S400 & S600 Maintenance Manual
Proprietary Statement This manual contains proprietary information of 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. Product Improvements Continuous improvement of products is a policy of Zebra Technologies.
7DEOH RI &RQWHQWV :DUUDQW\ ,QIRUPDWLRQ All Zebra products are sold with warranties. Refer to the User’s Guide for warranty information specific to each product. Here is some general information: 35,17(5 352'8&76 Printers. All printers (excluding printheads) are warranted against defect in material or workmanship for twelve (12) months from the purchase date. Proof of purchase or shipment date is required to validate the warranty period.
7DEOH RI &RQWHQWV 6833/,(6 352'8&76 Supplies are warranted to be free from defect in material and workmanship for a period of six (6) months for media and twelve (12) months for ribbon from the date of shipment by Zebra. This is provided the user has complied with storage guidelines, handling, and usage of the supplies in Zebra printers.
7DEOH RI &RQWHQWV 7DEOH RI &RQWHQWV 6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW Description ..............................................................................................................1-1 Printer Operating Modes ......................................................................................... 1-1 Specifications .......................................................................................................... 1-2 Agency Approvals ....................................................
7DEOH RI &RQWHQWV 6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Operator Indicators ................................................................................................. 2-1 Power Status Indicator (green) ......................................................................... 2-1 Printhead Status Indicator (yellow) ................................................................... 2-1 Paper/Ribbon Status Indicator (yellow) ............................................................
DEOH RI &RQWHQWV Calibration ............................................................................................................. 2-21 Auto Calibration .............................................................................................. 2-21 Manual Calibration ......................................................................................... 2-22 Ribbon Parameter Calibration ........................................................................ 2-23 Configuration Mode ..........
7DEOH RI &RQWHQWV 6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Maintenance Concepts ........................................................................................... 4-1 Equipment Safety Tips ............................................................................................ 4-2 Equipment Safety Tips (Continued) ........................................................................ 4-3 Personal Safety Tips ..............................................................................
7DEOH RI &RQWHQWV Downloading Firmware ......................................................................................... 4-39 Print Mechanism Assembly Removal ............................................................. 4-40 Printhead Assembly Removal and Installation ............................................... 4-41 Ribbon Supply Spindle Disassembly .............................................................. 4-44 Ribbon Supply Spindle Installation ............................................
7DEOH RI &RQWHQWV x S400/S600 Maintenance Manual 44895L Rev.
/LVW RI )LJXUHV /LVW RI )LJXUHV Figure 1-1. Safety Organizations .................................................................................. 1-2 Figure 1-2. Communication Cable Connections ........................................................... 1-9 Figure 1-3. RS-232 Connections................................................................................. 1-10 Figure 1-4. RS-232 Signal/ASCII Code Data .............................................................. 1-12 Figure 1-5.
/LVW RI )LJXUHV Figure 4-10. Cutter Module Reinstallation................................................................... 4-15 Figure 4-11. Pause and Cancel Key Label ................................................................. 4-18 Figure 4-12. Test, Formats 1 and 8............................................................................. 4-19 Figure 4-13. Test, Formats 2 and 9............................................................................. 4-19 Figure 4-14. Test, Formats 3 and 10..
/LVW RI )LJXUHV Figure 4-46. Replacing the Platen Roller .................................................................... 4-54 Figure 4-47. Ribbon Take-Up Motor ........................................................................... 4-55 Figure 4-48. Stepper Motor (Media Side).................................................................... 4-56 Figure 4-49. Stepper Motor (Electronics Side)............................................................ 4-57 Figure 4-50.
/LVW RI )LJXUHV xiv S400/S600 Maintenance Manual 44895L Rev.
/LVW RI 7DEOHV /LVW RI 7DEOHV Table 1-1. Font Matrix for 8 dot/mm (203 dpi) Printheads .......................................... 1-3 Table 1-2. Media Specifications.................................................................................. 1-4 Table 1-3. Memory Specifications .............................................................................. 1-5 Table 1-4. Physical Dimensions .................................................................................1-5 Table 1-5.
/LVW RI 7DEOHV xvi S400/S600 Maintenance Manual 44895L Rev.
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ 6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 'HVFULSWLRQ The Zebra Stripe S400 and S600 Thermal Printers are versatile label and ticket printers designed to print high-quality bar codes, various sizes and styles of alphanumeric characters, and graphics in either the thermal transfer or direct thermal mode. The Zebra Stripe printers have the flexibility to meet a wide variety of applications.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 6SHFLILFDWLRQV $JHQF\ $SSURYDOV + R Figure 1-1.
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ )RQWV Standard Printer Fonts Table 1-1. Font Matrix for 8 dot/mm (203 dpi) Printheads Font Matrix Baseline Dots Type* InterCharacter Gap Character Size Inches Millimeters Cell Width Font Matrix 1 6 U-L-D 0.044 0.030 33.87 1.13 0.75 1.33 2 9 U 0.054 0.044 22.58 1.38 1.13 0.89 2 12 U-L-D 0.089 0.059 16.93 2.25 1.50 0.67 23 5 20 OCR-B 0.138 0.098 10.16 3.50 2.50 0.40 21 3 16 U-L-D 0.128 0.079 12.70 3.25 2.00 0.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 0HGLD &RQVLGHUDWLRQV Table 1-2. Media Specifications S400 S600 Minimum media width 0.75" (19 mm) Maximum media width 4.5" (114 mm) Maximum media width (cutter installed) 4.0" (102 mm) Minimum media length (Tear-Off) 0.63" (16 mm) Minimum media length (Peel-Off) 1.0" (25 mm) Minimum media length (Cutter) 1.5" (38 mm) Maximum media length 36" (914 mm) Total thickness (includes liner) 0.0023" to 0.012" (0.058 mm to 0.305 mm) Core size 3.
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ 0HPRU\ Table 1-3.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 3ULQWLQJ &RQVLGHUDWLRQV Table 1-5. Printing Specifications S400 S600 Resolution 203 dots per inch (8 dots per mm) Dot Size 0.005" (0.127 mm) Minimum print width 0.75" (19 mm) Maximum print width 4.09" (104 mm) Minimum print length 0.005" (0.127 mm) (1 dot row) Maximum print length 36" (914 mm) Bar code modulus (“X”) dimension 5.0 mil to 55.0 mil 39" (990 mm) 3ULQWLQJ 0HWKRG Direct Thermal Printing (requires direct thermal media).
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ 5LEERQ &RQVLGHUDWLRQV Table 1-7. Ribbon Specifications S400 & S600 Ribbon Width Standard Length Core Size Minimum 1.57" (40 mm) Maximum 4.5" (114 mm) 2:1 media to ribbon roll ratio 984’ (300 m) 3:1 media to ribbon roll ratio 1400’ (427 m) Inner diameter 1.0" (25 mm) Outer diameter 3.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW &RPPXQLFDWLRQ ,QWHUIDFHV • • • Page 1-8 Serial Port ◊ RS-232 ◊ DB-9 ◊ Baud Rate (110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600) ◊ Parity (disabled, even, odd) ◊ Stop Bits (7 or 8 data bits) ◊ Handshake (XON/XOFF or DTR/DSR) ◊ Error Detection (on or off) ◊ A null modem (crossover cable must be used to connect to a host 9-pin connector (see Figure 1-2).
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ &RPPXQLFDWLRQ 6SHFLILFDWLRQV 6HULDO 'DWD &RPPXQLFDWLRQ ,QWHUIDFH 2YHUYLHZ The S400 and S600 printers have a single Data Terminal Equipment (DTE) port that supports RS-232 serial data communications. The RS-232 interface has a 9-pin DB-9S connector located at the rear of the printer.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 56 ,QWHUFRQQHFWLRQ The printer is configured as Data Terminal Equipment (DTE). Figure 1-3 illustrates the connections required to interconnect the printer with the 9-pin or 25-pin serial port connector on a PC.
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ Table 1-8. DB-9P Pinouts Pin Description 1 Not used. 2 RXD (RS-232 Receive Data): This is the serial data input to the printer from the host. 3 TXD (RS-232 Transmit Data): This lead is the serial data output from the printer. It is on this lead that printer status or XON-XOFF information is relayed to the host. 4 DTR (RS-232 Data Terminal Ready): This lead is a control output from the printer to the host.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW 6HULDO &RPPXQLFDWLRQ 6LJQDO /HYHOV RS-232 Transmit and Receive Data RS-232 data signals are defined as either MARK or SPACE while control signals are either On (active—positive voltage) or Off (inactive—negative voltage). Although the permitted voltage levels can range from 3 VDC to 25 VDC, both positive and negative, the levels for the S400 and S600 printers are shown in Figure 1-4.
'HVFULSWLRQ RI (TXLSPHQW 6HFWLRQ Table 1-9. Centronics Connector Pinouts 36-Pin Connector Description 1 STROBE — The high to low transition of this input signal latches the data at the eight DATA inputs into the printer. 2–9 DATA BITS 0 through 7 — Parallel data inputs to the printer. TTL input level HIGH (+5 V) corresponds to a Logic 1; level LOW (0 V) to a Logic 0.
6HFWLRQ 'HVFULSWLRQ RI (TXLSPHQW (OHFWURQLFV 6\VWHP %ORFN 'LDJUDP Printhead Assembly (S600) Printhead Assembly (S400) Ribbon Take-Up Motor Label Available Sensor (Peel Option) Media/Ribbon Sensor J4 J9 J3 J11 J5 Serial Port J1 J12 Control Panel J14 Head-Open Sensor Main Logic Board Parallel Port J6 J2 J10 J7 Cutter (option) Stepper Motor J1 J8 J13 J2 Power Supply Board Memory Expansion (option) Full Roll Switch (Peel Option) Power Source Figure 1-5.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 6HFWLRQ 2SHUDWLRQV 2YHUYLHZ This section contains information and adjustments for becoming acquainted with, adjusting, testing, and operating the printer. This information is also found in the User’s Guide. 2SHUDWRU ,QGLFDWRUV Refer to Figure 2-1. 3RZHU 6WDWXV ,QGLFDWRU JUHHQ Refer to Figure 2-2. Controlled by the power on/off (l/O) switch located on the left side near the AC power cord. On Primary power is applied to the printer.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 'DUNHQ 6WDWXV ,QGLFDWRU \HOORZ On Off Printer is in Configuration Mode. See “Adjusting the Printer Darkness” on page 2-26 and “Top of Label Position Adjustment” on page 2-28 for more information. Normal condition. 3RVLWLRQ 6WDWXV ,QGLFDWRU \HOORZ On Off Printer is in Configuration Mode. See “Tear-Off Position Adjustment” on page 2-27 for more information. Normal condition. &DOLEUDWH 6WDWXV ,QGLFDWRU \HOORZ On Off Printer is in Configuration Mode.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 2SHUDWRU &RQWUROV 3DXVH .H\ Allows the operator to interrupt the printing of a batch of labels. If Pause is pressed during printing, printing stops after completing the label being printed. If the printer is not printing, no printing can occur. )HHG V .H\ Forces the printer to feed one blank label. • If FEED is pressed during printing, a blank label feeds after the current batch of labels is completed. • If the printer is not printing, a blank label feeds immediately.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Serial Cable or Communication Interface Parallel Cable AC Power Cable AC Power On/Off Switch Figure 2-2. Power-On/Off Switch and Data Cable Connections Page 2-4 S400/S600 Maintenance Manual 44895L Rev.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ $FFHVVLQJ WKH 3ULQWHU To access the printer for loading and unloading media and ribbon, and for operator adjustments, do the following: 1. Refer to Figure 2-3. Lift the main door and swing it up and to the left until it rests on top of the right side cover. 2. Grasp the tab on top of the front door and carefully pull down until it rests on the desktop. Main Door Tab 1 2 Front Door Figure 2-3. Printer Access 44895L Rev.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 0HGLD /RDGLQJ Note • Media widths and thickness vary between applications. To maintain print quality from one application to another, refer to “Configuration Mode” on page 2-23. 7HDU 2II 0RGH 0HGLD /RDGLQJ 1. Turn the head-open lever counterclockwise to the OPEN position and raise the printhead. 2. Slide the media guide and the media supply guide as far out from the printer frame as possible. 3.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Ribbon Release Button Head-Open Lever Ribbon Supply Media Supply OPEN CLOSED Media Sensor Assembly Media Supply Hanger Media Supply Guide Media Guide Figure 2-4. Roll Media Loading Head-Open Lever Ribbon Release Button Ribbon Supply Media Supply OPEN CLOSED Rear-Loaded Fanfold Media Media Sensor Assembly Bottom-Loaded Fanfold Media Media Guide Media Supply Guide Media Supply Hanger Figure 2-5. Fanfold Media Loading 44895L Rev.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Ribbon Release Button Head-Open Lever Ribbon Supply Media Supply End of media on top of platen roller OPEN Cutter Module Media Supply Hanger Platen Roller Media Sensor Assembly Media Guide Media Supply Guide Figure 2-6.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 3HHO 2II 0RGH 0HGLD /RDGLQJ 1. Turn the head-open lever counterclockwise to the OPEN position and raise the printhead. 2. Slide the media guide and the media supply guide as far out from the printer frame as possible. 3. Remove the hold down hook. 4. Place the media roll on the media supply hanger and thread the media through the printhead assembly as shown in Figure 2-7. 5.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 5HPRYLQJ WKH /LQHU When the amount of liner wound on the liner rewind spindle reaches full capacity, the liner rewind spindle full sensor activates, the Paper/Ribbon LED flashes, and printing pauses. Use the following steps to remove the liner. Note • You do not need to turn the printer Off (O) for this procedure. 1. Unwind about 24 in (61 cm). of liner from the liner rewind spindle and cut it off at the spindle. 2.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Media Sensor Adjustment for Continuous Media Continuous media does not contain label start or end indicators. You must tell the printer, through the software, the length of each label. If you are using ZPL or ZPL II, include a Label Length (^LL) instruction in each label format you send to the printer. Refer to your ZPL II Programming Guide or instructions provided with your software driver.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 5LEERQ /RDGLQJ Note • Do not load ribbon if the printer is to be used in direct thermal mode. Caution: Do not use ribbon that is narrower than the media. Premature printhead failure may result due to excessive abrasion caused by thermal transfer media. $GMXVWLQJ WKH 5LEERQ 6XSSO\ 6SLQGOH The S400/S600 comes with a dual-tension ribbon supply spindle to provide the appropriate amount of tension on the ribbon. Normal Position Refer to Figure 2-9.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ /RDGLQJ WKH 5LEERQ Notes • For the direct thermal print method, ribbon is not used and should not be loaded in the printer when performing media calibration. Use ribbon that is wider than the media. The smooth liner of the ribbon protects the printhead from wear and premature failure due to excessive abrasion. Refer to Figure 2-10. 1. Adjust the ribbon supply spindle position for normal or low tension refer to “Adjusting the Ribbon Supply Spindle” on page 2-12.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 'DWD &DEOH ,QVWDOODWLRQ 3. Turn the printer Off (O). 4. Determine whether you are using a parallel data cable or serial data cable. 5. Follow your computer manufacturer’s instructions for installing data cables to the computer. You may need to turn off the computer before making any cable connections. 6. Refer to Figure 2-2 on page 2-4. Connect the printer data cable from the computer to the proper port on the rear of the printer.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 3ULQWHU 6HOI 7HVW 5HVHW 'HIDXOW 4XLFN 5HIHUHQFH &KDUW Table 2-1 lists the self tests and default resets that can be accessed by pressing and holding a front panel key or keys and turning power on. The “X” in the four columns on the right indicates which key or keys are pressed. The indicates that the self test is one that can be performed by the operator or maintenance personnel.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ &DQFHO .H\ 6HOI 7HVW Refer to Figure 2-11. This self test prints a listing of the printer’s configuration parameters stored in configuration (EEPROM) memory. Configuration can be changed temporarily (for specific label formats or ribbon and label stock) or permanently (by saving the new parameters in memory). Saving new parameters occurs whenever a printer configuration procedure is performed. To start the Cancel Key Self Test, press CANCEL while turning the power on.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 3DXVH .H\ 6HOI 7HVW Refer to Figure 2-12. This self test can be used to provide the test labels for making adjustments to the printer’s mechanical assemblies and Configuration Mode adjustments. To start the Pause Key Self Test, press and hold PAUSE while turning the power On (l). This self test consists of four individual test features: • The initial self test prints 15 labels at 2 in. (50.8 mm) per second (ips) (speed A), then automatically pauses the printer.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ )HHG .H\ 6HOI 7HVW The results of this self test determine the best darkness setting for a specific media and ribbon combination. Refer to Figure 2-13. The Feed Key Self Test prints a series of labels at various plus or minus darkness settings relative to the current darkness setting. The operator inspects these printouts and determines which printout has the best darkness setting.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 0RGH .H\ 6HOI 7HVW Note • The printer data cable must be connected to the host computer during this self test. Refer to Figure 2-14. This self test places the printer in a Communications Diagnostics Mode, in which the printer prints the ASCII characters and their corresponding hexadecimal values for any data received from the host computer. To start the Mode Key Self Test, press and hold MODE while turning the power On (l). )HHG DQG 3DXVH .
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Table 2-2.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ &DOLEUDWLRQ $XWR &DOLEUDWLRQ Auto calibration occurs when the printer is turned On (l) or when the printhead is opened and closed (with the printer turned on). During the procedure, the printer automatically determines the media type, label length, media and ribbon sensor settings, and printing method (direct thermal or thermal transfer). The procedure is set at the factory but may be changed via ZPL II command.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 0DQXDO &DOLEUDWLRQ Important • Perform manual calibration when using preprinted media, when in Manual Calibration Mode, or if auto calibrate does not work. During this procedure, the printer determines the media type, label length, media and ribbon sensor settings, and printing method. Media type is determined by sensing either continuous or non-continuous media as blank labels move through the printer. If noncontinuous media is sensed, label length is also calibrated.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 5LEERQ 3DUDPHWHU &DOLEUDWLRQ Note • Perform this procedure only if the manual calibration fails or if sensor assemblies are replaced. A manual calibration must be performed after the ribbon parameter calibration. To set the ribbon parameter to factory default values: 1. Turn the printer Off (O). 2. Open the printhead and remove the ribbon. 3. Press and hold FEED, CANCEL, and MODE while turning the power On (l). 4. After the printhead LED has flashed, load the ribbon.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 3ULQWLQJ DQG ([DPLQLQJ D &RQILJXUDWLRQ /DEHO First, it is a good idea to print out a configuration label to check the existing darkness setting. Also, once the ideal parameters for a particular media and ribbon combination have been determined, you can print a configuration label and save it for future reference. To get a configuration label, you can print a Cancel Key Self Test. Refer to Figure 2-11 on page 2-16.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 7HVWLQJ 3ULQW 'DUNQHVV 3DXVH .H\ 6HOI 7HVW 0HWKRG Another method of testing print darkness, with a test label that contains a large amount of printing, is performed with the Pause Key Self Test. First, you must determine how you want to proceed with the adjustments. 1. You can run the Pause Key Self Test without knowing your current darkness setting.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ $GMXVWLQJ WKH 3ULQWHU 'DUNQHVV Caution: Set Print Darkness to the lowest setting possible for desired print quality. Darkness set too high may cause ink smearing, ribbon wrinkle, or ribbon burning. The following procedure sets the darkness of the printing on the label. Note • It is not necessary to turn the printer power off to adjust this parameter. 1. Press MODE. The pause and darken LEDs turn on. 2.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 7HDU 2II 3RVLWLRQ $GMXVWPHQW Refer to Figure 2-15. This procedure sets the end-of-label position relative to the tear-off plate or cutter. The media stopping position is adjustable in increments of four dot rows at a time. The possible adjustment range is ± 80 dot rows or a distance of 0.392 in. (10 mm) up or down from the center. Adjust if the label is not being torn or cut at the correct position. 1. Press MODE twice. The pause and position LEDs turn on. 2.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 7RS RI /DEHO 3RVLWLRQ $GMXVWPHQW This procedure positions the printing on the label relative to the top edge of the label. Adjust if the printing is too close or too far away from the top or bottom edge of the label. 1. Press MODE twice briefly and then press and hold it for approximately five seconds (until the pause, darken, and calibrate LEDs turn on). 2. Press FEED (V) to move the printing closer to the top edge or CANCEL (W) to move away from the top edge.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 5RXWLQH $GMXVWPHQWV 3ULQWKHDG 3UHVVXUH $GMXVWPHQW If the printing is too light on one side of the label, or if a different thickness of media is used, the printhead pressure may need to be adjusted to provide the best print quality. Refer to Figure 2-17 and perform the following procedure: 1. Begin by performing a Pause Key Self Test. 2. After printing a few labels, press PAUSE and check the print quality. 3.
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ /LQHU 5HZLQG 3RZHU 5ROOHU $GMXVWPHQW Note • The rewind power roller is present only on printers with the Peel-Off Option. This roller is pre-set during manufacture for proper operation with most applications. Adjust this roller only when necessary. In Peel-Off Mode, proper media tracking is critical. The rewind power roller automatically turns along with the movement of media to ensure continuous rewind of the liner.
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Edge Guide Mark Power Roller Adjustment Up Liner Down Rewind Power Roller Figure 2-18. Liner Rewind Power Roller 44895L Rev.
2SHUDWLRQV 2YHUYLHZ Page 2-32 6HFWLRQ S400/S600 Maintenance Manual 44895L Rev.
7URXEOHVKRRWLQJ 6HFWLRQ 6HFWLRQ 7URXEOHVKRRWLQJ 7URXEOHVKRRWLQJ &KDUWV Consult the following charts when troubleshooting the printer. /LVW RI 7DEOHV Table 3-1. LED Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Table 3-2. Troubleshooting Chart (Problems with LED Indications) . . . . . . . . . . . . . . . 3-3 Table 3-3. Troubleshooting Chart (Print or Print Quality Related Problems) . . . . . . . . . 3-6 Table 3-4.
6HFWLRQ 7URXEOHVKRRWLQJ /(' 4XLFN 5HIHUHQFH &KDUW Table 3-1 is a quick reference troubleshooting chart based on the status of the LEDs after the Power-On Self Test has been completed (or attempts to complete) or during printer operation. Using the legend at the bottom of the table, match the LED condition of the printer to the chart. The rightmost column refers to possible solutions found in “Troubleshooting Chart (Problems with LED Indications)” on page 3-3. Table 3-1.
7URXEOHVKRRWLQJ 6HFWLRQ 7URXEOHVKRRWLQJ &KDUW 3UREOHPV ZLWK /(' ,QGLFDWLRQV Table 3-2 lists a number of problems or conditions that may be encountered with the printer. These condition or problems generally have LED indications as listed in Table 3-1, “LED Quick Reference Chart” on page 3-2. Table 3-2. Troubleshooting Chart (Problems with LED Indications) # 1 2 3 Symptom No LEDs turn on. All LEDs turn on and stay on and printer locks up while running Power-On Self Test.
6HFWLRQ 7URXEOHVKRRWLQJ Table 3-2. Troubleshooting Chart (Problems with LED Indications) (Cont.) # 9 10 11 12 Symptom Diagnosis Printer stops, pause and paper/ribbon LEDs both on. Printer stops, pause LED on and paper/ribbon LED flashing. Printer stops, pause LED on and printhead LED flashes. Printer stops, pause LED and printhead LED on. Media incorrectly loaded or not loaded. Load media correctly, then turn printer off and on. Cutter error. Clear jam, then open and close printhead.
7URXEOHVKRRWLQJ 6HFWLRQ Table 3-2. Troubleshooting Chart (Problems with LED Indications) (Cont.) # Symptom Diagnosis Action 16 Data LED single flash. CANCEL key pressed and a format deleted. No action required. 17 Data LED flashing. Printer receiving data. Printing resumes when data is received. 18 Data LED flashing slow. Printer sent a “stop transmitting” to the host computer. No action required. 19 Pause and Data LED alternately flashing, but all other LEDs on. Firmware error.
6HFWLRQ 7URXEOHVKRRWLQJ Table 3-3. Troubleshooting Chart (Problems with LED Indications) Symptom Dots missing in printed area of label. Diagnosis Dirty printhead. Clean printhead. Print quality problems. Check print quality. Printhead element going bad. Replace printhead. Possible media sensor problem. Loss of printing registration on labels. Adjust media sensor. Replace media sensor. Printer set for noncontinuous media, but Set printer for correct media. continuous media loaded.
7URXEOHVKRRWLQJ 6HFWLRQ Table 3-3. Troubleshooting Chart (Problems with LED Indications) (Cont.) Symptom Poor print quality. Misregistration/skips labels. Printing across web or in wrong position. Long tracks of missing print on several labels. 44895L Rev. 3 3/15/04 Diagnosis Action Darkness too low. Increase print darkness. Incorrect media and ribbon combination. Replace media or ribbon. Printhead adjustments incorrect. Perform required adjustments. Misadjusted media sensors.
6HFWLRQ 7URXEOHVKRRWLQJ 7URXEOHVKRRWLQJ &KDUW :ULQNOHG 5LEERQ Table 3-4. Troubleshooting Chart (Wrinkled Ribbon) Symptom Diagnosis Action Ribbon fed through printer Load ribbon correctly. incorrectly. Wrinkled ribbon. Incorrect darkness setting. Set darkness to lowest setting possible for good print quality. Incorrect printhead pressure or balance. Set pressure to minimum needed. Media not feeding properly. Media walking side to side.
7URXEOHVKRRWLQJ 6HFWLRQ 7URXEOHVKRRWLQJ &KDUW 6HWWLQJV RU 3DUDPHWHU 5HODWHG Table 3-6. Troubleshooting Chart (Settings or Parameter-Related) Symptom Changes in parameter settings did not take effect. Diagnosis Parameters set or saved incorrectly. Action Reload factory defaults, calibrate printer, then cycle power off and on. If problem continues, may be a problem with main Replace main logic board. logic board. Communications parameters incorrect.
6HFWLRQ 7URXEOHVKRRWLQJ Table 3-8. Printer Status Sensors Sensor Printhead Sensor What It Monitors Checks open/closed status of printhead lever. How It Works If printhead is open, printhead LED flashes. Checks for proper media loading. Media Sensor If printer runs out of media, If non-continuous media is used, sets label paper/ribbon LED turns on. length for individual labels. Ribbon Sensor Monitors presence of ribbon.
7URXEOHVKRRWLQJ 6HFWLRQ )DFWRU\ $VVLVWDQFH Should you encounter any problem that cannot be corrected with the aid of this manual, and you have Internet access, check out ZIP Support. If you cannot solve your problem via ZIP Support or do not have Internet access, contact your Distributor or Zebra Technologies Technical Support Department to minimize or avoid printer downtime. =,3 6XSSRUW • Can identify, diagnose, and resolve your questions in one brief, easy, online session.
7URXEOHVKRRWLQJ Page 3-12 6HFWLRQ S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 0DLQWHQDQFH &RQFHSWV Maintenance for the Zebra Stripe S400 and S600 thermal transfer demand printers can be divided into two basic categories: • Preventive Maintenance procedures and operator care instructions. These procedures may be performed by the operator as well as the service technician and should be performed on a regular basis.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH (48,30(17 6$)(7< 7,36 After reviewing each procedure, place a check in the box. o The AC power plug and IEC 320 connectors on all Zebra Printers must bear the certification mark of at least one international safety organization listed below. + R Page 4-2 o Unless indicated otherwise, turn the power Off (O) before performing any maintenance procedures to the printer.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ (TXLSPHQW 6DIHW\ 7LSV &RQWLQXHG o To ensure optimum printhead life, observe proper electrostatic safety precautions (for example; ESD, Electrostatic Service Device, wrist straps) when removing, handling, and replacing the printhead.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3HUVRQDO 6DIHW\ 7LSV Page 4-4 o Do not wear any jewelry (rings, watches, etc.) and loose clothing when servicing the printers. o Beware of “Pinch Points” on the printers. Be especially careful of: • Opening and closing covers • Printhead • Rewind Spindle • Platen Roller o Wear protective eye wear when removing E-Rings, C-Clips, and springs. o For personal and equipment safety, use a three-prong plug with a ground (earth) connection.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 3UHYHQWLYH 0DLQWHQDQFH 6FKHGXOH &OHDQLQJ ² *HQHUDO Caution: Use only the cleaning agents described in the following procedures. Damage can occur if the incorrect cleaning agents are used on this printer. Exterior – Clean the exterior surfaces of the printer as required by using a lint free cloth. Do not use solvents or harsh cleaning agents. If the unit is excessively dirty, a mild detergent solution or desktop cleaner may be used sparingly.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Table 4-1. Recommended Cleaning Schedule AREA METHOD Printhead Clean with a solution of 90% isopropyl alcohol and 10% distilled water. Platen Roller Clean with a solution of 90% isopropyl alcohol and 10% distilled water. Media Sensor Air blow. Media Path Clean with a solution of 90% isopropyl alcohol and 10% distilled water. Ribbon Path Air blow.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ &OHDQLQJ ² 3ULQWKHDG DQG 3ODWHQ 5ROOHU Inconsistent print quality such as voids in the bar codes or graphics may indicate a dirty printhead. For optimum performance, the printhead should be cleaned regularly with a swab soaked in 90% isopropyl alcohol and 10% distilled water. This cleaning procedure is the best thing you can do to maintain consistent, high quality printing.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3ULQWKHDG DQG 3ODWHQ 5ROOHU &OHDQLQJ 3URFHGXUH 1. Refer to Figure 4-1. Open the main door and front door. 2. Open the printhead by turning the locking lever counterclockwise. 3. Remove the media and ribbon if present. 4. Refer to Figure 4-2 on page 4-9. Use a cleaning swab to wipe the print elements from end to end. Allow a few seconds for the solution to evaporate. 5. Rotate the platen roller and clean thoroughly with a cleaning swab. 6.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Figure 4-2. Printhead Cleaning &OHDQLQJ WKH &XWWHU 0RGXOH The cutter module is an option available on the S400/S600 that requires periodic cleaning to remove paper dust and gummed label residue. The following procedure should be performed, as scheduled in Table 4-1, by the operator. However, depending on the application and media type, it may be necessary to clean the cutter more or less often.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Cutter Module Label Catch Tray Figure 4-3. Cutter Catch Tray Location Mounting Screw Cutter Cable Connector Figure 4-4. Cutter Connector and Mounting Screw Page 4-10 S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Mounting Posts Cutter Module Mounting Slots Figure 4-5. Cutter Module Removal Disassembling the Cutter Module 1. Lay the cutter module on a table or other surface. Hold the cutter module as shown in Figure 4-6 on page 4-12. Put your thumbs on the two wire spring loops and your index fingers on the top of the rear cutter blade guard. 2. To remove the rear cutter blade guard, first press down simultaneously on the two wire spring loops.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Wire Spring Loop Upper Cutter Blade Guard Rear Cutter Blade Guard Wire Spring Loop Figure 4-6. Cutter Module Disassembly Cleaning the Cutter Module 1. Remove any label material that has adhered to the cutter parts and use a small brush to remove any paper dust from the cutter module. 2. If pressure-sensitive media has been used, use a lint-free cloth soaked in an adhesive remover to clean all gum and label residue from the cutting blades and guards.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 4. 6HFWLRQ Lower the upper cutter bade guard back to its normal position. When reassembled, the back of the cutter module looks like Figure 4-9 on page 4-14. Upper Cutter Blade Guard Wire Spring Wire Spring Figure 4-7. Cutter Module Reassembly Metal Pin Pin Slot Rear Cutter Blade Guard Rear Cutter Blade Guard Wire Spring Cutter Side Panel Wire Spring Loop Cutter Side Panel Figure 4-8. Side View of Cutter Module Reassembly 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Figure 4-9. Reassembled Cutter Module Reinstall the Cutter Module 1. Refer to Figure 4-10 on page 4-15. Position the cutter module above the cutter mounting posts. Press down on the cutter module until the mounting slots engage the mounting posts on the printer. 2. Refer to Figure 4-4 on page 4-10. Tighten the mounting screws in a clockwise direction to hold the cutter module in position. 3.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Mounting Posts Cutter Module Mounting Slots Figure 4-10. Cutter Module Reinstallation /XEULFDWLRQ Caution: No lubricating agents of any kind should be used on the printer! Some commercially available lubricants will damage the finish and mechanical parts.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Note • The data cable must be removed from the printer (except for the Mode key test) prior to running the self tests. 3DXVH DQG &DQFHO .H\ 6HOI 7HVW Refer to Figure 4-11. This self test can be used to verify proper printer operation after parts have been replaced or adjusted. When activated, the printer prints a maximum of 500 head test labels. Each label backfeeds prior to printing and feeds forward to the rest position after printing.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Table 4-2.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Table 4-3.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Figure 4-12. Test, Formats 1 and 8 Figure 4-13. Test, Formats 2 and 9 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Figure 4-14. Test, Formats 3 and 10 Figure 4-15. Test, Formats 4 and 11 Page 4-20 S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Figure 4-16. Test, Formats 5 and 12 Figure 4-17. Test, Formats 6 and 13 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Figure 4-18. Test, Formats 7 and 14 ([WHQGHG 3ULQWHU 'LDJQRVWLFV Additional diagnostic tests are available for printhead assembly adjustments. These diagnostic tests are accessible only when the data cable is disconnected from the printer and a loopback connector is attached in its place. The serial loopback connector is a 9-pin “D” Type (DB9P – male) with pins 2 and 3, and pins 4 and 6 tied together.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ )HHG .H\ 5ROOEDFN 7HVW This test demonstrates the media movement capabilities of the printer and provides a test label to view while making print quality adjustments. With the loopback connector in place, press and hold FEED while turning the power On (l). After the Power-On Self Test, the printer begins printing the same series of label formats as shown in Table 4-3. then pauses at the end of each printed format.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Note • The desired result produces the darkest printing evenly across the label and lines printed on the test labels that are parallel to the top of the label. 10. Press PAUSE, let several more labels print, and then press PAUSE again. 11. Examine this set of labels and make any additional adjustments. 12. Repeat steps 10 and 11 until consistent print quality and parallelism is achieved. 13. Tighten the two printhead position locking screws. 14.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Braided Ground Strap Braided Ground Strap Printhead Position Locking Screw Printhead Position Locking Screw Printhead Adjustment Slot Printhead Adjustment Slot Strip Plate Figure 4-20. Printhead Position Adjustment (Top View) 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 7DNH /DEHO 6HQVRU $GMXVWPHQW The label sensor functions only when the printer is set to Peel-Off Mode. This mode requires that the peel-off option be installed. This sensor is not installed on printers without the peel-off option. Figure 4-21 shows the location of the take-label sensor. When the sensing beam is interrupted, printing and feeding are prevented. It may accept additional label formats if the buffer is not full.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 6WULS 3ODWH $GMXVWPHQW Refer to Figure 4-22. The ribbon strip plate position can be adjusted to provide proper tracking, and separation of the ribbon from the media after printing. If the ribbon does not track properly, or if ribbon wrinkle problems appear adjust the strip plate by following this procedure. 1. Begin printing labels by performing a Pause Key Self Test. 2. Loosen the screws securing the strip plate to the front of the printhead assembly.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH /LQHU 5HZLQG 6SLQGOH $GMXVWPHQW Refer to Figure 4-23 and follow the procedures below to adjust the liner rewind spindle tension. 1. Turn the printer Off (O) and remove all media and ribbon. 2. Tape the end of the 30" long Mylar tape (Zebra part # 01776) to the rewind spindle. 3. Wrap the Mylar strip around the rewind spindle in a clockwise direction. 4. Connect a 1000 gram spring scale to the Mylar strip. 5.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ (OHFWULFDO $GMXVWPHQWV 3ULQWKHDG 9ROWDJH $GMXVWPHQW Caution: The printhead voltage adjustment is critical to the life of the printhead. Do not use this adjustment to try to increase printing darkness. When a printhead or power supply board is replaced, the printhead voltage must be adjusted for the proper value. This adjustment provides the voltage applied to the print elements during the printing process. 1.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Table 4-4. Printhead Voltage Values (S400 Only) Printhead Voltage Formula: V Ω Resistance Voltage VDC = 0.78 + (0.49 × Resistance) Resistance Ω Voltage VDC 935 to 945 22.2 1092 to 1110 24.0 946 to 963 22.4 1111 to 1129 24.2 964 to 981 22.6 1130 to 1148 24.4 982 to 999 22.8 1149 to 1168 24.6 1000 to 1017 23.0 1169 to 1187 24.8 1018 to 1035 23.2 1188 to 1207 25.0 1036 to 1053 23.4 1208 to 1227 25.2 1054 to 1072 23.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Ground Wire Power Supply Board (Access RV2 through cutout in base.) RV2 Figure 4-24. Printhead Voltage Adjustment Potentiometer Location 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH &XWWHU 9ROWDJH $GMXVWPHQW Caution: Use caution around cutter blades. Keep fingers away from blades. The voltage applied to the printhead is the same voltage applied to the cutter module. The specific voltage applied to the cutter motor is controlled by the home position potentiometer. There are three cases in which you must adjust the cutter module’s home position potentiometer: • Before placing a new cutter module into service.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Side Plate Edge Embossed Line Sensor Disc Outer Cover Home Position Potentiometer Figure 4-25. Properly Adjusted Cutter Sensor Home Position Potentiometer Figure 4-26. Home Position Potentiometer 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH &RUUHFWLYH 0DLQWHQDQFH 7RROV 5HTXLUHG Open-End Wrench Set Spring Scale, 2200 gram and 1000 gram Metric Allen Wrench Set 0.010" Shim or Feeler Gauge Small Flat-Blade Screwdrivers 0.020" Shim or Feeler Gauge Phillips Screwdrivers Anti-Static Mat Digital Voltmeter Anti-Static Wrist Strap 5HPRYLQJ WKH 0DLQ 'RRU 1. Refer to Figure 4-27 on page 4-35. Lift the main door to swing it up and to the left until it rests on top of the right side cover. 2.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Main Door Tab 1 2 Front Door Figure 4-27. Opening Main and Front Doors Rear Cover Main Door Front Door Figure 4-28. Door and Cover Disassembly 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 7HDU 2II 3ODWH 5HPRYDO 1. Open the main door. 2. Grasp the tab on top of the front door and carefully pull down until it rests on the desktop. 3. Refer to Figure 4-29. Remove the two screws securing the tear-off plate. 4. Push up on the bottom of the tear-off plate, and pull the plate out. 5. Reverse the procedure to replace the tear-off plate. Tear-Off Plate 5 mm Hex Screws Figure 4-29.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ &RQWURO 3DQHO &LUFXLW %RDUG 5HSODFHPHQW 1. Turn the printer Off (O), and remove the AC power cord. 2. Remove the control panel assembly. 3. Refer to Figure 4-30. Remove the control panel board from the control panel cover by removing the two mounting screws. 4. Carefully align the replacement board over the mounting holes on the control panel cover and reinstall the two mounting screws. 5.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 0DLQ /RJLF %RDUG 5HPRYDO Caution: Observe proper electrostatic safety precautions when removing, handling, and replacing printed circuit boards. 1. Turn printer Off (O), and remove the AC power cord. 2. Remove the printer data cable. 3. Remove the rear cover. 4. Refer to Figure 4-31 on page 4-39. Note the position of all ribbon cable connectors and wire harness connectors. Remove all connectors to the main logic board. 5.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Mounting Holes Ground Ground J5 RV1 J4 J11 J9 J3 J12 F1 J1 J14 (Back of Board) J2 J13 Mounting Hole J7 Ground J6 J10 F2 F3 J8 Figure 4-31.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3ULQW 0HFKDQLVP $VVHPEO\ 5HPRYDO 1. Turn printer Off (O), and remove the AC power cord. 2. Remove the printer data cable. 3. Remove the media and ribbon. 4. Remove the main door, front door, and rear cover. 5. Remove the main logic board. 6. Refer to Figure 4-31 on page 4-39, and locate the printhead cable (J4 or J5). 7. Refer to Figure 4-32. Remove the ferrite assembly from around the printhead cable by sliding the clips off of the ferrites.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 3ULQWKHDG $VVHPEO\ 5HPRYDO DQG ,QVWDOODWLRQ 1. Turn printer Off (O), and remove the AC power cord. 2. Remove the printer data cable. 3. Remove the main door, front door, and rear cover. 4. Refer to Figure 4-22 on page 4-27. Remove the two screws securing the strip plate. 5. Rotate the head-open lever counterclockwise to remove the pressure on the printhead. 6. Refer to Figure 4-35 on page 4-43.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Braided Ground Straps Print Mechanism Assembly Figure 4-33. Braided Ground Strap Location Cutout Braided Ground Strap Print Mechanism Assembly Mounting Screw Printhead Cable Figure 4-34. Print Mechanism Assembly Mounting Screw Location Page 4-42 S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Nuts Print Mechanism Assembly Printhead Cable Assembly Printhead Assembly Figure 4-35. Printhead Assembly Removal/Installation 44895L Rev.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5LEERQ 6XSSO\ 6SLQGOH 'LVDVVHPEO\ Refer to Figure 4-36. 1. Turn printer Off (O), and remove the AC power cord. 2. Remove the printer data cable. 3. Remove any media and ribbon. 4. Ensure the dual-tension ribbon supply spindle outer spindle is in the retracted (pushed in) position to gain access to the set screws. 5.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 5LEERQ 6XSSO\ 6SLQGOH ,QVWDOODWLRQ 1. Use an emery cloth to remove burrs and nicks on the ribbon supply spindle shaft. 2. Refer to Figure 4-37. Slide the ribbon supply spindle subassembly on the ribbon supply spindle shaft. 3. Slide one of the cup and spring assemblies on the ribbon supply spindle shaft. 4. Place a 0.010" (.254 mm) shim or feeler gauge between the C-clip and ribbon supply spindle subassembly. 5.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 7. When rotated clockwise, the ribbon supply spindle subassembly encounters the spring and attempts to spin the ribbon supply spindle subassembly counterclockwise. 8. If the results in steps 6 and 7 are not achieved, repeat steps 2 through 7. 9. Refer to Figure 4-38. Slide the spindle assembly onto the shaft. 0.010" (0.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 10. Refer to Figure 4-39 on page 4-48. Reinstall the C-clip in the groove on the shaft. 11. Place a 0.020" (0.508 mm) shim or feeler gauge between the spindle assembly and the ribbon supply spindle subassembly. 12. Slide the outer spindle on the shaft. 13. Align the large notch on the outer spindle with the corresponding protrusion on the spindle assembly. The protrusion on the spindle assembly is in line with the metal core clip. 14.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 0.010" (0.254 mm) shim or feeler gauge placed between C-clip and ribbon supply spindle subassembly Ribbon Supply Spindle Subassemby Cup and Spring Assembly Set Screws Figure 4-39. Spindle Assembly Installation Figure 4-40. Spindle Assembly & Outer Spindle (Expanded) Figure 4-41. Spindle Assembly & Outer Spindle (Retracted) Page 4-48 S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 0HGLD 6HQVRU $VVHPEO\ 5HPRYDO Caution: Observe proper electrostatic safety precautions when removing, handling, and replacing printed circuit boards. 1. Turn printer Off (O), and remove the AC power cord and the printer data cable. 2. Remove media and ribbon. 3. Remove the main door and rear cover. 4. Refer to Figure 4-31 on page 4-39. Disconnect the wiring harness from J11 on the main logic board. 5. Refer to Figure 4-42 on page 4-50.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Media Sensor Assembly Upper Media Guide Assembly Figure 4-42. Media Sensor Assembly Shoulder Bolt and Idler Pulley Platen Roller 60 70 80 90 10 0 0 0 0 00 Spring Scale Stepper Motor 1 HE C IN S 2 3 Figure 4-43. Main Drive Belt Replacement and Adjustment Page 4-50 S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 0DLQ 'ULYH %HOW 5HPRYDO 5HSODFHPHQW DQG $GMXVWPHQW Printers without the Peel-Off Option Caution: Observe proper electrostatic safety precautions when removing, handling, and replacing printed circuit boards. 1. Turn printer Off (O), and remove the AC power cord and the printer data cable. 2. Remove media and ribbon. 3. Remove the main door and rear cover. 4. Remove the main logic board and media sensor assembly.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5. Refer to Figure 4-44. For the particular belt being replaced, loosen the shoulder bolt holding the idler pulley in position until the pulley freely moves up and down. 6. Remove the main drive belt and/or rewind spindle drive belt and install the new one. 7.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 3ODWHQ 5ROOHU 5HSODFHPHQW 1. Turn the printer Off (O), and remove the AC power cord and the data cable. 2. Remove media and ribbon. 3. Remove the main door, rear cover, and control panel assembly. 4. Remove the main logic board and media sensor assembly. Note • Scribing a mark into the main frame indicating the position of the idler pulley prior to performing step 5 may help when adjusting the belt tension. 5. Refer to Figure 4-45 on page 4-54.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Shoulder Bolt and Idler Pulley Platen Pulley Ground Chain Assembly Main Drive Belt Figure 4-45. Platen Roller Replacement Platen Bearings Outboard/Inboard Guides Platen Roller Bearings pictured here are installed this way for the S400 only. For the S600, rotate the bearings 180 degrees (turn upside down). Figure 4-46. Replacing the Platen Roller Page 4-54 S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 5LEERQ 7DNH 8S 0RWRU 5HSODFHPHQW 1. Turn the printer Off (O), and remove the AC power cord and the data cable. 2. Remove media and ribbon. 3. Remove the main door and rear cover. 4. Remove the main logic board. 5. Remove the main drive belt. 6. Refer to Figure 4-47 on page 4-55. Loosen the two screws and slide the bevel gear from the ribbon take-up spindle shaft. 7. Remove the ground chain assembly from around the idler pulley. 8.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6WHSSHU 0RWRU 5HSODFHPHQW 1. Turn the printer Off (O), and remove the AC power cord and data cable. 2. Remove media and ribbon. 3. Remove the main door and rear cover. 4. Remove the main logic board. 5. Remove the main drive belt. 6. Refer to Figure 4-48. Remove the screw, underneath the upper media guide assembly, holding the stepper motor to the main frame. 7. Refer to Figure 4-49 on page 4-57.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Stepper Motor Ground Wire Stepper Motor Cable Power Supply Board (J1) (access through cutout in base) Figure 4-49. Stepper Motor (Electronics Side) Caution: Observe proper electrostatic safety precautions when removing, handling, and replacing printed circuit boards. 3RZHU 6XSSO\ %RDUG 5HPRYDO 1. Turn the printer Off (O), and remove the AC power cord and the data cable. 2. Remove media and ribbon. 3. Remove the main door and rear cover. 4.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3RZHU 6XSSO\ %RDUG ,QVWDOODWLRQ Page 4-58 1. Refer to Figure 4-51 on page 4-60. Press the power supply board onto the three mounting snaps. 2. Reinstall the two mounting screws. 3. With the printer tilted up on the front cover, position the front hooks of the power supply base into the holes. 4. Route the ground wire through the opening in the base. 5. Engage the rear snaps by pivoting the power supply base assembly to the printer base. 6.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 1. Remove the screw in the middle of the media compartment that secures the main base and power supply base. 6HFWLRQ Screw 2. Remove the ground wire from the ground bar. 3. Insert flat-blade screwdriver tip into slot. 4. Gently pull the screwdriver handle Ground toward the front of the Wire printer until tab pops out of cutout (into the base). Tab Slot 5. Carefully pry the front of the power supply base downward to remove power supply. Figure 4-50.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Power Supply Base Mounting Screw Power Supply Board Mounting Screws Power Supply Board Power Supply Base Figure 4-51. Power Supply Assembly Exploded View Page 4-60 S400/S600 Maintenance Manual 44895L Rev.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ $& 3RZHU )XVH 5HSODFHPHQW Caution: The replacement fuse must have the ratings specified below. Serious damage may occur if a higher-rated fuse is installed. Refer to Figure 4-52. A user-replaceable AC power fuse is located just to the left of the power switch. For 120 VAC operation, a F5A/250V fuse is used. For 220 VAC operation, a F3A/250V is used. Note • Do not rely on a visual inspection to determine whether a fuse is blown.
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 2SWLRQV 0HPRU\ 8SJUDGH .LW ,QVWDOODWLRQ ,QVWUXFWLRQV Caution: Observe proper electrostatic safety precautions when removing, handling, and replacing printed circuit boards. 1. Turn the printer Off (O), and remove the AC power cord. 2. Remove the data cable. 3. Remove the rear cover. Note • It is not necessary to remove the main door or the front door if installing only the memory upgrade kit.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 4. Refer to Figure 4-53. Note the positions of all ribbon cable and wire harness connectors. Remove all connectors to the main logic board. 5. Remove the three screws securing the main logic board to the main frame. 6. Carefully grasping both sides of the main logic board, pull the board straight up from the power supply connector and out of the unit.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 10. Refer to Figure 4-55. With the memory board face up (100-pin connector to the left and pins up), carefully slide the memory board underneath the main logic board. 11. Align the three screw holes in the main logic board with the three holes in the connector on the memory board. Main Logic Board Memory Board Mounting Screw Mounting Screws Figure 4-55. Memory Board Mounting Screws 12.
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Important • Use full width media when performing the Cancel Key Self Test. Labels less than full width lose printing on the right side. Printing may run on to the next label when short labels. 18. Reconnect the AC power cord. 19. Reload media and ribbon. 20. Perform a Cancel Key Self Test. To start the Cancel Key Self Test, press and hold Cancel while turning the power On (l).
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Figure 4-56. Sample Before and After Configuration Labels (8 MB Memory Board Installed) Page 4-66 S400/S600 Maintenance Manual 44895L Rev.
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ 6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 'HVFULSWLRQ Use the mechanical assembly drawings 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. All parts in bold face are purchasable.
# Part No. 1 Description 44114* Screw, M4.2 × 1.41 × 8 Qty 3 2 44185M Front Door Retention Clip 1 3 44075-1 Rear Cover 1 44076-5 Front Door (S400) 1 44076-4 Front Door (S600) 1 44070-3 Main Door (Standard) 1 44070-4 Main Door (Quick Release) 1 4 5 6HFWLRQ Page 5-2 Table 5-1. Cover Assemblies 44895L Rev. 3 3/15/04 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV S400/S600 Maintenance Manual * Available only as HW44114 in quantities of 50.
6HFWLRQ Figure 5-1. Cover Assemblies 1 3 2 4 5 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev.
# Part No. 1 Description 44114* Screw, M4.2 × 1.41 × 8 2 Qty 3 44506M (A) LED/Button Array Maintenance Kit 1 3 44071-400M (B) Front Panel Cover Assembly (includes one Front Door Retention Clip, two M4.2 × 1.41 × 8 screws, and one M4 × 10 screw) 1 4 45925M Head-Open Sensor Flag 1 45195 Set Screw, 10–32 × 0.25 1 5 44123 Braided Ground Strap 1 7 44053 Screw, M3 × 0.
6HFWLRQ 8 7 12 2 1 44895L Rev. 3 3/15/04 S400/S600 Maintenance Manual Figure 5-2.
Page 5-6 # Part No. Description Qty 44052-400M Ribbon Take-Up Spindle Assembly (Tear-Off and Cutter Option) 1 44052-402M Ribbon Take-Up Spindle Assembly (Peel-Off Option) 1 1 2 30251* Washer, 0.836 × 0.390 × 0.048 1 44912-400M (C) Dual Torque Ribbon Supply Spindle Kit 1 4 44069 Media Bracket 1 5 44066-1M (B) Media Edge Guide & Thumb Screw 1 6 44068-1 Media Edge Guide 1 7 44067 Nylon Thumb Screw, M3.
2 8 11 C 9 12 2 12 13 } 10 3 5 7 S400/S600 Maintenance Manual 15 B 14 16 22 4 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev. 3 3/15/04 1 6 18 21 20 19 A 17 6HFWLRQ Page 5-7 Figure 5-3.
Part No. Description 1 44329-400M (A) Toggle Assembly 2 44360 Spring Washer 3 77687 Braided Ground Strap 4 44054 5 Screw, M3.5 × 20 01448* Screw, 6–32 × 0.37 6 44484** Screw, M4.2 × 1.41 × 25 7 44923*** Braided Ground Strap 8 45925M 44860† Screw, 10-32 × 1.5 SHCS 10 11 12 13 14 15 44339†† Hex Stand-Off 44180M (B) Print Mechanism Assembly (S400) 44204M (B) Print Mechanism Assembly (S600) 30466††† Washer, 0.26 × 0.63 × 0.06 07257‡ Washer, 0.438 × 0.188 × 0.049 44386‡‡ Screw, M4 × 0.
2 1 9 1 A A 10 12 3 11 B 14 5 4 12 13 S400/S600 Maintenance Manual 6 7 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev. 3 3/15/04 8 15 B 15 { Page 5-9 Figure 5-4. Toggle and Print Mechanism 6HFWLRQ 11 Print mechanism and mounting hardware only. See Table 5-5 and Figure 5-5 for printhead assembly and printhead cable.
# 1 Part No. 4 Qty 44999M (A) Printhead Assembly (S400) 1 44998M (A) Printhead Assembly (S600) 1 2 3 Description 10460* Nut, M3 × 2.4 × 5.5 2 44180M (B) Print Mechanism Assembly (S400) 1 44204M (B) Print Mechanism Assembly (S600) 1 44527 Printhead Cable Assembly (S400) 1 44920 Printhead Cable Assembly (S600) 1 44386** Screw, M4 × 0.7 × 16 1 6 07257*** Flat Washer, 0.438 × 0.188 × 0.049 1 30466† Washer, 0.26 × 0.63 × 0.06 * Available only as HW10460 in quantities of 25.
6HFWLRQ 44895L Rev. 3 3/15/04 S400/S600 Maintenance Manual Figure 5-5.
Table 5-6. Tear/ Cutter Media Sensor and Ribbon Guide # # Part No. 1 Description 44054* Screw, M3 × 20 Qty 1 2 44123 Braided Ground Strap 1 3 44190-400M (B) Ribbon Guide Assembly 1 4 44189 Anti-Static Brush 1 5 6 7 5 Ground Cable 1 30466*** Washer, 0.26 × 0.63 × 0.06 8 07257† Washer, 0.438 × 0.188 × 0.036 30393-008†† Screw, 8-32 × 0.
1 2 3 7 6 B 9 8 B S400/S600 Maintenance Manual 4 3 10 5 11 14 A 21 20 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev. 3 3/15/04 This end of the ground strap attaches to the print mechanism assembly. 5 C 12 19 18 17 16 13 Page 5-13 Figure 5-6.
# Part No. 1 44463M Description (A) Platen Guide Rod Kit Qty 1 2 30224* Crescent Ring 2 3 44147** Set Screw 2 44118 Shaft Collar, 0.377 × 0.750 1 5 44349M (B) Upper Media Rod Kit 1 6 44398M (C) Lower Guide Rod Kit 1 7 44346 Edge Guide 2 8 10473 Washer, M4 1 44114*** Screw, M4.2 × 1.41 × 8 3 9 10 44391 Anti-Static Brush 1 11 44218 Backing Rewind Hook 1 12 44284M (D) Media Take-Up Spindle Assembly 1 13 44390 Washer, 0.500 × 0.377 × 0.020 3 07257† Flat Washer, 0.
6HFWLRQ 6 13 13 10 6 7 5 44895L Rev. 3 3/15/04 S400/S600 Maintenance Manual 11 C B A 1 2 12 D 3 4 9 8 Figure 5-7.
# Part No. 1 Description Qty 44023-0M Stepper Motor (Tear-Off and Cutter Option) 1 44023-2M Stepper Motor (Peel-Off Option) 1 2 44216* Screw, M4.2 × 1.41 × 13 1 44177 Tear-Plate Ground Strap 1 4 44019 Idler Shaft 1 5 44025 Idler Pulley, 20T (Tear-Off and Cutter Option only) 1 Washer 0.198 × 0.75 × 0.085 (Tear-Off and Cutter Option) 1 Nut, M5 × 0.8 × 2.
6HFWLRQ 11 12 4 10 5 6 8 9 Figure 5-8. Tear/Cutter Drive System 7 3 1 2 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev.
# Part No. Description Qty # Part No. Description Qty 1 44359M (B) Peel-Off Upper Idler Assembly 1 21 44376 Washer, 0.420 × 0.254 × 0.010 3 2 44363 Screw, M5 × 0.8 × 25 1 22 44274 Bearing Plate 1 1 23 30104 Ball Bearing, 0.50 × 0.250 × 0.125 2 3 30261* Flat Washer, 0.442 × 0.255 × 0.020 4 44496 Peel Pulley Assembly 1 24 02252 External Crescent Ring 0.250 2 5 44359 Idler Spacer 1 25 44172-1 Ground Chain Assembly 1-3/4" 1 30163 Flat Washer, 0.720 × 0.262 × 0.
A 7 1 6 2 3 4 5 B 36 16 B S400/S600 Maintenance Manual 13 14 15 9 37 1 13 A 11 34 35 C A 10 12 19 8 33 17 30 31 16 15 18 24 20 D 18 E 12 10 11 32 22 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev. 3 3/15/04 15 E 29 E 26 24 21 23 13 27 28 18 21 13 21 25 23 Page 5-19 6HFWLRQ Figure 5-9.
# Part No. 1 Description 44114* Screw, M4.2 × 1.41 × 8 Qty 4 2 44282 Tear-Off Plate 1 3 44015 Platen Sleeve Bearing 2 4 44120 Outboard Guide 1 44182 Platen Roller (S400) 1 44214 Platen Roller (S600) 1 44121 Inboard Guide 1 44484** Screw, M4.2 × 1.41 × 25 1 5 6 7 9 44115*** Screw, M4 × 10 45770M 10 44004-400M 2 Power Supply Assembly 120/240 VAC 1 Base Cover 1 * Available only as HW44114 in quantities of 50. ** Available only as HW44484 in quantities of 10.
1 2 4 3 3 6 7 S400/S600 Maintenance Manual Bearings (item #3) pictured here are installed this way for the S400 only. For the S600, rotate bearings 180 degrees (turn upside down). 8 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev. 3 3/15/04 5 9 10 6HFWLRQ Page 5-21 Figure 5-10.
# Part No. Description Qty 1 44710M Cutter Maintenance Kit 1 2 44986 Catch Tray 1 3 10432M Plate Mounting Maintenance Kit 1 4 10432* Screw, M4 × 0.7 × 12 5 10474** Split Washer, M4 6 07257*** Washer, 0.438 × 0.188 × 0.036 7 44437M Cutter Mounting Maintenance Kit 3 2 3 1 44437 Mounting Bushing 2 9 44433 Spring Washer 2 10 44432 Locating Post 2 11 06223 Cable Clamp 0.188 1 12 44674 Cable 8 Cond DIN (Cutter Cable) 1 13 10461 Nut M4 × 0.
16 15 14 Note: The cutter option is not field-installable. Parts displayed below are for repairing the factory-installed option. These parts cannot be installed on non-cutter option printers. 13 S400/S600 Maintenance Manual 7 8 9 B 10 2 65 4 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 44895L Rev. 3 3/15/04 17 C 3 11 A 6 4 Page 5-23 Figure 5-11.
0DLQWHQDQFH Page 5-24 6HFWLRQ S400/S600 Maintenance Manual 44895L Rev.
,QGH[ $ AC Power Fuse Replacement .............. 4-61 Accessing the Printer .............................. 2-5 Additional Printer Self Tests ................. 2-14 Auto Calibration .................................... 2-21 % Bar Codes ............................................... 1-2 Bitmapped Fonts ..................................... 1-3 & Calibration ............................................. 2-21 Auto Calibration .............................. 2-21 Manual Calibration ..........................
,QGH[ * Green Light See Operator Indicators .................... 2-1 , International Characters ......................... 1-3 / Label Head Temp Test ............................. 4-21 Left Wrinkle ..................................... 4-19 Lower Smear Test ........................... 4-22 Pause and Cancel Key ................... 4-18 Right Wrinkle ................................... 4-19 Speed A .......................................... 4-20 Upper Smear Test ...........................
,QGH[ Parallel Data .......................................... 1-12 Connector Pinouts .......................... 1-13 Signal Levels ................................... 1-12 Pause and Cancel Key Self Test .......... 4-16 Pause Key ......................................2-3, 2-17 Pause Key Loopback Test .................... 4-22 Pause Status Indicator ............................ 2-1 Peel-Off Mode ......................................... 1-1 Personal Safety .......................................
,QGH[ See Operator Indicators .................... 2-1 Status Lights See Operator Indicators .................... 2-1 Stepper Motor Replacement ........ 4-56–4-57 7 Tear-Off Mode ................................................. 1-1 Plate Removal ................................. 4-36 Position Adjustment ........................ 2-27 Technical Support ................................. 3-11 Top of Label Position Adjustment ......... 2-28 Troubleshooting ......................................
