284 bidirectional parallel interface
(unless replaced with an optional print server port), and a USB 1.1 port. You may use any of these interface methods to send commands and label formats from a host to the printer.
Figure 9 • Cable Connections
1
2
3
1
2
3
Parallel interface connector (not available on units that have an optional print server port)
DB-9 serial interface connector
USB 1.1 connector
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Operations
Select a Communication Interface
15
Types of Connections
The method of connecting the printer to a data source depends on the communication options installed in the printer and the host. This section provides basic information about common interfaces.
When communicating via the serial data port (RS-232), the baud rate, number of data and stop bits, the parity, and the XON/XOFF or DTR control should be set to match those of the host
computer. See Password Level 3 Parameters on page 59 to configure these parameters. When
communicating via the parallel port or the USB port, the previously mentioned parameters do not apply.
RS-232 Serial A serial communication method consisting of data and control signals;
available as a standard feature on most PCs and other hosts. See Serial Data Port on page 360
.
• Advantages: Cables and connectors are readily available from computer equipment stores and suppliers; easy to connect; two-way communication between the host and the printer.
• Disadvantages: Slower than the parallel connection; limited to 50 feet (15.24 m) of cable.
Figure 10 • Communicating Using a Serial Data Port
1
Printer Computer
2
5
4 3
3
4
1
2
5
Null-modem adaptor (if using a standard modem cable)
9-pin male connector, connected to printer or null-modem adaptor
25-pin female connector, connected to computer
9-pin female connector, connected to computer
Maximum cable length = 50 ft. (15 m)
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16 Operations
Select a Communication Interface
IEEE 1284 Bidirectional Parallel A common communication method available on most
PCs and other hosts. See
Parallel Data Port on page 364 .
• Advantages: Fastest of the communication interfaces; cables and connectors are readily available from computer equipment stores and suppliers; two-way communication between the host and the printer; easy to connect.
• Disadvantages: Shorter recommended cable length of 6 feet (1.83 m) with a maximum of length 10 ft (3 m); many computers are equipped with only one parallel port, allowing only one IEEE 1284 bidirectional device to be connected at a time.
Figure 11 • Communicating Using a Parallel Port
Printer Computer
1
13291L-001 Rev. A
3
2
1
2
3
36-pin male connector, attaching to printer
25-pin male connector, attaching to computer
Maximum cable length = 10 ft. (3 m)
USB 1.1 Port Communicating using the USB port (see Figure 12 ) does not require special
settings. See
• Advantages: Many computers are equipped with more than one USB port, allowing multiple USB devices to be connected at one time; cables and connectors are readily available from computer equipment stores and suppliers; two-way communication between the host and the printer; easy to connect.
• Disadvantages: Cable length limited to 16.4 ft. (5 m).
S4M Maintenance Manual 10/27/05
Operations
Select a Communication Interface
17
Figure 12 • Communicating Using a USB Port
Printer Computer
1
3
5
2 4
3
4
1
2
5
“B” male connector, attaching to printer
“B” male connector, detail
“A” male connector, attaching to computer
“A” male connector, detail
Maximum cable length = 16.4 ft. (5 m)
Optional Print Servers Ethernet-based print servers also are available to connect your printer to a data source. Both wired and wireless options are available.
• With the ZebraNet Wireless Print Server board installed, a wireless PCMCIA card can be used to communicate with a network. For more information on this option, see the
ZebraNet Wireless Print Server User Guide.
• ZebraNet 10/100 Print Server (10/100 PS). For more information on 10/100 PS, see the
ZebraNet 10/100 Print Server User and Reference Guide.
Data Cable Requirements
Data cables must be fully shielded and fitted with metal or metallized connector shells.
Shielded cables and connectors are required to prevent radiation and reception of electrical noise.
To minimize electrical noise pickup in the cable:
• Keep data cables as short as possible.
• Do not bundle the data cables tightly with the power cords.
• Do not tie the data cables to power wire conduits.
Note • Zebra printers comply with FCC Rules and Regulations, Part 15 for Class B
Equipment using fully shielded, 6.5 ft. (2 m) data cables. Use of unshielded cables may increase radiation above the Class B limits.
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
18 Operations
Types of Media
Types of Media
The printer can use various types of media ( Table 4 ). Zebra strongly recommends the use of
Zebra-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to ensure against premature printhead wear.
Media Type
Non-Continuous
Roll Media
How It Looks
Table 4 • Types of Media
Description
Roll media is wound on a core that can be 1 in. to
3 in. (25 to 76 mm) in diameter. Labels have adhesive backing that sticks them to a liner, and they are separated by gaps, holes, notches, or black marks.
Tags are separated by perforations.
Figure 13 • Non-Continuous Web Media
Figure 14 • Black Mark Media
Figure 15 • Tag Stock
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Operations
Types of Media
19
Media Type
Non-Continuous
Fanfold Media
Table 4 • Types of Media (Continued)
How It Looks Description
Fanfold media is folded in a zigzag pattern. Fanfold media can have the same label divisions as noncontinuous roll media. The divisions would fall on or near the folds.
Continuous
Roll Media
Continuous media is wound on a core and is without gaps, holes, notches, or black marks. This allows the image to be printed anywhere on the label. With continuous media, use the transmissive sensor so the printer can detect when the media runs out.
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20 Operations
Ribbon Overview
Ribbon Overview
Note • This section applies only to printers that have the Thermal Transfer option installed.
Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be.
When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.
When to Use Ribbon
Thermal transfer media requires ribbon for printing while direct thermal media does not.
To determine if ribbon must be used with a particular media, perform a media scratch test.
To perform a label scratch test, complete these steps:
1.
Scratch the print surface of the media rapidly with your fingernail.
2.
Did a black mark appear on the media?
If a black mark...
Then the media is...
Does not appear on the media Thermal transfer. A ribbon is required.
Appears on the media Direct thermal. No ribbon is required.
Coated Side of Ribbon
Ribbon can be wound with the coated side on the inside or outside ( Figure 16
). This printer can only use ribbon that is coated on the outside. If you are unsure which side of a particular roll of ribbon is coated, perform an adhesive test or a ribbon scratch test to determine which side is coated.
Figure 16 • Ribbon Coated on Outside or Inside
Outside Inside
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10/27/05
Operations
Ribbon Overview
21
Adhesive Test
If you have labels available, perform the adhesive test to determine which side of a ribbon is coated. This method works well for ribbon that is already installed.
To perform an adhesive test, complete these steps:
1.
Peel a label from its liner.
2.
Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.
3.
Peel the label off of the ribbon.
4.
Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?
If ink from the ribbon...
Adhered to the label
Did not adhere to the label
Then...
The ribbon is coated on the outer surface.
The ribbon is coated on the inner surface and cannot be used in this printer. To verify this, repeat the test on the other surface of the roll of ribbon.
Ribbon Scratch Test
Perform the ribbon scratch test when labels are unavailable.
To perform a ribbon scratch test, complete these steps:
1.
Unroll a short length of ribbon.
2.
Place the unrolled section of ribbon on a piece of paper with the outer surface of the ribbon in contact with the paper.
3.
Scratch the inner surface of the unrolled ribbon with your fingernail.
4.
Lift the ribbon from the paper.
5.
Observe the results. Did the ribbon leave a mark on the paper?
If the ribbon...
Then...
Left a mark on the paper The ribbon is coated on the outer surface.
Did not leave a mark on the paper
The ribbon is coated on the inner surface and cannot be used in this printer. To verify this, repeat the test on the other surface of the roll of ribbon.
S4M Maintenance Manual 13291L-001 Rev. A
22 Specifications
General Specifications
General Specifications
General Specifications
Height
Width
Depth
Weight (without options)
Electrical
Temperature Operating
Storage
Relative Humidity Operating
Storage
Communication Interface
11.6 in.
10.7 in.
18.8 in.
295 mm
272 mm
477 mm
27.2 lbs.
12.4 kg
90–264 VAC, 47–63 Hz, 4 Amps (300 W)
40° to 104°F
–40° to 140°F
5° to 40°C
–40° to 60°C
20% to 85%, non-condensing
5% to 85%, non-condensing
• RS-232/CCITT V.24 serial data interface; 110 to
115000 baud, parity, bits/character, 7 or 8 data bit, and XON-XOFF, RTS/CTS or DTR/DSR handshake protocol required. 750mA at 5 V from pins 1 and 9.
• USB 1.1 data interface
• One of the following:
• 8-bit parallel data interface; supports IEEE
1284 bidirectional parallel; nibble mode compliant.
• 10/100 internal Ethernet
• 802.11b wireless card support
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Agency Approvals
Agency Approvals
Product Markings
• IEC60950-1
• EN55022: Class B
• EN55024
• EN61000-3-2,-3-3
• cULus
• CE Marking
• FCC-B
• ICES-003
• VCCI
• C-Tick
• NOM
• CCC
• GOST-R
• S-Mark (Argentina)
• MIC
• BSMI
System Description
Agency Approvals
23
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24 Specifications
Printing Specifications
Printing Specifications
Printing Specifications
Print resolution
Dot size
(width x length)
203 dpi
300 dpi
Maximum print width
Bar code modulus
(X) dimension
Programmable constant print speeds
203 dpi
300 dpi
203 dots/inch
300 dots/inch
203 dots/inch and 300 dots/inch
203 dots/inch
300 dots/inch
8 dots/mm
12 dots/mm
0.00492 in. x 0.00492 in.
0.125 mm x
0.125 mm
0.0033 in. x 0.0039 in.
0.084 mm x 0.099 mm
4.09 in. 104 mm
106 mm 4.1 in.
5 mil to 50 mil
3.3 mil to 33 mil
Per second:
2 in.
3 in.
4 in.
5 in.
6 in.
Per second:
51 mm
76 mm
102 mm
127 mm
152 mm
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Specifications
Media Specifications
25
Media Specifications
Media Specifications
Label length
Label width
Total thickness
(includes liner, if any)
Minimum (Tear-Off)
Minimum (Peel-Off)
Maximum
Minimum
Maximum
Minimum
Maximum
Maximum roll outside diameter
Inter-label gap
3-in. (76 mm) core
1-in. (25 mm) core
Minimum
Preferred
Maximum
Ticket/tag notch size (width x length)
Hole diameter
Notch or hole position
(Centered from inner media edge)
Minimum
Maximum
Density, in Optical Density Units (ODU) (black mark)
Maximum media density
Transmissive Sensor Fixed
0.7 in.
0.5 in.
39 in.
0.75 in.
4.5 in.
0.003 in.
0.010 in.
8 in.
6 in.
0.079 in.
0.118 in.
0.157 in.
0.25 in. × 0.12 in.
0.125 in.
0.15 in.
2.25 in.
> 1.0 ODU
< 0.5 ODU
7/16 in. (11 mm) from inside edge
17.8 mm
12.7 mm
991 mm
19 mm
114 mm
0.076 mm
0.25 mm
203 mm
152 mm
2 mm
3 mm
4 mm
6 mm × 3 mm
3 mm
3.8 mm
57 mm
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26 Specifications
Ribbon Specifications
Ribbon Specifications
Note • This section applies only to printers that have the Thermal Transfer option installed.
Ribbon must be wound with the coated side out.
Ribbon Specifications
Ribbon width
(Zebra recommends using ribbon at least as wide as the media to protect the printhead from wear.)
Standard lengths
Minimum
Maximum
>2 in.*
4.3 in.
51 mm*
109 mm
2:1 media to ribbon roll ratio
3:1 media to ribbon roll ratio
984 ft.
1476 ft.
300 m
450 m
Ribbon core inside diameter 1 in.
25.4 mm
* Depending on your application, you may be able to use ribbon narrower than 2 in. (51 mm), as long as the ribbon is wider than the media being used. To use a narrower ribbon, test the ribbon’s performance with your media to assure that you get the desired results.
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Specifications
Zebra Programming Language (ZPL II)
27
Zebra Programming Language (ZPL II)
• Communicates in printable ASCII characters
• Controlled via mainframe, mini, or PC
• Downloadable graphics, scalable and bitmap fonts, label templates and formats
• Object copying between memory areas
(RAM and PC memory card)
• Adjustable print cache
• Data compression
• Automatic memory allocation for “format while printing”
• Status messages to host upon request
• Format inversion (white on black)
• Mirror image printing
• Four-position field rotation
(normal/0°, 90°, 180°, and 270°)
• Slew command
• Programmable label quantities with print and pause control
• Automatic serialization of fields
• User-programmable password
Bar Codes
Bar code modulus “X” dimensions
• Picket fence (non-rotated) orientation:
• 203 dpi = 0.0049 in. mil to 0.049 in.
• 300 dpi = 0.0033 in. mil to 0.033 in.
• Ladder (rotated) orientation:
• 203 dpi = 0.0049 in. mil to 0.049 in.
• 300 dpi = 0.0039 in. mil to 0.039 in.
Two-dimensional bar codes
• Code 49
• Maxi Code
• PDF-417
• QR Code
• Codablock
• DataMatrix
• Micro-PDF417
Bar code ratios
• 2:1
• 7:3
• 5:2
• 3:1
Linear bar codes
• Code 11
• Code 39
• Code 93
• Code 128 with subsets A/B C and
UCC Case Codes
• ISBT-128
• UPC-A
• UPC-E
• EAN-8
• EAN-13
• UPC and EAN 2 or 5 digit extensions
• Plessey
• Postnet
• Standard 2 of 5
• Industrial 2 of 5
• Interleaved 2 of 5
• LOGMARS
• MSI
• Codabar
• RSS-14
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28 System Description
Standard Font Matrices
Standard Font Matrices
Bit mapped fonts A, B, D, E, F, G, H, and GS are expandable up to 10 times, height and width independent. However, fonts E and H (OCR-B and OCR-A) are not in spec when expanded.
The Scalable Smooth Font (CG Triumvirate Bold Condensed) is expandable on a dot-by-dot basis, height and width independent, while maintaining smooth edges, to a maximum of 1500
× 1500 dots.
IBM Code Page 850 International characters are available in fonts A, B, D, E, F, G, and Ø through software control.
Table 5 • Font Matrix for 8 dot/mm (203 dpi) Printheads
Matrix
Font
Height Width
Baseline
Dots
Inter-
Character
Gap
F
G
H
GS
A
B
C,D
E
26
60
21
24
9
11
18
28
13
40
13
24
5
7
10
15
21
48
21
24
7
11
14
23
R
S
P
Q
20
28
35
40
18
24
31
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
T
U
48
59
42
53
N/A
N/A
N/A
N/A
V
0
80 71 N/A
Default: 15 x 12
*U = Uppercase, L = Lowercase, D = Descenders
N/A
3
8
6
2
1
2
2
5
N/A
N/A
N/A
N/A
N/A
N/A
N/A
16
48
19
26
6
9
12
20
Cell
Width
Type*
Font
Matrix
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
U
U-L-D
OCR-B
U-L-D
U-L-D
OCR-A
SYMBOL
Character Size
Inches Millimeters
0.098
0.138
0.172
0.197
0.236
0.290
0.394
0.044
0.054
0.089
0.138
0.128
0.295
0.103
0.118
Height Width
Char/
Inch
Height
0.089
0.118
0.153
0.172
0.207
0.261
0.349
0.030
33.87
0.044
22.58
0.059
16.93
0.098
10.16
0.079
0.236
12.70
4.23
0.094
10.69
0.128
7.82
N/A
N/A
N/A
N/A
2.50
3.50
4.38
5.00
N/A
N/A
6.00
7.38
N/A 10.00
Scalable
1.13
1.38
2.25
3.50
3.25
7.50
2.63
3.00
Width
2.25
3.00
3.88
4.38
5.25
6.63
8.88
0.75
1.13
1.50
2.50
2.00
6.00
2.38
3.25
Char/ mm
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1.33
0.89
0.67
0.40
0.50
0.17
0.42
0.31
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
System Description
Standard Font Matrices
29
Table 6 • Font Matrix for 12 dot/mm (300 dpi) Printheads
Matrix
Font
Height Width
Baseline
Dots
Inter-
Character
Gap
Q
R
S
T
G
H
GS
P
A
B
C, D
E
F
9
11
18
41
26
60
30
24
20
28
35
40
48
5
7
10
20
13
40
19
24
18
24
31
35
42
7
11
14
32
21
48
30
24
N/A
N/A
N/A
N/A
N/A
U
V
59
80
53
71
N/A
N/A
*U = Uppercase, L = Lowercase, D = Descenders
N/A
N/A
2
6
3
1
2
8
9
2
N/A
N/A
N/A
N/A
N/A
Cell
Width
48
28
26
N/A
N/A
N/A
N/A
N/A
N/A
N/A
12
26
16
6
9
Type* Character Size
Inches
Font
Matrix
Height Width
U-L-D
U
U-L-D
OCR-B
U-L-D
U-L-D
OCR-A
Symbol
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
U-L-D
0.030
0.037
0.060
0.137
0.087
0.200
0.100
0.080
0.067
0.093
0.117
0.133
0.160
0.197
0.267
0.020
0.030
0.040
0.087
0.053
0.160
0.093
0.087
0.060
0.080
0.103
0.117
0.140
0.177
0.237
Char/
Inch
50.00
33.33
25.00
11.54
18.75
6.25
10.71
11.54
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Millimeters
5.08
2.54
2.03
1.69
2.37
2.96
3.39
4.06
5.00
6.77
0.76
0.93
1.52
3.47
2.20
Height Width
Char/ mm
0.25
0.42
0.45
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1.97
1.31
0.98
0.45
0.74
4.06
2.37
2.20
1.52
2.03
2.62
2.96
3.56
4.49
6.01
0.51
0.76
1.02
2.20
1.35
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30 System Description
Standard Font Matrices
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
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13291L-001 Rev. A S4M Maintenance Manual 10/27/05
2
Operations
This section assists the technician with “out of the box” installation, initial setup, and printer operation.
Contents
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
32 Operations
Load Media
Load Media
Use the instructions in this section to load roll media in Tear-Off mode (
). For instructions for loading fanfold media or for loading in different print modes, refer to the
User Guide.
Figure 17 • Tear-Off Mode Media Path
To Load Roll Media in Tear-Off Mode, complete these steps:
1.
Remove and discard one full revolution of labels or tags and any liner.
Labels Tag Stock
2.
Flip down the media supply guide.
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Operations
Load Media
33
3.
Place the roll of media on the media supply hanger. Push the roll as far back as it will go.
4.
Flip up the media supply guide, and then slide it in until it touches, but does not restrict, the edge of the roll.
5.
Press the printhead release latch to open the printhead assembly. Lift the printhead until it latches open.
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34 Operations
Load Media
6.
Slide out the media guide.
7.
Feed the media under the dancer assembly (
1
), through the slot in the transmissive sensor (
2
), and under the ribbon sensor (
3
).
3 2 1
8.
Push the media to the back of the transmissive sensor (
1
). Slide in the media guide (
2
) until it just touches the edge of the media.
1
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10/27/05
Operations
Load Media
35
9.
Close the printhead assembly.
10.
If the printer is paused (the PAUSE light is blinking), press PAUSE to enable printing.
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36 Operations
Load Ribbon
Load Ribbon
Note • This section applies only to printers that have the Thermal Transfer option installed.
Note • Always use ribbon that is wider than the media to protect the printhead from wear.
For direct thermal printing, do not load ribbon in the printer.
Figure 18 • Ribbon Path
2 3 4
1
3
4
1
2
Printhead assembly
Ribbon supply spindle
Ribbon take-up spindle
Tension blades
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Operations
Load Ribbon
37
To load ribbon, complete these steps:
1.
Set the ribbon supply spindle for normal or low tension.
• To place the ribbon supply spindle in the normal position, firmly pull out the spindle
end cap until it extends and clicks in place, as shown in Figure 19
. Use this setting for most applications.
• To place the ribbon supply spindle in the low-tension position, firmly push in the end cap until it retracts and clicks in place, as shown in
. Use this setting when using a narrow ribbon or if normal tension hampers ribbon movement.
Figure 19 • Ribbon Spindle—Normal and Low Tension
1 2
1
2
Normal Position (Spindle End Cap Extended)
Low-Tension Position (Spindle End Cap Retracted)
2.
Press the printhead release latch to open the printhead assembly. Lift the printhead until it latches open.
3.
Orient the ribbon with the loose end unrolling clockwise.
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38 Operations
Load Ribbon
4.
Place the ribbon roll onto the ribbon supply spindle (
1
) and push it all the way back.
1
5.
Pull the end of the ribbon under the printhead assembly (
2
) and out the front of the printer.
2
6.
Close the printhead assembly.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
7.
Wind the ribbon clockwise onto the ribbon take-up spindle (
3
).
Operations
Load Ribbon
39
3
Remove Used Ribbon
Remove used ribbon from the printer after the ribbon runs out or when switching from thermal transfer mode to direct thermal mode.
To remove used ribbon, complete these steps:
1.
If the ribbon has not run out, cut or break it before the ribbon take-up spindle (
1
).
Caution • Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may damage the spindle.
1
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40 Operations
Load Ribbon
2.
To loosen the ribbon, squeeze the ribbon against the ribbon take-up spindle tension blades (
1
). At the same time, turn the ribbon take-up spindle release knob counterclockwise (
2
).
The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.
1
2
3.
Slide the ribbon off of the ribbon take-up spindle.
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Operations
Calibrate the Printer
41
Calibrate the Printer
Auto Calibration
By default, the printer automatically calibrates on power up or when the printhead is closed.
During auto calibration, the printer determines the label length and sensor settings.
The results of the auto calibration are stored in the printer’s memory and are retained even if printer power is removed. These parameters remain in effect until the next calibration is performed.
Manual Calibration
Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the media and ribbon are detected more accurately. If you change the type of ribbon or media, your printer may operate better if you perform this calibration.
For instructions, refer to Calibrate Media and Ribbon Sensors on page 67
.
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42 Operations
Select or Adjust the Media Sensors
Select or Adjust the Media Sensors
This printer uses two types of media sensors: transmissive and reflective.
Select the Transmissive Sensor
The standard transmissive sensor (
Figure 20 ) is in a fixed position and enabled from the
control panel. For more information about the operation of this sensor, see
Figure 20 • Transmissive Sensor
1
1
Standard transmissive sensor
Adjust the Reflective Sensor
The reflective sensor is compatible with most types of media. With non-continuous media, the reflective sensor detects the start-of-label indicator (the notch, hole, black mark, or gap between die-cut labels). With both continuous media and non-continuous media, the sensor detects an out-of-paper condition. If you have difficulties with calibration while using this sensor, use the transmissive sensor (see
Select the Transmissive Sensor on page 42
).
Position the reflective sensor in the following way:
• directly under the notch, hole, or black mark with these types of labels
• anywhere along the width of the media if there is a gap between labels
• anywhere under the media for continuous media
The glow of the red light through the media may help you accurately position the sensor.
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Operations
Select or Adjust the Media Sensors
43
Figure 21 • Adjusting the Reflective Sensor
1
2
3
4
3
4
1
2
Printhead assembly
Reflective sensor
Reflective sensor positioning lever
Printhead release latch
To adjust the reflective sensor, complete these steps:
1.
See
. Press the printhead release latch.
2.
Lift the printhead until it latches open.
3.
Locate the reflective sensor positioning lever.
4.
Move the reflective sensor positioning lever across the width of the media until the reflective sensor aligns with the gap or notch.
5.
Close the printhead assembly.
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44 Operations
Adjust Printhead Pressure
Adjust Printhead Pressure
You may need to adjust printhead pressure if printing is too light on one side or if you use thick media.
See
. The pressure adjustment dials have four possible settings designated by blocks of increasing size embossed on the print mechanism. The smallest block (fully counterclockwise) is considered position 1, and the largest block (fully clockwise) is considered position 4.
Figure 22 • Printhead Pressure Adjustment Dials
1 2
1
2
Outside dial
Inside dial
To set printhead pressure, complete these steps:
1.
Use Table 7 to select the initial dial settings for your media.
Table 7 • Printhead Pressure
Media Width
1 in. (25.4 mm)
2 in. (51 mm)
3 in. (76 mm)
3.5 in. and up (89 mm and up)
Inside Dial
3
3
3
4
Outside Dial
2
3
1
1
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Operations
Adjust Printhead Pressure
45
2.
If necessary, adjust the pressure adjustment dials as follows:
If the media...
Requires higher pressure to print well
Shifts left while printing
Then...
Increase both dials one position.
Shifts right while printing
Prints too lightly on the left side of the label.
Increase the outside dial setting one position, or decrease the inside dial setting one position.
Increase the inside dial setting one position, or decrease the outside dial setting one position.
Increase the inside dial setting one position.
Prints too lightly on the right side of the label.
Increase the outside dial setting one position.
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46 Operations
Setup Mode
Setup Mode
After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the control panel displays
PRINTER READY
. You may now set printer parameters for your application using the control panel LCD and the buttons directly below it. If it becomes necessary to restore the initial printer defaults, see
FEED and PAUSE Self Test on page 103 .
Enter Setup Mode
To enter Setup mode, complete these steps:
1.
Press MENU .
2.
Use the left or right arrow to scroll through the parameters.
Leave Setup Mode
You can leave Setup mode at any time. As you leave Setup mode, you may choose to save or discard changes that you made, or you may return to where you were in Setup mode.
To exit Setup mode, complete these steps:
1.
Press MENU .
The printer displays
SAVE CHANGES
and activates the ENTER button.
2.
Do you wish to save changes that were made since you entered Setup mode?
If you wish to...
Then...
Save changes
Discard changes a.
a.
b.
Press ENTER .
The printer saves changes and exits Setup mode.
Press the up or down arrow to select
NO
.
Press ENTER .
The printer discards changes and exits Setup mode.
Return to Setup mode a.
Press MENU or any arrow button.
• MENU returns you to the same parameter.
• The left arrow takes you to the previous parameter.
• The right arrow takes you to the next parameter.
• The up or down arrow scrolls to other options in the same parameter.
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Operations
Password Protection of Parameters
47
Password Protection of Parameters
The printer has four levels of passwords. When you enter Setup mode on the control panel, only those parameters that are not password-protected are displayed. To see more parameters, you must enter an appropriate password at the
ADVANCED SETUP
prompt. After you enter a password correctly, you do not have to enter it again until you leave and reenter Setup mode.
When you are prompted for a password, enter the password for the level displayed or for a higher level. Entering a higher level password will unprotect the parameters for that level and for all levels below it (for example, unprotecting level 4 parameters also unprotects levels 1, 2, and 3).
The password levels and default passwords are shown in
.
Table 8 • Password Levels and Defaults
Password
Level
4
3
2
1
Features Controlled Default Password
All features, including sensor adjustments and other sensitive parameters
Installation and reconfiguration. The printer web-page interface also uses this password.
Label configuration operations (media type, label removal method, label length)
Darkness, Tear-Off position, label top
9999
1234
0000
0000
(unprotected)
(unprotected)
To enter a password when prompted, complete these steps:
1.
When the printer displays
ADVANCED SETUP X
, press ENTER .
The printer displays
PASSWORD
and the number
0000
.
2.
Enter the four-digit password for the password level displayed or for a higher level.
• The left and right arrows change the selected digit position.
• The up and down arrows change the value of the selected digit.
3.
After entering the password, press ENTER .
If you entered a valid password, additional parameters are displayed.
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48 Operations
Password Protection of Parameters
Note • When you enter a password at an
ADVANCED SETUP
prompt, the first parameter that you see is determined in part by whether you pressed the right arrow or the left arrow to get to the
ADVANCED SETUP
prompt:
• If you used the right arrow, the first parameter that you see is based on the password level that the printer prompted for (see
).
• If you used the left arrow, the first parameter that you see is based on which password you enter at the prompt, regardless of which password level the printer prompted for
(see
Table 9 • Right Arrow Used to Reach
ADVANCED SETUP
Prompt
Advanced
Setup Level
Prompted
3
4
1
2
Password
Level
Entered
1, 2, 3, or 4
2, 3, or 4
3 or 4
4
First Parameter Seen
DARKNESS
(top of level 1)
MEDIA TYPE
(top of level 2)
PRINT OUT
(top of level 3)
LABEL LEVEL
(top of level 4)
Table 10 • Left Arrow Used to Reach
ADVANCED SETUP
Prompt
Advanced
Setup Level
Prompted
1
1, 2
1, 2, 3
1, 2, 3, or 4
Password
Level
Entered
1
2
3
4
First Parameter Seen
LABEL TOP
(ZPL, EPL, APL-D)
(bottom of level 1)
Y FORMS ADJUST
(APL-I)
(bottom of level 1)
LENGTH
(bottom of level 2)
LANGUAGE
(bottom of level 3)
LANGUAGE
(bottom of level 4;
LANGUAGE
parameter appears in both level 3 and 4)
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Operations
Password Protection of Parameters
49
Changing Printer Passwords Using ZPL II
To change the password for any level, use the ^KP ZPL II command. The format is KPa,b where a is the password and b is the password level.
Password-Protect All Parameters. To password protect all parameters, send the
^KP ZPL II command with a different password for each level.
Disable Password To disable the password-protection feature for a particular level and those below it, set the password to 0000 using the ^KP ZPL II command. To enable the password-protection feature, send the ZPL II command with any non-zero number for a password.
Return to Default Passwords If you forget your passwords, the printer can be returned to the default factory settings, which makes the default passwords valid again. Use caution when returning the passwords to their default values because this also sets all other printer parameters back to their defaults.
To return the printer to the default factory settings using ZPL, send this command:
^XA
^JUF
^XZ
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50 Operations
Printing Configuration Labels
Printing Configuration Labels
After you load the media and ribbon (if necessary), print a printer configuration label and a network configuration label as records of your printer’s current settings. Keep the labels to use when troubleshooting printing problems. The options to print these labels are located in password level 3.
A configuration label lists the printer settings that are stored in configuration memory. A network configuration label lists the print server settings. For the correct settings, print a network configuration label after the printer connects to the network.
Note • If the printer is paused when you enter Setup mode, these labels will print after you exit
Setup mode and resume printing.
To print a printer configuration label or a network configuration label, complete these steps:
1.
On the control panel, press MENU .
The printer enters Setup mode and displays
DARKNESS
.
2.
Press the left arrow.
If a password is set for any levels, the printer displays
ADVANCED SETUP
with the level number, and the ENTER button is enabled. If no passwords are set, the printer displays
LANGUAGE
.
3.
What does the printer display?
If the printer displays...
Then...
ADVANCED SETUP 1
ADVANCED SETUP 2
ADVANCED SETUP 3
a.
b.
c.
d.
Press ENTER .
The printer displays
PASSWORD 0000
.
Use the left and right arrows to enter the password for level 3 or 4.
Press ENTER .
The printer displays
LANGUAGE
.
Use the left or right arrow to scroll through the parameters until you reach
PRINT OUT
.
ADVANCED SETUP 4
a.
You do not need to enter a password to access this parameter. Use the left or right arrow to scroll through the parameters until you reach
PRINT OUT
.
LANGUAGE
a.
Use the left or right arrow to scroll through the parameters until you reach
PRINT OUT
.
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Operations
Printing Configuration Labels
51
4.
Select the type of label to print.
To print a...
Then...
Printer configuration label a.
Scroll to
SETTINGS
.
b.
Press ENTER .
A printer configuration label prints ( Figure 23 ).
Figure 23 • Printer Configuration Label
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52 Operations
Printing Configuration Labels
To print a...
Then...
Network configuration label a.
Scroll to
NETWORK
.
b.
Press ENTER .
A network configuration label prints (
asterisk designates whether the wired or wireless print server is active. If no wireless print server is installed, the wireless portion of the label does not print.
Figure 24 • Network Configuration Label
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Operations
Select a Display Language
53
Select a Display Language
The
LANGUAGE
parameter is included in password level 3 and level 4 so you can easily reach the parameter to select a familiar language if you cannot read the one being displayed.
To change the language displayed, complete these steps:
1.
On the control panel, press MENU .
The printer enters Setup mode.
2.
Press the left arrow.
If a password is set for level 3 or 4, the printer displays
ADVANCED SETUP
with the level number, and the ENTER button is enabled. If no passwords are set for level 3 or 4, the printer displays
LANGUAGE
.
3.
What does the printer display?
If the printer displays...
Then...
ADVANCED SETUP 1
*
ADVANCED SETUP 2
*
ADVANCED SETUP 3
ADVANCED SETUP 4
*
* a.
b.
c.
LANGUAGE
*
* Displays in the last language selected.
Press ENTER .
The printer displays
PASSWORD 0000
*
.
Use the left and right arrows to enter the password for level 3 or 4.
Press ENTER .
The printer displays
LANGUAGE
*
.
Continue with the next step.
4.
Use the up and down arrows until you reach the language of your choice.
5.
Press MENU .
The printer prompts you to accept changes.
6.
Press ENTER to accept the language that you selected.
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54 Operations
Control Panel LCD Display
Control Panel LCD Display
Use the LCD display on the control panel to adjust printer settings.
Password Level 1 and 2 Parameters
Table 11 shows parameters in the order in which they appear when you press the right arrow
after entering Setup mode. Throughout this process, press the right arrow to continue to the next parameter or the left arrow to return to the previous parameter in the cycle.
Parameter
DARKNESS
Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 1 of 5)
(ZPL, APL-D, and APL-I modes)
DENSITY
(EPL mode only)
Explanation
Adjust Print Darkness
The best darkness setting depends on a variety of factors, including ribbon type, labels, and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.
Important • Set the darkness to the lowest setting that provides good print quality. If the darkness is set too high, the ink may smear, the ribbon may burn through, or the printhead may wear prematurely.
Note • The printer applies and saves the darkness setting immediately. Exiting Setup mode without saving changes does not restore the previous value.
If printing is too light or if there are voids in the printed areas, increase the darkness. If the printing is too dark or if there is spreading or bleeding of printed areas, decrease the darkness. Darkness settings also may be changed by the driver or software settings.
The
FEED Self Test on page 100 can be used to determine the best
darkness setting. Because the darkness setting takes effect immediately, you can see the results on labels that are currently printing.
Range (ZPL, APL-D, APL-I): 0.0 to +30.0
Default Value (ZPL, APL-D, APL-I): +10.0
Range (EPL): 7
Default Value (EPL): 0 to 15
To modify this parameter:
• Press the up arrow to increase value.
• Press the down arrow to decrease value.
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Operations
Control Panel LCD Display
55
Parameter
TEAR OFF
LABEL TOP
Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 2 of 5)
(ZPL, EPL, and APL-D modes)
X FORMS ADJUST
(APL-I mode only)
Y FORMS ADJUST
(APL-I mode only)
Explanation
Adjust Tear-Off Position
This parameter establishes the position of the labels over the tear-off/peel-off bar after printing. Each press of a button adjusts the tearoff position by one dot row.
Note • The printer applies and saves the tear-off setting immediately. Exiting Setup mode without saving changes does not restore the previous value.
Range (ZPL, EPL, APL-I): -120 to +120
Default Value (ZPL, EPL, APL-I): 0
Range (APL-D): +00i to +999i (inches), 0m to 2537m (metric)
Default Value (APL-D): +128i
Note • The APL-D default value does not position the label over the tear-off/peel-off bar. This is done to work with existing DPL label formats that account for this positioning.
To modify this parameter:
• Press the up arrow to increase value.
• Press the down arrow to decrease value.
Adjust Label Top Position
The label top position adjusts the print position vertically on the label.
Positive numbers adjust the label top position farther down the label (away from the printhead), and negative numbers adjust the position up the label
(toward the printhead).
The displayed value represents dots.
Range (ZPL, EPL, and APL-I): -120 to +120
Default Value (ZPL, EPL, and APL-I): 0
Range (APL-D): -0.64i to 0.64i (when printer is set to operate in inches)
Default Value (APL-D): 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Adjust Label Left Position
The label left position adjusts the print position horizontally on the label.
Positive numbers move the left edge of the image toward the center of the label by the number of dots selected while negative numbers shift the left edge of the image toward the left edge of the label.
Range: -120 to +120
Default Value: 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
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56 Operations
Control Panel LCD Display
Parameter
MEDIA TYPE
REMOVAL
Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 3 of 5)
SENSOR SELECT
Explanation
Set Media Type
Tells the printer which type of media you are using.
Selections:
• GAP/NOTCH—Use for non-continuous web media, non-continuous fanfold media, and tag stock.
• CONTINUOUS—Use for media that does not have divisions between labels.
• MARK—Use for non-continuous black mark media.
Default Value: GAP/NOTCH
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Select the Media Sensor
Use the setting that gives the best results. You can use the reflective sensor for most media.
• REFLECTIVE—Use with black mark media and most other media types.
• TRANSMISSIVE—Use with any media (other than black mark media) that does not work well with the reflective sensor.
To use the transmissive sensor with media that has holes or notches, verify that the holes or notches pass through the sensor so that the sensor can detect them. If the holes or notches do not pass through the sensor, use the reflective sensor.
Default Value: REFLECTIVE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Select the Label Removal Method
The label removal must correspond to the print mode. Be sure to select a label removal mode that your hardware configuration supports because some of the selections displayed are for optional printer features.
Selections: TEAR, PEEL, CUTTER, REWIND, DELAYED CUT
Default Value: TEAR
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Operations
Control Panel LCD Display
57
Parameter
Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 4 of 5)
PRINT SPEED
PRINT WIDTH
COMPAT. MODE
(APL-D mode only)
CONTROL CODES
(APL-D mode only)
Explanation
Adjust Print Speed
Adjusts the speed for printing a label (given in whole numbers of inches per second). Slower print speeds typically yield better print quality. Print speed changes take effect upon exiting Setup mode.
Range: 2 to 6 IPS
Default Value (ZPL, APL-I): 2 IPS
Default Value (EPL, APL-D): 6 IPS
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Set Print Width
Print width determines the printable area across the width of the label.
Important • Setting the width too narrow can result in portions of the label not being printed on the media. Setting the width too wide wastes formatting memory and can cause printing off the label and on the platen roller. This setting can affect the horizontal position of the label format if the image was inverted using the ^POI
ZPL II command.
Range: 2 to 832 for 8 dots/mm, 2 to 1248 for 12 dots/mm
Default Value: 832 for 8 dots/mm, 1248 for 12 dots/mm
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Set APL-D Compatibility Mode
Sets compatibility with DPL printers.
Selections: ON, OFF
Default Value: OFF
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Set APL-D Control Codes
Selections: STANDARD, MAINFRAME
Default Value: STANDARD
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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58 Operations
Control Panel LCD Display
LENGTH
Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 5 of 5)
Parameter
RESOLUTION
(APL-I mode only)
Explanation
Set Printer Resolution for APL-I
Sets the dot size for backward compatibility with some older APL-I printers.
Selections: 5 MIL, 10 MIL, 15 MIL
Default Value: 5 MIL
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Set Maximum Label Length
Maximum label length is used in conjunction with the calibration procedure. The value of this setting is the maximum label length that is used during the media portion of the calibration process. Only a few labels are required to set media sensors. Always set the value that is at least 1 in.
(25.4 mm) longer than the longest label to be used on the printer.
Selections:
AUTO
,
< 1 INCH
(25.4 mm) to
< 39 INCH
(991 mm)
Default Value:
AUTO
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
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Operations
Control Panel LCD Display
59
Password Level 3 Parameters
shows parameters in the order in which they appear when you press the right arrow after entering the Level 3 password. Throughout this process, press the right arrow to continue to the next parameter or the left arrow to return to the previous parameter in the cycle.
Parameter
PRINT OUT
MODULE A
Table 12 • Printer Parameters, Password Level 3 (Page 1 of 10)
(APL-D mode only)
Explanation
Print Selected Labels
This parameter allows you to print certain types of labels with information about the printer.
Selections:
•
SETTINGS
—Prints a printer configuration label. See Printing
Configuration Labels on page 50 .
•
•
FONTS
(ZPL, EPL, APL-D)—Prints a label that lists the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, Flash memory, optional memory cards, or font cards.
FORMATS
(ZPL, EPL, APL-D)—Prints a label that lists the available formats stored in the printer’s RAM, Flash memory, or optional memory card.
•
•
•
•
•
•
•
•
BARCODES
(ZPL only)—Prints a label that lists the available bar codes in the printer.
ALL
(ZPL, EPL)—Prints labels that list the available fonts, bar codes, images, formats, and the current printer and network configurations.
IMAGES
(ZPL, EPL, APL-D)—Prints a label that lists the images currently stored in the printer’s RAM, Flash memory, or optional memory cards.
NETWORK
(ZPL only)—Prints a network configuration label. See
Printing Configuration Labels on page 50
.
APLI SW SETUP
(APL-I only)
APLI HW SETUP
(APL-I only)
APLI PRT QUAL
(APL-I only)
APLI PITCH
(APL-I only)
To print labels:
1.
Press the up or down arrow to display label choices.
2.
Press ENTER to print the desired label.
Set Module A Storage Device for APL-D
Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2
Default Value: NONE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Parameter
MODULE B
(APL-D mode only)
PRINT PAGE
(APL-I mode only)
PRINT FORMAT
(APL-I mode only)
BAUD
Table 12 • Printer Parameters, Password Level 3 (Page 2 of 10)
PARALLEL COMM.
Explanation
Set Module B Storage Device for APL-D
Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2
Default Value: NONE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Set Parallel Communications
Select the communications port that matches the one being used by the host computer.
Selections: UNIDIRECTIONAL, BIDIRECTIONAL
Default Value: UNIDIRECTIONAL
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Print Stored APL-I Page
Up to 20 pages can be stored and printed.
Selections: 0 through 19
Default Value: 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Print Stored APL-I Format
Up to 100 formats can be stored and printed.
Selections: 0 through 99
Default Value: 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Set Baud
The baud setting of the printer must match the baud setting of the host computer for accurate communications to take place. Select the value that matches the one being used by the host computer.
Selections: 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800,
38400, 57600, 115200
Default Value: 9600
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Parameter
DATA BITS
Table 12 • Printer Parameters, Password Level 3 (Page 3 of 10)
Explanation
Set Data Bits
The data bits of the printer must match the data bits of the host computer for accurate communications to take place. Set the data bits to match the setting being used by the host computer.
Note • Code Page 850 requires the data bits to be set to 8 bits.
STATUS RESPONSE
(APL-I mode only)
RESPONSE FORMAT
(APL-I mode only)
PARITY
Selections: 7 BITS, 8 BITS
Default Value: 8 BITS
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Send APL-I Status Response
Determines if a response is sent after inquiry commands. The format is set with the
RESPONSE FORMAT
parameter.
Selections: ON, OFF
Default Value: ON
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Select APL-I Response Format
If
STATUS RESPONSE
is set to
ON
, this parameter determines the format of the response.
Selections: ASCII, BINARY
Default Value: ASCII
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Set Parity
The parity of the printer must match the parity of the host computer for accurate communications to take place. Select the parity that matches the one being used by the host computer.
Selections: NONE, ODD, EVEN
Default Value: NONE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Parameter
HOST HANDSHAKE
CONTROL CHAR
(ZPL mode only)
COMMAND CHAR
(ZPL mode only)
Table 12 • Printer Parameters, Password Level 3 (Page 4 of 10)
Explanation
Set Host Handshake
The handshake protocol of the printer must match the handshake protocol of the host computer for proper communications to take place. Select the handshake protocol that matches the one being used by the host computer.
Selections (ZPL, APL-D): XON/XOFF, DSR/DTR, RTS/CTS
Selections (EPL): DTR & XON/XOF, DTR, XON/XOFF
Selections (APL-I): XON/XOFF, DSR/DTR, RTS/CTS, APL-I
Default Value: XON/XOFF
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Set Control Character
The printer looks for this two-digit hexadecimal character to indicate the start of a ZPL/ZPL II control instruction.
Note • Do not use the same hexadecimal value for the control, command, and delimiter character. The printer must see different characters to work properly.
Range: 00 to FF
Default Value: 7E (tilde—displayed as an arrow)
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Set Command Character
The command prefix is a two-digit hexadecimal value used as a parameter place marker in ZPL/ZPL II format instructions. The printer looks for this two-digit hexadecimal character to indicate the start of a ZPL/ZPL II format instruction. See the ZPL II Programming Guide Volume I for more information.
Note • Do not use the same hexadecimal value for the control, command, and delimiter character. The printer must see different characters to work properly.
Range: 00 to FF
Default Value: 5E (caret)
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
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Parameter
DELIM. CHAR
(ZPL mode only)
HEXDUMP
Table 12 • Printer Parameters, Password Level 3 (Page 5 of 10)
(ZPL, EPL, APL-D modes)
CHANGE RTC DATE
Explanation
Set Delimiter Character
The delimiter character is a two-digit hexadecimal value used as a parameter place marker in ZPL/ZPL II format instructions. See the ZPL II
Programming Guide Volume I for more information.
Note • Do not use the same hexadecimal value for the control, command, and delimiter character. The printer must see different characters to work properly.
Range: 00 to FF
Default Value: 2C (comma)
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Hex Dump
The hexadecimal dump mode is a troubleshooting tool for checking the interconnection between the printer and the host computer. When
YES
is selected, all data sent from the host computer to the printer prints as straight ASCII characters, with the hexadecimal value below the ASCII text. The printer prints all characters received, including control codes, such as CR (carriage return). A sample printout is shown in
Communications Diagnostics Test on page 103 .
Selections: NO, YES
Default Value: NO
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Set RTC (Real-time clock) Date
If RTC is installed, this parameter allows you to set the RTC date.
Note • The printer saves the RTC date immediately.
To modify this parameter:
1.
Press ENTER .
The printer displays the current RTC date.
2.
Modify the values as follows:
• Press the right arrow to move to the next digit position.
• To increase the value, press the up arrow.
3.
• To decrease the value, press the down arrow.
Press ENTER to accept the value shown.
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Parameter
Table 12 • Printer Parameters, Password Level 3 (Page 6 of 10)
CHANGE RTC TIME
Explanation
Set RTC (Real-time clock) Time
If RTC is installed, this parameter allows you to set the RTC time.
Note • The printer saves the RTC time immediately.
LOAD DEFAULTS
INIT FLASH MEM
To modify this parameter:
1.
Press ENTER .
The printer displays the current RTC time.
2.
Modify the values as follows:
• Press the right arrow to move to the next digit position.
• To increase the value, press the up arrow.
3.
• To decrease the value, press the down arrow.
Press ENTER to accept the value shown.
Load Factory Defaults
Sets all parameters back to factory defaults.
Important • Use care when using this command. All printer parameters are reset to factory values with this command. If possible, print a configuration label to have as a record of the printer’s settings before loading defaults.
How to select this parameter:
1.
2.
Press ENTER .
The printer asks
ARE YOU SURE?
To load factory defaults, press ENTER to select
YES
. To cancel, press any other key.
Initialize Flash Memory
This parameter allows you to erase the printer’s Flash memory.
Important • The internal Flash memory is entirely erased with this command.
To select this parameter:
1.
Press ENTER to select
YES
.
The printer asks
ARE YOU SURE?
2.
To initialize Flash memory, press ENTER . To cancel, press any other key.
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Parameter
RIBBON
ZPL OVERRIDE
(ZPL mode only)
EPL OVERRIDE
(EPL mode only)
Table 12 • Printer Parameters, Password Level 3 (Page 7 of 10)
Explanation
Set Ribbon Use
Note • This parameter appears only for printers that have the
Thermal Transfer option installed.
Specifies the printing method: thermal transfer (using ribbon) or direct thermal (no ribbon).
Selections:
• YES (thermal transfer mode, with ribbon)
• NO (direct thermal mode, no ribbon)
Default Value: YES
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Override Certain ZPL Commands
Prevents the printer from accepting the following ZPL commands:
•
•
^MM
^MT
(media mode)
(media type direct thermal or thermal transfer)
• ^MN (media non-continuous or continuous)
Selections:
• NO—allows the printer to accept the listed ZPL commands.
• YES—tells the printer to ignore the listed ZPL commands.
Default Value: NO
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Override Certain EPL Commands
Prevents the printer from accepting certain EPL commands.
Selections:
• DISABLED—allows the printer to accept the listed EPL commands.
• ENABLED—tells the printer to ignore the listed EPL commands.
Default Value: DISABLED
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Parameter
Table 12 • Printer Parameters, Password Level 3 (Page 8 of 10)
SENSOR PROFILE
Explanation
Print Sensor Profile
Use the sensor profile ( Figure 25 ) to troubleshoot registration problems
that may occur if the media sensor detects preprinted areas on the media or if it experiences difficulty in determining web location. To adjust the sensitivity of the media and/or ribbon sensors, use
Note • The ribbon portion of the label appears only for printers that have the Thermal Transfer option installed.
Figure 25 • Sensor Profile
To select this parameter:
1.
Press ENTER to start this standard calibration procedure and print a media sensor profile.
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Table 12 • Printer Parameters, Password Level 3 (Page 9 of 10)
Parameter
MEDIA/RIBBON
CALIBRATE
(Thermal Transfer only)
MEDIA CALIBRATE
(Direct Thermal only)
Explanation
Calibrate Media and Ribbon Sensors
Use this procedure to adjust the sensitivity of the printer’s sensors. In a printer that has the Thermal Transfer option installed, both media and ribbon sensors are adjusted. In a Direct Thermal printer (no Thermal
Transfer option installed), only media sensors are adjusted, and the LCD displays for ribbon do not appear in this procedure.
Important • This procedure must be followed exactly as presented.
All of the steps must be performed even if only one of the sensors requires adjustment. You may press the left arrow at any step in this procedure to cancel the procedure.
How to select this parameter:
1.
2.
3.
Press ENTER to start the calibration procedure.
The
LOAD BACKING/REMOVE RIBBON
prompt displays.
Open the printhead.
Remove approximately 8 in. (203 mm) of labels from the backing, and pull the media into the printer so that only the backing is between the media sensors.
4.
5.
6.
7.
8.
Remove the ribbon (if used).
Press the right arrow to continue.
The message
CALIBRATING PLEASE WAIT
displays.
The printer adjusts the scale (gain) of the signals that it receives from the media and ribbon sensors. On the sensor profile, this essentially corresponds to moving the peak of the graph up or down to optimize the readings for your application.
RELOAD ALL
displays.
Reload the media and ribbon (if used).
Close the printhead.
Press the right arrow to continue.
The message
CALIBRATING PLEASE WAIT
displays.
The printer does a calibration; during this process, the printer determines the label length. To see the new readings on the new scale, print a sensor profile.
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Parameter
LANGUAGE
Table 12 • Printer Parameters, Password Level 3 (Page 10 of 10)
Explanation
Select the Display Language
This parameter allows you to display the control panel in the language of your choice. As soon as you select a language, all parameters are displayed in that language. Save changes as you exit Setup mode to save the language setting.
(
Selections: English (
ENGLISH
), Spanish (
ESPANOL
), French
FRANCAIS
), German (
Deutsch
), Italian (
ITALIANO
), Norwegian
(
NORSK
), Portuguese (
PORTUGUES
), Swedish (
SVENSKA
), Danish
(
DANSK
), Spanish2 (
ESPANOL2
), Dutch (
NEDERLANDS
), Finnish
(
SUOMI
), and Japanese.
Default Value: ENGLISH
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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ZebraNet
®
Wired and Wireless Print Server LCD Displays
The menu options shown in
display only if you have the ZebraNet PrintServer II, or
10/100 PrintServer, or Wireless Print Server installed and are operating in ZPL or EPL mode.
These parameters are considered part of Level 3.
CHANGE SUBNET
Table 13 • Print Server LCD Displays (Page 1 of 2)
Parameter
OBTAIN IP ADDRESS
CHANGE IP ADDRESS
Explanation
Obtain an IP Address
Selects the method by which an IP address will be assigned to the printer.
Selections: AUTO SELECT (dynamic), PERMANENT (user-specified)
Default Value: AUTO SELECT
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Change the Printer’s IP Address
This parameter can be modified only when
PERMANENT
is selected for
OBTAIN IP ADDRESS
.
Selections: 0 to 255 for each field
Default Value: 0.0.0.0
Note • Leading zeroes are not shown in the address. If an IP address contains more digits than can be displayed at one time, use the left or right arrows to scroll through the digits.
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Change the Subnet
This parameter can be modified only when
PERMANENT
is selected for
OBTAIN IP ADDRESS
.
Selections: 0 to 255 for each field
Default Value: 0.0.0.0
Note • Leading zeroes are not shown in the address. If an IP address contains more digits than can be displayed at one time, use the left or right arrows to scroll through the digits.
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
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Parameter
CHANGE GATEWAY
Table 13 • Print Server LCD Displays (Page 2 of 2)
CHANGE IP PROTOCOL
Explanation
Change the Gateway
This parameter can be modified only when PERMANENT is selected for
OBTAIN IP ADDRESS
.
Selections: 0 to 255 for each field
Default Value: 0.0.0.0
Note • Leading zeroes are not shown in the address. If an IP address contains more digits than can be displayed at one time, use the left or right arrows to scroll through the digits.
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Change the IP Protocol
Determines the method(s) by which the print server (wired or wireless) receives the IP address from the server.
This parameter can be modified only when
AUTO SELECT
is selected for
OBTAIN IP ADDRESS
.
Selections: ALL, GLEANING ONLY, RARP, BOOTP, DHCP,
DHCP AND BOOT
Default Value: ALL
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Password Level 4 Parameters
shows parameters in the order in which they appear when you press the right arrow after entering the level 4 password. Throughout this process, press the right arrow to continue to the next parameter or the left arrow to return to the previous parameter in the cycle.
Parameter
LABEL LEVEL
PAPER OUT
PAPER GAIN
RIBBON OUT
RIBBON GAIN
Table 14 • Printer Parameters, Password Level 4 (Page 1 of 3)
Explanation
Adjust Label Level
Range: 0 to 100
Default Value: 50
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Adjust Paper Out
Range: 0 to 100
Default Value: 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Adjust Paper Gain
Range: 0 to 255
Default Value: calibrated value
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Adjust Ribbon-Out Threshold
Range: 0 to 100
Default Value: calibrated value
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Adjust the Ribbon Gain Sensor
Range: 0 to 255
Default Value: calibrated value
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
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Parameter
TAKE LABEL
HEAD CLOSE
Table 14 • Printer Parameters, Password Level 4 (Page 2 of 3)
MEDIA POWER UP
Explanation
Adjust the Peel Sensor
This parameter appears only if the Peel option is installed.
Range: 0 to 100
Default Value: 66
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Select Media Power-Up Option
This parameter sets the action of the media when you turn on the printer.
Selections: CALIBRATION, LENGTH, SHORT CAL, NO MOTION,
FEED
Default Value: CALIBRATION
• Calibration—determines the length of the label and adjusts the sensor settings.
• Length—In continuous mode, feeds the last stored label length. In noncontinuous mode, calibrates based on the maximum label length setting (see
Set Maximum Label Length on page 58
).
• Short Cal—calibrates label length using the current sensor settings.
• No Motion—the media does not move. Press FEED to cause the printer to resynchronize to the start of the next label.
• Feed—feeds the labels to the first registration point.
To modify this parameter:
• Press the up or down arrow to display other choices.
Select Head Close Option
This parameter sets the action of the media when you close the printhead.
Selections: CALIBRATION, LENGTH, SHORT CAL, NO MOTION,
FEED
Default Value: CALIBRATION
• Calibration—determines the length of the label and adjusts the sensor settings.
• Length—In continuous mode, feeds the last stored label length. In noncontinuous mode, calibrates based on the maximum label length setting (see
Set Maximum Label Length on page 58
).
• Short Cal—calibrates label length using the current sensor settings.
• No Motion—the media does not move. Press FEED to cause the printer to resynchronize to the start of the next label.
• Feed—feeds the labels to the first registration point.
To modify this parameter:
• Press the up or down arrow to display other choices.
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Parameter
LANGUAGE
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Table 14 • Printer Parameters, Password Level 4 (Page 3 of 3)
Explanation
Select the Display Language
This parameter allows you to display the control panel in the language of your choice. As soon as you select a language, all parameters are displayed in that language. Save changes as you exit Setup mode to save the language setting.
Selections:
ENGLISH
, Spanish (
ESPANOL
), French (
FRANCAIS
),
German (
Deutsch
), Italian (
ITALIANO
), Norwegian (
NORSK
),
Portuguese (
PORTUGUES
), Swedish (
SVENSKA
), Danish (
DANSK
),
Spanish2 (
ESPANOL2
), Dutch (
NEDERLANDS
), Finnish (
SUOMI
), and
Japanese.
Default Value: ENGLISH
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Manufacturing Menu Parameters
The manufacturing menu is designed to simplify and speed up configuration changes by providing access to certain parameters from all password levels. For some parameters (such as
DARKNESS
or
DENSITY
), changes are saved immediately. For the remaining parameters, changes are saved automatically when you exit the manufacturing menu.
To access the manufacturing menu, complete these steps:
1.
Turn Off ( O ) the printer.
2.
Press and hold the up arrow.
3.
Turn On ( I ) the printer. Continue holding the up arrow until the printer displays
PRINTER
READY
.
4.
Release the up arrow.
5.
Press MENU .
The printer displays the parameters in the manufacturing menu. Table 15 shows
parameters in the order in which they appear when you press the right arrow. Throughout this process, press the right arrow to continue to the next parameter or the left arrow to return to the previous parameter in the cycle.
6.
To exit from the manufacturing menu, press MENU.
The printer saves changes and returns to the
PRINTER READY
display.
7.
To return to normal printer operation, turn the printer Off ( O ) and then back On ( I ).
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Parameter
PRINT OUT
Table 15 • Printer Parameters, Manufacturing Menu (Page 1 of 7)
Explanation
Print Selected Labels
This parameter allows you to print certain types of labels with information about the printer.
Selections:
•
SETTINGS
—Prints a printer configuration label. See Printing
Configuration Labels on page 50 .
•
FONTS
(ZPL, EPL, APL-D)—Prints a label that lists the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, Flash memory, optional memory cards, or font cards.
•
•
FORMATS
(ZPL, EPL, APL-D)—Prints a label that lists the available formats stored in the printer’s RAM, Flash memory, or optional memory card.
BARCODES
(ZPL only)—Prints a label that lists the available bar codes in the printer.
•
•
•
•
•
•
•
ALL
(ZPL, EPL)—Prints labels that list the available fonts, bar codes, images, formats, and the current printer and network configurations.
IMAGES
(ZPL, EPL, APL-D)—Prints a label that lists the images currently stored in the printer’s RAM, Flash memory, or optional memory cards.
NETWORK
(ZPL only)—Prints a network configuration label. See
Printing Configuration Labels on page 50
.
APLI SW SETUP
(APL-I only)
APLI HW SETUP
(APL-I only)
APLI PRT QUAL
(APL-I only)
APLI PITCH
(APL-I only)
To print labels:
1.
Press the up or down arrow to display label choices.
2.
Press ENTER to print the desired label.
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Parameter
Table 15 • Printer Parameters, Manufacturing Menu (Page 2 of 7)
SENSOR PROFILE
Explanation
Print Sensor Profile
Use the sensor profile ( Figure 25 ) to troubleshoot registration problems
that may occur if the media sensor detects preprinted areas on the media or if it experiences difficulty in determining web location. To adjust the sensitivity of the media and/or ribbon sensors, use
Note • The ribbon portion of the label appears only for printers that have the Thermal Transfer option installed.
Figure 26 • Sensor Profile
To select this parameter:
1.
Press ENTER to start this standard calibration procedure and print a media sensor profile.
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Parameter
DARKNESS
(ZPL, APL-D, and APL-I modes)
DENSITY
(EPL mode only)
Table 15 • Printer Parameters, Manufacturing Menu (Page 3 of 7)
Explanation
Adjust Print Darkness
The best darkness setting depends on a variety of factors, including ribbon type, labels, and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.
Important • Set the darkness to the lowest setting that provides good print quality. If the darkness is set too high, the ink may smear, the ribbon may burn through, or the printhead may wear prematurely.
Note • The printer applies and saves the darkness setting immediately.
TEAR OFF
If printing is too light or if there are voids in the printed areas, increase the darkness. If the printing is too dark or if there is spreading or bleeding of printed areas, decrease the darkness. Darkness settings also may be changed by the driver or software settings.
The
FEED Self Test on page 100 can be used to determine the best
darkness setting. Because the darkness setting takes effect immediately, you can see the results on labels that are currently printing.
Range (ZPL, APL-D, APL-I): 0.0 to +30.0
Default Value (ZPL, APL-D, APL-I): +10.0
Range (EPL): 7
Default Value (EPL): 0 to 15
To modify this parameter:
• Press the up arrow to increase value.
• Press the down arrow to decrease value.
Adjust Tear-Off Position
This parameter establishes the position of the labels over the tear-off/peel-off bar after printing. Each press of a button adjusts the tearoff position by one dot row.
Note • The printer applies and saves the tear-off setting immediately. Exiting Setup mode without saving changes does not restore the previous value.
Range (ZPL, EPL, APL-I): -120 to +120
Default Value (ZPL, EPL, APL-I): 0
Range (APL-D): +00i to +999i (inches), 0m to 2537m (metric)
Default Value (APL-D): +128i
Note • The APL-D default value does not position the label over the tear-off/peel-off bar. This is done to work with existing DPL label formats that account for this positioning.
To modify this parameter:
• Press the up arrow to increase value.
• Press the down arrow to decrease value.
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Parameter
MEDIA TYPE
REMOVAL
Table 15 • Printer Parameters, Manufacturing Menu (Page 4 of 7)
SENSOR SELECT
Explanation
Set Media Type
Tells the printer which type of media you are using.
Selections:
• GAP/NOTCH—Use for non-continuous web media, non-continuous fanfold media, and tag stock.
• CONTINUOUS—Use for media that does not have divisions between labels.
• MARK—Use for non-continuous black mark media.
Default Value: GAP/NOTCH
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Select the Media Sensor
Use the setting that gives the best results. You can use the reflective sensor for most media.
• REFLECTIVE—Use with black mark media and most other media types.
• TRANSMISSIVE—Use with any media (other than black mark media) that does not work well with the reflective sensor.
To use the transmissive sensor with media that has holes or notches, verify that the holes or notches pass through the sensor so that the sensor can detect them. If the holes or notches do not pass through the sensor, use the reflective sensor.
Default Value: REFLECTIVE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
Select the Label Removal Method
The label removal must correspond to the print mode. Be sure to select a label removal mode that your hardware configuration supports because some of the selections displayed are for optional printer features.
Selections: TEAR, PEEL, CUTTER, REWIND, DELAYED CUT
Default Value: TEAR
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
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Operations
Control Panel LCD Display
79
Parameter
LENGTH
LCD ADJUST
Table 15 • Printer Parameters, Manufacturing Menu (Page 5 of 7)
Explanation
Set Maximum Label Length
Maximum label length is used in conjunction with the calibration procedure. The value of this setting is the maximum label length that is used during the media portion of the calibration process. Only a few labels are required to set media sensors. Always set the value that is at least 1 in.
(25.4 mm) longer than the longest label to be used on the printer.
Selections:
AUTO
,
< 1 INCH
(25.4 mm) to
< 39 INCH
(991 mm)
Default Value:
AUTO
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Change LCD Darkness
This parameter changes the darkness of characters on the LCD.
Range: 0 to 19
Default Value: 10
To modify this parameter:
• To make the characters on the LCD darker, press the up arrow.
• To make the characters on the LCD lighter, press the down arrow.
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80 Operations
Control Panel LCD Display
TAKE LABEL
Table 15 • Printer Parameters, Manufacturing Menu (Page 6 of 7)
Parameter
MEDIA/RIBBON
CALIBRATE
(Thermal Transfer only)
MEDIA CALIBRATE
(Direct Thermal only)
Explanation
Calibrate Media and Ribbon Sensors
Use this procedure to adjust the sensitivity of the printer’s sensors. In a printer that has the Thermal Transfer option installed, both media and ribbon sensors are adjusted. In a Direct Thermal printer (no Thermal
Transfer option installed), only media sensors are adjusted, and the LCD displays for ribbon do not appear in this procedure.
Important • This procedure must be followed exactly as presented.
All of the steps must be performed even if only one of the sensors requires adjustment. You may press the left arrow at any step in this procedure to cancel the procedure.
How to select this parameter:
1.
2.
3.
Press ENTER to start the calibration procedure.
The
LOAD BACKING/REMOVE RIBBON
prompt displays.
Open the printhead.
Remove approximately 8 in. (203 mm) of labels from the backing, and pull the media into the printer so that only the backing is between the media sensors.
4.
5.
6.
7.
8.
Remove the ribbon (if used).
Press the right arrow to continue.
The message
CALIBRATING PLEASE WAIT
displays.
The printer adjusts the scale (gain) of the signals that it receives from the media and ribbon sensors. On the sensor profile, this essentially corresponds to moving the peak of the graph up or down to optimize the readings for your application.
RELOAD ALL
displays.
Reload the media and ribbon (if used).
Close the printhead.
Press the right arrow to continue.
The message
CALIBRATING PLEASE WAIT
displays.
The printer does a calibration; during this process, the printer determines the label length. To see the new readings on the new scale, print a sensor profile.
Adjust the Peel Sensor
This parameter appears only if the Peel option is installed.
Range: 0 to 100
Default Value: 66
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
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Operations
Control Panel LCD Display
81
Parameter
LOAD DEFAULTS
HEAD OPEN
Table 15 • Printer Parameters, Manufacturing Menu (Page 7 of 7)
DIRECT-THERMAL
Explanation
Load Factory Defaults
Sets all parameters back to factory defaults.
Important • Use care when using this command. All printer parameters are reset to factory values with this command. If possible, print a configuration label to have as a record of the printer’s settings before loading defaults.
How to select this parameter:
1.
2.
Press ENTER .
The printer asks
ARE YOU SURE?
To load factory defaults, press ENTER to select
YES
. To cancel, press any other key.
Show Printhead Status
This menu item provides visual feedback for the adjustment of the head open sensor. If the printhead is open,
OPEN
displays. If the printhead is closed,
CLOSED
displays. This value cannot be changed through the control panel.
Select Direct-Thermal Configuration
Direct-Thermal Only mode is a factory configuration setting for printers that are built without a ribbon handling system. Changing this parameter from
NO
to
YES
changes the printer configuration to Direct-Thermal Only operation after the printer power is cycled.
Selections:
• NO—The printer has a ribbon system and should not operate in
Direct-Thermal Only mode.
• YES—The printer does not have a ribbon system and must operate in
Direct-Thermal Only mode.
Default Value: NO
To modify this parameter:
1.
2.
Press the up or down arrow to toggle between the selections.
If you changed to
NO
: a.
Load printer defaults (see Load Factory Defaults on page 64
) to enable the ribbon handling system.
3.
b.
Perform media and ribbon calibration (see
Turn the printer power Off ( O ) and then back On ( I ).
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82 Operations
Control Panel LCD Display
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
3
Troubleshooting
10/27/05
This section provides information about LCD, print quality, communications, and other errors that you might need to troubleshoot. The tables provide symptoms, diagnoses of probable causes, and recommended actions that should result in proper printer operation. Working with these tables, the technician can diagnose printer faults and determine the needed repair.
Contents
S4M Maintenance Manual 13291L-001 Rev. A
84 Troubleshooting
General
General
Consult the troubleshooting tables in this section if you encounter a problem.
If you encounter a problem that you cannot correct with the aid of this manual, contact Zebra’s
Technical Support immediately to avoid or minimize printer downtime. Technical Support also can determine if the printer should be returned for repair.
Technical Support via the Internet is available 24 hours per day, 365 days per year. Go to http://www.zebra.com/support .
The Americas
Regional Headquarters
Zebra Technologies International,
LLC
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061.3109
U.S.A
T: +1 847 793 2600
Toll-free +1 800 423 0422
F: +1 847 913 8766
Technical Support
T: +1 847 913 2259
F: +1 847 913 2578
Hardware: [email protected]
Software: [email protected]
Customer Service Dept.
For printers, parts, media, and ribbon, please call your distributor, or contact us.
T: +1 866 230 9494
Europe, Africa, Middle East, and India
Regional Headquarters
Zebra Technologies Europe Limited
Zebra House
The Valley Centre, Gordon Road
High Wycombe
Buckinghamshire HP13 6EQ, UK
T: +44 (0)1494 472872
F: +44 (0) 1494 450103
Technical Support
T: +44 (0) 1494 768298
F: +44 (0) 1494 768210
Germany: [email protected]
France: [email protected]
Spain/Portugal: [email protected]
All other areas: [email protected]
Internal Sales Dept.
For printers, parts, media, and ribbon, please call your distributor, or contact us.
T: +44 (0) 1494 768316
F: +44 (0) 1494 768244
Asia Pacific
Regional Headquarters
Zebra Technologies Asia Pacific, LLC
16 New Industrial Road
#05-03 Hudson TechnoCentre
Singapore 536204
T: +65 6858 0722
F: +65 6885 0838
Technical Support
T: +65 6858 0722
F: +65 6885 0838
Customer Service
For printers, parts, media, and ribbon, please call your distributor, or contact us.
T: +65 6858 0722
F: +65 6885 0837
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Troubleshooting
Troubleshooting Checklists
85
Troubleshooting Checklists
If an error condition exists with the printer, review this checklist:
‰ Is there an error message on the LCD? If yes, see LCD Error Messages on page 86 .
‰ Did you receive a memory error? If yes, see
.
‰ Are noncontinuous labels being treated as continuous labels? If yes, see
and Ribbon Sensors on page 67 .
‰ Is the CHECK RIBBON light on when ribbon is loaded properly, or are noncontinuous labels being treated as continuous labels? If yes, see
Calibrate Media and Ribbon Sensors on page 67
.
‰ Are you experiencing problems with print quality? If yes, see
Print Quality Problems on page 90 .
‰ Are you experiencing communications problems? If yes, see
Communications Problems on page 94 .
If the labels are not printing or advancing correctly, review this checklist:
‰ Are you using the correct type of labels? Review the types of label in
.
.
‰ Does the printhead need to be adjusted? See
Adjust Printhead Pressure on page 44 for
more information.
‰ Do the sensors need to be calibrated? See Calibrate Media and Ribbon Sensors on page 67
for more information.
If none of the above suggestions correct the problem, review this checklist:
‰ Perform one or more of the self-tests given in
Printer Diagnostics on page 97
. Use the results to help identify the problem.
‰ If you are still having problems, see
for customer support information.
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86 Troubleshooting
LCD Error Messages
LCD Error Messages
The LCD displays messages when there is an error. See
for LCD errors, the possible causes, and the recommended solutions.
Table 16 • LCD Error Messages
LCD Display/
Printer Condition
ALERT
RIBBON OUT
The printer stops and the
ALERT light flashes.
Possible Cause Recommended Solution
In thermal transfer mode, ribbon is not loaded or incorrectly loaded.
In thermal transfer mode, the ribbon sensor is not detecting ribbon that is loaded incorrectly.
In thermal transfer mode, media is blocking the ribbon sensor.
In thermal transfer mode, the printer did not detect the ribbon even though it is loaded correctly.
Load ribbon correctly.
1.
Load ribbon correctly.
2.
Calibrate the sensors. See
.
1.
Load media correctly.
2.
Calibrate the sensors. See
.
1.
Print a sensor profile.See Print
Sensor Profile on page 66 . The
ribbon out threshold (marked by the word RIBBON ) is likely too high, above the black area that indicates where the ribbon is detected.
13291L-001 Rev. A
If you are using direct thermal media, the printer is waiting for ribbon to be loaded because it is incorrectly set for thermal transfer mode.
2.
Calibrate the sensors or load
printer defaults. See Calibrate
Media and Ribbon Sensors on page 67
.
Set the printer for Direct Thermal mode. See
S4M Maintenance Manual 10/27/05
Troubleshooting
LCD Error Messages
87
LCD Display/
Printer Condition
WARNING
RIBBON IN
The ALERT light flashes.
ALERT
PAPER OUT
The printer stops and the
ALERT light flashes.
ALERT
HEAD OPEN
The printer stops and the
ALERT light flashes.
WARNING
HEAD TOO HOT
The printer stops and the
ALERT light flashes.
Table 16 • LCD Error Messages (Continued)
Possible Cause Recommended Solution
Ribbon is loaded, but the printer is set for direct thermal mode.
Ribbon is not required with direct thermal media. If you are using direct thermal media, remove ribbon unless you are using it to protect the printhead. This error message will not affect printing.
If you are using thermal transfer media, which requires ribbon, set the printer for Thermal Transfer mode. See
Load media correctly. Media is not loaded or is loaded incorrectly.
Misaligned media sensor.
The printer is set for noncontinuous media, but continuous media is loaded.
The printhead is not fully closed.
The head open sensor is not working properly.
Check position of the media sensor.
Install proper media type, or reset printer for current media type and perform calibration.
Close printhead completely.
Replace the sensor.
Caution • The printhead may be hot enough to cause severe burns. Allow the printhead to cool.
Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
The printhead is over temperature.
Allow the printer to cool. Printing automatically resumes when the printhead elements cool to an acceptable operating temperature.
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88 Troubleshooting
LCD Error Messages
LCD Display/
Printer Condition
WARNING
HEAD COLD
The printer stops and the
ALERT light flashes.
HEAD ELE. BAD
The printer stops.
Table 16 • LCD Error Messages (Continued)
Possible Cause Recommended Solution
Caution • An improperly connected printhead data or power cable can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool.
Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
The printhead is under temperature.
Continue printing while the printhead reaches the correct operating temperature. If the error remains, the environment may be too cold for proper printing. Relocate the printer to a warmer area.
The printhead data cable is not properly connected.
Caution • Turn off (O) the printer before performing this procedure. Failure to do so can damage the printhead.
1.
Turn Off ( O ) the printer.
2.
Disconnect and reconnect the data cable to the printhead.
3.
Ensure that the cable connector is fully inserted into the printhead connector.
4.
Turn on ( I ) the printer.
Caution • The printhead may be hot enough to cause severe burns. Allow the printhead to cool.
Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
The printhead is not installed.
The printhead data cable is not connected.
The printhead is bad.
Caution • Turn off (O) the printer before performing this procedure. Failure to do so can damage the printhead.
1.
Turn Off ( O ) the printer.
2.
Disconnect and reconnect the data cable to the printhead.
3.
Ensure that the cable connector is fully inserted into the printhead connector.
4.
Turn on ( I ) the printer.
5.
If the problem persists, replace the printhead.
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Troubleshooting
Memory Errors
89
Memory Errors
The memory errors in
indicate that the printer does not have enough memory to perform the function shown on the second line of the LCD.
Problem/LCD Display
OUT OF MEMORY
CREATING BITMAP
OUT OF MEMORY
STORING BITMAP
OUT OF MEMORY
BUILDING FORMAT
OUT OF MEMORY
STORING FORMAT
OUT OF MEMORY
STORING GRAPHIC
OUT OF MEMORY
STORING FONT
Table 17 • Memory Errors
Possible Cause
Creating Bitmap
The bitmap size (label length/width) does not fit in available memory.
Storing Bitmap
Not enough memory is available to store the bitmap created.
Building Format
Label is too complex.
Storing Format
Format is too large to fit in available memory.
Storing Graphic
The graphic image is too large to fit in available memory.
Storing Font
Not enough memory available to store the font.
Recommended Solution
You may do any of the following:
• Press PAUSE . Send a ~HM ZPL command to the printer to display the amount of free memory. Then redesign the graphic/format to fit available memory, or remove items from memory to create more space.
• Press PAUSE to skip the formatting step in process and proceed to the next step.
With the printer paused, press CANCEL .
The printer skips the current label formatting process and goes to the next label.
• Turn the printer Off (O) and then On ( I ) to clear the printer’s memory.
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90 Troubleshooting
Print Quality Problems
Print Quality Problems
identifies problems with print quality, the possible causes, and the recommended solutions.
Table 18 • Print Quality Problems
Problem
General print quality issues
Wrinkled ribbon
Possible Cause
The printer is set at the incorrect print speed.
You are using an incorrect combination of labels and ribbon for your application.
The printer is set at an incorrect darkness level.
The printhead is dirty.
Ribbon fed through the machine incorrectly.
Incorrect burn temperature.
Recommended Solution
For optimal print quality, set the print speed to the lowest possible setting for your application
via control panel, the driver, or the software. See
Adjust Print Speed on page 57 . You may wish to
perform the
.
1.
Switch to a different type of media or ribbon to try to find a compatible combination.
2.
If necessary, consult your authorized Zebra reseller or distributor for information and advice.
For optimal print quality, set the darkness to the lowest possible setting for your application via
the control panel, the driver, or the software. See
Adjust Print Darkness on page 54
. You may wish
to perform the FEED Self Test on page 100
to determine the ideal darkness setting.
Clean the printhead according to the instructions
in Clean the Printhead and Platen Roller on page 113 .
Caution • The printhead may be hot enough to cause severe burns. Allow the printhead to cool.
Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
See
Incorrect or uneven pressure.
Media not feeding properly;
“walking” from side to side.
Print element damaged.
Set the darkness to the lowest possible setting for
good print quality. See Adjust Print Darkness on page 54
.
Set the pressure to the minimum needed for good print quality. See
Adjust Printhead Pressure on page 44
.
Make sure that media is snug by adjusting the media guide, or call a service technician.
Replace the printhead.
Long tracks of missing print on several labels Wrinkled ribbon.
See wrinkled ribbon causes and solutions in this table.
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Troubleshooting
Print Quality Problems
91
Table 18 • Print Quality Problems (Continued)
Problem
Fine, angular gray lines on blank labels
Printing too light or too dark over the entire label
Smudge marks on labels
Misregistration/skips labels
Misregistration and misprint of one to three labels
Vertical drift in top-of-form position
Possible Cause Recommended Solution
Wrinkled ribbon.
Media or ribbon is not designed for high-speed operation.
You are using an incorrect combination of labels and ribbon for your application.
You are using ribbon with direct thermal media.
Incorrect or uneven printhead pressure.
Media or ribbon is not designed for high-speed operation.
The printer is not calibrated.
See wrinkled ribbon causes and solutions in this table.
Replace supplies with those recommended for high-speed operation.
1.
Switch to a different type of media or ribbon to try to find a compatible combination.
2.
If necessary, consult your authorized Zebra reseller or distributor for information and advice.
Direct thermal media does not require ribbon. To check if you are using direct thermal media,
perform the label scratch test in When to Use
If you are using ribbon intentionally with direct thermal media, increase the darkness level, but note that high darkness levels may decrease printhead life. You may wish to perform the
to determine the ideal darkness setting.
Set the pressure to the minimum needed. See
Adjust Printhead Pressure on page 44 .
Replace supplies with those recommended for high-speed operation.
Recalibrate the printer.
Improper label format.
The platen roller is dirty.
Use correct label format.
See
Clean the Printhead and Platen Roller on page 113 .
Use media that meets specifications.
Media does not meet specifications.
Normal tolerances of mechanical parts and printer modes.
Note • A vertical drift of
± 4 to 6 dot rows
(approximately 0.5 mm) is within normal tolerances.
1.
Calibrate the printer.
2.
Adjust the label top position setting. See
Adjust Label Top Position on page 55 .
The printer is out of calibration.
Recalibrate the printer.
The platen roller is dirty.
See
Clean the Printhead and Platen Roller on page 113 .
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92 Troubleshooting
Print Quality Problems
Table 18 • Print Quality Problems (Continued)
Problem
Vertical image or label drift
The bar code printed on a label does not scan.
Possible Cause
The printer is using noncontinuous labels but is configured in continuous mode.
Improperly calibrated media sensor.
The platen roller is dirty.
Improper printhead pressure settings (toggles).
Improperly loaded ribbon or media.
Incompatible media.
Recommended Solution
Configure the printer for non-continuous and run calibration routine, if necessary.
See
Calibrate Media and Ribbon Sensors on page 67
.
Clean the platen roller. See Clean the Printhead and Platen Roller on page 113 .
Adjust the printhead pressure to ensure proper functionality.
Verify that the printer is loaded properly.
The bar code is not within specifications because the print is too light or too dark.
Not enough blank space around the bar code.
Ensure that the interlabel gaps or notches are 2 to
4 mm and consistently placed. Media must not exceed minimum specifications for mode of operation.
Perform the FEED Self Test on page 100 . Adjust
the darkness or print speed settings as necessary.
Leave at least 1/8 in. (3.2 mm) between the bar code and other printed areas on the label and between the bar code and the edge of the label.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Troubleshooting
Calibration Problems
93
Calibration Problems
identifies problems with calibration, the possible causes, and the recommended solutions.
Table 19 • Calibration Problems
Problem
Loss of printing registration on labels.
Excessive vertical drift in top-of-form registration.
Possible Cause
Improperly positioned media guides.
Media type set incorrectly.
Incorrect sensor being used for the media type.
Dirty platen roller.
Auto Calibrate failed.
Improperly loaded media or ribbon.
The sensors could not detect the media or ribbon.
Sensors dirty or media improperly positioned for the sensors to detect.
Recommended Solution
Ensure that the media guides are properly positioned.
Set the printer for the correct media type
(gap/notch, continuous, or mark). See Set Media
.
Manually select the correct sensor to use. See
Select the Media Sensor on page 56 .
Clean the platen roller according to the instructions in
Clean the Printhead and Platen
Ensure that media and ribbon are loaded correctly.
Manually calibrate the printer (see
Media and Ribbon Sensors on page 67
).
Ensure that the sensors are clean and that media is positioned properly.
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
94 Troubleshooting
Communications Problems
Communications Problems
identifies problems with communications, the possible causes, and the recommended solutions.
Table 20 • Communications Problems
Problem
A label format was sent to the printer but was not recognized.
A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or distorts the image on the label.
Possible Cause
The communication parameters are incorrect.
The serial communication settings are incorrect.
A label format was sent to the printer but was not recognized. No printing occurs.
The prefix and delimiter characters set in the printer do not match the ones in the label format.
Incorrect data is being sent to the printer.
Recommended Solution
Check the printer driver or software communications settings (if applicable).
Make sure you are using the correct
communication cable. See Data Cable
Requirements on page 17 for the requirements.
If a driver is used, check the driver communication settings for your connection.
Ensure that the flow control settings match.
Check the communication cable length. See
Data Cable Requirements on page 17 for
requirements.
Check the printer driver or software communications settings (if applicable).
Verify the prefix and delimiter characters. See
Set Command Character on page 62
Delimiter Character on page 63 for the
requirements.
Ensure that the label format being used matches the operating language of the printer.
See Printer Language Modes on page 8
.
Check the communication settings on the computer. Ensure that they match the printer settings.
If the problem continues, check the label format.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Troubleshooting
Ribbon Problems
95
Ribbon Problems
identifies problems that may occur with ribbon, the possible causes, and the recommended solutions.
Note • This section applies only to printers that have the Thermal Transfer option installed.
Table 21 • Ribbon Problems
Problem
Broken or melted ribbon
The printer does not detect when the ribbon runs out.
When the
RIBBON
parameter is set to
AUTO
, the printer remains in direct thermal mode (shown on the printer configuration label), even though ribbon is loaded correctly in the printer.
Possible Cause
Darkness setting too high.
The ribbon-out threshold is set too high to detect the ribbon.
On a sensor profile, the ribbon-out threshold (circled in
black bars that indicate the ribbon. This happens if you calibrate the printer without ribbon and later insert ribbon without recalibrating the printer or loading printer defaults.
Figure 27 • Ribbon-Out
Threshold Too High
Recommended Solution
1.
Reduce the darkness setting.
2.
Clean the printhead thoroughly.
1.
Print a sensor profile (see
), and note the location of the ribbon-out threshold (circled in
2.
Calibrate the printer, this time using ribbon, or load printer defaults. See
.
Important • Loading defaults resets all printer parameters back to factory defaults.
3.
Print another sensor profile, and compare it to the first one.
4.
If the ribbon-out threshold is still too high, you may manually change the value. See
Adjust Ribbon-Out Threshold on page 71 .
The printer indicates that ribbon is out, even though ribbon is loaded correctly.
The printer was not calibrated for the label and ribbon being used.
Perform the calibration procedure in
Media and Ribbon Sensors on page 67
.
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96 Troubleshooting
Miscellaneous Printer Problems
Miscellaneous Printer Problems
identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions.
Problem
The LCD displays a language that I cannot read
Table 22 • Miscellaneous Printer Problems
Possible Cause
The language parameter was changed through the control panel or a firmware command.
Recommended Solution
Perform the procedure in
.
The LCD is missing characters or parts of characters
The LCD may need replacing.
Run the Power-On Self Test on page 97
and check that the LCD display shows all characters.
If not, replace the LCD.
Changes in parameter settings did not take effect
Parameters are set incorrectly.
1.
Set parameters and save permanently.
2.
Turn the printer power Off ( O ) and then
On ( I ).
A command turned off the ability to change the parameter.
Refer to the Programming Guide for the printer language being used.
The printer fails to calibrate or detect the top of the label.
A command changed the parameter back to the previous setting.
If the problem continues, there may be a problem with the main logic board.
The printer was not calibrated for the label being used.
The printer is configured for continuous media.
The driver or software configuration is not set correctly.
Non-continuous labels are being treated as continuous labels.
The printer is configured for continuous media.
The printer was not calibrated for the media being used.
Internal electronic or firmware failure.
All lights are on, but nothing displays on the LCD, and the printer locks up.
The printer locks up while running the
Power-On Self Test.
Main logic board failure.
Refer to the Programming Guide for the printer language being used.
Replace the main logic board.
Perform the calibration procedure in
Media and Ribbon Sensors on page 67
.
Set the media type to noncontinuous media. See
Driver or software settings produce commands that can overwrite the printer configuration.
Check the driver or software media-related setting.
Set the media type to noncontinuous media. See
Perform the calibration procedure in
Media and Ribbon Sensors on page 67
.
Turn the printer power Off ( O ) and then On ( I ). If the printer locks up again, replace the main logic board.
Replace the main logic board.
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Troubleshooting
Printer Diagnostics
97
Printer Diagnostics
Self tests and other diagnostics provide specific information about the condition of the printer.
The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the printer. The most commonly used are the Power-On and the
CANCEL self tests.
Important • Use full-width media when performing self tests. If your media is not wide enough, the test labels may print on the platen roller.
Each self test is enabled by pressing a specific control panel key or combination of keys while turning the power On (I). Keep the key(s) pressed until the first indicator light turns off. The selected self test automatically starts at the end of the Power-On Self Test.
Note •
• When performing these self tests, do not send data to the printer from the host.
• If your media is shorter than the label to be printed, the test label continues on the next label.
• When canceling a self test prior to its actual completion, always reset the printer by turning the printer power Off ( O ) and then On ( l ).
Power-On Self Test
A Power-On Self Test (POST) is performed each time the printer is turned On ( l ). During this test, the control panel lights (LEDs) turn on and off to ensure proper operation. At the end of this self test, only the POWER LED remains lit. When the Power-On Self Test is complete, the media is advanced to the proper position.
To initiate the Power-On Self Test, complete these steps:
1.
Turn On ( I ) the printer using the power switch located to the side of the control panel.
The POWER LED illuminates. The other control panel LEDs and the LCD monitor the progress and indicate the results of the individual tests. All messages during the POST display in English; however, if the test fails, the resulting messages cycle through the international languages as well.
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98 Troubleshooting
Printer Diagnostics
CANCEL Self Test
The CANCEL
self test prints a configuration label ( Figure 28
).
To perform the CANCEL Self Test, complete these steps:
1.
Turn Off (O) the printer.
2.
Press and hold CANCEL while turning the printer On (I). Hold CANCEL until the first control panel light turns off.
A printer configuration label prints (
).
Figure 28 • Configuration Label
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PAUSE Self Test
This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies or to determine if any printhead elements are not working.
Figure 29 shows a sample printout.
To perform a PAUSE self test, complete these steps:
1.
Turn Off (O) the printer.
2.
Press and hold PAUSE while turning the power On (I). Hold PAUSE until the first control panel light turns off.
• The initial self test prints 15 labels at the printer’s slowest speed, and then automatically pauses the printer. Each time PAUSE is pressed, an additional 15 labels print.
shows a sample of the labels.
Figure 29 • PAUSE Test Label
• While the printer is paused, pressing CANCEL alters the self test. Each time PAUSE is pressed, 15 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a second time.
Each time PAUSE is pressed, 50 labels print at the printer’s slowest speed
• While the printer is paused, pressing CANCEL again alters the self test a third time.
Each time PAUSE is pressed, 50 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a fourth time.
Each time PAUSE is pressed, 15 labels print at the printer’s maximum speed.
• To exit this self test at any time, press and hold CANCEL .
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Printer Diagnostics
FEED Self Test
Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications.
During the FEED self test, labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label. The bar codes on these labels may be ANSI-graded to check print quality.
During this test, one set of labels is printed at 2 ips, and another set is printed at 6 ips. The darkness value starts at three settings lower than the printer’s current darkness value (relative darkness of –3) and increase until the darkness is three settings higher than the current darkness value (relative darkness of +3).
To perform a FEED self test, complete these steps:
1.
Print a configuration label to show the printer’s current settings.
2.
Turn Off (O) the printer.
3.
Press and hold FEED while turning the power On (I). Hold FEED until the first control panel light turns off.
The printer prints a series of labels (
Figure 30 ) at various speeds and at darkness settings
higher and lower than the darkness value shown on the configuration label.
Figure 30 • FEED Test Label
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4.
See
and Table 23 . Inspect the test labels and determine which one has the best
print quality for your application. If you have a bar code verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test.
Figure 31 • Bar Code Darkness Comparison
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Printer Diagnostics
Print Quality
Too dark
Slightly dark
“In-spec”
Slightly light
Too light
Table 23 • Judging Bar Code Quality
Description
Labels that are too dark are fairly obvious. They may be readable but not “in-spec.”
• The normal bar code bars increase in size.
• The openings in small alphanumeric characters may fill in with ink.
• Rotated bar code bars and spaces run together.
Slightly dark labels are not as obvious.
• The normal bar code will be “in-spec.”
• Small character alpha numerics will be bold and could be slightly filled in.
• The rotated bar code spaces are small when compared to the “in-spec” code, possibly making the code unreadable.
The “in-spec” bar code can only be confirmed by a verifier, but it should exhibit some visible characteristics.
• The normal bar code will have complete, even bars and clear, distinct spaces.
• The rotated bar code will have complete, even bars and clear, distinct spaces. Although it may not look as good as a slightly dark bar code, the bar code will be “in-spec.”
• In both normal and rotated styles, small alphanumeric characters look complete.
Slightly light labels are, in some cases, preferred to slightly dark ones for “in-spec” bar codes.
• Both normal and rotated bar codes will be in spec, but small alphanumeric characters may not be complete.
Labels that are too light are obvious.
• Both normal and rotated bar codes have incomplete bars and spaces.
• Small alphanumeric characters are unreadable.
5.
Note the relative darkness value and the print speed printed on the best test label.
6.
Add or subtract the relative darkness value from the darkness value specified on the configuration label. The resulting numeric value is the best darkness value for that specific label/ribbon combination and print speed.
7.
If necessary, change the darkness value to the darkness value on the best test label. See
Adjust Print Darkness on page 54
.
8.
If necessary, change the print speed to the same speed as on the best test label. See
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FEED and PAUSE Self Test
Performing this self test temporarily resets the printer configuration to the factory default values. These values are active only until power is turned off unless you save them permanently in memory. If the factory default values are permanently saved, a media calibration procedure must be performed.
To perform a FEED and PAUSE self test, complete these steps:
1.
Turn Off (O) the printer.
2.
Press and hold FEED and PAUSE while turning the power On (I).
3.
Hold FEED and PAUSE until the first control panel light turns off.
The printer configuration is temporarily reset to the factory default values. No labels print at the end of this test.
Communications Diagnostics Test
Do not perform the following test until all configuration and calibration parameters have been
set. For configuration information, see Control Panel LCD Display on page 54 .
This test is controlled from the control panel LCD display. See
Figure 32 shows a typical printout from this test. Turn the printer power Off (
O ) and then back
On ( I ) to exit this self test and return to normal operation.
Note • This test label prints upside-down.
Figure 32 • Communications Diagnostics Test Label
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Printer Diagnostics
Notes • ___________________________________________________________________
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4
Preventive and Corrective
Maintenance
This section provides various levels of printer maintenance required for optimum performance. This section also provides information on cleaning and general maintenance, replacement of major assemblies, and mechanical adjustments.
Contents
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Contents
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Safety Information
This section identifies general and specific safety information for the S4M printer.
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Personal Safety Tips
Personal Safety Tips
Caution • Risk of explosion if battery is replaced by an incorrect type, or in the wrong polarity.
Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration.
Caution • Beware of “pinch points” on the printers, especially:
• Opening and closing the covers
• Opening and closing the printhead
• Rewind spindle
• Platen roller
• Peel assembly
Caution • Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
Important • Do not wear loose clothing or jewelry such as rings, watches, or bracelets when servicing the printers.
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109
Equipment Safety Tips
• The AC power plug and IEC 320 connectors on all Zebra Printers must bear the certification mark of at least one of the international safety organizations listed below.
+
R
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Caution • Turn Off (O) the printer and disconnect it from the power source before performing any maintenance.
Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
Caution • Permanent damage to the Flash Memory will result if you turn on power to the print engine with Flash Memory chips installed in the wrong direction.
• Zebra printers comply with international regulations governing radiated emissions when using fully shielded data cables. Data cables must be fully shielded and fitted with metal or metallized connector shells. Required shielded data cables and connectors prevent radiation and reception of electrical noise. Use of unshielded data cables may increase radiated emissions above the regulated limits.
• Zebra recommends using Preventive Maintenance Kit (p/n 47362), or a solvent containing
90% isopropyl alcohol and 10% distilled water. Increase the percentage of alcohol as necessary for effective cleaning of:
• printheads
• platen rollers
• peel-off rollers
• pinch rollers
• media paths
• peel/tear bars
• spindles
• Ribbons used in the printers must be as wide as or wider than the media. If the ribbon is narrower than the media, areas of the printhead will be unprotected and subject to premature wear.
• To ensure the printer has proper ventilation and cooling, do not place any padding or cushioning material under the unit because this restricts airflow.
• Install the printer on a solid, level surface of sufficient size and strength to accommodate the physical dimensions and weight of the unit. The area enclosure in which the printer will operate must meet the environmental conditions specified in the Maintenance Manual or User Guide. Electrical power must be available and in close proximity to the printer.
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Equipment Safety Tips
Notes • ___________________________________________________________________
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Preventive Maintenance
This section contains procedures for routine preventive maintenance. An operator or technician may perform preventive maintenance, which consists of:
• Visual inspection
• Regular cleaning of the printhead, platen roller, peel roller, and pinch roller
• General cleaning of the print engine’s interior and exterior
See
Table 24 on page 112
for the preventive maintenance cleaning chart.
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112 Preventive and Corrective Maintenance
Lubrication
Lubrication
No lubrication is needed for this printer.
Caution • Some commercially available lubricants will damage the finish and the mechanical parts if used on this printer.
Cleaning Procedures
Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this printer.
Specific cleaning procedures are provided on the following pages.
shows the recommended cleaning schedule.
.
Table 24 • Recommended Cleaning Schedule
Area Method Interval
Printhead
Platen roller
Media sensors
Ribbon sensor
Solvent*
Solvent*
Air blow
Air blow
Direct Thermal Mode: After every roll of media (or 500 feet of fanfold media).
Thermal Transfer Mode: After every roll of ribbon or three rolls of media.
These intervals are intended as guidelines only.
You may have to clean more often, depending upon your application and media.
Media path
Ribbon path
Pinch roller. (part of Peel-Off option)
Tear-off/peel-off bar
Solvent*
Solvent*
Solvent*
Solvent* Once a month.
Take-label sensor Air blow Once every six months.
* Zebra recommends using Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl and
10% deionized water)
Clean the Exterior
You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.
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113
Clean the Printhead and Platen Roller
You can minimize printhead wear and maintain print quality with regular preventive measures.
Over time, the movement of media or ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion:
• Clean the printhead frequently, and use well-lubricated thermal transfer ribbons with backings optimized to reduce friction.
• Minimize printhead pressure and burn temperature settings by optimizing the balance between the two.
• Ensure that the thermal transfer ribbon is as wide or wider than the label media to prevent exposing the elements to the more abrasive label material.
For best results, clean the printhead after changing every roll of ribbon. Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty printhead.
Note • The printer can remain on while you are cleaning the printhead. In this way, all label formats, images, and all temporary parameter settings stored in the printer’s internal memory are saved. In addition, keep the peel engaged while cleaning the platen roller (media must be unloaded to do this) to reduce the risk of bending the tear-off/peel-off bar.
Figure 33 • Cleaning the Printhead and Platen Roller
1
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2
1
2
Printhead assembly
Platen roller
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114 Preventive and Corrective Maintenance
Cleaning Procedures
Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
To clean the printhead and platen roller, complete these steps:
1.
Open the printhead assembly.
2.
Remove the media and ribbon.
3.
Using the swab from the Preventive Maintenance Kit (part number 47362) or a solution of
90% Isopropyl alcohol and 10% deionized water and a cotton swab, wipe along the brown strip on the printhead assembly from end to end. Allow the solvent to evaporate.
4.
While manually rotating the platen roller, clean it thoroughly with the swab. Allow the solvent to evaporate.
5.
Reload media and ribbon, and close the printhead assembly.
Note • If performing this procedure does not improve print quality, try cleaning the printhead with Save-A-Printhead cleaning film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller for more information.
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115
Clean the Media Compartment and Sensors
To clean the media compartment and sensors, complete these steps:
1.
Brush or vacuum any accumulated paper lint and dust away from the media and ribbon paths.
2.
Brush or vacuum any paper lint and dust away from the sensors (see Figure 34
).
Figure 34 • Cleaning the Sensors
2
3
1
4
3
4
1
2
Take-label sensor
Ribbon sensor
Transmissive sensor
Reflective sensor
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116 Preventive and Corrective Maintenance
Cleaning Procedures
Clean the Peel-Off Assembly
The Peel-Off option is required.
The Peel assembly consists of several spring-loaded rollers to ensure the proper roller pressure. Use the peel release lever and your right hand to open and close the Peel assembly.
Doing this will keep your fingers away from the rollers.
Caution • Do not use your left hand to assist in closing the Peel assembly. The top edge of the Peel roller/assembly could pinch your fingers.
Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
If adhesive buildup affects peel-off performance, complete these steps:
1.
Press the printhead release latch to open the printhead assembly.
2.
Lift the printhead until it latches open.
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117
3.
Open the peel assembly by pivoting the module toward you.
4.
Remove any media backing to expose the pinch roller.
5.
While manually rotating the pinch roller, clean it thoroughly with the swab from the
Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl alcohol and 10% deionized water and a cotton swab. Allow the solvent to evaporate.
6.
Use the swab to remove excess adhesive from the tear-off/peel-off bar. Allow the solvent to evaporate.
10/27/05
Important • Apply minimum force when cleaning the tear-off/peel-off bar. Excessive force can cause the tear-off/peel-off bar to bend, which could have a negative effect on peel performance.
7.
Close the printhead assembly and the media door.
The printer is ready to operate.
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Cleaning Procedures
Notes • ___________________________________________________________________
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Corrective Maintenance
Corrective maintenance consists of the following:
• Troubleshooting printer faults to a modular level.
• Replacing or adjusting faulty or inoperable components.
• Returning the printer to proper operating condition.
Contents
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Corrective Maintenance
Required Tools
• Safety Glasses
• Standard screwdriver set
• Phillips screwdriver set
• Metric hex key (allen wrench) set
• Standard hex key (allen wrench) set
• Metric nut driver set
• Standard nut driver set
• Long needle nose pliers
• Four Inch (100 mm) Adjustable (Crescent) Wrench
• Antistatic wrist strap and mat
• Isopropyl Alcohol; Zebra’s Preventive Maintenance Kit, part number 47362 or a solution of 90% alcohol/10% de-ionized water
• Cotton swabs and lint free cloths
• 0.060 inch feeler gauge or shim
• Punch set
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Routine Referral Procedures
(RRP)
Routine Referral Procedures are commonly used steps that are performed often during corrective maintenance. These procedures are referenced throughout this section of the manual.
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Routine Referral Procedures
RRP No. 1: Remove the Electronics Cover
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Turn Off ( O ) the printer and disconnect the AC power cord and all data cables.
2.
See Figure 35 . Remove the electronics cover mounting screw and washer and then close
the media door.
Figure 35 • Remove the Mounting Screw
1
2
3
4
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3
4
1
2
Media Door
Electronics Cover Upper Flange
Electronics Cover Mounting Screw
Washer
3.
See
Figure 36 . Remove the four remaining mounting screws securing the electronics
cover.
4.
Remove the electronics cover by lifting straight up on the bottom lip of the electronics cover.
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1
Preventive and Corrective Maintenance
Routine Referral Procedures
123
Figure 36 • Electronics Cover Removal
1
2
Electronics Cover
Mounting Screws (4)
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Routine Referral Procedures
RRP No. 2: Install the Electronics Cover
1.
See
. Install the cover by aligning it and sliding down, ensuring the lower tabs are inside the base and the upper flanges are between the main frame and the media door.
2.
Install the four mounting screws on the back of the printer.
3.
See
. Open the media door and install the mounting screw and washer to secure the electronics cover.
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Print System
This section provides replacement, conversion, and installation procedures for the S4M print system.
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126 Preventive and Corrective Maintenance
Printhead Assembly
Printhead Assembly
This procedure is for installing the Printhead Assembly. Read these instructions thoroughly before performing this procedure.
Caution • Turn OFF (O) the printer and disconnect it from the power source before performing the following maintenance.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ 47362* Zebra Preventative Maintenance
Kit
‰ Anti-Static Wriststrap and Mat
‰ Metric Nutdriver Set
*. A solution of 90% isopropyl alcohol and 10% deionized water and clean swabs may be used in place of the Preventative Maintenance Kit.
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Remove the Printhead
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
Turn Off (O) the printer and disconnect the AC power cord and data cables.
3.
Open the media door and remove media and ribbon.
4.
See
. Note the current printhead pressure dial settings, and then rotate the two printhead pressure dials to position #1.
Figure 37 • Printhead Pressure Knobs
1 2 3
4
Front of Printer
3
4
1
2
Position #1
Position #4
Thumbscrew
Printhead pressure dials (2)
5.
See
. Remove the printhead thumbscrew.
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Printhead Assembly
6.
Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
Unlatch the print mechanism and lift and latch it in the open position.
Figure 38 • Printhead Assembly Mounting and Connections
1
2
3
7
4
6
5
5
6
7
3
4
1
2
Thumbscrew
Printhead pressure dials (2)
Print mechanism assembly
Printhead connectors
Printhead fork assembly
Locating holes
Ribbon guide plate
7.
Slide the printhead fork assembly out of the print mechanism.
8.
With the cable connectors exposed, carefully disconnect the two printhead cables from the printhead assembly. Remove and discard the old printhead assembly.
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Install the New Printhead
1.
Caution • An improperly connected printhead data or power cable may cause the printhead to generate excessive heat and/or a false HEAD COLD message to display while the printhead is hot enough to cause severe burns. Allow the printhead to cool.
Connect the printhead cables to the new printhead fork assembly and then carefully slide the assembly into the print mechanism.
Important • When mounting the printhead fork assembly onto the print mechanism, visually inspect and ensure the following:
• the cables are in their channels at the back of their carrier assembly
• the power cable is under data cable
• they are not binding on the print mechanism
2.
Ensure the two locating protrusions on the print mechanism mounting plate snap into the locating holes on the printhead fork assembly.
3.
Try to move the printhead fork assembly back and forth to make sure that it is engaged;
the assembly should not move. If the assembly moves, repeat step 2
.
Important • The printhead must be properly engaged with the ribbon guide plate to ensure proper print quality.
4.
Secure the printhead to the mechanism with the previously removed thumbscrew and close the print mechanism.
5.
Rotate the two printhead pressure dials to the desired position for your daily printing, as
on
.
6.
Caution • Do not use sharp objects to clean the printhead or platen roller.
Clean the printhead and platen roller using Zebra Preventive Maintenance Kit (47362).
7.
Reinstall media and ribbon and close the media door.
8.
Reconnect the AC power cord and data cables.
9.
Turn On ( l ) the printer.
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Printhead Upgrade Option
Printhead Upgrade Option
This procedure is for converting the drive system and printhead from 203 to 300 dpi or 300 to
203 dpi on the S4M printer. Read these instructions thoroughly before attempting to changeover the printhead and drive system.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ 47362* Zebra Preventive Maintenance
Kit
‰ Antistatic Wriststrap and Mat
‰ Metric and inch Feeler Gauges, must include: 0.060 in. (1.5mm)
‰ Metric Hex Key (Allen wrench) Set
*. A solution of 90% isopropyl alcohol and 10% deionized water and clean swabs may be used in place of the Preventative
Maintenance Kit.
99
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131
Remove the Printhead
1.
Open the media door.
2.
See
. Rotate the two printhead pressure dials to the #1 position.
Figure 39 • Locate the Printhead Pressure Dials
1 2 3
4 4
3
4
1
2
Position number one
Position number four
Thumbscrew
Printhead pressure dials (2)
3.
See
. Remove the thumbscrew to loosen the printhead fork assembly.
4.
Caution • Be sure the printhead is fully open and latched in the open position.
Unlatch the print mechanism and lift and latch it in the open position.
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Printhead Upgrade Option
Figure 40 • Printhead Removal and Installation
2
1
1
9
3
6
4
5
8 4
7
3
4
1
2
5
Printhead pressure dial
Thumbscrew
Print mechanism assembly
Locating hole
Printhead power connector
6
7
8
9
Printhead data connector
Lower guide
Printhead fork assembly
Mounting plate
5.
Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
Slide the printhead fork assembly out from the print mechanism assembly to expose the printhead cable connectors.
6.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device and disconnect both the printhead power and data cables and remove the printhead assembly.
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133
7.
See
. Remove the lower printhead guide by pushing the tabs away from the fork assembly.
Figure 41 • Remove the Lower Guide
1
3
2
1
2
3
Printhead fork assembly
Lower guide
Tabs (2)
Install the Printhead
1.
See
. Install the lower guide on the new printhead fork assembly
2.
Connect both printhead power and data cables to the printhead connectors and carefully slide them into position. Ensure the cables are in their proper channels and are not binding the printhead.
3.
Caution • An improperly connected printhead data or power cable may cause the printhead to generate excessive heat and/or a false HEAD COLD message to display while the printhead is hot enough to cause severe burns. Allow the printhead to cool.
See
. Install the new printhead fork assembly.
Important • When mounting the printhead fork assembly onto the print mechanism, visually inspect and ensure the following:
• the cables are in their channels at the back of their carrier assembly
• the power cable is under data cable
• they are not binding on the print mechanism
4.
Ensure the two locating protrusions on the print mechanism mounting plate snap into the locating holes on the printhead fork assembly. Move the assembly back and forth to be sure that it is engaged. There should be no movement.
Note • The printhead must be properly engaged with the ribbon guide plate to have the proper print quality.
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Printhead Upgrade Option
5.
Secure the printhead fork assembly to the printhead housing using the previously removed thumbscrew.
6.
See
. Rotate the two printhead pressure dials back to their original position.
7.
Caution • Do not use sharp objects to clean printhead or platen roller.
Clean the printhead and the platen roller.
Remove the Main Logic Board
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
Refer to RRP No. 1 on page 122 and remove the electronics cover.
3.
See
. Remove all cables from the main logic board (MLB).
Note • Take note of the location of all connectors on the main logic board.
3
4
1
2
5
6
F6
12
Figure 42 • Remove the Main Logic Board Connections
1
11 10
Printhead data (J3)
Power-in (J8)
Front panel (J2)
Stepper motor (J9)
Booster board (J7)
Ribbon sensor (P4)
7
6
2
4
3
5
9
8
7
8
9
10
11
12
Transmissive sensor (P9)
Reflective sensor (P7)
Take-label sensor (J19)
Communication expansion port (J17)
USB port (J14)
Serial port (J10)
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4.
See
. Remove the six screws and one nut securing the main logic board to the main frame of the printer.
5.
Remove the two studs and washers securing the serial port connector to the back of the printer.
Figure 43 • Remove the Main Logic Board
1
5 4
3
4
1
2
5
Main logic board nut
Main logic board mounting screws (6)
Main logic board
Lock washer (2)
Serial port mounting stud (2)
6.
Remove the main logic board from the printer.
3
2
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Conversion Procedure
The following steps will convert your printer from 203 dpi to 300 dpi. (To convert from 300 dpi to 203 dpi, the gears are installed in the opposite direction, with the smaller side of the pulley away from the printer when placed on the platen roller.)
1.
See
. Remove the compound gear mounting screw.
Figure 44 • Remove the Compound Gear
1
2
13291L-001 Rev. A
1
2
Mounting screw
Compound gear
2.
See
. Turn the gear around and reinstall it in the adjacent mounting hole.
3.
Ensure that it meshes properly with the clutch and the intermediate gears.
Figure 45 • Select the Compound Gear Position
THIS
SID
E
O
U
T
/2
H
IS
S
ID
E
OU
T/300 DP
I
200 dpi 300 dpi
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4.
See
. Using a hex key, loosen the stepper motor pivot screw and locking screw.
Figure 46 • Loosen the Stepper Motor
1 2
3
4
5
3
4
1
2
5
Pivot screw
Belt
Platen pulley
Platen pulley set screws (2)
Locking screw
5.
Swing the stepper motor up to remove tension from the belt and tighten the locking screw in this position.
6.
Remove the belt from the stepper motor drive gear/pulley.
7.
Remove and retain the two set screws on the platen roller pulley. Remove the pulley and belt. Discard the belt.
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8.
See
. Turn the pulley around and place it on the platen roller shaft.
Note • Make sure there is approximately a 0.020 in. (0.5 mm) clearance between the platen roller pulley and the printer frame.
Figure 47 • Turn the Compound Pulley Around
9.
Install the set screws in the outboard compound pulley. Rotate the compound pulley to align the set screws with the flat spots on the platen roller shaft.
Figure 48 • Align the Platen Roller Shaft
1
2
13291L-001 Rev. A
1
2
Set screws (2)
Flat spots (2)
10.
Tighten the two set screws to secure the pulley to the platen roller shaft.
11.
See
. Install the new belt supplied in the kit.
12.
Loosen the locking screw and nut.
Note • The belt should deflect under finger pressure, but no more than ¼ inch (6 mm).
13.
Caution • Do not over tighten the belt or damage to the bearings and platen roller will occur.
Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then the pivot screw.
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Reinstall the MLB
1.
See
. Reinstall the MLB in the printer using the screws, nut, and studs and washers previously removed.
2.
See
. Reconnect all the cables previously removed from the main logic board. Visually inspect and ensure the cables are in their proper location and seated in the connectors.
Reinstall the Electronics Cover
1.
Refer to RRP No. 2 on page 124 and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
Verify the Installation
1.
Press and hold CANCEL while turning On ( l ) the printer. A configuration label will print after the Power-On Self Test (POST) is completed.
Note • A 300 dpi configuration label prints smaller than a 203 dpi label.
2.
See
. Verify that the dpi is correct.
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Figure 49 • Configuration Label (200 dpi or 300 dpi)
3.
Turn Off ( O ) the printer.
4.
See
. Press and hold PAUSE while turning On ( l ) the printer. A Pause Test label will print to verify print quality.
Figure 50 • Pause Test Label
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Print Mechanism
This procedure is for installing the print mechanism in the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Flat-Blade Screwdriver Set
‰ Metric Hex Key (Allen wrench) Set
‰ Anti-Static Wriststrap and Mat
‰ Metric Nutdriver Set
‰ Metric and inch Feeler Gauges, must include: 0.060 in. (1.5mm)
‰ 4 inch crescent wrench
‰ 47362 Zebra Preventative Maintenance
Kit
‰ 77919 Pin Gauge (qty = 2)
‰ 77921 Cam
‰ Q10011 Screw
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Remove the Print Mechanism
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Rotate the two printhead pressure dials to the #1 position.
Figure 51 • Locate the Printhead Pressure Dials
1 2 3
4 4
3
4
1
2
Position number one
Position number four
Thumbscrew
Printhead pressure dials (2)
4.
See
. Remove any cable ties.
5.
Disconnect the printhead data cable from the main logic board (MLB), J3.
6.
Remove the printhead data cable from the cable clamps and pull it out from under the stepper motor and mounting bracket.
7.
Disconnect the printhead power cable from the power supply connector.
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Figure 52 • Disconnect the Print Mechanism
1 2 3 4
9 8 7 6
3
4
1
2
5
MLB
Printhead data cable
MLB connector J3
Cable clamp (2)
Printhead ground strap
8
9
6
7
Printhead power cable
Power supply connector
Stepper motor mounting bracket
Stepper motor
8.
Remove the printhead housing grounding strap mounting screw.
5
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9.
See
. Loosen and remove the two hex head screws, one phillips head screw, and washers securing the printhead housing assembly.
Figure 53 • Printhead Housing Mounting Screws
2
1
4
3
3
4
1
2
Printhead housing
Washers (3)
Phillips head mounting screw
Hex head mounting screw (2)
10.
Remove the printhead housing assembly from the printer.
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Install the New Print Mechanism
1.
Are you installing the print mechanism on a Direct Thermal Only S4M printer?
If…
No
Yes
Then…
Caution • Be careful not to touch the printhead with any tools. This could damage the printhead.
. Remove the and discard the ribbon strip plate from the new print
mechanism and then continue to step 2
.
Figure 54 • Remove the Ribbon Strip Plate
2
1
3
1
2
3
Mounting screws (2)
Flat washers (2)
Ribbon strip plate
+
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2.
See
. Feed the new cables through the print mechanism mounting hole.
3.
Install the three printhead housing mounting screws and washers while ensuring that the print mechanism mounting slots are raised to the bottom of the mounting screws. Snug the three mounting screws at this time.
Figure 55 • Insert the Print Mechanism
1
2
5
3
5
3
4
3
3
4
1
2
5
Print mechanism mounting hole
Print mechanism
Washers (3)
Phillips head mounting screw
Mounting screws (2)
4.
See
. Route the printhead data cable down and up behind the stepper motor mounting plate and connect to J3 on the MLB.
5.
Insert the data cable into the flat cable clamps
6.
Connect the printhead power cable to the power supply cable.
7.
Reinstall the ground strap.
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Adjust the Print Mechanism
1.
See
. Remove the strike plate cap by gently prying up one snap tab with a small flat blade screwdriver. Loosen the strike plate mounting screws 1/2 turn.
2.
See
. Set both printhead pressure dials to 3.
Figure 56 • Adjust the Print Mechanism
4
1
3
2
5
3
4
1
2
5
Strike plate cap
Adjustment screw
Strike plate
Strike plate mounting screws (2)
Print mechanism gap pin gauges (2)
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3.
. Using the screw provided in the kit, install the print mechanism adjustment cam on the printer main frame.
Note • The cam should be in contact with print mechanism and only be snug to allow it to turn with the wrench.
Figure 57 • Install the Adjustment Cam
3
2
1
13291L-001 Rev. A
1
2
3
Cam mounting hole
Cam
Mounting screw
4.
See
. Insert the print mechanism gap pin gauges through the holes that are provided in the front of the ribbon guide plate.
5.
Place a 4 inch crescent wrench on the print mechanism adjustment cam. While turning the wrench counterclockwise, push in and pull out the inside gap pin gauge until a small amount of friction can be felt.
6.
Tighten one of the print mechanism mounting screws.
7.
After adjusting the inside pin gauge, use a screwdriver and turn the adjustment screw on top of the latch plate strike.
8.
Push in and pull out the outside gap pin gauge until a small amount of friction can be felt.
Important • Check both pin gauges for equal amount of friction.
9.
Tighten the latch plate strike screws.
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10.
Tighten the remaining print mechanism mounting screws when equal pressure is obtained.
11.
. Check the gap on the ribbon/printhead open sensor and adjust as necessary.
Figure 58 • Ribbon/Printhead Open Sensor
1
2
4
3
3
4
1
2
Printhead housing
Gap, 0.060 in. (1.5 mm) ± 0.015 in. (0.381 mm)
Ribbon/Printhead open sensor
Mounting screw
12.
Use a 0.060 in. (1.5 mm) feeler gauge and check the distance between the ribbon/head open sensor assembly and the printhead housing. If the distance is incorrect, loosen the mounting screw for the ribbon/head open sensor and adjust for the proper distance. Once this distance is achieved, tighten the mounting screw.
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Reinstall the Electronics Cover
1.
See
and install the electronics cover.
2.
See
. Rotate the two printhead pressure dials to position 3.
3.
Reconnect AC power cord and data cables.
Verify the Installation
1.
See
. Hold PAUSE and CANCEL while turning On ( l ) the printer.
A Pause and Cancel Self Test Label will print.
Figure 59 • PAUSE and CANCEL Test Label
2.
Ensure that the black bar is mostly filled in solid and that the bottom line is parallel to the edge of the label. The black bar can have small voids of white.
3.
If further adjustments are needed, repeat step 4
4.
Repeat
step 1 through step 3 as needed until even resistance is felt.
5.
Replace the strike plate cap.
6.
See
. Remove the cam and cam mounting screw.
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Printhead Cables
This procedure is for installing the printhead power and data cables in the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Flat-Blade Screwdriver Set
‰ Metric Hex Key (Allen wrench) Set
‰ Anti-Static Wriststrap and Mat
‰ Metric Nutdriver Set
‰ Metric and inch Feeler Gauges, must include: 0.060 in. (1.5mm)
‰ 4 inch crescent wrench
‰ 47362 Zebra Preventative Maintenance
Kit
‰ 77919 Pin Gauge (qty = 2)
‰ 77921 Cam
‰ Q10011 Screw (Cam and Pin Gauge)
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Remove the Print Mechanism
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Rotate the printhead pressure dials to the #1 position.
Figure 60 • Locate the Printhead Pressure Knobs
1 2 3
4
1
2
3
4
Position number one
Position number four
Thumbscrew
Printhead pressure dials (2)
4
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4.
See
. Remove any cable ties.
5.
Disconnect the printhead data cable from the main logic board (MLB).
6.
Disconnect the printhead power cable from the power supply connector.
Figure 61 • Disconnect the Print Mechanism
1
2
3
6
3
4
1
2
5
6
Main logic board (MLB)
Printhead data cable
MLB connector J3
Printhead ground strap
Printhead power cable
Power supply connector
7.
Remove the printhead housing grounding strap mounting screw.
5
4
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8.
See
. Loosen and remove the two hex head screws, one phillips head screw, and washers securing the main frame.
Figure 62 • Printhead Housing Mounting Screws
2
1
4
3
3
4
1
2
Print mechanism
Washers (3)
Phillips head mounting screw
Hex head mounting screws (2)
9.
Remove the printhead housing assembly from the printer.
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Remove the Old Printhead Cables
1.
Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
See
. Remove the thumbscrew.
2.
Remove the printhead fork assembly from the print mechanism.
Figure 63 • Remove the Printhead Fork Assembly
1 2
5
4
3
3
4
1
2
5
Print mechanism
Thumbscrew
Printhead power cable
Printhead data cable
Printhead fork assembly
3.
Disconnect the printhead power and data cables.
4.
See
. Lay the print mechanism on its top and slide the cables toward the hinge and out.
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Printhead Cable
Figure 64 • Remove and Install the Cables
1
2
5
4
3
3
4
1
2
5
Printhead data cable
Printhead power cable
Hinge
Printhead data connector
Printhead power connector
Install the New Printhead Cables
1.
See
. Slide each of the cables through the hinge and into the print mechanism.
2.
Caution • An improperly connected printhead data or power cable may cause the printhead to generate excessive heat and/or a false HEAD COLD message to display while the printhead is hot enough to cause severe burns. Allow the printhead to cool.
See
. Connect the printhead cables to the printhead fork assembly.
3.
Reinstall the printhead fork assembly into the print mechanism.
Ensure that the printhead cables are up and away from the printhead to avoid damage to the new cables and to allow the printhead to seat properly.
4.
Use the thumbscrew removed previously to secure the printhead fork assembly.
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Reinstall the Print Mechanism
1.
See
. Feed the new cables through the print mechanism mounting hole.
2.
Install the three printhead housing mounting screws and washers while ensuring that the print mechanism mounting slots are raised to the bottom of the mounting screws. Snug the three mounting screws at this time.
Figure 65 • Insert the Print Mechanism
1
2
5
3
5
3
4
3
3
4
1
2
5
Print mechanism mounting hole
Print mechanism
Washers (3)
Phillips head mounting screw
Mounting screws (2)
3.
See
. Route the printhead data cable down and up behind the stepper motor mounting plate and connect to J3 on the MLB.
4.
Insert the data cable into the flat cable clamps.
5.
Connect the printhead power cable to the power supply connector.
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Printhead Cable
Adjust the Print Mechanism
1.
See
. Remove the strike plate cap by gently prying up one snap tab with a small flat blade screwdriver. Loosen the strike plate mounting screws 1/2 turn.
Figure 66 • Adjust the Print Mechanism
1
2
3
4
5
3
4
1
2
5
Strike plate cap
Adjustment screw
Strike plate
Strike plate mounting screws (2)
Print mechanism gap pin gauges (2)
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2.
. Using the screw provided in the kit, install the print mechanism adjustment cam on the printer main frame.
Note • The cam should be in contact with print mechanism and only be snug to allow it to turn with the 4 in. crescent wrench.
Figure 67 • Install the Adjustment Cam
3
2
1
10/27/05
1
2
3
Cam mounting hole
Cam
Mounting screw
3.
See
. Insert the print mechanism gap pin gauges through the holes that are provided in the front of the ribbon guide plate.
4.
Place a 4 inch crescent wrench on the print mechanism adjustment cam. While turning the wrench counterclockwise, push in and pull out the inside gap pin gauge until a small amount of friction can be felt.
5.
After aligning the inside pin gauge, use a screwdriver and turn the adjustment screw on top of the latch plate strike.
6.
Push in and pull out the outside gap pin gauge until a small amount of friction can be felt.
Double check both pin gauges for equal amount of friction.
7.
Tighten the latch plate strike screws.
8.
Tighten the print mechanism mounting screws when equal pressure is obtained.
9.
Remove and retain the cam and screw used for adjusting the print mechanism.
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10.
Replace the strike plate cap.
11.
. Check the gap on the ribbon/printhead open sensor and adjust as necessary.
Figure 68 • Ribbon/Printhead Open Sensor
1
2
4
3
3
4
1
2
Printhead housing
Gap, 0.060 in. (1.5 mm) ± 0.015 in. (0.381 mm)
Ribbon/Printhead open sensor
Mounting screw
12.
Use a 0.060 in. (1.5 mm) feeler gauge and check the distance between the ribbon/head open sensor assembly and the printhead housing. If the distance is incorrect loosen the mounting screw for the ribbon/head open sensor and adjust for the proper distance. Once this distance is achieved, tighten the mounting screw.
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Reinstall the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
Verify the Installation
1.
See
. Rotate the two printhead pressure dials to the position 3.
2.
Reconnect AC power cord and data cables.
3.
See
. Hold PAUSE and CANCEL while turning On ( l ) the printer; a Pause and
Cancel Self Test Label will print.
Figure 69 • Pause and Cancel Label
4.
Ensure that the black bar is mostly filled in solid and that the bottom line is parallel to the edge of the label. The black bar can have small voids of white.
5.
If further adjustments are needed, repeat step 3
.
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Printhead Release Latch
Printhead Release Latch
This procedure is for installing the printhead release latch in the S4M printer. Read these instructions thoroughly before performing this procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Flat-blade Screwdriver Set
‰ Standard Nutdriver Set
‰ Metric Nutdriver Set
‰ Punch Set
‰ Safety Goggles
‰ 4 inch crescent wrench
‰ Small Hammer
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Remove the Old Latch
1.
Turn Off ( O ) the printer and disconnect the AC power cord and data cables.
2.
See
. Open the media door and remove the ribbon and media.
Figure 70 • Media Door and Latch Location (S4M)
1
4
3
3
4
1
2
Media door
Latch assembly
Latch plate cover
Strike plate cap
2
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Printhead Release Latch
3.
See
. Remove the strike plate cap by placing a small screwdriver under the front edge and lifting upward.
4.
Remove the latch cover.
5.
Remove the two screws and the washer holding the latch strike plate to the side of the print mechanism.
6.
Remove the adjustment screw from the print mechanism. You will have to pull out on the bottom of the strike plate while removing the screw.
1
Figure 71 • Remove the Latch Assembly
2
3
4
5
12
8
7
6
11
10 9
3
4
1
2
5
6
Print mechanism
Adjustment screw
Strike plate cap
Strike plate
Washer
Strike plate mounting screws (2)
7
8
9
10
11
12
Latch plate cover
Latch plate
Spring pin
Compression spring
Platen housing
Ribbon guide plate
7.
Caution • Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
Using a small punch, lightly tap the spring pin out from the FRONT of the platen housing
(the direction is important). The compression spring may fall out.
Important • Tap lightly when removing the spring pin. The platen housing is a cast housing and may break if hit too hard.
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Install the New Latch Kit
1.
See
. Install the compression spring on the platen housing post.
2.
Align the latch with the spring pin holes.
3.
Insert the spring pin through the front hole of the latch and though the platen housing. The rear hole in the latch is the only small one and you will need to tap on the spring pin.
4.
Lightly tap the spring pin into the rear hole. Leave equal amounts of spring pin sticking out on each side of latch.
5.
Install the strike plate partially into print mechanism.
6.
. Install the adjustment screw into the strike plate by sliding it in the opening with the shoulder below the top piece of sheet metal and above the bottom piece of sheet metal.
Figure 72 • Adjustment Screw Location
1
3
2
10/27/05
1
2
3
Strike plate
Adjustment screw
Adjustment screw shoulder
7.
. Tighten the adjustment screw until the top of the strike plate is just below the top of the print mechanism.
8.
Install the two mounting screws and washer through the strike plate and into the print mechanism. Do not tighten at this time; leave them approximately ½ turn loose. Latch the print mechanism.
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Printhead Release Latch
Adjust the Print Mechanism
1.
See
. Insert the print mechanism gap pin gauges through the holes that are provided in the front of the ribbon guide plate.
Figure 73 • Adjust the Print Mechanism
1
2
3
5
4
6
3
4
1
2
5
6
Print mechanism adjustment cam
Strike plate cap
Adjustment screw
Strike plate
Strike plate mounting screws (2)
Print mechanism gap pin gauges (2)
2.
Turn the adjustment screw until a small amount of friction is felt on the gap pin gauge.
3.
Snug the two strike plate mounting screws.
4.
Verify, with gap pin gauge, that the inside print mechanism adjustment is correct. A slight friction should be felt when sliding the inside pin in and out of the inside hole.
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5.
Is the adjustment acceptable?
If…
No
Yes
Then…
Continue with
.
6.
Loosen the two strike plate screws.
7.
See
. Install the print mechanism adjustment cam on the printer frame with the screw provided in the kit.
Figure 74 • Print Mechanism Mounting Screws
1 2
3
4
10/27/05
3
4
1
2
Print mechanism
Adjusting cam
Hex head mounting screws (2)
Phillips head mounting screw
8.
Slightly loosen the three screws that secure the print mechanism assembly to the mainframe.
9.
Use a 4 inch crescent wrench on the print mechanism adjustment cam. While turning the wrench counterclockwise, push in and pull out the inside gap pin gauge until a small amount of friction can be felt. Snug the two hex head screws.
10.
After aligning the inside gap pin gauge, verify that the outside adjustment is correct.
Double-check both gap pin gauges for equal amount of friction. Tighten the latch strike plate screws.
11.
See
. Tighten the three printhead mechanism mounting screws when equal pressure is obtained.
12.
Remove the print mechanism adjustment cam by removing the mounting screw.
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Printhead Release Latch
13.
See
. Install the strike plate cap.
14.
Install the latch cover.
15.
Reinstall the ribbon and media.
16.
Close the media door and reconnect the AC power cord and data cables.
17.
Turn On ( l ) the printer.
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Printhead Pressure Dials
169
Printhead Pressure Dials
This procedure is for installing the printhead pressure dial on the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Flat-blade Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
‰ Masking Tape
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Printhead Pressure Dials
Remove the Printhead
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Turn Off (O) the printer and disconnect the AC power cord and all data cables.
2.
Open the media door, open the printhead, and remove media and ribbon.
3.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
4.
See
. Rotate the printhead pressure dials to the #1 position.
Figure 75 •
Locate the Printhead Pressure Dials
1 2 3
4
3
4
1
2
Position number one
Position number four
Thumbscrew
Printhead pressure dials (2)
4
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171
5.
Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
See
. Remove the printhead thumbscrew.
Figure 76 •
Remove the Printhead and Cable Connections
2
1
2
3
4
5
7
6
3
4
1
2
Thumbscrew
Printhead pressure dial
Print mechanism assembly
Printhead data cable
5
6
7
Printhead power cable
Printhead fork assembly
Locating holes
6.
Open the print mechanism, and lift and latch it in the vertical position.
7.
Slide the printhead fork assembly out of the print mechanism.
8.
Disconnect the two printhead cables from the printhead assembly.
9.
Remove the printhead assembly and set it aside on the anti-static mat.
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Printhead Pressure Dials
Remove the Old Pressure Dials
To remove the pressure dials you must partially disassemble the print mechanism.
1.
. Place a soft pad down on your workbench and lay the printer on it with the electronics cover side down.
2.
Open the media door.
Figure 77 • Set the Printer on the Electronics Cover Side (S4M)
3.
See
. Put a piece of masking tape over the pressure roller to secure it to the pressure bracket.
This is being done for ease of reinstallation of the roller and bracket.
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Printhead Pressure Dials
173
Figure 78 • Remove the Pressure Bracket and Roller
6 1
3
4
2
3
5
3
4
1
2
5
6
Print mechanism
Pressure bracket
Masking tape (2)
Pressure bracket mounting screw
Lifting spring
Lower print mechanism latch screw
4.
Loosen the lower print mechanism latch screw to allow the pressure bracket to be removed.
Important • To avoid print mechanism readjustment, do not loosen the top latch screw.
5.
Remove the pressure bracket mounting screw, and swing the bracket out of the way.
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174 Preventive and Corrective Maintenance
Printhead Pressure Dials
6.
See
. Lift the dials and springs out of the print mechanism.
Figure 79 • Remove the Pressure Dials
1
2
1
1
2
Pressure dial and spring
Pressure bracket
7.
See
. Remove the springs from the old dials and place them in the new dials.
Figure 80 • Remove Springs
1
2
1
2
Pressure dial
Spring
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175
Install the New Pressure Dials
1.
See
. Insert the new dials and springs into the print mechanism.
2.
See
. Reinstall the pressure bracket and roller and then remove the masking tape.
3.
Retighten the lower print mechanism latch screw.
4.
See
. Connect the printhead cables to the printhead fork assembly, and carefully slide the assembly into the print mechanism ensuring the data cable and
power cable are kept away from the printhead lifting spring (see Figure 78 on page 173 ).
5.
See
. Ensure the two locating protrusions on the print mechanism mounting plate snap into the locating holes on the printhead fork assembly. Move the assembly back and forth to be sure that it is engaged. There should be no movement.
6.
Secure the printhead to the mechanism with the previously removed thumbscrew and close the print mechanism.
7.
Set the printer up on the base.
8.
Open the print mechanism and latch it in the open position.
9.
Caution • Do not use sharp objects to clean the printhead or platen roller.
Using the Zebra Preventive Maintenance Kit (Zebra part number 47362), clean the printhead and platen roller.
10.
Reinstall media and ribbon.
11.
See
. Rotate the two printhead pressure dials to the desired position for your daily printing.
12.
Reinstall media and ribbon.
13.
Close the media door.
14.
Reconnect the AC power cord and data cables.
15.
Turn On ( l ) the printer.
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Printhead Pressure Dials
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Sensors
This section provides replacement and installation procedures for the S4M sensors.
Contents
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Transmissive Sensor
Transmissive Sensor
This procedure is for installing the transmissive sensor in the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Wire Cutters
‰ AntiStatic Mat and Wrist Strap
‰ Safety Goggles
‰ Metric Nutdriver Set
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Transmissive Sensor
179
Remove the Old Transmissive Sensor
Remove the Stepper Motor
1.
See
and remove the electronics cover.
2.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
3.
See
. Locate the stepper motor and drive belt.
Figure 81 • Locate Drive System Components
1 2
3
10/27/05
6 5
1
2
3
4
5
6
Main logic board (MLB) J9
Stepper motor
Drive belt
Platen pulley
Locking screw
Pivot screw
4.
Disconnect the stepper motor cable from the main logic board (MLB), J9.
5.
Remove the locking screw and nut.
6.
Remove the pivot screw and then remove the stepper motor.
S4M Maintenance Manual
4
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180 Preventive and Corrective Maintenance
Transmissive Sensor
Remove the Old Transmissive Sensor
1.
Disconnect the transmissive sensor from the main logic board (P9).
2.
See
. Remove the transmissive sensor mounting screw, and then remove the transmissive sensor.
Figure 82 • Remove the Transmissive Sensor
1
3
4
1
2
Mounting screw
Transmissive sensor
Guide pin hole
Access hole
4 3 2
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181
Install the New Transmissive Sensor
1.
See
. Align the transmissive sensor to the main frame with the guide pin in the guide pin hole, and the mounting hole lining up with the mounting hole in the main frame.
2.
Feed the sensor wires through the proper access hole under the printhead assembly.
3.
Run the transmissive sensor wires through the protective wrap and then connect it to the main logic board (P9).
Reinstall the Stepper Motor and Gear/Pulley
1.
. Install the stepper motor by sliding the gear/pulley through the drive belt. Secure in position with the pivot screw, but do not tighten at this time.
2.
Reinstall the locking screw and nut, but do not tighten at this time
Note • Belt should deflect under finger pressure but no more than ¼ inch (6 mm).
3.
Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then the pivot screw.
4.
Connect the stepper motor power cable to J9 on the MLB.
5.
See
and install the electronics cover.
Select the Media Sensor (password Level 2)
You must select the correct Sensor Select setting for your printer application. See Select the
to change the setting using the control panel. Refer to the programming guide for your printer to change the setting using the programming commands.
Note • Changing the Sensor Select setting initiates an auto-calibration.
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Ribbon/Printhead Open Sensor
Ribbon/Printhead Open Sensor
This procedure is for installing the ribbon/printhead open sensor in the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
‰ Metric and inch Feeler Gauges, must include: 0.060 in. (1.5mm)
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Ribbon/Head Open Sensor Assembly
Ribbon/Printhead Open Sensor
183
Remove the Old Sensor
1.
See
and remove the electronics cover.
2.
See
. Disconnect the sensor cable from the MLB (P4).
3.
Remove the cable wires from the protective wrap.
Figure 83 • Disconnect the Ribbon/Head Open Sensor (S4M)
1
2
3
4
3
4
1
2
Main logic board (MLB)
MLB connector (P4)
Protective wrap
Access hole
4.
See
. Remove the screw securing the ribbon/head open sensor assembly.
5.
Pull the ribbon sensor cable and connector through the main frame.
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184 Ribbon/Head Open Sensor Assembly
Ribbon/Printhead Open Sensor
Figure 84 • Ribbon Sensor Removal and Installation
1
2
3
1
2
3
Ribbon/Head open sensor assembly
Mounting screw
Access hole
Install the New Ribbon/Head Open Sensor Assembly
1.
See
and Figure 83 . Route the sensor wires, with connector, through the access
hole in the printer mainframe.
2.
Place the sensor cable wires back into the protective wrap.
3.
Connect the media sensor cable to the main logic board at P4.
4.
Install the ribbon/head open sensor to the mainframe with the new screw. Do not tighten it at this time.
5.
See
. Using a 0.060 ± 0.015 inch (1.5 mm) feeler gauge, check the distance between the ribbon/head open sensor assembly and the printhead mechanism assembly.
Once this distance is achieved, tighten the mounting screw.
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Ribbon/Printhead Open Sensor
185
Figure 85 • Gap Measurement between Print Mechanism and Sensor
1
0.060 in.(1.5 mm)
±0.015 in.
2
1
2
Gap
Mounting screw
Reinstall the Electronics Cover
1.
See
and install the electronics cover.
2.
Install media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
5.
After the Power-on Self Test (POST), unlatch the printhead mechanism. Look at the front panel to ensure the error/alert LED flashes and the LCD displays ALERT HEAD OPEN.
6.
Close the printhead.
Calibrate the Printer
Perform this procedure only if the thermal transfer option is installed.
1.
Press MENU to enter the Setup Mode.
2.
Press the right arrow ( ) until
ADVANCED SETUP 3
is displayed.
3.
Press ENTER , the printer displays
PASSWORD
and the number
0000
.
4.
Enter the four-digit password for the password level displayed. The factory default password for is 1234.
The left and right arrows change the selected digit position. The up and down arrows change the value of the selected digit.
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186 Ribbon/Head Open Sensor Assembly
Ribbon/Printhead Open Sensor
5.
After entering the password, press ENTER .
If you entered a valid password, additional parameters are displayed.
6.
Press the right arrow ( ) until MEDIA/RIBBON CALIBRATE is displayed.
7.
Press ENTER to start the calibration procedure.
The
LOAD BACKING/REMOVE RIBBON
prompt displays.
8.
Open the printhead.
9.
Remove approximately 8 in. (203 mm) of labels from the backing, and pull the media into the printer so that only the backing is between the media sensors.
10.
Remove the ribbon.
11.
Close the printhead.
12.
Press ENTER to continue.
CALIBRATING PLEASE WAIT
displays.
The printer adjusts the scale (gain) of the signals that it receives from the media and ribbon sensors based on the specific media and ribbon combination being used. On the sensor profile, this corresponds to moving the peak of the graph up or down to optimize the readings for your application.
When calibration is complete,
RELOAD ALL
displays.
13.
Open the printhead and pull the media forward until a label is positioned under the media sensor.
14.
Reload the ribbon (if used) and close the printhead.
15.
Press ENTER to continue.
The printer performs an auto-calibration. During this process, the printer checks the readings for the media and ribbon based on the new scale established, determines the label length, and determines the print mode. To see the new readings on the new scale, print a sensor profile.
After the auto-calibration is complete, MEDIA/RIBBON CALIBRATE is displayed.
16.
Press MENU.
SAVE CHANGES displays.
17.
Press the up ( ) or down arrows ( ) to select YES.
18.
Press ENTER to permanently save the calibration and return to PRINTER READY.
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Preventive and Corrective Maintenance
Reflective Media Sensor
187
Reflective Media Sensor
This procedure is for installing the reflective media sensor in the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Flat-blade Screwdriver Set
‰ Anti-Static Wriststrap and Mat
‰ Safety Goggles
‰ Wire Cutters
Note • Before starting, print a configuration label by pressing and holding CANCEL while turning On ( l ) the printer.
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188 Preventive and Corrective Maintenance
Reflective Media Sensor
Remove the Electronics Cover
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
Turn Off ( O ) the printer and disconnect the AC power cord and all data cables.
3.
Open the media door and remove media and ribbon.
4.
See
and remove the electronics cover.
Remove the Old Media Sensor Assembly
1.
See
. Disconnect the media sensor connector from the MLB (P7).
2.
Remove the wires from the protective wrap and then feed the wires with the connector through the access hole in the frame.
Figure 86 • Media Sensor Connection to MLB
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3
4
1
2
1 2
Main logic board (MLB)
MLB connector P7
Protective wrap
Access hole
S4M Maintenance Manual
3 4
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Preventive and Corrective Maintenance
Reflective Media Sensor
189
3.
. Cut the cable tie securing the media sensor wires inside the wire way of the platen roller housing.
4.
Gently remove the latch cover.
Figure 87 • Media Sensor Removal
1
2
3
10/27/05
4
5 4
6
3
4
1
2
5
6
Platen roller housing
Cable tie
Wireway
Media sensor holder tabs (2)
Media sensor assembly
Latch cover
5.
Slide the media sensor carrier all the way out until it stops, and then gently press down on the carrier and slide the carrier until it drops out of the platen housing.
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190 Preventive and Corrective Maintenance
Reflective Media Sensor
Install the New Media Sensor Assembly
1.
See
. Route the media sensor wires through the wireway in the platen roller assembly and through the access hole in the printer frame. Reinstall the cable tie previously cut in the wireway.
Note • Ensure the wire harness inside the platen roller housing wireway has no twists and travels freely the entire route.
2.
Align the media sensor carrier slots with the slides provided on the platen roller assembly and slide the carrier part way in. Gently press down on the media sensor carrier and push the carrier past the stop.
3.
Release the carrier and push it back and forth to verify traveling its entire route on the platen housing tracks. Reinstall the platen assembly latch cover.
4.
Route the wires behind the ground strap from the printhead.
5.
See
. Insert the wires into the protective wrap.
6.
Connect the media sensor to the main logic board (P7).
Reinstall the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect the AC Power cord and data cables.
4.
Turn On ( l ) the printer.
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Take-Label Sensor
191
Take-Label Sensor
This procedure is for installing the take-label sensor board in the S4M printer. Read these instructions thoroughly before performing this procedure. Installing for the first time or replacing the take-label sensor board requires the partial disassembly of the printer.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Material
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
Remove the Control Panel
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
Disconnect the control panel ribbon cable from J2 on the main logic board (MLB).
4.
If installed, remove the take-label sensor cable from J19 on the MLB and then remove it from the conduit.
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Take-Label Sensor
Figure 88 • Remove and Install the Control Panel
1
2 3 4
5 6
7
8
9
13 12
11 10
5
6
7
3
4
1
2
Main frame
Main logic board (MLB)
J19, Take-label sensor
Control panel cable
J2, control panel
Mounting screw
Split washer
8
9
10
11
12
13
Star washer
Control panel
Tab
Cable access hole
Access hole
Conduit
5.
Remove the mounting screw and washers securing the control panel.
6.
Tip the top of the control panel away from the main frame enough to release the two tabs inserted into the base and then pull it out of the base.
7.
Carefully guide the control panel cable and the take-label sensor cable, if installed, through their access holes.
8.
Are you replacing a defective take-label sensor?
If...
Yes
No
Then...
Continue with Remove the Take-Label Sensor Board on page 193 .
Go to
Install the Take-Label Sensor Board on page 194 .
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Take-Label Sensor
193
Remove the Take-Label Sensor Board
1.
See
. Locate the take-label sensor board on the control panel.
2.
Remove and discard the mounting screws and then lift the board out of the control panel and discard it.
Figure 89 • Remove and Install the Take-Label Sensor
1
2
1
2
Take-label sensor board
Mounting screws (2)
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194 Preventive and Corrective Maintenance
Take-Label Sensor
Install the Take-Label Sensor Board
1.
See
. Align the take-label sensor board with the two guide posts and install it on the posts, ensuring the posts are inserted in the board.
Figure 90 • Install the Take-Label Sensor Board
1
2
3
3
4
1
2
Control panel
Take-label sensor board
Mounting screws (2)
Guide posts (2)
4
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Take-Label Sensor
195
Figure 91 • Install the Take-Label Sensor Board on the Mounting Posts
1
1
2
Mounting posts (2)
Screw holes (2)
2.
Install the two mounting screws supplied in the kit.
2
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196 Preventive and Corrective Maintenance
Take-Label Sensor
Reinstall the Control Panel
1.
Tip the top of the control panel away from the main frame and insert the two tabs in the mounting holes in the base.
1
Figure 92 • Install the Control Panel in the Base
2 3
4
2
5
1
6
3
13291L-001 Rev. A
3
4
1
2
5
6
Base
Control panel
Notch
Tabs (2)
Access holes (2)
Slots (2)
2.
See
. Guide the control panel cable through the access hole in the front of the main frame. Connect it to J2 on the MLB.
3.
Guide the take-label sensor cable around and through the lower access hole in the main frame.
4.
Route the take-label sensor cable through the conduit and then connect it to J19 on the
MLB.
5.
See
. Tip the top of the control panel toward the main frame ensuring the take-label sensor cable is in the notch in the control panel and between the main frame and the platen roller housing leg.
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Take-Label Sensor
197
6.
See
. Install the screw and washer to secure the control panel to the main frame.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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198 Preventive and Corrective Maintenance
Take-Label Sensor
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Drive System
This section provides replacement and installation procedures for the printer’s drive system.
Contents
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200 Preventive and Corrective Maintenance
Ribbon Take-Up Spindle Clutch
Ribbon Take-Up Spindle Clutch
This procedure is for installing the Ribbon Take-up Spindle Clutch into the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Hex Key (Allen Wrench) Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
‰ Metric and inch Feeler Gauges, must include: 0.020 (.508mm)
Remove the Main Logic Board
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
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Ribbon Take-Up Spindle Clutch
201
3.
See
. Remove all cables from the main logic board (MLB).
Note • Take note of the location of all cables on the main logic board.
3
4
1
2
5
6
12
Figure 93 • Remove the Main Logic Board Connections
1
F6
11 10
Printhead data (J3)
Power-in (J8)
Front panel (J2)
Stepper motor (J9)
Booster board (J7)
Ribbon sensor (P4)
7
6
2
4
3
5
9
8
7
8
9
10
11
12
Transmissive sensor (P9)
Reflective sensor (P7)
Take-label sensor (J19)
Communication expansion port (J17)
USB port (J14)
Serial port (J10)
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Ribbon Take-Up Spindle Clutch
4.
See
. Remove the six screws and one nut securing the main logic board to the frame of the printer.
5.
Remove the two studs and washers securing the serial port connector to the back of the printer.
Figure 94 • Remove the Main Logic Board
1
5 4
3
3
4
1
2
Main logic board nut (1)
Main logic board mounting screws (6)
Main logic board (MLB)
Serial port mounting studs (2)
6.
Remove the main logic board from the printer.
7.
Do you have a wireless option board installed?
If…
No
Yes
Then…
Go to
Remove the Old Ribbon Take-up Spindle Clutch on page 204 .
Continue to next step.
2
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Ribbon Take-Up Spindle Clutch
203
Remove the Wireless Board
1.
See
. Remove the two mounting screws securing the wireless board to the back cover.
Figure 95 • Remove Wireless Board
2
3
1
4
5
3
4
1
2
5
6
Mounting screws (2)
Mounting bracket
Bracket mounting screw
Wireless
Option B
oard
Upper mounting standoff
Lower mounting standoff
2.
Remove the upper mounting standoff.
3.
Remove the lower mounting standoff.
4.
Remove the wireless board and set it aside on the anti-static mat.
6
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Ribbon Take-Up Spindle Clutch
Remove the Old Ribbon Take-up Spindle Clutch
1.
. Remove the top mounting screw for the bracket and then loosen the bottom screw.
2.
Move the mounting bracket to gain access to the ribbon take-up spindle clutch gear.
Figure 96 • Move the Mounting Bracket
1 2 3 4
3
4
1
2
Bracket
Intermediate gear
Mounting screw
Mark the outside of the compound gear.
3.
Mark the compound gear with a marker so you will know the proper position of the gear.
4.
Remove the compound gear mounting screw.
5.
Remove the compound gear.
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205
6.
See Figure 97 . Loosen the two set screws on the ribbon take-up spindle collar and slide the
collar off of the shaft.
7.
Remove the plastic thrust washer, bearing, and clutch gear assembly from the shaft of the ribbon take-up spindle assembly.
Figure 97 • Ribbon Take-Up Spindle Assembly/Disassembly
6
5
3
2
1
7
4
5
6
7
3
4
1
2
Compound gear mounting screw
Compound gear
Collar
Clearance—0.020 in. (0.508 mm)
Thrust washer
Clutch gear w/spring
Washer
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Ribbon Take-Up Spindle Clutch
Install the New Clutch Assembly
1.
See
. Slide the clutch gear assembly, bearing, plastic thrust washer, and collar onto the end of the ribbon take-up spindle assembly shaft. Ensure the clutch assembly gear meshes with the compound gear.
2.
Place a 0.020 in. (0.508 mm) feeler gauge between the thrust washer and the collar. From the media side, push in on the ribbon take-up spindle. Tighten the two set screws in the collar and ensure the ribbon take-up spindle turns freely.
Reinstall the Compound Gear
1.
See
. Reinstall the compound gear with your mark facing out.
2.
See
. Align the mounting bracket with the mounting hole and then reinstall the top mounting screw.
3.
Tighten the bottom mounting screw.
4.
Do you have a wireless option card?
If…
No
Yes
Then…
.
. Reinstall the wireless option board.
Reinstall the MLB
1.
See
. Reinstall the MLB.
2.
See
. Reconnect all cables to the MLB.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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207
Ribbon Take-Up Spindle
This procedure is for installing the Ribbon Take-Up Spindle into the S4M printer. Read these instructions thoroughly performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Hex Key (Allen Wrench) Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
‰ Metric and inch Feeler Gauges, must include: 0.020 (0.508mm)
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Ribbon Take-Up Spindle
Remove the Main Logic Board
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Remove all cables from the main logic board (MLB).
Note • Take note of the location of all connectors on the main logic board.
3
4
1
2
5
6
F6
12
Figure 98 • Remove the Main Logic Board Connections
1
11 10
Printhead data (J3)
Power-in (J8)
Front panel (J2)
Stepper motor (J9)
Booster board (J7)
Ribbon sensor (P4)
7
6
2
4
3
5
9
8
7
8
9
10
11
12
Transmissive sensor (P9)
Reflective sensor (P7)
Take-label sensor (J19)
Communication expansion port (J17)
USB port (J14)
Serial port (J10)
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4.
See
. Remove the six screws and one nut securing the main logic board to the frame of the printer.
5.
Remove the two studs and washers securing the serial port connector to the back of the printer.
Figure 99 • Remove the Main Logic Board
1
5 4
3
3
4
1
2
5
Main logic board nut (1)
Main logic board mounting screws (6)
Main logic board (MLB)
Lock washers (2)
Serial port mounting studs (2)
6.
Remove the main logic board from the printer.
7.
Do you have a wireless option board installed?
If…
No
Yes
Then…
Go to
.
Continue to Remove the Wireless Option Board on page 210
2
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Ribbon Take-Up Spindle
Remove the Wireless Option Board
1.
. Remove the two mounting screws securing the wireless board to the back cover.
Figure 100 • Remove Wireless Board
2
1
3
4
3
4
1
2
5
Mounting screws (2)
Mounting bracket
Wireless option board
Upper mounting standoff
Lower mounting standoff
2.
Remove the upper mounting standoff.
3.
Remove the lower mounting standoff.
4.
Remove the wireless board and set it aside on the anti-static mat.
5
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Remove the Old Ribbon Take-up Spindle Assembly
1.
See
. Remove the top mounting screw for the bracket and then loosen the bottom screw.
2.
Move the mounting bracket to gain access to the ribbon take-up spindle clutch gear.
Figure 101 • Move the Mounting Bracket
1 2 3 4
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3
4
1
2
Bracket
Intermediate gear
Mounting screw
Mark the outside of the compound gear.
3.
Mark the compound gear with a marker so you will know the proper position of the gear.
4.
Remove the compound gear mounting screw.
5.
Remove the compound gear.
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Ribbon Take-Up Spindle
6.
See
. Loosen the two set screws on the ribbon take-up spindle collar and slide the collar off of the shaft.
7.
Remove the plastic thrust washer, bearing, and clutch gear assembly from the shaft of the ribbon take-up spindle assembly.
Figure 102 • Ribbon Take-Up Spindle Assembly/Disassembly
6
5
3
2
1
7
4
5
6
7
3
4
1
2
Compound gear mounting screw
Compound gear
Collar
Clearance—0.020 in. (0.508 mm)
Thrust washer
Clutch gear w/spring
Washer
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8.
See
. From the media side, remove the ribbon take-up spindle assembly and washer by sliding it out of the printer.
Figure 103 • Ribbon Take-Up Spindle Assembly/Disassembly
1
2
3
7
6
4
5
1
2
3
4
Collar
Thrust washer
S4M clutch gear
Washer
5
6
7
Ribbon take-up spindle assembly
Washer
Clearance—0.020 in.
(0.508 mm)
Install the New Ribbon Take-Up Spindle Assembly
1.
. Slide the washer removed previously onto the ribbon take-up spindle assembly shaft.
2.
On the media side, slide the ribbon take spindle shaft through the hole in the main frame.
3.
On the electronics side, place the washer, gear clutch assembly, plastic thrust washer, and collar onto the end of the ribbon take-up assembly shaft. Ensure the gear clutch assembly gear meshes with the other compound gear.
4.
Place a 0.020 in. (0.508 mm) feeler gauge between the thrust washer and the collar. From the media side, push in on the ribbon take-up spindle. Tighten the two screws in the collar and ensure the ribbon take-up spindle turns freely.
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Ribbon Take-Up Spindle
Complete the Installation
1.
Did you remove a wireless option board?
If…
No
Yes
Then…
. a.
b.
See Figure 100 on page 210 . Reinstall the wireless option board.
.
Install the MLB
1.
. Align the mounting bracket with the mounting hole and then reinstall the top mounting screw.
2.
Tighten the bottom mounting screw.
3.
See
. Reinstall the MLB.
4.
See
. Reconnect all cables to the MLB.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Ribbon Supply Spindle
215
Ribbon Supply Spindle
This procedure is for installing the ribbon supply spindle into the S4M printer. Read these instructions thoroughly before performing this procedure.
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Standard Hex Key (Allen Wrench) Set
‰ Metric Hex Key (Allen Wrench) Set
‰ Standard Open-End Wrench Set
‰ Metric Open-End Wrench Set
‰ Standard Nutdriver Set
‰ Anti-Static Wriststrap and Mat
‰ Metric Nutdriver Set
‰ 01773 Spindle Torque Adjustment Kit
‰ 77593 Remove Tool
‰ 77620 (Qty = 2) Washer
‰ 77598 Nut
‰ 77594 Screw M4 x 0.70 x 60 mm
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Ribbon Supply Spindle
Remove the Old Ribbon Supply Spindle
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
See
and remove the electronics cover.
2.
See
. Remove the stepper motor locking screw and the stepper motor pivot screw.
3.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Figure 104 • Disconnect the Stepper Motor
1
2
3
1
2
3
Main logic board (MLB)
Connector J9
Stepper motor cable
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Figure 105 • Stepper Motor Removal and Installation
2
3
1
6
3
4
1
2
5
6
Stepper motor
Intermediate gear
Pivot screw
Belt
Locking screw
Pivot plate
5
4
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Ribbon Supply Spindle
4.
See
. Remove the ribbon supply spindle mounting screw and washer.
Figure 106 • Remove the Ribbon Supply Spindle Mounting Screw
1
1
2
Ribbon spindle mounting screw
Ribbon spindle mounting washer
5.
Push the spindle out of the main frame.
2
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219
6.
See
. Slide the spindle remove tool over the ribbon supply spindle on the printer.
7.
Install the screw into the end of the spindle assembly until it bottoms out.
8.
Slide the washer over the end of the screw until it is against the remove tool.
9.
Install the nut until it rests against the washer.
Figure 107 • Using the Remove Tool
1
2
3
4
5
3
4
1
2
5
Spindle assembly
Spindle remove tool
Washer
Screw
Nut
10.
While holding the remove tool and using the nut driver, turn the nut clockwise to remove the ribbon supply spindle from the printer.
11.
Remove the nut, washer, and screw from the spindle.
12.
Slide the remove tool from the spindle.
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Ribbon Supply Spindle
Install the New Ribbon Supply Spindle Assembly
1.
See Figure 108 . Place a small amount of grease on the tolerance rings of the ribbon supply
spindle shaft.
Figure 108 • Lubrication
Put grease here.
2.
See
. Install the thin washer onto the spindle shaft.
Figure 109 • Install the Thin Washer
13291L-001 Rev. A
1
2
1
2
Thin washer
Ribbon supply spindle shaft
3.
See
. Slide the remove tool onto the new spindle assembly, then gently push the ribbon supply spindle assembly into the printer main frame.
Note • In
, do not use force or pound on the ribbon supply spindle or the remove tool.
4.
See
Figure 110 . Install the tool screw into the spindle shaft until it bottoms out.
5.
Slide the washer over the end of the screw until it is against the main frame.
6.
Install the nut until it rests against the washer.
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221
Figure 110 • Spindle Installation
1
2
10/27/05
1
2
Nut
Screw
7.
While holding the remove tool, turn the nut clockwise to draw the ribbon supply spindle into the printer. Once the spindle is in the printer, turn the spindle nut ½ turn counterclockwise and remove the screw, nut, and washer.
8.
Reinstall the spindle mounting screw and washer previously removed.
9.
See
. Reinstall the intermediate gear, ensuring the gears mesh properly.
10.
Loosely reinstall the stepper motor using the pivot screw, locking screw, and adjustment nut.
Note • The belt should have some deviation, but no more than ¼ inch.
11.
While lifting up on the stepper motor, reinstall the drive belt. Release the stepper motor to provide tension on the belt.
12.
Ensure the belt tension is correct and tighten the locking screw to secure the motor.
13.
Tighten the pivot screw.
14.
See
. Reconnect the stepper motor cable to J9 on the MLB.
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222 Preventive and Corrective Maintenance
Ribbon Supply Spindle
15.
Set the tension on the ribbon supply spindle to either the high or low setting depending on the width of the ribbon.
Note • If your ribbon is wide, use the high tension setting. If you experience ribbon slippage, use the low tension setting.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Hanger Assembly
223
Media Hanger Assembly
This procedure is for installing the media hanger assembly into the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
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Hanger Assembly
Remove the Main Logic Board
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
Open the media door and remove the media and ribbon
4.
See
. On the electronics side, disconnect all cables from the main logic board.
Note • Take note of the orientation of all cables on the main logic board.
3
4
1
2
5
6
F6
Figure 111 • Disconnect the Main Logic Board Connections
1
12
11 10
Printhead data (J3)
Power-in (J8)
Front panel (J2)
Stepper motor (J9)
Booster board (J7)
Ribbon sensor/head open (P4)
7
6
2
4
3
5
9
8
7
8
9
10
11
12
Transmissive sensor (P9)
Reflective sensor (P7)
Take-label sensor (J19)
Communication expansion port
(J17)
USB port (J14)
Serial port (J10)
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5.
See
Figure 112 . Remove the six screws and one nut securing the main logic board to the
back of the printer.
6.
Remove the two studs and washers securing the serial port connector to the printer.
Figure 112 • Remove the Main Logic Board
1
5 4
3
3
4
1
2
4
Main logic board nut
Main logic board mounting screws (6)
Main logic board (MLB)
Lock washers (2)
Serial port mounting studs (2)
7.
Remove the main logic board from the printer.
2
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Hanger Assembly
8.
See
Figure 113 . Remove the four hanger mounting screws and then remove the hanger
from the printer.
Figure 113 • Remove/Install the Hanger Assembly
1
1
2
1
2
Hanger assembly mounting screws (4)
Hanger assembly
Install the New Hanger Assembly Kit
1.
See Figure 113 . Install the new hanger assembly using the four mounting screws removed
previously.
2.
See
Figure 112 on page 225 . Install the main logic board in the printer using the six
mounting screws and one nut removed previously.
3.
Reinstall the two studs and washers securing the serial port.
4.
See
. Reconnect all the cables previously disconnected from the main logic board. Visually inspect and ensure the cables are in their proper location and seated in the connectors.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect the AC Power cord and data cables.
4.
Turn On ( l ) the printer.
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Stepper Motor and Gear/Pulley
227
Stepper Motor and Gear/Pulley
This procedure is for installing the stepper motor and gear/pulley in the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Hex Key (Allen Wrench) Set
‰ Anti-Static Wriststrap and Mat
‰ Metric Nutdriver Set
Remove the Old Stepper Motor
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
Figure 114 . Locate the stepper motor and drive belt.
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Stepper Motor and Gear/Pulley
Figure 114 • Locate Drive System Components
1 2
3
6
5
3
4
1
2
5
6
MLB J9
Stepper motor
Drive belt
Platen pulley
Locking screw
Pivot screw
4.
Disconnect the stepper motor cable from the main logic board (MLB), J9.
5.
Remove the locking screw and nut.
6.
Remove the pivot screw and then remove the stepper motor.
4
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229
Install the New Stepper Motor and Gear
1.
See
Figure 114 on page 228 . Install the stepper motor by sliding the gear/pulley through
the drive belt. Secure in position with the pivot screw, but do not tighten at this time.
2.
Reinstall the locking screw and nut, but do not tighten at this time
Note • Belt should deflect under finger pressure but no more than ¼ inch (6 mm).
3.
Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then the pivot screw.
4.
Connect the stepper motor power cable to J9 on the MLB.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Gears and Pulley
Gears and Pulley
This procedure is for installing the drive system maintenance kit into the S4M printer. Read these instructions thoroughly before attempting to perform this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Hex Key (Allen Wrench) Set
‰ Anti-Static Wriststrap and Mat
‰ Metric Nutdriver Set
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Remove the Main Logic Board
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
Figure 115 . Remove all cables from the main logic board (MLB).
Note • Take note of the location of all cables on the main logic board.
Figure 115 • Remove the Main Logic Board Cables
1
12
6
2
4
3
11 10
5
7
F6
9
8
3
4
1
2
5
6
Printhead data (J3)
Power-in (J8)
Front panel (J2)
Stepper motor (J9)
7
8
9
10
11
12
Transmissive sensor (P9)
Reflective sensor (P7)
Take-label sensor (J19)
Communication expansion
Port (J17)
USB port (J14)
Serial port (J10)
Booster board (J7)
Ribbon Sensor/Head Open
(P4)
4.
See
Figure 116 . Remove the six screws and one nut securing the main logic board to the
frame of the printer.
5.
Remove the two studs and washers securing the serial port connector to the back of the printer.
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Gears and Pulley
Figure 116 • Remove the Main Logic Board
5 4
3
4
1
2
5
Main logic board nut (1)
Main logic board mounting screws (6)
Main logic board (MLB)
Serial port mounting studs (2)
Lock washers (2)
6.
Remove the main logic board from the printer.
3 2
1
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Remove the Drive Belt
1.
See
Figure 117 . Locate the stepper motor and drive belt.
Figure 117 • Locate Drive System Components
1 2
3 4
10/27/05
8
7
6
5
9
3
4
1
2
5
Compound gear
Mounting screw
Intermediate gear
Set screws (2)
Compound pulley
8
9
6
7
Drive belt
Locking screw
Stepper motor
Pivot screw
2.
Loosen the pivot screw and locking screw, then remove the stepper motor and remove the drive belt.
Note • The compound pulley has two drive wheels that allow for 200 or 300 dpi operation. Note the location and orientation of the drive belt on the pulley before removing.
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Gears and Pulley
Remove the Stepper Motor, Pulley, and Gears
1.
Remove the locking screw and nut.
2.
Remove the pivot screw and then remove the stepper motor and set it aside.
3.
Remove the intermediate gear.
4.
Remove the compound gear mounting screw.
5.
Loosen the two set screws and remove the platen roller pulley. Note the orientation of the pulley.
Install the New Gears and Compound Pulley
1.
See
Figure 118 . What is the dpi for your printer?
If… Then…
200 dpi Install the set screws as shown for 200 dpi.
300 dpi Install the set screws as shown for 300 dpi.
Figure 118 • Select the Orientation of the Compound Pulley and Set Screws
200 dpi 300 dpi
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235
2.
See
Figure 119 . Slide the pulley onto the platen pulley shaft in the proper orientation and
align the set screws with the flat spots on the platen roller shaft.
Figure 119 • Align Flat Spots on the Shaft
1
2
2
1
2
Set screws (2)
Platen roller shaft flat spots
3.
See Figure 117 . Leave approximately 1/32 in. (0.80 mm) from the main frame and tighten
the set screws.
4.
Install the intermediate gear, stepper motor, and drive belt. Secure in position with the pivot screw, do not tighten at this time.
5.
Reinstall the locking screw and nut, do not tighten at this time.
Note • The belt should deflect under finger pressure but no more than ¼ inch (6 mm).
6.
Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then the pivot screw.
Caution • Do not over tighten the belt, damage to the bearings and platen roller will occur.
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Gears and Pulley
7.
See
. Select the proper orientation for the compound gear, 200 or 300 dpi.
Figure 120 • Select the Proper Compound Gear Position
1 2
THIS
SID
E
O
U
T
/2
H
IS
S
ID
E
OU
T/300 DP
I
1
2
For 200 dpi, face this side out
For 300 dpi, face this side out
8.
Install the compound gear and slightly tighten the mounting screw. Ensure all gears mesh together and then tighten the mounting screw.
Reinstall the MLB
1.
See
Figure 116 on page 232 . Reinstall the MLB.
2.
See
Figure 115 on page 231 . Reconnect all cables to the MLB.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Peel-Off/Tear-Off Bar
237
Peel-Off/Tear-Off Bar
This procedure is for installing the peel-off/tear-off bar in the printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ 2.5 mm Hex Key (Supplied)
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Peel-Off/Tear-Off Bar
Remove the Front Cover
1.
Turn Off ( O ) the printer and remove the AC power cord and data cables.
2.
Open the media door and remove the media and ribbon.
3.
See
. Carefully remove the latch cover.
4.
Using a small flat-blade screwdriver, pry the front cover off.
Figure 121 • Remove the Latch and Front Covers
1
3
2
3
4
13291L-001 Rev. A
3
4
1
2
Media door
Latch cover
Front cover
Flat-blade screwdriver
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Peel-Off/Tear-Off Bar
239
Replace the Peel-Off/Tear-Off Bar
1.
Remove the two peel-off/tear-off bar mounting screws.
Figure 122 • Remove and Install the Peel-Off/Tear-Off Bar
1
10/27/05
2
3
1
2
3
Peel-off/tear-off bar
Peel-off/tear-off bar mounting screws (2)
Rest the bumps on the housing here
2.
Lift the peel-off/tear-off bar out of the platen housing.
3.
Install the new peel-off/tear-off bar into the platen housing. Do not tighten the mounting screws at this time.
Note • You may find it is easier to insert the left side first.
4.
Lift the peel-off/tear-off bar up slightly. Push the peel-off/tear-off bar back against the horizontal mounting bar of the platen housing and then back down until the bumps are resting on the mounting bar.
5.
Tighten the mounting screws while keeping pressure down on the peel-off/tear-off bar.
6.
See
. Reinstall the front cover.
7.
Reinstall the latch cover.
8.
Reinstall the media and ribbon.
9.
Reconnect the AC power cord and apply power.
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240 Preventive and Corrective Maintenance
Peel Option
Peel Option
This procedure is for installing the peel option into the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Flat-Blade Screwdriver Set
‰ Metric Hex Key (Allen Wrench) Set
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241
Remove the Front Cover
1.
Turn Off ( O ) the printer and remove the AC power cord and data cables.
2.
Open the media door and remove the media and ribbon.
3.
See
. Carefully remove the latch cover.
4.
Using a small flat-blade screwdriver, pry the front cover off.
Figure 123 • Remove the Latch and Front Covers
1
3 2
3
4
10/27/05
3
4
1
2
Media door
Latch cover
Front cover
Use flat-blade screwdriver here
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242 Preventive and Corrective Maintenance
Peel Option
5.
Reinstall the latch cover.
6.
Do you have an existing peel option?
If…
No
Yes
Then…
Continue to next step.
Go to Remove the Peel Assembly on page 243
.
Remove the Tear Bar
1.
See
. Remove the two tear bar mounting screws.
Figure 124 • Remove the Tear Bar
1
2
1
2
Tear bar
Mounting screws (2)
2.
Remove the tear bar.
3.
Go to Install the Peel Assembly on page 244 .
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Peel Option
243
Remove the Peel Assembly
1.
See
. Remove the two mounting screws and then remove the peel assembly.
Figure 125 • Remove Old Peel Assembly
1
1
2
2
Peel assembly
Mounting screws (2)
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Peel Option
Install the Peel Assembly
1.
See
. Using the hex key (Allen wrench) supplied, install the two mounting screws from the kit into the tear bar mounting screw holes. Tighten them to within 1/8 in. of the platen housing.
Figure 126 • Install Peel Assembly
3
4
1
2
6
5
3
4
1
2
5
6
Peel assembly
Mounting slots (2)
Mounting screws (2)
Platen housing
Rest pems on housing here
Peel lever
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245
2.
See
. Notice the pems and the mounting slots.
Figure 127 • Rear View of Peel Assembly
1
2
1
2
Mounting slots (2)
Pems (2)
3.
See
. Install the peel assembly with the pems to the rear and the opening in the mounting slot to the top. a.
Insert the mounting slot opening over the two screws and lift up on the assembly. b.
Now push the assembly back against the vertical surface of the platen housing then down, so that the pems are resting on the horizontal surface of the platen housing.
4.
Maintain a slight pressure downward on the peel assembly to keep the pems on the horizontal surface, and tighten the mounting screws.
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Peel Option
Install the New Front Cover
1.
See
. Insert the front cover mounting tabs through the mounting holes in the base.
2.
Install the two rivets though the two tabs and into the base mounting holes.
Figure 128 • Install the Front Cover
3
4
2
3
4
1
2
Front cover
Plastic rivets (2_
Rivet open
Rivet closed
3.
Reinstall the media and ribbon.
4.
Reinstall the AC power cord and data cables.
5.
Turn On ( l ) the printer.
1
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Peel Option
247
Select the Peel Mode
1.
Press MENU to enter the Setup Mode.
2.
Use the left or right arrow to scroll through the parameters until REMOVAL is displayed.
3.
Use the up or down arrow until PEEL is displayed.
4.
Press MENU .
The printer displays SAVE CHANGES and activates the ENTER button.
5.
Press ENTER .
The printer saves changes and exits Setup mode
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Static Brush
Static Brush
This procedure is for installing the static brush assembly in the printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
• S4M User CD
• S4M User Guide
• S4M Quick Reference Guide
Tools Required
Tools • You need these tools to complete this procedure:
‰ Metric Nutdriver Set
Remove the Old Static Brush Assembly
1.
Turn Off ( O ) the printer and disconnect the AC power cord.
2.
Open the media cover and remove all media and ribbon.
3.
See
. Remove the two mounting screws securing the brush assembly.
4.
Remove the brush assembly from the printer.
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Static Brush
249
Figure 129 • Remove and Install the Static Brush Assembly (S4M)
1
2
1
2
Mounting screws (2)
Static brush assembly
Install the New Static Brush Assembly
1.
See
. Secure the new static brush assembly to the printer frame with two mounting screws.
2.
Reinstall the ribbon and media and close the media cover.
3.
Reconnect the AC power cord, data cables and turn On ( l ) the printer.
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Dancer Assembly
Dancer Assembly
This procedure is for installing the dancer assembly in the printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Long Needle Nose Pliers
‰ Flat-Blade Screwdriver Set
‰ Safety Goggles
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Remove the Old Dancer Assembly
1.
Turn Off ( O ) the printer and disconnect the power cord and all data cables.
2.
See
. Open the media door and remove the media and ribbon.
Figure 130 • Open the Media Door
Dancer Maintenance Kit
Dancer Assembly
251
1
2
1
2
Media door
Dancer assembly
3.
See
. Relieve the spring tension from the dancer assembly by using a long needle nose pliers to move the torsion spring leg off the printer post.
4.
Caution • Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
Remove the E-ring, then slide off the bearings, the dancer, and the torsion spring.
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Dancer Assembly
Figure 131 • Dancer Assembly
5
6
1
2
3
4
3
4
1
2
5
6
Torsion spring
Dancer
E-ring
Flanged bearing (2)
Printer post
Dancer tab
Install the New Dancer Assembly
1.
See
. Install the new torsion spring, the first bearing, the dancer, the second bearing, and finally the E-ring.
2.
Place the dancer assembly torsion spring back to its operating position against the printer post and dancer tab. Ensure there is tension on the dancer assembly.
3.
Reinstall media and ribbon, and then close the media door.
4.
Reconnect the AC power cord and data cables.
5.
Turn On ( l ) the printer.
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Outer Media Guide
253
Outer Media Guide
This procedure is for installing the outer media guide in the printer. Read these instructions thoroughly before installing this kit.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver, Stubby ‰ Safety Goggles
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Outer Media Guide
Remove the Outer Media Guide
1.
Turn Off ( O ) the printer and disconnect the AC power cord.
2.
Open the media side cover and remove all media and ribbon from the printer.
3.
Caution • Wear protective eye wear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
See
and Figure 133 . Remove the thumb nut or screw, washer, and spring.
4.
Lift the outer media guide out of the platen housing.
Figure 132 • Remove the Old Outer Media Guide
1
2
1
2
Outer media guide
Mounting nut or screw
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Install the Outer Media Guide
1.
See
. Place the new outer media guide in the platen assembly.
2.
Install the spring and washer on the outer media guide screw.
Figure 133 • Install the New Outer Media Guide
1
2
3
4
3
4
1
2
Outer media guide
Washer
Compression spring
Screw
3.
Install the outer media guide thumbnut or screw, spring, and washer to secure the outer media guide.
4.
Reinstall the media and ribbon and close the media door.
5.
Reconnect the AC power cord.
6.
Turn On ( l ) the printer.
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Outer Media Guide
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Roller System
This section provides replacement and installation procedures for the S4M roller system.
Contents
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258 Preventive and Corrective Maintenance
Platen Roller
Platen Roller
This kit includes the parts and documentation necessary to install the Platen Roller
Maintenance Kit into the following printers: Z Series
®
(S4M™. Read these instructions thoroughly before installing this kit.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Flat-blade Screwdriver Set
‰ Metric Hex Key (Allen Wrench) Set
‰ Needle Nose Pliers
‰ Safety Goggles
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Platen Roller
259
Remove the Platen Roller Pulley and Belt
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Loosen the stepper motor locking screw and pivot screw. Remove the drive belt from the stepper motor.
Figure 134 • Stepper Motor Pivot Screw and Locking Screw
3
2
4
1
5
6
10/27/05
3
4
1
2
5
6
Stepper motor
Pivot screw
Belt
Platen pulley
Platen pulley set screws (2)
Locking screw
4.
Pivot up the stepper motor and remove the drive belt.
Note • Make a note of the orientation of the platen pulley and around which section of the platen pulley the belt is installed.
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260 Preventive and Corrective Maintenance
Platen Roller
5.
Loosen the two set screws on the platen pulley.
6.
Remove the pulley and belt from the platen roller shaft.
7.
Do you have a peel printer?
If…
No
Yes
Then…
Go to
Remove the Front Cover on page 261
.
Continue to Remove the Peel Assembly .
Remove the Peel Assembly
1.
See
. Remove the two mounting screws and remove the peel assembly.
Figure 135 • Remove Old Peel Assembly
1
2
1
2
Peel assembly
Mounting screws (2)
2.
Go to Remove the Platen Roller on page 263 .
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261
Remove the Front Cover
Figure 136 • Remove the Lower Front Cover
1
3
2
2
1
2
3
Latch cover
Lower front cover
Tabs (2)
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Platen Roller
Remove the Tear Bar
1.
Remove the two mounting screws securing the tear bar, and then remove it.
2.
Note the orientation and location of the tear bar; there are several incorrect ways to reinstall the tear bar. Using a marker, label the appropriate areas with Up and Out.
Figure 137 • Remove the Tear Bar and Latch Cover
1
2
3
1
2
3
Tear bar
Mounting screws (2)
Latch cover
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Platen Roller
263
Remove the Platen Roller
1.
Caution • Wear protective eye wear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
See
. Using two flatblade screwdrivers or a pair of needle-nose pliers, squeeze and push up on the barbed legs of the outboard spring clip to disengage it from the platen housing.
Note • The inner spring clip does not have to be removed to remove the platen roller and bearings.
Figure 138 • Spring Clip Removal
1
2
3 3
10/27/05
1
2
3
Clip
Cut-out
Barbed legs (2)
2.
Locate the circular cut-out on the top of the outer spring clip, insert a screwdriver, gently pry up and remove the clip.
Note • If needed, loosen the inboard clip using the same procedure.
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264 Preventive and Corrective Maintenance
Platen Roller
3.
See
. Remove and discard the platen roller and bearings.
Figure 139 • Remove the Platen Roller and Bearings
2
3
4
1
1
3
4
1
2
Bearings (2)
Inboard clip
Outboard clip
Wave washer
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265
Install the Platen Roller
1.
Caution • Wear protective eye wear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
See
. If removed insert a new spring clip part way in the inboard platen housing.
Note • The flat side of the bearing must face up.
2.
Install the inboard bearing on the inboard platen shaft.
3.
Insert the platen shaft through the inboard clip.
a.
Start the new inboard bearing into the clip.
b.
Work the inboard bearing back and forth until the bearing is up against the clip.
c.
The round side of the bearing goes down into the housing.
4.
Once the inboard bearing is fully against the clip, angle up the outboard end of the platen just enough to slide on the wave washer and outboard bearing. Seat the platen roller and bearings in the platen housing.
5.
Verify that the bearings are seated in the housing with the flat side up.
6.
Position the outer clip straight over the circular part of the outboard bearing.
7.
With a pair of pliers or other small tool, lightly tap in a downward motion on the spring clips until they completely seat (snap) into the housing.
8.
Does your printer have a tear bar?
If…
No
Yes
Then…
a.
See Figure 137 on page 262 . Reinstall the tear bar.
b.
See Figure 136 on page 261 and
Figure 137 on page 262 . Reinstall the
lower front cover and latch cover.
c.
9.
Orient the compound pulley belt in the correct pulley position as noted in
on
and then reinstall the belt around the original pulley.
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266 Preventive and Corrective Maintenance
Platen Roller
Figure 140 • Select the Orientation of the Compound Pulley
200 dpi 300 dpi
10.
See
. Slide the pulley onto the platen pulley shaft in the proper orientation and align the set screws with the flat spots on the platen roller shaft.
Figure 141 • Align Flat Spots on the Shaft
1
2
2
1
2
Set screws (2)
Platen roller shaft flat spots
11.
Leave approximately 1/32 in. (0.80 mm) from the main frame and tighten the set screws.
12.
Caution • Do not over tighten the drive belt, or damage to the bearings and platen roller will occur. The belt should deflect under finger pressure but no more than ¼ inch
(6 mm).
Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then the pivot screw.
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267
Reinstall the Peel Assembly
1.
See
. Install the two mounting screws, using a hex key into the tear bar mounting screw holes. Tighten them to within 1/8 in. of the platen housing.
Figure 142 • Install Peel Assembly
3
4
1
2
6
5
3
4
1
2
5
6
Peel assembly
Mounting slots (2)
Mounting screws (2)
Platen housing
Rest Pems on housing here.
Peel lever
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268 Preventive and Corrective Maintenance
Platen Roller
2.
See
. Notice the pems and the mounting slots.
Figure 143 • Rear View of Peel Assembly
1
2
1
2
Mounting slots (2)
Pems (2)
1
3.
See
. Install the peel assembly with the pems to the rear and the opening in the mounting slot to the top. a.
Insert the mounting slot opening over the two screws and lift up on the assembly. b.
Now push the assembly back against the vertical surface of the platen housing then down, so that the pems are resting on the horizontal surface of the platen housing.
4.
Keep a slight pressure downward on the peel assembly, to keep the pems on the horizontal surface, and tighten the mounting screws.
5.
Reinstall the latch cover.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Pinch Roller
269
Pinch Roller
This kit includes the parts and documentation necessary to install the pinch roller into the printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Flat-blade Screwdriver Set
‰ Awl
‰ Safety Goggles
‰ Metric Hex Key (Allen Wrench) Set
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Pinch Roller
Remove the Pinch Roller
1.
Turn Off ( O ) the printer and disconnect the AC power cord and all data cables.
2.
Open the media door and remove media and ribbon from the printer.
3.
See
. Lower the pinch roller holder assembly to the open position.
4.
Caution • Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
See
. Using a small flat blade screwdriver or an awl, remove and discard the two E-rings.
Note • If you have trouble reaching the E-rings and have a peel assembly installed, you
may have to remove it to access the E-rings. See Figure 145 . Loosen the two mounting
screws, and then remove the peel assembly from the printer.
5.
Remove and discard the bearings and old pinch roller.
Figure 144 • Removing and Installing E-rings and Bearings
1
2 3
4
2
1
5
5
6
3
4
1
2
5
6
E-rings (2)
Roller bearings (2)
Pinch roller
Groove for E-rings (2)
Pinch roller mounting holes (2)
Pinch roller holder assembly
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Pinch Roller
271
Install the Pinch Roller
1.
See
. Install the new pinch roller in the notches in the pinch roller holder assembly.
2.
Install the two new bearings on the shaft of the pinch roller, flange facing out, as shown.
3.
Install two new E-rings in the grooves on the roller shaft.
4.
See
. If you had to remove the peel assembly, reinstall it using the two screws previously removed. Ensure the assembly is firmly seated. Apply downward pressure on the peel assembly as you tighten the two screws.
5.
Raise the pinch roller assembly to the closed position. Ensure the pinch roller holder assembly snaps into position and exerts force on the platen roller.
Figure 145 • Installing the Pinch Roller Assembly
2
1
3
4
3
10/27/05
3
4
1
2
Peel assembly
Mounting screws (2)
Mounting holes (2)
Pinch roller
6.
Reinstall the media and ribbon.
7.
Reconnect the AC power cord and data cables.
8.
Turn On ( l ) the printer.
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272 Preventive and Corrective Maintenance
Pinch Roller
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Printed Circuit Boards
This section provides replacement and installation procedures for the various printed circuit boards and power systems in the S4M printer.
Contents
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Control Panel
Control Panel
This procedure is for installing the control panel in the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
Remove the Old Control Panel
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
Disconnect the control panel ribbon cable from J2 on the main logic board (MLB).
4.
If installed, remove the take-label sensor cable from J19 on the MLB and then remove it from the conduit.
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Control Panel
275
Figure 146 • Remove and Install the Control Panel
1
2
3
4 5
6
7
8
9
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13 11 10
12
5
6
7
3
4
1
2
Main frame
Main logic board (MLB)
J19
Control panel cable
J2
Mounting screw
Split washer
8
9
10
11
12
13
Star washer
Control panel
Tab
Cable access hole
Access hole
Conduit
5.
Remove the mounting screw and washers securing the control panel.
6.
Tip the top of the control panel away from the main frame enough to release the two tabs inserted into the base and then pull it out of the base.
7.
Carefully guide the control panel cable and the take-label sensor cable, if installed, through their access holes.
8.
Is there a take-label sensor board in the old control panel?
If…
No
Yes
Then…
Go to
Install the New Control Panel on page 279
.
Continue with Remove the Take-Label Sensor Board on page 276 .
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Control Panel
Remove the Take-Label Sensor Board
1.
See
. Locate the take-label sensor board on the control panel.
2.
Remove the mounting screws and then lift the board out of the control panel.
Figure 147 • Remove and Install the Take-Label Sensor Board
1
2
1
2
Take-label sensor board
Mounting screws (2)
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Control Panel
277
Install the Take-Label Sensor Board
1.
See Figure 148 . Align the take-label sensor board with the two guide posts and install it on
the posts, ensuring the posts are inserted in the board.
Figure 148 • Install the Take-Label Sensor Board
1
2
3
3
4
1
2
Control panel
Take-label sensor board
Mounting screws (2)
Guide posts (2)
4
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Control Panel
Figure 149 • Install the Take-Label Sensor Board on the Mounting Posts
1
2
1
2
Posts (2)
Screw holes (2)
2.
See
. Reinstall the two mounting screws.
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Control Panel
279
Install the New Control Panel
1.
Tip the top of the control panel away from the main frame and insert the two tabs in the mounting holes in the base.
1
Figure 150 • Install the Control Panel in the Base
2 3
4
2
5
1
6
3
10/27/05
3
4
1
2
5
6
Base
Control panel
Notch
Tabs (2)
Access holes (2)
Slots (2)
2.
See
. Guide the control panel cable through the access hole in the front of the main frame. Connect it to J2 on the MLB.
3.
Do you have a take-label sensor?
If…
No
Yes
Then…
a.
Guide the take-label sensor cable around and through the lower access hole in the main frame.
b.
Route the take-label sensor cable through the conduit and then connect it to
J19 on the MLB. Continue to step 4
.
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Control Panel
4.
. Tip the top of the control panel toward the main frame and ensure that the take-label sensor, if installed, cable is in the notch in the control panel and between the main frame and the platen roller housing leg.
5.
. Reinstall the screw and washers to secure the control panel to the main frame.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Main Logic Board
281
Main Logic Board
This procedure is for installing the main logic board in the S4M printer. Read these instructions thoroughly before attempting this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Standard Nutdriver Set
‰ Anti-Static Wriststrap and Mat
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Main Logic Board
Remove the Old Main Logic Board
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Remove all cables from the main logic board.
Note • Take note of the location of all connectors on the main logic board.
3
4
1
2
5
6
F6
Figure 151 • Remove the Main Logic Board Connections
1
12
11 10
Printhead data (J3)
Power-in (J8)
Front panel (J2)
Stepper motor (j9)
Booster board (J7)
Ribbon sensor, head open sensor (P4)
7
6
2
4
3
5
9
8
7
8
9
10
11
12
Transmissive sensor (P9)
Reflective sensor (P7)
Take-label sensor (J19)
Communication expansion port (J17)
USB port (J14)
Serial port (J10)
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Main Logic Board
283
4.
See
. Remove the six screws and one nut securing the main logic board to the frame of the printer.
5.
Remove the two studs and washers securing the serial port connector to the back of the printer.
Figure 152 • Remove the Main Logic Board
1
5 4
3
3
4
1
2
5
Main Logic Board Nu t (1)
Main logic board mounting screws (6)
Main logic board (MLB)
Lock washers (2)
Serial port mounting studs (2)
6.
Remove the main logic board from the printer.
2
Install the New Main Logic Board
1.
Remove the new main logic board assembly from its packaging.
2.
See
. Install the new main logic board in the printer using the screws, nut, and studs and washers previously removed.
3.
See
. Reconnect all the cables previously removed from the main logic board.
Visually inspect and ensure the cables are in their proper location and seated in the connectors.
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Main Logic Board
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Press the up arrow ( ) while turning On ( l ) the printer.
5.
After the Power-On Self Test (POST) is completed, press MENU .
6.
Press the right arrow ( ) until DIRECT THERMAL is displayed.
7.
What type of S4M printer do you have?
If you have… Then…
Direct Thermal Press the up or down arrows ( or ) until NO is displayed.
Thermal Transfer Press up or down arrows ( or ) until YES is displayed.
8.
Press MENU to exit.
9.
Turn off the printer.
10.
Press and hold CANCEL while turning On ( l ) the printer. A configuration label will print after the Power-On Self Test (POST) is completed.
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Corrective Maintenance
Replace the Main Logic Board (MLB) Fuse
285
Mail Logic Board Fuse
This procedure is for installing a replacement main logic board (MLB) fuse in the S4M printer.
Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
1.
Disconnect the AC power cord and data cables.
2.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
3.
See
. Remove the electronics cover.
4.
See Figure 153 . Using a needle nose pliers, locate and carefully remove the fuse (F6) from
the MLB.
Figure 153 • Locate and Remove the MLB Fuse
F6
Fuse 1A 125V
F6
5.
Install the new fuse.
6.
See
. Reinstall the electronic cover.
7.
Reconnect the AC power cord and data cables.
8.
Turn On ( l ) the printer.
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Real Time Clock
Real Time Clock
This procedure is for installing the Real Time Clock (RTC) option board in the S4M printer.
Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Material
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Needle Nose Pliers
‰ Wire Cutters
‰ Anti-Static Wriststrap and Mat
‰ Safety Goggles
1.
Are you replacing a defective RTC option board?
If...
Yes
No
Then...
Go to Remove the RTC Option Board on page 287
.
Go to
Install the RTC Option Board on page 289
.
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Real Time Clock
287
Remove the RTC Option Board
1.
See
. Locate the RTC option board.
Figure 154 • Locate the RTC Option Board
1
2
1
2
RTC option board
Main logic board (MLB)
2.
Are you installing the RTC option board for the first time?
If…
Yes
No
Then…
Go to Install the RTC Option Board on page 289
.
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Real Time Clock
3.
Caution • Wear protective eye wear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.
See
. To remove the standoffs, use a needle nose pliers to pull out the pins in each of the standoffs and then pull the body of each to remove them from the MLB and the
RTC board.
Figure 155 • Remove and Install the Spacers and Standoffs
Open
Closed
4
5
1 3
Pull
8
2
6
Standoff
7
+
9
7
8
5
6
9
3
4
1
2
RTC option board
Main logic board (MLB)
Standoffs (2)
Pins (2)
Standoff body (2)
Spacers (2)
Locking tabs (2)
Battery
J1 on RTC board
4.
Squeeze the spacer locking tab with the needle nose pliers while lifting the board slightly, and then do the same to the other spacer to remove the RTC option board.
5.
Continue to
step 3 of Install the RTC Option Board on page 289 .
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Real Time Clock
289
Install the RTC Option Board
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
. First time installation only: Install the plastic spacers into the left two holes in the MLB.
Figure 156 • Install the Spacers
2
1
Install the spacers here.
10/27/05
1
2
Main logic board (MLB)
Spacers (2)
3.
See
and Figure 157 . Install the RTC option board on to the spacers, J1 of the
RTC board facing J5 on the MLB; push down until they lock.
Figure 157 • Install the RTC Option Board
1
+
2
3
1
2
3
4
5
Battery
RTC option board
J1 RTC board
J5 MLB
Spacers (2)
S4M Maintenance Manual
5
4
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Real Time Clock
4.
. Ensure the pin is pulled out of the standoff and then insert the standoff, spring up, through one of the holes on the right side of the RTC board and into the MLB until it snaps in place.
5.
Push the pin in as far as possible to lock the standoff.
6.
Repeat
step 4 and step 5 for the other standoff.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Press and hold CANCEL while turning On ( l ) the printer.
A configuration label prints. (See Figure 158 .)
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Real Time Clock
291
5.
See
. Check the configuration label to verify the RTC board was recognized. If it is not recognized, the circled display will not be visible.
Figure 158 • Configuration Label
RTC date and time visible.
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Real Time Clock
Set the RTC
1.
See
. Press MENU , then .
Note • To enter the password, press to increase the value, to decrease the value, to move the curser to the left, and to move the curser to the right.
The factory default password is 1234.
2.
Press ENTER ; PASSWORD is displayed. The cursor is under the first number.
3.
Press or to change the number to the first one of your password and then press to move the cursor under the next number and change it. Continue until all numbers are changed to the correct password and then press ENTER .
Figure 159 • Control Panel
POWER ALER T
Cursor
4.
Press until RTC DATE is displayed, and then enter the correct date using the same procedure as you did to enter the password.
5.
After the date is correct, press one more time to display the RTC TIME.
6.
Change it to the correct time, and then press ENTER .
7.
Save the changes.
a.
Press MENU . SAVE CHANGES will be displayed. b.
Press ENTER . SAVING CHANGES appears until PRINTER READY is displayed.
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Booster Board
293
Booster Board
This procedure is for installing the booster board into the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Caution • A qualified service technician must perform this installation.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
Remove the Booster Board
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Remove the booster board cable (J7) from the main logic board.
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Booster Board
4.
Remove the three booster board mounting screws. Remove the booster board from the printer.
Figure 160 • Remove the Booster Board
3
1
2
2
1
2
3
Booster board
Booster board mounting screws (3)
Connector J7
Install the New Booster Board
1.
See Figure 160 . Install the new booster board using the three mounting screws provided in
the kit.
2.
Connect the booster board cable (J7) to the main logic board.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Power Supply
295
Power Supply
This procedure is for installing the power supply into the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following maintenance.
Caution • A qualified service technician must perform this installation.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-static Wriststrap and Mat
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Power Supply
Remove the Power Supply
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Remove the three power supply mounting screws.
Note • Once the lower power supply mounting screw is loose, the power supply spacer needs to be reinstalled.
Figure 161 • Remove/Install the Power Supply
2
1
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3
4
5
6
7
5
6
7
3
4
1
2
Power supply mounting screw M3 x 0.5 x 6
Power supply mounting screw M4 x 0.7 x 6
Power supply
Power supply mounting nut
Power supply mounting washer
Power supply spacer
Power supply mounting screw M3 x 0.5 x 18
4.
Disconnect the two power supply cables and move the wire harness out from the wire clip.
5.
Remove the power supply from the printer
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Power Supply
297
Install the New Power Supply
1.
See
. Place the new power supply into the printer. Reinstall the three power supply mounting screws, nut, washer, and the power supply spacer.
2.
Reconnect the two power supply cables and place the wire harness into the wire clip.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm
10/100 Internal ZebraNet PrintServer II,
Wireless Print Server, Parallel Port, and No Comm Option
This procedure is for installing the 10/100 internal ZebraNet
®
PrintServer II, wireless print server, or parallel port kits into the S4M printer. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Reference Materials
• S4M User CD
• S4M User Guide
• S4M Quick Reference Guide
• S4M Maintenance Manual (contact your authorized Zebra reseller for purchasing information).
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set
‰ Metric Nutdriver Set
‰ Anti-Static Wriststrap and Mat
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10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm
299
Remove the Main Logic Board
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.
2.
See
and remove the electronics cover.
3.
See
. Remove all cables from the main logic board.
Note • Take note of the location of all connectors on the main logic board.
3
4
1
2
5
6
F6
Figure 162 • Remove the Main Logic Board Connections
1
12
11
Printhead data (J3)
Power-in (J8)
Front panel (J2)
Stepper motor (J9)
Booster board (J7)
Ribbon sensor, head Open
(P4)
10
7
6
2
4
3
5
9
8
7
8
9
10
11
12
Transmissive sensor (P9)
Reflective sensor (P7)
Take-label sensor (J19)
Communication expansion port (J17)
USB (J14)
Serial port (J10)
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10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm
4.
See
. Remove the six screws and one nut securing the main logic board to the frame of the printer.
5.
Remove the two studs and washers securing the serial port connector to the back of the printer.
Figure 163 • Remove the Main Logic Board
1
5
4
3
2
3
4
1
2
5
Main logic board nut (1)
Main logic board mounting screws (6)
Main logic board
Serial port mounting studs (2)
Parallel port mounting screws (2)
6.
Remove the main logic board from the printer.
7.
Is there a 10/100 internal ZebraNet PrintServer, wireless print server, or parallel port kit already installed on the printer?
If…
No
Yes
Then…
Go to
Install the Parallel Port Board, 10/100 Internal ZebraNet PrintServer,
No Communication, or the Wireless Print Server on page 303 .
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301
8.
See
. Remove the two screws securing the parallel port connector, the internal ZebraNet PrintServer, or the wireless print server to the back of the printer.
9.
See
. For the Internal ZebraNet PrintServer board and the parallel port;
Remove the standoff and then the internal ZebraNet PrintServer or parallel option board from the printer.
Figure 164 • Install/Remove the Internal ZebraNet PrintServer Board or the Parallel Port
3
1
2
3
Standoff
Internal ZebraNet PrintServer board or parallel port
Mounting screws (2)
2
1
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10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm
10.
See
. For the wireless print server board; Remove the two standoffs and mounting screws from the wireless print server board.
11.
Remove the wireless print server board from the printer.
Figure 165 • Install/Remove the Wireless Print Server Board
1
3
1
3
2
1
2
3
Standoff
Wireless print server board
Mounting screws (2)
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10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm
303
Install the Parallel Port Board, 10/100 Internal ZebraNet
PrintServer, No Communication, or the Wireless Print
Server
Are you installing the 10/100 PrintServer for the first time?
If…
No
Yes
Then…
a.
See Figure 166 . Remove the two short standoffs shown.
b.
Remove the two washers, they are used as spacers when there is no option board installed.
c.
Figure 166 • Remove the Short Standoffs
1 2
4
3
10/27/05
3
4
1
2
Washer (must be used when there is no wireless option installed)
Standoff
Standoff
Washer (must be used when there is no option board installed)
1.
See Figure 164 on page 301 . For the 10/100 Internal ZebraNet PrintServer board and
the parallel port; install the board using the standoff. Install the 40 pin cable that will go to the main logic board.
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10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm
2.
See Figure 165 on page 302 . For the wireless print server board; install the board using
the two standoffs and mounting screws. Install the 40 pin cable that will go to the main logic board.
3.
See
. For the no communication option. Both washers must be installed.
4.
See
. Using the two screws supplied to install the bracket on the back of the printer.
Figure 167 • Install the Bracket for the No Communications Option
1
1
1
2
Mounting screws (2)
Bracket
2
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305
Reinstall the Main Logic Board
1.
See
. Install the main logic board in the printer using the six screws and one nut removed previously.
2.
Reinstall the two screws and washers securing the option board and the two studs and washers securing the serial port to the back panel.
3.
See
. Reinstall all the cables previously removed from the main logic board. Visually inspect and ensure the cables are in their proper location and seated in the connectors.
Install the Electronics Cover
1.
See
and install the electronics cover.
2.
Reinstall the media and ribbon.
3.
Reconnect AC power cord and data cables.
4.
Turn On ( l ) the printer.
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Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Exterior Components
This section provides replacement and installation procedures for the S4M printer’s exterior components.
Contents
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Electronics Cover
Electronics Cover
This procedure is for installing the S4M electronics cover. Read these instructions thoroughly before performing this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Phillips Screwdriver Set ‰ Metric Nutdriver Set
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Electronics Cover
309
Remove the Old Electronics Cover
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Turn Off ( O ) the printer and disconnect the AC power cord and all data cables.
2.
See
. Remove the electronics cover mounting screw and washer and then close the media door.
Figure 168 • Remove the Mounting Screw
1
10/27/05
2
3
4
3
4
1
2
Media door
Electronics cover upper flange
Electronics cover mounting screw
Washer
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Electronics Cover
3.
See
. Remove the four remaining mounting screws securing the electronics cover.
4.
Remove the electronics cover by lifting straight up on the bottom lip of the electronics cover.
Figure 169 • Electronics Cover Removal
1
2
1
2
Electronics cover
Mounting screws (4)
Install the New Electronics Cover
1.
See
. Install the new cover by aligning it and sliding down, ensuring the lower tabs are inside the base and the upper flanges are between the main frame and the media door.
2.
Install the four mounting screws on the back of the printer.
3.
See
. Open the media door and install the mounting screw and washer.
4.
Reconnect the AC power cord and data cables.
5.
Turn On ( l ) the printer.
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Preventive and Corrective Maintenance
Media Door
311
Media Door
This procedure is for installing the media door assembly on the S4M printer. Read these instructions thoroughly before starting this procedure.
Caution • Turn Off (O) the printer and disconnect it from the power source before performing the following procedure.
Prepare for Installation
Reference Materials
The following manuals and CDs may be helpful references while performing this procedure.
• S4M User Guide
• S4M User Guide CD
• S4M Maintenance Manual CD
Tools Required
Tools • You need these tools to complete this procedure:
‰ Metric Nutdriver Set
Remove the Old Media Door
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
Turn Off ( O ) the printer and disconnect the AC power cord and all data cables.
2.
See Figure 170 . Open the media door and remove the four hinge mounting screws and washers.
3.
Remove the media door.
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Media Door
Figure 170 • Remove/Install Media Door
1
3
2
3
4
4
2
3
4
1
2
Media door
Hinges (2)
Washers (4)
Hinge mounting screws (4)
Install the New Media Door
1.
Install the new door by aligning the front hinge with the two most forward holes. The front hole is a locating hole; install this first and then install the other three hinge mounting screws and washers.
2.
Reconnect AC power cord and data cables.
3.
Turn On ( l ) the printer.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
5
Maintenance and Drawings
10/27/05
This section illustrates parts and assemblies common to the S4M and gives their maintenance part numbers.
Use the mechanical assembly drawings in this section when troubleshooting or replacing components and use the associated parts list when ordering replacement parts. Item parts that do not have associated part numbers are not available and need to be ordered using the next highest assembly number.
Contents
Ribbon/Printhead Open Sensor Assembly Maintenance Kit . . . . . . . . . . . . . . . . . . . . . 330
S4M Maintenance Manual 13291L-001 Rev. A
314 Maintenance and Drawings
Contents (Continued)
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings 315
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
316 Maintenance and Drawings
Media Side Main Printer Assemblies
Table A • Media Side Main Printer Assemblies
Item Part Number
1
20070M
2
20053
3
20069M
4
77085M
5
78302M
6
20004M
7
20067-104M
Description
Media Door Assembly, Maintenance Kit (see
Lower Rear Cover
Ribbon Supply Spindle Maintenance Kit (see
Static Brush Assembly, Maintenance Kit (see
Media Hanger Assembly, Maintenance Kit (see Table P on page 336
Ribbon Take-up Spindle Maintenance Kit (see
203 dpi Print Mechanism Maintenance Kit (see
0
)
)
)
Qty
1
1
1
1
1
1
1
20067-106M
8
79030
9
77238M
10
777675M
11
77752M
12
20038
300 dpi Print Mechanism Maintenance Kit (see
Platen Housing
Dancer Assembly (see
Ribbon/Head Open Assembly Maintenance Kit (see
Transmissive Sensor Maintenance Kit (see
Lower Front Cover, Tear
)
20039
13
20060M
Lower Front Cover, Peel
Control Panel Assembly Maintenance Kit (see
Bold = Part available for purchase
)
)
1
1
1
1
1
1
1
Light italic = Part not available for purchase, listed and shown for reference only
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
1
13
Maintenance and Drawings
Media Side Main Printer Assemblies
317
Figure A • Media Side Main Printer Assemblies
2
5
3
4
6
12
11
10 9
8 7
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
318 Maintenance and Drawings
Electronics Side Main Printer Assemblies
Table B • Electronics Side Main Printer Assemblies
Item Part Number
1
20071M
2
HW77123
3
20001M
Description
Washer, 0.379 × 0.53 × 0.056 (sold in quantities of 25)
Ribbon Take-up Spindle Clutch Maintenance Kit (see
)
4
20002
5
6
77181
77227
7
20006
Compound Gear
Intermediate Gear
Compound Pulley
Belt, 0.080P 139T, 203 dpi
20005
8
20008M
9
20100M
Belt, 0.080P 128T, 300 dpi
Stepper Motor and Gear/Pulley (see
Main Logic Board Maintenance Kit (4 MB) (see
)
)
20101M
10
28420-001M
Main Logic Board Maintenance Kit (64 MB) (see
Booster Board Maintenance Kit (see
Bold = Part available for purchase
Light italic = Part not available for purchase, listed and shown for reference only
Qty
1
1
1
1
1
1
1
1
1
1
1
1
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
1
Maintenance and Drawings
Electronics Side Main Printer Assemblies
319
Figure B • Electronics Side Main Printer Assemblies
4
5
2
3
6 7
8
9 10
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
320 Maintenance and Drawings
Print Mechanism/Printhead Assembly
Table C • Print Mechanism/Printhead Assembly
Item Part Number
7
8
5
6
3
4
1
2
HW77047
77172M
77134
77660
77276
77048 (78810)
77659
HW10473
9
HWQ10011
10
41400M
41401M
11
77173
12
HW77043
13
77049-104
14
HW79041
N/S
20106M
N/S = Not Shown
Magnetic Latch
Strike Plate Cap
Lower Printhead Guide
Ribbon Strip Plate
Description
Thumbscrew, M3 × 0.5 (sold in quantities of 5)
Pressure Dial Maintenance Kit
Compression Spring, 0.17 × 0.24 × 0.62
Adjustment Screw, M4 × 0.7 (part of 77112M)
Latch Strike Plate (part of 77112M)
Flat Washer, M4 (part of 77112M) (sold in quantities of 25)
Screw, M4 × 0.7 × 10 (part of 77112M) (sold in quantities of 100)
Printhead Kit 203 dpi Maintenance Kit (see
Printhead Kit 300 dpi Maintenance Kit (see
Screw, M3 × 0.5 × 6 (sold in quantities of 25)
Washer, 0.250 × 0.125 × 0.023 (sold in quantities of 25)
Printhead Cable Maintenance Kit (see
Bold = Part available for purchase
Light italic = Part not available for purchase, listed and shown for reference only
)
)
)
Qty
2
1
2
1
1
1
2
1
1
2
1
1
2
1
1
2
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
2
13
14
4
3
Maintenance and Drawings
Print Mechanism/Printhead Assembly
321
Figure C • Print Mechanism/Printhead Assembly
1
2
3
5
6
7
8
9
10
12
9
11
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
322 Maintenance and Drawings
Printhead Maintenance Kit
Table D • Printhead Maintenance Kit
Item
1
1
Part Number
41400M
41401M
Bold=Part available for purchase
Description
Printhead Kit 203 dpi Maintenance Kit
Printhead Kit 300 dpi Maintenance Kit
Light italic=Part not available for purchase, listed and shown for reference only
Figure D • Printhead Maintenance Kit
Qty
1
1
1
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Printhead Cable Maintenance Kit
323
Table E • Printhead Cable Maintenance Kit
Item Part Number
4
5
6
Ref
20106M
1
2
3
20082
20080
Q06020
HWQ10011
77921
77919
Bold=Part available for purchase
Printhead Power Cable
Printhead Data Cable
Cable Tie, 0.09 × 3.62
Description
Printhead Cable Maintenance Kit
Screw, M4 × 0.7 × 10 (sold in quantities of 100)
Print Mechanism Adjustment Cam
Print Mechanism Gap Pin Gauge
Light italic=Part not available for purchase, listed and shown for reference only
Figure E • Printhead Cable Maintenance Kit
Qty
1
1
2
1
1
1
1
1
2
3
4 5
6
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
324 Maintenance and Drawings
Platen Drive System
Table F • Platen Drive System
Item Part Number
7
8
5
6
3
4
1
2
77752M
20043M
77807M
77023M
9
77767M
10
HW77237
45939
HW46128
78123
10401
11
HW77078
12
HW77283
13
77258
14
HW77231
15
77112M
Bold=Part available for purchase
Screw, M4 × 1.4 × 13
Screw, M3 × 0.5 × 4
Description
Transmissive Sensor Maintenance Kit (see
Outer Media Guide Maintenance Kit
Light italic=Part not available for purchase, listed and shown for reference only
Washer, Flat Nylon 0.37 × 0.19 × 0.05 (sold in quantities of 25)
Compression Spring, 0.19 × 0.24 × 0.35
Media Sensor Assembly Maintenance Kit (see
Platen Roller Maintenance Kit (see
Peel Tear Bar (part of 77625M)
Ribbon/Open sensor Maintenance Kit (see Table J on page 330
Screw, M4 × 0.700 × 10 mm (sold in quantities of 5)
)
Flat Washer, 0.500 × 0.195 × 0.090 (sold in quantities of 25)
Screw, M4 × 0.700 × 16 mm (sold in quantities of 25)
Screw, M3 × 8 mm (sold in quantities of 25)
Print Mechanism Latch Maintenance Kit (see
)
)
)
Qty
1
1
1
1
1
1
1
1
1
1
3
2
1
2
1
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
8
1
2
11
9 10 13
12
Figure F • Platen Drive System
Maintenance and Drawings
Platen Drive System
325
3
7
4
5
6
14
11
10
15
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
326 Maintenance and Drawings
Latch Assembly Maintenance Kit
Table G • Latch Assembly Maintenance Kit
Item Part Number
9
10
11
12
13
7
8
5
6
3
4
1
77112M
2
77048 (77810)
77276
77659
HW10473
HWQ10011
77236
77226
77195
77194
HW77043
77921
77919
Bold = Part available for purchase
Latch Maintenance Kit
Adjustment Screw
Strike Plate Cap
Latch Strike Plate
Description
Flat Washer, M4 (sold in quantities of 25)
Screw, M4 × 0.7 × 10 (sold in quantities of 100)
Latch Plate Cover
Latch
Compression Spring, 0.875 × 0.360 × 0.029
Slot Spring Pin
Screw, M3 × 0.5 × 6 mm (sold in quantities of 25)
Cam
Print Mechanism Gap Pin Gauge, 0.094 in. (2.388 mm)
Light italic = Part not available for purchase, listed and shown for reference only
Qty
1
1
1
1
2
2
1
1
1
1
1
1
1
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Latch Assembly Maintenance Kit
327
Figure G • Latch Assembly Maintenance Kit
10
1
2
9
3
4
5
8
6
7
11 12
13
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
328 Maintenance and Drawings
Platen Roller Maintenance Kit
Table H • Platen Roller Maintenance Kit
Item Part Number
Ref
77023M
1
2
3
4
5
77023
77423
77298
77426
78184
Bold = Part available for purchase
Description
Platen Roller Maintenance Kit
Platen Roller
Inner Spring Clip
Spring Washer, 0.612 × 0.40 × 0.009
Platen Bearing
Outer Spring Clip
Light italic = Part not available for purchase, listed and shown for reference only
Figure H • Platen Roller Maintenance Kit
Qty
1
1
1
1
2
1
4
2
1
3 4
5
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
(Reflective) Media Sensor Assembly Maintenance Kit
329
Table I • (Reflective) Media Sensor Assembly Maintenance Kit
Item Part Number
REF
77807M
1
2
77807
HWQ06020
Bold = Part available for purchase
Description
Reflective Media Sensor Assembly Maintenance Kit
Media Sensor Assembly
Cable Tie, 0.090 × 3.630 (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure I • (Reflective) Media Sensor Assembly Maintenance Kit
Qty
1
1
3
1
2
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
330 Maintenance and Drawings
Ribbon/Printhead Open Sensor Assembly Maintenance Kit
Table J • Ribbon/Printhead Open Sensor Assembly Maintenance Kit
Item Part Number
REF
77767M
1
2
77765
HW77237
Bold = Part available for purchase
Description
Ribbon/Printhead Open Sensor Assembly Maintenance Kit
Ribbon/Printhead Open Sensor Assembly
Screw, M3 × 0.70 × 10 mm (sold in quantities of 5)
Light italic = Part not available for purchase, listed and shown for reference only
Figure J • Ribbon/Printhead Open Sensor Assembly Maintenance Kit
Qty
1
1
1
1
2
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Transmissive Sensor Assembly Maintenance Kit
331
Table K • Transmissive Sensor Assembly Maintenance Kit
Item Part Number
REF
77752M
1
2
3
77752
HW44216
HWQ06020
Bold = Part available for purchase
Description
Transmissive Sensor Assembly Maintenance Kit
Transmissive Sensor Assembly
Screw, M4.2 x 1.14 x 13 (sold in quantities of 25)
Cable Tie, 0.09 x 3.62 (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure K • Transmissive Sensor Assembly Maintenance Kit
Qty
1
2
1
1
1
2
3
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
332 Maintenance and Drawings
Dancer Assembly Maintenance Kit
Table L • Dancer Assembly Maintenance Kit
Item Part Number
Ref
77238M
1
2
3
4
77256
77909
77928
HW06313
Bold = Part available for purchase
Dancer Assembly Maintenance Kit
Torsion Spring
Bearing, 0.38 × 0.63 × 0.50
4 inch Dancer
Description
E-ring External 0.375 (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure L • Media Handling System
1
2 3
2
4
Qty
2
1
1
1
1
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Ribbon Supply Spindle Maintenance Kit
333
Table M • Ribbon Supply Spindle Maintenance Kit
Item Part Number
6
7
4
5
Ref
77085M
1
2
3
8
9
10
HW10432
HW44356
HW44390
77085
77594
77598
01660
77620
77621
77593
Bold = Part available for purchase
Description
Ribbon Supply Spindle Maintenance Kit
Screw, M4 x 0.7 12 Cap (sold in quantities of 25)
Washer, 0.198 x 0.75 x 0.085 (sold in quantities of 25)
Washer, 0.500 x 0.377 x 0.020 (sold in quantities of 25)
Ribbon Supply Spindle Assembly
Screw, M4 x 60 mm
Nut, Ribbon Supply Spindle Kit
Grease
Washer, Ribbon Supply Spindle Kit
Driver, 7 mm Nut Ribbon Supply Spindle Kit
Tool, Ribbon Supply Spindle Remove Kit
Light italic = Part not available for purchase, listed and shown for reference only
Figure M • Ribbon Supply Spindle Maintenance Kit
Qty
1
1
1
2
1
1
1
1
1
1
1
10
1 2 3
4
8
Grease
7
5 6
9
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
334 Maintenance and Drawings
Static Brush Maintenance Kit
Table N • Static Brush Maintenance Kit
Item Part Number
Ref
77302M
1
2
77302
HW77237
Bold =Part available for purchase
Static Brush Maintenance Kit
Static Brush Assembly
Description
Screw, M3 × 0.70 × 10 mm (sold in quantities of 5)
Light italic = Part not available for purchase, listed and shown for reference only
Figure N • Static Brush Maintenance Kit
Qty
1
1
2
1
2
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Ribbon Take-up Spindle Maintenance Kit
335
Table O • Ribbon Take-up Spindle Maintenance Kit
Item Part Number
Ref
20004M
1
20004
Bold =Part available for purchase
Description
Ribbon Take-up Assembly Maintenance Kit
Ribbon Take-up Assembly
Light italic = Part not available for purchase, listed and shown for reference only
Figure O • Ribbon Take-up Spindle Maintenance Kit
Qty
1
1
1
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
336 Maintenance and Drawings
Media Hanger Maintenance Kit
Table P • Media Hanger Maintenance Kit
Item Part Number
Ref
20069M
1
2
20069
806136-608
Bold =Part available for purchase
Media Hanger Maintenance Kit
Media Hanger
Description
Screw, Triplask 6-19 × 1/2
Light italic = Part not available for purchase, listed and shown for reference only
Figure P • Media Hanger Maintenance Kit
1
Qty
1
1
4
2
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Media Door Maintenance Kit
337
Table Q • Media Door Maintenance Kit
Item Part Number
Ref
20070M
1
2
3
20070
HW77237
HW43482
Bold =Part available for purchase
Description
Media Door Maintenance Kit
Media Door Assembly
Screw, M4 × 0.7 × 10 (sold in quantities of 5)
External Lock Washer, 4 mm
Light italic = Part not available for purchase, listed and shown for reference only
Figure Q • Media Door Maintenance Kit
Qty
4
4
1
1
1
3
2
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
338 Maintenance and Drawings
Peel Option Kit
Table R • Peel Option Kit
Item Part Number
6
7
4
5
Ref
20046
1
2
3
78002
HW77231
30449
29300
20065
20060-12
20039
Bold =Part available for purchase
Peel Option Kit
Peel Assembly
Mounting Button
Take-Label Sensor Board
Screw
Lower Front Peel Panel
Description
Screw, M3 × 8 mm Flanged (sold in quantities of 25)
2 mm Hex Key (Allen wrench)
Light italic = Part not available for purchase, listed and shown for reference only
Figure R • Peel Option Kit
1
3
2
Qty
2
1
1
1
2
1
1
1
4
7
5
6
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Peel Assembly Maintenance Kit
339
Table S • Peel Assembly Maintenance Kit
Item Part Number
Ref
78002M
1
2
3
78002
30449
HW77231
Bold =Part available for purchase
Description
Peel Assembly Maintenance Kit
Peel Assembly
2 mm Hex Key (Allen wrench)
Screw, M3 × 8 mm Flanged (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure S • Peel Assembly Maintenance Kit
Qty
1
2
1
1
1
3
2
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
340 Maintenance and Drawings
Pinch Roller Maintenance Kit
Table T • Pinch Roller Maintenance Kit
Item Part Number
Ref
77197M
1
2
3
77197
HW10094
49203
Bold =Part available for purchase
Pinch Roller Maintenance Kit
Pinch Roller
Ball Bearing
Description
E-ring 3 mm (two extra supplied) (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure T • Pinch Roller Maintenance Kit
1
Qty
4
2
1
1
3
2
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Electronics Cover Maintenance Kit
341
Table U • Electronics Cover Maintenance Kit
Item Part Number
Ref
20071M
1
2
20071
HW43495
Electronics Cover
Description
S4M Electronics Cover Maintenance Kit
3
4
HW43482
HW77237
Bold =Part available for purchase
Screw, M3 × 0.5 × 6, w/External Lock Washer
(sold in quantities of 25)
Lock Washer, External, 4 mm (sold in quantities of 25)
Screw, M4 × 0.7 × 10 (sold in quantities of 5)
Light italic = Part not available for purchase, listed and shown for reference only
Qty
1
1
1
1
4
Figure U • Electronics Cover Maintenance Kit
1
2
3
4
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
342 Maintenance and Drawings
Control Panel and Take-Label Maintenance Kits
Table V • Control Panel and Take-Label Maintenance Kits
Item Part Number
REf
20060M
1
2
3
4
Ref
20065M
5
6
20060
20060-21
20060-9
20060-14
20065
20060-12
Bold = Part available for purchase
Control Panel Maintenance Kit
Control Panel
External Lock Washer
Split Lock Washer
Screw
Take-Label Board
Screw
Description
Take-Label Maintenance/Option Kit
Light italic = Part not available for purchase, listed and shown for reference only
Figure V • Control Panel and Take-Label Maintenance Kits
1
2 3 4
Qty
1
2
1
1
1
1
1
1
5
6
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Stepper Motor Maintenance Kit
343
Table W • Stepper Motor Maintenance Kit
Item Part Number
Ref
20008M
1
2
3
4
20008
HW77239
HW10432
HW44924
Bold = Part available for purchase
Stepper Motor Assembly
Description
Stepper Motor and Gear/Pulley Maintenance Kit
Adjustment Nut (sold in quantities of 25)
Screw, M4 × 0.7 × 12 (sold in quantities of 25)
Screw, M3 × 0.5 × 8 (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure W • Stepper Motor Maintenance Kit
Qty
1
1
1
1
1
1
4
3 2
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
344 Maintenance and Drawings
Main Logic Board Maintenance Kit
Table X • Main Logic Board Maintenance Kit
Item Part Number
Ref
20100M
1
Ref
20101M
1
29301-001
29301-002
Bold = Part available for purchase
Description
Main Logic Board Maintenance Kit (4 Meg)
Main Logic Board Assembly (4 Meg)
Main Logic Board Assembly Kit (64 Meg)
Main Logic Board Assembly (64 Meg)
Light italic = Part not available for purchase, listed and shown for reference only
Figure X • Main Logic Board Maintenance Kit
Qty
1
1
1
1
1
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Real Time Clock (RTC) Maintenance/Option Kit
345
Table Y • Real Time Clock (RTC) Maintenance/Option Kit
Item Part Number
Ref
20009M
1
2
3
20009
29647
29648
Bold = Part available for purchase
RTC Option/Maintenance Kit
RTC Option Board
Plastic Spacer
Description
Heat Sink Standoff w/Spring
Light italic = Part not available for purchase, listed and shown for reference only
Figure Y • Real Time Clock (RTC) Option/Maintenance Kit
Qty
2
2
1
1
2
1
+
3
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
346 Maintenance and Drawings
Booster Board Maintenance Kit
Table Z • Booster Board Maintenance Kit
Item Part Number
Ref
28420-001M
1
2
28420-099
HW10401
Bold = Part available for purchase
Booster Board Maintenance Kit
Booster Board
Description
Screw, M3 ×0.5 × 0.4 (sold in quantities of 50)
Light italic = Part not available for purchase, listed and shown for reference only
Figure Z • Booster Board Maintenance Kit
Qty
1
1
3
1
2
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Power Supply Maintenance Kit
347
Table AA • Power Supply Maintenance Kit
Item Part Number
Ref
29600M
1
29600
Bold = Part available for purchase
Power Supply
Description
Power Supply Maintenance kit
Light italic = Part not available for purchase, listed and shown for reference only
Figure AA • Power Supply Maintenance Kit
Qty
1
1
1
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
348 Maintenance and Drawings
Ribbon Take-up Spindle Clutch Maintenance Kit
Table AB • Ribbon Take-up Spindle Clutch Maintenance Kit
Item Part Number
Ref
20001M
1
2
3
4
5
78118
77126
77115
20001
Bold = Part available for purchase
N/A Clutch Hub
Clutch Spring
Clutch Gear
Description
Ribbon Take-up Spindle Clutch Maintenance Kit
Collar, 0.379 × 0.750 × 0.200
Washer, 0.375 × 0.750 × 0.062
Light italic = Part not available for purchase, listed and shown for reference only
Figure AB • Ribbon Take-up Clutch Maintenance Kit
Qty
1
1
1
1
1
1
1 2 3
4
5
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Gears and Pulley Maintenance Kit
349
Table AC • Gears and Pulley Maintenance Kit
Item Part Number
Ref
20002M
1
2
3
4
5
20002
77181
77227
10856
77225
Bold = Part available for purchase
Compound Gear
Intermediate Gear
Compound Pulley
Set Screw, M4 × 0.7
Screw, M5 × 20
Description
Gears and Pulley Maintenance Kit
Light italic = Part not available for purchase, listed and shown for reference only
Figure AC • Gears and Pulley Maintenance Kit
Qty
1
1
1
1
1
1
1
2
3
4
5
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
350 Maintenance and Drawings
Wireless PCMCIA Board Maintenance/Option Kit
Table AD • Wireless PCMCIA Board Maintenance/Option Kit
Item Part Number
Ref
20064M
1
29881-099
Bold = Part available for purchase
Wireless PC Board
Description
Wireless PrintServer Maintenance Kit
Light italic = Part not available for purchase, listed and shown for reference only
Figure AD • Wireless PCMCIA Board Maintenance/Option Kit
Qty
1
1
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
10/100 and Parallel Port Maintenance/Option Kits
351
Table AE • 10/100 and Parallel Port Maintenance/Option Kits
Item Part Number
Ref
20063M
1
Ref
20037M
2
29691-099
29831-099
Bold = Part available for purchase
Parallel Port PC Board
Description
10/100 Printserver Option Maintenance Kit
10/100 Printserver PC Board
Parallel Port Option Maintenance Kit
Light italic = Part not available for purchase, listed and shown for reference only
Figure AE • 10/100 and Parallel Port Maintenance/Option Kits
Qty
1
1
1
1
1
2
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
352 Maintenance and Drawings
Hardware View 1 (Media Compartment)
Table AF • Hardware View 1 (Media Compartment)
Item
7
8
5
6
3
4
1
2
9
Part Number
HW44114
HW77237
HW43482
HW07257
HW77283
77371
HW10473
HW77078
20049
Bold = Part available for purchase
Rubber Foot
Description
Screw, M4.2 × 8 (sold in quantities of 50)
Screw, M4 × 0.7 × 10 (sold in quantities of 5)
External Lock Washer, 4 mm (sold in quantities of 25)
Flat Washer, 0.438 × 0.188 × 0.049 (sold in quantities of 25)
Screw, M4 × 0.7 × 16 (sold in quantities of 25)
Screw, M4 × 12
Flat Washer M4 (sold in quantities of 25)
Flat Washer, 0.500 × 0.195 × 0.090 (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Qty
2
5
4
1
6
20
5
4
4
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Hardware View 1 (Media Compartment)
353
Figure AF • Hardware View 1 (Media Compartment)
3
5
2
4
2
9
8
1
3
2 mp
5
7
6
2
9
3
2
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
354 Maintenance and Drawings
Hardware View 2 (Printer Rear)
Table AG • Hardware View 2 (Printer Rear)
Item
1
2
Part Number
HW77237
HW43495
3
4
HW01155
HW22416
Bold = Part available for purchase
Description
Screw, M4 × 0.7 × 10 (sold in quantities of 5)
Screw w/external lock washer, M3 × 0.5 × 6
(sold in quantities of 25)
Lock Washer (sold in quantities of 100)
Standoff, 4-40 (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure AG • Hardware View 2 (Printer Rear)
Qty
5
7
2
2
13291L-001 Rev. A
1
2
1
S4M Maintenance Manual
3 & 4
2
1
10/27/05
Maintenance and Drawings
Hardware View 3 (Printer Front)
355
Table AH • Hardware View 3 (Printer Front)
Item
1
2
3
Part Number
HW77043
HW77231
29300
Bold = Part available for purchase
Screw, M3 × 8
Push Rivet
Description
Screw, M3 × 0.5 × 6 (sold in quantities of 25)
Light italic = Part not available for purchase, listed and shown for reference only
Figure AH • Hardware View 3 (Printer Front)
Qty
2
4
2
10/27/05
2 2
1
2
3
S4M Maintenance Manual 13291L-001 Rev. A
356 Maintenance and Drawings
Hardware View 4 (Electronics Side)
Table AI • Hardware View 4 (Electronics Side)
Item
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
Part Number
HW10401
HW10460
10423
HW77239
HW10432
HW77237
10407
10412
20098
HW44924
806136-608
20077
20097
20079
20091
HW44356
Bold = Part available for purchase
Screw, M4 × 0.7 × 6
Screw, M3 × 0.5 × 18
Spacer
Screw, 2-28 × 3/16
Standoff, M3 × 0.5 × 60
MLB Bracket
Description
Screw, M3 × 0.5 × 4 (sold in quantities of 50)
Nut, M3 × 2.4 × 5.5 (sold in quantities of 25)
Adjustment Nut (sold in quantities of 25)
Screw, M4 × 0.7 × 12 (sold in quantities of 25)
Screw, M4 × 0.7 × 10 (sold in quantities of 5)
External Lock Washer, M3 × 0.5 × 10
Screw, M3 × 0.5 × 8 (sold in quantities of 25)
Standoff, M3 × 0.5 M/F × 21.4
Standoff, M3 × 0.5 M/F × 10
Washer, 0.198 × 0.75 × 0.085
Light italic = Part not available for purchase, listed and shown for reference only
Qty
1
1
1
3
1
1
6
1
1
3
1
1
2
4
4
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Maintenance and Drawings
Hardware View 4 (Electronics Side)
357
Figure AI • Hardware View 4 (Electronics Side)
1
2 1
10/27/05
11
1
3
4 & 5
10
12
9
13
2, 7, & 8
6
2 14
12
3
14
2
14
11
12
16
S4M Maintenance Manual
5
15
13291L-001 Rev. A
358 Maintenance and Drawings
Hardware View 4 (Electronics Side)
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
A
Data Ports
This section describes the standard communication ports available to connect the printer to your computer or network.
Contents
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
360 Data Ports
Serial Data Port
Serial Data Port
See
RS-232 Serial on page 15 for basic cabling information.
To communicate using the serial data port of the printer, you must choose the number of data bits, parity, and handshaking. Parity applies only to data transmitted by the printer because the parity of received data is ignored.
The values selected must be the same as those used by the host equipment connected to the printer. Default printer settings are 9600 baud, 8 data bits, no parity, and XON/XOFF. The printer will accept any host setting for stop bits.
Hardware Control Signal Descriptions
For all RS-232 input and output signals, the printer follows both the Electronics Industries
Association (EIA) RS-232 and the Consultative Committee for International Telegraph and
Telephone (CCITT) V.24 standard signal level specifications.
When DTR/DSR handshaking is selected, the Data Terminal Ready (DTR) control signal output from the printer controls when the host computer may send data. DTR ACTIVE
(positive voltage) permits the host to send data. When the printer places DTR in the
INACTIVE (negative voltage) state, the host must not send data.
Note • When XON/XOFF handshaking is selected, data flow is controlled by the ASCII
Control Codes DC1 (XON) and DC3 (XOFF). The DTR Control lead has no effect.
Request To Send (RTS) is a control signal from the printer that is connected to the Clear To
Send (CTS) input at the host computer.
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Data Ports
Serial Data Port
361
Pin Configuration
Connect the serial data cable to the female DB-9 connector on the back of the printer. For all
RS-232 connections through a DB-25 cable, use a DB-9 to DB-25 interface module (see DB-9
to DB-25 Connections on page 363 ).
shows the pin configuration of the serial data connector.
Pin No.
7
8
5
6
3
4
1
2
9
Table A-1 • Serial Connector Pin Configuration
Name Description
+5 VDC Connected to Pin 9
RXD Receive data—data input to printer
TXD
DTR
Transmit data—data output from printer
Data terminal ready—output from printer
SG
DSR
RTS
CTS
Signal ground
Data set ready—input to printer
Request to send—output from printer
Clear to send—input to printer
+5 VDC +5 VDC at 750 mA (connected to Pin 1)
The maximum current draw may be limited by option configuration.
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
362 Data Ports
Serial Data Port
RS-232 Interface Connections
The printer is configured as Data Terminal Equipment (DTE). Figure A-1 shows the internal
connections of the printer’s RS-232 connector.
Note • Use a null modem (crossover) cable to connect the printer to a computer or any other
DTE device.
Figure A-1 • RS-232 DB9 MLB Connections
13291L-001 Rev. A
+5VDC
R1
1 K
When the printer is connected via its RS-232 interface to Data Communication Equipment
(DCE) such as a modem, use a standard RS-232 (straight-through) interface cable.
illustrates the connections required for this cable.
2
3
6
7
4
5
8
9
Figure A-2 • RS-232 to DCE Cable Connectors
DTE
(Printer)
DCE
(Modem, etc.)
RXD (receive data)
TXD (transmit data)
DTR (data terminal ready)
SG (signal ground)
DSR (data set ready)
RTS (request to send)
CTS (clear to send)
+5 VDC signal source
2
3
6
7
4
5
8
9
NOTE • Pin 1 is unused and unterminated at the printer.
S4M Maintenance Manual 10/27/05
10/27/05
Data Ports
Serial Data Port
363
DB-9 to DB-25 Connections
To connect the printer’s RS-232 DB-9 interface to a DB-25 connector, an interface adapter is required. A generic DB-25 adapter can be used, although the +5 VDC signal source would not
be passed through the adapter. Figure A-3 shows the connections required for the DB-9 to
DB-25 interface.
Figure A-3 • DB-9 to DB-25 Cable Connections
Male DB-9 Adapter
Connector
(plugs into printer)
2
3
4
5
6
7
8
9
RXD
TXD
DTR
SG
DSR
RTS
CTS
+5 VDC
SIGNAL
Female DB-25 Adapter
Connector
(plugs into cable)
FG
TXD
1
2
RXD
RTS
CTS
DSR
SG
+5 VDC
SIGNAL
DTR
20
3
4
5
6
7
9
NOTE: Pin 1 of DB-9 connector is unused and unterminated.
Modem Connection
When the printer is connected via its RS-232 interface to Data Communication Equipment
(DCE) such as a modem, use a standard RS-232 (straight-through) interface cable.
shows the connections required for this cable.
2
5
6
7
3
4
8
9
Figure A-4 • RS-232 Cable Connections
DTE
(Printer)
RXD (receive data)
TXD (transmit data)
DTR (data terminal ready)
SG (signal ground)
DSR (data set ready)
RTS (request to send)
CTS (clear to send)
+5 VDC signal source
DCE
(Modem, etc.)
2
5
6
7
3
4
8
9
NOTE: Pin 1 is unused and unterminated at the printer.
S4M Maintenance Manual 13291L-001 Rev. A
364 Data Ports
Parallel Data Port
Parallel Data Port
The parallel data interface supports IEEE 1284 bidirectional parallel communications in nibble mode. The parallel interface provides a means of communication that typically is faster than the serial interface methods. In this method, the bits of data that make up a character are sent all at one time over several wires in the cable, one bit per wire.
When communicating via the parallel port, the values selected on the printer must be the same as those used by the host equipment connected to the printer. Port selection for status information is determined by the channel sending the request. The parallel port can be set for bidirectional or unidirectional communication. The default setting is bidirectional.
Parallel Cabling Requirements
See
IEEE 1284 Bidirectional Parallel on page 16
for basic cabling information.
A standard 36-pin parallel connector is available on the back of the printer for connection to the data source. An IEEE-1284 compatible bidirectional parallel data cable is required when this communication method is used. The required cable must have a standard 36-pin parallel connector on one end that is plugged into the mating connector located at the rear of the printer. The other end of the cable connects to the printer connector at the host computer. Port selection for status information is determined each time the printer is turned on.
Parallel Port Interconnections
shows the pin configuration and function of a standard computer-to-printer parallel cable.
Table A-2 • Parallel Cable Pin Configuration
36-Pin Connectors Description
1
2–9
10
11
12
13
14
15
16, 17
18
19–30 nStrobe/HostClk
Data Bits 1–8 nACK/PtrClk
Busy/PtrBusy
PError/ACKDataReq
Select/Xflag nAutoFd/HostBusy
Not used
Ground
+5 V at 750 mA
The maximum current draw may be limited by option configuration.
Ground
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Data Ports
Parallel Data Port
365
Table A-2 • Parallel Cable Pin Configuration (Continued)
36-Pin Connectors Description
31
32
33, 34
35
36 ninit nFault/NDataAvail
Not used
+5 V through a 1.8 K
Ω Resistor
NSelectin/1284 active
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
366 Data Ports
USB 1.1 Port
USB 1.1 Port
See
for basic cabling information.
A USB 1.1 port (which is USB 1.0 compatible) is available to connect your printer to the host equipment. The industry-standard USB cable has an A-male connector on one end and a
B-male connector on the other end as shown in Figure A-5 .
Figure A-5 • USB Connectors
Printer
1
Computer
3
5
2
3
4
1
2
5
“B” male connector, attaching to printer
“B” male connector, detail
“A” male connector, attaching to computer
“A” male connector, detail
Maximum cable length = 16.4 ft. (5 m)
4
Note • Use a USB 1.1-certified compliant cable no longer than 16.4 ft (5 m) long.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
A
Glossary
10/27/05
alphanumeric Indicating letters, numerals, and characters such as punctuation marks.
backfeed When the printer pulls the media and ribbon (if used) backward into the printer so that the beginning of the label to be printed is properly positioned behind the printhead.
Backfeed occurs when operating the printer in Tear-Off and Applicator modes.
bar code A code by which alphanumeric characters can be represented by a series of adjacent stripes of different widths. Many different code schemes exist, such as the universal product code (UPC) or Code 39.
black mark A registration mark found on the underside of the print media that acts as a start-
of-label indication for the printer. (See continuous media .)
calibration (of a printer) A process in which the printer determines some basic information needed to print accurately with a particular media and ribbon combination. To do this, the printer feeds some media and ribbon (if used) through the printer and senses whether to use the direct thermal or thermal transfer print method, and (if using non-continuous media) the length of individual labels or tags.
character set The set of all letters, numerals, punctuation marks, and other characters that can be expressed by a particular font or bar code.
check digit A character added to a bar code symbol that indicates to the scanner that it has read the symbol correctly.
configuration The printer configuration is a group of operating parameters specific to the printer application. Some parameters are user selectable, while others are dependent on the installed options and mode of operation. Parameters may be switch selectable, control panel programmable, or downloaded as ZPL II commands. A configuration label listing all the current printer parameters may be printed for reference.
continuous media Label or tag-stock media that has no notch, gap, or web (media liner only) to separate the labels or tags. The media is one long piece of material.
S4M Maintenance Manual 13291L-001 Rev. A
368 Glossary
13291L-001 Rev. A
core diameter The inside diameter of the cardboard core at the center of a roll of media or ribbon.
diagnostics Information about which printer functions are not working that is used for troubleshooting printer problems.
die-cut media A type of label stock that has individual labels stuck to a media liner. The labels may be either lined up against each other or separated by a small distance. Typically the
material surrounding the labels has been removed. (See non-continuous media
.)
direct thermal A printing method in which the printhead presses directly against the media.
Heating the printhead elements causes a discoloration of the heat-sensitive coating on the media. By selectively heating the printhead elements as the media moves past, an image is printed onto the media. No ribbon is used with this printing method. Contrast this with
direct thermal media Media that is coated with a substance that reacts to the application of direct heat from the printhead to produce an image.
dynamic RAM The memory devices used to store the label formats in electronic form while they are being printed. The amount of DRAM memory available in the printer determines the maximum size and number of label formats that can be printed. This is volatile memory that loses the stored information when power is turned off.
fanfold media Media that comes folded in a rectangular stack. Contrast this with
.
firmware This is the term used to specify the printer’s operating program. This program is downloaded to the printer from a host computer and stored in FLASH memory. Each time the printer power is turned on, this operating program starts. This program controls when to feed the media forward or backward and when to print a dot on the label stock.
FLASH memory FLASH memory is non-volatile and maintains the stored information intact when power is off. This memory area is used to store the printer’s operating program. In addition, this memory can be used to store optional printer fonts, graphic formats, and complete label formats.
Font A complete set of alphanumeric characters in one style of type. Examples include
CG Times™, CG Triumvirate Bold Condensed™.
ips (inches-per-second) The speed at which the label or tag is printed. Zebra printers can print from 1 ips to 12 ips.
label An adhesive-backed piece of paper, plastic, or other material on which information is printed.
label backing (liner) The material on which labels are affixed during manufacture and which is discarded or recycled by the end-users.
liquid crystal display (LCD) The LCD is a back-lit display that provides the user with either operating status during normal operation or option menus when configuring the printer to a specific application.
S4M Maintenance Manual 10/27/05
10/27/05
Glossary 369
light emitting diode (LED) Indicators of specific printer status conditions. Each LED is either off, on, or blinking depending on the feature being monitored.
lock-up This is the term generally used to describe a fault condition that, for no apparent reason, causes the printer to stop working.
media Material onto which data is printed by the printer. Types of media include: tag stock, die-cut labels, continuous labels (with and without media liner), non-continuous media, fanfold media, and roll media.
media sensor This sensor is located behind the printhead to detect the presence of media and, for non-continuous media, the position of the web, hole, or notch used to indicate the start of each label.
non-continuous media Media that contains an indication of where one label/printed format ends and the next one begins. Examples are die-cut labels, notched tag-stock, and stock with black mark registration marks.
non-volatile memory Electronic memory that retains data even when the power to the printer is turned off.
notched media A type of tag stock containing a cutout area that can be sensed as a start-oflabel indicator by the printer. This is typically a heavier, cardboard-like material that is either cut or torn away from the next tag. (See
print speed The speed at which printing occurs. For thermal transfer printers, this speed is expressed in terms of ips (inches per second). Zebra offers printers that can print from 1 ips to
12 ips.
printhead wear The degradation of the surface of the printhead and/or the print elements over time. Heat and abrasion can cause printhead wear. Therefore, to maximize the life of the printhead, use the lowest print darkness setting (sometimes called burn temperature or head temperature) and the lowest printhead pressure necessary to produce good print quality. In the thermal transfer printing method, use ribbon that is as wide or wider than the media to protect the printhead from the rough media surface.
registration Alignment of printing with respect to the top of a label or tag.
ribbon A band of material consisting of a base film coated with wax or resin “ink.” The inked side of the material is pressed by the printhead against the media. The ribbon transfers ink onto the media when heated by the small elements within the printhead. Zebra ribbons have a coating on the back that protects the printhead from wear.
ribbon wrinkle A wrinkling of the ribbon caused by improper alignment or improper printhead pressure. This wrinkle can cause voids in the print and/or the used ribbon to rewind unevenly. This condition should be corrected by performing adjustment procedures.
roll media Media that comes supplied rolled onto a core (usually cardboard). Contrast this with
supplies A general term for media and ribbon.
S4M Maintenance Manual 13291L-001 Rev. A
370 Glossary
symbology The term generally used when referring to a bar code.
tag A type of media having no adhesive backing but featuring a hole or notch by which the tag can be hung on something. Tags are usually made of cardboard or other durable material.
tear-off A mode of operation in which the user tears the label or tag stock away from the remaining media by hand.
thermal transfer A printing method in which the printhead presses an ink or resin coated ribbon against the media. H eating the printhead elements causes the ink or resin to transfer onto the media. By selectively heating the printhead elements as the media and ribbon move
past, an image is printed onto the media. Contrast this with direct thermal .
void A space on which printing should have occurred, but did not due to an error condition such as wrinkled ribbon or faulty print elements. A void can cause a printed bar code symbol to be read incorrectly or not at all.
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Index
A
active control panel buttons, 4
adhesive test for ribbon coating, 21
adjustments
label left side, 55 label top, 55
print speed, 57 print width, 57
APL-D
set Module A storage device, 59
set Module B storage device, 60
setting compatibility mode, 57 setting control codes, 57
APL-I
adjust label left position, 55
print stored format, 60 print stored page, 60
10/27/05
B bar codes
black mark media
booster board
C
calibration
media and ribbon sensors, 67, 80
setting for head close, 72 setting for media power up, 72
CANCEL button
changing dpi through printhead upgrade, 130
checklist
S4M Maintenance Manual 13291L-001 Rev. A
372 Index cleaning
media compartment and sensors, 115
printhead and platen roller, 113
recommended cleaning schedule, 112
communication interfaces
communications diagnostics test
configuration
changing password-protected parameters, 47
configuration label
printing from control panel, 50
printing using CANCEL self test, 98
continuous media
control panel
D dancer assembly
13291L-001 Rev. A data source
default values
direct thermal mode
setting through control panel, 65
display language selection, 53
dpi change through printhead upgrade, 130
drive system
E
electronics side
F
FEED button
Flash memory initialization, 64
font list, 59, 75 formats list, 59, 75
S4M Maintenance Manual 10/27/05
Index 373
G
gears and pulley
H
hardware control signal descriptions, 360
hardware parts list
HEAD COLD
HEAD TOO HOT
I
inspect for shipping damage, 10
interfaces
IEEE 1284 bidirectional parallel, 16
international safety organization marks, 13
L
label top
language selection
latch assembly
10/27/05 S4M Maintenance Manual
M main logic board
replacement, 281 replacement procedure, 281
manufacturing menu parameters, 74
media
continuous roll media, 19 fanfold, 19
media compartment
media hanger
media sensor
parts list
reflective sensor adjustment, 42
replacement
transmissive sensor location, 42
13291L-001 Rev. A
374 Index
N
navigation through parameters, 46
network configuration label, 50
non-continuous media
O
ordering ribbon and media, xxi
outer media guide
override EPL commands, 65 override ZPL commands, 65
P parallel port
setting parallel communications, 60
13291L-001 Rev. A parts list
gears and pulley maintenance kit, 349
hardware
printhead assembly/print mechanism, 320
ribbon take-up spindle clutch, 348
ribbon/printhead open sensor, 330
password
PAUSE button
S4M Maintenance Manual 10/27/05
peel-off mode
cleaning peel-off assembly, 116
installing or replacing the Peel Option, 240
parts list
selecting label removal method, 56, 78
pin configuration
pinch roller
platen drive system
platen roller
power
connect to power source, 12 power cord specifications, 12
power supply
pressure dial replacement, 169
print configuration label
print darkness adjustment, 54, 77
print mechanism
print modes
specify label removal method, 56, 78
print quality troubleshooting, 90
print server
print speed adjustment, 57 print width adjustment, 57
printer resolution for APL-I, 58
printhead
pressure dial replacement, 169
printhead replacement procedure, 126
printhead open sensor
printhead release latch
pulley and gears
R
Real-Time Clock (RTC)
reflective sensor
relative humidity requirements, 11
removal method for labels, 56, 78
Index 375
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
376 Index replacement procedure
ribbon take-up spindle clutch, 200
ribbon/printhead open sensor, 182
stepper motor and gear/pulley, 227
reset factory defaults, 64, 81
ribbon
RIBBON IN
ribbon sensor
ribbon supply spindle
13291L-001 Rev. A S4M Maintenance Manual ribbon take-up spindle
ribbon take-up spindle clutch
roll media
routine cleaning schedule, 112
Routine Referral Procedures (RRP)
remove the electronics cover, 122
RS-232 serial interface
S safety
equipment safety tips, 109 equipment tips, 109
personal safety tips, 108 personal tips, 108
saving changes to parameters, 46
scratch test
communications diagnostics, 103
sensors
transmissive sensor location, 42
serial port
setup
Setup mode
10/27/05
shipping
report damage, 10 reshipping the printer, 10
specifications
agency approvals and markings, 23
Zebra Programming Language (ZPL), 27
static brush
stepper motor
T tag stock
take-label sensor
tear-off mode
adjust tear-off position, 55, 77
selecting label removal method, 56, 78
thermal transfer mode
setting through control panel, 65
top of label
transmissive sensor
troubleshooting
types of media
continuous roll media, 19 fanfold media, 19
U
USB 1.1 port
W
wireless print server
Z
Zebra Programming Language (ZPL)
command character, 62 control character, 62
Index 377
10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
378 Index
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
13291L-001 Rev. A S4M Maintenance Manual 10/27/05
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061.3109 U.S.A.
Telephone: +1 847.634.6700
Facsimile: +1 847.913.8766
Zebra Technologies Europe Limited
Zebra House
The Valley Centre, Gordon Road
High Wycombe
Buckinghamshire HP13 6EQ, UK
Telephone: +44 (0) 1494 472872
Facsimile: +44 (0) 1494 450103
Zebra Technologies Asia Pacific, LLC
16 New Industrial Road
#05-03 Hudson TechnoCentre
Singapore 536204
Telephone: +65 6858 0722
Facsimile: +65 6885 0838
Part Number: 13291L-001 Rev. A
© 2005 ZIH Corp.
advertisement
Key Features
- Industrial/Commercial
- High-volume label printing
- Tear-off and peel-off options
- Serial, parallel, USB, and Ethernet
- Printhead pressure adjustment
- Media sensor selection
- Setup mode
- ZPL II programming language
- Preventive maintenance procedures
- Printhead and sensor replacement
