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10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
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). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Install the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Roller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
- Maintenance Manual 1
- List of Tables 10
- List of Figures 11
- Proprietary Statement 17
- About This Document 19
- Who Should Use This Document 20
- Section Description 20
- Contacts 21
- Document Conventions 22
- FEED button 23
- CANCEL button 23
- System Description 25
- External View 26
- Control Panel 27
- FEED active 28
- Right arrow active 28
- FEED FEED 28
- Appearance 29
- Control Panel Lights 30
- Printer Media Compartment 31
- Printer Language Modes 32
- Before You Begin 33
- Handling the Printer 34
- Select a Site for the Printer 35
- Power Cord Specifications 36
- Connector Locations 38
- Types of Connections 39
- Data Cable Requirements 41
- Types of Media 42
- Ribbon Overview 44
- If ink from the 45
- If the ribbon... Then 45
- General Specifications 46
- Agency Approvals 47
- Printing Specifications 48
- Media Specifications 49
- Ribbon Specifications 50
- Bar Codes 51
- Standard Font Matrices 52
- Load Media 56
- 6. Slide out the media guide 58
- PAUSE to enable printing 59
- Load Ribbon 60
- Close the printhead assembly 62
- Remove Used Ribbon 63
- Adjust the Reflective Sensor 66
- Adjust Printhead Pressure 68
- Media Width 68
- If the media... Then 69
- Setup Mode 70
- If you wish to... Then 70
- PASSWORD and the number 0000 71
- Printing Configuration Labels 74
- To print a... Then 75
- Select a Display Language 77
- LABEL TOP 79
- X FORMS ADJUST 79
- Y FORMS ADJUST 79
- PRINT SPEED 81
- PRINT WIDTH 81
- COMPAT. MODE 81
- CONTROL CODES 81
- RESOLUTION 82
- Password Level 3 Parameters 83
- MODULE B 84
- PARALLEL COMM 84
- PRINT PAGE 84
- PRINT FORMAT 84
- HOST HANDSHAKE 86
- CONTROL CHAR 86
- COMMAND CHAR 86
- DELIM. CHAR 87
- CHANGE RTC DATE 87
- ZPL OVERRIDE 89
- EPL OVERRIDE 89
- ZebraNet 93
- CHANGE GATEWAY 94
- OBTAIN IP ADDRESS 94
- CHANGE IP PROTOCOL 94
- AUTO SELECT is selected 94
- Password Level 4 Parameters 95
- FEED to cause the 96
- LANGUAGE 97
- Manufacturing Menu Parameters 98
- To print labels: 99
- SENSOR PROFILE 100
- DARKNESS 101
- TEAR OFF 101
- MEDIA TYPE 102
- SENSOR SELECT 102
- LCD ADJUST 103
- Parameter Explanation 104
- To modify this parameter: 104
- Operations 105
- Control Panel LCD Display 105
- Troubleshooting 107
- The Americas 108
- Asia Pacific 108
- Troubleshooting Checklists 109
- LCD Error Messages 110
- LCD Display/ 110
- Printer Condition 110
- RIBBON) is likely too 110
- HEAD COLD 112
- HEAD ELE. BAD 112
- Memory Errors 113
- PAUSE. Send a ~HM ZPL 113
- Print Quality Problems 114
- Note • A vertical drift of 115
- Calibration Problems 117
- Communications Problems 118
- Ribbon Problems 119
- O) and then 120
- O) and then On (I). If 120
- Printer Diagnostics 121
- CANCEL self tests 121
- CANCEL Self Test 122
- PAUSE Self Test 123
- FEED Self Test 124
- Print Quality Description 126
- FEED and PAUSE Self Test 127
- Preventive and Corrective 129
- Maintenance 129
- Contents 130
- Safety Information 131
- Personal Safety Tips 132
- Equipment Safety Tips 133
- Preventive Maintenance 135
- Lubrication 136
- Cleaning Procedures 136
- Area Method Interval 136
- Clean the Peel-Off Assembly 140
- Corrective Maintenance 143
- Required Tools 144
- Routine Referral Procedures 145
- Electronics Cover 147
- Mounting Screws (4) 147
- Print System 149
- Printhead Assembly 150
- Prepare for Installation 150
- Remove the Printhead 151
- Install the New Printhead 153
- Printhead Upgrade Option 154
- Install the Printhead 157
- Remove the Main Logic Board 158
- Conversion Procedure 160
- Reinstall the MLB 163
- Verify the Installation 163
- Turn Off (O) the printer 164
- Figure 50 • Pause Test Label 164
- Print Mechanism 165
- Remove the Print Mechanism 166
- If… Then… 169
- Adjust the Print Mechanism 171
- Printhead Cables 175
- Printhead Cable 177
- Reinstall the Print Mechanism 181
- Printhead Release Latch 186
- Remove the Old Latch 187
- 4. Remove the latch cover 188
- Install the New Latch Kit 189
- Install the latch cover 192
- Turn On (l) the printer 192
- Printhead Pressure Dials 193
- Remove the Old Pressure Dials 196
- Transmissive Sensor 202
- Remove the Stepper Motor 203
- Ribbon/Printhead Open Sensor 206
- Remove the Old Sensor 207
- Calibrate the Printer 209
- RELOAD ALL displays 210
- Reflective Media Sensor 211
- CANCEL while 211
- Remove the Electronics Cover 212
- Take-Label Sensor 215
- If... Then 216
- Mounting posts (2) 219
- Screw holes (2) 219
- Reinstall the Control Panel 220
- Install the Electronics Cover 221
- Drive System 223
- Ribbon Take-Up Spindle Clutch 224
- Remove the Wireless Board 227
- 5. Remove the compound gear 228
- Reinstall the Compound Gear 230
- Ribbon Take-Up Spindle 231
- Complete the Installation 238
- Install the MLB 238
- Ribbon Supply Spindle 239
- Ribbon spindle mounting screw 242
- Media Hanger Assembly 247
- Hanger Assembly 249
- Stepper Motor and Gear/Pulley 251
- Gears and Pulley 254
- Remove the Drive Belt 257
- Peel-Off/Tear-Off Bar 261
- Remove the Front Cover 262
- Peel Option 264
- Remove the Tear Bar 266
- Remove the Peel Assembly 267
- Install the Peel Assembly 268
- Install the New Front Cover 270
- Select the Peel Mode 271
- Static Brush 272
- Static Brush Assembly Kit 273
- Dancer Assembly 274
- Dancer Maintenance Kit 275
- 5. Turn On (l) the printer 276
- Outer Media Guide 277
- Remove the Outer Media Guide 278
- Install the Outer Media Guide 279
- Roller System 281
- Platen Roller 282
- Remove the Platen Roller 287
- Install the Platen Roller 289
- Reinstall the Peel Assembly 291
- Pinch Roller 293
- Remove the Pinch Roller 294
- Install the Pinch Roller 295
- Printed Circuit Boards 297
- Take-label sensor board 300
- Mounting screws (2) 300
- Posts (2) 302
- Install the New Control Panel 303
- Main Logic Board 305
- MENU to exit 308
- If you have… Then… 308
- Mail Logic Board Fuse 309
- Real Time Clock 310
- Remove the RTC Option Board 311
- Install the RTC Option Board 313
- RTC date and 315
- Set the RTC 316
- Booster Board 317
- Install the New Booster Board 318
- Power Supply 319
- Remove the Power Supply 320
- Install the New Power Supply 321
- Reference Materials 322
- Tools Required 322
- Exterior Components 331
- Media Door 335
- Remove the Old Media Door 335
- Install the New Media Door 336
- Maintenance and Drawings 337
- Contents (Continued) 338
- N/S = Not Shown 344
- Printhead Maintenance Kit 346
- Platen Drive System 348
- Platen Roller Maintenance Kit 352
- Media Sensor Assembly 1 353
- Static Brush Assembly 1 358
- Ribbon Take-up Assembly 1 359
- Media Hanger 1 360
- Screw, Triplask 6-19 × 1/2 4 360
- Media Door Maintenance Kit 361
- Peel Option Kit 362
- Peel Assembly Maintenance Kit 363
- Pinch Roller Maintenance Kit 364
- Stepper Motor Maintenance Kit 367
- Booster Board 1 370
- Power Supply 1 371
- Wireless PC Board 1 374
- Screw, M3 × 8 4 379
- Push Rivet 2 379
- Data Ports 383
- Serial Data Port 384
- Description 385
- RS-232 Interface Connections 386
- DB-9 to DB-25 Connections 387
- Parallel Data Port 388
- USB 1.1 Port 390
- Glossary 391
- HEAD COLD message, 88 397
- HEAD TOO HOT message, 87 397
- RIBBON IN message, 87 400
- © 2005 ZIH Corp 404
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