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10/27/05 S4M Maintenance Manual 13291L-001 Rev. A
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Routine Referral Procedures (RRP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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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