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S4M™

Industrial/Commercial Printer

Maintenance Manual

Summary of content (404 pages)

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S4M™ Industrial/Commercial Printer Maintenance Manual
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© 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; E3®; and AGFA fonts. Software © ZIH Corp.
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Contents Proprietary Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xx How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xx Contacts . . . . . . . . . . .
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iv Contents Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents Select a Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Level 1 and 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Level 3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Level 4 Parameters . . . . .
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vi Contents Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Printhead Upgrade Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents 5 • Maintenance and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Media Side Main Printer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics Side Main Printer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism/Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Maintenance Kit . . . . . . . . . . . . . . . . .
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viii Contents A • Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 Serial Data Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware Control Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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List of Tables Table 1 • Control Panel Buttons ..............................................................................5 Table 2 • Control Panel Lights.................................................................................6 Table 3 • Operating Temperature and Humidity ...................................................11 Table 4 • Types of Media.......................................................................................18 Table 5 • Font Matrix for 8 dot/mm (203 dpi) Printheads ..
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x List of Tables Table H • Platen Roller Maintenance Kit ...........................................................328 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 ....................................................
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List of Figures Figure 1 • Sample Figure with Callouts ............................................................ xxiii Figure 2 • Exterior of Printer ..................................................................................2 Figure 3 • Location of Control Panel Buttons and Lights .......................................3 Figure 4 • Example of Active Control Panel Buttons .............................................4 Figure 5 • Media Compartment ..................................................
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xii List of Figures Figure 32 • Communications Diagnostics Test Label ........................................103 Figure 33 • Cleaning the Printhead and Platen Roller ........................................113 Figure 34 • Cleaning the Sensors ........................................................................115 Figure 35 • Remove the Mounting Screw ...........................................................122 Figure 36 • Electronics Cover Removal ...................................................
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List of Figures Figure 79 • Remove the Pressure Dials ..............................................................174 Figure 80 • Remove Springs ...............................................................................174 Figure 81 • Locate Drive System Components ...................................................179 Figure 82 • Remove the Transmissive Sensor ....................................................180 Figure 83 • Disconnect the Ribbon/Head Open Sensor (S4M) ..........................
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xiv List of Figures Figure 126 • Install Peel Assembly .....................................................................244 Figure 127 • Rear View of Peel Assembly .........................................................245 Figure 128 • Install the Front Cover ...................................................................246 Figure 129 • Remove and Install the Static Brush Assembly (S4M) ..................249 Figure 130 • Open the Media Door ......................................................
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List of Figures Figure B • Electronics Side Main Printer Assemblies ........................................319 Figure C • Print Mechanism/Printhead Assembly ..............................................321 Figure D • Printhead Maintenance Kit ................................................................322 Figure E • Printhead Cable Maintenance Kit ......................................................323 Figure F • Platen Drive System ..................................................................
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xvi List of Figures Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________________________________
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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.
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xviii Proprietary Statement Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________________________
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About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xx How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xx Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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: 13291L-001 Rev. A Section Description System Description on page 1 This section provides an overview of the printer. Included are specifications of the printer and a brief explanation of each component and its function.
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About This Document Contacts 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 Technical Support Customer Service Dept. Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.
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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.
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About This Document Document Conventions 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 MENU 1 ENTER CANCEL PAUSE 2 1 2 10/27/05 FEED FEED button CANCEL button S4M Maintenance Manual 13291L-001 Rev.
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xxiv About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ____________
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1 System Description 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 External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Printer Media Compartment . . . . . . . . . . . . . . . . .
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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 1 2 3 4 5 13291L-001 Rev.
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System Description Control Panel 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.
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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.
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System Description Control Panel Table 1 • Control Panel Buttons Button MENU Appearance MENU ENTER ENTER CANCEL CANCEL Function/Description Enters and exits Setup mode. 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.
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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. Table 2 • Control Panel Lights Light POWER ALERT PAUSE (part of the PAUSE button) FEED (part of the FEED button) CANCEL (part of the CANCEL button) 13291L-001 Rev. A Appearance POWER ALERT PAUSE FEED CANCEL Function/Description Indicates that the printer is on.
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System Description Printer Media Compartment 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.
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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
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Operations Before You Begin 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.
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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.
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Operations Select a Site for the Printer 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.
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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.
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Operations Connect the Printer to a Power Source • 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 (Figure 7).
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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.
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Operations Select a Communication Interface 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.
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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.
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Operations Select a Communication Interface Figure 12 • Communicating Using a USB Port Printer Computer 1 3 5 4 2 1 2 3 4 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.
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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.
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Operations Types of Media Table 4 • Types of Media (Continued) Media Type How It Looks Description Non-Continuous Fanfold Media 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.
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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.
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Operations Ribbon Overview 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.
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22 Specifications General Specifications General Specifications General Specifications Height 11.6 in. 295 mm Width 10.7 in. 272 mm Depth 18.8 in. 477 mm Weight (without options) 27.2 lbs. 12.4 kg Electrical 90–264 VAC, 47–63 Hz, 4 Amps (300 W) Temperature Relative Humidity Operating 40° to 104°F 5° to 40°C Storage –40° to 140°F –40° to 60°C Operating 20% to 85%, non-condensing Storage 5% to 85%, non-condensing Communication Interface 13291L-001 Rev. A • RS-232/CCITT V.
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System Description Agency Approvals Agency Approvals 10/27/05 Agency Approvals • • • • IEC60950-1 EN55022: Class B EN55024 EN61000-3-2,-3-3 Product Markings • • • • • • • • • • • • cULus CE Marking FCC-B ICES-003 VCCI C-Tick NOM CCC GOST-R S-Mark (Argentina) MIC BSMI S4M Maintenance Manual 13291L-001 Rev.
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24 Specifications Printing Specifications Printing Specifications Printing Specifications Print resolution Dot size (width x length) 13291L-001 Rev. A 203 dots/inch 8 dots/mm 300 dots/inch 12 dots/mm 203 dpi 0.00492 in. x 0.00492 in. 0.125 mm x 0.125 mm 300 dpi 0.0033 in. x 0.0039 in. 0.084 mm x 0.099 mm Maximum print width 203 dpi 4.09 in. 104 mm 300 dpi 4.1 in. 106 mm Bar code modulus (X) dimension 203 dots/inch 5 mil to 50 mil 300 dots/inch 3.
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Specifications Media Specifications Media Specifications Media Specifications Label length Minimum (Tear-Off) 0.7 in. 17.8 mm Minimum (Peel-Off) 0.5 in. 12.7 mm Maximum 39 in. 991 mm Minimum 0.75 in. 19 mm Maximum 4.5 in. 114 mm Total thickness (includes liner, if any) Minimum 0.003 in. 0.076 mm Maximum 0.010 in. 0.25 mm Maximum roll outside diameter 3-in. (76 mm) core 8 in. 203 mm 1-in. (25 mm) core 6 in. 152 mm Inter-label gap Minimum 0.079 in. 2 mm Preferred 0.118 in.
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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.) Minimum >2 in.* 51 mm* Maximum 4.3 in. 109 mm Standard lengths 2:1 media to ribbon roll ratio 984 ft. 300 m 3:1 media to ribbon roll ratio 1476 ft.
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Specifications Zebra Programming Language (ZPL II) 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) Mirro
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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.
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System Description Standard Font Matrices Table 6 • Font Matrix for 12 dot/mm (300 dpi) Printheads Matrix Font Height Width Type* Character Size Inches Baseline Dots InterCharacter Gap Cell Width Font Matrix Height Width Millimeters Char/ Inch Height Width Char/ mm A 9 5 7 1 6 U-L-D 0.030 0.020 50.00 0.76 0.51 1.97 B 11 7 11 2 9 U 0.037 0.030 33.33 0.93 0.76 1.31 C, D 18 10 14 2 12 U-L-D 0.060 0.040 25.00 1.52 1.02 0.98 E 41 20 32 6 26 OCR-B 0.
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30 System Description Standard Font Matrices Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _____________
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2 Operations This section assists the technician with “out of the box” installation, initial setup, and printer operation. Contents Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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32 Operations Load Media Load Media Use the instructions in this section to load roll media in Tear-Off mode (Figure 17). 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. 13291L-001 Rev.
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Operations Load Media 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. 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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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 2 13291L-001 Rev.
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Operations Load Media 9. Close the printhead assembly. 10. If the printer is paused (the PAUSE light is blinking), press PAUSE to enable printing. 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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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 1 2 3 4 13291L-001 Rev.
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Operations Load Ribbon 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 Figure 19.
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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.
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Operations Load Ribbon 7. Wind the ribbon clockwise onto the ribbon take-up spindle (3). 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.
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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. 13291L-001 Rev.
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Operations Calibrate the Printer 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.
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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 Select the Media Sensor on page 56.
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Operations Select or Adjust the Media Sensors Figure 21 • Adjusting the Reflective Sensor 1 2 3 4 1 2 3 4 Printhead assembly Reflective sensor Reflective sensor positioning lever Printhead release latch To adjust the reflective sensor, complete these steps: 1. See Figure 21. Press the printhead release latch. 2. Lift the printhead until it latches open. 3. Locate the reflective sensor positioning lever. 4.
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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 Figure 22. 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.
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Operations Adjust Printhead Pressure 2. If necessary, adjust the pressure adjustment dials as follows: 10/27/05 If the media... Then... Requires higher pressure to print well Increase both dials one position. Shifts left while printing Increase the outside dial setting one position, or decrease the inside dial setting one position. Shifts right while printing Increase the inside dial setting one position, or decrease 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.
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Operations Password Protection of Parameters 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.
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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 Table 9).
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Operations Password Protection of Parameters 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.
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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.
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Operations Printing Configuration Labels 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 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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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 (Figure 24). An 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 13291L-001 Rev.
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Operations Select a Display Language 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.
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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.
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Operations Control Panel LCD Display Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 2 of 5) Parameter Explanation TEAR OFF 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.
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56 Operations Control Panel LCD Display Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 3 of 5) Parameter Explanation MEDIA TYPE 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.
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Operations Control Panel LCD Display Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 4 of 5) Parameter Explanation PRINT SPEED 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.
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58 Operations Control Panel LCD Display Table 11 • Printer Parameters, Password Levels 1 and 2 (Page 5 of 5) Parameter Explanation RESOLUTION 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 (APL-I mode only) To modify this parameter: • Press the up or down arrow to scroll through the selections.
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Operations Control Panel LCD Display Password Level 3 Parameters Table 12 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.
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60 Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 2 of 10) Parameter Explanation MODULE B Set Module B Storage Device for APL-D Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2 Default Value: NONE (APL-D mode only) To modify this parameter: • Press the up or down arrow to scroll through the selections. PARALLEL COMM. Set Parallel Communications Select the communications port that matches the one being used by the host computer.
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Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 3 of 10) Parameter Explanation DATA BITS 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.
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62 Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 4 of 10) Parameter Explanation HOST HANDSHAKE 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.
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Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 5 of 10) Parameter Explanation DELIM. CHAR 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.
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64 Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 6 of 10) Parameter Explanation CHANGE RTC TIME 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. To modify this parameter: 1. 2. • • • 3. LOAD DEFAULTS Press ENTER. The printer displays the current RTC time. Modify the values as follows: Press the right arrow to move to the next digit position.
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Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 7 of 10) Parameter Explanation RIBBON 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).
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66 Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 8 of 10) Parameter Explanation SENSOR PROFILE 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 Calibrate Media and Ribbon Sensors on page 67.
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Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 9 of 10) Parameter Explanation MEDIA/RIBBON CALIBRATE 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.
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68 Operations Control Panel LCD Display Table 12 • Printer Parameters, Password Level 3 (Page 10 of 10) Parameter Explanation LANGUAGE 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.
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Operations Control Panel LCD Display ZebraNet® Wired and Wireless Print Server LCD Displays The menu options shown in Table 13 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.
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70 Operations Control Panel LCD Display Table 13 • Print Server LCD Displays (Page 2 of 2) Parameter Explanation CHANGE GATEWAY 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.
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Operations Control Panel LCD Display Password Level 4 Parameters Table 14 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.
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72 Operations Control Panel LCD Display Table 14 • Printer Parameters, Password Level 4 (Page 2 of 3) Parameter Explanation TAKE LABEL 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. MEDIA POWER UP Select Media Power-Up Option This parameter sets the action of the media when you turn on the printer.
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Operations Control Panel LCD Display Table 14 • Printer Parameters, Password Level 4 (Page 3 of 3) Parameter Explanation LANGUAGE 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.
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74 Operations Control Panel LCD Display 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.
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Operations Control Panel LCD Display Table 15 • Printer Parameters, Manufacturing Menu (Page 1 of 7) Parameter Explanation PRINT OUT 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.
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76 Operations Control Panel LCD Display Table 15 • Printer Parameters, Manufacturing Menu (Page 2 of 7) Parameter Explanation SENSOR PROFILE 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 Calibrate Media and Ribbon Sensors on page 67.
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Operations Control Panel LCD Display Table 15 • Printer Parameters, Manufacturing Menu (Page 3 of 7) Parameter Explanation DARKNESS 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.
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78 Operations Control Panel LCD Display Table 15 • Printer Parameters, Manufacturing Menu (Page 4 of 7) Parameter Explanation MEDIA TYPE 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.
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Operations Control Panel LCD Display Table 15 • Printer Parameters, Manufacturing Menu (Page 5 of 7) Parameter Explanation LENGTH 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.
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80 Operations Control Panel LCD Display Table 15 • Printer Parameters, Manufacturing Menu (Page 6 of 7) Parameter Explanation MEDIA/RIBBON CALIBRATE 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.
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Operations Control Panel LCD Display Table 15 • Printer Parameters, Manufacturing Menu (Page 7 of 7) Parameter Explanation LOAD DEFAULTS 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: Press ENTER.
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82 Operations Control Panel LCD Display Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________
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3 Troubleshooting 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 Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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Troubleshooting Troubleshooting Checklists 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 Memory Errors on page 89. Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensors on page 67.
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86 Troubleshooting LCD Error Messages LCD Error Messages The LCD displays messages when there is an error. See Table 16 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. Load ribbon correctly.
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Troubleshooting LCD Error Messages Table 16 • LCD Error Messages (Continued) LCD Display/ Printer Condition WARNING RIBBON IN 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. The ALERT light flashes.
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88 Troubleshooting LCD Error Messages Table 16 • LCD Error Messages (Continued) LCD Display/ Printer Condition WARNING HEAD COLD The printer stops and the ALERT light flashes. 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.
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Troubleshooting Memory Errors Memory Errors The memory errors in Table 17 indicate that the printer does not have enough memory to perform the function shown on the second line of the LCD. Table 17 • Memory Errors Problem/LCD Display Possible Cause Recommended Solution OUT OF MEMORY CREATING BITMAP Creating Bitmap The bitmap size (label length/width) does not fit in available memory. OUT OF MEMORY STORING BITMAP Storing Bitmap Not enough memory is available to store the bitmap created.
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90 Troubleshooting Print Quality Problems Print Quality Problems Table 18 identifies problems with print quality, the possible causes, and the recommended solutions. Table 18 • Print Quality Problems Problem Possible Cause Recommended Solution General print quality issues The printer is set at the incorrect print speed. 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.
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Troubleshooting Print Quality Problems Table 18 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Fine, angular gray lines on blank labels Wrinkled ribbon. See wrinkled ribbon causes and solutions in this table. Printing too light or too dark over the entire label Media or ribbon is not designed for high-speed operation. Replace supplies with those recommended for high-speed operation. You are using an incorrect combination of labels and ribbon for your application.
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92 Troubleshooting Print Quality Problems Table 18 • Print Quality Problems (Continued) Problem Possible Cause Vertical image or label drift The printer is using Configure the printer for non-continuous and run noncontinuous labels but is calibration routine, if necessary. configured in continuous mode. The bar code printed on a label does not scan. 13291L-001 Rev. A Recommended Solution Improperly calibrated media sensor. See Calibrate Media and Ribbon Sensors on page 67.
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Troubleshooting Calibration Problems Calibration Problems Table 19 identifies problems with calibration, the possible causes, and the recommended solutions. Table 19 • Calibration Problems Problem Possible Cause Recommended Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. Improperly positioned media guides. Ensure that the media guides are properly positioned. Media type set incorrectly.
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94 Troubleshooting Communications Problems Communications Problems Table 20 identifies problems with communications, the possible causes, and the recommended solutions. Table 20 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the printer but was not recognized. The communication parameters are incorrect. Check the printer driver or software communications settings (if applicable). Make sure you are using the correct communication cable.
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Troubleshooting Ribbon Problems Ribbon Problems Table 21 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 Possible Cause Recommended Solution Broken or melted ribbon Darkness setting too high. 1. Reduce the darkness setting. 2. Clean the printhead thoroughly. The printer does not detect when the ribbon runs out.
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96 Troubleshooting Miscellaneous Printer Problems Miscellaneous Printer Problems Table 22 identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions. Table 22 • Miscellaneous Printer Problems Problem Possible Cause Recommended Solution The LCD displays a language that I cannot read The language parameter was changed through the control panel or a firmware command. Perform the procedure in Select a Display Language on page 53.
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Troubleshooting Printer Diagnostics 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.
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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). Figure 28 • Configuration Label 13291L-001 Rev.
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Troubleshooting Printer Diagnostics 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.
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100 Troubleshooting 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.
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Troubleshooting Printer Diagnostics 4. See Figure 31 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.
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102 Troubleshooting Printer Diagnostics Table 23 • Judging Bar Code Quality Print Quality Description Too dark 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 Slightly dark labels are not as obvious. • The normal bar code will be “in-spec.
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Troubleshooting Printer Diagnostics 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.
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104 Troubleshooting 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 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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106 Preventive and Corrective Maintenance Contents Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______
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Safety Information This section identifies general and specific safety information for the S4M printer. Contents Personal Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Equipment Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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108 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Equipment Safety Tips 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 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.
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110 Preventive and Corrective Maintenance 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. Contents Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. Table 24 shows the recommended cleaning schedule. .
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Preventive and Corrective Maintenance Cleaning Procedures 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.
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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.
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Preventive and Corrective Maintenance Cleaning Procedures 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).
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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.
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Preventive and Corrective Maintenance Cleaning Procedures 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.
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118 Preventive and Corrective Maintenance 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 Routine Referral Procedures (RRP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Electronics Cover . . . .
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120 Preventive and Corrective Maintenance 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 •
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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. Contents Remove the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Install the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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122 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Routine Referral Procedures Figure 36 • Electronics Cover Removal 1 2 1 2 10/27/05 Electronics Cover Mounting Screws (4) S4M Maintenance Manual 13291L-001 Rev.
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124 Preventive and Corrective Maintenance Routine Referral Procedures RRP No. 2: Install the Electronics Cover 1. See Figure 36 on page 123. 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 Figure 35 on page 122. 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. Contents Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Upgrade Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Cables . .
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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.
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Preventive and Corrective Maintenance Printhead Assembly 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 Figure 37.
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128 Preventive and Corrective Maintenance 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 1 2 3 4 5 6 7 Thumbscrew Printhead pressure dials (2) Print mechanism assembly Printhead connectors Printhead fork assembly Locating holes Ribbon guide plate 7.
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Preventive and Corrective Maintenance Printhead Assembly 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.
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130 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Printhead Upgrade Option Remove the Printhead 1. Open the media door. 2. See Figure 39. Rotate the two printhead pressure dials to the #1 position. Figure 39 • Locate the Printhead Pressure Dials 1 2 4 1 2 3 4 3 4 Position number one Position number four Thumbscrew Printhead pressure dials (2) 3. See Figure 40. Remove the thumbscrew to loosen the printhead fork assembly. 4. Caution • Be sure the printhead is fully open and latched in the open position.
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132 Preventive and Corrective Maintenance Printhead Upgrade Option Figure 40 • Printhead Removal and Installation 2 1 1 3 9 6 4 5 8 4 7 1 2 3 4 5 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 Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
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Preventive and Corrective Maintenance Printhead Upgrade Option 7. See Figure 41. 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 Figure 41. 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.
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Preventive and Corrective Maintenance Printhead Upgrade Option 5. Secure the printhead fork assembly to the printhead housing using the previously removed thumbscrew. 6. See Figure 39 on page 131. 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.
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Preventive and Corrective Maintenance Printhead Upgrade Option 4. See Figure 43. 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 1 2 3 4 5 2 Main logic board nut Main logic board mounting screws (6) Main logic board Lock washer (2) Serial port mounting stud (2) 6.
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Preventive and Corrective Maintenance Printhead Upgrade Option 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 Figure 44. Remove the compound gear mounting screw. Figure 44 • Remove the Compound Gear 2 1 1 2 Mounting screw Compound gear 2. See Figure 45.
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Preventive and Corrective Maintenance Printhead Upgrade Option 4. See Figure 46. Using a hex key, loosen the stepper motor pivot screw and locking screw. Figure 46 • Loosen the Stepper Motor 1 2 3 4 5 1 2 3 4 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.
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138 Preventive and Corrective Maintenance Printhead Upgrade Option 8. See Figure 47. 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.
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Preventive and Corrective Maintenance Printhead Upgrade Option Reinstall the MLB 1. See Figure 43 on page 135. Reinstall the MLB in the printer using the screws, nut, and studs and washers previously removed. 2. See Figure 42 on page 134. 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.
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140 Preventive and Corrective Maintenance Printhead Upgrade Option Figure 49 • Configuration Label (200 dpi or 300 dpi) 3. Turn Off (O) the printer. 4. See Figure 50. 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 13291L-001 Rev.
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Preventive and Corrective Maintenance Print Mechanism 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.
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142 Preventive and Corrective Maintenance Print Mechanism 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 RRP No. 1 on page 122 and remove the electronics cover. 3. See Figure 51. Rotate the two printhead pressure dials to the #1 position.
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Preventive and Corrective Maintenance Print Mechanism Figure 52 • Disconnect the Print Mechanism 2 1 4 3 5 9 1 2 3 4 5 8 MLB Printhead data cable MLB connector J3 Cable clamp (2) Printhead ground strap 7 6 7 8 9 6 Printhead power cable Power supply connector Stepper motor mounting bracket Stepper motor 8. Remove the printhead housing grounding strap mounting screw. 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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144 Preventive and Corrective Maintenance Print Mechanism 9. See Figure 53. 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 1 2 3 4 Printhead housing Washers (3) Phillips head mounting screw Hex head mounting screw (2) 10. Remove the printhead housing assembly from the printer. 13291L-001 Rev.
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Preventive and Corrective Maintenance Print Mechanism Install the New Print Mechanism 1. Are you installing the print mechanism on a Direct Thermal Only S4M printer? If… Then… No Continue to step 2. Yes Caution • Be careful not to touch the printhead with any tools. This could damage the printhead. See Figure 54. Remove the and discard the ribbon strip plate from the new print mechanism and then continue to step 2.
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146 Preventive and Corrective Maintenance Print Mechanism 2. See Figure 55. 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.
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Preventive and Corrective Maintenance Print Mechanism Adjust the Print Mechanism 1. See Figure 56. 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 Figure 51 on page 142. Set both printhead pressure dials to 3.
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148 Preventive and Corrective Maintenance Print Mechanism 3. See Figure 57. 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 1 2 3 Cam mounting hole Cam Mounting screw 4. See Figure 56 on page 147.
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Preventive and Corrective Maintenance Print Mechanism 10. Tighten the remaining print mechanism mounting screws when equal pressure is obtained. 11. See Figure 58. Check the gap on the ribbon/printhead open sensor and adjust as necessary. Figure 58 • Ribbon/Printhead Open Sensor 1 2 4 1 2 3 4 3 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.
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150 Preventive and Corrective Maintenance Print Mechanism Reinstall the Electronics Cover 1. See RRP No. 2 on page 124 and install the electronics cover. 2. See Figure 51 on page 142. Rotate the two printhead pressure dials to position 3. 3. Reconnect AC power cord and data cables. Verify the Installation 1. See Figure 59. 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.
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Preventive and Corrective Maintenance Printhead Cable 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.
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152 Preventive and Corrective Maintenance Printhead Cable 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 RRP No. 1 on page 122 and remove the electronics cover. 3. See Figure 60. Rotate the printhead pressure dials to the #1 position. Figure 60 • Locate the Printhead Pressure Knobs 1 2 4 1 2 3 4 13291L-001 Rev.
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Preventive and Corrective Maintenance Printhead Cable 4. See Figure 61. 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 3 2 4 6 1 2 3 4 5 6 5 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.
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154 Preventive and Corrective Maintenance Printhead Cable 8. See Figure 62. 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 1 2 3 4 Print mechanism Washers (3) Phillips head mounting screw Hex head mounting screws (2) 9. Remove the printhead housing assembly from the printer. 13291L-001 Rev.
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Preventive and Corrective Maintenance Printhead Cable Remove the Old Printhead Cables 1. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. See Figure 63. 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 1 2 3 4 5 Print mechanism Thumbscrew Printhead power cable Printhead data cable Printhead fork assembly 3. Disconnect the printhead power and data cables. 4.
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156 Preventive and Corrective Maintenance Printhead Cable Figure 64 • Remove and Install the Cables 1 2 3 5 4 1 2 3 4 5 Printhead data cable Printhead power cable Hinge Printhead data connector Printhead power connector Install the New Printhead Cables 1. See Figure 64. Slide each of the cables through the hinge and into the print mechanism. 2.
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Preventive and Corrective Maintenance Printhead Cable Reinstall the Print Mechanism 1. See Figure 65. 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.
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158 Preventive and Corrective Maintenance Printhead Cable Adjust the Print Mechanism 1. See Figure 66. 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 1 2 3 4 5 13291L-001 Rev.
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Preventive and Corrective Maintenance Printhead Cable 2. See Figure 67. 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 1 2 3 Cam mounting hole Cam Mounting screw 3. See Figure 66 on page 158.
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160 Preventive and Corrective Maintenance Printhead Cable 10. Replace the strike plate cap. 11. See Figure 68. Check the gap on the ribbon/printhead open sensor and adjust as necessary. Figure 68 • Ribbon/Printhead Open Sensor 1 2 4 1 2 3 4 3 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.
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Preventive and Corrective Maintenance Printhead Cable Reinstall the Electronics Cover 1. See RRP No. 2 on page 124 and install the electronics cover. 2. Reinstall the media and ribbon. Verify the Installation 1. See Figure 60 on page 152. Rotate the two printhead pressure dials to the position 3. 2. Reconnect AC power cord and data cables. 3. See Figure 69. 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.
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162 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Printhead Release Latch Remove the Old Latch 1. Turn Off (O) the printer and disconnect the AC power cord and data cables. 2. See Figure 70. Open the media door and remove the ribbon and media. Figure 70 • Media Door and Latch Location (S4M) 1 4 3 1 2 3 4 10/27/05 2 Media door Latch assembly Latch plate cover Strike plate cap S4M Maintenance Manual 13291L-001 Rev.
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164 Preventive and Corrective Maintenance Printhead Release Latch 3. See Figure 71. 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.
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Preventive and Corrective Maintenance Printhead Release Latch Install the New Latch Kit 1. See Figure 71 on page 164. 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.
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166 Preventive and Corrective Maintenance Printhead Release Latch Adjust the Print Mechanism 1. See Figure 73. 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 4 5 6 1 2 3 4 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.
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Preventive and Corrective Maintenance Printhead Release Latch 5. Is the adjustment acceptable? If… Then… No Continue with step 6. Yes Go to step 13. 6. Loosen the two strike plate screws. 7. See Figure 74. 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 1 2 3 4 Print mechanism Adjusting cam Hex head mounting screws (2) Phillips head mounting screw 8.
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168 Preventive and Corrective Maintenance Printhead Release Latch 13. See Figure 71 on page 164. 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. 13291L-001 Rev.
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Preventive and Corrective Maintenance Printhead Pressure Dials 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.
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170 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Printhead Pressure Dials 5. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. See Figure 76. Remove the printhead thumbscrew. Figure 76 • Remove the Printhead and Cable Connections 2 1 2 3 4 5 7 6 1 2 3 4 Thumbscrew Printhead pressure dial Print mechanism assembly Printhead data cable 5 6 7 Printhead power cable Printhead fork assembly Locating holes 6.
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172 Preventive and Corrective Maintenance Printhead Pressure Dials Remove the Old Pressure Dials To remove the pressure dials you must partially disassemble the print mechanism. 1. See Figure 77. 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 Figure 78. Put a piece of masking tape over the pressure roller to secure it to the pressure bracket.
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Preventive and Corrective Maintenance Printhead Pressure Dials Figure 78 • Remove the Pressure Bracket and Roller 6 1 2 3 4 3 5 1 2 3 4 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.
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174 Preventive and Corrective Maintenance Printhead Pressure Dials 6. See Figure 79. 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 Figure 80. Remove the springs from the old dials and place them in the new dials. Figure 80 • Remove Springs 1 2 1 2 13291L-001 Rev.
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Preventive and Corrective Maintenance Printhead Pressure Dials Install the New Pressure Dials 1. See Figure 79 on page 174. Insert the new dials and springs into the print mechanism. 2. See Figure 78 on page 173. Reinstall the pressure bracket and roller and then remove the masking tape. 3. Retighten the lower print mechanism latch screw. 4. See Figure 76 on page 171.
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176 Preventive and Corrective Maintenance Printhead Pressure Dials Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________
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Sensors This section provides replacement and installation procedures for the S4M sensors. Contents Transmissive Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon/Printhead Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reflective Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Take-Label Sensor . . . . . . . . . . . . . . . . . .
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178 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Transmissive Sensor Remove the Old Transmissive Sensor Remove the Stepper Motor 1. See RRP No. 1 on page 122 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 Figure 81. Locate the stepper motor and drive belt.
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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 Figure 82. Remove the transmissive sensor mounting screw, and then remove the transmissive sensor. Figure 82 • Remove the Transmissive Sensor 1 4 1 2 3 4 13291L-001 Rev.
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Preventive and Corrective Maintenance Transmissive Sensor Install the New Transmissive Sensor 1. See Figure 82. 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).
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182 Preventive and Corrective Maintenance 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.
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Ribbon/Head Open Sensor Assembly Ribbon/Printhead Open Sensor Remove the Old Sensor 1. See RRP No. 1 on page 122 and remove the electronics cover. 2. See Figure 83. 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 1 2 3 4 2 3 4 Main logic board (MLB) MLB connector (P4) Protective wrap Access hole 4. See Figure 84. Remove the screw securing the ribbon/head open sensor assembly. 5.
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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 Figure 84 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.
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Ribbon/Head Open Sensor Assembly Ribbon/Printhead Open Sensor Figure 85 • Gap Measurement between Print Mechanism and Sensor 0.060 in.(1.5 mm) ±0.015 in. 2 1 1 2 Gap Mounting screw Reinstall the Electronics Cover 1. See RRP No. 2 on page 124 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.
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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.
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Preventive and Corrective Maintenance Reflective Media Sensor 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.
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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 RRP No.
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Preventive and Corrective Maintenance Reflective Media Sensor 3. See Figure 87. 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 4 4 5 6 1 2 3 4 5 6 Platen roller housing Cable tie Wireway Media sensor holder tabs (2) Media sensor assembly Latch cover 5.
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190 Preventive and Corrective Maintenance Reflective Media Sensor Install the New Media Sensor Assembly 1. See Figure 87 on page 189. 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.
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Preventive and Corrective Maintenance Take-Label Sensor 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.
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192 Preventive and Corrective Maintenance Take-Label Sensor Figure 88 • Remove and Install the Control Panel 1 2 3 4 13 1 2 3 4 5 6 7 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 5 6 8 7 12 11 9 10 Star washer Control panel Tab Cable access hole Access hole Conduit 5. Remove the mounting screw and washers securing the control panel. 6.
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Preventive and Corrective Maintenance Take-Label Sensor Remove the Take-Label Sensor Board 1. See Figure 89. 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 10/27/05 Take-label sensor board Mounting screws (2) S4M Maintenance Manual 13291L-001 Rev.
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194 Preventive and Corrective Maintenance Take-Label Sensor Install the Take-Label Sensor Board 1. See Figure 90. 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 4 1 2 3 4 13291L-001 Rev.
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Preventive and Corrective Maintenance Take-Label Sensor Figure 91 • Install the Take-Label Sensor Board on the Mounting Posts 1 2 1 2 Mounting posts (2) Screw holes (2) 2. Install the two mounting screws supplied in the kit. 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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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. Figure 92 • Install the Control Panel in the Base 2 3 1 4 2 5 1 1 2 3 4 5 6 6 3 Base Control panel Notch Tabs (2) Access holes (2) Slots (2) 2. See Figure 88 on page 192. Guide the control panel cable through the access hole in the front of the main frame. Connect it to J2 on the MLB. 3.
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Preventive and Corrective Maintenance Take-Label Sensor 6. See Figure 88 on page 192. Install the screw and washer to secure the control panel to the main frame. Install the Electronics Cover 1. See 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. 4. Turn On (l) the printer. 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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198 Preventive and Corrective Maintenance Take-Label Sensor Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _________________________________________________________________________
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Drive System This section provides replacement and installation procedures for the printer’s drive system. Contents Ribbon Take-Up Spindle Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-Up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Hanger Assembly . . . . . . . .
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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.
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Preventive and Corrective Maintenance Ribbon Take-Up Spindle Clutch 3. See Figure 93. Remove all cables from the main logic board (MLB). Note • Take note of the location of all cables on the main logic board.
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202 Preventive and Corrective Maintenance Ribbon Take-Up Spindle Clutch 4. See Figure 94. 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 4 5 3 2 1 2 3 4 Main logic board nut (1) Main logic board mounting screws (6) Main logic board (MLB) Serial port mounting studs (2) 6.
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Preventive and Corrective Maintenance Ribbon Take-Up Spindle Clutch Remove the Wireless Board 1. See Figure 95. Remove the two mounting screws securing the wireless board to the back cover. Figure 95 • Remove Wireless Board 2 3 1 4 5 6 1 2 3 4 5 6 Mounting screws (2) Mounting bracket Bracket mounting screw Wireless Option Board Upper mounting standoff Lower mounting standoff 2. Remove the upper mounting standoff. 3. Remove the lower mounting standoff. 4.
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204 Preventive and Corrective Maintenance Ribbon Take-Up Spindle Clutch Remove the Old Ribbon Take-up Spindle Clutch 1. See Figure 96. 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 1 2 3 4 2 3 4 Bracket Intermediate gear Mounting screw Mark the outside of the compound gear. 3.
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Preventive and Corrective Maintenance Ribbon Take-Up Spindle Clutch 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 7 1 2 3 4 5 6 7 10/27/05 2 1 4 Compound gear mounting screw Compound gear Collar Clearance—0.020 in. (0.
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206 Preventive and Corrective Maintenance Ribbon Take-Up Spindle Clutch Install the New Clutch Assembly 1. See Figure 97. 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.
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Preventive and Corrective Maintenance Ribbon Take-Up Spindle 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.
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Preventive and Corrective Maintenance 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 RRP No. 1 on page 122 and remove the electronics cover. 3. See Figure 98. Remove all cables from the main logic board (MLB). Note • Take note of the location of all connectors on the main logic board.
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Preventive and Corrective Maintenance Ribbon Take-Up Spindle 4. See Figure 99. 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 1 2 3 4 5 2 Main logic board nut (1) Main logic board mounting screws (6) Main logic board (MLB) Lock washers (2) Serial port mounting studs (2) 6.
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210 Preventive and Corrective Maintenance Ribbon Take-Up Spindle Remove the Wireless Option Board 1. See Figure 100. Remove the two mounting screws securing the wireless board to the back cover. Figure 100 • Remove Wireless Board 2 1 3 4 5 1 2 3 4 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.
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Preventive and Corrective Maintenance Ribbon Take-Up Spindle Remove the Old Ribbon Take-up Spindle Assembly 1. See Figure 101. 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 1 2 3 4 2 3 4 Bracket Intermediate gear Mounting screw Mark the outside of the compound gear. 3.
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212 Preventive and Corrective Maintenance Ribbon Take-Up Spindle 6. See Figure 103. 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 7 1 2 3 4 5 6 7 13291L-001 Rev. A 2 1 4 Compound gear mounting screw Compound gear Collar Clearance—0.020 in. (0.
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Preventive and Corrective Maintenance Ribbon Take-Up Spindle 8. See Figure 103. 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 1 Collar 5 2 3 4 Thrust washer S4M clutch gear Washer 6 7 5 Ribbon take-up spindle assembly Washer Clearance—0.020 in. (0.508 mm) Install the New Ribbon Take-Up Spindle Assembly 1. See Figure 103 on page 213.
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214 Preventive and Corrective Maintenance Ribbon Take-Up Spindle Complete the Installation 1. Did you remove a wireless option board? If… Then… No Continue to Install the MLB. Yes a. b. See Figure 100 on page 210. Reinstall the wireless option board. Continue to Install the MLB. Install the MLB 1. See Figure 101 on page 211. Align the mounting bracket with the mounting hole and then reinstall the top mounting screw. 2. Tighten the bottom mounting screw. 3. See Figure 99 on page 209.
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Preventive and Corrective Maintenance Ribbon Supply Spindle 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.
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216 Preventive and Corrective Maintenance Ribbon Supply Spindle Remove the Old Ribbon Supply Spindle Note • Retain all parts removed during disassembly, unless otherwise directed. 1. See RRP No. 1 on page 122 and remove the electronics cover. 2. See Figure 105. 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.
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Preventive and Corrective Maintenance Ribbon Supply Spindle Figure 105 • Stepper Motor Removal and Installation 2 3 1 6 1 2 3 4 5 6 10/27/05 5 4 Stepper motor Intermediate gear Pivot screw Belt Locking screw Pivot plate S4M Maintenance Manual 13291L-001 Rev.
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218 Preventive and Corrective Maintenance Ribbon Supply Spindle 4. See Figure 106. Remove the ribbon supply spindle mounting screw and washer. Figure 106 • Remove the Ribbon Supply Spindle Mounting Screw 1 2 1 2 Ribbon spindle mounting screw Ribbon spindle mounting washer 5. Push the spindle out of the main frame. 13291L-001 Rev.
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Preventive and Corrective Maintenance Ribbon Supply Spindle 6. See Figure 107. 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 1 2 3 4 5 5 Spindle assembly Spindle remove tool Washer Screw Nut 10.
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220 Preventive and Corrective Maintenance 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 Figure 109. Install the thin washer onto the spindle shaft. Figure 109 • Install the Thin Washer 1 2 1 2 Thin washer Ribbon supply spindle shaft 3. See Figure 107 on page 219.
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Preventive and Corrective Maintenance Ribbon Supply Spindle Figure 110 • Spindle Installation 1 2 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 Figure 105 on page 217.
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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 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. 4.
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Preventive and Corrective Maintenance Hanger Assembly 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.
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Preventive and Corrective Maintenance 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 RRP No. 1 on page 122 and remove the electronics cover. 3. Open the media door and remove the media and ribbon 4. See Figure 111. On the electronics side, disconnect all cables from the main logic board.
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Preventive and Corrective Maintenance Hanger Assembly 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 2 3 1 2 3 4 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.
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226 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Stepper Motor and Gear/Pulley 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.
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228 Preventive and Corrective Maintenance Stepper Motor and Gear/Pulley Figure 114 • Locate Drive System Components 1 6 1 2 3 4 5 6 3 2 5 4 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. 13291L-001 Rev.
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Preventive and Corrective Maintenance Stepper Motor and Gear/Pulley 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.
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230 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Gears and Pulley 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 RRP No. 1 on page 122 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.
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232 Preventive and Corrective Maintenance Gears and Pulley Figure 116 • Remove the Main Logic Board 1 5 4 3 1 2 3 4 5 2 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. 13291L-001 Rev.
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Preventive and Corrective Maintenance Gears and Pulley Remove the Drive Belt 1. See Figure 117. Locate the stepper motor and drive belt. Figure 117 • Locate Drive System Components 1 8 9 1 2 3 4 5 Compound gear Mounting screw Intermediate gear Set screws (2) Compound pulley 6 7 8 9 2 3 4 5 7 6 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.
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234 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Gears and Pulley 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.
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Preventive and Corrective Maintenance Gears and Pulley 7. See Figure 120. Select the proper orientation for the compound gear, 200 or 300 dpi. Figure 120 • Select the Proper Compound Gear Position 1 THIS S E D ID E T/200 DPI OU 1 2 2 OU T/300 D PI THIS SI 236 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.
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Preventive and Corrective Maintenance Peel-Off/Tear-Off Bar 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.
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238 Preventive and Corrective Maintenance 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 Figure 121. 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 4 3 3 2 1 2 3 4 13291L-001 Rev.
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Preventive and Corrective Maintenance Peel-Off/Tear-Off Bar 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 2 1 2 3 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.
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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.
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Preventive and Corrective Maintenance Peel Option 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 Figure 123. 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 4 3 1 2 3 4 10/27/05 3 2 Media door Latch cover Front cover Use flat-blade screwdriver here S4M Maintenance Manual 13291L-001 Rev.
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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… Then… No Continue to next step. Yes Go to Remove the Peel Assembly on page 243. Remove the Tear Bar 1. See Figure 124. 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. 13291L-001 Rev.
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Preventive and Corrective Maintenance Peel Option Remove the Peel Assembly 1. See Figure 125. Remove the two mounting screws and then remove the peel assembly. Figure 125 • Remove Old Peel Assembly 1 2 1 2 10/27/05 Peel assembly Mounting screws (2) S4M Maintenance Manual 13291L-001 Rev.
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244 Preventive and Corrective Maintenance Peel Option Install the Peel Assembly 1. See Figure 126. 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 5 6 1 2 3 4 5 6 13291L-001 Rev.
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Preventive and Corrective Maintenance Peel Option 2. See Figure 127. 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 Figure 126 on page 244. 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.
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246 Preventive and Corrective Maintenance Peel Option Install the New Front Cover 1. See Figure 128. 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 1 1 2 3 4 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. 13291L-001 Rev.
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Preventive and Corrective Maintenance Peel Option 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 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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248 Preventive and Corrective Maintenance 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.
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Static Brush Assembly Kit Static Brush 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 Figure 129. 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. 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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250 Preventive and Corrective Maintenance 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.
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Dancer Maintenance Kit Dancer Assembly Remove the Old Dancer Assembly 1. Turn Off (O) the printer and disconnect the power cord and all data cables. 2. See Figure 130. Open the media door and remove the media and ribbon. Figure 130 • Open the Media Door 1 2 1 2 Media door Dancer assembly 3. See Figure 131. 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.
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252 Dancer Maintenance Kit Dancer Assembly Figure 131 • Dancer Assembly 5 6 1 2 3 4 1 2 3 4 5 6 Torsion spring Dancer E-ring Flanged bearing (2) Printer post Dancer tab Install the New Dancer Assembly 1. See Figure 131. 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.
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Preventive and Corrective Maintenance Outer Media Guide 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.
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254 Preventive and Corrective Maintenance 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 Figure 132 and Figure 133. Remove the thumb nut or screw, washer, and spring. 4.
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Preventive and Corrective Maintenance Outer Media Guide Install the Outer Media Guide 1. See Figure 133. 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 1 2 3 4 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.
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256 Preventive and Corrective Maintenance Outer Media Guide Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _________________________________________________________________________
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Roller System This section provides replacement and installation procedures for the S4M roller system. Contents Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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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.
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Preventive and Corrective Maintenance Platen Roller 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 RRP No. 1 on page 122 and remove the electronics cover. 3. See Figure 134. Loosen the stepper motor locking screw and pivot screw.
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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… Then… No Go to Remove the Front Cover on page 261. Yes Continue to Remove the Peel Assembly. Remove the Peel Assembly 1. See Figure 135. 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.
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Preventive and Corrective Maintenance Platen Roller Remove the Front Cover Figure 136 • Remove the Lower Front Cover 1 3 2 2 1 2 3 10/27/05 Latch cover Lower front cover Tabs (2) S4M Maintenance Manual 13291L-001 Rev.
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262 Preventive and Corrective Maintenance 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 13291L-001 Rev.
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Preventive and Corrective Maintenance Platen Roller 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 Figure 138. 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.
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264 Preventive and Corrective Maintenance Platen Roller 3. See Figure 139. Remove and discard the platen roller and bearings. Figure 139 • Remove the Platen Roller and Bearings 2 3 4 1 1 1 2 3 4 13291L-001 Rev.
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Preventive and Corrective Maintenance Platen Roller 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 Figure 139 on page 264. 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.
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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 Figure 141. 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.
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Preventive and Corrective Maintenance Platen Roller Reinstall the Peel Assembly 1. See Figure 142. 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 5 6 1 2 3 4 5 6 10/27/05 Peel assembly Mounting slots (2) Mounting screws (2) Platen housing Rest Pems on housing here. Peel lever S4M Maintenance Manual 13291L-001 Rev.
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268 Preventive and Corrective Maintenance Platen Roller 2. See Figure 143. 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 Figure 142 on page 267. 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.
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Preventive and Corrective Maintenance Pinch Roller 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.
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270 Preventive and Corrective Maintenance 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 Figure 145. 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 Figure 144.
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Preventive and Corrective Maintenance Pinch Roller Install the Pinch Roller 1. See Figure 144. 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 Figure 145. If you had to remove the peel assembly, reinstall it using the two screws previously removed. Ensure the assembly is firmly seated.
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272 Preventive and Corrective Maintenance Pinch Roller Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___
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Printed Circuit Boards This section provides replacement and installation procedures for the various printed circuit boards and power systems in the S4M printer. Contents Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mail Logic Board Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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274 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Control Panel Figure 146 • Remove and Install the Control Panel 1 2 4 3 13 1 2 3 4 5 6 7 Main frame Main logic board (MLB) J19 Control panel cable J2 Mounting screw Split washer 8 9 10 11 12 13 5 6 8 7 11 9 10 12 Star washer Control panel Tab Cable access hole Access hole Conduit 5. Remove the mounting screw and washers securing the control panel. 6.
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276 Preventive and Corrective Maintenance Control Panel Remove the Take-Label Sensor Board 1. See Figure 147. 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 13291L-001 Rev.
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Preventive and Corrective Maintenance Control Panel 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 4 1 2 3 4 10/27/05 Control panel Take-label sensor board Mounting screws (2) Guide posts (2) S4M Maintenance Manual 13291L-001 Rev.
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278 Preventive and Corrective Maintenance 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 Figure 148 on page 277. Reinstall the two mounting screws. 13291L-001 Rev.
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Preventive and Corrective Maintenance Control Panel 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. Figure 150 • Install the Control Panel in the Base 2 3 1 4 2 5 1 1 2 3 4 5 6 6 3 Base Control panel Notch Tabs (2) Access holes (2) Slots (2) 2. See Figure 146 on page 275. Guide the control panel cable through the access hole in the front of the main frame. Connect it to J2 on the MLB. 3.
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280 Preventive and Corrective Maintenance Control Panel 4. See Figure 150. 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. See Figure 146 on page 275. Reinstall the screw and washers to secure the control panel to the main frame. Install the Electronics Cover 1. See RRP No. 2 on page 124 and install the electronics cover. 2.
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Preventive and Corrective Maintenance Main Logic Board 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.
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Preventive and Corrective Maintenance 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 RRP No. 1 on page 122 and remove the electronics cover. 3. See Figure 151. Remove all cables from the main logic board. Note • Take note of the location of all connectors on the main logic board.
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Preventive and Corrective Maintenance Main Logic Board 4. See Figure 152. 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 2 3 1 2 3 4 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.
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284 Preventive and Corrective Maintenance Main Logic Board Install the Electronics Cover 1. See 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. 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.
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Corrective Maintenance Replace the Main Logic Board (MLB) Fuse 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.
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286 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Real Time Clock Remove the RTC Option Board 1. See Figure 154. Locate the RTC option board. Figure 154 • Locate the RTC Option Board 1 1 2 2 RTC option board Main logic board (MLB) 2. Are you installing the RTC option board for the first time? 10/27/05 If… Then… Yes Go to Install the RTC Option Board on page 289. No Continue to step 3. S4M Maintenance Manual 13291L-001 Rev.
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288 Preventive and Corrective Maintenance 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 Figure 155. 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.
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Preventive and Corrective Maintenance Real Time Clock 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 Figure 156. 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. 1 2 Main logic board (MLB) Spacers (2) 3.
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290 Preventive and Corrective Maintenance Real Time Clock 4. See Figure 155 on page 288. 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 RRP No. 2 on page 124 and install the electronics cover. 2.
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Preventive and Corrective Maintenance Real Time Clock 5. See Figure 158. 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. 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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292 Preventive and Corrective Maintenance Real Time Clock Set the RTC 1. See Figure 159. 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.
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Preventive and Corrective Maintenance Booster Board 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.
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294 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Power Supply 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.
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296 Preventive and Corrective Maintenance 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 RRP No. 1 on page 122 and remove the electronics cover. 3. See Figure 161. 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.
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Preventive and Corrective Maintenance Power Supply Install the New Power Supply 1. See Figure 161 on page 296. 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 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.
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298 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance 10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm 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 RRP No. 1 on page 122 and remove the electronics cover. 3. See Figure 162.
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300 Preventive and Corrective Maintenance 10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm 4. See Figure 163. 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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Preventive and Corrective Maintenance 10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm 8. See Figure 164 or Figure 165. 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 Figure 164. 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.
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302 Preventive and Corrective Maintenance 10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm 10. See Figure 165. 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 13291L-001 Rev.
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Preventive and Corrective Maintenance 10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm 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… Then… No Continue to step 1. Yes 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.
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304 Preventive and Corrective Maintenance 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 Figure 166 on page 303. For the no communication option. Both washers must be installed. 4. See Figure 167.
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Preventive and Corrective Maintenance 10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm Reinstall the Main Logic Board 1. See Figure 163 on page 300. 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 Figure 162 on page 299.
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306 Preventive and Corrective Maintenance 10/100 Internal ZebraNet PrintServer, Wireless Print Server, Parallel Port, No Comm Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______
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Exterior Components This section provides replacement and installation procedures for the S4M printer’s exterior components. Contents Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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308 Preventive and Corrective Maintenance 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.
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Preventive and Corrective Maintenance Electronics Cover 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 Figure 168. Remove the electronics cover mounting screw and washer and then close the media door.
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310 Preventive and Corrective Maintenance Electronics Cover 3. See Figure 169. 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 Figure 169 on page 310.
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Preventive and Corrective Maintenance Media Door 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.
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312 Media Door Maintenance Kit Media Door Figure 170 • Remove/Install Media Door 1 3 2 2 3 4 4 1 2 3 4 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.
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5 Maintenance and Drawings 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 Media Side Main Printer Assemblies . . . . . . . . . . . . . . . . . .
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314 Maintenance and Drawings Contents (Continued) Booster Board Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle Clutch Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gears and Pulley Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Maintenance and Drawings Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________
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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 20067-106M 8 79030 9 77238M 10 777675M 11 77752M 12 20038 13 20060M 20039 Description Qty Media Door Assembly, Maintenance Kit (see Table Q on page 337) Lower Rear Cover Media Hanger Assembly, Maintenance Kit (see Table P on page 336) Ribbon Supply Spindle Maintenance Kit (see Table M o
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Maintenance and Drawings Media Side Main Printer Assemblies Figure A • Media Side Main Printer Assemblies 1 2 3 13 4 6 5 12 10/27/05 11 10 9 S4M Maintenance Manual 8 7 13291L-001 Rev.
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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 4 20002 5 77181 6 7 77227 20006 20005 8 20008M 9 20100M 20101M 10 28420-001M Description Electronics Cover (see Table U on page 341) Washer, 0.379 × 0.53 × 0.056 (sold in quantities of 25) Ribbon Take-up Spindle Clutch Maintenance Kit (see Table AB on page 348) Compound Gear Intermediate Gear Compound Pulley Belt, 0.
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Maintenance and Drawings Electronics Side Main Printer Assemblies Figure B • Electronics Side Main Printer Assemblies 1 2 3 6 9 10 7 8 4 10/27/05 5 S4M Maintenance Manual 13291L-001 Rev.
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320 Maintenance and Drawings Print Mechanism/Printhead Assembly Table C • Print Mechanism/Printhead Assembly Item Part Number 1 HW77047 2 77172M 3 77134 4 77660 5 77276 6 77048 (78810) 7 77659 8 HW10473 9 HWQ10011 10 41400M 41401M 11 77173 12 HW77043 13 77049-104 14 HW79041 N/S 20106M Description Thumbscrew, M3 × 0.5 (sold in quantities of 5) Pressure Dial Maintenance Kit Compression Spring, 0.17 × 0.24 × 0.62 Magnetic Latch Strike Plate Cap Adjustment Screw, M4 × 0.
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Maintenance and Drawings Print Mechanism/Printhead Assembly Figure C • Print Mechanism/Printhead Assembly 1 2 2 3 3 5 4 13 6 14 7 9 8 10 12 9 11 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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322 Maintenance and Drawings Printhead Maintenance Kit Table D • Printhead Maintenance Kit Item Part Number 1 41400M 1 41401M Description Qty Printhead Kit 203 dpi Maintenance Kit Printhead Kit 300 dpi Maintenance Kit 1 1 Bold=Part available for purchase Light italic=Part not available for purchase, listed and shown for reference only Figure D • Printhead Maintenance Kit 1 13291L-001 Rev.
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Maintenance and Drawings Printhead Cable Maintenance Kit Table E • Printhead Cable Maintenance Kit Item Ref Part Number Description 20106M 1 20082 2 20080 3 Q06020 4 HWQ10011 5 77921 6 77919 Printhead Cable Maintenance Kit Printhead Power Cable Printhead Data Cable Cable Tie, 0.09 × 3.62 Screw, M4 × 0.
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324 Maintenance and Drawings Platen Drive System Table F • Platen Drive System Item 1 Part Number Description Qty 1 1 1 1 1 1 1 1 1 1 10 HW77237 Transmissive Sensor Maintenance Kit (see Table K on page 331) Screw, M4 × 1.4 × 13 Outer Media Guide Maintenance Kit Washer, Flat Nylon 0.37 × 0.19 × 0.05 (sold in quantities of 25) Compression Spring, 0.19 × 0.24 × 0.35 Screw, M3 × 0.
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Maintenance and Drawings Platen Drive System Figure F • Platen Drive System 1 3 2 8 4 5 6 7 11 9 10 12 13 14 11 10 15 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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326 Maintenance and Drawings Latch Assembly Maintenance Kit Table G • Latch Assembly Maintenance Kit Item 1 Part Number 77112M 2 77048 (77810) 3 77276 4 77659 5 HW10473 6 HWQ10011 7 77236 8 77226 9 77195 10 77194 11 HW77043 12 77921 13 77919 Description Latch Maintenance Kit Adjustment Screw Strike Plate Cap Latch Strike Plate 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.
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Maintenance and Drawings Latch Assembly Maintenance Kit Figure G • Latch Assembly Maintenance Kit 1 2 3 4 5 6 8 7 9 11 12 13 10 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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328 Maintenance and Drawings Platen Roller Maintenance Kit Table H • Platen Roller Maintenance Kit Item Ref Part Number 77023M 1 77023 2 77423 3 77298 4 77426 5 78184 Description Qty Platen Roller Maintenance Kit Platen Roller Inner Spring Clip Spring Washer, 0.612 × 0.40 × 0.
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Maintenance and Drawings (Reflective) Media Sensor Assembly Maintenance Kit Table I • (Reflective) Media Sensor Assembly Maintenance Kit Item REF 1 2 Part Number Description Qty Reflective Media Sensor Assembly Maintenance Kit 77807 Media Sensor Assembly HWQ06020 Cable Tie, 0.090 × 3.
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330 Maintenance and Drawings Ribbon/Printhead Open Sensor Assembly Maintenance Kit Table J • Ribbon/Printhead Open Sensor Assembly Maintenance Kit Item REF Part Number 77767M 1 2 Description Qty Ribbon/Printhead Open Sensor Assembly Maintenance Kit 77765 Ribbon/Printhead Open Sensor Assembly HW77237 Screw, M3 × 0.
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Maintenance and Drawings Transmissive Sensor Assembly Maintenance Kit Table K • Transmissive Sensor Assembly Maintenance Kit Item REF 1 2 3 Part Number Description Qty Transmissive Sensor Assembly Maintenance Kit 77752 Transmissive Sensor Assembly HW44216 Screw, M4.2 x 1.14 x 13 (sold in quantities of 25) HWQ06020 Cable Tie, 0.09 x 3.
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332 Maintenance and Drawings Dancer Assembly Maintenance Kit Table L • Dancer Assembly Maintenance Kit Item Ref Part Number 77238M 1 77256 2 77909 3 77928 4 HW06313 Description Qty Dancer Assembly Maintenance Kit Torsion Spring Bearing, 0.38 × 0.63 × 0.50 4 inch Dancer E-ring External 0.
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Maintenance and Drawings Ribbon Supply Spindle Maintenance Kit Table M • Ribbon Supply Spindle Maintenance Kit Item Ref 1 2 3 4 5 6 7 8 9 10 Part Number Description 77085M HW10432 HW44356 HW44390 77085 77594 77598 01660 77620 77621 77593 Qty 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.
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334 Maintenance and Drawings Static Brush Maintenance Kit Table N • Static Brush Maintenance Kit Item Ref Part Number 77302M 1 2 Description Static Brush Maintenance Kit 77302 Static Brush Assembly HW77237 Screw, M3 × 0.70 × 10 mm (sold in quantities of 5) Qty 1 1 2 Bold =Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure N • Static Brush Maintenance Kit 1 2 13291L-001 Rev.
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Maintenance and Drawings Ribbon Take-up Spindle Maintenance Kit Table O • Ribbon Take-up Spindle Maintenance Kit Item Ref 1 Part Number 20004M Description Ribbon Take-up Assembly Maintenance Kit 20004 Ribbon Take-up Assembly Qty 1 1 Bold =Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure O • Ribbon Take-up Spindle Maintenance Kit 1 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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336 Maintenance and Drawings Media Hanger Maintenance Kit Table P • Media Hanger Maintenance Kit Item Ref Part Number 20069M 1 2 Description Qty Media Hanger Maintenance Kit 20069 Media Hanger 806136-608 Screw, Triplask 6-19 × 1/2 1 1 4 Bold =Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure P • Media Hanger Maintenance Kit 1 2 13291L-001 Rev.
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Maintenance and Drawings Media Door Maintenance Kit Table Q • Media Door Maintenance Kit Item Ref Part Number Description Media Door Maintenance Kit 20070 Media Door Assembly HW77237 Screw, M4 × 0.
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338 Maintenance and Drawings Peel Option Kit Table R • Peel Option Kit Item Ref Part Number 20046 1 78002 2 HW77231 3 30449 4 29300 5 20065 6 20060-12 7 20039 Description Qty Peel Option Kit Peel Assembly Screw, M3 × 8 mm Flanged (sold in quantities of 25) 2 mm Hex Key (Allen wrench) Mounting Button Take-Label Sensor Board Screw Lower Front Peel Panel 1 1 2 1 1 1 2 1 Bold =Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only F
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Maintenance and Drawings Peel Assembly Maintenance Kit Table S • Peel Assembly Maintenance Kit Item Ref 1 2 3 Part Number 78002M Description Peel Assembly Maintenance Kit 78002 Peel Assembly 30449 2 mm Hex Key (Allen wrench) HW77231 Screw, M3 × 8 mm Flanged (sold in quantities of 25) Qty 1 1 1 2 Bold =Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure S • Peel Assembly Maintenance Kit 1 3 10/27/05 2 S4M Maintenance Manual 1329
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340 Maintenance and Drawings Pinch Roller Maintenance Kit Table T • Pinch Roller Maintenance Kit Item Ref Part Number 77197M 1 2 3 Description Pinch Roller Maintenance Kit 77197 Pinch Roller HW10094 E-ring 3 mm (two extra supplied) (sold in quantities of 25) 49203 Ball Bearing Qty 1 1 4 2 Bold =Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure T • Pinch Roller Maintenance Kit 1 3 13291L-001 Rev.
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Maintenance and Drawings Electronics Cover Maintenance Kit Table U • Electronics Cover Maintenance Kit Item Ref Part Number 20071M 1 20071 2 HW43495 3 HW43482 4 HW77237 Description Qty S4M Electronics Cover Maintenance Kit Electronics Cover 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.
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342 Maintenance and Drawings Control Panel and Take-Label Maintenance Kits Table V • Control Panel and Take-Label Maintenance Kits Item REf Part Number 20060M 1 20060 2 20060-21 3 20060-9 4 20060-14 Ref 20065M 5 20065 6 20060-12 Description Qty Control Panel Maintenance Kit Control Panel External Lock Washer Split Lock Washer Screw Take-Label Maintenance/Option Kit Take-Label Board Screw 1 1 1 1 1 1 1 2 Bold = Part available for purchase Light italic = Part not available for purchase,
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Maintenance and Drawings Stepper Motor Maintenance Kit Table W • Stepper Motor Maintenance Kit Item Ref Part Number Description 20008M 1 20008 2 HW77239 3 HW10432 4 HW44924 Qty Stepper Motor and Gear/Pulley Maintenance Kit Stepper Motor Assembly Adjustment Nut (sold in quantities of 25) Screw, M4 × 0.7 × 12 (sold in quantities of 25) Screw, M3 × 0.
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344 Maintenance and Drawings Main Logic Board Maintenance Kit Table X • Main Logic Board Maintenance Kit Item Ref Part Number 20100M 1 Ref 20101M 1 Description Main Logic Board Maintenance Kit (4 Meg) 29301-001 Main Logic Board Assembly (4 Meg) Main Logic Board Assembly Kit (64 Meg) 29301-002 Main Logic Board Assembly (64 Meg) Qty 1 1 1 1 Bold = Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure X • Main Logic Board Maintenance
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Maintenance and Drawings Real Time Clock (RTC) Maintenance/Option Kit Table Y • Real Time Clock (RTC) Maintenance/Option Kit Item Ref Part Number 20009M 1 2 3 Description Qty RTC Option/Maintenance Kit 20009 RTC Option Board 29647 Heat Sink Standoff w/Spring 29648 Plastic Spacer 1 1 2 2 Bold = Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure Y • Real Time Clock (RTC) Option/Maintenance Kit 2 1 + 3 10/27/05 S4M Maintenance M
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346 Maintenance and Drawings Booster Board Maintenance Kit Table Z • Booster Board Maintenance Kit Item Ref Part Number 28420-001M 1 2 Description Booster Board Maintenance Kit 28420-099 Booster Board HW10401 Screw, M3 ×0.5 × 0.4 (sold in quantities of 50) Qty 1 1 3 Bold = Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure Z • Booster Board Maintenance Kit 1 2 13291L-001 Rev.
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Maintenance and Drawings Power Supply Maintenance Kit Table AA • Power Supply Maintenance Kit Item Ref 1 Part Number 29600M Description Power Supply Maintenance kit 29600 Power Supply Qty 1 1 Bold = Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure AA • Power Supply Maintenance Kit 1 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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348 Maintenance and Drawings Ribbon Take-up Spindle Clutch Maintenance Kit Table AB • Ribbon Take-up Spindle Clutch Maintenance Kit Item Ref Part Number Description Ribbon Take-up Spindle Clutch Maintenance Kit Collar, 0.379 × 0.750 × 0.200 Washer, 0.375 × 0.750 × 0.
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Maintenance and Drawings Gears and Pulley Maintenance Kit Table AC • Gears and Pulley Maintenance Kit Item Ref Part Number 20002M 1 20002 2 77181 3 77227 4 10856 5 77225 Description Gears and Pulley Maintenance Kit Compound Gear Intermediate Gear Compound Pulley Set Screw, M4 × 0.
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350 Maintenance and Drawings Wireless PCMCIA Board Maintenance/Option Kit Table AD • Wireless PCMCIA Board Maintenance/Option Kit Item Ref Part Number 20064M 1 Description Wireless PrintServer Maintenance Kit 29881-099 Wireless PC Board Qty 1 1 Bold = Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure AD • Wireless PCMCIA Board Maintenance/Option Kit 13291L-001 Rev.
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Maintenance and Drawings 10/100 and Parallel Port Maintenance/Option Kits Table AE • 10/100 and Parallel Port Maintenance/Option Kits Item Ref Part Number 20063M 1 Ref 2 20037M Description Qty 10/100 Printserver Option Maintenance Kit 29691-099 10/100 Printserver PC Board Parallel Port Option Maintenance Kit 29831-099 Parallel Port PC Board 1 1 1 1 Bold = Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure AE • 10/100 and Parallel
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352 Maintenance and Drawings Hardware View 1 (Media Compartment) Table AF • Hardware View 1 (Media Compartment) Item Part Number 1 HW44114 2 HW77237 3 HW43482 4 HW07257 5 HW77283 6 77371 7 HW10473 8 HW77078 9 20049 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.
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Maintenance and Drawings Hardware View 1 (Media Compartment) Figure AF • Hardware View 1 (Media Compartment) 1 2 3 3 3 mp 2 2 4 5 5 6 2 8 9 10/27/05 7 2 S4M Maintenance Manual 9 13291L-001 Rev.
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354 Maintenance and Drawings Hardware View 2 (Printer Rear) Table AG • Hardware View 2 (Printer Rear) Item Part Number 1 HW77237 2 HW43495 3 HW01155 4 HW22416 Description Qty Screw, M4 × 0.7 × 10 (sold in quantities of 5) Screw w/external lock washer, M3 × 0.
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Maintenance and Drawings Hardware View 3 (Printer Front) Table AH • Hardware View 3 (Printer Front) Item Part Number 1 HW77043 2 HW77231 3 29300 Description Qty Screw, M3 × 0.5 × 6 (sold in quantities of 25) Screw, M3 × 8 Push Rivet 2 4 2 Bold = Part available for purchase Light italic = Part not available for purchase, listed and shown for reference only Figure AH • Hardware View 3 (Printer Front) 1 2 2 2 3 10/27/05 S4M Maintenance Manual 13291L-001 Rev.
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356 Maintenance and Drawings Hardware View 4 (Electronics Side) Table AI • Hardware View 4 (Electronics Side) Item Part Number 1 HW10401 2 HW10460 3 10423 4 HW77239 5 HW10432 6 HW77237 7 10407 8 9 10 10412 20098 HW44924 11 806136-608 12 20077 13 20097 14 20079 15 20091 16 HW44356 Description Screw, M3 × 0.5 × 4 (sold in quantities of 50) Nut, M3 × 2.4 × 5.5 (sold in quantities of 25) Screw, M4 × 0.7 × 6 Adjustment Nut (sold in quantities of 25) Screw, M4 × 0.
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Maintenance and Drawings Hardware View 4 (Electronics Side) Figure AI • Hardware View 4 (Electronics Side) 1 1 2 1 3 4 & 5 9 10 11 2, 7, & 8 12 13 12 6 2 14 3 15 14 2 11 10/27/05 14 12 16 S4M Maintenance Manual 5 13291L-001 Rev.
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358 Maintenance and Drawings Hardware View 4 (Electronics Side) Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _____________________________________________________________________
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A Data Ports This section describes the standard communication ports available to connect the printer to your computer or network. Contents Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware Control Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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Data Ports Serial Data Port 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). Table A-1 shows the pin configuration of the serial data connector. Table A-1 • Serial Connector Pin Configuration 10/27/05 Pin No.
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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.
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Data Ports Serial Data Port 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.
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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.
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Data Ports Parallel Data Port Table A-2 • Parallel Cable Pin Configuration (Continued) 36-Pin Connectors 31 ninit 32 nFault/NDataAvail 33, 34 10/27/05 Description Not used 35 +5 V through a 1.8 KΩ Resistor 36 NSelectin/1284 active S4M Maintenance Manual 13291L-001 Rev.
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366 Data Ports USB 1.1 Port USB 1.1 Port See USB 1.1 Port on page 39 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.
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A Glossary 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.
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368 Glossary 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.
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Glossary 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.
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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.
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Index A B active control panel buttons, 4 adhesive test for ribbon coating, 21 adjustments label left side, 55 label top, 55 LCD darkness, 79 print speed, 57 print width, 57 printhead pressure, 44 reflective sensor, 42 tear-off position, 55, 77 agency approvals, 23 ALERT light, 6 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 settings, 59, 75 print stored format, 60 print stored page
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372 Index cleaning exterior of printer, 112 media compartment and sensors, 115 peel-off assembly, 116 printhead and platen roller, 113 recommended cleaning schedule, 112 command character, 62 communication interfaces overview and location, 14 types of connections, 15, 359 communications diagnostics test overview, 103 selecting hex dump mode, 63 communications problems, 94 components of printer, 7 configuration changing password-protected parameters, 47 viewing printer settings, 50 configuration label prin
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Index G gap/notch, 56, 78 gears and pulley parts list, 349 replacement, 230 general specifications, 22 left side adjustment, 55 liability, xvii load factory defaults, 64, 81 load media, 32 load ribbon, 36 lubrication, 112 H M handshaking protocol, 62 hardware control signal descriptions, 360 hardware parts list electronics side, 356 media compartment, 352 printer front, 355 printer rear, 354 HEAD COLD message, 88 HEAD TOO HOT message, 87 hex dump mode, 63 host handshake, 62 humidity requirements, 11 m
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374 Index N navigation through parameters, 46 network configuration label, 50 No Comm option, 298 non-continuous media described, 18 specifying, 56, 78 O operating conditions, 11 Operating mode, 4 optional print servers, 17 ordering ribbon and media, xxi outer media guide parts list, 324 replacement, 253 override EPL commands, 65 override ZPL commands, 65 P parallel port cabling requirements, 364 overview, 16 parts list, 351 pin configuration, 364 replacement, 298 setting parallel communications, 60 set
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Index peel-off mode cleaning peel-off assembly, 116 installing or replacing the Peel Option, 240 parts list peel assembly, 339 Peel option, 338 selecting label removal method, 56, 78 personal safety tips, 108 pin configuration parallel port, 364 serial port, 361 pinch roller parts list, 340 replacement, 269 platen drive system parts list, 324 platen roller parts list, 328 ports, 359 position label sensor, 42 power connect to power source, 12 power cord specifications, 12 power supply parts list, 347 site s
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376 Index replacement procedure 10/100 print server, 298 booster board, 293 control panel, 274 dancer assembly, 250 electronics cover, 308 gears and pulley, 230 main logic board, 281 main logic board fuse, 285 media door, 311 media hanger, 223 outer media guide, 253 parallel port, 298 Peel Option, 240 pinch roller, 269 power supply, 295 print mechanism, 141 printhead assembly, 126 printhead cable, 151 printhead pressure dials, 169 printhead release latch, 162 Real-Time Clock (RTC), 286 reflective sensor,
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Index shipping report damage, 10 reshipping the printer, 10 spacing requirements, 11 specifications agency approvals and markings, 23 bar codes, 27 general, 22 media, 25 power cord, 12 printing, 24 ribbon, 26 Zebra Programming Language (ZPL), 27 specify media type, 56, 78 speed adjustments, 57 standard data ports, 359 static brush parts list, 334 replacement, 248 stepper motor parts list, 343 replacement, 227 storing the printer, 10 surface for the printer, 11 T tag stock described, 18 specifying, 56, 78
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378 Index Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________________________________________
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Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A. Telephone: +1 847.634.6700 Facsimile: +1 847.913.