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Zebra 44118

1. istae dire 4 3 Percona NPS CNET TE 4 4 Preventive Maintenance Schedule 4 5 Ceanna cnt ase sh doen asd e a 4 5 Cleaning Printhead and Platen Roller 4 7 Printhead and Platen Roller Cleaning Procedure 4 8 Cleaning the Guter MOduUlg eee 4 9 Remove the cutter module from the printer 4 9 Disassembling the Gutter Module acsi rre rrr 4 11 Cleaning the Cotter oer 4 12 Reassemble the Cutter Module 2 42444 4 4 12 Reinstall the Cutter Module s 4 14 Bec ba Cuter 4 14 EETA EEA 4 15 4 15 Printer Self Test Reset Default Quick Reference Chart 4 15 Pause and Cancel Key Self Test 4 16 Feed and Cancel Key Self Test 4 16 escroa 4 22 Pause Key Loopback 4 22 Feed Koy Rollback 4 23 AJUSTES E E a 4 23 Printhead Position Adjustment
2. Figure 2 13 Feed Key Self Test Printout Page 2 18 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Mode Key Self Test Note printer data cable must be connected to the host computer during this self test Refer to Figure 2 14 This self test places the printer in a Communications Diagnostics Mode in which the printer prints the ASCII characters and their corresponding hexadecimal values for any data received from the host computer To start the Mode Key Self Test press and hold MODE while turning the power On 1 Feed and Pause Key Factory Default Reset If itis ever necessary to return the printer configuration to factory default values press FEED and PAUSE at the same time while turning the power On I The default values remain active until the power is turned off To save the default values in memory press MODE four times The darken position and calibrate LEDs cycle on and then off indicating the values have been saved Refer to Table 2 2 for a list of factory default values Feed Pause and Mode Key Reset Communication Parameter Default To reset the communication parameters only press and hold FEED PAUSE and MODE while turning the power On 1 The communication parameters are reset to 9600 baud 8 bit work length no parity and 1 stop bit To make these settings permanent press MODE four times The darken position and calibrate LEDs flash ind
3. Figure 4 11 Pause and Cancel Key Label S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 LEFT WRINKLE TEST PRINTING AT SPEED A N Q o Figure 4 12 Test Formats 1 and 8 RIGHT WRINKLE TEST PRINTING AT SPEED A Figure 4 13 Test Formats 2 and 9 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 19 Section 4 Preventive and Corrective Maintenance sCODE 39 xCODE 39 Figure 4 14 Test Formats 3 and 10 USEABLE AREA 012345678901234567890123456 PRINTING SPEED A Figure 4 15 Test Formats 4 and 11 Page 4 20 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 HEAD TEMP TEST PRINTING AT SPEED COUNT 0001 Figure 4 16 Test Formats 5 and 12 UA AA ET EET RE EIE EE E EE DLL x0123456789012345678901234x UPPER SMEAR TEST PRINTING AT SPEED A Figure 4 17 Test Formats 6 and 13 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 21 Section 4 Preventive and Corrective Maintenance LOWER SMEAR TEST PRINTING AT SPEED 01234567890 1234567890 1234 LLL AT Figure 4 18 Test Formats 7 and 14 Extended Printer Diagnostics Additional diagnostic tests are available for printhead assembly adjustments These diagnostic tests are accessible only when the data
4. 2 2 Data Status odi le ate 2 1 Green Light es 2 1 Paper Ribbon Status 2 1 P iisa SlallS 2 1 Power Status 2 1 Printhead Status 2 1 Yellow Light oce re es 2 1 Operators Indicators Position Status ence 2 2 Optional aces bine 1 3 P Paper Ribbon Status Indicator 2 1 44895L Rev 3 3 15 04 44895L Rev 3 3 15 04 Parallel Data ite ap erc eripere 1 12 Connector Pinouts 1 13 Signal Levels 1 12 Pause Cancel Key Self Test 4 16 PAUSOK GY toritate 2 3 2 17 Pause Key Loopback Test 4 22 Pause Status Indicator 2 1 Peel Off Mode 1 1 Personal od perire 4 4 Physical Dimensions 1 5 Platen Roller Replacement 4 53 4 54 Position Status Indicator 2 2 Power On Off Switch 2 3 Power Status Indicator 2 1 Power Supply seo 4 57 Board Installation 4 58 4 60 Board Removal 4 57 4 60 Power On Self 2 14 Print Darkness 2 23 Setting Manu
5. 3 9 Troubleshooting Chart Cutter Related 3 9 or Seno ONE o 3 10 Recommended Cleaning 4 6 Self Test and Calibration Reference 4 17 Seguence of FONT TIES Ead Enel UIN 4 18 Printhead Voltage Values S400 4 30 Printhead Voltage Values 5600 4 30 5 2 Board and Control 5 4 Media Supply m Ribbon Supply and Ribbon Take Up 5 6 Toggle and Print MEC 5 8 Print Mechanism and Printhead Assembly 5 10 Tear Cutter Media Sensor and Ribbon 5 12 E T T 5 14 Peay ter Drive s NI T T T 5 16 Peel Option Drive Sy IBI cn erated edie 5 18 Platen and Power DUBBI i 5 20 G ter 5 22 5400 5600 Maintenance Manual XV List of Tables 1 ew Zebra xvi S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Description of Equipment Section 1 Description of Equipment Description The Zebra Stripe S400 and S600 Thermal Pr
6. 2 29 Liner Rewind Power Roller Adjustment re rre ein 2 30 Adjusting the Rewind Power Roller lt 2 30 Section 3 Troubleshooting Troubleshooting Egit ooo oo oo Emm 3 1 Listot 3 1 LED Quick Reference 3 2 Troubleshooting Chart Problems with LED Indications 3 3 Troubleshooting Chart Wrinkled Ribbon 3 8 Troubleshooting Chart Jammed or Stuck Labels 3 8 Troubleshooting Chart Settings or Parameter Related 3 9 Printer Ec c A 3 9 Troubleshooting Chart Cutter Related 3 9 E m cere rer tere re 3 11 ZIP SUPON M M P A 3 11 TET IT T 3 11 Repair Service Department TR D o oo oS 3 11 Returning EOUIBIIOBE Lon HERD ea Fab cv imu amid lea oie 3 11 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual vii Table of Contents Section 4 Preventive and Corrective Maintenance ARIA CRI DEA 4 1 Enuipment 4 2 Equipment Tips Ome
7. eU RR FOU Hte M nd FT M OE Ni 2 2 Figure 2 2 Power On Off Switch and Data Cable Connections 2 4 Figure E PUN ACCESS addere d Viu TR D cabs 2 5 Figure 2 4 Roll Media EDU 2 7 Figure 2 5 Fanfold Media Loading 2 7 Figure 2 6 Cutter Mode Media Loading iioii ree rre 2 8 Figure 2 7 Peel Off Mode Media 2 8 Figure 2 8 Media Sensor 2 444244 2 11 Figure 2 9 Dual Tension Ribbon Supply Spindle Adjustment 2 12 Figure 2 10 Ribbon Loading 2 13 Figure 2 11 Cancel Key Self Test Printout Configuration Label 2 16 Figure 2 12 Pause Key Sell Test PHP IOHE 2 17 Figure 2 13 Feed Key Self Test 2 04 4 404 0 2 18 Figure 2 14 Mode Key Self Test 1 2 19 Figure 2 15 Tear Ofr Position 2 27 Figure 2 16 Adjusting the Print of the Top of 2 28 Figure 2 17 Printhead Pressure Adjustment 2 29 Figure 2 18 Liner Rewind Power Roller 2 31 Figure 4 1 Main D
8. 3 8 Table 3 6 Troubleshooting Chart Settings or Parameter Related 3 9 Table 3 7 Troubleshooting Chart Cutter 3 9 Table 3 8 Explanation of 3 10 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 3 1 Section 3 Troubleshooting LED Quick Reference Chart Table 3 1 is a quick reference troubleshooting chart based on the status of the LEDs after the Power On Self Test has been completed or attempts to complete or during printer operation Using the legend at the bottom of the table match the LED condition of the printer to the chart The rightmost column refers to possible solutions found in Troubleshooting Chart Problems with LED Indications on page 3 3 Table 3 1 LED Quick Reference Chart Paper x ignem Power Printhead Ribbon Pause Data Darken Position Calibrate Table 3 2 Item 1 re 3 AE AE AE AE 4 AE AE 34 AE 5 AE AE AE 6 AE ae 7 re re re 8 re re 9 ae e 10 It e e e e 11 AE AE 12 a 13 re re 14 re 15 re 16 re 17 ae
9. is 1 1 Plate 4 36 Position Adjustment 2 27 Technical Support 5 nnns 3 11 Top of Label Position Adjustment 2 28 Troubleshooting e 3 1 Cutter Related 3 9 Jammed or Stuck Labels 3 8 LED Quick Reference Chart 3 2 Printer Status Sensors 3 9 3 10 Problems with LED Indications 3 3 3 6 Settings or Parameter Related 3 9 Wrinkled Ribbon 3 8 Y Yellow Light See Operator Indicators 2 1 2 Zebra Programming Language 1 7 ZIP SUD POM 3 11 1 7 Index 4 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04
10. 1 5 dm oe DINEPSONI E I 1 5 Consideratione Mr 1 6 aiit it Boi g s TT TT 1 6 ti e NER D TA 1 6 Fibbon Laudatio ru paci d lini DPI uad FE E Rad iu fa 1 7 Zebra Programming Language ZPL I 1 7 Communication Interfaces 1 8 Communication 5 SC 1 9 Serial Data Communication Interface Overview 1 9 Standard Serial Communication Connector 1 9 Lied HAE LR ir as 1 10 Serial Communication Signal Levels 1 12 RS 232 Transmit and Receive Data esr 1 12 Cenmonice Parallel Data Fart 1 12 x d t 1 12 Parallel Data Signal Levels aem 1 12 Electronics Systemi Block DISUP SITE 1 14 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual v Table of Contents Section 2 Operations Overview Stl MOS REATO 2 1 Power Status Indicator DEBIT 2 1 Printhead Status Indicator yell uuu eiie 2 1 Paper Ribbon Status Indicator yellow 2 1 Pause Status Indicator vB QW cracens 2 1 Data
11. 4 23 actu t to M e e DIDI 1 3 Bitmapped 1 3 International Characters 1 3 Matrix 203 1 3 Optional easet rae eir Eu 1 3 Scalable assistive dete die 1 3 scatet d dett 1 3 Index 1 G Green Light See Operator Indicators 2 1 International Characters 1 3 L Label Head Temp Test 4 21 Left Wrinkle rre 4 19 Lower Smear Test 4 22 Pause and Cancel Key 4 18 Right Wrinkle 4 19 Speed A 4 20 Upper Smear Test 4 21 Language Zebra Programming 1 7 LED Quick Reference Chart 3 2 Liner Rewind Power Roller Adjustment 2 30 Loading Ribbon Supply Spindle 2 12 Lubrication sc oet 4 15 M Main Drive Belt aaa E 4 51 4 52 Logic Board 4 38 Downloading Firmware 4 39 Installation 4 38 39 Removal 4 38 Manual Calibration 2 22 Mechanical Adjustments 4 23 Liner Rewind Spindle 4 28 Printhead Position 4 23 4 25 SU Ip PIBte tomo cast dus
12. APARECE BEL 2 14 Power Onm Self TU 2 14 Additonal Sel o m 2 14 Printer Self Test Reset Default Quick Reference Chart 2 15 Cancel TEST asrining noa a 2 16 Fase KE de DAE qe OCT aE 2 17 nre dad MATERA HORREA GRE RA rdi 2 18 Mode qe 2 19 Feed and Pause Key Factory Default Reset 2 19 Feed Pause and Mode Key Reset Communication Parameter Default 2 19 vi S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Table of Contents DAO ca E enemas ere ee 2 21 AUW CADNO MA 2 21 Lu Ei gr ir Mtr 2 22 Ribbon Parameter Calibration 2 23 Ori UT DOR Mode sireeni 2 23 ee 2 23 Printing and Examining a Configuration Label 2 24 Testing Print Darkness Feed Key Self Test Method 2 24 Testing Print Darkness Pause Key Self Test Method 2 25 To Set Darkness Setting Manually erre creen 2 25 To Start the Pause Key Self 2 25 Adjusting the Printer DarKNESS ee 2 26 Tear Off Position Adjustment 2 27 Top ot Label Position Adjustment 2 28 HOUDD 2 29 Printhead Pressure Adjustment
13. 5 D 5 D 5 a gt 3 z lt suime Maintenance and Assembly Drawings 041409 pue 91607 2 6 aunbi4 Page 5 5 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 9 enue 0095 0075 VO GL E 146877 Table 5 3 Media Supply Ribbon Supply Table 5 3 Media Supply Ribbon Supply and Ribbon Take Up and Ribbon Take Up Part No Description Qty Part No Description Qty Ribbon Take Up Spindle Assembly 15 44339111 Hex Stand Off 1 44052 400M 1 Tear Off and Cutter Option 16 44356 Washer 0 198 x 0 75 0 085 1 44052 402M 2 Assembly 1 17 44043 RTU Motor Assembly 1 18 4427841 Assembly 1 34 1 2 30251 Washer 0 836 x 0 390 x 0 048 1 19 44198M Ribbon Take Up Motor Cable 1 3 44912 400M C Dual Torque Ribbon Supply Spindle Kit 1 20 44481 Ground Chain Assembly 1 3 8 4 144069 Media Bracket 1 ae 21 44114444 Screw M4 2 x 1 41 8 2 5 44066 1M B Media Edge Guide amp Thumb Screw 1 5 104324 Screw x 0 7 1 gt x 0 6 44068 1 Media Edge Guide 1 Available only as HW30251 in quantities of 25 7 44067 Nylon Thumb Screw M3 5 x 6 x 5 1 Available only as HW44176 in quantities of 25 Available only as HW44053 in quantities of 10 8 44176
14. Roller For the S600 rotate the bearings 180 degrees turn upside down Figure 4 46 Replacing the Platen Roller Page 4 54 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Ribbon Take Up Motor Replacement 1 Turn the printer Off O and remove the AC power cord and the data cable Remove media and ribbon Remove the main door and rear cover Remove the main logic board Remove the main drive belt ux Refer to Figure 4 47 on page 4 55 Loosen the two screws and slide the bevel gear from the ribbon take up spindle shaft e Remove the ground chain assembly from around the idler pulley Remove the screw securing the ground chain assembly to the ribbon supply spindle shaft 9 Remove the two screws securing the ribbon tension motor assembly and mounting bracket to the main frame 10 Install the replacement ribbon tension motor assembly by reversing steps 6 through 9 11 Perform a main drive belt tension adjustment 12 Reinstall the main logic board rear cover and main door 13 Perform the ribbon take up spindle tension adjustment 14 Reinstall the media and ribbon 15 Reconnect the AC power cord and data cable Turn the printer On I and test for proper operation Da 0 g Ground Chain Assembly to ribbon supply spindle shaft Mounting Screws Set Screws Bevel Gear Ground Cha
15. 4 Observe the ends of the rear cutter blade guard and note the small metal pins protruding toward the inside During the reassembly procedure these pins will be mounted into the corresponding mounting slots in the cutter side panels 5 To provide complete access to the area to be cleaned raise the upper cutter blade guard as shown in Figure 4 6 on page 4 12 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 11 Section 4 Preventive and Corrective Maintenance Wire Spring Loop Upper Cutter RA Blade Guard Rear Cutter Blade Guard Wire Spring Loop Figure 4 6 Cutter Module Disassembly Cleaning the Cutter Module 1 Remove any label material that has adhered to the cutter parts and use a small brush to remove any paper dust from the cutter module 2 f pressure sensitive media has been used use a lint free cloth soaked in an adhesive remover to clean all gum and label residue from the cutting blades and guards 3 If tag stock was used use 90 isopropyl alcohol and 10 distilled water to remove any dirt Reassemble the Cutter Module 1 Refer to Figure 4 7 on page 4 13 Position the two wire springs down against the lower cutter blade 2 Place the rear cutter blade guard over the wire springs perpendicular to its final position Place your thumbs on the top flat part of the guard Note Ensure that the ends of the rear cutter blade guard are positioned on the outside of the cutter side p
16. 5400 5600 Maintenance Manual Proprietary Statement This manual contains proprietary information of Zebra Technologies It is intended solely for the information and use of parties operating and maintaining the equipment described herein Such proprietary information may not be used reproduced or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Product Improvements Continuous improvement of products is a policy of Zebra Technologies All specifications and designs are subject to change without notice FCC Compliance Statement Note This equipment has been tested and found to comply with the limits for a Class A Digital Device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the product manuals may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense In order to ensure compliance this printer must be used with a Shielded Power Cord and Shielded Communication Cables The user is cautioned that any changes or modifications not exp
17. SLF 18 19 LED Off AF Alternate Flashing SF Single Flash Z LED On F Flashing SLF Slow Flashing Page 3 2 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Troubleshooting Troubleshooting Chart Problems with LED Indications Table 3 2 lists a number of problems or conditions that may be encountered with the printer These condition or problems generally have LED indications as listed in Table 3 1 LED Quick Reference Chart on page 3 2 Table 3 2 Troubleshooting Chart Problems with LED Indications Symptom Diagnosis Action 1 No LEDs turn on No AC power applied to the printer Ensure AC power cable is connected to a working voltage Source Faulty AC power fuse Replace fuse No voltage from the power supply Replace power supply All LEDs turn on and stay on and printer locks up while running Power On Self Test An improper configuration was set Reload factory defaults and then set correct parameters Main logic board faulty or loose interconnecting cables Ensure cables are properly connected Replace main logic board Power LED on and all 3 other LEDs off No printer operation possible Printer misconfigured for peel off mode or peel off option not installed If peel off option is installed check take label sensor If peel off option is not installed check printer config
18. 4 19 Test Formats 4 20 Test Formats 4 and 11 00200 0 0000 nennen 4 20 Tesr Fons D ONG Te 4 21 TSL FOMA O and Toen 4 21 7 and Taon a aae 4 22 Printhead Pressure 4 23 Printhead Position Adjustment Top View 4 25 Take Labal Sensor 4 26 Fate 4 27 Liner Rewind Spindle 4 28 Printhead Voltage Adjustment Potentiometer Location 4 31 Properly Adjusted Cutter 4 33 Home Position uiii cono FRE HEURE PERPE ODER SUPE IgE d edet 4 33 Opening Main and Front DOOTS 4 35 Door and Cover Disassembly 4 35 Eo tuli NP 4 36 Control Panel Assembly MEC M 4 37 Main Logic BOATO c 4 39 Printhead Cable Ferrite assembly eren t nitate inerat 4 40 Braided Ground Strap Location 4 42 Print Mechanism Assembly Mounting Screw Location 4 42 Printhead Assembly Removal Installation 4 43 Dual Tension Ribbon Supply 4 44 Ri
19. Figure 4 53 Logic Board Conntector and Mounting Screw Location Page 4 62 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 4 Refer to Figure 4 53 Note the positions of all ribbon cable and wire harness connectors Remove all connectors to the main logic board Remove the three screws securing the main logic board to the main frame Carefully grasping both sides of the main logic board pull the board straight up from the power supply connector and out of the unit A gentle rocking motion of the main logic board may be necessary to release it from the power supply board 7 Inspect the back of the main logic board Remove any contaminants with a cotton swab and isopropyl alcohol 90 alcohol and 10 distilled water on J14 found at the left edge of the board when looking at the back of the board Lay the main logic board on the anti static mat face up Refer to Figure 4 54 on page 4 63 Remove the three mounting screws from the memory board and put aside for use later Main Logic Board Memory Board Mounting Screw c I sai By NOILNY d H 5 H H la H gt gt 2 15 26 Mounting Screws Figure 4 54 Memory Board 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 63 Preventive and Corrective Maintenance 10 11 12 13 14 15 16 17 Refer Fig
20. 4 23 Take Label Sensor AdjUS MEN rite Ee oe 4 26 ven cre seen Pn eee ry 4 27 Liner Rewind Spindle Adjustment 4 28 imc Fa pl A 4 29 Printhead Yoltage 2 n jp Me 4 29 Cutter Voltage Adjustment Orge Tu Ea rid RU eL r 4 32 T T 4 34 Bio dz io e E 4 34 Removing the Maii 4 34 Removing h Fram DOO e 4 34 Removing the Rear Covet 4 34 MITTITUR 4 36 Panel Assembly Removal 4 36 Control Panel Circuit Board 4 37 Main Logie Board TRUE EH MADRE FU DANI DUREE ra 4 38 Logie Board Installatori RU leen 4 38 viii S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Table of Contents ep eee 4 39 Print Mechanism Assembly Removal 4 40 Printhead Assembly Removal and Installation 4 41 Ribbon Supply Spindle Disassembly 4 44 Ribbon Supply Spindle Installation 4 45 Media Sensor Assembly Removal acscccc
21. Print element damaged S400 S600 Maintenance Manual Replace printhead Page 3 7 Section 3 Troubleshooting Troubleshooting Chart Wrinkled Ribbon Page 3 8 Table 3 4 Troubleshooting Chart Wrinkled Ribbon Symptom Diagnosis Action Wrinkled ribbon Ribbon fed through printer incorrectly Load ribbon correctly Incorrect darkness setting Set darkness to lowest setting possible for good print quality Incorrect printhead pressure or balance Set pressure to minimum needed Media not feeding properly Media walking side to side Make sure media is running parallel to main frame with balance adjustment Incorrect dual tension spindle setting Pull spindle end cap out when using wide media to obtain normal higher tension Strip plate needs adjusting Perform adjustments Ribbon supply spindle tension needs adjusting Perform adjustments Printhead needs realigning with platen roller Perform adjustments Ribbon take up spindle tension needs adjusting Perform adjustments Troubleshooting Chart Jammed or Stuck Labels Table 3 5 Troubleshooting Chart Jammed or Stuck Labels Symptom Diagnosis Action In Peel Off Mode skewed or stuck labels Label adhesive material causing media movement problems Perform maintenance and clean printer Media and liner not properly aligned in printer
22. Reinstall the three mounting screws making sure the mounting screw in the upper right hand side of the main logic board goes through the braided ground strap first Reconnect all ribbon and wire harness cables Replace the rear cover 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Mounting Holes Ground J3 Mounting Hole Ground J5 M d N gt 822 132421111154 J12 TE diu Bre ibm i nuu ue Lies 269 J14 x Back of Board J13 J10 F3 is 72 ro p eee Figure 4 31 Main Logic Board J1 Serial Port J10 Full Roll Switch Assembly J2 Parallel Port 411 Media Ribbon Sensor Assembly J3 Ribbon Take Up Motor Assembly J12 Control Panel Assembly J4 Printhead Assembly S600 413 Not Used 45 Printhead Assembly S400 J14 Option Connector on back of board 46 Not Used RV1 Spindle Tension Adjustment J7 Cutter Assembly F1 5 MF 2A 250V J8 Power Supply Assembly F2 E 5A 125V 49 Label Available Sensor Assembly 250 125 Downloading Firmware To download the correct version of firmware go to www zebra com firmware and choose the your printer model Choose a version from the firmware matrix and follow the directions Or call 44895L Rev 3 3 15 04 USA 1 847 913 2259 Euro
23. J3 J11 J5 Serial Pot 4 J12 Control Panel Main Logic Board J14 Head Open Sensor Parallel Port 4 J2 J6 J10 J7 48 J13 Memory Expansion option J2 Power Full Roll 1 p ior ai Supply Switch Power Source Figure 1 5 Electronic Block Diagram Page 1 14 S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Section 2 Operations Overview This section contains information and adjustments for becoming acquainted with adjusting testing and operating the printer This information is also found in the User s Guide Operator Indicators Refer to Figure 2 1 Power Status Indicator green Refer to Figure 2 2 Controlled by the power on off I O switch located on the left side near the AC power cord On Primary power is applied to the printer Off Printer has been turned off or is not receiving power Printhead Status Indicator yellow A printhead over temperature condition exists Printing stops until the On printhead cools then printing resumes automatically A printhead under temperature condition exists Printing continues Off Normal condition Flashing The printhead is open Paper Ribbon Status Indicator yellow On Me
24. R A e 2 14 Calibration Quick Reference 2 15 Cancel 2 16 Feed Key o cu ae EN MU 2 18 Mode Key 2 19 Pause and Cancel 4 16 Pause 2 17 2 14 Reference Table 4 17 Self Test Reference Table 4 17 Serial Data Connector 1 9 DB 9 Pinouts 1 11 RS 232 Interconnection 1 10 RS 232 Signal Levels 1 11 Specifications Agency Approvals 1 2 COMMUNICATION 1 9 Media Considerations 1 4 Media Handling 1 4 a ie tesi tec te 1 5 MIGIrODIOGOSSOFE 1 5 Physical Dimensions 1 5 Print Speeds 1 6 Printing Considerations 1 6 Printing Method 1 6 Ribbon Considerations 1 7 Serial Data 1 9 Status Indicators Index 3 See Operator Indicators 2 1 Status Lights See Operator Indicators 2 1 Stepper Motor Replacement 4 56 4 57 T Tear Off
25. frame Refer to Figure 4 29 on page 4 36 Remove the tear off plate Remove the platen roller by lifting up on the end with the platen pulley and pivoting the platen bearings out of the slots 10 Remove the platen pulley from the platen roller 11 Install the platen bearings nylon spacer washers ground chain assembly and the platen pulley on the replacement platen roller as shown in Figure 4 45 Note Refer to Figure 4 46 on page 4 54 Ensure the platen bearings are oriented with the off center holes at the top when installed 12 Reinstall the platen roller by sliding the outside platen bearing into its cutout and dropping the inside platen bearing into its slot 13 Reattach the ground chain assembly to the main frame 14 Reinstall the main drive belt 15 Adjust the main drive belt tension 16 Reinstall the main logic board and media sensor assembly 17 Reinstall the tear off plate control panel assembly rear cover and main door 18 Reload media and ribbon 19 Reconnect AC power cord and data cable Turn the printer On 1 and test for proper operation 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 53 Section 4 Preventive and Corrective Maintenance Shoulder Bolt and Idler Pulley Platen Ground Chain Assembly Main Drive Belt Figure 4 45 Platen Roller Replacement Platen 0 Bearings pictured here are installed this way for the S400 only
26. 10BaseT connectivity are available through an external connection to the parallel port 9 IPX LAT NetBIOS Net BEUI TCP IP protocols are supported with a data burst rate of 150 KB HP bitronics mode is supported to provide bi directional high speed SNMP compatible and supports MIB and Parallel MIB as well as MPSPON Novell NetWare PC console configuration utility IPX Page 1 8 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Description of Equipment Communication Specifications Serial Data Communication Interface Overview The S400 and S600 printers have a single Data Terminal Equipment DTE port that supports RS 232 serial data communications The RS 232 interface has a 9 pin DB 9S connector located at the rear of the printer For all RS 232 data and control input and output signals the S400 and S600 printers follow both the Electronic Industries Association s EIA RS 232 and the Consultative Committee for International Telephony and Telegraphy CCITT V 24 specifications Standard Serial Communication Connector Refer to Figure 1 2 The DTE Port is DB 9P connector located at the rear of the printer It provides connection to a host via RS 232 signaling The pinouts and signal descriptions for the DTE port are found in Table 1 8 E H Serial Cable or AS Communication gt Inter
27. 15 04 44895L Rev 3 3 15 04 A AC Power Fuse Replacement 4 61 Accessing the Printer 2 5 Additional Printer Self Tests 2 14 Auto Calibration 2 21 B a eas 1 2 Bitmapped Fonts 1 3 2 21 Auto Calibration 2 21 Manual Calibration 2 22 Ribbon Parameter 2 23 Status Indicator a cedes 2 2 Calibration Reference Table 4 17 Cancel Key 2 3 2 16 Cleaning Cutter Module 4 9 4 15 E 4 5 Interior esset Rete eins 4 5 Media and Ribbon Path 4 5 Printhead and Platen 4 7 tan 4 6 Codes Bariin oot 1 2 Communication TRU 1 8 Specifications 1 9 Configuration 2 24 Configuration Mode 2 23 Control Panel 4 36 Circuit Board Replacement 4 37 REMOVAL 4 36 Cutter Modest ort tos etes 1 1 D Darken Status Indicator 2 2 Data Cable Installation 2 14 Data Status Indicator 2 1 Diadriosll6S 4 15 Cal
28. 4 Start Parity Bit Data Bits Bit m Space Mark 1 Logic 0 Figure 1 4 RS 232 Signal ASCII Code Data Centronics Parallel Data Port The S400 and S600 printers have a standard 36 pin Centronics parallel connector instead of a serial port available at the rear of the printer for connection to a parallel data source This data communication method sends the bits of data that make up each character all at one time over several wires in the cable one bit per wire Parallel Port Interconnections Table 1 9 on page 1 13 shows the pin configuration and function of a standard PC to printer Centronics parallel cable Parallel Data Signal Levels Parallel data signals are defined as either HIGH or LOW while control signals are either active or inactive meaning that some control signals are active HIGH while others are active LOW The voltage levels that represent these conditions are Data Signal Voltage Level HIGH 5 VDC LOW 0 VDC Page 1 12 S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Description of Equipment Section 1 Table 1 9 Centronics Connector Pinouts 44895L Rev 3 3 12 04 36 Pin Description Connector 1 STROBE The high to low transition of this input signal latches the data at the eight DATA inputs into the printer 2 9 DATA BITS 0 through 7 Parallel data in
29. 4 27 Media Loading 2 6 Cutter Mode esee 2 6 Fanfold Media 2 6 Peel Off Mode 2 0 Removing the Liner 2 10 Foll Media 2 6 Tear Off Mode 2 6 Index 2 S400 S600 Maintenance Manual Media Sensor 2 10 Media Sensor Assembly 4 49 Installation 4 49 4 50 Removal 4 49 1 5 Upgrade 4 62 Memory Specifications 1 5 Mode 1 1 External Rewind 1 1 Id 1 1 Printer Operating 1 1 Tear Off 1 1 Mode Key 2 3 2 19 Modes Printer Operating 1 1 Operating Modes Printer 1 1 Operations Overview 2 1 Operator Controls oet reddere 2 3 Cancel Key 2 3 Feed Key etit rende 2 3 Mode Key 2 3 noe cu ES 2 3 Pause 2 3 Operator Indicators 2 1 Calibrate Status 2 2 Darken Status
30. Guide Assembly Figure 4 42 Media Sensor Assembly Shoulder Bolt and Idler Pulley Spring Scale Stepper Motor Figure 4 43 Main Drive Belt Replacement and Adjustment Page 4 50 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Main Drive Belt Removal Replacement and Adjustment Printers without the Peel Off Option Caution Observe proper electrostatic safety precautions when removing handling and replacing printed circuit boards B e 10 11 Turn printer Off O and remove the AC power cord and the printer data cable Remove media and ribbon Remove the main door and rear cover Remove the main logic board and media sensor assembly Note Scribing a mark into the printer main frame indicating the position of the idler pulley prior to performing the next step may help when adjusting the belt tension b Refer to Figure 4 43 on page 4 50 Loosen the shoulder bolt holding the idler pulley in position until the pulley freely moves up and down Remove the main drive belt and install the new one Hook a 1000 gram spring scale to the belt as shown in Figure 4 43 on page 4 50 and carefully pull up on the idler pulley to increase belt tension When a scale reading of 500 grams 100 grams creates a deflection of 14 6 4 mm tighten the shoulder bolt Reinstall the media sensor assembly
31. Part available for purchase Light italic Part not available for purchase listed and shown for reference only u01 99S 5 5 D 5 D 5 a gt 3 z lt suime Maintenance and Assembly Drawings e OQ gs 1 o Te aon ae C 772 i V To x W E zv 1 Y e Figure 5 7 Peel Off Option Front View 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 5 15 91 6 enuen soueusjuley 0095 0075 VO GL E 146877 Table 5 8 Tear Cutter Drive System Part No Description Qty i 44023 0M Stepper Motor Tear Off and Cutter Option 1 44023 2M Stepper Motor Peel Off Option 1 44216 Screw M4 2 x 1 41 x 13 1 44177 Tear Plate Ground Strap 1 44019 Idler Shaft 1 5 44025 Idler Pulley 20T Tear Off and Cutter 1 Option only Washer 0 198 x 0 75 x 0 085 2 finm Tear Off and Cutter Option 44055 Nut M5 x 0 8 x 2 6 1 44172 2 Ground Chain Assembly 1 1 8 1 45189 5 Main Drive Belt S400 600 Peel Off 1 Option 9 45189 6 Main Drive Belt S600 Tear Off and Cutter 1 Option 45189 8 Main Drive Belt 160T S400 Tear Off and 1 Cutter Option 44017 Platen Pulley S400 1 44022 Platen Pulley 50T S600 1 11 44485 Screw x 8 1 12 441001 Set Screw M3 x 0 5 x 6 1 Available only as H
32. Refer to Figure 4 51 on page 4 60 Press the power supply board onto the three mounting snaps Reinstall the two mounting screws With the printer tilted up on the front cover position the front hooks of the power supply base into the holes Route the ground wire through the opening in the base 5 Engage the rear snaps by pivoting the power supply base assembly to the printer base 6 Insert the screw in the middle of the media compartment that secures the main base to power supply base together Refer to Figure 4 49 on page 4 57 Connect the ground wire to the riot ground bar Replace the main logic board Reconnect all ribbon cable and wire harness connectors to the main logic board 10 Reconnect the AC power cord and perform the voltage adjustment described in Printhead Voltage Adjustment on page 4 29 11 Replace the rear cover and main door 12 Reload media and ribbon 13 Reconnect the data cable Turn the printer On and test for proper operation Page 4 58 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 1 Remove the screw in the middle of the media compartment that secures the main base and power supply base 2 Remove the ground wire from the ground bar EN E 3 Insert flat blade screwdriver tip into slot 4 Gently pull the screwdriver handle toward the front of the ire printer until tab pops out of cutout into th
33. Ribbon incorrectly loaded Reload ribbon correctly then turn or not loaded printer off and on Printer stops pause LED Liner rewind spindle is full Remove liner from spindle 10 on and paper ribbon LED flashing Ribbon not calibrated Recalibrate the ribbon Mairunetioning HbboN Replace ribbon sensor sensor Printhead not fully closed Close printhead completely Printer stops pause LED 11 on and printhead LED pen Senso Check head open sensor and flashes not detecting flag or flag flag for proper operation not in proper position Printhead element Printer resumes printing when Printer stops pause LED Overheated printhead element cools 12 j and printhead LED on Power supply Printer resumes printing when over temperature power supply cools PAUSE was accidentally Press PAUSE to resume or intentionally pushed operation You may do the following 1 Check for proper Communication Not enough memory to Sonmauralion 1 Download graphics 2 With PAUSE on use the Printer stops and pause 2 Create bitmap not 13 display the amount of free LED on enough memory for memoj length of label y 3 With PAUSE on press 3 2 CANCEL to skip that label POX format and continue to the next one 4 Cycle power off and on to clear printer memory and start again Printhead LED on but _ Printhead is Chee pint dually sos 14 P x Printhead heats by printing or printing continues under t
34. Status Madicator C 2 1 Darken Status Indicator yellgw csiawiasiniccisnsasiestaissiausrisiseraisnsiasteiasisivatenssrianiass 2 2 Position Status Indicator CVellw eere FER MEHR 2 2 Calibrate Status 2 2 SIGS DEAD 2 3 Fause Im 2 3 i cbr mec e eae 2 3 eoo Fors o 2 3 Mode Kay Me 2 3 xc R8 6l 0j EM 2 3 uai emm HH 2 5 Media Loading uides cupabre idi etUm bbs Le Wa qu di cd 2 6 Tes bI Mode Media Loading anesini 2 6 Cutter Mode Media Loading sssrinin 2 6 Mode Media Loading 2 9 i up 2 10 Adjusting the Media Sensor RII LEER 2 10 Media Sensor Adjustment for Non Continuous Media 2 10 Media Sensor Adjustment for Continuous Media 2 11 tT 2 12 Adjusting the Ribbon Supply 2 sr Ee our ue 2 12 cd xlii rm 2 12 Law Tension Fe ON 2 12 Loading the RIBBON 2 13 Dsed cme 2 13 Data Cable
35. Upper media plate needs cleaning Reload media Adjust power roller Remove jam and clean upper media plate S400 S600 Maintenance Manual Label jam in rear area of printhead 44895L Rev 3 3 15 04 Troubleshooting Troubleshooting Chart Settings or Parameter Related Table 3 6 Troubleshooting Chart Settings or Parameter Related Symptom Diagnosis Action Changes in parameter settings did not take effect Parameters set or saved incorrectly Reload factory defaults calibrate printer then cycle power off and on If problem continues may be a problem with main logic board Replace main logic board ZPL sent to printer but not recognized Data LED remains off Communications parameters incorrect Print a configuration label to verify host computer and printer settings match If they do perform Mode Key Self Test to check for format or overrun errors Prefix and delimiter characters set in printer do not match ones used in ZPL Set characters to match ZPL format If problem continues check ZPL format for changed cT and Printer does not successfully auto calibrate Printhead open Close printhead Preprinted media being used Perform manual calibration Media out Printer Status Sensors Load media and check media sensor The printer contains several status sensors that indicate con
36. WIDTH 104 0 8 11 18 LABEL LENGTH LABEL LENGTH 39 IN MAXIMUM LENGTH MAXIMUM LENGTH RS232 SERIAL COMM SERIAL COMM NONE 2 PORT 2 NET PORT 9690 BAUD BAUD 8 BITS DATA BITS DATA BITS NONE PARITY PRRITY XON XOFF HOST HANDSHAKE HOST HANDSHAKE NONE PROTOCOL PROTOCOL 900 NETMORK ID NETWORK ID NORMAL MODE COMMUNICATIONS COMMUNICATIONS lt gt CONTROL PREFIX lt gt CONTROL PREFIX SEH FORMAT PREFIX lt gt SEH FORMAT PREFIX 5 2CH DELIMITER CHAR 2CH DELIMITER CHAR FPL II ZPL MODE ZPL MODE MEDIA POWER UP HERD CLOSE BACKFEED LABEL LEFT POSITION WEB S MEDIA S RIBBON S MARK S MARK MED S MEDIA LED RIBBON LED MARK LED MODES ENABLED MODES DISABLED MEDIA POWER UP HEAD CLOSE BACKFEED LABEL LEFT POSITION WEB 5 MARK 5 MARK MED 5 MEDIA LED RIBBON LED MARK LED MODES ENABLED MODES DISABLED 832 8 MM FULL RESOLUTION 832 8 FULL RESOLUTION V27 8 0 lt FIRMWARE V2788 lt FIRMWARE CUSTOMIZED CONFIGURATION CUSTOMIZED CONF IGURAT ION 244 MEMORY 24 MEMORY MEMORY MEMORY E MEMORY E MEMORY CHIP ID baee mes ihe CHIP ID OPTION OPTION FIRMWARE I
37. indicates whether the self test should be performed by the operator user and or maintenance personnel These tests produce sample labels and provide specific information that helps the operator maintenance personnel determine the operating conditions for the printer self tests without the require special tools or knowledge and are for repair and maintenance of the printer and only should be performed by maintenance personnel Detailed information on the operator self tests are found in Section Operations Overview Detailed information on maintenance personnel only self tests immediately follows 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 15 Section 4 Preventive and Corrective Maintenance Note The data cable must be removed from the printer except for the Mode key test prior to running the self tests Pause and Cancel Key Self Test Refer to Figure 4 11 This self test can be used to verify proper printer operation after parts have been replaced or adjusted When activated the printer prints a maximum of 500 head test labels Each label backfeeds prior to printing and feeds forward to the rest position after printing A serialized number prints on each label To start the Pause and Cancel Key Self Test press and hold PAUSE and CANCEL while turning the power on Press PAUSE or turn the power off to stop printing Feed and Cancel Key Self Test This self test is normally performed during the manufactur
38. life of the printhead Do not use this adjustment to try to increase the printing darkness 11 Print test labels to determine print quality Adjust the strip plate as described in Strip Plate Adjustment on page 4 27 only if experiencing ribbon wrinkle or if the ribbon is not tracking properly Adjust the printhead as described in Printhead Position Adjustment on page 4 23 only if necessary replacement printheads are pre aligned at the factory 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 41 Section 4 Preventive and Corrective Maintenance Braided Ground Straps Print Mechanism Assembly Figure 4 33 Braided Ground Strap Location Cutout Braided Ground Strap 1 m a Print Mechanism Wags Figure 4 34 Print Mechanism Assembly Mounting Screw Location Page 4 42 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Print Mechanism Assembly Printhead Cable Assembly 1 MEM Printhead Assembly Figure 4 35 Printhead Assembly Removal Installation 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 43 Section 4 Preventive and Corrective Maintenance Ribbon Supply Spindle Disassembly Refer to Figure 4 36 1 Turn printer Off and remove the AC power cord 2 Remove the printer data cable 3 Remove any media and ribbon 4 Ensure the dual tension rib
39. of prod ucts found to be defective in material or workmanship during the warranty period Zebra may in its discretion issue a credit for any such defective products in such amount as it deems reasonable Warranty Exclusions amp Conditions Statement The warranties provided above are the only warranties applicable No other warranties expressed or implied are given Zebra does not make any IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE in connection with its sale of products or services While Zebra s desire is to be responsive to specific needs and questions Zebra does not assume responsibility for any specific application to which any products are applied including but not limited to compatibility with other equipment All statements technical information or recommendations relating to Zebra products are based upon tests believed to be reliable yet do not constitute a guaranty or warranty Zebra s maximum liability for warranty claims is limited to the invoice price of the product claimed defective Zebra does not assume responsibility for delays or replacement or repair of products Zebra shall not under any circumstances whatsoever be liable to any party for loss of profits lost data diminution of good will or any other special or consequential damages whatsoever with respect to any claim made under agreement with Zebra Specifically for software Zebra is not liable for any incidental or consequential damage
40. of the sensor components They should point directly at one another Also verify that the format sent contains the peel off mode command Take Label Sensors Figure 4 21 Take Label Sensor Location Page 4 26 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Strip Plate Adjustment Refer to Figure 4 22 The ribbon strip plate position can be adjusted to provide proper tracking and separation of the ribbon from the media after printing If the ribbon does not track properly or if ribbon wrinkle problems appear adjust the strip plate by following this procedure 1 Begin printing labels by performing a Pause Key Self Test 2 Loosen the screws securing the strip plate to the front of the printhead assembly Position the strip plate for proper ribbon tracking Ensure the ribbon does not wrinkle and stays flat and smooth when fed to the upper ribbon guide when FEED is pressed Note If the strip plate is too high the result is a noisy operation and possible wrinkle especially on the backfeed Smudging or print quality problems result if the strip plate is positioned too low 4 Tighten the strip plate adjustment screws 5 Perform another Pause Key Self Test checking for ribbon wrinkle and proper ribbon tracking Readjust the strip plate as necessary 6 If ribbon wrinkle and or tracking problems persist check the torque settings of the ribbon take up spindle as
41. power cord 19 Reload media and ribbon 20 Perform a Cancel Key Self Test To start the Cancel Key Self Test press and hold Cancel while turning the power On 1 The printer runs through a Power On Self Test and then prints the configuration label Note Refer to Figure 4 56 on page 4 66 This self test prints a listing of the printer s current configuration parameters that are currently stored in configuration EEPROM memory 21 Inspect the label to determine if the main logic board recognizes the amount of memory that was installed If the label indicates NOT INITIALIZED turn the printer off and run the test again this is normal for the first time power up with the optional memory Note If the installed memory is still not recognized turn the printer off remove the power cord and repeat steps 5 through 7 Remove the memory board and reclean the gold pads on J14 of the main logic board Repeat steps 9 through 21 22 Reinstall the rear cover AC power cord and data cable 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 65 Section 4 Preventive and Corrective Maintenance E pM PRINTER CONFIGURATION PRINTER CONFIGURATION ee 20 DARKNESS DARKNESS 1000 TEAR OFF TEAR OFF TERR OFF PRINT MODE PRINT MODE NON MEDIA TYPE MEDIA TYPE SENSOR TYPE SENSOR TYPE THERMAL TRANS PRINT METHOD PRINT METHOD PRINT WIDTH PRINT
42. print quality adjustments With the loopback connector in place press and hold FEED while turning the power On I After the Power On Self Test the printer begins printing the same series of label formats as shown in Table 4 3 then pauses at the end of each printed format Press PAUSE to begin printing the next format Sample labels are shown in Figures 4 11 through 4 18 PAUSE can be used to stop and restart the printing operation When the printer is paused CANCEL can be used to move to the next label format Mechanical Adjustments Printhead Position Adjustment 1 Ensure the printer is loaded with full width media and ribbon and has had a media calibration performed with this combination of media and ribbon 2 Referto Adjust the two printhead pressure screws for equal pressure Head Open Lever Toggle Pressure Knobs Figure 4 19 Printhead Pressure Screws Turn the printer Off O Remove the cutter module Refer to Figure 4 20 on page 4 25 Loosen but do not remove the two printhead position locking screws two full turns then finger tighten them 6 Perform a Pause Key Self Test by pressing and holding PAUSE while turning the printer On I 7 When the printer completes its Power On Self Test it will begin the Pause Key Self Test Once the Pause Key Self Test begins let several labels print and then press PAUSE Examine the labels and make adjustments as required Using a flat blade screwdriver adjust t
43. stops after completing a cut cycle It can be viewed between the outer cover and the side plate The desired stopping position of the censor disc is when the embossed line on the sensor disc is aligned with the edge of the side plate 5 Refer to Figure 4 26 on page 4 33 Adjust the home position potentiometer with the potentiometer adjustment tool Zebra part 01428 until the embossed line on the sensor disc is in alignment with the side plate edge 6 Turn the power Off O and install the cutter module Page 4 32 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Side Plate Edge Embossed Line Sensor Disc Home Position Potentiometer Figure 4 25 Properly Adjusted Cutter Sensor Home Position Potentiometer Figure 4 26 Home Position Potentiometer 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 33 Section 4 Preventive and Corrective Maintenance Corrective Maintenance Tools Required Open End Wrench Set Spring Scale 2200 gram and 1000 gram Metric Allen Wrench Set 0 010 Shim or Feeler Gauge Small Flat Blade Screwdrivers 0 020 Shim or Feeler Gauge Phillips Screwdrivers Anti Static Mat Digital Voltmeter Anti Static Wrist Strap Removing the Main Door 1 Refer to Figure 4 27 on page 4 35 Lift the main door to swing it up and to the left until it rests on top of the right side cover 2 Using both hands slide the main d
44. tension tighten the locking screws 12 Reload the media and ribbon and test the printer s liner rewind function Mylar Strip Rewind Spindle teased Spring Scale Locking Nut Figure 4 23 Liner Rewind Spindle Adjustment Page 4 28 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Electrical Adjustments Printhead Voltage Adjustment Caution The printhead voltage adjustment is critical to the life of the printhead Do not use this adjustment to try to increase printing darkness When a printhead or power supply board is replaced the printhead voltage must be adjusted for the proper value This adjustment provides the voltage applied to the print elements during the printing process 1 Calculate the proper printhead voltage using the formula or values found in Table 4 4 on page 4 30 for the S400 or Table 4 5 on page 4 30 for the S600 Notes The S400 printhead resistance value can be read from the fork bracket label RXXXX where is the value in ohms The S600 printhead resistance value can be read from the label on the printhead R XXX ohms 2 Refer to Figure 4 28 on page 4 35 Remove the rear cover 3 Refer to Figure 4 31 on page 4 39 Attach a voltmeter between F2 and ground on the main logic board 4 Turn the printer On 1 and let it complete the Power On Self Test Refer to Figure 4 24 on page 4 31 Lo
45. the top of the label approximately 15 32 in 11 mm from its original position Page 2 28 PRINTER CONFIGURATION 7 2 DARKNESS PRINTER CONFIGURATION 1 Position of EM CPCSUFX 832 CUDA MHARE NF IGURSTION ORY FIRMWARE IN THIS PRINTER IS CCPYRIGHTEC 1 6 FIRMWARE 14 THIS PRINTER 15 COPYRIGHTED Label direction out or printer Figure 2 16 Adjusting the Print of the Top of Label 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Routine Adjustments Printhead Pressure Adjustment If the printing is too light on one side of the label or if a different thickness of media is used the printhead pressure may need to be adjusted to provide the best print quality Refer to Figure 2 17 and perform the following procedure 1 Begin by performing a Pause Key Self Test 2 After printing a few labels press PAUSE and check the print quality 3 If necessary increase or decrease the toggle pressure using the knurled adjustment nuts at the top of the toggle shafts Example 1 If printing is acceptable on the left side but too light on the right increase the toggle pressure by turning the right toggle pressure knob clockwise 1 Example 2 If printing is acceptable on the right side but too dark on the left decrease the t
46. 1 Press MODE The pause and darken LEDs come on 2 Press and release CANCEL W to decrease the setting each time waiting for the darken LED to flash once before pressing again Continue to press CANCEL W until the LED does not flash This means you are at setting 0 3 Press and release FEED A to increase the setting each time waiting for the LED to flash once before pressing again Continue to press FEED until you count up to 10 factory default or to your desired setting 4 Press MODE three times The mode LEDs will flash to indicate that the settings have been saved permanently to memory 5 Press PAUSE to resume printing You are now ready to start the Pause Key Self Test To Start the Pause Key Self Test Press and hold PAUSE while turning the printer On I This self test consists of four individual test features initial self test prints 15 labels at 2 in 50 8 mm per second ips speed then automatically pauses the printer Each time PAUSE is pressed an additional 15 labels print up to a maximum of 9999 labels While the printer is paused pressing CANCEL once alters the self test Now each time PAUSE is pressed 15 labels print at 6 152 4 mm ips speed D up to a maximum of 9999 labels While the printer is paused pressing CANCEL a second time alters the self test again Now each time PAUSE is pressed 50 labels print at 2 50 8 mm ips up to a maximum of 9999 labels While the p
47. 4 11 Apply gentle upward pressure to the left and right ends while raising the cutter module up and away from the mounting posts If necessary rock the cutter module side to side to loosen it 1 2 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 9 Section 4 Preventive and Corrective Maintenance Mounting Screw Figure 4 4 Cutter Connector and Mounting Screw Page 4 10 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Posts 4 Mounting Slots Figure 4 5 Cutter Module Removal Disassembling the Cutter Module 1 Lay the cutter module on a table or other surface Hold the cutter module as shown in Figure 4 6 on page 4 12 Put your thumbs on the two wire spring loops and your index fingers on the top of the rear cutter blade guard 2 remove the rear cutter blade guard first press down simultaneously on the two wire spring loops While still pressing down on the wire spring loops press the rear cutter guard back toward you and over the top of the loops You are trying to tuck the wire spring loops under the cutter blade guard 3 Continue pressing the rear cutter guard toward you and allow the back edge of the guard to pop up as it comes free from its holders You may now remove the rear cutter guard by lifting it off of the module Note The wire springs may flip up out of position during this process They will be repositioned during reassembly
48. 4895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 27 Section 2 Operations Overview Top of Label Position Adjustment This procedure positions the printing on the label relative to the top edge of the label Adjust if the printing is too close or too far away from the top or bottom edge of the label 1 Press MODE twice briefly and then press and hold it for approximately five seconds until the pause darken and calibrate LEDs turn on Press FEED A to move the printing closer to the top edge or CANCEL W to move away from the top edge Each press of either of these keys equals eight dot rows or approximately 0 0394 in Press MODE twice The mode LEDs will flash to indicate that the settings have been saved to memory Press PAUSE to exit the Pause Mode and turn off the pause LED Example In Figure 2 16 the configuration label printed on the right was printed first It was decided to move the print closer to the top edge in the direction approximately 15 32 in 11 mm Notice that the label top line of the configuration label on the right has a value of 012 Divided 15 32 in 11 mm by 0 0394 in 925 mm 11 89 round to 12 Press CANCEL 12 times completing the adjustment procedures will give us the configuration label shown on the left when you print a new configuration label The printed configuration label on the left has a LABEL TOP line value of 084 and the printing is closer to
49. 5 0075 VO GL E 146877 Table 5 10 Platen and Power Supply Part No Description Qty 1 44114 Screw 4 2 x 1 41 x 8 4 2 44282 Tear Off Plate 1 3 44015 Platen Sleeve Bearing 2 4 44120 Outboard Guide 1 44182 Platen Roller S400 1 44214 Platen Roller 5600 1 6 44121 Inboard Guide 1 7 44484 Screw 4 2 x 1 41 x 25 1 8 44115 Screw M4 x 10 2 9 145770M Power Supply Assembly 120 240 VAC 1 10 44004 400M Base Cover 1 Available only as HW44114 in quantities of 50 Available only as HW44484 in quantities of 10 Available only as HW44115 in quantities of 10 Bold Part available for purchase Light italic Part not available for purchase listed and shown for reference only u01 99S 5 5 D 5 D 5 a gt 3 z lt suime VO GL E 166877 enuen eoueuejure v 0095 0075 12 5 Bearings item 3 pictured here are installed this way for the S400 only For the S600 rotate bearings 180 degrees turn upside down Figure 5 10 Platen and Power Supply Ajquiessy 22 5 enuen soueusjuley 0095 0075 VO GL E 146877 Table 5 11 Cutter Option Part No Description Qty 1 44710 Cutter Maintenance Kit 1 2 44986 Catch Tray 1 3 10432M Pl
50. DE while turning the power On 1 After the printhead LED has flashed load the ribbon Close the printhead oD Press MODE 4 times to save parameters Note A label automatically prints showing the ribbon sensor profile Configuration Mode Configuration Mode allows you to fine tune the internal printer configuration settings for your application In this mode you can change the following parameters Printer darkness Rest position of the media with respect to the web or inter label gap Position of printing relative to the top of the label Media and ribbon sensor values Label length Printing method Media type continuous or non continuous Create a printout of the printer configuration by performing the Cancel Key Self Test To set the printer configuration to factory defaults refer to Feed and Pause Key Factory Default Reset on page 2 19 The ZPL II Programming Guide contains information on instructions that may be sent to the printer to disable the Mode key and set specific label format values for each of these parameters If you are not using ZPL Il refer to the instructions provided with your software to determine whether it allows you to change these parameters Print Darkness Differences in types of media ribbon and the wear on thermal printhead elements may make it necessary to adjust the print darkness setting to achieve proper printing 44895L Rev 3 3 12 04 5400 5600 Maintenan
51. Door S600 1 44070 3 Main Door Standard 1 44070 4 Main Door Quick Release 1 Available only as HW44114 in quantities of 50 Bold Part available for purchase Light italic Part not available for purchase listed and shown for reference only u01 99S 5 5 D 5 D 5 a gt 3 z lt suime Maintenance and Assembly Drawings seiquiessy 19402 1 ainbi4 Page 5 3 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 6 oDeg enuen soueusjuley 0095 0075 Table 5 2 Logic Board and Control Panel Part No Description Qty 1 44114 Screw 4 2 x 1 41 8 3 2 44506 LED Button Array Maintenance Kit 1 B Front Panel Cover Assembly a ari M4 x 10 screw 4 45925M Head Open Sensor Flag 1 5 45195 Screw 10 32 x 0 25 1 6 44123 Braided Ground Strap 1 7 44053 Screw x 0 6 x 10 2 8 44784M C Main Logic Board S400 1 44782M C Main Logic Board S600 1 9 22416 Hex Stand Off 4 40 2 10 01155 Lock Washer 4 2 11 44077 Ground Bezel 1 12 44115 Screw M4 x 10 1 91 eu 146877 Available only as HW44114 in quantities of 50 Available only as HW01155 in quantities of 100 Available only as HW44115 in quantities of 10 BoldzPart available for purchase Light italic Part not available for purchase listed and shown for reference only 5
52. INTER CONFIGURATION DARKNESS TEAR OFF PRINT MODE PARITY HOST HANDSHAKE PROTOCOL i COMMUHI CATIONS CONTROL PREFIX FORMAT PREFIX DELIMITER CHAR ZPL ZPL MODE CALIBRATION MEDIA POWER UP CALIBRATION HEAD CLOSE DEFAULT MARK MED 5 MEDIA LED RIBBON LED MARK LED MODES ENABLED MODES DISABLED Pao RMWARE CONFIGURATION MEMORY NONE OPTION VERSION IDLE DISPLAY DATE NO RTC INSTLD RTC TIME TIRMUARE IN THIS PRINTER 15 COPYRIGHTED Figure 2 11 Cancel Key Self Test Printout Configuration Label S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Pause Key Self Test Refer to Figure 2 12 This self test can be used to provide the test labels for making adjustments to the printer s mechanical assemblies and Configuration Mode adjustments To start the Pause Key Self Test press and hold PAUSE while turning the power On 1 This self test consists of four individual test features initial self test prints 15 labels at 2 in 50 8 per second ips speed then automatically pauses the printer Each time PAUSE is pressed an additional 15 labels print up to a maximum of 9999 labels While the printer is paused pressing CANCEL once alters the self test Now each time PAUSE is pressed 15 labels print at 6 ips 152 4 mm speed D up to a maximum of 9999 labels While the printer is paused pressing CANCEL a second time
53. Motor Cable Power Supply Board J1 access through cutout in base Figure 4 49 Stepper Motor Electronics Side J Observe proper electrostatic safety precautions when removing handling and replacing printed circuit boards Cy Caution Power Supply Board Removal Turn the printer Off and remove the AC power cord and the data cable Remove media and ribbon Remove the main door and rear cover Remove the main logic board B ge M 22 Refer to Figure 4 49 Disconnect the stepper motor cable from the power supply board J1 Disconnect the ground wire leading from the power supply board to the ground bar Refer to Figure 4 50 on page 4 59 Remove the screw in the middle of the media compartment that secures the main base to the power supply base together 8 Insert a flat blade screwdriver tip into the slots shown in Figure 4 50 on page 4 59 9 Gently pull the screwdriver handle toward the front of the printer until the tabs pop out of the cutout tabs slide into the base N D 10 Carefully pry the front of the power supply base downward to remove the assembly 11 Refer to Figure 4 51 on page 4 60 Remove the two mounting screws that secure the power supply board to the base 12 Pivot the board off the front snaps 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 57 Section 4 Preventive and Corrective Maintenance Power Supply Board Installation 1
54. N THIS PRINTER IS COPYRIGHTED FIRMWARE IN THIS PRINTER IS COPYRIGHTED Figure 4 56 Sample Before and After Configuration Labels 8 MB Memory Board Installed Page 4 66 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Maintenance and Assembly Drawings Section 5 Maintenance and Assembly Drawings Description Use the mechanical assembly drawings when troubleshooting or replacing components and use the associated parts list when ordering replacement parts Item parts that do not have associated part numbers are not available and need to be ordered using the next highest assembly number All parts in bold face are purchasable All parts in light face italic are not purchasable but may be available as part of a maintenance kit Hardware parts in light face are not available as an individual part but may be purchased as part of a hardware kit 7 Caution V J The printer electronics is susceptible to static discharge Before proceeding it is i recommended that the technician wear an antistatic strap connected to the printer chassis 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 5 1 2 6 enuen soueusjuley 0095 0075 VO GL E 146877 Table 5 1 Cover Assemblies Part No Description Qty 1 44114 Screw 4 2 1 41 x 8 3 2 44185 Front Door Retention Clip 1 3 144075 1 Rear Cover 1 2 44076 5 Front Door S400 1 44076 4 Front
55. Peel Off Mode Improperly adjusted media edge guides or power roller Check edge guides and power roller Adjust as necessary Vertical drift in top of form registration Incorrect media loading or media sensor adjustments Reload media or adjust sensors as necessary Light vertical lines approximately 0 006 0 15 mm wide running through all labels Dirty printhead or ribbon rollers Clean printhead and ribbon rollers Defective printhead elements Replace printhead Light printing or no printing on left or right side of label Printhead pressure needs balancing Perform printhead balance adjustments Short printed lines at 45 to label edge on left or right side of label Too much printhead pressure Reduce toggle pressure Truncated print no print or FEED operates incorrectly while using non continuous media Media or ribbon improperly loaded Reload media or ribbon Incorrect media sensor position or sensitivity Adjust media sensor Fine gray lines on blank labels at angles Wrinkled ribbon See Troubleshooting Chart Wrinkled Ribbon on page 3 8 Misregistration and misprint of one to three labels Media pulled when motor not moving Open and close printhead so it calibrates to find label length Incorrect media sensor position or sensitivity Adjust media sensor Auto calibrate failed Perform manual calib
56. Standard Printer Fonts Table 1 1 Font Matrix for 8 dot mm 203 dpi Printheads Font Matrix Character Size Inter Inches Millimeters Height Width Baseline Character Gell Font Matrix Char Char Dots Gap Width Height Width Inch Height Width dis A 9 5 7 1 6 U L D 0 044 0 030 33 87 1 13 0 75 1 33 B 11 7 11 2 9 0 0 054 0 044 22 58 1 38 1 13 0 89 18 10 14 2 12 U L D 0 089 0 059 16 93 2 25 1 50 0 67 E 28 15 23 5 20 OCR B 0 138 0 098 10 16 3 50 2 50 0 40 F 26 13 21 3 16 U L D 0 128 0 079 12 70 3 25 2 00 0 50 G 60 40 48 8 48 U L D 0 295 0 236 4 23 7 50 6 00 0 17 H 21 13 21 6 19 OCR A 0 103 0 094 10 69 2 63 2 38 0 42 GS 24 24 24 2 26 SYMBOL 0 118 0 128 7 82 3 00 3 25 0 31 P 20 18 N A N A N A U L D 0 098 0 089 N A 2 50 2 25 N A Q 28 24 N A N A N A U L D 0 138 0 118 N A 3 50 3 00 N A R 35 31 N A N A N A U L D 0 172 0 153 N A 4 38 3 88 N A S 40 35 N A N A N A U L D 0 197 0 172 N A 5 00 4 38 N A T 48 42 N A N A N A U L D 0 236 0 207 N A 6 00 5 25 N A U 59 53 N A N A N A U L D 0 290 0 261 N A 7 38 6 63 N A V 80 71 N A N A N A U L D 0 394 0 349 N A 10 00 8 88 N A U Uppercase L Lowercase D Descenders Bitmapped Fonts Zebra standard A B D E F G E H and GS Standard magnification up to 10 times vertical and horizontal independent Scalable Fonts One s
57. T ioy Q OB A CALIBRATE MODE ME 6 o Figure 4 2 Printhead Cleaning Cleaning the Cutter Module The cutter module is an option available on the 5400 5600 that requires periodic cleaning to remove paper dust and gummed label residue The following procedure should be performed as scheduled in Table 4 1 by the operator However depending on the application and media type it may be necessary to clean the cutter more or less often procedures described Note In figures shown media and ribbon have been removed for clarity It is not necessary to remove the media or ribbon prior to performing the maintenance Caution Do not exchange cutter modules between different printers The cutter module adjustment are optimized during installation to work with a particular printer and may not perform correctly if placed on a different printer Remove the cutter module from the printer Turn the printer s AC power Off O Refer to Figure 4 3 on page 4 10 Remove the cutter catch tray by lifting it up and away from the front of the cutter module Refer to Figure 4 1 on page 4 8 Raise the main door and lower the front door Refer to Figure 4 4 on page 4 10 Gently pull straight down on the cutter cable connector to remove it from the cutter module Turn the cutter mounting screw in a counterclockwise direction until it is loose Hold the cutter module as shown in Figure 4 5 on page
58. W44216 in quantities of 25 Available only as HW44356 in quantities of 25 Available only as HW44172 2 in quantities of 10 t Available only as HW44100 in quantities of 25 Bold Part available for purchase Light italic Part not available for purchase listed and shown for reference only u01 99S 5 5 D 5 D 5 a gt 3 z lt suime Maintenance and Assembly Drawings wa sAs 8 6 eunDiJ Y e e UMEN f t a 5 17 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 81 6 enuen 0095 00 VO GL E 146877 Table 5 9 Peel Off Option Drive System Table 5 9 Peel Off Option Drive System Part No Description Qty Part No Description Qty 1 44359 Peel Off Upper Idler Assembly 1 21 44376 Washer 0 420 x 0 254 x 0 010 3 2 44363 Screw 5 x 0 8 x 25 1 22 44274 Bearing Plate 1 3 30261 Flat Washer 0 442 x 0 255 x 0 020 1 23 30104 Ball Bearing 0 50 x 0 250 x 0 125 2 4 44496 Peel Pulley Assembly 1 24 02252 External Crescent Ring 0 250 2 5 44359 dler Spacer 1 25 44172 1 Ground Chain Assembly 1 3 4 1 6 30163 Flat Washe
59. Wire Clip 1 Available only as HW44100 in quantities of 25 9 44466 Ground Cable 1 Available only as HW44084 in quantities of 10 ttt Available only as HW44339 in quantities of 10 10 44053 Screw x 0 6 x 10 1 Available only as HW44356 in quantities of 25 tt Available only as HW44278 in quantities of 25 11 44118 Shaft Collar 0 377 x 0 750 1 ttt Available only as HW44114 in quantities of 50 12 441004 Set Screw x 0 5 6 4 q Available only as HW10432 in quantities of 25 BoldzPart available for purchase 13 4408413 Washer 0 70 x 0 38 x 0 03 4 Light italic Part not available for purchase listed and shown for reference only 14 44046 2 Bevel Gear 60T 1 u01 99S 5 5 D 5 D 2 gt 3 lt suime Maintenance and Assembly Drawings Figure 5 3 Media Supply Ribbon Supply and Ribbon Take Up 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 5 7 8 oDeg enuen soueusjuley 0095 0075 Table 5 4 Toggle and Print Mechanism Part No Description Qty 1 44329 400 A Toggle Assembly 1 2 44360 Spring Washer 1 3 77687Braided Ground Strap 1 4 44054 Screw M3 5 x 20 1 5 01448 Screw 6 32 x 0 37 2 6 44484 Screw M4 2 x 1 41 x 25 1 7 44923 Braided Ground Strap 1 8 45925M Head Open Sensor Flag 1 9 448601 Screw 10 32 x 1 5 SHCS 1 10 44339 Hex Sta
60. abel gap 0 16 4 mm Ticket tag notch size W x L 0 08 x 0 48 2 mm x 12 mm Media Handling Tear Off Mode Labels produced in strips Peel Off Mode Labels dispensed and peeled from the liner Cutter Mode Labels are printed and individually cut Rewind Mode Labels are externally rewound requires optional media rewinder not available from Zebra Technologies These options are not found on all printers S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Memory Description of Equipment Table 1 3 Memory Specifications S400 S600 Flash ROM firmware 1 MB 1 MB Standard DRAM MB 2 Available Standard Flash Memory 0 1 MB 4 amp 8 MB Flash 4 amp 8 MB Flash Memory Upgrades Options Modules Modules Microprocessor 32 Bit RISC Options 1 MB Flash expansion S400 only 4 MB Flash expansion 8 MB Flash expansion Peel Off mode with liner only rewind feature Cutter with label catch tray Scalable and bitmap smooth fonts available for text Ethernet Factory installed contact your authorized Zebra distributor for information Physical Dimensions Table 1 4 Physical Dimensions S400 amp S600 Height 13 330 mm Width 8 25 210 mm Depth 17 432 mm Weight without options 17 lbs 7 71 kg 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 1 5 Section 1 Description of E
61. abel length media and ribbon sensor settings and printing method direct thermal or thermal transfer The procedure is set at the factory but may be changed via ZPL II command Note If the printer fails to auto calibrate when you are using preprinted labels or preprinted liner or if the printer does not auto calibrate at all refer to Manual Calibration on page 2 22 1 Load the media and ribbon 2 the printer On I 3 Several blank labels feed completing the auto calibration procedure 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 21 Section 2 Operations Overview Manual Calibration Manual Calibration Mode or if auto calibrate does not work Q Important Perform manual calibration when using preprinted media when During this procedure the printer determines the media type label length media and ribbon sensor settings and printing method Media type is determined by sensing either continuous or non continuous media as blank labels move through the printer If non continuous media is sensed label length is also calibrated If ribbon is sensed the thermal transfer print method is configured If ribbon is not sensed the direct thermal print method is configured The results of the calibration are stored in the printer s memory and are retained even if power is removed These parameters remain in effect until the next calibration is performed Notes Perform this procedure onl
62. able 2 2 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 3 7 Table 3 8 Table 4 1 Table 4 2 Table 4 3 Table 4 4 Table 4 5 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 5 6 Table 5 7 Table 5 8 Table 5 9 Table 5 10 Table 5 11 44895L Rev 3 3 12 04 List of Tables Font Matrix for 8 dot mm 203 dpi Printheads siiciissssiicinesserssiesioccsreereviaraen 1 3 Media specie MON eea E Um 1 4 Memory cci H 1 5 1 5 Pining em 1 6 1 6 Ribbon Specifications 1 7 aisi enl apetece LT Daun e Rio GPL HU FP I pP PR Lo DIM e YE 1 11 Cenponos Connector PINOUT s aiite cen tick anas e eet 1 13 Self Test and Calibration Quick Reference 2 15 Factory Default Valles 2 20 LED Oiek Reterente 3 2 Troubleshooting Chart Problems with LED 3 3 Troubleshooting Chart Print or Print Quality Related Problems 3 6 Troubleshooting Chart Wrinkled 3 8 Troubleshooting Chart Jammed or Stuck Labels 3 8 Troubleshooting Chart Settings or Parameter Related
63. al condition N POWER O K PRINTHEAD e PAPER RIBBON PAUSE FEED Qe DATA CANCEL Q AW DARKEN Oe POSITION OR CALIBRATE MODE Figure 2 1 Front Panel A Page 2 2 S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Operator Controls Pause Key Allows the operator to interrupt the printing of a batch of labels If Pause is pressed during printing printing stops after completing the label being printed If the printer is not printing no printing can occur Feed A Key Forces the printer to feed one blank label f FEED is pressed during printing a blank label feeds after the current batch of labels is completed If the printer is not printing a blank label feeds immediately Cancel V Key When in Pause Mode this key cancels print jobs If there are no print jobs in queue pressing CANCEL cancels the next print job to be sent to the printer e If there is one print job in the queue pressing CANCEL once cancels the current print job If there is more than one print job in the queue pressing and holding CANCEL for several seconds cancels all print jobs in memory Mode Key MODE puts the printer in Configuration Mode for more information see Configuration Mode on page 2 23 and activates the automatic media calibration procedure Power ON OFF Switch Refer to Figure 2 2 On the lef
64. ally 2 25 Festing 2 24 Print Mechanism Assembly Removal 4 40 Print Speed Sern eon 1 6 Printer Operating Modes 1 1 Printhead Assembly Removal and Installation 4 43 Pressure Adjustment 2 29 Status Indicator 2 1 Printing Considerations 1 6 Printing Method 1 6 Programming Language Zebra 1 7 R Ranges Environmental 1 2 Op rating 1 2 1 2 Removing Front DOOF xir tet 4 34 LIFIBE iiit icio dens pasada tede eto 2 10 DOOR Jue ibat o i 4 34 Rear Cover sais cient 4 34 S400 S600 Maintenance Manual Used Ribbon 2 13 Repair Service Department 3 11 Requirements Electrical 1 2 Returning Equipment 3 11 RIBBON nin de 1 7 Parameter 2 23 Supply Spindle Disassembly 4 44 Supply Spindle Installation 4 45 4 48 Take Up Motor Replacement 4 55 Routine Adjustments 2 29 Printhead Pressure 2 29 Rewind Power Roller 2 30 S Scalable Fols 1 3
65. alters the self test again Now each time PAUSE is pressed 50 labels print at 2 ips 50 8 mm up to a maximum of 9999 labels While the printer is paused pressing CANCEL a third time alters the self test again Now each time PAUSE is pressed 50 labels print at 6 ips 152 4 mm up to a maximum of 9999 labels AERE Figure 2 12 Pause Key Self Test Printout 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 17 Section 2 Operations Overview Feed Key Self Test The results of this self test determine the best darkness setting for a specific media and ribbon combination Refer to Figure 2 13 The Feed Key Self Test prints a series of labels at various plus or minus darkness settings relative to the current darkness setting The operator inspects these printouts and determines which printout has the best darkness setting The value next to Relative Darkness on the printout is added to or subtracted from the current darkness value The following procedure sets the darkness of the printing on the label To start the Feed Key Self Test press and hold FEED while turning the power On I Note To maximize the life of the printhead use the lowest setting that provides the necessary print quality 1 Press MODE The pause and darken LEDs turn on 2 If the Feed Key Self Test produces a positive value press FEED A the number of times indicated o
66. anels 3 Referto Figure 4 8 on page 4 13 Press the rear cutter blade guard down and forward rotating the guard as you proceed to lock the mounting pins into position in the cutter side panel mounting slots Slide the guard forward until the two wire spring loops pop up on the backside of the guard Note Ensure that the wire springs remain positioned under the rear cutter blade guard when assembly is completed Page 4 12 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 4 Lower the upper cutter bade guard back to its normal position When reassembled the back of the cutter module looks like Figure 4 9 on page 4 14 Upper Cutter Wire Spring Blade Guard Wire Spring Figure 4 7 Cutter Module Reassembly Rear Cutter Rear Cutter Blade Guard Blade Guard Metal Wire Spring Loop Cutter Cutter Side Panel Side Panel Figure 4 8 Side View of Cutter Module Reassembly 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 13 Section 4 Preventive and Corrective Maintenance Figure 4 9 Reassembled Cutter Module Reinstall the Cutter Module 1 Referto Figure 4 10 on page 4 15 Position the cutter module above the cutter mounting posts Press down on the cutter module until the mounting slots engage the mounting posts on the printer 2 Refer to Figure 4 4 page 4 10 Tighten the mounting screws in a clockwise direction to hold the cutter module in po
67. ate Mounting Maintenance Kit 1 4 10432 Screw M4 x 0 7 x 12 3 5 10474 Split Washer M4 2 6 07257 Washer 0 438 x 0 188 x 0 036 3 7 44437 Cutter Mounting Maintenance Kit 1 8 44437Mounting Bushing 2 9 44433 Spring Washer 2 10 44432 Locating Post 2 11 06223 Cable Clamp 0 188 1 12 44674 Cable 8 Cond DIN Cutter Cable 1 13 10461 Nut M4 x 0 7 1 14 44434 Plate 1 15 011594 External Lock Washer 6 1 16 30781 Ground Cable 1 17 4405341 0 6 x 10 1 Available only as HW10432 in quantities of 25 Available only as HW10474 in quantities of 25 Available only as HW07257 in quantities of 25 Available only as HW01159 in quantities of 100 Available only as HW44053 in quantities of 10 Bold Part available for purchase Light italic Part not available for purchase listed and shown for reference only u01 99S 5 5 D 5 D 5 a gt 3 z lt suime VO GL E 166877 enuen eoueuejure v 0095 0075 52 Note The cutter option is not field installable Parts displayed below are for repairing the factory installed option These parts cannot be installed on non cutter option printers Figure 5 11 Cutter Option 5 5 t 5 5 a gt o o 3 5 lt suime Maintenance Section 5 Page 5 24 S400 S600 Maintenance Manual 44895L Rev 3 3
68. available and in close proximity to the printer 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 3 Section 4 Preventive and Corrective Maintenance Personal Safety Tips Do not wear any jewelry rings watches etc and loose clothing when servicing the printers Beware of Pinch Points on the printers Be especially careful of Opening and closing covers Printhead Rewind Spindle Platen Roller Wear protective eye wear when removing E Rings C Clips and springs For personal and equipment safety use a three prong plug with a ground earth connection Page 4 4 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Preventive Maintenance Schedule Cleaning General Caution Use only the cleaning agents described in the following procedures Damage can occur if the incorrect cleaning agents are used on this printer Exterior Clean the exterior surfaces of the printer as required by using a lint free cloth Do not use solvents or harsh cleaning agents If the unit is excessively dirty a mild detergent solution or desktop cleaner may be used sparingly Interior As required remove any dirt lint accumulated in the interior of the printer by using a softbristle brush dry compressed air or vacuum cleaner It is a good practice to inspect these areas with each media change Media and Ribbon Paths Clean with a solution of 90 isopr
69. bbon Release Ribbon Supply Button Printhead Assembly Media Supply Label Media Supply Guide Media Supply Hanger AMNES Liner Only Platen Guide Rod Rewind Power Roller Hold Down Hook Liner Rewind Spindle Lower Guide Rod Guide Rod Media Sensor Assembly Media Guide Figure 2 7 Peel Off Mode Media Loading Page 2 8 S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Peel Off Mode Media Loading 1 Turn the head open lever counterclockwise to the OPEN position and raise the printhead 2 Slide the media guide and the media supply guide as far out from the printer frame as possible Remove the hold down hook 4 Place the media roll on the media supply hanger and thread the media through the printhead assembly as shown in Figure 2 7 5 From the front of the printer pull the media through the printhead assembly until approximately 24 in 61 cm of media extends out from the printer Remove the labels from the liner 6 Thread the liner behind the lower label available sensor through the slot under the rewind power roller and below the lower guide rod to the liner rewind spindle 7 Wind the liner counterclockwise three or four times around the liner rewind spindle Ensure the edge of the liner material is against the round plate at the far end of the spindle 8 Place the hold down hook over the liner and insert both ends into the small sl
70. bbon Supply Spindle Subassembly Installation 4 45 Spindle Assembly 4 46 Spindle Assembly Installaliohi erase rer enne cp nonae renti 4 48 Spindle Assembly amp Outer Spindle Expanded 4 48 Spindle Assembly amp Outer Spindle Retracted 4 48 Media 4 50 Main Drive Belt Replacement and Adjustment 4 50 Peel Off Drive Belt 2 2 422 1 4 52 Platen Roller Heplacembrituss vobia bete eda bp ERE ME DRE PEDE EUR 4 54 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 List of Figures Figure 4 46 Replacing the Platen 2 22 4 54 Figure 4 47 Ribbon Take Up Po DE EROR EHI 4 55 Figure 4 48 Stepper Motor Media 4 56 Figure 4 49 Stepper Motor Electronics 5 4 57 Figure 4 50 Power Supply Assembly 4 59 Figure 4 51 Power Supply Assembly Exploded 4 60 Figure 4 52 Fuss Holder 4 61 Figure 4 53 Main Logic Board Conntector and Mounting Screw Locati
71. ble sensor detects this label and pauses printing until the operator removes the label then the next label prints The liner rewind spindle holds one half of the liner from a standard size media roll The rewind spindle full sensor detects when the spindle is full then pauses Cutter Mode When the media is in the rest idle position the start of the label to be printed is directly under the printhead The printer prints the entire label and automatically cuts the label after it is printed The cutter catch tray catches the completed labels The cutter automatically cycles through one cutting motion when the printer s power is turned On 1 When printing labels cutter activation is determined by a command sent to the printer by the host computer from either ZPL II or from a different software driver External Rewind Mode Some applications call for the media to be rewound onto a core as the labels are printed The Stripe printer does not have an internal media rewind capability The liner rewind spindle is not designed to rewind label stock An external rewinder is required for this application An external rewinder is not available from Zebra Technologies When the media is in the rest idle position the start of the label to be printed is directly under the printhead After the label is printed the media feeds forward until the start of the next label is under the printhead The media never backfeeds in this mode When the printer complet
72. bon as shown in Figure 2 10 Do not to crease or wrinkle the ribbon Wind the ribbon onto the ribbon take up spindle for several turns in a clockwise direction 6 Close the printhead assembly by turning the head open lever clockwise to the CLOSED position i Ribbon Upper Ribbon Ribbon Release Suppl Guide Arm Button pply Head Open Lever Figure 2 10 Ribbon Loading Diagram Removing Used Ribbon Refer to Figure 2 10 1 Cut the ribbon between the upper ribbon guide roller and the ribbon take up spindle 2 Press the ribbon release button and slide the ribbon off of the ribbon take up spindle 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 2 13 Section 2 Operations Overview Data Cable Installation Turn the printer Off O Determine whether you are using a parallel data cable or serial data cable Follow your computer manufacturer s instructions for installing data cables to the computer You may need to turn off the computer before making any cable connections 6 Refer to Figure 2 2 on page 2 4 Connect the printer data cable from the computer to the proper port on the rear of the printer Power On Self Test A Power On Self Test is performed automatically each time the printer is turned on This test checks for proper initialization of various electronic circuits and establishes starting parameters as those stored in the printer s memory During this test sequence the front panel LEDs turn on and of
73. bon supply spindle outer spindle is in the retracted pushed in position to gain access to the set screws 5 Rotate the outer spindle to locate and loosen the two set screws securing the cup and spring assembly to the ribbon supply spindle shaft Slide the cup and spring assembly and the outer spindle off the shaft Remove the C clip Slide the spindle assembly off the shaft Rotate the ribbon supply spindle subassembly to locate and loosen the two set screws securing the cup and spring assembly to the ribbon supply spindle shaft 10 Slide the ribbon supply spindle subassembly off the shaft Cup and Spring Ribbon Supply Assembly pindle Subassemby 4 Spindle Assembly S oY Cup and Spring Assembly Set Screws Figure 4 36 Dual Tension Ribbon Supply Disassembly Page 4 44 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Ribbon Supply Spindle Installation 1 2 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 45 Use an emery cloth to remove burrs and nicks on the ribbon supply spindle shaft Refer to Figure 4 37 Slide the ribbon supply spindle subassembly on the ribbon supply spindle shaft Slide one of the cup and spring assemblies on the ribbon supply spindle shaft Place a 0 010 254 mm shim or feeler gauge between the C clip and ribbon supply spindle subassembly While applying light
74. c categories Preventive Maintenance procedures and operator care instructions These procedures may be performed by the operator as well as the service technician and should be performed on a regular basis Preventive maintenance consists of a visual inspection and general cleaning of the interior and exterior of the printer as well as cleaning the printhead and the associated media and ribbon paths e Corrective Maintenance provides the service technician detailed steps for resolving faults by adjusting or replacing components or modules 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 1 Section 4 Preventive and Corrective Maintenance EQUIPMENT SAFETY TIPS After reviewing each procedure place a check in the box The AC power plug and IEC 320 connectors on all Zebra Printers must bear the certification mark of at least one international safety organization listed below NOAGOOUOOKM we di Co YOO ar 0 O amp Cc Ww cz Unless indicated otherwise turn the power Off before performing any maintenance procedures to the printer To prevent damage to the spindles do not lubricate the S400 and S600 printer spindle assemblies To prolong printhead life when reinstalling the printhead secure the grounding strap to the printhead mounting screw Zebra printers comply with international regulations governing radiated emissions when using fully shielded data cables Data cabl
75. cable is disconnected from the printer and a loopback connector is attached in its place The serial loopback connector is a 9 pin D Type DB9P male with pins 2 and 3 and pins 4 and 6 tied together The parallel loopback connector is a standard 36 pin parallel connector mounted to a small printed circuit board This connector is available from Zebra Technologies as part 44680 For each of these diagnostic tests the printer transmits the test label format out of the data connector to the loopback connector The loopback connector passes the test label format to the printer as received data and the test label is printed Pause Key Loopback Test This test demonstrates the media movement capabilities of the printer and provides a test label to view while making print quality adjustments With the loopback connector in place press and hold PAUSE while turning the power On 1 After the Power On Self Test 500 head test labels print Each label backfeeds prior to printing and feeds to the rest position after printing A serialized number prints on each label Press PAUSE to stop and restart the printing operation The labels should look like the one in Figure 4 11 on page 4 18 Page 4 22 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Feed Key Rollback Test This test demonstrates the media movement capabilities of the printer and provides a test label to view while making
76. cate RV2 on the power supply board and adjust until the voltmeter reads the value determined in step 1 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 29 Section 4 Preventive and Corrective Maintenance Page 4 30 Table 4 4 Printhead Voltage Values S400 Only Printhead Voltage Formula 0 78 0 49 x Resistance Q Voltage VDC Resistance Voltage VDC 935 to 945 22 2 1092 to 1110 24 0 946 to 963 22 4 1111 to 1129 24 2 964 to 981 22 6 1130 to 1148 24 4 982 to 999 22 8 1149 to 1168 24 6 1000 to 1017 23 0 1169 to 1187 24 8 1018 to 1035 23 2 1188 to 1207 25 0 1036 to 1053 23 4 1208 to 1227 25 2 1054 to 1072 23 6 1228 to 1247 25 4 1073 to 1091 23 8 1248 to 1265 25 6 Table 4 5 Printhead Voltage Values S600 Only Printhead Voltage Formula V 0 78 0 673 x Resistance Resistance Q Voltage VDC Resistance Q Voltage VDC 680 to 688 22 2 795 to 808 24 0 689 to 701 22 4 809 to 822 24 2 702 to 714 22 6 823 to 836 24 4 715 to 727 22 8 837 to 850 24 6 727 to740 23 0 851 to 864 24 8 741 to 754 23 2 865 to 879 25 0 755 to 767 23 4 880 to 893 25 2 768 to 781 23 6 894 to 908 25 4 782 to 794 23 8 909 to 920 25 6 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 OM Ground Wire Power Supply Board Access RV2 throug
77. cccccciacetectncsieucesetvassenenescuceveniesnceevvanenes 4 49 Media Sensor Assembly Installation 2 4 49 Main Drive Belt Removal Replacement and Adjustment 4 51 Printers without the Peel Off Option 4 51 Printers Equipped With the Peel Off Option 4 51 Platen Koller Replacement 4 53 Ribbon Take Up Motor Replacement 22 cases center 4 55 Stepper Motor Replacement 4 56 Power Supply Board Removal 4 57 Power Supply Board Instalatori 4 58 AD Power Fuse Replacement cs a erat cece ha Qus supe Up EAE 4 61 vu Me Gnd ST NP 4 62 Memory Upgrade Kit Installation Instructions 4 62 Section 5 Maintenance and Assembly Drawings Pc goa Meme eo 5 1 448951 Rev 3 3 12 04 S400 S600 Maintenance Manual ix Table of Contents 1 ew Zebra x S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 List of Figures List of Figures Figure CAM ZANE 1 2 Figure 1 2 Communication Cable Connections 1 9 Figure 1 3 CASTING 1 10 Figure 1 4 RS 232 Signal ASCIl Code Data essere 1 12 1 5 25s T Pete 1 14 Figure e T Front
78. ce Manual Page 2 23 Section 2 Operations Overview Printing and Examining a Configuration Label First it is a good idea to print out a configuration label to check the existing darkness setting Also once the ideal parameters for a particular media and ribbon combination have been determined you can print a configuration label and save it for future reference To get a configuration label you can print a Cancel Key Self Test Refer to Figure 2 11 on page 2 16 To start the Cancel Key Self Test press and hold CANCEL while turning the printer On 1 The printer runs through a Power On Self Test then prints the configuration label The first item on the configuration label is the darkness setting It is displayed as a number between 0 and 30 The sample shown in Figure 2 11 on page 2 16 lists as darkness setting of 20 The factory default for this value is 10 If you already know the darkness setting for a particular combination of media and ribbon you may skip to Adjusting the Printer Darkness on page 2 26 Note Use full width media when performing the self tests Labels less than full width lose printing on the right side Printing may run on to the next label when using short labels Testing Print Darkness Feed Key Self Test Method Refer to Figure 2 11 on page 2 16 The Feed Key Self Test prints a series of labels at various plus or minus darkness settings relative to the current darkness setting and at various print
79. chase listed and shown for reference only u01 99S 5 5 D 5 D 2 gt 3 lt suime Maintenance and Assembly Drawings Figure 5 6 Tear Cutter Media Sensor Ribbon Guides and Media Guide This end of the ground strap attaches to the print mechanism assembly 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 5 13 1 9 enuen soueusjuley 0095 0075 VO GL E 146877 Table 5 7 Peel Off Option Front View Available only as HW30224 in quantities of 50 Available only as HW44147 in quantities of 25 Available only as HW44114 in quantities of 50 t Available only as HW07257 in quantities of 25 tt Available only as HW44386 in quantities of 25 Part No Description Qty 1 44463M A Platen Guide Rod Kit 1 2 30224 Crescent Ring 2 3 44147 Set Screw 2 4 144118 Shaft Collar 0 377 x 0 750 1 5 44349 B Upper Media Rod Kit 1 6 144398 Lower Guide Rod Kit 1 7 44346 Edge Guide 2 8 10473 Washer 4 1 9 44114 Screw M4 2 x 1 41 x 8 3 10 44391 Anti Static Brush 1 11 44218 Backing Rewind Hook 1 12 44284M Media Take Up Spindle Assembly 1 13 44390 Washer 0 500 x 0 377 x 0 020 3 14 07257 Flat Washer 0 438 1 41 x 25 1 15 44383 Ground Cable Assembly 1 16 4438611 Screw M4 x 0 7 x 16 1 17 44191 Ground Chain Assembly 1 Bold
80. commended only when normal tension hampers ribbon movement To place the spindle in the low tension position firmly push the spindle end cap until it clicks into place Spindle End Cap Extended normal Blades Aligned Align blades if ribbon width is greater than 2 4 in 61 mm Spindle End Cap Retracted low tension Figure 2 9 Dual Tension Ribbon Supply Spindle Adjustment Page 2 12 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Loading the Ribbon Notes For the direct thermal print method ribbon is not used and should not be loaded in the printer when performing media calibration Use ribbon that is wider than the media The smooth liner of the ribbon protects the printhead from wear and premature failure due to excessive abrasion Refer to Figure 2 10 1 Adjust the ribbon supply spindle position for normal or low tension refer to Adjusting the Ribbon Supply Spindle on page 2 12 Note Step 2 can be skipped if the ribbon width is 2 4 in 61 mm or less Align the blades on the two sections of the spindle as shown in Figure 2 9 Place the ribbon roll on the ribbon supply spindle so the ribbon unwinds toward the front of the printer from under the roll Ensure the core is pushed against the stop and the ribbon is aligned squarely with the core 4 Open the printhead assembly by turning the head open lever counterclockwise to the OPEN position 5 Thread the rib
81. d turn counterclockwise Remove the screwdriver Grasp the fuse holder cap with your fingers and remove from the fuse holder Remove the blown fuse from the fuse holder cap and insert the proper fuse Replace the fuse holder cap by placing it into the fuse holder Insert the tip of a flat blade screwdriver into the slot found on the fuse holder cap Press in on the cap and turn clockwise until the cap will no longer turn Remove the screwdriver ci W E AC Power S Fuse AC Power On Off Switch To open turn To close counterclockwise turn clockwise Figure 4 52 Fuse Holder Location 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 61 Section 4 Preventive and Corrective Maintenance Options Memory Upgrade Kit Installation Instructions af Caution V J Observe proper electrostatic safety precautions when removing handling and replacing i printed circuit boards 1 Turn the printer Off O and remove the AC power cord 2 Remove the data cable 3 Remove the rear cover Note It is not necessary to remove the main door or the front door if installing only the memory upgrade kit Mounting Holes Ground J4 J9 J3 J12 ad 14 a 5 i 2 p _ 2 2 MB J14 Back of a 2 a Board e lt Mounting Hole Ground 48
82. detailed in this section and adjust the tension as required Figure 4 22 Strip Plate Adjustment 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 27 Section 4 Preventive and Corrective Maintenance Liner Rewind Spindle Adjustment Refer to Figure 4 23 and follow the procedures below to adjust the liner rewind spindle tension 1 Turn the printer Off and remove all media and ribbon Tape the end of the 30 long Mylar tape Zebra part 01776 to the rewind spindle Wrap the Mylar strip around the rewind spindle in a clockwise direction Connect a 1000 gram spring scale to the Mylar strip Pull the spring scale to create the tension measurement oa onm The rotation of the rewind spindle created by pulling on the spring scale should be smooth and similar to the pace of sweep of a clocks second hand Ensure there is no platen movement when measuring the rewind spindle tension 7 When the rewind spindle is moving smoothly with even pull read the tension setting on the spring scale The correct tension should be 700 grams 100 50 8 Ifthe tension is incorrect use a pair of utility pliers and hold the locking nut stationary while rotating the rewind spindle until there is easy access to the locking Screws Use a wrench driver to loosen the locking nut screws 10 Using the utility pliers turn the nut clockwise to increase tension and counterclockwise to decrease tension 11 After achieving the correct
83. dia is out Off Normal condition Media and ribbon if used are properly loaded Direct Thermal Mode Ribbon is in printer Flashing Thermal Transfer Mode Ribbon is out Peel Off Mode Liner rewind spindle full Pause Status Indicator yellow On Printer has stopped all printing operations Off Normal condition Data Status Indicator green On Data processing or printing is taking place but no data is being received Off No data is being received or processed CANCEL was pressed and a format was successfully deleted from Single Flash the print queue Flashing Data is being received Slow Flashing The printer sent a stop transmitting command to the host computer 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 2 1 Section 2 Operations Overview Darken Status Indicator yellow Printer is in Configuration Mode See Adjusting the Printer On Darkness on page 2 26 and Top of Label Position Adjustment on page 2 28 for more information Off Normal condition Position Status Indicator yellow Printer is in Configuration Mode See Tear Off Position Adjustment on page 2 27 for more information Off Normal condition Calibrate Status Indicator yellow On Printer is in Configuration Mode See Top of Label Position Adjustment on page 2 28 for more information Off Norm
84. ditions by either stopping printing or turning on an LED Troubleshooting Chart Cutter Related Table 3 7 Troubleshooting Chart Cutter Related The cutter is not cutting labels cleanly Symptom Diagnosis Action Gutter Node skewed OT Dirty cutter Clean cutter module stuck labels Dirty cutter Clean cutter Dull cutter blades Replace cutter module Jamming up with labels or labels being cut more than once Dirty cutter Clean cutter Label length too short Increase label length 44895L Rev 3 3 15 04 Labels not being cut at all Cutter option not available Cutter option installed at the factory Noncutter units not retrofittable Cutter option not installed or enabled S400 S600 Maintenance Manual Check cutter configuration Page 3 9 Section 3 Troubleshooting Page 3 10 Table 3 8 Printer Status Sensors Sensor What It Monitors How It Works Printhead Sensor Checks open closed status of printhead lever If printhead is open printhead LED flashes Media Sensor Checks for proper media loading If non continuous media is used sets label length for individual labels If printer runs out of media paper ribbon LED turns on Ribbon Sensor Monitors presence of ribbon If printer runs out of ribbon paper ribbon LED flashes Label Available Sensor Peel Off option only In Peel Off Mode chec
85. e Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 10 11 12 13 14 15 16 17 18 20 21 22 23 Refer to Figure 4 39 on page 4 48 Reinstall the C clip in the groove on the shaft Place a 0 020 0 508 mm shim or feeler gauge between the spindle assembly and the ribbon supply spindle subassembly Slide the outer spindle on the shaft Align the large notch on the outer spindle with the corresponding protrusion on the spindle assembly The protrusion on the spindle assembly is in line with the metal core clip Carefully slide the outer spindle on to the spindle assembly to the first notch Refer to Figure 4 41 on page 4 48 If it is pushed on too far simply pull the outer spindle away from the spindle assembly until it looks like Figure 4 40 on page 4 48 Slide the cup and spring assembly on the shaft While applying light pressure against the cup and spring assembly and with the 0 020 shim or feeler gauge between the spindle assembly and the ribbon supply spindle sub assembly tighten the two set screws on the cup and spring assembly Note Rotate the outer spindle to access the set screws Once the cup and spring assembly is tightened remove the shim feeler gauge The outer spindle and spindle assembly should have some play on the shaft When rotated counterclockwise the outer spindle and spindle assembly spins freely until it encounters the spring Con
86. e base Slot 5 Carefully pry the front of the power supply base downward to remove power supply Figure 4 50 Power Supply Assembly Removal 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 59 Section 4 Preventive and Corrective Maintenance Power Supply Power Supply r Supply i el a Screws ima TAAN mE ii io Dl d ey SS Power Supply Power Supply Base Figure 4 51 Power Supply Assembly Exploded View Page 4 60 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 AC Power Fuse Replacement Caution The replacement fuse must have the ratings specified below Serious damage may occur if a higher rated fuse is installed Refer to Figure 4 52 A user replaceable AC power fuse is located just to the left of the power switch For 120 VAC operation a F5A 250V fuse is used For 220 VAC operation a F3A 250V is used Note Do not rely on a visual inspection to determine whether a fuse is blown Always turn the printer off and remove the power cord Then remove the fuse from the fuse holder or circuit board and test with an ohmmeter A good fuse gives a short 0 ohm indication 1 Turn the printer Off O and remove the AC power cord 2 Insert the tip of a flat blade screwdriver into the slot found on the fuse holder cap Press in on the cap an
87. emperature 4 moving printer to a warmer area 15 Pause LED flashing walling JORUSer Remove Label peeled label S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Troubleshooting Table 3 2 Troubleshooting Chart Problems with LED Indications Cont Symptom Diagnosis Action 16 Data LED single flash No action required a format deleted 17 Data LED flashing Printer receiving data dates received Printer sent a stop 18 Data LED flashing slow transmitting to the host No action required computer Pause and Data LED 19 alternately flashing but all Firmware error Download and install firmware other LEDs on 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 3 5 Section 3 Troubleshooting Page 3 6 Table 3 3 Troubleshooting Chart Problems with LED Indications Symptom Diagnosis Action Dots missing in printed area of label Dirty printhead Clean printhead Print quality problems Check print quality Printhead element going bad Replace printhead Loss of printing registration on labels Possible media sensor problem Adjust media sensor Replace media sensor Printer set for non continuous media but continuous media loaded Set printer for correct media Loss of printing registration on labels for
88. eplace the tear off plate 5 mm Hex Screws Figure 4 29 Tear Off Plate Control Panel Assembly Removal Caution Observe proper electrostatic safety precautions when removing handling and replacing printed circuit boards 1 Turn the power and remove the AC power cord Remove the front door Remove the rear cover Refer to Figure 4 30 page 4 37 Remove the screw securing the control panel assembly Remove the screw that secures the ribbon cable strain relief to the main frame Refer to Figure 4 31 on page 4 39 Detach the control panel ribbon cable from the main logic board J12 7 Grasp the control panel assembly by its sides and carefully lift it out of the base guide slots Page 4 36 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Control Panel Circuit Board Replacement 1 Turn the printer Off O and remove the AC power cord Remove the control panel assembly 3 Refer to Figure 4 30 Remove the control panel board from the control panel cover by removing the two mounting screws 4 Carefully align the replacement board over the mounting holes on the control panel cover and reinstall the two mounting screws 5 Remount the control panel assembly in the base guide slots and secure into the main frame by reinstalling the mounting screw 6 Refer to Figure 4 31 on page 4 39 Reattach the control pane
89. es a batch of labels printing stops The speed and tension of the rewind operation is strictly a function of the external rewind unit 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 1 1 Section 1 Description of Equipment Specifications Agency Approvals 9 92 Q 00 699 vedi e Sy OQ 0 BP Cc mw cS Figure 1 1 Safety Organizations Bar Codes The following bar codes are available Check digit calculation where applicable Codabar Supports ratios of 2 1 and 3 1 Codablock Code 11 Code 39 Supports ratios of 2 1 and 3 1 Code 49 Code 93 Code 128 Supports serialization in all subsets B and C and UCC Case C Codes Datamatrix EAN 8 EAN 13 EAN EXTENSIONS Industrial 2 of 5 Electrical Requirements Auto select 110 VAC 20 or 230 VAC 15 48 62 Hz 3 Amps 110 VAC 1 5 Amps 230 VAC Interleaved 2 of 5 Supports ratios of 2 1 and 3 1 and supports Modulus 10 Check Digit LOGMARS MaxiCode MSI PDF 417 Plessey POSTNET QR Standard 2 of 5 UPC A UPC E UPC EXTENSIONS Micro PDF417 Environmental Ranges for Operation and Storage Operating Temperature 40 F to 105 F 5 C to 40 C Storage 40 F to 140 F 40 C to 60 C Relative Humidity Operating 20 to 85 non condensing Relative Humidity Storage 5 to 85 non condensing Page 1 2 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Description of Equipment Section 1 Fonts
90. es must be fully shielded and fitted with metal or metalized connector shells Required shielded data cables and connectors prevent radiation and reception of electrical noise Use of unshielded data cables may increase radiated emissions above the regulated limits Page 4 2 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Equipment Safety Tips Continued 9 ensure optimum printhead life observe proper electrostatic safety precautions for example ESD Electrostatic Service Device wrist straps when removing handling and replacing the printhead Zebra recommends using solvent containing 90 isopropyl alcohol and 10 distilled water for cleaning Printheads Platen Rollers Peel Off Roller Media Path Peel Tear Bar Spindles Ribbons used in the printers must be as wide as or wider than the media If the ribbon is narrower than the media areas of the printhead will be unprotected and subject to premature wear To ensure the printer has proper ventilation and cooling do not place any padding or cushioning material under the unit because this restricts air flow Install Zebra printers on a solid level surface of sufficient size and strength to accommodate the physical dimensions and weight of the unit The area enclosure in which the printer will operate must meet the environmental conditions specified in the maintenance manual or User s Guide Electrical power must be
91. eys and turning power on The X in the four columns on the right indicates which key or keys are pressed The V indicates that the self test is one that can be performed by the operator or maintenance personnel These tests produce sample labels and provide specific information that helps the operator or maintenance personnel determine operating conditions for the printer Self tests without the v are for repair and maintenance of the printer and should be performed only by maintenance personnel Detailed information on the operator self tests immediately follows this chart Detailed information on maintenance personnel only self tests are found in Preventive and Corrective Maintenance on page 4 1 along with extended diagnostics Note The printer data cable must be removed from the printer except for the Mode Key Self Test prior to running the self tests Table 2 1 Self Test and Calibration Quick Reference Chart Operator Description Pause Feed Cancel Mode Cancel Key Self Test Produces printer configuration label printout X Pause Key Self Test Produces test 4 printouts for adjustments 15 or 50 labels X 2 or 6 ips Feed Key Self Test Produces test printouts to determine the best darkness X setting Mode Key Self Test Produces a Communications Diagnostic Mode printout T Factory Default Reset Resets printer configuration to factory default values Communicatio
92. f to ensure proper operation Once completed only the Power LED remains on If other LEDs are on refer to Troubleshooting on page 3 1 Additional Printer Self Tests These tests produce sample labels and provide specific information that helps the operator determine the operating conditions for the printer Each self test is enabled by pressing and holding in a specific key while turning the power switch On 1 Press the key until the front panel LEDs turn on When the Power On Self Test is complete the selected printer self test automatically starts Notes When performing self tests except for the Mode Key Self Test disconnect the printer data cable from the printer Use full width media when performing self tests Labels less than full width lose printing on the right side Printing may run on to the next label when using short labels When canceling a self test before its completion turn the printer power switch Off O and back On 1 When performing the self tests in Peel Off Mode remove the labels as they become available When the cutter option is installed and enabled labels printed during the self test are automatically cut as they are printed Page 2 14 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Printer Self Test Reset Default Quick Reference Chart Table 2 1 lists the self tests and default resets that can be accessed by pressing and holding a front panel key or k
93. face Parallel Cable L AC Power Cable AC Power On Off Switch Figure 1 2 Communication Cable Connections 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 1 9 Section 1 Description of Equipment RS 232 Interconnection The printer is configured as Data Terminal Equipment DTE Figure 1 3 illustrates the connections required to interconnect the printer with the 9 pin or 25 pin serial port connector on a PC 25 Pin D Sub to 9 Pin D Sub Null Modem Cable DB 25P DB 9S Connector Connector to PC to Printer 2 TXD DCD 1 3 RXD RXD 2 RTS TXD 4 3 5 CTS DTR 4 6 DSR GND 5 7 GND DSR 6 DCD RTS 8 7 50 DTR 9 D Sub to 9 Pin D Sub Null Modem Cable DB 9S DB 9P Connector Connector to PC to Printer 1 DCD 4 2 RXD RXD 2 3 TXD TXD 3 4 DTR DTR 4 5 GND GND 5 6 DSR DSR 6 7 RTS RTS 7 8 CTS CTS g Figure 1 3 RS 232 Connections Page 1 10 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Description of Equipment Table 1 8 DB 9P Pinouts Pin Description Not used RXD RS 232 Receive Data This is the serial data input to the printer from the host TXD RS 232 Transmit Data This lead is the serial data output from the printer It is on this lead that printer status or XON XOFF information is relayed to the host DTR RS 232 Data Terminal Ready This lead is a control output fr
94. h cutout in base RV2 Figure 4 24 Printhead Voltage Adjustment Potentiometer Location 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 31 Section 4 Preventive and Corrective Maintenance Cutter Voltage Adjustment Caution Use caution around cutter blades Keep fingers away from blades The voltage applied to the printhead is the same voltage applied to the cutter module The specific voltage applied to the cutter motor is controlled by the home position potentiometer There are three cases in which you must adjust the cutter module s home position potentiometer Before placing a new cutter module into service printhead is installed on the printer cutter module is installed on a printer other than the one it was previously adjusted for 1 Turn the printer power O Load media and ribbon if not already installed 2 Attach the new cutter module to the cutter cable connector on the printer and lay it on the table or on the inside of the printer s open front door Note Do not mount the cutter module at this time 3 Perform a Pause and Cancel Key test press and hold PAUSE and CANCEL while turning the printer On Note Do not allow the printed labels to pass through the cutter module Let them accumulate on the table or floor 4 Refer to Figure 4 25 on page 4 33 While the labels are printing observe where the sensor disc on the cutter module
95. he User s Guide has caused defect in the thermal printhead for which a warranty claim is made Software Software is warranted to be free of defects in material and workmanship for 30 days from the date of purchase In the event of notification within the warranty period of defects Zebra will replace the defective diskette or documentation Batteries Mobile printer batteries are warranted to be free of defects in material and workmanship for 90 days from date of purchase In the event of notification within the warranty period Zebra will replace the defective battery provided there had not been damage resulting from user abuse Parts All parts maintenance kits options kits and accessories are warranted to be free of defects in material and workmanship for 90 days except where otherwise denoted from date of purchase This warranty becomes void if the item is modified improperly installed or used or damaged by accident or neglect 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual iii Table of Contents SUPPLIES PRODUCTS Supplies are warranted to be free from defect in material and workmanship for a period of six 6 months for media and twelve 12 months for ribbon from the date of shipment by Zebra This is provided the user has complied with storage guidelines handling and usage of the supplies in Zebra printers Zebra s sole obligation under these warranties is to furnish parts and labor for the repair or possible replacement
96. he position adjustment slots to change the printhead position forward and rearward and adjust for parallelism 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 23 Section 4 Preventive and Corrective Maintenance 10 11 12 13 14 15 Note The desired result produces the darkest printing evenly across the label and lines printed on the test labels that are parallel to the top of the label Press PAUSE let several more labels print and then press PAUSE again Examine this set of labels and make any additional adjustments Repeat steps 10 and 11 until consistent print quality and parallelism is achieved Tighten the two printhead position locking screws Press PAUSE let several more labels print then press PAUSE again Examine this set of labels to make sure the print quality and parallelism are still good If the adjustment slipped when you tightened the printhead position locking screws loosen them then repeat steps 9 13 until the print quality and parallelism are good Tighten the printhead position locking screws Notes If after the above adjustments the print quality is even but not dark enough perform Adjusting the Printer Darkness on page 2 26 until optimum darkness is achieved If optimum darkness still cannot be achieved it may be necessary to perform the Printhead Pressure Adjustment on page 2 29 To extend the life of the printhead use the lowest toggle pressure that produces
97. he procedures in Media Loading on page 2 6 Ensure minimal sideways movement during the printing process by positioning the left edge of the liner even with the edge guide mark on the tear off peel off plate Position the outer media guides against the outside edge of the media but no so tight as to bind the material When the rewind power roller is properly adjusted the liner should have even tension across its entire width and be wrapped snugly around all guides and rollers If the tension is not even the liner may slide walk to the left or the right as printing occurs This can cause print registration problems on the labels Note Balancing the tension increases the reliability of the printer to provide properly printed labels by preventing the liner from walking Adjusting the Rewind Power Roller 1 Referto Figure 2 18 Locate the power roller adjustment screw 2 Use a screwdriver to turn the power roller adjustment screw counterclockwise to increase the tension on the right side of the rewind power roller Turn the power roller adjustment screw clockwise to decrease the tension on the right side of the rewind power roller Note The adjustment changes the position of the right end of the rewind power roller only The left end remains stationary 3 Use Feed Key Self Test to print several labels to ensure tracking is maintained and tension on both edges of the liner remains consistent Remember to remove each labe
98. he shoulder bolt Rewind Spindle Drive Belt Adjustment When a scale reading of 1800 grams 225 grams creates a deflection of 1 4 6 4 mm tighten the shoulder bolt Reinstall the media sensor assembly main logic board main door and rear cover Reload media and ribbon Reconnect the AC power cord and data cable Turn the printer On 1 and test for proper operation Rewind Spindle Belt Tension 2300 gm 225 gm Shoulder bolt and idler pulley for rewind spindle belt adjustment Shoulder bolt and idler pulley for main drive belt adjustment Main Drive Belt Tension 1800 gm 225 gm Figure 4 44 Peel Off Drive Belt Adjustment S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Platen Roller Replacement 1 Turn the printer Off O and remove the AC power cord and the data cable Remove media and ribbon Remove the main door rear cover and control panel assembly ON Remove the main logic board and media sensor assembly Note Scribing a mark into the main frame indicating the position of the idler pulley prior to performing step 5 may help when adjusting the belt tension 5 Refer to Figure 4 45 on page 4 54 Loosen the shoulder bolt holding the idler pulley in position until the pulley freely moves up and down Remove the main drive belt Remove the screw securing the platen roller ground chain assembly to the main
99. ibration Reference Table 4 17 S400 S600 Maintenance Manual Extended Diagnostics 4 22 Feed Key Rollback Test 4 23 Head Temp Test Label 4 20 4 21 Left Wrinkle Label 4 19 Lower Smear Test Label 4 22 Pause amp Cancel Key Label 4 18 Pause and Cancel Key Self Test 4 16 Pause Key Loopback Test 4 22 Right Wrinkle Label 4 19 Self Test Reference Table 4 17 Sequence of Formats 4 18 Speed A Label 4 20 Upper Smear Test Label 4 21 Usable Area Speed A Label 4 20 Downloading Firmware 4 39 E Electrical Adjustments 4 29 Cutter Voltage 4 32 4 33 Printhead Voltage 4 29 4 31 Electrical Requirements 1 2 Electronics System Block Diagram 1 14 Environmental Ranges 1 2 Equipment Safety 4 2 External Rewind Mode 1 1 F Factory Assistance 3 11 Factory Default Reset 2 19 Factory Default Values 2 20 Feed and Pause Key 2 19 Feed Key 2 3 2 18 Feed Key Rollback Test
100. icating the changes have been saved To return to Printing Mode turn the power off then on FES FO394 25 AA oE 46 53 5E 46 4F 33 39 34 2C 32 35 5E 41 41 N 18 10 FDCOO00 2C 31 38 2C 31 30 5E 46 44 28 30 30 Pr dr A Amir Ar el 29 39 39 39 2D 39 39 39 39 SE 46 53 BA FOO 50 AAN 18 SE 46 4F 30 2C 35 30 5E 41 41 4E 2C 31 38 2C 1 O0 FDCENTER STA 31 30 5E 46 44 43 45 54 45 52 20 53 54 41 Figure 2 14 Mode Key Self Test Printout 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 2 19 Section 2 Operations Overview Table 2 2 Factory Default Values Page 2 20 S400 S600 Maintenance Manual Parameter Default Value Backfeed Default Baud 9600 Calibration Auto Darkness 10 Data Bits 8 bits character Error Detection On Handshake XON XOFF Head Close Calibration Label Top 00 Left Position 000 Media Type Non Continuous Web Sensing Parallel Port Enabled Parity None Print Method Thermal Transfer Print Mode Tear Off Print Width 104 mm ZPL Control Prefix 7E ZPL Delimiter Char 2 ZPL Format Prefix 5E ZPL Mode ZPL Il 44895L Rev 3 3 12 04 Operations Overview Calibration Auto Calibration Auto calibration occurs when the printer is turned On 1 or when the printhead is opened and closed with the printer turned on During the procedure the printer automatically determines the media type l
101. in Assembly to idler pulley Ribbon Tension Motor Assembly Figure 4 47 Ribbon Take Up Motor 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 55 Section 4 Preventive and Corrective Maintenance Stepper Motor Replacement Page 4 56 1 oa 10 11 12 13 14 Turn the printer Off O and remove the AC power cord and data cable Remove media and ribbon Remove the main door and rear cover Remove the main logic board Remove the main drive belt Refer to Figure 4 48 Remove the screw underneath the upper media guide assembly holding the stepper motor to the main frame Refer to Figure 4 49 on page 4 57 Disconnect the stepper motor cable J1 from the power supply board Carefully grasping the stepper motor turn it counterclockwise and remove it from the slots Reverse steps 6 through 8 to install the replacement stepper motor Replace the main drive belt and adjust the tension Replace the main logic board Replace the rear cover and main door Reload media and ribbon Reconnect the AC power cord and data cable Turn the printer On 1 and test for proper operation Printhead Assembly Upper Media Guide Assembly Stepper Motor Mounting Screw Stepper Motor Figure 4 48 Stepper Motor Media Side 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Stepper Motor Ground Wire Stepper
102. in factory service and repair Zebra Technologies USA Zebra Technologies Europe Limited UK Phone 1 847 913 2259 Phone 44 0 1494 472872 Fax 1 847 913 2578 Returning Equipment A Return Materials Authorization RMA number is required for all equipment being returned Contact Zebra Technologies Technical Support Department to obtain an RMA number Equipment returned for service without prior authorization may be refused Whenever possible the original shipping container should be used Should it become necessary to ship your printer carefully pack the printer in a suitable container to avoid damage during transit A note describing the failure must be enclosed with the unit Replacement shipping containers can be ordered by contacting Zebra Technologies Technical Support Department If other containers are used packaging material similar to the original factory packaging should be used Remove all media from the printer Enclose the unit in a protective dustproof bag and ensure that the unit floats in an outer carton of shock absorbing material 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 3 11 Troubleshooting Section 3 Page 3 12 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Section 4 Preventive and Corrective Maintenance Maintenance Concepts Maintenance for the Zebra Stripe S400 and S600 thermal transfer demand printers can be divided into two basi
103. ing Language ZPL Il ASCII data commands provide the following features e Downloadable graphics scalable and e Communicates in printable ASCII bitmap fonts and formats with data characters compression e Controlled via mainframe mini Bit image data transfer and printing PC or other data entry device including mixing of text and graphics Serialized fields in spec OCR A e Format inversion and OCR B Mirror image printing e UPC EAN at nominal 100 Four position field rotation 0 90 180 270 degrees only Slew command RAM and Memory Card e Programmable quantity with print pause 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 1 7 Section 1 Description of Equipment Communication Interfaces Serial Port 0 RS 232 DB 9 o Baud Rate 110 300 600 1200 2400 4800 9600 14400 19200 28800 38400 57600 Parity disabled even odd Stop Bits 7 or 8 data bits Handshake XON XOFF or DTR DSR Error Detection on or off lt gt o oc A null modem crossover cable must be used to connect to a host 9 pin connector see Figure 1 2 Anull modem cable must be used to connect to a host 25 pin connector see Figure 1 2 Parallel Port 36 Centronics o Bi directional port o Parallel operation can be enabled or disabled in the firmware 9 8 bit Parallel Data Interface supporting IEEE 1284 bi directional nibble mode e Ethernet o Thinnet and
104. ing process or after a major overhaul of the mechanical assemblies This test prints seven preprogrammed formats at 6 ips and 2 ips The printer automatically pauses after each format Table 4 3 shows the sequence of formats Refer to Figures 4 12 through 4 18 for sample label formats Page 4 16 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Table 4 2 Self Test and Calibration Reference Table Operator Description Pause Key Feed Key Cancel Key Mode Key 4 Cancel Key Self Test Produces a printer configuration label printout X Pause Key Self Test Produces test printouts for adjustments 15 or 50 labels 2 or 6 ips X Feed Key Self Test Produces test printouts to determine the best darkness setting Mode Key Self Test Produces a communications diagnostic mode printout Factory Default Reset Resets printer configuration to factory default values 1 5 55 Communication Parameter Default Reset Resets printer communication parameters to 9600 baud 8 bit work length no parity and 1 stop bit S Manual Calibration Printer determines the media type label length media and ribbon sensor settings and printing method Pause and Cancel Key Self Test Serialized test printouts verify proper printer operation 500 maximum Ribbon Parameter Calibration Sets ribbon parameters
105. inter data cable Remove media and ribbon Remove the main door and rear cover Refer to Figure 4 31 on page 4 39 Disconnect the wiring harness from J11 on the main logic board Refer to Figure 4 42 on page 4 50 Slide out the upper media guide assembly Locate the two mounting screws securing the media sensor assembly to the main frame Using a long reach magnetic tip screwdriver remove the two mounting screws Remove the media sensor assembly Media Sensor Assembly Installation 1 gt A Remove the wiring harness from W1 the media sensor board and connect it to W1 on the replacement board Install the media sensor assembly on to the main frame ensuring the wiring harness attached to W1 on the media sensor board is threaded through the cutout in the main frame Using a long reach magnetic tip screwdriver carefully reinstall the two mounting Screws Refer to Figure 4 31 on page 4 39 Reconnect the wiring harness from the media sensor board to J11 on the main logic board Refer to Figure 4 42 on page 4 50 Reinstall the upper media guide assembly Reinstall the media and ribbon Reinstall the main door and rear cover Reconnect the AC power cord and data cable Turn the printer On and recalibrate the media Verify proper printer operation 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 49 Section 4 Preventive and Corrective Maintenance Media Sensor Upper Media Assembly
106. inters are versatile label and ticket printers designed to print high quality bar codes various sizes and styles of alphanumeric characters and graphics in either the thermal transfer or direct thermal mode The Zebra Stripe printers have the flexibility to meet a wide variety of applications Zebra Programming Language 11 ZPL Il allows the programmer to format the printed material ZPL II is transparent to protocol converters and allows the Zebra Stripe printers to be easily integrated with most systems and host mainframes Printer Operating Modes Tear Off Mode When the media is in the rest idle position the webbing between labels is over the tear off peel off plate To print a label the printer first backfeeds the media until the start of the label is directly under the printhead then prints the entire label The operator then tears off the label and a new label can be printed Peel Off Mode When the media is in the rest idle position the start of the label to be printed is slightly in front of the printhead To print a label the printer first backfeeds the media until the start of the label is directly under the printhead then prints the entire label In this mode once the label is printed the media passes over the tear off peel off plate at a sharp angle The liner is peeled away from the label and winds around the liner rewind spindle The media feeds forward until most of the label hangs loose from the liner The label availa
107. ior to cleaning If the power is turned off all label formats images and parameter settings stored in RAM will be lost Permanent parameter settings stored in Flash memory will be retained When power is turned back on it may be necessary to reload some information items into the printer s memory 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 7 Section 4 Preventive and Corrective Maintenance Printhead and Platen Roller Cleaning Procedure Page 4 8 1 Boo mm el Refer to Figure 4 1 Open the main door and front door Open the printhead by turning the locking lever counterclockwise Remove the media and ribbon if present Refer to Figure 4 2 on page 4 9 Use a cleaning swab to wipe the print elements from end to end Allow a few seconds for the solution to evaporate Rotate the platen roller and clean thoroughly with a cleaning swab Brush or vacuum any accumulated paper lint and dust away from all of the rollers and the media and ribbon sensors Reload the ribbon and or media Close and latch the printhead Close the main and front doors and restore power if previously turned off Run the Pause Key Self Test to check print quality Main Door Tab Front Door Figure 4 1 Main Door and Front Door 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 PAPER R Ogo PAUSE FEED Cd X CANCEL Wonen aw POSI
108. ks to see whether a label is available Once a label prints it passes between the two parts of this sensor and causes printer to pause When label is removed printing resumes Liner Rewind Spindle Full Sensor Peel Off option only Senses when liner rewind spindle is full of used liner S400 S600 Maintenance Manual When spindle is full paper ribbon LED flashes 44895L Rev 3 3 15 04 Troubleshooting Factory Assistance Should you encounter any problem that cannot be corrected with the aid of this manual and you have Internet access check out ZIP Support If you cannot solve your problem via ZIP Support or do not have Internet access contact your Distributor or Zebra Technologies Technical Support Department to minimize or avoid printer downtime ZIP Support e identify diagnose and resolve your questions one brief easy online session ZIP Support is updated regularly by Zebra product experts guaranteeing the most comprehensive timely product information available High speed accurate intuitive database uses text and graphics Available any time all time zones 24 hours a day 365 days a year Access ZIP Support at http support zebra com Technical Support Zebra Technologies USA Zebra Technologies Europe Limited UK Phone 1 847 793 2259 Phone 44 0 1494 536644 Fax 1 847 913 2578 Fax 44 0 1494 450103 Repair Service Department For
109. l as it is automatically peeled away from the liner Example 1 Figure 2 18 illustrates an improperly adjusted rewind power roller On the left side the liner is not contacting the rewind power roller This is because the liner has more tension on the right edge than on the left By turning the power roller adjustment screw clockwise the tension in the right side decreases Adjust screw until the tension is equal on the left and right sides of the rewind power roller and the liner tracking is maintained Page 2 30 S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Power Roller Adjustment Rewind Power Roller Figure 2 18 Liner Rewind Power Roller 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 2 31 Operations Overview Section 2 Page 2 32 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Troubleshooting Section 3 Troubleshooting Troubleshooting Charts Consult the following charts when troubleshooting the printer List of Tables Table 3 1 LED Quick Reference 3 2 Table 3 2 Troubleshooting Chart Problems with LED Indications 3 3 Table 3 3 Troubleshooting Chart Print or Print Quality Related Problems 3 6 Table 3 4 Troubleshooting Chart Wrinkled Ribbon 3 8 Table 3 5 Troubleshooting Chart Jammed or Stuck
110. l ribbon cable to the main logic board J12 Reinstall the ribbon cable strain relief to the main frame Reinstall the rear cover and front door Control Panel Cover Control Panel Ribbon Cable Strain Relief Figure 4 30 Control Panel Assembly 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 37 Section 4 Preventive and Corrective Maintenance Main Logic Board Removal YI Caution Observe proper electrostatic safety precautions when removing handling and replacing printed circuit boards Page 4 38 m Turn printer and remove the AC power Remove the printer data cable Remove the rear cover Refer to Figure 4 31 on page 4 39 Note the position of all ribbon cable connectors and wire harness connectors Remove all connectors to the main logic board Remove the three screws securing the main logic board Carefully grasping both sides of the main logic board pull the board straight up from the power supply connector and out of the unit A gentle rocking motion may be necessary to release it from the power supply board Main Logic Board Installation 1 Refer to Figure 4 31 on page 4 39 Align connector J8 at the bottom of the main logic board with the mating power supply board connector J2 Press the main logic board straight down until connector J8 has seated completely onto the power supply board
111. m and Printhead Assembly Part No Description Qty 44999M A Printhead Assembly S400 1 44998M A Printhead Assembly S600 1 2 10460 Nut M3 x 2 4 x 5 5 2 44180M B Print Mechanism Assembly S400 1 E 44204M B Print Mechanism Assembly S600 1 44527 Printhead Cable Assembly S400 1 44920 Printhead Cable Assembly S600 1 44386 5 M4 x 0 7 x 16 1 07257 Flat Washer 0 438 x 0 188 x 0 049 1 304664 Washer 0 26 x 0 63 x 0 06 1 Available only as HW10460 in quantities of 25 Available only as HW44386 in quantities of 25 Available only as HW07257 in quantities of 25 t Available only as HW30466 in quantities of 25 Bold Part available for purchase Light italic Part not available for purchase listed and shown for reference only u01 99S 5 5 D 5 D 5 a gt 3 z lt suime Maintenance and Assembly Drawings pue 6 6 5 11 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 21 5 enuen 0095 0075 VO GL E 146877 Table 5 6 Cutter Media Sensor and Ribbon Guide Table 5 6 Tear Cutter Media Sensor and Ribbon Guide Part No Description Qty Part No Desc
112. main logic board main door and rear cover Reload media and ribbon Reconnect the AC power cord and data cable Turn the printer On 1 and test for proper operation Printers Equipped With the Peel Off Option Caution printed circuit boards f M Y Observe proper electrostatic safety precautions when removing handling and replacing Boe Turn the printer Off O and remove the AC power cord and the printer data cable Remove media and ribbon Remove the main door and rear cover Remove the main logic board and media sensor assembly Note Scribing a mark into the main frame indicating the position of the idler pulley prior to performing the next step may help when adjusting the belt tension 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 51 Section 4 Preventive and Corrective Maintenance 10 11 12 Page 4 52 Refer to Figure 4 44 For the particular belt being replaced loosen the shoulder bolt holding the idler pulley in position until the pulley freely moves up and down Remove the main drive belt and or rewind spindle drive belt and install the new one Hook a 2200 gram spring scale to the new main drive or rewind spindle drive belt dependant on which one is being replaced adjusted and carefully pull up on the idler pulley to increase belt tension Main Drive Belt Adjustment When a scale reading of 900 grams 225 grams creates a deflection of 1 4 6 4 mm tighten t
113. media through the printhead assembly as shown in Figure 2 6 Note end of the media must be positioned on top of the platen roller 4 Adjust the media supply guide and media guide against the outer edge of the media Note These guides must not cause pressure or excessive drag on the media 5 With the end of the media positioned directly on top of the platen roller close the head open lever The printer automatically feeds out and cuts one label when power is turned On 1 6 Perform the media sensor position adjustment Page 2 6 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Ribbon Release Button Head Open Lever Media Supply CLOSED Media Sensor Assembly Media Guide Media Supply Guide Figure 2 4 Roll Media Loading Ribbon Release Head Open Button Ribbon Lever Supply Media Supply Rear lioaded Fanfold Media Bottom Loaded nfold Media Media Guide Media Supply Media Supply Guide Hanger Media Sensor Assembly Figure 2 5 Fanfold Media Loading 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 7 Section 2 Operations Overview Ribbon Release Button Ribbon Head Open Supply Lever End of media on top of platen roller Cutter Module Media Supply Hanger Media Sensor Assembly Media Guide Media Supply Guide Figure 2 6 Cutter Mode Media Loading Head Open Lever Ri
114. mooth font CG Triumvirate Bold Condensed has the ability to expand using the standard Zebra expansion routines expanding on a dot by dot basis height and width independent while maintaining smooth edges to a maximum of 1500 x 1500 dots International Characters IBM Code Page 850 International Character Sets available in fonts D E F and 2 through software control Optional Fonts Factory Field Installed Scalable Futura CG Triumvirate CG Palacio Univers GC Triumvirate Condensed Century Schoolbook Cyrillic East European Turkish Greek Factory Field Installed Bitmapped Futura Bold CG Triumvirate Bold CG Palacio Bold CG Times Bold Univers Bold CG Triumvirate Bold Condensed 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 1 3 Section 1 Page 1 4 Media Considerations Description of Equipment Table 1 2 Media Specifications S400 S600 Minimum media width 0 75 19 mm Maximum media width 4 5 114 mm Maximum media width cutter installed 4 0 102 mm Minimum media length Tear Off 0 63 16 mm Minimum media length Peel Off 1 0 25 mm Minimum media length Cutter 1 5 38 mm Maximum media length 36 914 mm 39 990 mm Total thickness includes liner 0 0023 to 0 012 0 058 mm to 0 305 mm Core size 3 0 76 mm Maximum roll diameter 8 203 mm Minimum Inter label gap 0 08 2 mm 10 118 3 mm preferred Maximum Inter l
115. n Parameter Default Reset v Resets printer communication parameters to 9600 baud 8 bit work length no parity and 1 stop bit Manual Calibration Determines media v type label length media and ribbon sensor X X X settings and printing method Pause and Cancel Key Self Test Serialized test printouts that verify proper X X printer operation 500 maximum Ribbon Parameter Calibration Sets ribbon parameters to factory default values 5 Note This test is performed only when sensor assemblies are replaced or when manual calibration fails A Manual Calibration must be performed after the Ribbon Parameter Calibration Feed and Cancel Key Self Test Preprograms label test formats for major X X overhauls 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 15 Section 2 Operations Overview Page 2 16 Cancel Key Self Test Refer to Figure 2 11 This self test prints a listing of the printer s configuration parameters stored in configuration EEPROM memory Configuration can be changed temporarily for specific label formats or ribbon and label stock or permanently by saving the new parameters in memory Saving new parameters occurs whenever a printer configuration procedure is performed To start the Cancel Key Self Test press CANCEL while turning the power on The printer first runs through a Power On Self Test then prints the configuration label PR
116. n the printout gt Example If the best label has Relative Darkness 3 press FEED three times 3 Ifthe value on the Feed Key Self Test printout is a negative value press CANCEL W the number of times indicated on the printout h Example If the best label has Relative Darkness 2 press CANCEL twice 4 Press MODE three times The mode LEDs flash to indicate the settings have been saved to memory 5 Press PAUSE to exit Pause Mode and turn off the pause LED Positive value Negative value Press FEED A Press CANCEL V 3 times during 2 times during adjustment 2 adjustment Relative Darkness 03 Print Speed 2 in sec Relative Darkness 2 Print Speed 2 in sec V1 Oo 5 V1 5 6 Saat B Im 2 mA 50 y 58 E 595 5 E X 5 A el 1 0 2 3 7 men 2 es Z 5 x 7 5 i 0 08 o 4 a SSS 02 T 0 7 zm x 2 a a _ 1 _ B DE NN DTE EL M E 4 i t 00 quM sm Ml s WATE EE
117. nd Off 1 44180M B Print Mechanism Assembly S400 1 44204M B Print Mechanism Assembly S600 1 12 30466111 Washer 0 26 x 0 63 x 0 06 1 13 07257 Washer 0 438 x 0 188 x 0 049 1 14 44386 Screw M4 x 0 7 x 16 1 15 0626241 Nut 6 32 2 VO GL E 146877 Available only as HW01448 in quantities of 25 Available only as HW44484 in quantities of 10 Available only as HW44923 in quantities of 5 t Available only as HW44860 in quantities of 25 tt Available only as HW44339 in quantities of 10 ttt Available only as HW30466 in quantities of 25 t Available only as HW44860 in quantities of 25 tt Available only as HW44386 in quantities of 25 ttt Available only as HW06262 in quantities of 25 5 5 D 5 D 2 gt 3 lt Bold Part available for purchase Light italic Part not available for purchase listed and shown for reference only Maintenance and Assembly Drawings ROMS E Ke EY 7 ia 8 i A 2 3 Bat TAN E dn c A A pe A A 5 5 g 5 5 gt D E c zuo 0 coo eg e ZH ESSE BUR 5 D D iL 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 5 9 01 6 enue 0095 0075 VO GL E 146877 Table 5 5 Print Mechanis
118. 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 Zebra Barcode Anything Bar One Element Energy Equalizer Integration w o Modification Orion Stretch Stripe The World s 1 Name in Bar Code Track One Ultracode When It s on the Line Z Band Zebra Mate Z Series Z Ultimate ZebraNet ZPL II and ZPL are registered trademarks of Zebra Technologies All other trademarks and registered trademarks are property of their respective owners Copyright 2002 Zebra Technologies All rights reserved 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual ii Table of Contents Warranty Information All Zebra products are sold with warranties Refer to the User s Guide for warranty information specific to each product Here is some general information PRINTER PRODUCTS Printers All printers excluding printheads are warranted against defect in material or workmanship for twelve 12 months from the purchase date Proof of purchase or shipment date is required to validate the warranty period The warranty becomes void if the equipment is modified improperly installed or used damaged by accident or neglect or if any parts are improperly installed or replaced by the user NOTE Products returned must be packaged in the original or comparable packing and shipping c
119. oggle pressure by turning the left toggle pressure knob counterclockwise 4 Press PAUSE to continue printing and check for proper print quality 5 Repeat steps 2 through 4 as needed Notes Using the lowest pressure that produces the desired print quality can extend printhead life Do not increase overall head pressure to increase darkness unless the continued increase of the darkness setting does not provide satisfactory results When using narrow media adjust the toggle pressure knob that is away from the side frame to zero or the minimum required for acceptable print This reduces the wear on those areas of the printhead and the platen where ribbon and media are not present Head Open Lever Toggle Pressure Knobs Figure 2 17 Printhead Pressure Adjustment 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 29 Section 2 Operations Overview Liner Rewind Power Roller Adjustment Note The rewind power roller is present only on printers with the Peel Off Option This roller is pre set during manufacture for proper operation with most applications Adjust this roller only when necessary In Peel Off Mode proper media tracking is critical The rewind power roller automatically turns along with the movement of media to ensure continuous rewind of the liner When adjusting this roller the operating position may vary due to the type width and thickness of the liner Before performing this adjustment review t
120. om the printer to the host When the DTR control line from the printer is active positive voltage the host can send data to the printer When DTR is inactive negative voltage the host cannot send data to the printer This condition occurs when the printer is configured for DTR DSR hardware handshaking and the communication buffer is within 256 characters of its capacity Signal ground for RS 232 Not tied to frame ground This lead serves as the voltage reference between the interfaced devices DSR RS 232 Data Set Ready This is a control input to the printer from the host The printer monitors this lead to determine whether the host is ready to receive data status from the printer RTS RS 232 Request to Send This is a control output from the printer to the host RTS is active positive voltage when the printer is On 1 An active RTS indicates that the printer is ready to receive data Not used 5V Fused Output 1 Amp Max 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual Page 1 11 Section 1 Description of Equipment Serial Communication Signal Levels RS 232 Transmit and Receive Data RS 232 data signals are defined as either MARK or SPACE while control signals are either On active positive voltage or Off inactive negative voltage Although the permitted voltage levels can range from 3 VDC to 25 VDC both positive and negative the levels for the S400 and S600 printers are shown in Figure 1
121. on 4 62 AIRY e 4 63 Figure 4 55 Memory Board Mounting 2 4480 4 64 Figure 4 56 Sample Before and After Configuration Labels 8 MB Memory Board m 4 66 Fig re 5 1 Cover a 5 3 Figur 5 2 Logic Board and Control Panel casas eim eases cede 5 5 Figure 5 3 Media Supply Ribbon Supply and Ribbon Take Up 5 7 Figure 5 4 Toggle and Print MacHSDISITI 5 9 Figure 5 5 Print Mechanism and Printhead Assembly 5 11 Figure 5 6 Tear Cutter Media Sensor Ribbon Guides and Media Guide 5 13 Figure 5 7 Peel Off Option Front View tira onere pnta ser 5 15 Figure 5 8 Tear Gulter Drive System Eua e pb La 5 17 Figure 5 9 Peel Option and Peel Drive System 5 19 Figure 5 10 Platen and Power SIply creda 5 21 Foure 5 11 Cuter DITION 5 23 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual xiii List of Figures xiv S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 List of Tables Table 1 1 Table 1 2 Table 1 3 Table 1 4 Table 1 5 Table 1 6 Table 1 7 Table 1 8 Table 1 9 Table 2 1 T
122. ontainer In the event equipment is not so packaged or if shipping damage is evident it will not be accepted for service under warranty Surface transportation charges for return to customers in the continental United States is paid by Zebra Otherwise Zebra pays CPT carriage paid to nearest airport customer pays customs duties taxes and freight from airport to destination If Zebra determines that the product returned for warranty service or replacement is not defective as herein defined the customer will pay all handling and transportation costs Printheads Since printhead wear is part of normal operation the original printhead is covered by a limited warranty as indi cated below Warranty period begins on purchase date Printhead Warranty Period Barcode label printer printheads 6 months Card printer printheads 12 months To qualify for this warranty the printhead must be returned to the factory or to an authorized service center Customers are not required to purchase Zebra supplies media and or ribbons for warranty qualification However if it is determined that the use of other manufacturer supplies has caused any defect in the printhead for which a warranty claim is made the user is responsible for Zebra s labor and material charges required to repair the defect The warranty becomes void if the printhead is physically worn or damaged also if it is determined that failure to follow the preventive maintenance schedule listed in t
123. oor ang Front euet i 4 8 Figure 4 2 Printhead Cleaning gt 4 9 Figure 4 3 Tray 4 10 Figure 4 4 Cutter Connector and Mounting 4 10 Figure 4 5 Cutter Module Removal 1 rre rtr me rer tnter nn ruant koe 4 11 Figure 4 6 Cutter Module 4 12 Figure 4 7 Cutter Module Reassembly tat nre kenn 4 13 Figure 4 8 Side View of Cutter Module Reassembly 4 13 Figure 4 9 Reassembled Cutter 2 4 14 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual xi xii Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 Figure 4 19 Figure 4 20 Figure 4 21 Figure 4 22 Figure 4 23 Figure 4 24 Figure 4 25 Figure 4 26 Figure 4 27 Figure 4 28 Figure 4 29 Figure 4 30 Figure 4 31 Figure 4 32 Figure 4 33 Figure 4 34 Figure 4 35 Figure 4 36 Figure 4 37 Figure 4 38 Figure 4 39 Figure 4 40 Figure 4 41 Figure 4 42 Figure 4 43 Figure 4 44 Figure 4 45 List of Figures Cutter Module Feinstallallofi csc cca ea cae eo ert tm sdareadecaceederenciewianccranae 4 15 Pause and Cancel Key Lapel 4 18 TES Pose T Beier RE Ee ea PE 4 19 And E
124. oor toward the rear of the printer Lift the end of the main door nearest the front of the printer pivoting it to the rear and off the main frame Removing the Front Door 1 Open the main door 2 Grasp the tab on top of the front door and carefully pull down until it rests on the desktop 3 Refer to Figure 4 27 on page 4 35 Notice the front door s hinges in three places on the base of the printer Grasp the front door near the left and right hinge Pull the left side away from base while pivoting on the right side Removing the Rear Cover 1 Refer to Figure 4 28 on page 4 35 Remove the three cover screws attaching the rear cover to the main frame 2 Lift the rear cover straight up approximately Ye 12 7 mm then slide off toward the rear Page 4 34 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Main Door Front Door Figure 4 27 Opening Main and Front Doors Rear Cover Front Door Figure 4 28 Door and Cover Disassembly 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 35 Section 4 Preventive and Corrective Maintenance Tear Off Plate Removal 1 Open the main door 2 Grasp the tab on top of the front door and carefully pull down until it rests on the desktop Refer to Figure 4 29 Remove the two screws securing the tear off plate Push up on the bottom of the tear off plate and pull the plate out Reverse the procedure to r
125. opyl alcohol and 10 distilled water No other cleaning fluids or sprays should be used Table 4 1 lists a recommended cleaning schedule showing the area method and interval for cleaning the printer Actual schedule should be adjusted based on volume of labels printed and environmental conditions where the printer is located 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 5 Section 4 Preventive and Corrective Maintenance Table 4 1 Recommended Cleaning Schedule AREA METHOD INTERVAL Clean with a solution of 90 isopropyl alcohol and 10 distilled water Platen Roller Clean with a solution of 90 isopropyl alcohol and 10 distilled water Media Sensor Air blow Media Path Clean with a solution of 90 isopropyl alcohol and 10 distilled water Ribbon Path Air blow Rewind Power Roller Peel Off Clean with a solution of 90 isopropyl alcohol and 10 distilled water Upper Guide Rod Peel Off Clean with a solution of 90 isopropyl alcohol and 10 distilled water Platen Guide Rod Peel Off Clean with a solution of 90 isopropyl alcohol and 10 distilled water Lower Guide Rod Peel Off Clean with a solution of 90 isopropyl alcohol and 10 distilled water After every roll of media or 500 feet 150 m of fanfold media when in direct thermal mode After every roll of ribbon when printing in thermal transfer mode Cutter Assembly If u
126. ots in the round plate at the far end of the spindle Rotate the liner rewind spindle counterclockwise to remove any slack in the liner 9 Adjust the media supply guide inward until it is just touching the outer side of the media supply roll Lock the guide in place with the locking screw 10 Adjust the outer edge guides on the lower guide rod and the platen guide rod until they just touch the outer edge of the media and liner without causing the material to buckle 11 Adjust the media guide until it just touches the outer edge of the media and liner without causing the material to buckle 12 Close the head open lever 13 Refer to Adjusting the Media Sensor on page 2 10 and perform the media sensor position adjustment 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 9 Section 2 Operations Overview Page 2 10 Removing the Liner When the amount of liner wound on the liner rewind spindle reaches full capacity the liner rewind spindle full sensor activates the Paper Ribbon LED flashes and printing pauses Use the following steps to remove the liner Note You do not need to turn the printer Off for this procedure 1 Unwind about 24 in 61 cm of liner from the liner rewind spindle and cut it off at the spindle 2 Pull out the hold down hook and slide the liner off of the spindle and discard Feed the new starting edge of the liner through the mechanism and attach it to the liner rewind spindle a
127. p Main Door m Lo ui HH ay Front Door Figure 2 3 Printer Access 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 5 Section 2 Operations Overview Media Loading Note Media widths and thickness vary between applications To maintain print quality from one application to another refer to Configuration Mode on page 2 23 Tear Off Mode Media Loading 1 Turn the head open lever counterclockwise to the OPEN position and raise the printhead 2 Slide the media guide and the media supply guide as far out from the printer frame as possible 3 Roll Media place the media roll on the media supply hanger and thread the media through the printhead assembly as shown in Figure 2 4 4 Fanfold Media feed fanfold media through either the bottom or rear access slot of the printer as shown in Figure 2 5 5 Adjust the media supply guide and media guide against the outer edge of the media Note These guides must not cause pressure or excessive drag on the media 6 Close the head open lever 7 Perform the media sensor position adjustment Cutter Mode Media Loading 1 Turn the head open lever counterclockwise to the OPEN position and raise the printhead 2 Slide the media guide and the media supply guide as far out from the printer frame as possible 3 Place the media roll on the media supply hanger and thread the
128. pe 44 0 1494 536644 S400 S600 Maintenance Manual Page 4 39 Section 4 Preventive and Corrective Maintenance Print Mechanism Assembly Removal 1 NO a PF 10 11 12 13 Page 4 40 Turn printer Off and remove the AC power cord Remove the printer data cable Remove the media and ribbon Remove the main door front door and rear cover Remove the main logic board Refer to Figure 4 31 on page 4 39 and locate the printhead cable J4 or J5 Refer to Figure 4 32 Remove the ferrite assembly from around the printhead cable by sliding the clips off of the ferrites Rotate the head open lever counterclockwise to remove the pressure on the printhead Refer to Figure 4 33 on page 4 42 Locate the braided ground straps on the print mechanism assembly that lead to the main frame and to the riot bar on the electronics side of the printer Remove the screws securing the braided ground strap to the main frame Refer to Figure 4 34 on page 4 42 Remove the single screw with two washers on the electronics side of the printer securing the print mechanism assembly to the main frame and riot bar Carefully slide the printhead cable through the cutout in the main frame and remove the printhead assembly Reverse the procedures to reinstall the print mechanism assembly Test the unit and perform a printhead position adjustment if necessary Ribbon Cable Clip Ferrite Figure 4 32 Printhead Cable Fe
129. pressure against the cup and spring assembly tighten the two set screws on the cup and spring assembly Note Rotate the ribbon supply spindle subassembly to access the set screws 0 010 0 254 mm shim or feeler gauge placed between C clip and ribbon supply spindle subassembly Ribbon Supply Spindle Subassemby Cup and Spring Assembly Figure 4 37 Ribbon Supply Spindle Subassembly Installation Once the cup and spring assembly is tightened remove the shim feeler gauge The ribbon supply spindle subassembly should have some play on the shaft When rotated counterclockwise the ribbon supply spindle subassembly spins freely until it encounters the spring Continuing to turn the ribbon supply spindle subassembly counterclockwise produces a snap and the ribbon supply spindle subassembly moves freely Section 4 Preventive and Corrective Maintenance 7 When rotated clockwise the ribbon supply spindle subassembly encounters the spring and attempts to spin the ribbon supply spindle subassembly counterclockwise If the results in steps 6 and 7 are not achieved repeat steps 2 through 7 Refer to Figure 4 38 Slide the spindle assembly onto the shaft 0 010 0 254 mm shim or feeler gauge placed between C clip and ribbon supply spindle subassembly Ribbon Supply Spindle Subassemby Cup and Spring Assembly Figure 4 38 Spindle Assembly Installation Page 4 46 5400 5600 Maintenanc
130. puts to the printer TTL input level HIGH 5 V corresponds to a Logic 1 level LOW 0 V to a Logic 0 ACKNOWLEDGE This printer output is an active LOW pulse indicating that 10 the printer has received the previous character and is ready to accept another data character 11 BUSY This printer output is active HIGH whenever it cannot accept data 12 ERROR This output signal is active HIGH whenever the printer is out of paper or ribbon SELECT The function of this output signal is determined by a printer 13 configuration In the default condition SELECT is active HIGH whenever the parallel port is on and enabled 14 AUTOFEED Not used 15 33 and 34 Not used 16 19 30 SIGNAL GROUNDS The logic grounds and returns for all input and output signals 17 Chassis ground for cable shield connection 18 5V fused output 1 amp max 31 INITIALIZE Reset Not used FAULT This printer output is active LOW whenever any of the following error 32 conditions are present Head Open Head Too Hot Paper Out Ribbon Out or Rewind Full if optional rewind is used 35 5V resistive 36 SEL IN Connected but not used S400 S600 Maintenance Manual Page 1 13 Section 1 Description of Equipment Electronics System Block Diagram Printhead Printhead Label Available Assembly Assembly Sensor S400 S600 Peel Option Ribbon Media Ribbon Take Up Sensor Motor JA J9
131. quipment Printing Considerations Table 1 5 Printing Specifications S400 S600 Resolution 203 dots per inch 8 dots per mm Dot Size 0 005 0 127 mm Minimum print width 0 75 19 mm Maximum print width 4 09 104 mm Minimum print length 0 005 0 127 mm 1 dot row Maximum print length 36 914 mm 39 990 Bar code modulus dimension 5 0 mil to 55 0 mil Printing Method Direct Thermal Printing requires direct thermal media A substrate typically paper is coated with a chemical that changes to a dark color upon exposure to heat over a period of time to form an image Thermal Transfer Printing The printhead is in contact with a ribbon that releases ink above a certain threshold temperature Print Speeds Table 1 6 Print Speeds S400 S600 Programmable 2 4 61 mm 2 4 61 mm 5 127 mm constant printing 3 76 mm 3 76 mm 6 152 mm speeds 4 102 mm 4 102 mm Page 1 6 S400 S600 Maintenance Manual 44895L Rev 3 3 12 04 Description of Equipment Ribbon Considerations Table 1 7 Ribbon Specifications S400 amp S600 Minimum 1 57 40 mm Maximum 4 5 114 mm 2 1 media to ribbon roll ratio 984 300 m 3 1 media to ribbon roll ratio 1400 427 m Inner diameter 1 0 25 mm Ribbon Width Standard Length Core Size Outer diameter 3 2 81 mm Zebra Programm
132. r 0 720 x 0 262 x 0 047 1 26 44275 Power Roller 1 7 44142 Square Nut 1 27 10461 Nut M4 x 0 7 2 8 45189 7 Belt 118T 1 28 44293 Eccentric Spring 1 9 44358 C Media Take Up Idler Assembly 1 29 44292 Eccentric Power Roller 1 10 44489 Shoulder Screw M5 x 0 8 x 8 2 30 44383 Ground Cable Assembly 11 44487 Idler pulley 0 750 2 31 44191 Ground Chain Assembly 1 12 10476 Flat Washer M5 2 32 441761 Wire Clip 3 13 44114 Screw 4 2 1 41 8 7 33 44387 Screw M3 5 x 0 6 x 6 3 14 44488 dler Bracket 1 34 10427 Screw M4 x 0 70 x 10 2 15 44536M A Take Label Sensor Assembly 1 35 44282 Tear Off Plate 1 16 44216 Screw M4 2 x 1 41 x 13 3 36 44023 2 Stepper Motor Peel Off Option 1 17 44665M Full Roll Switch Assembly 1 Available only as HW30261 in quantities of 25 Available only as HW44114 in quantities of 50 18 44275M E Power Roller Assembly 1 Available only as HW44216 in quantities of 25 19 45189 5 Peel Off Main Drive Belt 1 Available only as 44176 in quantities of 25 20 44368 D Carrier Idler Assembly 1 Light italic Part not available for purchase listed and shown for reference only u01 99S 5 5 D 5 D 5 a gt 3 z lt suime Maintenance and Assembly Drawings Figure 5 9 Peel Option and Peel Drive System 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 5 19 02 5 enuen soueusjuley 009
133. ration When using ribbon wider than 2 4 61 mm image gets lighter or smears near end of roll of ribbon Ribbon appears to slow down or stop Too much back tension on ribbon S400 S600 Maintenance Manual Adjust dual tension ribbon supply spindle to provide low tension by pushing in spindle end cap 44895L Rev 3 3 15 04 Troubleshooting Table 3 3 Troubleshooting Chart Problems with LED Indications Cont Symptom Diagnosis Action Poor print quality Darkness too low Increase print darkness Incorrect media and ribbon combination Replace media or ribbon Printhead adjustments incorrect Perform required adjustments Misregistration skips labels Misadjusted media sensors Perform media sensor adjustments Also try recalibrating Improper ZPL format Correct ZPL format Printing across web or in wrong position Loss of registration indicating media sensor problem Adjust media sensor position Adjust media sensor sensitivity Printer set for continuous media but non continuous media loaded Set printer for correct type of media Peel Off Mode Improperly adjusted media edge guides or power roller Reposition and adjust as necessary Long tracks of missing print on several labels 44895L Rev 3 3 15 04 Wrinkled ribbon See Troubleshooting Chart Wrinkled Ribbon on page 3 8
134. re the length of each label If you are using ZPL or ZPL Il include a Label Length 11 instruction in each label format you send to the printer Refer to your ZPL II Programming Guide or instructions provided with your software driver Note When using continuous media position the Media Sensor anywhere over the media so an Out of Media condition can still be sensed Media Sensor Adjustment Lever Media Guide Figure 2 8 Media Sensor Adjustment 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 11 Section 2 Operations Overview Ribbon Loading Note Do not load ribbon if the printer is to be used in direct thermal mode af Caution Do not use ribbon that is narrower than the media Premature printhead failure may result due to excessive abrasion caused by thermal transfer media Adjusting the Ribbon Supply Spindle The S400 S600 comes with a dual tension ribbon supply spindle to provide the appropriate amount of tension on the ribbon Normal Position Refer to Figure 2 9 In the normal position the dual tension ribbon supply spindle provides the desired amount of ribbon back tension for different ribbon widths To place the spindle in the normal position firmly pull the spindle end cap until it clicks into place Low Tension Position The low tension position is used in limited applications with ribbons wider than 2 4 in 61 mm to provide lower back tension The low tension position is re
135. ressly approved by Zebra Technologies could void the user s authority to operate the equipment Canadian DOC Compliance Statement This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio interference regulations of the Canadian Department of Communications Liability Disclaimer Zebra Technologies takes steps to assure that its published Engineering specifications and manuals are correct however errors do occur Zebra Technologies reserves the right to correct any such errors and disclaims liability resulting therefrom No Liability for Consequential Damage In no event shall Zebra Technologies or anyone else involved in the creation production or delivery of the accompanying product including hardware and software be liable for any damages whatsoever including without limitation loss of business profits business interruption loss of business information or other pecuniary loss arising out of the use of or the results of use of or inability to use such product even if Zebra Technologies has been advised of the possibility of such damages Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages the above limitation may not apply to you Copyrights The copyrights in this manual and the label printer described therein are owned by Zebra Technologies All rights are reserved Unauthorized reproduction
136. rinter is paused pressing CANCEL a third time alters the self test again Now each time PAUSE is pressed 50 labels print at 6 152 4 ips up to a maximum of 9999 labels conserve labels check the sample labels in tests 1 or 2 of the Pause Key Self Test If you are not satisfied with the print darkness quality proceed to Adjusting the Printer Darkness on page 2 26 and adjust accordingly Run test 1 or 2 of the Pause Key Self Test and repeat the procedures if the desired print darkness is still not achieved 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 25 Section 2 Operations Overview Adjusting the Printer Darkness Caution Set Print Darkness to the lowest setting possible for desired print quality Darkness set too high may cause ink smearing ribbon wrinkle or ribbon burning The following procedure sets the darkness of the printing on the label Note It is not necessary to turn the printer power off to adjust this parameter 1 Press MODE The pause and darken LEDs turn on 2 Press FEED A to increase or CANCEL W to decrease the darkness setting Refer to Figure 2 11 on page 2 16 Example 1 The configuration label lists a darkness setting 20 You know your media and ribbon combination should be 15 Press CANCEL five times Refer to Figure 2 13 Example 2 After running the Feed Key Self Test you have determined that the label that looks the best has a relative darknes
137. ription Qty 1 44054 Screw M3 x 20 1 C Upper Media Guide Plate Assembly 44140 400M f 1 2 44123 Braided Ground Strap 1 14 Tear Off and Cutter Option only 3 44190 400M B Ribbon Guide Assembly 1 44140 402M C Upper Media Guide Plate Assembly 1 Peel Off Option only 4 44189 Anti Static Brush 1 15 44109 Stationary Guide 1 5 44114 Screw M4 2 x 1 41 x 8 5 16 44110 1 Adjustable Guide 1 6 44466 Ground Cable 1 17 30208 Flat Washer 0 50 x 0191 x 0 03 1 7 30466 Washer 0 26 x 0 63 x 0 06 1 18 40194ti Curved Washer 0 344 x 0 172 x 0 006 1 8 072574 Washer 0 438 x 0 188 x 0 036 1 ER 19 44016 Upper Media Guide 1 9 30393 00811 Screw 8 32 x 0 500 1 20 010034 Washer 0 381 x 0 126 x 0 042 1 10 44968 Ribbon Out Reflective Bracket 1 A Media 5 Bi 21 10403 Screw M3 x 0 5 x 6 1 edia Sensor Assembly 11 44135 400M Standard 1 Available only as HW44054 in quantities of 10 Available only as HW44114 in quantities of 50 44911M A Media Sensor Assembly Black Mark 1 Available only as HW30466 in quantities of 25 T Available only as HW07257 in quantities of 25 12 44747 Media Ribbon Sensor Cable 1 tt Available only as HW30393 008 in quantities of 25 13 44011 Media Guide 1 tit Available only as 44484 in quantities of 10 t Available only as HW30208 in quantities of 25 tt Available only as HW40194 in quantities of 25 Bold Part available for purchase Light italic Part not available for pur
138. rrite assembly 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Printhead Assembly Removal and Installation 1 Turn printer Off O and remove the AC power cord Remove the printer data cable Remove the main door front door and rear cover Bo pm Refer to Figure 4 22 on page 4 27 Remove the two screws securing the strip plate 5 Rotate the head open lever counterclockwise to remove the pressure on the printhead 6 Refer to Figure 4 35 on page 4 43 Using an open end wrench remove the two nuts securing the printhead assembly to the print mechanism assembly Note Do not remove loosen or adjust the two screws on top of the printhead assembly They are used only when a printhead alignment is necessary 7 Carefully remove the printhead cable from the printhead assembly 8 Install the replacement printhead assembly by reversing steps 4 through 7 Notes When installing the printhead cable to the printhead assembly ensure the insulation sleeve is pushed as far forward toward the printhead assembly as possible Do not remove loosen or adjust the two screws on top of the replacement printhead assembly They are used only when a printhead alignment is necessary 9 Reconnect the AC power cord 10 Perform a voltage calibration as described in Printhead Voltage Adjustment on page 4 29 Caution The printhead voltage adjustment is critical to the
139. s caused by abuse or misapplication of the software or by its use in violation of the U S copyright law or international treaty No salesperson representative or agent of Zebra is authorized to make any guaranty warranty or representation that contradicts the foregoing Any waiver alteration addition or modification to the foregoing warranties must be in writing and signed by an executive officer of Zebra to be valid 44895L Rev 3 3 12 04 S400 S600 Maintenance Manual iv Table of Contents Table of Contents Section 1 Description of Equipment a E E E E E E E 1 1 Printer Operating Modes 1 1 DE e epu E RHET 1 2 a E 1 2 Ae 1 2 Enn i c a Li AETR 1 2 Environmental Ranges for Operation and Storage 1 2 POMS 1 3 Standard Printer TB 1 3 Bian Ed MR eye ey emery 1 3 cinis FONS NRI T 1 3 International Characters i pred bela xi POE Ru HR EXTR HERE n td Flan 1 3 tet ry OREL EU EUM DE 1 3 Media SSIS UIE P n 1 4 FROM IED TEE TERT TT ILI TU 1 4 HC dre e ANN E T m 1 5 d 1 5 EE E E
140. s described in Peel Off Mode Media Loading on page 2 9 4 While holding the media in position against the tear off peel off plate open and close the printhead without disturbing the media position The printer is now ready to print more labels Adjusting the Media Sensor Refer to Figure 2 8 When the printer is turned On 1 it performs a self test and configures its operating characteristics Some of these characteristics are determined by the position of the media sensor The media sensor assembly consists of two sections The media passes between a stationary light source and a movable light sensor The light source is positioned below the media while the light sensor is above the media Media Sensor Adjustment for Non Continuous Media This type of media has some type of physical characteristic web notch perforation etc that indicates the start or end of each label 1 Turn the head open lever counterclockwise to the OPEN position and raise the printhead 2 Look through the front of the print mechanism and locate the media sensor adjustment lever 3 Reposition the sensor until the top of the adjustment lever is in line with the notch in the media 4 Close the head open lever 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Media Sensor Adjustment for Continuous Media Continuous media does not contain label start or end indicators You must tell the printer through the softwa
141. s of 03 Press FEED A three times Example 3 After manually resetting the darkness to the factory default of 10 you run the Pause Key Self Test and determine the labels are too light Make your best estimate and press FEED A the necessary number of times 3 Press MODE three times The mode LEDs flash to indicate the settings have been saved permanently to memory 4 Press PAUSE to exit Pause Mode and turn off the pause LED Page 2 26 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Tear Off Position Adjustment Refer to Figure 2 15 This procedure sets the end of label position relative to the tear off plate or cutter The media stopping position is adjustable in increments of four dot rows at a time The possible adjustment range is 80 dot rows or a distance of 0 392 in 10 mm up or down from the center Adjust if the label is not being torn or cut at the correct position 1 Press MODE twice The pause and position LEDs turn on 2 To adjust the label position press FEED A to move the label forward out of the printer or CANCEL W to move the label back into the printer 3 Press MODE twice The mode LEDs flash to indicate that the settings have been saved to memory 4 Press PAUSE to exit Pause Mode and turn off the pause LED 1 4 Label Motion Figure 2 15 Tear Off Position Adjustment Nominal factory set tear line location usually 00 4
142. sing continuous pressure sensitive media Citrus based adhesive remover After every roll of media or more often depending on application and media Cutter Assembly If using tag stock or liner only Clean with a solution of 90 isopropyl alcohol and 10 distilled water Air blow After every 2 or 3 rolls of media Tear Off Peel Off Plate Clean with a solution of 90 isopropyl alcohol and 10 distilled water Once a month Exterior Mild detergent or desktop cleaner As needed Interior Air blow brush vacuum As needed Label Available Sensor Air blow 6 months 500 rolls Belts Visual inspection for wear 6 months 500 rolls Page 4 6 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Cleaning Printhead and Platen Roller Inconsistent print quality such as voids in the bar codes or graphics may indicate a dirty printhead For optimum performance the printhead should be cleaned regularly with a swab soaked in 90 isopropyl alcohol and 10 distilled water This cleaning procedure is the best thing you can do to maintain consistent high quality printing Zebra recommends performing the cleaning procedure when installing a new roll of ribbon when installing a new roll of direct thermal media or after having printed 500 feet 150 m of continuous or fanfold media Itis not necessary to turn the power off pr
143. sition 3 Position the cutter cable connector so the flat side of the connector faces away from the printer Insert the connector up into the mating connector on the cutter module 4 Replace the cutter catch tray on to the two mounting slots located on the front of the cutter module Test the Cutter Operation 1 If necessary reload ribbon and media into the printer Close the printer s front door and main door Note When loading media make sure the end of the label is positioned on top of the platen roller then close the printhead latch 2 When the printer is turned on the cutter module will cycle through one cutting operation and be ready to print labels 3 Further tests may be performed by running a Pause Key Self Test Page 4 14 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Mounting Posts Cutter Module Mounting Slots Figure 4 10 Cutter Module Reinstallation Lubrication Caution No lubricating agents of any kind should be used on the printer Some commercially available lubricants will damage the finish and mechanical parts Diagnostics Printer Self Test Reset Default Quick Reference Chart Table 4 2 lists the self tests and default resets that can be accessed by pressing and holding a front panel key or keys and turning the power On I The X in the four columns on the right indicates which key or keys are pressed The
144. speeds Inspect these printouts to determine which printout has the best darkness setting The value next to Relative Darkness on the printout is added to or subtracted from the current darkness value If the label with the best appearance has a value of OO no adjustments are necessary To start the Feed Key Self Test press and hold FEED while turning the power On I The printer runs through a Power On Self Test then starts printing the Feed Key Self Test labels Examine the labels and proceed to Adjusting the Printer Darkness on page 2 26 Page 2 24 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Testing Print Darkness Pause Key Self Test Method Another method of testing print darkness with a test label that contains a large amount of printing is performed with the Pause Key Self Test First you must determine how you want to proceed with the adjustments 1 You can run the Pause Key Self Test without knowing your current darkness setting You can run the test examine the labels and then perform the procedure Adjusting the Printer Darkness on page 2 26 using your best guess as to how far to increase or decrease the setting to the optimal setting 2 You set the darkness to the factory default value or anything you wish then run the Pause Key Self Test and then perform the procedure Adjusting the Printer Darkness on page 2 26 To Set Darkness Setting Manually
145. t side of the printer near the AC power cord is the power On Off switch Turn the power Off O before connecting or disconnecting any cables Turning the switch On 1 activates the printer and it performs a Power On Self Test as it begins operation Turning the printer power On 1 while holding down certain front panel keys launches additional printer self tests immediately following the Power On Self Test These tests are described later in this section External influences such as lightning storms or unwanted noise on the power or data cables may cause erratic printer behavior Turning the AC power Off and back On 1 may reestablish proper printer operation 44895L Rev 3 3 12 04 5400 5600 Maintenance Manual Page 2 3 Section 2 Operations Overview Serial Cable Communication Interface Parallel Cable o AC Power Cable AC Power On Off Switch Figure 2 2 Power On Off Switch and Data Cable Connections Page 2 4 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Accessing the Printer To access the printer for loading and unloading media and ribbon and for operator adjustments do the following 1 Refer to Figure 2 3 Lift the main door and swing it up and to the left until it rests on top of the right side cover 2 Grasp the tab on top of the front door and carefully pull down until it rests on the deskto
146. the desired print quality 16 17 18 Page 4 24 If labels are printing properly press PAUSE to stop printing Press MODE three times The Mode LEDs flash and the settings are permanently saved to memory To exit the Pause Key Self Test the printer must be turned Off O 5400 5600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Braided Ground Strap Braided Ground Strap Bos EE Printhead Printhead Position Position Locking Locking Screw Screw Printhead Printhead Adjustment Adjustment Slot Slot Strip Plate Figure 4 20 Printhead Position Adjustment Top View Page 4 25 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Section 4 Preventive and Corrective Maintenance Take Label Sensor Adjustment The label sensor functions only when the printer is set to Peel Off Mode This mode requires that the peel off option be installed This sensor is not installed on printers without the peel off option Figure 4 21 shows the location of the take label sensor When the sensing beam is interrupted printing and feeding are prevented It may accept additional label formats if the buffer is not full When the label is removed the next label prints automatically There is no sensitivity adjustment of the take label sensor Sensors are attached and aligned at the factory when the peel off option is installed If a problem is encountered check the alignment
147. tinuing to turn the outer spindle and spindle assembly counterclockwise produces a snap and the ribbon supply spindle subassembly moves freely Rotating in a clockwise direction the outer spindle and spindle assembly encounter the spring and attempt to spin the outer spindle and spindle assembly in the counterclockwise direction Push in the outer spindle until it is flush against the spindle assembly The outer spindle and spindle assembly should now spin freely clockwise and counterclockwise with no restrictions If the results in steps 17 18 and 19 are not achieved repeat steps 9 through 19 Replace the printer data cable and AC power cord Reload media and ribbon and test the printer operation 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 47 Section 4 Preventive and Corrective Maintenance 0 010 0 254 mm shim or feeler gauge placed between C clip and ribbon supply spindle subassembly Ribbon Supply Spindle Subassemby Cup and Spring Assembly Figure 4 41 Spindle Assembly amp Outer Spindle Retracted Page 4 48 S400 S600 Maintenance Manual 44895L Rev 3 3 15 04 Preventive and Corrective Maintenance Section 4 Media Sensor Assembly Removal Caution Observe proper electrostatic safety precautions when removing handling and replacing printed circuit boards P O M 7 8 Turn printer Off and remove the AC power cord and the pr
148. to factory default values X X X Note This test is performed only when sensor assemblies are replaced or if a manual calibration fails A manual calibration procedure must be performed after the ribbon parameter calibration Feed and Cancel Key Self Test Preprogrammed label test formats for major overhauls 44895L Rev 3 3 15 04 S400 S600 Maintenance Manual Page 4 17 Section 4 Preventive and Corrective Maintenance Table 4 3 Sequence of Formats Format of Labels Speed Test Function Figure 1 20 6 ips Speed D Left Ribbon Wrinkle Test 4 12 2 20 6 ips Speed D Right Ribbon Wrinkle Test 4 13 3 20 6 ips Speed D Bar Code Wrinkle Test Code 39 4 14 4 10 6 ips Speed D Usable Area Test 4 15 5 10 6 ips Speed D Head Temperature Test 4 16 6 10 6 ips Speed D Upper Smear Test 4 17 7 10 6 ips Speed D Lower Smear Test 4 18 8 20 2 ips Speed A Left Ribbon Wrinkle Test 4 12 9 20 2 ips Speed A Right Ribbon Wrinkle Test 4 13 10 20 2 ips Speed A Bar Code Wrinkle Test Code 39 4 14 11 10 2 ips Speed A Usable Area Test 4 15 12 10 2 ips Speed A Head Temperature Test 4 16 13 10 2 ips Speed A Upper Smear Test 4 17 14 10 2 ips Speed A Lower Smear Test 4 18 Page 4 18 12345678901 234567896 1234567896 1234567896 1234567896 12345678901234 S67
149. uration and ensure peel off mode is not selected Main logic board faulty or loose interconnecting cables Ensure cables are properly connected Replace main logic board Calibrate LED turns off 4 after 5 seconds but all other LEDs stay on Boot block error Download new boot block and firmware Replace main logic board Calibrate and position 5 LEDs off but all other LEDs on Dynamic RAM failed Replace main logic board Calibrate position and 6 darken LEDs off but all other LEDs on Firmware decompression error Download and install firmware Calibrate position 7 darken and data LEDs off but all other LEDs on Firmware error Download and install firmware Calibrate position darken data and pause LEDs off but all other LEDs on 44895L Rev 3 3 15 04 Firmware error S400 S600 Maintenance Manual Download and install firmware Page 3 3 Section 3 Troubleshooting Table 3 2 Troubleshooting Chart Problems with LED Indications Cont Page 3 4 Symptom Diagnosis Action Media incorrectly loaded Load media correctly then turn or not loaded printer off and on Printer stops pause and Cutter error Clear jam then open and close 9 paper ribbon LEDs both printhead 9p Calibration error Recalibrate printer Misadjusted media Check position and sensitivity sensor media sensor
150. ure 4 55 With the memory board face up 100 connector to the left and pins up carefully slide the memory board underneath the main logic board Align the three screw holes in the main logic board with the three holes in the connector on the memory board Main Logic Board Memory Board Mounting 9 28 POT 979929955559 313 3AQVNI 3399 3 v1 LAZY 96277 La cs Mounting Screws Figure 4 55 Memory Board Mounting Screws Finger tighten the three screws through the main logic board and the memory board Align connector J8 at the bottom of the main logic board with the mating connector on the power supply board Note Do not over torque screws Starting with the center screw tighten all screws Press straight down on the main logic board until connector J8 has seated completely onto the power supply board Reinstall the three screws securing the main logic board to the main frame Refer to Figure 4 53 on page 4 62 Reconnect all ribbon cable and wire harness connectors 44895L Rev 3 3 15 04 5400 5600 Maintenance Manual Page 4 64 Preventive and Corrective Maintenance Section 4 Important Use full width media when performing the Cancel Key Self Test Labels less than full width lose printing on the right side Printing may run on to the next label when short labels 18 Reconnect the AC
151. y once to put the printer into manual calibration After that press MODE three times and FEED once when changing media a label prints showing the sensor profile If the printer is in Peel Off Mode the operator must catch the labels as they peel away from the liner 1 2 3 eo Oo DN ok 2 22 Turn printer power Place the head open lever in the OPEN position Remove the ribbon Remove approximately six labels from the media roll enough so only the liner is threaded under the media sensor Reload the media Press and hold PAUSE FEED and CANCEL Turn the power switch On 1 After the calibrate LED goes out release PAUSE FEED and CANCEL When the printhead LED flashes reload the ribbon Ensure the media sensor is properly positioned Close the printhead A media and ribbon sensor profile prints Note To return to auto calibration press and hold PAUSE CANCEL and MODE when you turn the printer on 5400 5600 Maintenance Manual 44895L Rev 3 3 12 04 Operations Overview Ribbon Parameter Calibration Note Perform this procedure only if the manual calibration fails or if sensor assemblies are replaced A manual calibration must be performed after the ribbon parameter calibration To set the ribbon parameter to factory default values 1 Turn the printer Off Open the printhead and remove the ribbon Press and hold FEED CANCEL and MO

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