110PAX4 Maint Manual

Zebra
110PAX4
Print Engine
Maintenance Manual
Customer Order # 57515L-001
Manufacturer Part # 57515L-001 Rev. 1
2005 ZIH Corp.
The copyrights in this manual and the label print engine described therein are
owned by Zebra Technologies Corporation. Unauthorized reproduction of this
manual or the software in the label print engine may result in imprisonment of up
to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be
subject to civil liability.
This product may contain ZPL
, ZPL II
, and ZebraLink programs; Element

Energy Equalizer
Circuit; E3
; and AGFA fonts.

Software ZIH Corp. All rights reserved worldwide.
ZebraLink and all product names and numbers are trademarks, and Zebra, the
Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit are
registered trademarks of ZIH Corp. All rights reserved worldwide.
CG Triumvirate is a trademark of AGFA Monotype Corporation. All rights
reserved worldwide. CG Triumvirate(tm) font AGFA Monotype Corporation.
Intellifont
portion AGFA Monotype Corporation. All rights reserved

worldwide. UFST is a registered trademark of AGFA Monotype Corporation. All
rights reserved worldwide.
All other brand names, product names, or trademarks belong to their respective
holders.
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual iii
Cont ent s
About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Print Engine Exterior View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Indicator Lights (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Agency Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Communications Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Zebra Programming Language (ZPL II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Bar Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
iv 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
Cont ents
Standard Print Engine Font Matrices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applicator Pin Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Print Engine Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Print Engine Assembly Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Peel Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ribbon Tension Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DC Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AC Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Peel Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Applicator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unpack and Inspect the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Report Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Store the Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Print Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install the Print Engine in an Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connect the Print Engine to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Standard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Optional Print Servers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DB-15 Applicator Interface Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Interface Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Data Cable Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Media and Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Load Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remove Used Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Parameters Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Exit Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Contents
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual v
Changing Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Front Panel LCD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ZebraNet
Print Server LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Calibrate the Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Toggle Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Printhead Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Power Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Troubleshooting Checklists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Communications Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Miscellaneous Print Engine Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Print Engine Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Additional Print Engine Self Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4 Preventive and Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Equipment Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Personal Safety Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Tools Required for Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Recommended Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Cleaning the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Cleaning the Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Cleaning the Printhead and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Cleaning the Peel Bar and Media Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
vi 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
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Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Print Quality Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Prepare for Making Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Printhead Parallelism Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Printhead Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Printhead Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Printhead Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Strip Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Ribbon Sensor Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Reflective Media Sensor Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Upper Pinch Roller Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Adjusting the Elastomer Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Media Tracking Cam Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Routine Referral Procedures (RRPs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Printhead Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Compound Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Stepper Motor Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Ribbon Take-Up Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Ribbon Supply Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Roller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Peel Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Auxiliary Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
PCMCIA Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Wireless PCMCIA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Compact Flash and PCMCIA Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Print Server Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Applicator Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
AC Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Door-Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Contents
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual vii
5 Maintenance and Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
A Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Parallel Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Serial Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Serial Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
RS-232 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Applicator Interface Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Applicator Interface Connector Pin Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 318
J umper Configurations for +5 V I/O Applicator Interface Board . . . . . . . . . . . . . . . . 320
Proprietary Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Printer Software and Firmware License Agreement . . . . . . . . . . . . . . . . . . . . 329
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
viii 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
Cont ents

Notes ___________________________________________________________________
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57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual ix
About Thi s Doc ument
This section provides you with contact information, document structure and organization, and
additional reference documents.
Contents
Who Should Use This Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
How This Document Is Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
x 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
About Thi s Document
Who Should Use This Document
Who Should Use This Document
This Maintenance Manual is intended for use by any person who needs to perform routine
maintenance, upgrade, or troubleshoot problems with the print engine.
How This Document Is Organized
The Maintenance Manual is set up as follows:
Section Description
About This Document onpageix This section provides you with contact
information, document structure and organization,
and additional reference documents.
System Description onpage1 This chapter provides an overview of the print
engine and its components. Specifications of the
print engine and a brief explanation of each main
component and its function are included.
Operations onpage27 This chapter provides the tasks that you must
complete and the issues that you must consider
before you load and configure your print engine.
Troubleshooting onpage89 This section contains tables showing symptom,
diagnosis, and action columns. These tables help
the technician to diagnose print engine faults and
determine the repair needed.
Preventive and Corrective
Maintenance onpage107
This section provides various levels of print
engine maintenance required for optimum
performance. This section also provides
information on cleaning and general maintenance,
replacement of major assemblies, and mechanical
adjustments.
Maintenance and Assembly Drawings
onpage267
This section contains mechanical assembly
drawings and parts lists. Included are illustrations
of parts and assemblies common to all 110PAX4
models, as well as their part numbers.
Maintenance kits and their contents are also listed.
Data Ports onpage313 This appendix describes the standard
communication ports available to connect the print
engine to your computer or network.
Glossary onpage335 The glossary provides a list of common terms.
About This Document
Contacts
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual xi
Contacts
You can contact Zebra Technologies at any of the following:
Visit us at: http://www.zebra.com
Our Mailing Addresses:
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061.3109 U.S.A
Telephone: +1 847.634.6700
Fax: +1 847.913.8766
Zebra Technologies Europe Limited
Zebra House
The Valley Centre, Gordon Road
High Wycombe
Buckinghamshire HP13 6EQ, UK
Telephone: +44 (0)1494 472872
Fax: +44 (0)1494 450103
Support
You can contact Zebra support at:
Web Address: www.zebra.com/SS/service_support.htm
US Phone Number +1 847.913.2259
UK/International Phone Number +44 (0) 1494 768289
Note The web address is case-sensitive.
xii 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
Document Conventions
Document Conventions
The following conventions are used throughout this document to convey certain information:
Alternate Color (online only) Cross-references contain hot links to other sections in this
guide. If you are viewing this guide online in .pdf format, you can click the cross-reference
(blue text) to jump directly to its location.
Command Line Examples All command line examples appear in Cour i er New font.
For example, type the following to get to the Post-Install scripts in the bi n directory:
Zt ool s
Files and Directories All file names and directories appear in Cour i er New font. For
example, the Zebr a<ver si on number >. t ar file and the / r oot directory.
Cautions, Important, Note, and Example
Caution Warns you of the potential for electrostatic discharge.
Caution Warns you of a potential electric shock situation.
Caution Warns you of a situation where excessive heat could cause a burn.
Caution Advises you that failure to take or avoid a specific action could result in physical
harm to you.
Caution Advises you that failure to take or avoid a specific action could result in physical
harm to the hardware.
Important Advises you of information that is essential to complete a task.
Note Indicates neutral or positive information that emphasizes or supplements important
points of the main text.
Example Provides an example, often a scenario, to better clarify a section of text.
About This Document
Related Documents
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual xiii
Illustration Callouts Callouts are used when an illustration contains information that needs
to be labeled and described. A table that contains the labels and descriptions follows the
graphic. Figure1 provides an example.
Figure 1 Sample Figure with Callouts
Related Documents
The following documents and CDs might be helpful references:
Tools Tells you what tools you need to complete a given task.
1 SETUP/EXIT button
2 CALIBRATE button
2 1
57512L-001 110PAX4 User Guide
57511-001 PAX4 Series User CD
57515L-001 110PAX4 Print Engine Maintenance Manual
57513L-001 110PAX4 Quick Reference Guide
49560 PAX4 Maintenance Manual CD
45541L ZPLProgramming Guide Vol. 1
45542L ZPLProgramming Guide Vol. 2
45631 ZPL IIProgramming Guide CD
45537L ZebraNetPrintServer IIUser and Reference Guide
45630 ZebraNetPrintServer II CD
47619L ZebraNet10/100 Print Server User Guide
45638 ZebraNet10/100 Print Server CD
13422L ZebraNetWireless Print Server User Guide
xiv 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
Related Documents

Notes ___________________________________________________________________
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__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
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57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 1
1
Syst em Desc r i pt i on
This chapter provides an overview of the print engine and its components. Specifications of
the print engine and a brief explanation of each main component and its function are included.
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Indicator Lights (LEDs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Communications Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Zebra Programming Language (ZPL II). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standard Print Engine Font Matrices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applicator Pin Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Print Engine Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Print Engine Assembly Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Peel Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ribbon Tension Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Contents (Continued)
2 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
Syst em Descri pt i on
AC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Media Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Peel Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Applicator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
System Description
General
General
This technical service guide contains information about service and maintenance of Zebras
110PAX4 print engine. The 110PAX4 thermal transfer print engine consists of the 203 dot/inch
and the 300 dot/inch models.
All models are available in right-hand and left-hand configurations. They are versatile,
pressure-sensitive label print engines designed to print high-quality bar codes, various sizes
and styles of alphanumeric characters, and graphics in thermal transfer mode.
All print engines have the flexibility to meet a variety of applications. The Zebra Programming
Language (ZPL II) allows the programmer to format the printed material. ZPL II is transparent
to protocol converters and allows for easy integration of the 110PAX4 print engines into most
systems and host main frames.
Print Engine Exterior View
Print Engine Exterior View
Print engines are available in a right-hand configuration (media moves from left to right,
Figure1) and a left-hand configuration (media moves from right to left, Figure2).
Figure 1 Right-Hand (RH) Print Engine
Figure 2 Left-Hand (LH) Print Engine
1 Media Door
2 Front Panel
3 Power Switch
2
3
1
2
3
1
System Description
Front Panel
Front Panel
All controls and indicators for the print engine are located on the front of the print engine on
the front panel (Figure3). The Liquid Crystal Display (LCD) shows operating status and
feature parameters. The front panel buttons are used to control the print engine operations and
to set parameters. The front panel lights (LEDs) indicate the print engines status.
Figure 3 Front Panel
Front Panel Buttons
The front panel buttons are shown in Table1.
1 Buttons
2 LCD
3 Lights/LEDs
2 1 3 1
Table 1 Front Panel Buttons
Button Description/Function
BLACK OVALS The two black ovals are used to change values for the parameter displayed on the
LCD. Common uses include increasing or decreasing a value, answering yes or no,
indicating ON or OFF, and scrolling through choices.
PREVIOUS Scrolls the LCD to the previous parameter.
NEXT Scrolls the LCD to the next parameter.
SETUP/EXIT Enters and exits Setup mode.
PAUSE Stops and restarts the printing process or removes error messages and clears the LCD.
When the print engine is paused, the PAUSE light is on.
If the print engine is idle, it enters Pause mode immediately.
If the print engine is printing, the label is completed before the printing process
stops.
Front Panel
Front Panel Indicator Lights (LEDs)
The front panel lights are described in Table2.
CANCEL CANCEL functions only in PAUSE mode. Pressing CANCEL has these effects:
Cancels the label format that is currently printing.
If no label format is printing, the next one to be printed is canceled.
If no label formats are waiting to be printed, CANCEL is ignored.
To clear the print engines entire label format memory, press and hold CANCEL until
the DATA light turns off.
FEED Feeds a blank label.
If the print engine is idle or paused, the label is fed immediately.
If the print engine is printing, the label is fed after the current batch finishes
printing.
CALIBRATE CALIBRATE functions only in PAUSE mode. Press CALIBRATE to recalibrate for
proper media length, to set media type (continuous/noncontinuous), and to set print
method (direct thermal/thermal transfer).
Table 1 Front Panel Buttons (Continued)
Button Description/Function
Table 2 Front Panel Lights
LED OFF Indicates ON Indicates FLASHING Indicates
POWER
(Green)
Print engine is
OFF, or no power
to print engine.
Power switch is ON, and power is
being supplied to print engine.
PAUSE
(Yellow)
Normal operation. One of the following:
Print engine is paused because of
an error condition (printhead,
ribbon, or paper error). Usually
occurs in conjunction with
another LED.
PAUSE was pressed.
A pause was requested from the
Applicator Port.
A pause was received as part of
the label format.
DATA
(Green)
No data being
received or
processed.
Data is processing or printing is
taking place. No data is being
received.
Print engine is receiving data
from or sending status
information to the host computer.
System Description
Front Panel
MEDIA
(Yellow)
Normal operation.
Media properly
loaded.
Out of media. (Print engine is
paused, LCD displays error
message, and PAUSE light is ON).
RIBBON
(Yellow)
Normal operation.
Ribbon properly
loaded.
Ribbon in while print engine is in
direct thermal mode, or no ribbon
loaded while print engine is in
thermal transfer mode. Print engine
is paused, LCD displays error
message, and PAUSE light is ON.
ERROR
(Orange)
No print engine
errors.
Print engine error exists. Check
the LCD for status.
Table 2 Front Panel Lights (Continued)
LED OFF Indicates ON Indicates FLASHING Indicates
Power On/Off Switch
Power On/Off Switch
The power on/off switch is located on the top of the print engine housing, as shown in
Figure4. When this switch is placed in the ON (I) position, the POWER light turns on, and the
print engine automatically performs a Power-On Self Test (POST). For more information, see
Power-On Self Test onpage100.
Figure 4 Print Engine Power Switch
System Description
General Specifications
Physical
For installation information, refer to the User Guide.
Environmental Conditions
Agency Approvals
.
Height 11.8 in. (300mm)
Width 9.6 in. (245mm)
Depth 18.831 in. (478.31mm)
Weight 36 lb. (16.3 kg)
Operating Temperature
Thermal Transfer
Direct Thermal
41F to 104F (5C to 40C)
32F to 104F (0C to 40C)
Non-condensing relative humidity
Operation
Storage
20% to 95%
5% to 95%
Storage temperature 40 F to 160 F (40 C to 71 C)
Agency Approvals IEC 60950-1
EN55022, Class A
EN61000-6-2
Product Markings cULus
CE Mark
FCC-A
ICES-003
VCCI
C-Tick
CCC
Gost-R
Electrical Specifications
Communications Specifications
Memory
Power Supply Universal Power Supply with power-factor correcting 90264
VAC, 4763 Hz
Power Consumption
Idle
Printing
19 W
375 W (maximum)
Fuses 5 Amp, 250 VAC, 5 20mm IEC style, as supplied with the
print engine
Parallel Interface Bidirectional high-speed Centronics Parallel (36-pin
connector)
IEEE 1284-compliant software protocol (standard)
Serial Interfaces Serial RS-232C w/DTR hardware handshake via DB-9
connector (standard)
Serial RS-422/485 via 2- or 4-wire w/XON/XOFF
handshake on alternate pins of DB-9 connector (standard)
Configurable baud rates between 110 and 57.6K baud with
7 or 8data bits, standard parity, 1 or 2 stop bits
Fused +5V @ 750 mA supplied at pin 9 of the DB-9
connector
Network Connections ZebraNet 10/100PrintServer
Applicator Interface with
DC15F Connector
North America
Europe
5V I/O port
24-28V I/O port
Standard 10.0 MB RAM
2.0 MB Flash
Flash Options Up to 256 MB Compact Flash
32 MB PC memory card
System Description
Zebra Programming Language (ZPL II)
Bar Codes
Communicates in printable ASCII
characters
Controlled via mainframe, mini, or PC
Downloadable graphics, scalable and
bitmap fonts, label templates and formats
Object copying between memory areas
(RAM and PC memory card)
Adjustable print cache
Data compression
Automatic memory allocation for
format while printing
Bit image data transfer and printing,
mixed text/graphics
Status messages to host upon request
Format inversion (white on black)
Mirror image printing
Four-position field rotation
(normal/0, 90, 180, and 270)
Slew command
Programmable label quantities with print
and pause control
Automatic serialization of fields
User-programmable password
Portable Data Terminal
In-Spec OCR-A and OCR-B
Bar code modulus X dimensions
Picket fence (non-rotated) orientation:
203 dpi =0.0049 in. mil to 0.049 in.
300 dpi =0.0033 in. mil to 0.033 in.
Ladder (rotated) orientation:
203 dpi =0.0049 in. mil to 0.049 in.
300 dpi =0.0039 in. mil to 0.039 in.
Linear bar codes
Code 11
Code 39
Code 93
Code 128 with subsets A/B C and
UCC Case Codes
ISBT-128
UPC-A
UPC-E
EAN-8
EAN-13
UPC and EAN 2 or 5 digit extensions
Plessey
Postnet
Standard 2of 5
Industrial 2 of 5
Interleaved 2 of 5
LOGMARS
MSI
Codabar
RSS-14
Two-dimensional bar codes
Code 49
Maxi Code
PDF-417
QR Code
Codablock
DataMatrix
Micro-PDF417
Bar code ratios
2:1
7:3
5:2
3:1
Printing Specifications
Printing Specifications
Specification 112PAX4 113PAX4
Resolution 203 dots per inch
(8 dots per mm)
300 dots per inch
(12 dots per mm)
Dot size 0.0049 in. x 0.0049 in.
(0.125mm x 0.125mm)
0.0033 in. x 0.0039 in.
(0.084mm x 0.100mm)
First dot location (from inside media edge) 0.093 in. (2.4mm)
0.035 in. (0.89mm)
0.093 in. (2.4mm)
0.035 in. (0.89mm)
Maximum print width 4.1 in. (104mm) 4.2 in. (106mm)
Maximum print length (with full width media)
Non-continuous
Continuous
39 in. (990mm)
150 in. (3.810mm)
39 in. (990mm)
100 in. (2,540mm)
Programmable constant printing speeds
(per second)
2.4 in. (61mm)
3 in. (76mm)
4 in. (102mm)
5 in. (127mm)
6 in. (152mm)
7 in. (178mm)
8 in. (203mm)
9 in. (229mm)
10 in. (254mm)
11 in. (279mm)
12 in. (305mm)
2.9 in. (74mm)
3 in. (76mm)
4 in. (102mm)
5 in. (127mm)
6 in. (152mm)
7 in. (178mm)
8in. (203mm)
System Description
Media Specifications
Media Specifications
Media width
(label and
liner)
Minimum 0.625 in (16mm)
Maximum 4.5 in. (114mm)
Label length Minimum Applicator mode 0.5 in. (12.7mm) with backfeed on
0.25 in. (6mm) with backfeed off
Tear-off mode 0.5 in. (12.7mm) with backfeed on
0.25 in. (6mm) with backfeed off
Registration tolerance
(not including label/liner
position tolerances)
Vertical
(concurrent labels)
0.040 in. (1.0mm)
(in Applicator mode)
Horizontal 0.040 in. (1.0mm)
Total thickness (including liner) 0.0058 in. to 0.010 in. (0.148mm to 0.256mm)
Interlabel Gap
(TransmissiveSensor)
Minimum 0.079 in. (2mm)
Preferred 0.118 in. (3mm)
Maximum 0.157 in. (4mm)
Notch Size (W x L) 0.25 in. x 0.12 in. (6mm x 3mm)
Position On inside edge, <0.8 in (<20mm) from leading
edge of media
Hole Minimum 0.125 in. (3.2mm)
Position 0.25 to 3.0 in. (6.3 to 76.2mm) from inside edge
<0.8 in. (<20mm) from leading edge of media
Black Mark
(Reflective Sensor)
Vertical length (parallel
to inside media edge)
0.12 in. to 0.43 in. (3mm to 11mm)
Horizontal width
(perpendicular to inside
media edge)
0.43 in. (11mm)
Position Within 0.04 in. (1mm) of the inside edge and
<0.8 in (20mm) from leading edge of media
Print Line to Peel Bar Distance 0.464 in. (11.8mm)
Media Unwind Force Steady State Must be uniform and must not exceed
2lb. (907g)
Transient (Start/Stop) Must not exceed 4lb. (1814 g)
Media Rewind Force Applicator take-up pull tension must be uniform
from 1 to 4 lb. (454 to 1818 g) and must not vary
more than 20% during operation.
Ribbon Specifications
Ribbon Specifications
Standard Print Engine Font Matrices
Bit mapped fonts A, B, D, E, F, G, H, and GS are expandable up to 10 times, height and width
independent. However, fonts E and H (OCR-B and OCR-A) are not in spec when expanded.
The Scalable Smooth Font (CG Triumvirate Bold Condensed) is expandable on a dot-by-dot
basis, height and width independent, while maintaining smooth edges, to a maximum of 1500
1500 dots.
IBM Code Page 850 International characters are available in fonts A, B, D, E, F, G, and
through software control.
Thickness 4.5 microns
Width (wound coated side out) 1.0 in. to 4.2 in. (25.4mm to 107mm)
Maximum length 2955 ft. (900 m)
Roll size
Inner core diameter
Maximum roll size
1.0 in. (25.4mm)
4.2 in. (107mm)
System Description
Standard Print Engine Font Matrices
Table 3 Font Matrix for 8 dot/mm (203 dpi) Printheads
Font
Matrix Type* Character Size
Height Width
Baseline
Dots
Inter-
Character
Gap
Cell
Width
Font
Matrix
Inches Millimeters
Height Width
Char/
Inch
Height Width
Char/
mm
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 U 0.054 0.044 22.58 1.38 1.13 0.89
C,D 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
0 Default: 15 x 12 U-L-D Scalable
*U =Uppercase, L =Lowercase, D =Descenders
Table 4 Font Matrix for 12 dot/mm (300 dpi) Printheads
Font
Matrix Type* Character Size
Height Width
Baseline
Dots
Inter-
Character
Gap
Cell
Width
Font
Matrix
Inches Millimeters
Height Width
Char/
Inch
Height Width
Char/
mm
A 9 5 7 1 6 U-L-D 0.030 0.020 50.00 0.76 0.51 1.97
B 11 7 11 2 9 U 0.037 0.030 33.33 0.93 0.76 1.31
C, D 18 10 14 2 12 U-L-D 0.060 0.040 25.00 1.52 1.02 0.98
E 41 20 32 6 26 OCR-B 0.137 0.087 11.54 3.47 2.20 0.45
F 26 13 21 3 16 U-L-D 0.087 0.053 18.75 2.20 1.35 0.74
G 60 40 48 8 48 U-L-D 0.200 0.160 6.25 5.08 4.06 0.25
H 30 19 30 9 28 OCR-A 0.100 0.093 10.71 2.54 2.37 0.42
GS 24 24 24 2 26 Symbol 0.080 0.087 11.54 2.03 2.20 0.45
P 20 18 N/A N/A N/A U-L-D 0.067 0.060 N/A 1.69 1.52 N/A
Q 28 24 N/A N/A N/A U-L-D 0.093 0.080 N/A 2.37 2.03 N/A
R 35 31 N/A N/A N/A U-L-D 0.117 0.103 N/A 2.96 2.62 N/A
S 40 35 N/A N/A N/A U-L-D 0.133 0.117 N/A 3.39 2.96 N/A
T 48 42 N/A N/A N/A U-L-D 0.160 0.140 N/A 4.06 3.56 N/A
U 59 53 N/A N/A N/A U-L-D 0.197 0.177 N/A 5.00 4.49 N/A
V 80 71 N/A N/A N/A U-L-D 0.267 0.237 N/A 6.77 6.01 N/A
*U =Uppercase, L =Lowercase, D =Descenders
Applicator Pin Interface
Table 5 110PAX4 Applicator Pin Interface
Pin
#
Signal
Name
Signal
Type
Functional Description
1* SIGNAL GROUND
(+5V Return)
Ground JP1 IN Ground return for Internal +5 power source and is
available here for remote opto-isolators, if required.
(J P2 IN)
JP1 OUT Ground return for External +5V power source.
(J P2 OUT)
1* SIGNAL GROUND
(+24-28V Return)
Ground Customer must provide this external power.
2* +5V
(Fused at 750mA)
Power JP2 IN Internal +5V power source supplies power to
internal opto-isolators and is available here for remote opto-
isolators, if required. (J P1 IN)
JP2 OUT External +5V power source must be connected
here to supply power to internal opto-isolators.
2* +24-28V
(Fused at 750mA)
Power Customer must provide this external power.
3 START PRINT Input PULSE MODE The label printing process begins on the
HIGH to LOW transition of this signal, if a format is ready.
Deassert this signal HIGH to inhibit printing a new label.
LEVEL MODE Assert LOW to enable print engine to
begin printing if a format is ready. The print engine prints a
new label as long as the signal is asserted. When deasserted,
the currently printing label is completed and the print engine
stops and waits for this input to be reasserted LOW.
4 FEED Input When the print engine is in an Idle state or in Pause, assert
this input LOW to trigger repeated feeding of blank labels.
Deassert HIGH to stop feeding blank labels and to register to
the top of the next label.
5 PAUSE Input To toggle the current Pause state, this input must be asserted
LOW for 200milliseconds or until the SERVICE
REQUIRED output (pin 10) changes state.
6 REPRINT Input If the REPRINT feature is enabled, this input must be
asserted LOW to cause the print engine to reprint the last
label. (See the Configuration and Calibration Section.)
If the REPRINT feature is disabled, this input is ignored.
7 +28VDC
(Fused at 500mA)
Power Interface Power Supply supplies power to external sensors
as required.
* Applicator Boards are provided with separate part numbers for the +5V version and the +24-28V version.
System Description
8 POWER GROUND
(+28VDC return)
Ground Interface Power Ground
9 RIBBON LOW Output If the RIBBON LOW feature is enabled and the amount
of ribbon remaining on the supply spool is below a
specific threshold level, this output is asserted HIGH.
If the RIBBON LOW feature is disabled, this output lead
is disabled.
(See the Configure and Calibration Section.)
10 SERVICE
REQUIRED
Output If the media cover or printhead is open, the ribbon or
media is out, the print engine is paused, or an operational
fault has occurred, this output is asserted LOW.
If the applicator RESYNCH mode is set to Error Mode,
this signal also asserts low for a resynch error.
11 END PRINT Output OFF: Applicator Port is Off.
MODE 1: Asserted LOW only while the print engine is
moving the label forward; otherwise deasserted HIGH.
MODE 2: Asserted HIGH only while the print engine is
moving the label forward; otherwise deasserted LOW.
MODE 3: (Default) Asserted LOW for 20milliseconds
when a label has been completed and positioned. Not
asserted during continuous printing.
MODE 4: Asserted HIGH for 20milliseconds when a label
has been completed and positioned. Not asserted during
continuous printing.
12 MEDIA OUT Output Asserted LOW when media is out.
13 RIBBON OUT Output Asserted LOW when ribbon is out.
14 DATA READY Output Asserted LOW when sufficient data has been received to
begin printing the next label.
Deasserted HIGH whenever printing stops after the
current label due to either a PAUSE condition or the
absence of a label format.
15 SPARE Output To be determined
Table 5 110PAX4 Applicator Pin Interface (Continued)
Pin
#
Signal
Name
Signal
Type
Functional Description
* Applicator Boards are provided with separate part numbers for the +5V version and the +24-28V version.
Print Engine Options
Print Engine Options
Internal and External ZebraNet 10/100 Print Server
Advanced counter
8 MB, 32 MB PCMCIA Flash Card
Additional fonts available on PCMCIA Flash Cards
32 MB, 64 MB, 128 MB, 256 MB Compact Flash Memory Card
Wireless option (provides socket for PCMCIA Radio Card)
Firmware support for downloadable TrueType fonts
System Description
Main Print Engine Assembly Locations
Platen Roller
See Figure5. The platen roller provides the frictional force to drive media under the printhead.
It also provides the compliant surface that resists the printhead pressure necessary for
conventional thermal transfer printing. It is driven by the print engines stepper motor through
two drive belt stages.
Figure 5 Platen Roller
Platen Roller
Peel Roller Assembly
See Figure6. The 110PAX4 Series peel roller assembly is located farther away from previous
assemblies, allowing the label sensors to be located closer to the print line. The assembly
consists of a spring-loaded knurled roller in a pivoting frame that can be unlatched to allow
media liner loading.
The supported pivoting frame is around inboard and outboard pins. In the latched position, the
knurled roller is in position for the media liner to achieve a wrap angle around the elastomer
peel roller. This increases the driving force on the liner that assists in reducing liner slack and
improves label peeling.
Figure 6 Peel Roller Assembly
Peel
Roller
Latch
Peel Roller
Bracket Assembly
Mounting Screw
Peel Roller
Bracket Assembly
Open/Close
System Description
Ribbon Tension Control Assembly
See Figure7. The ribbon tension control assemblys main function is to provide appropriate
output to the DC motors on the ribbons supply and take-up spindles in response to ribbon
dancer arm movement to control the ribbons tension.
Figure 7 Ribbon Tension Control Assembly
A magnet is attached to each dancer arm. In the center of each magnets path is a fixed location
Hall effect sensor mounted on the main frame. As the dancer arm moves in response to
changes in the ribbons tension, the magnetic flux varies, causing the output voltage to vary
accordingly. The voltage is processed by the ribbon/tension control subsystems electronics
and provides the appropriate signals to the motor control board for the DC motors and thereby
the ribbons tension.
Ribbon Supply
Spindle Assembly
Ribbon Take-Up
Spindle Assembly
Lower Dancer
Assembly
Upper Dancer
Assembly
DC Power Supply Assembly
See Figure8. The DC power supply provides power for the printhead, the +5V system power,
and the stepper motor drive circuit.
Figure 8 DC Power Supply Assembly (RH Shown)
AC Power Supply Assembly
See Figure9. This modified board contains a transformer and choke to allow +32 VDC to be
generated for use by the printhead
Figure 9 AC Power Supply Board
System Description
Drive System
See Figure10. The 110PAX4 drive system uses a series of pitch timing belts and pulleys. The
staged belt drive systems consist of one stage from stepper motor to a compound pulley and
another serpentine stage from the compound pulley to the pinch and peel rollers. The final
stage is from the compound pulley to the platen shaft.
The serpentine belt uses a stationary backside idler pulley to maximize timing belt wrap angle
around the pinch and peel roller pulleys. The serpentine belt also uses a spring-loaded
backside idler pulley to maintain belt tension during backfeed. Both serpentine and platen
shaft belts are constantly pretensioned by means of an extension spring.
Figure 10 Drive System
Auxiliary Pulley
Platen Pulley
Compound
Pulley
Stepper Motor
Pulley
Stepper Belt
Tensioner
Idler
Pulley
Slack Side
Idler Pulley
Peel Roller Pulley
Pinch Roller Pulley
Auxiliary Pulley
Stepper Belt
Tensioner
Stepper Motor
Pulley
Idler
Pulley
Pinch Roller Pulley Platen Pulley
Slack Side
Idler Pulley
Peel Roller Pulley
Right-Hand
Print Engine
Left-Hand
Print Engine
Compound
Pulley
Media Sensor
See Figure11. The media sensor uses an LED array in a fixed location under the media with a
moveable photo transistor above the media in line with the LED array. The black mark sensor
is on the same board as the LED array.
Figure 11 Media Sensor
There are seven LEDs in the array and one black mark sensor on the lower media sensor board
inside the pinch roller assembly. The LED array and black mark sensor are pointed upward at
the back of the media. In operating position, the photo transistor is on the upper media sensor
board inside the channel pinch roller assembly. The photo transistor is pointing downward
toward the top of the media.
Reflective
Media Sensor
Transmissive
Media Sensor
Transmissive
Media Sensor
System Description
Peel Bar
See Figure12. The peel bar creates a sharp edge over which the media liner is tensioned to
separate and present the label to the applicators label transport mechanism.
Figure 12 Peel Bar
Applicator Interface
See Figure13. The applicator interface allows the print engine to be controlled by and its
status monitored from an external program logic controller (PLC).
Figure 13 Applicator Interface
Peel Bar
Applicator
Interface

Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
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2
Oper at i ons
This chapter provides the tasks that you must complete and the issues that you must consider
before you load and configure your print engine.
If you have completed the tasks and resolved issues in the checklist in Before You Begin
onpage29, use this chapter to load the print engine, to calibrate the print engine, and to print
configuration labels.
Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unpack and Inspect the Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Report Shipping Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Store the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Print Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install the Print Engine in an Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connect the Print Engine to a Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Cord Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Select a Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Standard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Optional Print Servers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DB-15 Applicator Interface Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Interface Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Data Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Media and Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Parameters Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Operat i ons
Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Changing Password-Protected Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Default Password Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Front Panel LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ZebraNet
Print Server LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Calibrate the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Toggle Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Printhead Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Power Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Operations
Installation
Installation
Before You Begin
Review this checklist, and resolve any issues before you begin setting up your print engine.
Unpack and Inspect the Print Engine Have you unpacked the print engine and
inspected it for damage? If you have not, see Unpack and Inspect the Print Engine
onpage30.
Install the Print Engine Have you considered what factors will affect how the print
engine is installed into an applicator? Is the print engine mounted in an applicator? For
information, see Print Engine Installation onpage31.
Attach a Power Cord Do you have the correct power cord for your print engine? If
you are unsure, see Power Cord Specifications onpage38. To attach the power cord and
connect the print engine to a power source, see Connect the Print Engine to a Power
Source onpage37.
Connect to a Data Source Have you determined how the print engine will connect to
a data source (usually a computer)? For more information, see Select a Communication
Interface onpage39.
Select Media Do you have the correct media for your application? If you are unsure,
see Types of Media onpage42.
Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if
needed? If you are unsure, see Ribbon onpage50.
Operat i ons
Unpack and Inspect the Print Engine
Unpack and Inspect the Print Engine
When you unpack the print engine, save all packing materials and boxes. Inspect the print
engine for possible damage incurred during shipment.
Inspect the print engine for possible damage incurred during shipment.
Check all exterior surfaces for damage.
Raise the media door, and inspect the media compartment for damage to components.
Report Shipping Damage
If you discover shipping damage upon inspection:
Immediately notify the shipping company of the damage, and file a damage report with
them. Zebra is not responsible for any damage incurred during shipment of the equipment
and does not repair this damage under warranty.
Keep all packaging material for shipping company inspection.
Notify your authorized Zebra reseller.
Store the Print Engine
If you are not placing the print engine into immediate operation, repackage it using the original
packing materials. You may store the print engine under the following conditions:
Temperature: 40 to 160F (40 to 71C)
Relative humidity: 5% to 95% non-condensing
Shipping
If you must ship the print engine, remove any ribbon from the spindles to avoid damaging the
print engine. Carefully pack the print engine into the original container or a suitable alternate
container to avoid damage during transit. A shipping container can be purchased from Zebra if
the original packaging has been lost or destroyed.
Operations
Print Engine Installation
This section provides basic information for mounting the print engine into an applicator. The
illustrations in this section show the print engine from different angles and include
measurements and clearance needs.
Requirements
Stability When the print engine is mounted, the complete assembly must be physically
stable. When the print engine is loaded with ribbon and media, the equipment must not
become physically unstable.
Ventilation and Temperature Provide ventilation for the print engine mounting enclosure
to remove heat and ensure uninterrupted, trouble-free operation of the print engine. Ambient
air temperature surrounding the print engine must not exceed the following:
Temperature: 32 to 105F (0 to 41C)
Relative humidity: 20% to 95% non-condensing
Power Requirements Consider the current rating of the print engine during installation.
When power is applied to the print engine and the enclosing equipment, an overload condition
must not be created.
Grounding Requirements Maintain reliable grounding of the print engine. Pay particular
attention to the AC power supply connections so that earth ground is maintained through the
AC power input connector.
Clearance for Cables and Connectors Allow ample space at the rear of the print engine
for electronic connectors and dressing of the following cables: IEC power cord, serial and/or
parallel host communication cable, optional host communication cable (Ethernet), and the
discrete signal (applicator) interface cable.
Power Cord Requirements The IEC power cord does not have a strain relief on the print
engine. If the operating characteristics of the applicator include vibration or strain on the
power cord, provide an appropriate clamping mechanism to avoid unintentional disconnection
of the power cord from the print engine.
Operat i ons
Figure 14 Front View of Right-Hand Print Engine
Operations
Figure 15 Right Side View of Right-Hand Print Engine
Operat i ons
Figure 16 Rear View of Right-Hand Print Engine
Operations
Figure 17 Top View of Right-Hand Print Engine
Operat i ons
Install the Print Engine in an Applicator
This section provides the basic instructions for installing the print engine into an applicator.
To install the print engine into an applicator, complete these steps:
1. See Figure18. Install the center mounting bolt into the center hole on the applicator.
2. Carefully place the keyhole on the center mounting bolt.
3. Install the four corner mounting screws to secure the print engine to the applicator.
Figure 18 Front View of 110PAX4 Print Engine in Applicator
Caution If the print engine is installed improperly, it could fall out of the applicator and
cause injury. The center mounting bolt and four mounting screws must be installed and
secured. See Figure 18 for the location of the bolt and screws.
Note The keyhole and the center mounting bolt are designed to support the print engine
and assist in installing and removing the four mounting screws.
1 Mounting screws (four total)
2 Keyhole
3 Center mounting bolt (shown inside hole on applicator)
2 1
1
1
3
1
Operations
Connect the Print Engine to a Power Source
The power supply in the print engine automatically detects the applied line voltage and works
in the 90 to 264 VAC, 47 to 63 Hz range.
Refer to Figure19. The AC power cord must have a three-prong female connector on one end
that plugs into the mating AC power connector at the rear of the print engine. If a power cable
was not included with your print engine, refer to Power Cord Specifications onpage38.
To connect the print engine to a power source, complete these steps:
1. Turn Off (O) the print engine power switch (located on the top of the print engine
housing).
2. Plug the power cord into the AC power connector on the rear of the print engine.
Figure 19 Power Connection
3. Plug the other end of the power cord into the power source.
Caution For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use
an IEC 320 female connector and the appropriate region-specific three-conductor
grounded plug configuration.
1 AC power connector
Left-Hand Right-Hand
1 1
Operat i ons
Power Cord Specifications
Depending on how your print engine was ordered, a power cord may or may not be included.
If one is not included or if the one included is not suitable for your requirements, refer to the
following guidelines:
The overall cord length must be less than 9.8ft. (3.0 m).
The cord must be rated for at least 5 A, 250 V.
The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic
interference. The third wire in the power cord grounds the connection (Figure20).
Figure 20 Power Cord Specifications
The AC power plug and the IEC 320 connector must bear the certification mark of at least
one of the known international safety organizations shown in Figure21.
Figure 21 International Safety Organization Marks
1 AC power plug for your country
2 3-conductor HAR cable
3 IEC 320 connector
4 Contact view of plug(a) neutral, (b) earth, (c) live
1 2 3 4
a
b
c
+
R
Operations
Select a Communication Interface
The way that you connect your print engine to a data source depends on the communication
options installed in the print engine. See Data Ports onpage313 for control signal
descriptions and other additional information.
Standard Connections
Refer to Figure22. The print engine comes standard with both an Electronics Industries
Association (EIA) RS-232 serial interface (DB-9 connector) and an IEEE 1284 bidirectional
parallel interface. You may use either of these interface methods to send commands and label
formats from a host to the print engine.
Figure 22 Cable Connections
Caution Connecting a data communications cable while the power is ON may damage
the print engine.
Note You must supply all interface cables for your application. Refer to Data Cable
Requirements onpage41 for specific cable requirements.
1 DB-15 applicator interface port
2 Parallel interface connector
3 DB-9 serial interface connector
1
3
2
2
3
1
Operat i ons
Optional Print Servers
ZebraNet Wireless Print Server. For more information on this option, see the ZebraNet
Wireless Print Server User Guide (part number 13422L-001).
ZebraNet 10/100 Print Server (10/100 PS). For more information on 10/100 PS, see the
ZebraNet 10/100 Print Server User and Reference Guide (part number 47619L-001).
DB-15 Applicator Interface Connector
A DB-15 Applicator Interface Connector provides communication between the print engine
and the associated applicator hardware. In some applications, control signal timing may be a
critical element in the performance of the print engine.
System Considerations
Communications Code The print engine sends and receives American Standard Code for
Information Interchange (ASCII). This code consists of 128 characters (256 for Code Page
850) including uppercase and lowercase letters, numbers, punctuation marks, and various
control codes.
Interfaces The method of interfacing the print engine to a data source depends on the
communication options installed in the print engine and the host. The standard interfaces are
an RS-232 serial data port and an IEEE 1284 bidirectional parallel port.
Communication Specifications When communicating via an asynchronous serial data
port (RS-232), the baud rate, number of data and stop bits, the parity, and the XON/XOFF or
DTR control are user-selectable and should be set to match those of the host computer. When
communicating via the IEEE 1284 bidirectional parallel port, the previously mentioned
parameters do not apply. Refer to Changing Password-Protected Parameters onpage60 to
configure the communication parameters for the print engine.
Interface Considerations
RS-232 A serial communication method consisting of data and control signals; available as a
standard feature on most PCs and other hosts.
Advantages: Cables and connectors are readily available from computer equipment stores
and suppliers; easy to connect; two-way communication between the host and the print
engine.
Disadvantages: Slower than the parallel connection; limited to 50 feet (15.24 m) of cable.
IEEE 1284 Bidirectional Parallel A common communication method available on most
PCs and other hosts.
Advantages: Fastest of the four communication interfaces; cables and connectors are
readily available from computer equipment stores and suppliers; two-way communication
between the host and the print engine; easy to connect.
Disadvantages: Shorter recommended cable length of 6 feet (1.83 m); many computers
are equipped with only one parallel port, allowing only one IEEE 1284 bidirectional
device to be connected at a time.
Operations
Data Cable Requirements
Data cables must be fully shielded and fitted with metal or metallized connector shells.
Shielded cables and connectors are required to prevent radiation and reception of electrical
noise.
To minimize electrical noise pickup in the cable:
Keep data cables as short as possible.
Do not bundle the data cables tightly with the power cords.
Do not tie the data cables to power wire conduits.
Note Zebra print engines comply with FCC Rules and Regulations, Part 15 for Class A
Equipment using fully shielded, 6.5 ft. (2 m) data cables. Use of unshielded cables may
increase radiation above the Class B limits. Print engines comply with FCC Rules and
Regulations, Part 15, Subpart J , for Class A equipment, using fully-shielded 6-foot (2-meter)
data cables. Use of longer cables or unshielded cables may increase radiated emissions above
the Class A limits.
Operat i ons
Media and Ribbon
Media and Ribbon
Types of Media
The print engine can use various types of media (Table1). We strongly recommend the use of
Zebra-brand supplies for continuous high-quality printing. A wide range of paper,
polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the
printing capabilities of the printer and to ensure against premature printhead wear.
Table 1 Types of Media
Media Type How It Looks Description
Non-Continuous Roll
Media
The media is wound on a core. Individual
labels are separated by a gap, notch, hole,
or black mark, which enables you to see
where one label ends and the next one
begins. When using media that has holes
or notches, position the media sensor
directly over a hole or notch. Figure23
and Figure24 shows different types of
non-continuous media.
Figure 23 Non-Continuous Web Media
Figure 24 Non-Continuous Black Mark Media
Operations
Media and Ribbon
Continuous
Roll Media
The media is wound on a core and is
without gaps, holes, notches, or black
marks. This allows the image to be printed
anywhere on the label.
Fanfold Media The media is folded in a zigzag pattern.
RFID Smart Media
(for use with
RFID-capable print
engines only)
Each label has a radio frequency
identification (RFID) chip and antenna
inlay embedded between the label and the
liner. The media is made from the same
materials and adhesives as non-RFID
labels. The outline of the transponder
(which varies by manufacturer) can be
seen through the label. All smart labels
have memory that can be read, and many
have memory that can be encoded.
Table 1 Types of Media (Continued)
Media Type How It Looks Description
Operat i ons
Media and Ribbon
Load Media
Figure25 identifies the media-handling components of a right-hand print engine. A left-hand
unit contains a mirror image of these components. Figure26 onpage45 shows the print
engine with media loaded.
Figure 25 Components for Media Loading (Right-Hand)
1 Printhead latch 7 Pinch roller release button
2 Printhead assembly 8 Pinch roller assembly
3 Peel bar 9 Peel roller assembly
4 Media liner roller 10 Peel roller latch
5 Printhead locking pin 11 Lower guide post
6 Media guide 12 Upper guide post
1
2
5
6 8 9 7
3
4
12
11
10
Operations
Media and Ribbon
Figure 26 Loaded Media
To load media, complete these steps:
1. Load media on the media supply reel of the applicator (refer to the applicators user
guide).
2. Open the media door.
3. See Figure27. Press the release button on the pinch roller assembly, and allow the
assembly to pivot up.
Figure 27 Opening the Pinch Roller
4. See Figure28. Slide the outer media guide all the way out.
1 Pinch roller assembly
2 Pinch roller release button
2
1
Operat i ons
Media and Ribbon
Figure 28 Sliding the Outer Media Guide
5. See Figure29. Open the printhead assembly by unlatching the printhead latch from the
locking pin.
Figure 29 Opening the Printhead Assembly
6. See Figure30. Thread the media under the upper guide post, below the pinch roller
assembly, and under the printhead assembly.
7. See Figure30. Extend approximately 30 in. (75cm.) of media past the peel bar. Remove
and discard the labels from this exposed media.
1 Outer media guide
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
1 Printhead latch
2 Locking pin
1
1
2
Operations
Media and Ribbon
Figure 30 Threading the Media
8. See Figure31. Position the media so that it is aligned with and just touching the inner
media guide.
9. See Figure31. Position the outer media guide so that it just touches the outer edge of the
media.
Figure 31 Adjusting the Outer Media Guide
1 Upper guide post
2 Pinch roller assembly
3 Printhead assembly
4 Label
5 Liner
1 Inner media guide
2 Outer media guide
3 Media
1 2
3
4
5
1
2
3
Operat i ons
Media and Ribbon
10. See Figure27 onpage45. Press down on the pinch roller assembly until it locks closed.
11. See Figure29 onpage46. Close the printhead assembly by rotating the printhead latch
until it latches onto the locking pin.
12. See Figure32. Raise the peel roller latch so that the peel roller assembly pivots down.
Figure 32 Releasing the Peel Roller Assembly
13. See Figure33. Thread the media liner around the peel bar, under the media liner roller,
and through the peel roller assembly.
Figure 33 Threading the Liner
1 Peel roller latch
2 Peel roller assembly
Note If the applicator has an air tube, route the media liner between the air tube and the
peel bar. Do not thread the media liner over the air tube.
1 Lower guide post
2 Peel bar
3 Media liner roller
4 Peel roller assembly
1
2
2 3 4 1
Operations
Media and Ribbon
14. See Figure34. Rotate the peel roller assembly up until it locks into the closed position.
Figure 34 Closed Peel Roller Assembly
15. See Figure33. Thread the media liner past the lower guide post and around the take-up
spindle of the applicator (refer to the applicators user guide).
16. Close the media door.
Operat i ons
Media and Ribbon
Ribbon
Ribbon is a thin film that is coated on one side with wax or wax resin, which is transferred to
the media during the thermal transfer process. The media determines whether you need to use
ribbon and how wide the ribbon must be.
When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is
narrower than the media, areas of the printhead are unprotected and subject to premature wear.
When to Use Ribbon
Thermal transfer media requires ribbon for printing while direct thermal media does not.
Todetermine if ribbon must be used with a particular media, perform a media scratch test.
To perform a label scratch test, complete these steps:
1. Scratch the print surface of the media with your fingernail.
2. Did a black mark appear on the media?
Coated Side of Ribbon
Ribbon can be wound with the coated side on the inside or outside (Figure35). This print
engine can only use ribbon that is coated on the outside. If you are unsure which side of a
particular roll of ribbon is coated, perform an adhesive test or a ribbon scratch test to
determine which side is coated.
Figure 35 Ribbon Coated on Outside or Inside
If a black mark... Then the media is...
Does not appear on the media Thermal transfer. A ribbon is required.
Appears on the media Direct thermal. No ribbon is required, though
ribbon may be used to help protect the printhead
from abrasion with the media.
Outside Inside
Operations
Media and Ribbon
Adhesive Test
If you have labels available, perform the adhesive test to determine which side of a ribbon is
coated. This method works well for ribbon that is already installed.
To perform an adhesive test, complete these steps:
1. Peel a label from its liner.
2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.
3. Peel the label off of the ribbon.
4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?
Ribbon Scratch Test
If you do not have labels available, perform the ribbon scratch test. This method works best for
ribbon that is not installed.
To perform a ribbon scratch test, complete these steps:
1. Unroll a short length of ribbon.
2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the
ribbon in contact with the paper.
3. Scratch the inner surface of the unrolled ribbon with your fingernail.
4. Lift the ribbon from the paper.
5. Observe the results. Did the ribbon leave a mark on the paper?
If ink from the ribbon... Then...
Adhered to the label The ribbon is coated on the outer surface.
Did not adhere to
thelabel
The ribbon is coated on the inner surface. To verify this,
repeat the test on the inner surface of the roll of ribbon.
If the ribbon... Then...
Left a mark on the paper The ribbon is coated on the outer surface.
Did not leave a mark on
the paper
The ribbon is coated on the inner surface. To verify this,
repeat the test on the other surface of the roll of ribbon.
Operat i ons
Media and Ribbon
Load Ribbon
Use ribbon with thermal transfer media. The ribbon must be coated on the outside and wider
than the media. If the ribbon is narrower than the media, areas of the printhead are unprotected
and subject to premature wear.
Figure36 identifies the ribbon system components inside the media compartment of a right-
hand print engine. A left-hand unit contains a mirror image of these components. Figure37
onpage53 shows the print engine with ribbon loaded.
Figure 36 Components for Ribbon Loading
1 Ribbon supply spindle 7 Printhead assembly
2 Ribbon take-up spindle 8 Locking pin
3 Upper dancer assembly 9 Ribbon sensor
4 Idler roller 10 Ribbon sensor reflector
5 Auxiliary roller 11 Lower dancer assembly
6 Printhead latch
1 2
3
4
6
7
11
9 10 8
5
Operations
Media and Ribbon
Figure 37 Loaded Ribbon
To load ribbon, complete these steps:
1. See Figure38. Place a full ribbon roll onto the ribbon supply spindle so the ribbon rotates
as shown, and then push the roll toward the print engine frame until it is fully seated.
Figure 38 Placing Ribbon on the Ribbon Supply Spindle
2. See Figure39. On the lower dancer assembly, squeeze the opening tabs to pivot open the
dancer arm.
3. See Figure39. Carefully thread the ribbon through the lower dancer assembly, and then
slowly release the dancer arm.
1 Ribbon supply spindle with media
1 1
Operat i ons
Media and Ribbon
Figure 39 Opening a Dancer Assembly
4. See Figure40. Thread the ribbon between the ribbon sensor and the ribbon sensor
reflector.
Figure 40 Ribbon Sensor
5. See Figure41. Open the printhead assembly by unlatching the printhead latch from the
locking pin.
1 Opening tabs
2 Ribbon
1 Ribbon sensor reflector
2 Ribbon sensor
1 2
2 1
Operations
Media and Ribbon
Figure 41 Opening the Printhead Assembly
6. See Figure42. Thread the ribbon under the printhead assembly and then up toward the
auxiliary roller.
Figure 42 Threading Ribbon under the Printhead Assembly
7. See Figure43. Thread the ribbon over the auxiliary roller, around the idler roller, and then
up toward the upper dancer assembly.
1 Printhead latch
2 Locking pin
printhead to cool.
1 Auxiliary roller
2 Printhead assembly
1
2
2
1
Operat i ons
Media and Ribbon
Figure 43 Threading Ribbon around Rollers
8. See Figure39 onpage54. On the upper dancer assembly, squeeze the opening tabs to
pivot open the dancer arm.
9. See Figure39 onpage54. Carefully thread the ribbon through the upper dancer assembly,
and then slowly release the dancer arm.
10. See Figure44. Install an empty ribbon core onto the ribbon take-up spindle, and push the
core toward the print engine frame until it is fully seated.
11. See Figure44. Attach the end of the ribbon to the empty ribbon core with adhesive tape or
a label, and wind for several turns in the direction shown. Ensure that the ribbon winds
evenly on the spindle.
Figure 44 Loading Ribbon on the Ribbon Take-Up Spindle
12. See Figure41 onpage55. Close the printhead assembly by pivoting the printhead latch
onto the locking pin.
13. Close the media door.
1 Idler roller
2 Auxiliary roller
1 Ribbon take-up spindle with empty ribbon core
1
2
1 1
Operations
Media and Ribbon
Remove Used Ribbon
To remove used ribbon, complete these steps:
1. Open the media door.
2. Examine the ribbon. Did the ribbon run out?
If... Then...
Yes a. Remove the empty core from the ribbon supply spindle. Save the core
to use on the ribbon take-up spindle when you load ribbon.
b. Remove the used ribbon and core from the ribbon take-up spindle.
c. Install new ribbon following the instructions in Load Ribbon
onpage52.
No a. Cut the ribbon near the ribbon take-up spindle.
b. Remove the used ribbon and core from the ribbon take-up spindle.
c. Locate an empty ribbon core. If necessary, remove and discard the
used ribbon from the core removed in the previous step.
d. See Figure44 onpage56. Install the empty ribbon core onto the
ribbon take-up spindle, and push the core toward the print engine
frame until it is fully seated.
e. Thread the remaining ribbon on the ribbon supply spindle following
the instructions in Load Ribbon onpage52.
f. See Figure44 onpage56. Attach the end of the ribbon to the empty
ribbon core with adhesive tape or a label, and wind for several turns
in the direction shown. Ensure that the ribbon winds evenly on the
spindle.
Operat i ons
Parameters Overview
Parameters Overview
After you have installed the media and ribbon and the Power-On Self Test (POST) is complete,
the front panel displays PRINTER READY. You may now set print engine parameters for
your application using the front panel display and the buttons directly below it. If it becomes
necessary to restore the initial print engine defaults, see PAUSE Self Test onpage102 and
FEED Self Test onpage103.
Enter Setup Mode
To enter Setup Mode, complete these steps:
1. Press SETUP/EXIT to enter Setup mode.
2. Press either NEXT or PREVIOUS to scroll through the parameters.
Important Certain printing conditions may require that you adjust printing parameters, such
as print speed, darkness, or print mode. These conditions include (but are not limited to):
printing at high speeds
peeling the media
the use of extremely thin, small, synthetic, or coated labels
Because these and other factors affect print quality, run tests todetermine the best combination
of print engine settings and media for your application. A poor match may limit print quality
or print rate, or the print engine may not function properly in the desired print mode.
Note If the print engine is operating on an IP network, you can change the print engines
parameters in these additional ways:
with ZebraLink WebView (ZebraNet
10/100 PrintServer or ZebraNet Wireless Print

Server required). For information, see the appropriate print server user guide.
with the SetWLAN configuration utility (ZebraNet Wireless Print Server required). For
information, see the ZebraNet Wireless Print Server User Guide.
Operations
Parameters Overview
Exit Setup Mode
To leave Setup mode, complete these steps:
1. Press SETUP/EXIT.
The LCD displays SAVE CHANGES.
2. Press the left or right oval to display the save options (Table2).
3. Press NEXT to select the displayed choice.
When the configuration and calibration sequence is done, PRINTER READY displays.
Table 2 Save Options When Leaving Setup Mode
LCD Description
PERMANENT Stores values in the print engine even when power is turned
Off (O).
TEMPORARY Saves the changes until power is turned Off (O).
CANCEL Cancels all changes made since you entered Setup mode,
except for changes made to the darkness and tear-off settings,
which go into effect as soon as they are made.
LOAD DEFAULTS Restores all parameters other than the network settings back
to the factory defaults.
Note Loading factory defaults causes the print engine to
auto-calibrate.
LOAD LAST SAVE Loads values from the last permanent save.
DEFAULT NET Restores the wired and wireless network settings back to
factory defaults.
Operat i ons
Changing Password-Protected Parameters
Changing Password-Protected Parameters
Certain parameters, including the communication parameters, are password-protected by
factory default.
The first time that you attempt to change a password-protected parameter, the print engine
displays ENTER PASSWORD. Before you can change the parameter, you must enter the
four-digit numeric password. After you have entered the password correctly, you do not have
to enter it again unless you leave Setup mode by pressing SETUP/EXIT or by turning Off (O)
the print engine.
To enter a password for a password-protected parameter, complete
these steps:
1. At the password prompt, use the left oval to change the selected digit position.
2. When you have selected the digit that you wish to change, use the right oval to increase
the selected digit value. Repeat these two steps for each digit of the password.
3. After entering the password, press NEXT.
The parameter you selected to change is displayed. If the password was entered correctly,
you can change the value.
Default Password Value
The default password value is 1234. The password can be changed using the ^KP (Define
Password) ZPL II instruction or through ZebraLink

WebView (ZebraNet
PrintServer II,
10/100 Print Server, or Wireless Print Server required).
Disable the Password Protection Feature
You can disable the password protection feature so that it no longer prompts you for a
password by setting the password to 0000 via the ^KP ZPL/ZPL II command. To re-enable the
password-protection feature, send the ZPL/ZPL II command ^KPx, where x can be any
number from 1 to 9999.
Caution Do not change password-protected parameters unless you have a complete
understanding of the parameters functions. If the parameters are set incorrectly, the print
engine may function unpredictably.
Operations
Front Panel LCD
Front Panel LCD
Use the LCD display on the front panel to adjust print engine settings. Table3 shows
parameters in the order in which they are displayed when you press NEXT after entering Setup
mode. Throughout this process, press NEXT to continue to the next parameter, or press
PREVIOUS to return to the previous parameter in the cycle. When a parameter is changed, an
asterisk (*) is shown in the upper left corner of the display to indicate that the value is different
from the one currently active in the print engine. Table4 onpage80 shows the additional
parameters that appear when a wired or wireless print server is installed in the print engine.
Table 3 Print Engine Parameters (Sheet 1 of 19)
Parameter Action/Explanation
Adjust Print Darkness
Darkness (burn duration) settings depend on a variety of factors, including
ribbon type, media, and the condition of the printhead. You may adjust the
darkness for consistent high-quality printing.
If printing is too light or if there are voids in printed areas, you should
increase the darkness. If printing is too dark or if there is spreading or
bleeding of printed areas, you should decrease the darkness. Darkness
settings also may be changed by the driver or software settings.
The FEED Self Test onpage103 can be used to determine the best
darkness setting. Because the darkness setting takes effect immediately,
you can see the results on labels that are currently printing.
Important Set the darkness to the lowest setting that provides good print
quality. If the darkness is set too high, the ink may smear, the ribbon may
burn through, or the printhead may wear prematurely.
Press the right oval to increase darkness.
Press the left oval to decrease darkness.
Default: +4.0
Range: 00.0 to +30.0
Adjust Print Speed
Adjusts the speed for printing a label (given in inches per second). Slower
print speeds typically yield better print quality. Print speed changes take
effect upon exiting Setup mode.
Press the right oval to increase the value.
Press the left oval to decrease the value.
Default: 2 IPS
Range: 2 to 12 IPS for 203 dpi, 2 to 8 IPS for 300 dpi
Adjust Slew Speed
Adjusts the speed for feeding a blank label (given in inches per second).
Default: 6 IPS
Range: 1 to 12 IPS
DARKNESS +4.0
- +
PRINT SPEED
2 IPS +
SLEW SPEED
6 IPS +
Operat i ons
Front Panel LCD
Adjust Backfeed Speed
If backfeed is on, adjusts the speed at which the label backs up before
printing (given in inches per second).
Default: 2 IPS
Range: 1 to 12 IPS
Adjust the Tear-Off Position
This parameter establishes the position of the media over the
tear-off/peel-off bar after printing. Positive numbers move the media out
and negative numbers move the media in. For more information, see
Tear-Off Position Adjustment onpage129.
Each press of an oval adjusts the tear-off position by four dot rows.
Default: +0
Range: 120 to +120
Select Print Mode
Print mode settings tell the print engine the method of media delivery that
you wish to use.
Press either oval to display other choices.
Default: APPLICATOR
Selections: TEAR-OFF, REWIND, APPLICATOR
Set Media Type
This parameter tells the print engine the type of media that you are using.
Selecting continuous media requires that you include a label length
instruction in your label format (^LLxxxx if you are using ZPL or
ZPL II).
When non-continuous media is selected, the print engine feeds media to
calculate label length (the distance between two recognized registration
points of the inter-label gap, webbing, or alignment notch or hole).
Default: NON-CONTINUOUS
Selections: CONTINUOUS, NON-CONTINUOUS
BACKFEED SPEED
2 IPS +
TEAR OFF +000
- +
PRINT MODE
-APPLICATOR +
MEDIA TYPE
-NON-CONTINUOUS+
Operations
Front Panel LCD
Set the Sensor Type
This parameter tells the print engine whether you are using media with a
web (gap/space between labels, notch, or hole) to indicate the separations
between labels or if you are using media with a black mark printed on the
back. If your media does not have black marks for registration on the back,
leave your print engine at the default (WEB).
Default: WEB
Selections: WEB, MARK
Select Print Method
The print method parameter tells the print engine the method of printing
that you wish to use: direct thermal (no ribbon) or thermal transfer (using
thermal transfer media and ribbon).
Default: THERMAL TRANSFER
Selections: THERMAL TRANSFER, DIRECT THERMAL
Note Selecting direct thermal when using thermal transfer media and
ribbon creates a print engine error condition, but printing continues.
Set Print Width
Determines the printable area across the width of the label given the
resolution of the print engine.
To change value shown:
1. Press the left oval to move the cursor.
2. Press the right oval to increase the value of the digit.
To change the unit of measurement:
1. Press the left oval until the unit of measurement is active.
2. Press the right oval to toggle to a different unit of measure (mm,
inches, or dots).
Default: 104 MM for 203 dpi print engines; 105 8/12 MM for 300dpi
print engines
NOTE: Setting the width too narrow can result in portions of the label not
being printed on the media. Setting the width too wide wastes formatting
memory and can cause printing off the label and on the platen roller. This
setting can affect the horizontal position of the label format if the image
was inverted using the ^POI ZPL II command.
SENSOR TYPE
-WEB +
PRINT METHOD
-THERMAL-TRANS.+
PRINT WIDTH
- 104 0/8 MM +
Operat i ons
Front Panel LCD
Set Maximum Label Length
This parameter is used during the media portion of the calibration process.
Always set maximum label length to a value that is at least 1.0 in.
(25.4mm) greater than the actual label length (Figure45). If the value is
set to a smaller value than the label length, the print engine assumes that
continuous media is loaded, and the print engine cannot calibrate.
For example, if the label length is 5.0inches (126mm) including the
interlabel gap, set the parameter for 6.0inches (152mm). If the label
length is 7.5 inches (190mm), set the parameter for 9.0inches (229 mm).
Default: 39.0 inches (988 mm).
Range: Values are adjustable in one-inch (25.4 mm) increments.
Figure 45 Label Length
MAXIMUM LENGTH
-39.0 IN 988 MM
}
1 Label length (including interlabel gap)
2 Interlabel gap
3 Set maximum label length to approximately
this value
3
1
2
Operations
Front Panel LCD
Set Early Warning for Media
When this parameter is enabled, the print engine provides warnings when
labels are running low.
Note Update the number of labels per roll when beginning use of the
Early Warning System. Also, the print engine does not make any
adjustments when power is turned Off (O) and On(I).
Press the right or left oval to display other choices.
Default: MEDIA DISABLED
Selections: MEDIA DISABLED, MEDIA ENABLED
To change the Early Warning settings:
1. When the LCD displays EARLY WARNING, press the right or left
oval until the desired setting is listed on the LCD. (If you are
prompted for a password, enter your password using the instructions
in Changing Password-Protected Parameters onpage60.)
When the print engine detects that less than 15% of the labels remain,
WARNING MEDIA LOW appears on the LCD. If the alert function
has been enabled, an alert is also sent. When the printhead is opened
and then closed after a media warning has been received, the LCD
prompts with MEDIA REPLACED?.
Press the right oval to select YES to clear the warning and reset the
label counter.
2. When setting the Early Warning for maintenance, the LCD prompts
HEAD CLEAN?.
3. Press the right oval to select YES.
Set Early Warning for Maintenance
When this parameter is enabled, the print engine provides warnings when
the printhead needs to be cleaned.
Note Update the number of labels per roll when beginning use of the
Early Warning System. Also, the print engine does not make any
adjustments when power is turned Off (O) and On(I).
Default: MAINTENANCE DISABLED
Selections: MAINTENANCE DISABLED, MAINTENANCE
ENABLED
To change the Early Warning settings:
1. When the LCD displays EARLY WARNING, press the right or left
oval until the desired setting is listed on the LCD. (If you are
prompted for a password, enter your password using the instructions
in Changing Password-Protected Parameters onpage60.)
When setting the Early Warning for maintenance, the LCD prompts
HEAD CLEAN?.
EARLY WARNING
MEDIA DISABLED
EARLY WARNING
MAINT. OFF
Operat i ons
Front Panel LCD
List Fonts
Press the right oval to print a label that lists the available fonts in the
print engine, including standard print engine fonts plus any optional
fonts. Fonts may be stored in RAM, Flash memory, optional PCMCIA
font cards, or CompactFlash cards.
List Bar Codes
Press the right oval to print a label that lists the available bar codes in
the print engine. Bar codes may be stored in RAM, Flash memory,
optional PCMCIA cards, or CompactFlash cards.
List Images
Press the right oval to print a label that lists the available images stored
in the print engines RAM, Flash memory, optional memory card,
PCMCIA cards, or CompactFlash cards.
List Formats
Press the right oval to print a label that lists the available formats stored
in the print engines RAM, Flash memory, optional EPROM, or optional
memory card.
List Setup
Press the right oval to print a configuration label, which lists the current
print engine configuration.
List Network Settings
This selection is used to print a network configuration label, which lists the
settings for any print server that is installed.
Press the right oval to print a network configuration label.
List All
Press the right oval to print labels that list the available fonts, bar codes,
images, formats, and the current print engine and network
configurations.
LIST FONTS
PRINT
LIST BAR CODES
PRINT
LIST IMAGES
PRINT
LIST FORMATS
PRINT
LIST SETUP
PRINT
LIST NETWORK
PRINT
LIST ALL
PRINT
Operations
Front Panel LCD
Initialize Memory Card
Caution Perform this operation only when it is necessary to erase all
previously stored information from the optional PCMCIA card or
CompactFlash card.
1. Press the right oval to select YES. (If you are prompted to enter the
password, see Changing Password-Protected Parameters onpage60.
The front panel LCD asks ARE YOU SURE?.
2. Do you wish to continue?
Press the left oval to select NO to cancel the request and return to
INITIALIZE CARD prompt.
Press the right oval to select YES and begin initialization.
When initialization is complete, the print engine automatically exits
Setup mode, and the front panel displays PRINTER READY. If you
exit Setup mode while initialization is still in process, the front panel
display flashes between the phrases CHECKING B: MEMORY and
PRINTER IDLE.
Note Depending on the amount of memory in the memory card,
initialization may take up to 5 minutes to complete.
Initialize Flash Memory
Caution Perform this operation only when it is necessary to erase all
previously stored information from Flash memory.
1. Press the right oval to select YES. (If you are prompted to enter the
password, see Changing Password-Protected Parameters onpage60.
The display shows INITIALIZE FLASH?
The display shows ARE YOU SURE?.
3. Do you wish to continue?
Press the left oval to select NO to cancel the request and return to the
INITIALIZE FLASH prompt.
Press the right oval to select YES and begin initialization.
When initialization is complete, the print engine automatically exits
Setup mode, and the front panel displays PRINTER READY. If you
exit Setup mode while initialization is still in process, the front panel
display flashes between the phrases CHECKING E: MEMORY and
PRINTER IDLE.
Note Depending on the amount of free FLASH memory, initialization
may take up to 1 minute to complete.
FORMAT CARD:
A: B:
INIT FLASH MEM
YES
Operat i ons
Front Panel LCD
Print Sensor Profile
The media sensor profile may be used to troubleshoot registration
problems that may be caused when the media sensor detects preprinted
areas on the media or experiences difficulty in determining web location.
Press the right oval to start this standard calibration procedure and print
a media sensor profile.
Figure46 shows a media sensor profile. If the sensitivity of the media
and/or ribbon sensors must be adjusted, use Calibrate Media and Ribbon
Sensor Sensitivity onpage69 to adjust sensor sensitivity.
Figure 46 Media Sensor Profile
SENSOR PROFILE
PRINT
Operations
Front Panel LCD
Calibrate Media and Ribbon Sensor Sensitivity
Use this procedure to adjust sensitivity of media and ribbon sensors.
Important This procedure must be followed exactly as presented. All of
the steps must be performed even if only one of the sensors requires
adjustment. You may press the left oval at any step in this procedure to
cancel the procedure.
1. Press the right oval to start the calibration procedure.
The LOAD BACKING prompt displays.
2. Open the printhead.
3. Remove approximately 8in. (203 mm) of labels from the backing, and
pull the media into the print engine so that only the backing is between
the media sensors.
4. Leave the printhead open.
5. Press the right oval to continue.
The REMOVE RIBBON prompt displays.
6. Remove the ribbon (if used).
7. Close the printhead.
The message CALIBRATING PLEASE WAIT displays.
The print engine adjusts the scale (gain) of the signals that it receives
from the media and ribbon sensors based on the specific media and
ribbon combination being used. On the sensor profile, this essentially
corresponds to moving the peak of the graph up or down to optimize
the readings for your application.
When calibration is complete, RELOAD ALL displays.
9. Open the printhead and pull the media forward until a label is
positioned under the media sensor.
10. Reload the ribbon (if used).
11. Close the printhead.
The print engine performs an auto-calibration. During this process, the
print engine checks the readings for the media and ribbon based on the
new scale established, determines the label length, and determines the
print mode. To see the new readings on the new scale, print a sensor
profile.
Set Parallel Communications
Select the communications port that matches the one being used by the
host computer.
Default: BIDIRECTIONAL
Selections: BIDIRECTIONAL, UNIDIRECTIONAL
MEDIA AND RIBBON
CALIBRATE
PARALLEL COMM.
- BIDIRECTIONAL +
Operat i ons
Front Panel LCD
Set Serial Communications
Select the communications port that matches the one being used by the
host computer.
Important Do not change this parameter from the default. The print
engine supports only RS-232. This parameter will be eliminated in a future
version of the firmware.
Default: RS-232
Selections: RS-232, RS-422/485, RS-485 MULTIDROP
Set Baud
The baud setting of the print engine must match the baud setting of the
host computer for accurate communications to take place. Select the value
that matches the one being used by the host computer.
Default: 9600
Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800,
38400, 57600, 115200
Set Data Bits
The data bits of the print engine must match the data bits of the host
computer for accurate communications to take place. Set the data bits to
match the setting being used by the host computer.
Note Code Page850 requires the data bits to be set to 8 bits. See the
ZPL II Programming Guide for more information.
Default: 8BITS
Selections: 7BITS, 8BITS
Set Parity
The parity of the print engine must match the parity of the host computer
for accurate communications to take place. Select the parity that matches
the one being used by the host computer.
Default: NONE
Selections: EVEN, ODD, NONE
Set Host Handshake
The handshake protocol of the print engine must match the handshake
protocol of the host computer for communication to take place. Select the
handshake protocol that matches the one being used by the host computer.
Default: XON/XOFF
Selections: XON/XOFF, DTR/DSR, RTS/CTS
SERIAL COMM
- RS232 +
BAUD
- 9600 +
DATA BITS
- 8 BITS
PARITY
- EVEN +
HOST HANDSHAKE
- XON/XOFF +
Operations
Front Panel LCD
Set Protocol
Protocol is a type of error checking system. Depending on the selection, an
indicator may be sent from the print engine to the host computer signifying
that data has been received. Select the protocol that is requested by the
host computer. Further details on protocol can be found in the ZPL II
Programming Guide.
Default: NONE
Selections: NONE, ZEBRA, ACK_NAK
Note Zebra is the same as ACK_NAK, except that Zebra response
messages are sequenced. If Zebra is selected, the print engine must use
DTR/DSR host handshake protocol.
Set Network ID
Network ID is used to assign a unique number to a print engine. This gives
the host computer the means to address a specific print engine. This does
not affect TCP/IP or IPX networks.
1. Press the left oval to move to the next digit position.
Default: 000
Range: 000 to 999
PROTOCOL
- NONE +
NETWORK ID
- 000 +
Operat i ons
Front Panel LCD
Set Communications Mode
The communication diagnostics mode is a troubleshooting tool for
checking the interconnection between the print engine and the host
computer. When DIAGNOSTICS is selected, all data sent from the host
computer to the print engine prints as straight ASCII characters, with the
hex value below the ASCII text. The print engine prints all characters
received, including control codes, like CR (carriage return). A sample
printout is shown below.
Notes on diagnostic printouts are defined as follows:
FE indicates a framing error.
OE indicates an overrun error.
PE indicates a parity error.
NE indicates noise.
1. Press the right or left oval to toggle between the choices.
2. For any errors, check that your communication parameters are correct.
3. Set the print width equal to or less than the label width used for the
test. See Set Print Width onpage63 for more information.
Default: NORMAL MODE
Selections: NORMAL MODE, DIAGNOSTICS
Figure 47 Diagnostics Sample Label
Set Control Prefix Character
The print engine looks for this two-digit hex character to indicate the start
of a ZPL/ZPL II control instruction. The H that is displayed indicates
Hexadecimal and is not part of the value.
Note Do not use the same hex value for the control, format, and delimiter
character. The print engine must see different characters to work properly.
Default: 7E (tildedisplayed as a black square)
Range: 00 to FF
COMMUNICATIONS
- NORMAL MODE +
CONTROL PREFIX
- < >7EH +
Operations
Front Panel LCD
Set Format Prefix Character
The format prefix is a two-digit hex value used as a parameter place
marker in ZPL/ZPL II format instructions. The H that is displayed
indicates Hexadecimal and is not part of the value. The print engine looks
for this hex character to indicate the start of a ZPL/ZPL II format
instruction. See theZPL II Programming Guide Volume I for more
information.
Note Do not use the same hex value for the control, format, and
delimiter character. The print engine must see different characters to work
properly.
Default: 5E (caret)
Range: 00 to FF
Set Delimiter Character
The delimiter character is a two-digit hex value used as a parameter place
marker in ZPL/ZPL II format instructions. See theZPL II Programming
Guide Volume I for more information.
Note Do not use the same hex value for the control, format, and
delimiter character. The print engine must see different characters to work
properly.
Default: 2C (comma)
Range: 00 to FF
Select ZPL Mode
The print engine remains in the selected mode until it is changed by this
front panel instruction or by using a ZPL/ZPL II command. The print
engine accepts label formats written in either ZPL or ZPL II, eliminating
the need to rewrite any ZPL formats that already exist. See the ZPL II
Programming Guide for more information on the differences between ZPL
and ZPL II.
Default: ZPL II
Selections: ZPL II, ZPL
FORMAT PREFIX
- <^>5EH +
DELIMITER CHAR
- <,>2CH +
ZPL MODE
- ZPL II +
Operat i ons
Front Panel LCD
Select Media Power-Up Option
This parameter sets the action of the labels when the print engine is turned
on.
Press the right or left oval to display the choices.
Default: CALIBRATION
Selections: FEED, CALIBRATION, LENGTH, SHORT CAL, and NO
MOTION
Feedfeeds the labels to the first registration point.
Calibrationdetermines the length of the label and adjusts the sensor
settings.
LengthIn continuous mode, feeds the last stored label length. In
noncontinuous mode, calibrates based on the maximum label length
setting (see Set Maximum Label Length onpage64).
Short Calcalibrates label length using the current sensor settings.
No Motionthe media does not move. You must press FEED to cause
the print engine to resynch to the start of the next label.
Select Head Close Option
Press the right or left oval to display the choices.
Default: CALIBRATION
Selections: FEED, CALIBRATION, LENGTH, SHORT CAL, and NO
MOTION
Feedfeeds the labels to the first registration point.
Calibrationdetermines the length of the label and adjusts the sensor
settings.
LengthIn continuous mode, feeds the last stored label length. In
non-continuous mode, calibrates based on the maximum label length
setting (see Set Maximum Label Length onpage64).
Short Calcalibrates label length using the current sensor settings.
No Motionthe media does not move. You must press FEED to cause
the print engine to resynch to the start of the next label.
Select Backfeed Sequence
This parameter establishes when label backfeed occurs after a label is
removed in applicator mode. It has no effect in Rewind mode. This
parameter setting can be superseded by the ~J S instruction when received
as part of a label format (refer to ZPL II Programming Guide Volume I).
Default: BEFORE
Selections: DEFAULT, AFTER, BEFORE, OFF
MEDIA POWER UP
- CALIBRATION +
HEAD CLOSE
- CALIBRATION +
BACKFEED
- BEFORE +
Operations
Front Panel LCD
Adjust Label Top Position
The label top position adjusts the print position vertically on the label.
Positive numbers adjust the label top position further down the label (away
from the printhead); negative numbers adjust the position up the label
(toward the printhead). The displayed value represents dots.
Default: +000
Range: 120 to +120 dots
Adjust Left Position
This parameter establishes how far from the left edge of a label the format
begins to print by adjusting horizontal positioning on the label. Positive
numbers adjust the printing away from the main frame by the number of
dots selected; negative numbers shift printing toward the main frame. The
displayed value represents dots.
1. Press the left oval to move the cursor.
2. Press the right oval to change between +and to increase the value of
the digit.
3. For a negative value, enter the value before changing to the minus
sign.
Default: 0000
Range: 9999 to +9999 dots
Set the Head Resistor Value
Caution This parameter should be changed only by qualified service
personnel. Do not set the value higher than that shown on the
printhead. Setting a higher value may damage the printhead.
This value has been preset at the factory to match the resistance value of
the printhead. It does not need to be changed unless the printhead or the
main logic board is replaced.
1. Look on the printhead for the label that shows the resistance value
(value). Take note of this value before installing the replacement
printhead.
Initial Value: Factory-set to match the printhead shipped with your print
engine.
Default Value: 0500
Range: 0500 to 2000
LABEL TOP +000
- +
LEFT POSITION
- 0000 +
HEAD RESISTOR
- 0500 OHMS +
Operat i ons
Front Panel LCD
Set the Applicator Port
Determines the action of the applicator port.
Note Set this value as suggested by the applicator manufacturer.
Off: The applicator port is off.
Mode 1: Asserts the ~END_PRINT signal low while the print
engine is moving the label forward.
Mode 2: Asserts the ~END_PRINT signal high while the print
engine is moving the label forward.
Mode 3: Asserts the ~END_PRINT signal low for 20milliseconds
when a label has been completed and positioned. Not asserted during
continuous printing modes.
Mode 4: Asserts the ~END_PRINT signal high for 20 milliseconds
when a label has been completed and positioned. Not asserted during
continuous printing modes.
Default: OFF
Selections: OFF, MODE 1, MODE 2, MODE 3, MODE 4
Select Start Print Signal
This parameter determines how the print engine reacts to the Start Print
Signal input on pin 3 of the applicator interface connector at the rear of the
print engine.
Pulse ModeLabels print when the signal transitions from HIGH to
LOW.
Level ModeLabels print as long as the signal is asserted LOW.
Caution Start Print Signal is set by the applicator manufacturer and
should not be changed unless the factory defaults have been reloaded.
Please make a note of it. While other choices are valid, the print engine
must be returned to its designated setting for it to work properly.
Default: PULSE MODE
Selections: PULSE MODE, LEVEL MODE
APPLICATOR PORT
- OFF +
START PRINT SIG
- PULSE MODE +
Operations
Front Panel LCD
Select Resynch Mode
This parameter determines how the print engine reacts if the label
synchronization is lost and the label top is not where expected.
Feed ModeIf the label top is not where expected, the print engine
feeds a blank label to find the label top position.
Error ModeIf the label top is not where expected, the print engine
stops, enters Pause mode, displays the message Error
Condition Feed Label, flashes the ERROR light, and
asserts the Service Required signal (pin 10 on the Applicator
Interface Connector).
To resynch the media to the top of the label in Error mode, press
PAUSE to exit Pause mode. The ERROR light stops flashing, and the
Service Required signal is deactivated. The action of the print engine
is determined by the Head Close configuration selection (see
Select Head Close Option onpage74).
Press the right or left oval to toggle between choices.
Default: FEED MODE
Selections: FEED MODE, ERROR MODE
Set Ribbon Low Mode
When the Ribbon Low feature is off, the output signal (Pin 9) does not
function, the LOW RIBBON warning is not displayed, and the print
engine continues to print until it runs out of ribbon.
When the Ribbon Low feature is set to any of the lengths, output signal
(Pin9) on the applicator port is functional. When the amount of ribbon on
the supply spindle reaches the specific length, the output signal asserts
HIGH to provide a RIBBON LOW warning.
Default: 25M
Selections: OFF, 25M, 50M, 75M, 100M
Set Reprint Mode
When the Reprint feature is enabled, the reprint input signal (Pin 6) on the
applicator port is functional. When the input signal is asserted, the last
label printed is printed again. (This includes non-printing labels.) When
the Reprint feature is disabled, the reprint input signal is ignored.
Note The ^SP ZPL command is ignored when the Reprint feature is
enabled. When the Reprint feature is disabled, the ^SP command can be
used. In addition, when a received label format is canceled prior to
printing, the reprint function for the previous label is also canceled. Refer
to the ZPL II Programming Guide for additional information.
Default: DISABLED
Range: ENABLED, DISABLED
RESYNCH MODE
- FEED MODE +
RIBBON LOW MODE
- 25M +
REPRINT MODE
- DISABLED +
Operat i ons
Front Panel LCD
These parameters are automatically set during the calibration procedure
and should be changed only by a qualified service technician. Refer to the
ZPL II Programming Guide for information on these parameters.
Press NEXT repeatedly to skip these parameters.
Adjust LCD Display
This parameter allows you to adjust the brightness of your LCD if it is
difficult to read.
Press the left oval to decrease the value (reduce brightness).
Press the right oval to increase the value (increase brightness).
Default: 10
Range: 00 to 19
Select Format Convert
Selects the bitmap scaling factor. The first number is the original dots per
inch (dpi) value; the second, the dpi to which you would like to scale.
Default: NONE
Selections: NONE, 150 300, 150 600, 200 600, 300 600
Set RTS Takeup Dancer Arm Calibration Value
This parameter is used as a diagnostic tool to monitor the voltage supplied
to the Ribbon Tensioning System Takeup Dancer Arm.
Set RTS Supply Dancer Arm Calibration Value
This parameter is used as a diagnostic tool to monitor the voltage supplied
to the Ribbon Tensioning System Supply Dancer Arm.
WEB S. 073
- +
MEDIA S. 075
- +
RIBBON S. 071
- +
MARK S. 000
- +
MARK MED S. 000
- +
MEDIA LED 082
- +
MARK LED 005
- +
RIBBON LED 008
- +
LCD ADJUST +10
- +
FORMAT CONVERT
- NONE +
RTS TAKEUP ARM
XXX
RTS SUPPLY ARM
XXX
Operations
Front Panel LCD
ZebraNet
Print Server LCD Displays

The menu options shown in Table4 display only if you have the ZebraNet 10/100PrintServer
or the Wireless Print Server installed.
Select Idle Display
This parameter selects the LCD options for the real-time clock.
Note If the default value is not selected, pressing either oval briefly
displays the firmware version of the print engine.
Default: FIRMWARE VERSION
Selections: MM/DD/YY (24 HOUR), MM/DD/YY (12HOUR),
DD/MM/YY (24 HOUR), DD/MM/YY (12HOUR), FW VERSION
Set RTC Date
This parameter allows you to set the date following the convention
selected in IDLE DISPLAY.
2. Press the right oval to change the value of the digit.
Set RTC Time
This parameter allows you to set the time following the convention
selected in IDLE DISPLAY.
2. Press the right oval to change the value of the digit.
Select the Display Language
This parameter allows you to change the language displayed on the front
panel LCD.
Default: ENGLISH
Selections: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN,
NORWEGIAN, PORTUGUESE, SWEDISH, DANISH, SPANISH 2,
DUTCH, FINNISH, J APAN
IDLE DISPLAY
- FW VERSION +
RTC DATE
- 01/31/01 +
RTC TIME
- 14:55 +
LANGUAGE
-ENGLISH +
Operat i ons
Front Panel LCD
Table 4 Print Server LCD Displays
LOAD LAN FROM?
1
This parameter, which serves the same function as the ^NP ZPL command,
specifies whether to use the printers or the print servers IP settings at bootup.
Accepted Values: PRINTER, PRINTSERVER
Default Value: PRINTER
WIRED PS
CHECK?
1
This parameter, which serves the same function as the ^NB ZPL command, tells the
printer whether to search for a wired print server at bootup.
Accepted Values: YES, NO
Default Value: NO
IP PROTOCOL
2
IP Protocol
Allows either the user (permanent) or the server (dynamic) to select the IP address.
If a dynamic option is chosen, this selection determines the method(s) by which the
print server (wired or wireless) receives the IP address from the server.
Default: ALL
Selections: ALL, GLEANING ONLY, RARP, BOOTP, DHCP, DHCPAND
BOOTP, PERMANENT
Note Use of GLEANING ONLY is not recommended when the Wireless Print
Server is installed.
IP ADDRESS
2
IP Address
This parameter allows you to select the IP address if PERMANENT was chosen in
IP PROTOCOL. (If a dynamic option was chosen, the user cannot select the
address.)
SUBNET MASK
2
Subnet Mask
This parameter selects the part of the IP address that is considered to be part of the
local network. It can be reached without going through the default gateway.
DEFAULT
GATEWAY
2
Default Gateway
This parameter allows you to select the IP address that the network traffic is routed
through if the destination address is not part of the local network.
1 Appears only when the ZebraNet Wireless Print Server is installed.
2 These parameters appear after the system recognizes the existence of a ZebraNet print server (wired or wireless). After the
print server is recognized, all zeroes (000.000.000.000) will display until the printer obtains an IP address or defaults to
address 192.168.254.254.
3 If a wireless password is set, you must enter the wireless password (not the printer password) to access this parameter.
4 This parameter appears 1) when no wireless card is inserted or 2) when the wireless card is associated to the WLAN and the
card supports LEAP.
Operations
Front Panel LCD
MAC ADDRESS
1,3
MAC Address
This parameter cannot be changed through the front panel.
ESSID
1,3
ESSID
This parameter cannot be changed through the front panel.
AUTH. TYPE
1,3
Authentication Type
Default: OPEN
Selections: OPEN, SHARED
LEAP MODE
3,4
An encryption method that is available with some wireless cards. Set the LEAP
user name and password through the printer web pages.
Accepted Values: ON, OFF
Default Value: OFF
ENCRYPTION
MODE
1,3
Encryption Mode
Default: OFF
Selections: OFF, 40-BIT, 128-BIT
ENCRYPTION
INDEX
1,3
Encryption Index
Default: 1
Selections: 1, 2, 3, 4
RESET
NETWORK
2,3
Reset Network
This option resets the wireless card and the print server when the wireless option is
running. Selecting this option has no effect when the wireless option is not running,
when there is no card inserted, or when the wireless password is anything other
than the default (zero).
The LCD prompts ARE YOU SURE?.
Press the left oval to select NO to cancel the request.
Press the right oval to select YES and reset the network.
Table 4 Print Server LCD Displays (Continued)
1 Appears only when the ZebraNet Wireless Print Server is installed.
2 These parameters appear after the system recognizes the existence of a ZebraNet print server (wired or wireless). After the
print server is recognized, all zeroes (000.000.000.000) will display until the printer obtains an IP address or defaults to
address 192.168.254.254.
3 If a wireless password is set, you must enter the wireless password (not the printer password) to access this parameter.
4 This parameter appears 1) when no wireless card is inserted or 2) when the wireless card is associated to the WLAN and the
card supports LEAP.
Operat i ons
Calibrate the Print Engine
Calibrate the print engine when it is first put into service. Calibration allows the print engine to
establish the proper settings for the specific media and ribbon used in your application. You
may calibrate the print engine at other times as needed. Table5 shows the different methods
for calibration.
Table 5 Types of Calibration
Type of Calibration Description When/How It Occurs
Auto-calibration The print engine automatically sets
the value it detects for the spaces
between labels.
Occurs at the following times:
When the print engine is first
turned on if CALIBRATION is
selected for MEDIA POWER UP
(see Select Media Power-Up
Option onpage74)
When the print engine feeds media
after the printhead is closed if
CALIBRATION is selected for
HEAD CLOSE (see Select Head
Close Option onpage74).
As part of both the sensor profile
and media and ribbon sensor
calibration procedures.
Long (Standard)
Calibration
The print engine does the following:
feeds media and ribbon
sets the values it detects for media
length, media type (continuous or
non-continuous), and print mode
(thermal transfer or direct thermal)
updates the sensor values
To perform a long calibration, do one
of the following:
Press PAUSE on the front panel to
pause the print engine, and then
press CALIBRATE.
Select CALIBRATION for the
MEDIA POWER UP or HEAD
CLOSE parameter (see Select
Media Power-Up Option
onpage74 or Select Head Close
Option onpage74).
Short Calibration The print engine calibrates using the
current sensor values rather than
detecting the spaces between labels
and resetting the sensors. This
calibration sequence uses fewer
labels than the long calibration
sequence, but it is less reliable
because the values that are stored in
the sensors could be incorrect.
Select SHORT CAL for the MEDIA
POWER UP or HEAD CLOSE
parameter (see Select Media
Power-Up Option onpage74 or
Select Head Close Option
onpage74).
Operations
Calibrating Sensor Sensitivity
The Media and Ribbon Sensor Calibration procedure includes the following functions:
Prompts the user to load just the liner in the media sensor path and remove the ribbon from
the ribbon sensor area.
Prepares the print engine to adjust automatically the gain of the media sensor amplifier on
the media sensor to produce a 3-volt output while sensing just the liner.
Prepares the print engine to adjust the gain of the ribbon sensor amplifier on the ribbon
sensor to produce a 2-volt output while no ribbon is in the path of the ribbon sensor.
Sensing Typical Thermal Transfer Non-Continuous Die-Cut Labels
Once the user has loaded the liner and removed the ribbon, continuing the process adjusts the
gain of the sensor amplifiers. The result of this process is indicated on the Print Configuration
Label as:
Media LEDDuty cycle applied to the media sensor amplifier on the media sensor to
achieve the 3-volt output while viewing only the liner.
Ribbon LEDDuty cycle applied to the ribbon sensor amplifier on the ribbon sensor to
achieve the 2-volt output while viewing only the reflector (ribbon out condition).
Reinstalling the ribbon and media and continuing the process (media is feeding) automatically
adjusts the remaining sensor values needed for the print engine to function properly. These
values are determined as follows:
The maximum label length setting is read and the print engine begins feeding labels to
determine the web sensor value. This value is indicated on the Print Configuration Label as:
Web SensorThe voltage level distinguishing liner only from label plus liner,
specified as a percentage of 5 volts.
Sensor Profile
Calibration
The print engine auto-calibrates and
prints a media sensor profile.
Select the SENSOR PROFILE
option on the front panel. See Print
Sensor Profile onpage68 for
instructions.
Media and Ribbon
Sensor Sensitivity
Calibration
One of the most common
adjustments to print engine settings.
The print engine resets the sensitivity
of the sensors to detect correctly the
media and ribbon that you are using.
If you change the type of ribbon
and/or media, you might need to reset
the sensitivity of the media and
ribbon sensors. When the sensors are
at their new sensitivity, the print
engine performs an auto-calibration.
Select the MEDIA AND RIBBON
CALIBRATE option on the front
panel. See Calibrate Media and
Ribbon Sensor Sensitivity onpage69
for instructions.
Table 5 Types of Calibration (Continued)
Type of Calibration Description When/How It Occurs
Operat i ons
Media SensorThe Paper Out value equals a certain percentage of 5 volts. This is
hard-coded at 75% (5 volts 75% =3.75 volts).
The ribbon sensor value is calculated and indicated on the Print Configuration Label as:
Ribbon SensorDetermined by taking 75% of the minimum ribbon in calculation.
This is displayed as a percentage of 5 volts.
The label length is now measured by feeding one label and indicated on the Print
Configuration Label as:
Label LengthThe distance (in dot rows) between the rising edge of consecutive peaks
as it crosses the web value minus 2 mm.
Calibrating Media and Ribbon Sensor Sensitivity
Enter Program Mode by pressing SETUP/EXIT when the LCD Panel displays PRINTER
READY. Press NEXT until the LCD displays SENSOR PROFILE.
Setting Communication Parameters
Communication parameters must be set correctly for the print engine to receive data from the
host. These parameters ensure that the print engine and host are speaking the same language.
All communications parameters are password protected.
Note Ensure that the Media Type and Maximum Length values have been configured
prior to performing this calibration process. If the maximum length is set to a value less than
the length of the labels, the calibration process assumes that continuous media is in the print
engine.
Operations
Toggle Positioning
Toggle Positioning
Proper toggle positioning is important for proper print quality. The toggle should be positioned
approximately midway across the width of the media.
To adjust the toggle, complete these steps:
1. See Figure48. Loosen the position locking nut by rotating it to the left.
2. Slide the toggle to the desired position on the toggle shaft.
3. Finger tighten the position locking nut by rotating it to the right.
Figure 48 Toggle Positioning (Right-Hand Unit Shown)
1 Toggle shaft
2 Position locking nut
2
1
Operat i ons
Printhead Pressure Adjustment
Before adjusting the printhead pressure, check that the toggle is positioned correctly. See
Toggle Positioning onpage85.
You may need to adjust the printhead pressure in the following instances:
if there is noticeable bleed or swelling in the printed image (too much pressure)
if there are voids (too little pressure)
if the darkness setting (burn duration) is set properly, but printing is too light (too little
pressure)
To adjust printhead pressure, complete these steps:
1. See Figure49. As a starting point for adjustment, set the position of the adjusting nut so
that when the locking nut is tightened, it is approximately 7/16 in. (11 mm) from the yoke.
2. Refer to Adjust Print Darkness onpage61 to set the darkness value (burn duration)
appropriately for your media and ribbon.
3. Refer to PAUSE Self Test onpage102 to print test labels.
4. Adjust the position of the adjusting nut until the print quality is acceptable (turning it
clockwise increases the spring pressure, and counterclockwise decreases the pressure).
Use the lowest pressure that provides the desired print quality.
5. Hold the adjusting nut in position, and tighten the locking nut against it.
Figure 49 Printhead Pressure Adjustment
Note Printhead and drive system (belts and bearings) life can be maximized by using the
lowest pressure that produces the desired print quality.
1 Yoke
2 Locking nut
3 Adjusting nut
7/16 inch
(11 mm)
2
3
1
Operations
Power Fuse Replacement
The print engine uses a metric-style fuse (5 20 mm IEC) rated for 5 Amps at 250 Volts that
bears the certification mark of a known international safety organization (see Figure21
onpage38). The power entry module comes with two approved fuses in the fuse holder: one is
in-circuit and the other is a spare.
To replace a fuse, complete these steps:
1. See Figure50. Turn off the print engine and unplug the power cord from the back of the
print engine.
2. Using a small-blade screwdriver, remove the fuse holder from the power entry module at
the rear of the print engine.
3. Carefully remove the fuse from the in-circuit location.
4. To remove the spare fuse, gently push the point of a pencil or the end of a paperclip
through one of the two holes in the fuse holder. Repeat through the other hole.
5. Insert the spare fuse in the in-circuit location.
6. Place a new fuse in the spare fuse location.
7. Reinstall the fuse holder into the power entry module at the rear of the print engine.
8. Reconnect the power cord and turn the print engine on.
The print engine should be ready for operation and the POWER light should be on. If
power is not restored, an internal component failure may have occurred, and the print
engine may require servicing. See Troubleshooting Checklists onpage90.
Figure 50 Installing a Fuse
Operat i ons

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3
Tr oubl eshoot i ng
This section contains tables showing symptom, diagnosis, and action columns. These tables
help the technician to diagnose print engine faults and determine the repair needed.
This chapter provides you with information about LCD, print quality, communications, and
other errors that you might need to troubleshoot. The following tables provide symptoms,
diagnoses of probable causes, and recommended actions that should result in proper print
engine operation.
Contents
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Miscellaneous Print Engine Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Print Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Additional Print Engine Self Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Communications Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Troubl eshoot i ng
Troubleshooting Checklists
If you encounter any problems that cannot be corrected with the aid of this manual, contact
Zebras Technical Support immediately to minimize or avoid print engine downtime.
Technical Support can also assist in determining if the print engine should be returned for
repair (see the Product Support Services sheet at the back of this manual).
Troubleshooting Checklists
If an error condition exists with the print engine, review this checklist:
Is there an error message on the LCD? If yes, see LCD Error Messages onpage91 for
more information.
Is the CHECK RIBBON light on when ribbon is loaded properly, or are noncontinuous
labels being treated as continuous labels? If yes, see Calibrating Media and Ribbon
Sensor Sensitivity onpage84.
Are you experiencing problems with print quality? If yes, see Print Quality Problems
onpage94.
Are you experiencing communications problems? If yes, see Communications Problems
onpage97.
If the labels are not printing or advancing correctly, review this checklist:
Are you using the correct type of labels? Review the types of label in Types of Media
onpage42.
Review the label- and ribbon-loading illustrations in Load Media onpage44 and Load
Ribbon onpage52.
Check the position of the media sensor and move if necessary, as shown in Adjusting the
Sensors onpage130.
Does the printhead need to be adjusted? See Printhead Pressure Adjustment onpage86
for more information.
Do the sensors need to be calibrated? See Calibrating Media and Ribbon Sensor
Sensitivity onpage84 for more information.
If none of the above suggestions correct the problem, review this checklist:
Perform one or more of the self-tests given in Print Engine Diagnostics onpage100. Use
the results to help identify the problem.
If you are still having problems, see Support onpagexi for customer support information.
Troubleshooting
LCD Error Messages
LCD Error Messages
The LCD displays messages when there is an error. See Table6 for LCD errors, the possible
causes, and the recommended solutions.
Table 6 LCD Error Messages
LCD Display/
Print Engine Condition
Possible Cause Recommended Solution
Print engine stops; RIBBON
light ON, ERROR light
flashes.
In thermal transfer mode, ribbon is
not loaded or incorrectly loaded.
Load ribbon correctly. See Load
Ribbon onpage52.
In thermal transfer mode, the
ribbon sensor is not detecting
ribbon that is loaded incorrectly.
1. Load ribbon correctly. See Load
Ribbon onpage52.
2. Calibrate the sensors. See
Calibrating Media and Ribbon
In thermal transfer mode, media is
blocking the ribbon sensor.
1. Load media correctly. See Load
Media onpage44.
2. Calibrate the sensors. See
Calibrating Media and Ribbon
RIBBON light ON, ERROR
light flashes.
Ribbon is loaded, but the print
engine is set for direct thermal
mode.
Ribbon is not required with direct
thermal media. Remove ribbon unless
you are using it to protect the
printhead. This error message will not
affect printing.
Print engine stops; MEDIA
light ON, ERROR light
flashes.
Media is not loaded or is loaded
incorrectly.
Load media correctly. See Load Media
onpage44.
Misadjusted media sensor. Check position of the media sensor.
The print engine is set for
noncontinuous media, but
continuous media is loaded.
Install proper media type, or reset print
engine for current media type and
perform calibration.
Print engine stops and
ERROR light flashes.
The printhead is not fully closed. Close printhead completely.
The head open sensor is not
working properly.
Call a service technician.
ERROR CONDITION
RIBBON OUT
WARNING
RIBBON IN
ERROR CONDITION
PAPER OUT
ERROR CONDITION
HEAD OPEN
Troubl eshoot i ng
LCD Error Messages
Caution The printhead may be hot enough to cause severe
burns. Allow the printhead to cool.
Caution Observe proper electrostatic safety precautions when
handling any static-sensitive components such as circuit boards
and printheads.
The printhead is over temperature. Printing automatically resumes when
the printhead elements cool to an
acceptable operating temperature.
Caution An improperly connected printhead data or power
cable can cause this error message. The printhead may be hot
enough to cause severe burns. Allow the printhead to cool.
Caution Observe proper electrostatic safety precautions when
handling any static-sensitive components such as circuit boards
and printheads.
The printhead is under
temperature.
Continue printing while the printhead
reaches the correct operating
temperature. If the error remains, the
environment may be too cold for
proper printing. Relocate the print
engine to a warmer area.
The printhead data cable is not
properly connected.
Caution You must turn off the print
engine before performing this
procedure. Failure to do so can
damage the printhead.
1. Turn off (O) the print engine.
2. Disconnect and reconnect the data
cable to the printhead.
3. Ensure that the cable connector is
fully inserted into the printhead
connector.
4. Turn on (I) the print engine.
Table 6 LCD Error Messages (Continued)
LCD Display/
Print Engine Condition
Possible Cause Recommended Solution
WARNING
HEAD TOO HOT
WARNING
HEAD COLD
Troubleshooting
Memory Errors
Memory Errors
The memory errors in Table7 indicate that the print engine does not have enough memory to
perform the function shown on the second line of the LCD.
Table 7 Memory Errors
Problem/LCD Display Possible Cause Recommended Solution
Creating Bitmap
The bitmap size (label
length/width) does not fit in
available memory.
You may do any of the following:
1. With PAUSE on, send a ~HM ZPL
command to the print engine to
display the amount of free memory.
Then do one of the following:
Redesign graphic/format to fit
available memory or remove
items from memory to create
more space.
Press PAUSE to skip the
formatting step in process and
proceed to the next step.
2. With PAUSE on, press CANCEL.
The print engine skips the current
label formatting process and goes to
the next label.
3. Turn the print engine OFF (O) and
then ON (I) to clear the print engines
memory.
4. Upgrade the print engine to a larger
memory size.
Storing Bitmap
Not enough memory is
available to store the bitmap
created.
Building Format
Label is too complex.
Storing Format
Format is too large to fit in
available memory.
Storing Graphic
The graphic image is too large
to fit in available memory.
Storing Font
Not enough memory available
to store the font.
OUT OF MEMORY
CREATING BITMAP
OUT OF MEMORY
STORING BITMAP
OUT OF MEMORY
BUILDING FORMAT
OUT OF MEMORY
STORING FORMAT
OUT OF MEMORY
STORING GRAPHIC
OUT OF MEMORY
STORING FONT
Troubl eshoot i ng
Print Quality Problems
Table8 identifies problems with print quality, the possible causes, and the recommended
solutions.
Table 8 Print Quality Problems
Problem Possible Cause Recommended Solution
General print
quality issues
You are using an incorrect
combination of labels and
ribbon for your application.
Consult your authorized Zebra reseller or
distributor for information and advice.
The print engine is set at the
incorrect print speed.
For optimal print quality, set the print speed to
the lowest possible setting for your application
via ZPL II, the driver, or the software. See
Adjust Print Speed onpage61.
The print engine is set at an
incorrect darkness level.
For optimal print quality, set the darkness to the
lowest possible setting for your application via
the front panel, the driver, or the software. See
Adjust Print Darkness onpage61.
The printhead is dirty. Clean the printhead according to the instructions
in Cleaning the Printhead and Rollers
onpage115.
Caution The printhead may be hot
enough to cause severe burns. Allow
the printhead to cool.
Caution Observe proper
electrostatic safety precautions
when handling any static-sensitive
components such as circuit boards
and printheads.
Troubleshooting
Wrinkled ribbon Ribbon fed through the
machine incorrectly.
See Load Ribbon onpage52.
Incorrect burn temperature. Set the darkness to the lowest possible setting
for good print quality. See Adjust Print
Darkness onpage61.
Incorrect or uneven pressure. Set the pressure to the minimum needed for
good print quality. See Printhead Pressure
Adjustment onpage86.
Media not feeding properly;
walking from side to side.
Make sure that media is snug by adjusting the
media guide, or call a service technician.
The strip plate needs adjusting. Perform adjustment (seeSection 4 for strip plate
adjustment).
The printhead needs vertical
adjustment.
Perform adjustment (seeSection 4 for printhead
adjustment).
The printhead and platen roller
need to be realigned.
Perform adjustment (seeSection 4 for printhead
adjustment).
Long tracks of
missing print on
several labels
Wrinkled ribbon. See wrinkled ribbon causes and solutions in this
table.
Print element damaged. Replace printhead (see Section 4 for printhead
removal).
Fine, angular gray
lines on blank labels
Wrinkled ribbon. See wrinkled ribbon causes and solutions in this
table.
Light printing or no
printing on the left
or right side of the
label
Printhead pressure needs
adjustment, printhead out of
alignment, or toggle in
incorrect position.
See Toggle Positioning onpage85 and
Printhead Pressure Adjustment onpage86.
Call a service technician.
Printing too light or
too dark over the
entire label
Media or ribbon is not
designed for high-speed
operation.
Replace supplies with those recommended for
high-speed operation.
Incorrect or uneven printhead
pressure.
Set the pressure to the minimum needed. See
Printhead Pressure Adjustment onpage86.
Smudge marks on
labels
Media or ribbon not designed
for high-speed operation.
Replace supplies with those recommended for
high-speed operation.
Misregistration/skips
labels
Media sensor not positioned
correctly.
Perform media sensor position adjustment.
The print engine not
calibrated.
Recalibrate the print engine.
Improper label format. Use correct label format.
Table 8 Print Quality Problems (Continued)
Troubl eshoot i ng
Misregistration and
misprint of one to
three labels
Media sensor is not positioned
correctly.
Place media sensor in proper position.
The platen roller is dirty. Clean the platen roller according to the
instructions in Cleaning the Printhead and
Rollers onpage115.
Media does not meet
specifications.
Use media that meets specifications.
Vertical drift in
top-of-form position
A plus or minus 4 to 6 dot row
(approximately 0.5 mm)
vertical drift is acceptable due
to different tolerances of
mechanical parts and print
engine modes.
1. Calibrate print engine.
2. Adjust the label top position setting. See
Adjust Label Top Position onpage75.
The print engine is out of
calibration.
Recalibrate the print engine.
The platen roller is dirty. Clean the platen roller according to the
instructions in Cleaning the Printhead and
Rollers onpage115.
Vertical image or
label drift
Print engine using non-
continuous labels but
configured in continuous
mode.
Configure the print engine for non-continuous
and run calibration routine, if necessary.
Incorrectly positioned media
sensor.
Ensure the media sensor is properly positioned
to read a single/consistent interlabel gap.
Improperly calibrated media
sensor.
See Calibrating Media and Ribbon Sensor
Sensitivity onpage84.
The platen roller is dirty. Clean the platen roller.
Improper printhead pressure
settings (toggles).
Adjust the printhead pressure to ensure proper
functionality.
Improperly loaded ribbon or
media.
Verify that the ribbon and media are properly
loaded.
Incompatible media. Ensure that the interlabel gaps or notches are
2to 4 mm and consistently placed. Media must
not exceed minimum specifications for mode of
operation.
Table 8 Print Quality Problems (Continued)
Troubleshooting
Communications Problems
Communications Problems
Table9 identifies problems with communications, the possible causes, and the recommended
solutions.
Table 9 Communications Problems
A label format was sent to
the print engine but was
not recognized. The
DATA light does not
flash.
The communication
parameters are incorrect.
Check the print engine driver or software
communications settings (if applicable).
If you are using serial communication, check
the serial port setting in the front panel menu.
See Set Serial Communications onpage70.
Make sure you are using the correct
communication cable. See Data Cable
Requirements onpage41 for the requirements.
Using the front panel controls, check the
protocol setting. It should be set to NONE. See
Set Protocol onpage71.
If a driver is used, check the driver
communication settings for your connection.
the print engine. Several
labels print, then the
print engine skips,
misplaces, misses, or
distorts the image on the
label.
The serial communication
settings are incorrect.
Ensure that the flow control settings match.
Check the communication cable length. See
Data Cable Requirements onpage41 for
requirements.
Check the print engine driver or software
communications settings (if applicable).
the print engine but was
not recognized. The
DATA light flashes but no
printing occurs.
The prefix and delimiter
characters set in the print
engine do not match the
ones in the label format.
Verify the prefix and delimiter characters. See
Set Format Prefix Character onpage73 and
Set Delimiter Character onpage73 for the
requirements.
Incorrect data is being sent
to the print engine.
Ensure that ZPL II is being used.
Check the communication settings on the
computer. Ensure that they match the print
engine settings.
If the problem continues, check the ZPL II
format for changed ^CC, ^CT, and ^CD.
Troubl eshoot i ng
Miscellaneous Print Engine Problems
Table10 identifies miscellaneous problems with the print engine, the possible causes, and the
recommended solutions.
Table 10 Miscellaneous Print Engine Problems
Broken or melted
ribbon
Darkness setting too high. 1. Reduce the darkness setting.
2. Clean the printhead thoroughly.
Ribbon tension
dancer(s) oscillate
erratically
Ribbon core is not standard
size and is slipping on the
spindle.
Replace ribbon with one that has a standard core
size.
Missing LCD
characters or parts
of characters
The LCD may need replacing. Run Power-On Self Test and check that LCD
display shows all characters. If not, replace
LCD.
Changes in
parameter settings
did not take effect
Parameters are set incorrectly. 1. Set parameters and save permanently.
2. Turn the print engine power Off (O) and then
On (I).
A ZPL command has turned
off the ability to change the
parameter.
Refer to the ZPL Programming Guide or call a
service technician.
A ZPL command has changed
the parameter back to the
previous setting.
Refer to the ZPL Programming Guide or call a
service technician.
If the problem continues, there
may be a problem with the
main logic board.
Replace the main logic board
(see Section 4, Corrective Maintenance).
The print engine
fails to calibrate or
detect the top of the
label.
The print engine was not
calibrated for the label being
used.
Perform the calibration procedure in Calibrating
Media and Ribbon Sensor Sensitivity
onpage84.
The print engine is configured
for continuous media.
Set the media type to noncontinuous media. See
Set Media Type onpage62.
The driver or software
configuration is not set
correctly.
Driver or software settings produce ZPL
commands that can overwrite the print engine
configuration. Check the driver or software
media-related setting.
Non-continuous
labels are being
treated as continuous
labels.
The print engine is configured
for continuous media.
Set the media type to noncontinuous media. See
Set Media Type onpage62.
used.
onpage84.
Troubleshooting
The ribbon light is
on even though
ribbon is loaded
correctly.
used.
onpage84.
All lights on, but
nothing displays on
the LCD, and the
print engine
locks up.
Internal electronic or firmware
failure.
Turn the print engine power Off (O) and then
On (I). If the print engine locks up again, replace
the main logic board (see Main Logic Board
onpage235).
Print engine locks up
while running the
Power-On Self Test.
Main Logic Board failure. Replace the main logic board
(see Main Logic Board onpage235).
Table 10 Miscellaneous Print Engine Problems (Continued)
Troubl eshoot i ng
Print Engine Diagnostics
Self tests and other diagnostics provide specific information about the condition of the print
engine. The most commonly used are the Power-On and the CANCEL self tests.
Power-On Self Test
A Power-On Self Test (POST) is performed each time the print engine is turned ON. During
this test, the front panel lights (LEDs) turn on and off to ensure proper operation. At the end of
this self test, only the POWER LED remains lit. When the Power-On Self Test is complete, the
media is advanced to the proper position.
To initiate the Power-On Self Test, turn ON (I) the print engine using the power switch on the
control panel. The POWER LED illuminates. The other control panel LEDs and the LCD
monitor the progress and indicate the results of the individual tests. All messages during the
POST display in English; however, if the test fails, the resulting messages cycle through the
international languages as well.
Additional Print Engine Self Tests
These self tests produce sample printouts and provide specific information that helps
determine the operating conditions for the print engine.
Each self test is enabled by pressing a specific front panel key or combination of keys while
turning the power On (I). Keep the key(s) pressed until the first indicator light turns off. The
selected self test automatically starts at the end of the Power-On Self Test.
Caution Full width media should be used when performing self tests. If your media is not
wide enough, the test labels may print on the platen roller and damage it. To prevent this
from happening, check the print width using Set Print Width on page 63, and ensure that
the width is correct for the media that you are using.
Note
When performing these self tests, do not send data to the print engine from the host.
If your media is shorter than the label to be printed, the test label continues on the next label.
When canceling a self test prior to its actual completion, always reset the print engine by
turning the print engine power OFF and then ON.
If print engine is in applicator mode and the liner is being taken up by the applicator, the
operator must manually remove the labels as they become available.
Troubleshooting
CANCEL Self Test
The CANCEL self test prints a configuration label, which tells you the settings for the print
engine stored in configuration (EEPROM) memory (Figure51). The settings may be changed
either temporarily (for specific label formats or ribbon and label stock) or permanently (by
saving the new parameters in EEPROM memory). New parameters are saved whenever a print
engine calibration procedure is performed. Refer to Front Panel LCD onpage61 for further
details on changing parameters.
To perform the CANCEL Self Test, complete these steps:
1. Turn Off (O) the print engine.
2. Press and hold CANCEL while turning the power On (I). Hold CANCEL until the first
front panel light turns off.
A print engine configuration label prints (Figure51).
Figure 51 Configuration Label
Troubl eshoot i ng
PAUSE Self Test
This self test can be used to provide the test labels required when making adjustments to the
print engines mechanical assemblies. Figure52 shows a sample printout.
To perform a PAUSE self test, complete these steps:
2. Press and hold PAUSE while turning the power On (I). Hold PAUSE until the DATA light
turns off.
The initial self test prints 15 labels at the print engines slowest speed, and then
automatically pauses the print engine. Each time PAUSE is pressed, an additional 15
labels print. Figure52 shows a sample of the labels.
Figure 52 PAUSE Test Label
While the print engine is paused, pressing CANCEL alters the self test. Each time
PAUSE is pressed, 15 labels print at 6in. (152 mm) per second.
While the print engine is paused, pressing CANCEL again alters the self test a second
time. Each time PAUSE is pressed, 50 labels print at the print engines slowest speed
While the print engine is paused, pressing CANCEL again alters the self test a third
time. Each time PAUSE is pressed, 50 labels print at 6in. (152 mm) per second.
While the print engine is paused, pressing CANCEL again alters the self test a fourth
time. Each time PAUSE is pressed, 15 labels print at the print engines maximum
speed.
To exit this self test at any time, press and hold CANCEL.
Troubleshooting
FEED Self Test
The labels printed during this print quality test depend on the dot density of the printhead.
300 dpi print engines: 7 labels are printed at the 2 ips and 8 ips print speeds.
203 dpi print engines: 7 labels are printed at the 2 ips and 12 ips print speeds.
Each label is printed at a different darkness setting, starting at three settings below the
currently configured value and increasing until it is three settings darker than the configured
value. The relative darkness and speed are printed on each label. The bar codes on these labels
can be ANSI-graded to check print quality.
To perform a FEED self test, complete these steps:
1. Print a configuration label to show the print engines current settings.
3. Press and hold FEED while turning the power On (I). Hold FEED until the DATA light
turns off.
The print engine prints a series of labels (Figure53) at various speeds and at darkness
settings higher and lower than the darkness value shown on the configuration label.
Figure 53 FEED Test Label
4. Inspect the labels and determine which one has the best print quality for your application.
The darkness value printed on that label is added to (plus) or subtracted from (minus) the
darkness value specified on the configuration label. The resulting numeric value (0to30)
is the best darkness value for that specific label/ribbon combination and print speed.
5. Enter the corresponding darkness and print speed values into the print engine through the
front panel.
Troubl eshoot i ng
FEED Key and PAUSE Key
Performing this self test temporarily resets the print engine configuration to the factory default
values. These values are active only until power is turned off unless you save them
permanently in memory. If the factory default values are permanently saved, a media
calibration procedure must be performed. You must also reset the head resistance value and the
verifier and applicator port settings to their required values.
To perform a FEED and PAUSE self test, complete these steps:
2. Press and hold FEED and PAUSE while turning the power On (I). Hold FEED and
PAUSE until the DATA light turns off.
No labels print at the end of this test.
Table11 indicates which print engine function controls each of the configuration parameters:
Table 11 Control of Print Engine Parameters
Parameter Controlled By
Darkness Configuration, ZPL, and WebView
Tear Off Configuration, ZPL, and WebView
Print Mode Configuration, ZPL, and WebView
Media Type Calibration, Configuration, ZPL, and WebView
Sensor Type Configuration, ZPL, and WebView
Print Method Calibration, Configuration, ZPL, and WebView
Print Width Configuration, ZPL, and WebView
Label Length Calibration, Configuration, ZPL, and WebView
Maximum Length Configuration, WebView, and Memory Size
Host Port Configuration and WebView
Baud Configuration, ZPL, and WebView
Data Bits Configuration, ZPL, and WebView
Parity Configuration, ZPL, and WebView
Stop Bits Configuration, ZPL, and WebView
Host Handshake Configuration, ZPL, and WebView
Protocol Configuration, ZPL, and WebView
Network ID Configuration, ZPL, and WebView
Communications Configuration, ZPL, and WebView
Control Prefix Configuration, ZPL, and WebView
Troubleshooting
Format Prefix Configuration, ZPL, and WebView
Delimiter Character Configuration, ZPL, and WebView
ZPL Mode Configuration, ZPL, and WebView
Media Power Up Configuration, ZPL, and WebView
Head Close Configuration, ZPL, and WebView
Backfeed Configuration, ZPL, and WebView
Label Top Configuration, ZPL, and WebView
Left Position Configuration, ZPL, and WebView
Head Resistance Configuration (must match head resistance label value), ZPL, and
WebView
Verifier Port Configuration, ZPL, and WebView
Applicator Port Configuration, ZPL, and WebView
Start Print Signal Configuration, ZPL, and WebView
Resynch Mode Configuration, ZPL, and WebView
Ribbon Low Mode Configuration, ZPL, and WebView
Reprint Mode Configuration, ZPL, and WebView
Web Sensor Configuration, ZPL, and WebView
Media Sensor Configuration, ZPL, and WebView
Ribbon Sensor Configuration, ZPL, and WebView
Mark Sensor Configuration, ZPL, and WebView
Mark Media Sensor Configuration, ZPL, and WebView
Media LED Configuration, ZPL, and WebView
Ribbon LED Configuration, ZPL, and WebView
Mark LED Configuration, ZPL, and WebView
LCD Adjust Configuration and WebView
Modes Enabled ZPL and WebView
Modes Disabled ZPL and WebView
Resolution Fixed (head type switch)
Socket 1 ID Fixed (option EPROMS)
Firmware Fixed (code EPROMS)
Configuration Configuration and WebView
Table 11 Control of Print Engine Parameters (Continued)
Troubl eshoot i ng
Communications Diagnostics Test
Do not perform the following test until all configuration and calibration parameters have been
set. For configuration information, see Front Panel LCD onpage61.
This test is controlled from the front panel display. See Set Communications Mode onpage72.
Figure54 shows a typical printout from this test. Turn off the power to exit this self test and
return to normal operation.
Figure 54 Communications Diagnostics Test Label
Memory Fixed (SIMM size and 1 MB standard)
B:Memory Fixed (option card)
J 12 Interface Fixed
J 9 Interface Fixed
J 8 Interface Fixed
J 7 Interface Fixed
Table 11 Control of Print Engine Parameters (Continued)
Note The communications test label prints upside-down.
4
Pr event i ve and Cor r ec t i ve
Mai nt enanc e
This section provides various levels of print engine maintenance required for optimum
performance. This section also provides information on cleaning and general maintenance,
replacement of major assemblies, and mechanical adjustments.
Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Equipment Safety Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Personal Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Printhead Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Compound Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Stepper Motor Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Ribbon Take-Up Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Ribbon Supply Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Roller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Peel Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Auxiliary Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
PCMCIA Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Wireless PCMCIA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Compact Flash and PCMCIA Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Print Server Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Main Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Prevent i ve and Correct i ve Mai nt enance
Applicator Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

AC Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Door-Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Saf et y I nf or mat i on
This section identifies general and specific safety information for the 110PAX4 print engine.
Contents
Equipment Safety Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Personal Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Safety InformationEquipment Safety Tips
Equipment Safety Tips
The AC power plug and IEC 320 connectors on all Zebra Printers must bear the
certification mark of at least one of the international safety organizations listed below.
Unless indicated otherwise, turn Off (O) the power before performing any maintenance
procedures on the printer. Disconnect the AC power cord from the power source.
Zebra printers comply with international regulations governing radiated emissions when
using fully shielded data cables. Data cables must be fully shielded and fitted with metal
or metallized 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.
Zebra recommends using Preventive Maintenance Kit (p/n 47362), or a solvent containing
90% isopropyl alcohol and 10% distilled water. Increase the percentage of alcohol as
necessary for effective cleaning of:
Printheads
Platen Rollers
Peel-Off Rollers
Pinch Rollers
Media Paths
Peel/Tear Bars
Spindles
Caution Turn Off (O) the printer and disconnect it from the power source before
performing any maintenance.
Important Permanent damage to the Flash Memory will result if you turn on power to the
print engine with Flash Memory chips installed in the wrong direction.
Caution Observe proper electrostatic safety precautions when handling any
static-sensitive components such as circuit boards and printheads.
+
R
Preventive and Corrective Maintenance
Safety InformationEquipment Safety Tips
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 airflow.
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 Guide. Electrical power must be available and in close
proximity to the printer.
Safety InformationPersonal Safety Tips
Personal Safety Tips
Caution Risk of explosion if battery is replaced by an incorrect type, or in the wrong
polarity.
Important Beware of Pinch Points on the printers, especially:
Opening and closing the covers
Opening and closing the printhead
Rewind Spindle
Platen Roller
Important Do not wear any jewelry, such as rings, watches, bracelets, etc. or loose clothing
when servicing the printers.
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
Caution For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use
an IEC 320 female connector and the appropriate region-specific, three-conductor
grounded plug configuration.
Pr event i ve Mai nt enanc e
An operator or technician may perform preventive maintenance, which consists of:
Visual inspection
Regular cleaning of the printhead, platen roller, peel roller, and pinch roller
General cleaning of the print engines interior and exterior
See Table12 onpage114 for the Preventive Maintenance Chart.
Contents
Tools Required for Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Recommended Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cleaning the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cleaning the Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cleaning the Printhead and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cleaning the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cleaning the Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cleaning the Peel Bar and Media Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Preventive MaintenanceTools Required for Preventive Maintenance
Tools Required for Preventive Maintenance
Recommended Preventive Maintenance Schedule
Lubrication
47362* Zebra Preventative Maintenance
Kit
Cotton Swabs
Lint-Free Cloth Isopropyl Alcohol
* A solution of 90% isopropyl alcohol and 10% deionized water and clean swabs may be used in place of
the Preventative Maintenance Kit.
Table 12 Preventive Maintenance Schedule
Area Method Interval
Printhead Solvent* Perform these procedures at the following times:
When CLEAN HEAD NOW appears.
Direct Thermal Print Mode: After every roll of
labels or 500ft (150m) of fanfold labels.
Thermal Transfer Print Mode: After every roll
(1500ft. or 450m) of ribbon.
Platen roller Solvent*
Transmissive media sensor Air blow
Reflective media sensor Air blow
Media path Solvent*
Ribbon sensor Air blow
Door-open sensors Air blow Monthly
Tear-off/peel-off bar Solvent*
* Use Zebra Preventative Maintenance kit, part number 47362, or a solution of 90%isopropyl alcohol and
10%deionized water.
Caution This print engine does not require lubrication. Applying lubricants may damage
your print engines finish and decrease the performance of its electromechanical parts.
Preventive MaintenanceCleaning the Exterior
Cleaning the Exterior
Clean the exterior surfaces of the 110PAX4 print engine with a lint-free cloth.
Do not use solvents or harsh cleaning agents.
If the unit is excessively dirty, use a mild detergent solution or desktop cleaner sparingly.
Cleaning the Interior
Clean the interior surfaces of the 110PAX4 print engines as required.
Remove any dirt, lint, or label dust accumulated in the interior using a soft-bristled brush
or vacuum cleaner.
Cleaning the Printhead and Rollers
Poor print quality such as uneven print darkness, blank areas in bar codes, or graphics, or
illegible numbers and letters may indicate a dirty printhead and/or platen roller. See Table12
onpage114 for the correct interval for cleaning the printhead and platen roller.
Cleaning the Printhead
To clean the printhead, complete these steps:
1. See Figure55. Open the front cover and open the printhead by rotating the toggle locking
lever to its fully open position.
2. Remove the media and ribbon if present.
3. See Figure55. Locate the printhead elements.
The print elements are located within the brown strip just behind the chrome strip on the
printhead.
4. Using Zebra Preventive Maintenance Kit (p/n 47362), or a clean cotton swab moistened
with a solution of 90% isopropyl alcohol and 10% deionized water, wipe the printhead
elements from end to end.
Allow a few seconds for the solvent to evaporate.
5. After cleaning, if the cotton swab is dirty, repeat step 4.
The print elements are located within the brown strip just behind the chrome strip on the
printhead. Allow a few seconds for the solvent to evaporate.
Note The printhead and platen roller may be cleaned with the print engine power switch is in
the On (l) position.
Preventive MaintenanceCleaning the Printhead and Rollers
Figure 55 Printhead and Platen Roller Cleaning
Cleaning the Rollers
To clean the rollers, complete these steps:
1. Check the platen roller for stuck labels and adhesive residue.
2. Check the peel roller assembly for stuck labels and adhesive residue.
3. To clean the platen roller, peel roller, or pinch roller, wet a clean lint-free cloth with
isopropyl alcohol and, using your fingers, rotate the roller while repeatedly wiping the full
length of the roller.
4. Using a lint-free cloth dampened with isopropyl alcohol, wipe away dust and lint that may
have accumulated on the media and ribbon paths.
5. Reload ribbon and media and close and latch the toggle locking lever.
6. Close the front cover and restore power.
7. If necessary, run the PAUSE Key Self Test to check print quality.
Printhead
Assembly
Cotton-Tipped
Applicator
Printhead
Elements
(Shaded area)
Printhead Locking
Lever
Platen
Roller
Peel Bar
Cotton-Tipped
Applicator
Preventive MaintenanceCleaning the Peel Bar and Media Path
Cleaning the Peel Bar and Media Path
In case of a label jam, the peel bar and peel roller can be accessed for cleaning.
To clean the peel bar and media path, complete these steps:
1. See Figure55 onpage116. Rotate the printhead locking lever clockwise for right-hand
print engines, counterclockwise for left-hand print engines, and open the printhead to its
fully open position.
2. Check the entire media path for stuck labels and adhesive residue.
3. Remove any stuck labels from the peel bar and remove all adhesive residue.
4. See Figure56 and Figure57. Brush, blow, or vacuum any accumulated paper lint and dust
away from all of the rollers, media, and ribbon sensors.
Figure 56 Media Sensor Locations
(Right-Hand Model Shown)
Note Remove media to make the following cleaning procedure easier.
Transmissive
Media Sensors
Reflective
Media Sensor
Preventive MaintenanceCleaning the Peel Bar and Media Path
Figure 57 Side View of Ribbon Sensor Locations
5. Reload ribbon and media.
6. Close and latch the printhead locking lever.
7. Close the front cover.
8. Restore power, and run the PAUSE Key Self Test to check print quality.
Ribbon
Sensor
Ribbon Sensor
Reflector
Printhead
Cor r ec t i ve Mai nt enanc e
This section outlines adjustments and alignments for the 110PAX4 print engine.
Contents
Print Quality Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Printhead Parallelism Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Printhead Balance Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Printhead Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Printhead Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Strip Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Print Darkness Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Tear-Off Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Adjusting the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Adjusting the Media Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Maintaining Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Routine Referral Procedures (RRPs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Remove and Open the 110PAX4 Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Close and Reinstall Print Engine in Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Corrective MaintenanceCorrective Maintenance
Corrective Maintenance
If a problem occurs with a 110PAX4 print engine, the service technician should first ensure that
the unit is being used properly, and then begin to troubleshoot. After the problem has been
determined, refer to the appropriate adjustment or replacement procedure to correct the
problem.
Maintenance procedures listed here apply to both right-hand and left-hand print engines unless
otherwise individually noted.
Tools Required
Phillips Screwdriver Set
Flat-blade Screwdriver Set
Screwdriver, Flat-Blade 1/32 in. 1/4
in., Extended Reach (10in. shaft),
Magnetic
Screwdriver, Phillips No. 1, Extended
Reach (10in. shaft), Magnetic
Hex Head Driver 7/64 in. Extended
Reach (10in. shaft)
Standard Hex Key (Allen Wrench) Set
Metric Hex Key (Allen Wrench) Set
Standard Open-End Wrench Set
Standard Nutdriver Set
Potentiometer Adjustment Tool
Torque Wrench calibrated in inch-
pounds
Anti-Static Wrist Strap and Mat
Needle Nose Pliers
Metric and Inch Feeler Gauges, must
include:
0.010 (.0254mm), 0.020 (.508mm), &
0.060 in. (1.5mm)
Snap Ring Tool
Safety Goggles
Wire Cutters
Metric Open-End Wrench Set
Metric Nutdriver Set
Multimeter
Note Most fasteners are metric.
Corrective MaintenancePrint Quality Adjustments
Print Quality Adjustments
There are five interrelated adjustments for obtaining optimum print quality and increased
printhead life:
printhead parallelism
printhead balance
printhead position
printhead pressure
strip plate position
To achieve optimum results with print quality adjustments, install full-width media and ribbon.
The illustrations and adjustment procedures reference a right-hand print engine. Left-hand
print engine positions and rotations are in the opposite direction.
The order in which the following adjustments are performed depends on the print quality of
the labels printed during the previous PAUSE test. The first two print quality adjustments,
Parallelism and Balance, must be completed prior to attempting to locate the optimum
printhead position. As with the other adjustments, Parallelism and Balance are interrelated.
Adjusting one may affect the position of the other.
Prepare for Making Adjustments
Prior to performing print quality adjustments, follow these steps:
1. Open the print engine front cover.
2. Position the toggle at the center of the printhead mechanism.
3. See Figure58. Compress the toggle spring by turning the lower knurled nut clockwise
until the distance from the top of the toggle foot to the bottom of the lower knurled nut
equals 11/16inch (17 mm).
Figure 58 Toggle Spring
Important Excessive toggle pressure leads to increased printhead wear and decreased
printhead life. Increase printhead life by combining minimum toggle pressure and optimum
printhead position over the platen roller.
7/16 in. (11 mm)
11/16 in. (17 mm)
4. Print a PAUSE Key Self Test by holding down PAUSE while turning the print engine
power On(l).
The preliminary speed for the PAUSE test label is 2 inches per second (ips) (50 mm per
second).
Pressing CANCEL changes the speed to 6 ips (125 mm per second). Cancelling again
yields 2 ips again, and another cancel returns the print engine to 6 ips. Pressing CANCEL
for the fifth time produces the maximum speed for the print engine, 8 ips (200mm per
second) for 300 dpi, and 12 ips (300 mm per second) for 200 dpi.
At top speeds, adjustment is critical, so use the higher print speed for testing the results of
these adjustments.
Printhead Parallelism Adjustment
Adjusting the printhead parallelism squares the printhead to the media path. This ensures the
media and the printhead are in parallel alignment.
1. Check the PAUSE Key Self Test labels to ensure the uppermost line on the test label is
parallel to the top edge of the label within a tolerance of 0.020 in. (0.5 mm).
If the print lines are not parallel with the top of the label, adjust the printhead to achieve
parallelism.
2. See Figure59. Loosen the two hex head (Allen) screws at the top rear of the print
mechanism.
Note The order in which the following adjustments are performed depends on the print
quality of the labels printed during the previous PAUSE test.
The first two Print Quality Adjustments, Parallelism and Balance, must be completed prior
to attempting to locate the optimum printhead position. As with the other adjustments,
Parallelism and Balance are interrelated. Adjusting one may affect the position of the
other.
Note Excessive toggle pressure leads to increased printhead wear and decreased
printhead life.
Note Increase printhead life by combining minimum toggle pressure and optimum
printhead position over the platen roller.
Important Prior to starting this adjustment, ensure the installed media is squared with the
peel bar. The media must run parallel to the main frame of the print engine to achieve
consistent print quality. Check for parallelism by measuring the distance from the main frame
to the media where it enters and leaves the print engine.
Note Two hex head (Allen) screws clamp the print mechanism in position once the
parallelism adjustment is completed. For proper adjustment, loosen these screws, and then
gently tighten again until only a slight movement of the print mechanism is permitted.
3. Adjust the parallel location of the uppermost test label print lines by turning very slightly
one of the two horizontally positioned parallelism adjustment screws at the back of the
print mechanism.
In very slight increments, adjust each side as necessary to align the uppermost lines of the
test label in parallel with the top edge of the label.
4. If the printhead was set at its default position before starting this procedure, no adjustment
toward the front of the print engine should be needed.
However, if necessary, move the printhead forward by turning the adjustment screws
counterclockwise.
5. To check the results of this adjustment, run additional PAUSE Self Test labels to check for
proper parallelism.
6. Once parallelism is achieved, tighten the two top hex head (Allen) screws and print more
PAUSE Self Test labels for verification.
Figure 59 Printhead Parallelism Adjustment
Access Holes
(2)
Locking
Screw
Parallelism
Adjustment
Screw
Parallelism
Adjustment
Screw
Full View of
Printhead
Close-Up View
of Printhead
Locking
Screw
Locking Screws
Printhead Balance Adjustment
The balance hub position is adjustable to produce an even pressure across the full width of the
printhead and platen roller.
1. Print a PAUSE Key Self Test label by pressing PAUSE while turning On (l) the power.
2. After printing a few labels, pause the print engine and reduce the Darkness configuration
parameter value until the test labels are a charcoal-gray color.
3. Print more PAUSE Key Self Test labels and observe the print quality.
4. Is the printing even?
5. See Figure60. Loosen the balance adjustment locking screw.
Figure 60 Printhead Balance Adjustment
If the printing is... Then...
Even The printhead balance does not need to be adjusted.
Skip to Printhead Position Adjustment on page125.
Uneven
(light or missing printing is
observed on one side)
Continue to step 5.
Locking
Screw
Locking
Screw
Adjustment
Screw
Adjustment
Screw
Compression
Spring
Full View of
Hub
Close-Up View
of Hub
Note If the label printing is darker on the inside, closest to the main frame, turn the top
adjustment screw clockwise to balance the pressure. If the printing is darker on the
outside, turn the top adjustment screw counterclockwise. Continue to print PAUSE Key
Self Test labels while adjusting the hub for even printing.
6. Balance the printhead pressure by turning the hub adjusting screw with an Allen wrench.
7. When even print quality is achieved, tighten the hub locking screw.
8. Print PAUSE Key Test labels to verify that parallelism is correct.
9. If parallelism is out of tolerance, perform the printhead parallelism adjustment.
Check the printhead balance again.
Printhead Position Adjustment
When the printhead is parallel to the media and is balanced, fine-tune the printhead position by
adjusting the head for optimum print quality. See Figure61 for the location of the printhead
position adjustment screws used in the following procedure.
1. Print test labels using the PAUSE Key Self Test.
2. Loosen the two hex head (Allen) screws at the top rear of the print mechanism.
Figure 61 Printhead Position Adjustment
Note Ensure the printhead parallelism has been adjusted before continuing.
Access Holes
(2)
Locking
Screw
Position
Adjustment
Screw
Position
Adjustment
Screw
Full View of
Printhead
Close-Up View
of Printhead
Locking
Screw
Locking Screws
3. With full width media installed, move the toggle to the center of the printhead.
4. Set the Darkness configuration parameter value to achieve the optimum print quality.
5. Turn both screws 1/8 turn clockwise to move the printhead backward and observe the
changes in print quality.
6. Turn both screws 1/4 turn counterclockwise to move the printhead forward and observe
the changes in print quality.
7. Determine which adjustment improved print quality and make small equal adjustments
until optimum print quality is achieved.
8. Decrease the Darkness until the PAUSE Key Self Test labels are a charcoal-gray color.
9. Inspect the PAUSE test labels for streaks, flouring, and other print quality problems.
10. If necessary, readjust both screws equally and determine whether print quality problems
are corrected.
11. Increase Darkness until the PAUSE test labels are printed at optimum resolution and
contrast.
12. Tighten the two holding screws at the top rear of the print mechanism.
13. Because printhead parallelism, printhead balance, and printhead position are interrelated,
inspect the test labels for changes in these settings and readjust, if necessary.
Note Two hex head (Allen) screws clamp the print mechanism in position once the
position adjustment is completed. For proper adjustment, loosen these screws, and then
gently tighten again until only slight movement of the print mechanism is permitted.
Note Rotating the adjustment screws clockwise moves the printhead backward. Rotating
the adjustment screws counterclockwise moves the printhead forward. Make adjustments
in small increments. Rotate both screws equally to ensure parallelism is not altered.
Using lower printhead pressure and Darkness settings can extend printhead life. If printing is
too light on one side, a thick media is used, or a narrow width media is used, printhead
pressure may require adjustment.
1. See Figure62. Print PAUSE Key Self Test labels to check print quality.
2. To increase printhead pressure, loosen the upper knurled nut on the toggle and adjust the
lower knurled nut downward. Bring the upper nut down to lock the lower nut in place.
3. To decrease printhead pressure, loosen the upper knurled nut and bring the lower knurled
nut upward. Bring the upper nut down to lock the lower nut in place.
4. Adjust the printhead pressure for optimum print quality.
5. Adjust Darkness to the optimum level for the installed media.
Figure 62 Adjusting Toggle Pressure
Note Different media and ribbon combinations may require different toggle pressure
settings. Obtain an initial setting by turning the lower knurled nut clockwise until the distance
from the top of the toggle foot to the bottom of the lower knurled nut equals 11/16 in. (17 mm).
See Prior to Performing Print Quality Adjustments on page 4-14.
Upper Toggle
Adjusting Nut
Lower Toggle
Adjusting Nut
Toggle Foot
Toggle Pivot
Shaft
Strip Plate Adjustment
The strip plate position is a very important part of the total printhead adjustment procedure.
The strip plate is factory adjusted for proper tracking and separation of the ribbon from the
media after printing. Perform this adjustment procedure only after good print quality has been
achieved.
Figure 63 Strip Plate Adjustment
1. See Figure63. Print PAUSE Key Self Test labels.
2. Press PAUSE and, after the print engine pauses, observe the ribbon for possible problems
such as wrinkling, uneven pressure, etc.
3. Slightly loosen the two screws holding the strip plate to the front of the printhead
assembly.
4. While printing labels, lower the strip plate until the ribbon is flat and smooth.
5. Tighten the strip plate mounting screws and print a minimum of 25 labels while checking
for ribbon wrinkle, tracking, and media/ribbon separation problems.
Strip Plate
Strip Plate
Mounting Screws
Corrective MaintenancePrint Darkness Adjustment
Print Darkness Adjustment
Due to differences in types of media and ribbon and wear on thermal printhead elements, it
may be necessary to adjust the Darkness configuration parameter to achieve desired print
quality. Turning the print engine Off (O) is not required for the new setting to take effect.
To adjust the Darkness, use the following procedure:
1. Begin printing a few labels. See Section 2 and use the PAUSE and CANCEL Key Self
Test label or one of your own formats.
2. Using the front panel display and keys, adjust the Darkness setting to obtain the preferred
print quality.
Decreasing the value in the display produces a lighter image. Increasing the value
produces a darker image.
Tear-Off Position Adjustment
This LCD parameter adjustment sets the rest position of the media over the peel bar after
printing (see Adjust the Tear-Off Position onpage62). To achieve the proper tear-off position,
press the right oval key to increase the value or the left oval key to decrease the value. Each
press of the key moves the tear-off position by four dot rows (positive values move the media
farther out over the peel bar).
Default: +0
Range: 120 to +120
Figure 64 Tear-Off Position Adjustment
Figure64 shows how higher values move the label farther out from the print engine (moves
the tear line closer to the leading edge of the next label) while lower values move the label into
the print engine (moves the tear line closer to the edge of the label just printed).
Caution Set the darkness to the lowest setting possible for optimum print quality.
Darkness set too high for a given ribbon may cause ink smearing, ribbon wrinkle, and
burning through the ribbon, as well as premature printhead failure.
Media
Direction
Factory-Set
Tear Line
Location is 00
Corrective MaintenanceAdjusting the Sensors
Adjusting the Sensors
This section describes how to adjust the media sensors.
Transmissive Media Sensor Position
The transmissive media sensor senses either the web between labels or a hole or notch in the
print media to determine the length of the label. The media sensor is factory set at the default
position of approximately 2 in. (50 mm) out from the print engine main frame. This position
should be sufficient for any width label, so little or no repositioning should be required when
using media with a web.
If transmissive sensor adjustment is necessary, complete these steps:
1. Refer to Figure65. How does the current media indicate the start of labels?
Figure 65 Transmissive Media Sensor Adjustment
If the media... Then...
Has notches or holes
between labels
Slide the transmissive sensor slide along the pinch roller
assembly so the point of the indicator aligns with the notch
or hole in the media.
Uses interlabel gaps Position the transmissive sensor slide approximately at the
center of the media width.
Transmissive
Sensor Slide
Corrective MaintenanceAdjusting the Sensors
Ribbon Sensor Position
Figure66 shows the location of the ribbon sensor in the bottom inside of print mechanism
housing. Because the ribbon sensor is mounted in a fixed position, no adjustment is required.
Reflective Media Sensor Position
See Figure66. The reflective media sensor is mounted in a fixed position and cannot be
adjusted.
Figure 66 Reflective Media Sensor Locations
Reflective
Media Sensor
Corrective MaintenanceAdjusting the Media Tracking
Adjusting the Media Tracking
This section includes instructions for adjusting the upper pinch roller, the elastomer pinch
roller, and the media tracking cam.
Upper Pinch Roller Adjustment
1. See Figure67. Prepare two narrow media strips, each approximately 1in. (25 mm) wide
and 12 in. (300 mm) long.
2. Unlatch the upper pinch roller assembly and place the end of the media strips across the
elastomer pinch roller, one at the innermost edge and one at the outermost edge.
3. Relatch the assembly to capture the media strips.
Figure 67 Media Strip Placement
4. See Figure68. Slowly pull the media strips in opposite directions and note the force
needed to pull them through the assembly.
Figure 68 Pressure Testing
(Left-Hand Model Shown)
Upper Pinch
Roller
Assembly
Elastomer
Pinch Roller
(Shaded)
Media
Strip
Media
Strip
Upper Pinch
Roller
Assembly
Media
Strip
Media
Strip
Adjustment
Cam
(Shaded)
Cam Screw
Upper Pinch
Roller Mounting
Screw
Upper Pinch Roller
Mounting Screw
5. Was the force required approximately equal?
6. If the inner media strip required more force to remove, the adjustment cam must be rotated
clockwise. If the inner media strip required less force to remove, the adjustment cam must
be rotated counterclockwise.
7. See Figure68. To adjust the upper pinch roller pressure, loosen the two mounting screws
until they are just snug.
8. Loosen the cam screw until the cam is just free to rotate.
9. Use a small, flat-blade screwdriver in the groove in the cam to rotate it.
10. Make small adjustments, tighten the screws, and retest the pressure with the media strips.
When the pulling force is approximately equal, the assembly is properly adjusted.
Note The media strips should require approximately equal force to pull them out of the
pinch rollers. The position of the inner end of the assembly is adjustable up and down by
the cam. Adjusting the cam so the lobe rotates downward applies more pressure, and
adjusting it so the lobe rotates upward applies less pressure.
If... Then...
No a. Continue to step 6.
Yes a. The roller assembly is positioned properly.
b. Skip to Adjusting the Elastomer Pinch Roller on page134.
Note The elastomer pinch roller may require adjustment following this procedure.
Adjusting the Elastomer Pinch Roller
To adjust the Elastomer Pinch Roller, complete these steps:
1. Run a Pause test, and observe how the labels print in relation to the main frame of the print
engine.
2. How are the labels printing?
If the labels Then...
Print parallel to
the main frame
No adjustment is needed.
Run away from
the main frame
The labels need to be adjusted towards the main frame, and away
from the front of the print engine.
a. See Figure69. Loosen the cam plate screw until it is just
snug.
b. Loosen the cam screw until the cam is just free to rotate.
Use a small, flat-blade screwdriver to make the elastomer
pinch roller adjustment.
If you have... Then....
A right-hand print engine Turn the cam counterclockwise to
move the roller to the left.
A left-hand print engine Turn the cam clockwise to move the
roller to the right.
Run toward the
main frame
The labels need to be adjusted away from the main frame, and
towards the front of the print engine.
a. See Figure69. Loosen the cam plate screw until it is just
snug.
b. Loosen the cam screw until the cam is just free to rotate.
Use a small, flat-blade screwdriver to make the elastomer
pinch roller adjustment.
If you have... Then....
A right-hand print engine Turn the cam clockwise to move the
roller to the right.
A left-hand print engine Turn the cam counterclockwise to
move the roller to the left.
Note This is a trial-and-error adjustment.
Figure 69 Pressure Adjustment
Upper Pinch
Roller
Assembly
Adjustment
Cam
(Shaded)
Cam Screw
Upper Pinch
Roller Mounting
Screw
Upper Pinch
Roller Mounting
Screw
Media Tracking Cam Adjustment
There is a cam that can be used to correct media tracking. Perform this adjustment only as a
last resort and only after checking all other adjustments.
1. See Figure70. Take measurements at the media entrance and media exit to determine how
far out of parallel the media is with the main frame.
Figure 70 Cam Adjustment
2. Use a Phillips screwdriver to loosen the cam locking screw for the elastomer pinch roller
only.
3. Adjust the cam position as required.
4. Run test labels, take measurements, and repeat step 3 until required results are achieved.
Note Turning the elastomer pinch roller cam clockwise shifts the media toward the main
frame at the exit end as it passes through the print engine mechanics. Turning the pinch
roller cam counterclockwise shifts the media toward the main frame at the entrance end.
Peel Roller
Adjustment Cam
(Shaded)
Cam Screw
Pinch Roller
Cam Plate
Locking Screw
Corrective MaintenanceMaintaining Spindles
5. Tighten the Phillips screw to secure the cam in position.
Maintaining Spindles
Ribbon spindles in the PAX print engine are maintenance free.
Note Zebra does not recommend adjusting the elastomer peel roller cam for media
tracking. This is a factory setting that should not require further adjustment.
Corrective MaintenanceRoutine Referral Procedures (RRPs)
Routine Referral Procedures (RRPs)
Routine Referral Procedures are commonly used steps that are performed often during
corrective maintenance. These procedures are referenced throughout this section of the
manual.
RRP No. 1: Remove and Open the 110PAX4 Print Engine
Remove the Print Engine from the Applicator
1. Turn Off (O) the print engine and disconnect the AC power cord and interface cables.
2. Open the front cover, unlatch the printhead lever, and remove media and ribbon from the
print engine.
3. Close and latch the printhead lever, and then close the front cover.
4. See Figure71. Remove the four corner mounting screws securing the print engine to the
applicator.
5. Loosen, but do not remove the center mounting bolt.
6. To remove the print engine from the applicator, lift the print engine off the center
mounting bolt and place on a workbench.
Figure 71 Front View of Print Engine in Applicator
Applicator
Front Cover
Front Panel
Applicator
Mounting Screws
(2)
Applicator Mounting Screws
Center
Mounting
Bolt
On/Off Switch
Open the Rear Enclosure
7. See Figure73. Remove the seven electronics enclosure cover mounting screws.
Lift up on the electronics enclosure cover to remove it.
Figure 72 Rear View of the Removal and Installation of the
Electronics Enclosure Cover
8. See Figure73. From the back of the print engine, remove the two screws securing the rear
enclosure.
Figure 73 Rear View of Rear Enclosure Mounting Screw Location
(Right-Hand Print Engine Shown)
Electronics
Enclosure
Screws (7)
Electronics
Enclosure
Cover
Electronics
Enclosure Screws
9. See Figure74. From inside the front of the print engine, remove the two recessed rear
enclosure mounting screws with star washers.
Figure 74 Front View of Recessed Enclosure Mounting Screw Locations
(Right-Hand Print Engine Shown with Front Cover Open)
10. Carefully swing the electronics enclosure open.
Recessed Rear
Mounting Screw
Recessed Rear
Mounting Screw
RRP No. 2: Close and Reinstall Print Engine in Applicator
Close the Rear Enclosure
1. Carefully swing the electronics enclosure closed.
2. Ensure that wires are routed properly and are not causing any obstructions.
3. See Figure74. From inside the front of the print engine, replace the two recessed rear
enclosure mounting screws with star washers.
4. See Figure73. From the back of the print engine, replace the two screws securing the rear
enclosure.
5. See Figure71. Replace the electronics cover and the seven mounting screws.
Ensure that the wires are routed properly and are not causing any obstructions.
Reinstall the Print Engine in the Applicator
6. To reinstall the print engine into the applicator, carefully place the keyhole on the center
mounting bolt.
7. See Figure71. Replace and tighten the four corner mounting screws securing the print
engine to the applicator.
8. Tighten the center mounting bolt.
Resume Printer Operation
9. Open the front cover, unlatch the printhead lever, and reinsert the media and ribbon in the
print engine.
10. Close and latch the printhead lever.
11. Reconnect the AC power cord and interface cables.
12. Turn On (l) the print engine.

Notes ___________________________________________________________________
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__________________________________________________________________________
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__________________________________________________________________________
__________________________________________________________________________
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Pr i nt Syst em
This section provides replacement, conversion, and installation procedures for the 110PAX4
print system, including the following:
printhead
toggle assembly
Contents
Printhead Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Printhead Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Print SystemPrinthead Replacement
Printhead Replacement
Tools Required
Installation Instructions
Remove the Old Printhead Assembly
1. Turn Off (O) the printer and disconnect the AC power cord.
2. Open the front cover and unlatch the printhead toggle locking lever.
3. Remove media and ribbon from the print engine.
4. Push printhead toggle off to the side.
5. See Figure75. Loosen the printhead mounting screw.
Flat-Blade Screwdriver Set Anti-Static Wrist Strap
Anti-Static Mat Zebra Preventive Maintenance Kit (Part Number
47362) or a solution of 90% isopropyl alcohol and 10%
deionized water and cotton swabs
Caution An improperly seated printhead data or power cable may cause the
printhead to generate excessive heat and/or a false HEAD COLD message to display
while the printhead is hot enough to cause severe burns. Allow the printhead to cool.
Figure 75 View of the Printhead from Inside the Front Cover
6. See Figure76. While holding the printhead, remove the power connector, and then the
printhead data connector.
7. Remove and discard the old printhead.
Replace the New Printhead Assembly
1. See Figure76. Reconnect the printhead power cable and data cable to their appropriate
connectors. Seat both connectors firmly into place.
Printhead
Mounting
Screw
Printhead
Toggle Locking
Lever
Note Prior to installing the new printhead, make a note of the resistance value located on the
right side of the manufacturers label. The R value is given in ohms.
Caution An improperly seated printhead data or power cable may cause the printhead to
generate excessive heat and/or a false HEAD COLD message to display while the
printhead is hot enough to cause severe burns.
Figure 76 Front View of Printhead Connections
2. See Figure77. Fit the new printhead into the mounting bracket by aligning the printhead
alignment posts into the printhead alignment holes.
Figure 77 Detailed View of Printhead and Bracket Alignment
Data
Connector
Printhead
Printhead
Assembly Mounting
Bracket
Power Connector
Printhead
Alignment
Post
Printhead
Alignment
Hole
Printhead
Alignment
Post
Printhead
Alignment
Hole
Printhead Assembly
Mounting Bracket
3. Verify the printhead is seated properly, and then carefully guide the printhead mounting
screw into the printheads aluminum body. After the screw is aligned properly, tighten it
until snug. Do not over-tighten.
4. Apply the cleaning solution to the cotton swab and clean the print element (gray area) of
the new printhead.
5. Reload media and ribbon into the print engine.
6. Ensure the printhead toggle is positioned in the center of the media.
1. Connect the AC power cord and turn On (I) the print engine.
2. After the print engine completes the Power On Self Test (POST), set the printhead
resistance value to match the new printhead.
a. Press Setup/Exit to enter the Setup mode.
b. Press Next to scroll to the Head Resistor parameter.
c. You will be prompted to enter the four-digit password. (The default password value is
1234.) The Left Black Oval key changes the digit position. The Right Black Oval key
increases the digit value. Enter the password, and press Next.
d. Enter the new resistance value of the new printhead. (This value is located on the far
right of the label. The value appears as R=xxxx, where xxxx is the resistance value.)
e. Press Setup/Exit to leave Setup mode.
f. To save the new value in permanent memory, press Next to select Permanent. (Or,
press the Right or Left Black Oval keys to scroll through all available parameters. For
additional details, refer to the User Guide.)
3. Turn Off (0) the power and then turn the power On (I) to initialize the new resistance
value.
4. Print a configuration label by pressing Cancel during power up.
5. Check print quality. If an adjustment is required, see Print Quality Adjustments
onpage121.
Print SystemPrinthead Conversion
Printhead Conversion
Tools Required
Printhead Replacement
1. See Figure78. Hold the printhead from underneath and loosen the printhead mounting
screw.
Figure 78 Printhead Mounting Screw
Flat-Blade Screwdriver Set Anti-Static Wrist Strap
Anti-Static Mat Zebra Preventive Maintenance Kit (Part Number
47362) or a solution of 90% isopropyl alcohol and 10%
deionized water and cotton swabs
Printhead
Mounting
Screw
2. See Figure79. While holding the printhead, remove the power connector first, and then
the printhead data connector.
3. Remove the old printhead.
Figure 79 Printhead Removal and Installation
Install the New Printhead Assembly
1. See Figure79 onpage149. Reconnect the printhead power cables to their appropriate
connectors. Seat both connectors firmly into place.
2. Align the new printhead into the mounting bracket.
3. See Figure80. Align the printhead alignment posts into the printhead alignment slots.
Data
Connector
Printhead
Printhead
Assembly Mounting
Bracket
Power Connector
Note Prior to installing the new printhead, make a note of the resistance value located on the
right side of the manufacturers label. The R value is given in ohms.
Caution An improperly seated printhead data or power cable may cause the printhead to
generate excessive heat and/or a false HEAD COLD message to display while the
printhead is hot enough to cause severe burns.
Figure 80 Printhead Alignment
4. Verify the printhead is seated properly, and then carefully guide the printhead mounting
screw into the printheads aluminum body. When the screw is aligned properly, tighten it
until snug. Do not over-tighten this screw.
5. Clean the new printhead.
6. To remove the print engine from the applicator and open the electronics enclosure,
complete RRP No. 1 on page138.
Pulley and Belt Replacement
1. See Figure81. Loosen, but do not remove, the compound pulley mounting screws.
Note Use Preventative Maintenance Kit, part number 47362, or a solution of
90%isopropyl alcohol and 10% deionized water.
Printhead
Alignment
Post
Printhead
Alignment
Hole
Printhead
Alignment
Post
Printhead
Alignment
Hole
Printhead Assembly
Mounting Bracket
Figure 81 Rear View of Print Engine
2. Remove the stepper motor belt tensioner pulley.
3. Walk the stepper motor belt off of the compound pulley.
4. Turn the print engine until it rests with the media door face down.
5. Loosen and remove the stepper motor mounting screws.
6. Remove the stepper motor.
7. Loosen the two stepper motor pulley set screws.
8. Slide the stepper motor pulley off of the shaft.
9. See Figure82. Place the new stepper motor pulley on the shaft ensuring a 3/16 in.
(4.76 mm) gap between the pulley and the stepper motor.
10. Tighten the set screws on the two flats on the stepper motor shaft.
Note Save the old printhead, stepper motor pulley, and stepper motor belt for reverse
conversion.
Stepper Motor
Mounting
Screws
(4)
Stepper Motor
Belt
Compound Pulley
Assembly
Mounting Screws
(2)
Stepper Motor
Belt Tensioner
Pulley
Compound
Pulley
Figure 82 Stepper Motor Pulley Adjustment
11. See Figure83. Place the new belt around the stepper motor pulley.
12. Ensure the stepper motor standoff is positioned properly over the standoff pins and place
the stepper motor on top of the stepper motor standoff.
13. Reinstall and tighten the stepper motor mounting screw.
Stepper
Motor
Pulley
Stepper Motor
Assembly
3/16 in.
Gap
Figure 83 Removal and Installation of Stepper Motor and Belt
l
14. See Figure81 onpage151. Walk the other end of the belt onto the compound pulley.
Replace the stepper motor idler pulley.
15. Place 6 pounds of static tension on the stepper motor belt by putting pressure on the
compound pulley, and then tighten the compound pulley mounting screws.
16. Turn the print engine back to the upright position.
17. To reinstall the print engine into the applicator and resume printer operation, complete
RRP No. 2 on page141.
Stepper Motor
Mounting Screws (4)
Stepper Motor
Assembly
Stepper Motor
Pulley Assembly
Stepper Motor
Standoff
Stepper Motor
Drive Belt
Print SystemToggle Assembly
Toggle Assembly
Tools Required
Removing the Toggle Assembly
complete RRP No. 1 on page138
2. See Figure84. Remove the two screws from the wire track bracket that secure the bundled
wires.
Figure 84 Cable Clamp and Head-Open Flag Removal
Metric Hex Key (Allen Wrench) Set Phillips Screwdriver Set
Safety Glasses Standard Screwdriver Set
Note Retain all parts removed during disassembly, unless otherwise directed.
Cable
Clamps
Push-In
Fastener
Head-Open
Flag
Auxiliary
Roller
Wire Track
Bracket
3. Remove the two screws that secure the head-open sensor mounting bracket to the
mainframe. Flip both brackets straight down to avoid damage to the head open flag.
4. See Figure84. Open the front cover and unlatch the printhead locking lever.
5. Remove the push-in fastener that secures the head-open flag to the toggle shaft.
6. Remove and discard the head-open flag.
7. Remove the C-clip and remove the auxiliary roller drive belt tension pulley.
8. Remove the screw from the printhead locking lever. Remove the locking lever.
9. See Figure85. Loosen, but do not remove, the left set screw in the hub in a right-hand
PAX, or the right screw in the hub in a left-hand PAX.
Figure 85 Loosening and Tightening the Hub
Note You may need to slide the bracket to the side to avoid damaging and permit access
the head open flag.
printhead to cool.
Hub
Adjustment
Screw
Toggle
Toggle
Shaft
End Plate
Adjustment
Screw
Set Screw
Set Screw
Printhead Locking
Lever Screw
Printhead Locking
Lever
Note If the wrong screw is loosened in the hub, the printhead adjustment may be affected.
10. See Figure86. Remove the four mounting screws that secure the end plate.
11. Remove the C-clip in the plastic bushing.
12. Insert a flat blade screwdriver behind the end plate along the slanted edge of the end plate
and twist the screwdriver.
13. Push the toggle shaft in toward the main frame of the print engine.
14. Pry the end plate partially out and pivot the end plate up. This provides clearance for the
toggle shaft to be removed.
Figure 86 Toggle Replacement
15. See Figure86. Remove the two remaining C-clips that retains the toggle assembly on the
toggle shaft. Slide the toggle assembly off the shaft and discard.
16. Slide the toggle shaft back, down, and then out.
17. Discard the old toggle assembly and toggle shaft.
Push-In
Fastener
C-Clips (4)
Toggle
Set
Screw
Printhead
Locking Lever
End Plate
Attaching Screws
(4)
Printhead Locking
Lever Screw
Head-Open
Flag
Plastic Bushing
End Plate
Bronze Bushing
Toggle Shaft
Hub
Auxiliary Roller
Drive Belt Tension
Pulley
Installing the New Toggle Assembly
1. See Figure86. Slide the new toggle assembly onto the new toggle shaft.
2. On the toggle shaft, install the two C-clips that retain the toggle assembly.
3. See Figure86. Slide the toggle shaft into the brass bushing in the main frame, and then
insert the outside end of the shaft into the plastic bushing in the end plate.
4. Secure the end plate by pushing it back into place and replacing the four attaching screws.
5. See Figure85. Tighten the left set screw in the hub in a right-hand PAX, and the right set
screw in the hub in a left-hand PAX.
6. See Figure85 or Figure86. Reinstall the printhead locking lever and secure it by installing
the latch screw. The toggle shaft end should be flush with the outside of the latch.
7. See Figure86. On the far end, install the auxiliary roller drive belt tension pulley,
C-clip, new head-open flag, and push-in fastener.
8. See Figure84. Reinstall the wire track bracket with the two mounting screws.
9. Reinstall the head-open bracket with the two mounting screws.
10. Complete RRP No. 2 on page141.

Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Dr i ve Syst em
This section provides replacement and installation procedures for the 110PAX4 print system,
including the following:
belts
pulleys
stepper motor
ribbon motor and gears
Contents
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Compound Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Stepper Motor Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Ribbon Take-Up Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Ribbon Supply Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Drive SystemBelts
Belts
Tools Required
Identify the Belts
See Figure87 to identify all belts in the 110PAX4.
Phillips Screwdriver Set Metric Hex Key (Allen Wrench) Set
Flat-blade Screwdriver Set Anti-Static Wriststrap and Mat
Drive SystemBelts
Figure 87 Drive Belts on Right-Hand and Left-Hand Models
Remove the Old Belts
Auxiliary
Roller Drive
Belt
Right-Hand Print Engine
Left-Hand Print Engine
Platen Roller
Drive Belt
Auxiliary
Roller Drive
Belt
Pinch/Peel Roller
Drive Belt
Stepper Motor
Drive Belt
Stepper Motor
Drive Belt
Pinch/Peel Roller
Drive Belt
Platen Roller
Drive Belt
Drive SystemBelts
1. Loosen one of the slack side idler pulley mounting screws, and then remove the second
screw.
Figure 88 Locate the Idler Pulleys
If you have... Then...
A right-hand print engine See Figure88.
A left-hand print engine See Figure89.
Compound Pulley &
Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
Slack Side Idler Pulley
& Mounting Screws
Drive SystemBelts
Figure 89 Locate the Idler Pulleys
2. Loosen the two screws securing the stepper motor belt tensioner pulley located alongside
of the stepper motor.
3. Raise the tensioner pulley as high as it will go, and then snug one of the screws.
4. Loosen the compound pulley mounting screws to relieve the belt tension.
5. Use a flat-blade screwdriver to push down on one side of the compound pulley base until
the screw is at the top of the slot, and then snug down this screw.
6. Repeat step 5 for the other screw.
7. Remove the stepper motor belt by pulling out on the bottom of the belt while turning the
compound pulley.
8. Remove the pinch/peel roller drive belt (middle belt on the compound pulley).
9. See Figure90 or Figure91. Locate the cable support bracket and then remove the
mounting screw and swing the bracket out of your way.
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Compound Pulley &
Mounting Screws
Drive SystemBelts
Figure 90 Locate the Platen Pulley and the Cable Support Bracket
Figure 91 Locate the Platen Pulley and the Cable Support Bracket
10. Walk the platen roller drive belt off of the platen pulley and remove it from the compound
pulley.
Platen Roller
Pulley Cable Support
Bracket
Mounting
Screw
Platen Roller
Pulley
Cable Support
Bracket
Mounting
Screw
Drive SystemBelts
11. See Figure92 or Figure93. Remove the wire track bracket mounting screw.
12. Remove the two mounting screws securing the head open sensor bracket.
13. Swing the two brackets up and out of the way of the auxiliary roller drive belt.
Figure 92 Remove the Head Open Sensor and Wire Track Brackets
Figure 93 Remove the Head Open Sensor and Wire Track Brackets
Note Be careful to bypass the Head-Open flag located behind the wire track bracket.
Mounting
Screw
Mounting
Screw
Mounting
Screw
Head-Open
Sensor Bracket
Wire Track
Bracket
Mounting
Screw
Mounting
Screw
Mounting
Screw
Head-Open
Sensor Bracket
Wire Track
Bracket
Drive SystemBelts
14. See Figure94 or Figure95. Remove the C-clip and platen bearing on the platen shaft from
the front of the print engine.
Figure 94 Remove Platen Roller C-Clip and Bearing
Figure 95 Remove Platen Roller C-Clip and Bearing
15. See Figure96. Loosen the two set screws securing the platen pulley to the platen roller.
C-Clip
Bearing
C-Clip
Bearing
Drive SystemBelts
Figure 96 Remove the Platen Pulley
16. Slide the platen roller out of the platen pulley.
17. Remove the auxiliary roller drive belt.
Install the New Replacement Belts
1. See Figure97. Install the auxiliary roller belt on to the auxiliary pulley.
Install the belt onto the platen pulley between the inboard side of the pulley and the belt
separator.
Set Screw
Set Screw
Right-Hand
Print Engine
Left-Hand Print
Engine
Platen
Roller
Set Screw
Set Screw
Platen
Roller
Drive SystemBelts
Figure 97 Platen Pulley Belt Separator
2. See Figure96. Slide the platen pulley onto the platen roller.
3. Align the flats of the platen roller with the set screws of the platen pulley, and then tighten
the set screws.
4. See Figure94 onpage166 or Figure95 onpage166. From the front of the printer,
reinstall the platen bearing and C-clip.
5. See Figure98. Install the platen roller belt.
The belt must be installed on the compound pulley first, positioned on the innermost
pulley, and then walked onto the platen roller pulley. The separator should be between the
two belts.
Separator
Inboard
Outboard
Drive SystemBelts
Figure 98 View of Belt Path
6. See Figure99. Reinstall the cable support bracket.
Insert the tab in the hole above the mounting hole in the main frame, align the mounting
holes, and then install the screw and tighten.
Auxiliary Pulley
Platen Pulley
Compound
Pulley
Stepper Motor
Pulley
Stepper Belt
Tensioner
Idler
Pulley
Slack Side
Idler Pulley
Peel Roller Pulley
Pinch Roller Pulley
Auxiliary Pulley
Stepper Belt
Tensioner
Stepper Motor
Pulley
Idler
Pulley
Slack Side
Idler Pulley
Peel Roller Pulley
Right-Hand
Print Engine
Left-Hand
Print Engine
Compound
Pulley
Drive SystemBelts
Figure 99 Locate the Locator Hole and Tab
7. See Figure92 onpage165 or Figure93 onpage165. Reinstall the head open and wire
track brackets.
8. Install the pinch/peel belt; the belt must be installed on the middle pulley of the compound
pulley. Place the belt on the peel roller pulley, pinch roller pulley, and follow the belt path
shown in Figure98 onpage169.
9. See Figure88 onpage162 or Figure89 onpage163. Reinstall the screw removed earlier
from the slack side idler pulley and tighten both screws. Ensure the pinch/peel belt rides
on the top of the slack side idler pulley.
10. See Figure98 onpage169. Install the stepper motor belt. The belt must be installed on the
stepper motor first, and then walked onto the compound pulley.
11. Loosen the screws in the compound pulley base to raise it and increase the tension on the
belt.
12. Turn the platen roller several times to seat the belts inside the pulleys. Tighten the
compound pulley base screws.
13. Loosen the screws on the stepper belt tensioner.
Slide the tensioner down until the slack is taken out of the belt, and then push down just a
little more and tighten the screws.
14. To reinstall the cover and replace the print engine in the applicator, complete RRP No. 2
on page141.
Mounting
Screw
Mounting
Hole
Locator
Hole
Locator
Tab
Drive SystemCompound Pulley
Compound Pulley
Tools Required
Remove the Compound Pulley
screw.
2. What model print engine do you have?
Standard Allen Wrench Set Phillips Screwdrivers
Metric Open-End Wrench Set Long Needle-Nose Pliers
Anti-Static Wriststrap and
Mat
Safety Glasses
If you have a... Then...
Right-hand model See Figure100.
Left-hand model See Figure101.
Compound Pulley &
Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Compound Pulley &
Mounting Screws
7. Repeat for the other screw.
compound pulley.
10. See Figure102 or Figure103. Locate the cable support bracket and then remove the
mounting screw and swing the bracket out of your way.
Figure 102 Platen Roller Pulley and the Cable Support Bracket
Cable Support
Bracket
Platen Roller
Pulley
Mounting
Screw
Figure 103 Platen Roller Pulley and the Cable Support Bracket
11. Walk the platen roller drive belt off of the platen pulley and remove it from the compound
pulley assembly. Discard the platen roller drive belt.
12. See Figure104 or Figure105. Remove the wire track bracket mounting screw.
Figure 104 Head Open Sensor and Wire Track Brackets
Cable Support
Bracket
Platen Roller
Pulley
Mounting
Screw
Mounting
Screw
Mounting
Screw
Mounting
Screw
Head-Open
Sensor Bracket
Wire Track
Bracket
Figure 105 Head Open Sensor and Wire Track Brackets
13. Remove the two mounting screws securing the head open sensor bracket.
14. Swing the two brackets up and out of the way of the compound pulley assembly.
15. Use a long needle-nose pliers and lift the spring off of the long spring stud.
16. Remove the compound pulley assembly and bracket mounting screws.
Install the Compound Pulley
1. Use a long needle-nose pliers and reinstall the spring onto the long spring stud.
2. Install the new compound pulley assembly and bracket using the mounting screws
previously removed.
3. See Figure106. Install the new platen roller belt around the compound pulley.
The belt must be installed on the compound pulley first, positioned on the innermost
pulley, and then walked onto the platen roller pulley. The separator should be between the
two belts.
Mounting
Screw
Mounting
Screw
Mounting
Screw
Head-Open
Sensor Bracket
Wire Track
Bracket
Figure 106 View of Belt Paths
4. See Figure107. Reinstall the cable support bracket.
Insert the tab in the hole above the mounting hole in the main frame, align the mounting
holes, and then install the screw and tighten.
Auxiliary Pulley
Platen Pulley
Compound
Pulley
Stepper Motor
Pulley
Stepper Belt
Tensioner
Idler
Pulley
Slack Side
Idler Pulley
Peel Roller Pulley
Pinch Roller Pulley
Auxiliary Pulley
Stepper Belt
Tensioner
Stepper Motor
Pulley
Idler
Pulley
Slack Side
Idler Pulley
Peel Roller Pulley
Right-Hand
Print Engine
Left-Hand
Print Engine
Compound
Pulley
Figure 107 Locator Hole and Tab
5. Reinstall the compound pulley assembly.
6. See Figure104 on page174 or Figure105 on page175. Reinstall the head open and wire
track brackets.
shown in Figure106.
8. See Figure100 on page172 or Figure101 on page172. Reinstall the screw removed
earlier from the slack side idler pulley and tighten both screws. Ensure the pinch/peel belt
rides on the top of the slack side idler pulley.
9. See Figure106 onpage176. Install the stepper motor belt. The belt must be installed on
the stepper motor first, and then walked onto the compound pulley.
belt.
Mounting
Screw
Mounting
Hole
Locator
Hole
Locator
Tab
Drive SystemStepper Motor Pulley
Stepper Motor Pulley
Tools Required
Remove Stepper Pulley and Belt
screw.
Standard Hex Key (Allen
Wrench) Set
Anti-Static Wriststrap and Mat
Small Flat-blade Screwdriver
Metric Open-End Wrench Set Phillips Screwdriver Set
Compound Pulley &
Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Compound Pulley &
Mounting Screws
5. See Figure110. Turn the print engine until it rests with the media door face down.
6. Remove the stepper motor assembly mounting screws, and then remove the stepper motor
from the stepper motor standoff.
7. Remove the stepper motor belt from the compound pulley and the stepper motor pulley
and discard.
Figure 110 Stepper Motor and Belt Removal/Install
8. Loosen the two stepper motor pulley set screws.
9. Slide the stepper motor pulley from the shaft and discard.
Stepper Motor
Mounting Screws (4)
Stepper Motor
Assembly
Stepper Motor
Pulley Assembly
Stepper Motor
Standoff
Stepper Motor
Drive Belt
Install the New Stepper Motor Pulley and Belt
1. See Figure111. Place the new stepper motor pulley on the shaft.
Make sure there is a 3/16 in. (4.76 mm) gap between the pulley and the stepper motor
assembly.
2. Tighten the set screws.
3. See Figure110 onpage180. While holding the new stepper motor belt around the stepper
motor pulley, place the stepper motor assembly onto the standoff.
4. Reinstall and tighten the stepper motor mounting screws.
5. Turn the compound pulley several times to seat the belt inside the pulley.
Stepper
Motor
Pulley
Stepper Motor
Assembly
3/16 in.
Gap
Drive SystemStepper Motor
Stepper Motor
Tools Required
Remove Stepper Motor Assembly
screw.
Small Flat-blade Screwdriver Phillips Screwdriver Set
Metric Open-End Wrench Set Standard Hex Key (Allen Wrench) Set
Anti-Static Wriststrap and
Mat
Compound Pulley &
Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Compound Pulley &
Mounting Screws
5. Turn the print engine until it rests with the media door face down.
6. See Figure114. Remove the stepper motor mounting screws, and then remove the stepper
motor from the stepper motor standoff.
7. Remove the stepper motor belt from the compound pulley and the stepper motor pulley.
Figure 114 Stepper Motor and Belt Removal/Install
8. Loosen the two stepper motor pulley set screws, and then slide the stepper motor pulley
off of the shaft.
Install the New Stepper Motor Pulley and Belt
1. See Figure115. Place the old stepper motor pulley on the new stepper motor shaft.
Make sure there is a 3/16 in. (4.76 mm) gap between the pulley and the stepper motor, and
then tighten the set screws.
Stepper Motor
Mounting Screws (4)
Stepper Motor
Assembly
Stepper Motor
Pulley Assembly
Stepper Motor
Standoff
Stepper Motor
Drive Belt
2. See Figure115. While holding the stepper motor belt around the stepper motor pulley,
place the new stepper motor onto the standoff.
3. Reinstall and tighten the stepper motor mounting screws.
4. Place the other end of the stepper motor belt onto the compound pulley.
Turn the compound pulley several times to seat the belt inside the pulley.
5. See Figure112 or Figure113. Loosen the screws on the stepper belt tensioner.
Stepper
Motor
Pulley
Stepper Motor
Assembly
3/16 in.
Gap
Drive SystemRibbon Take-Up Motor
Ribbon Take-Up Motor
Tools Required
Remove the Ribbon Take-Up DC Motor
1. See Figure116 onpage187. At the back of the print engine, locate the ribbon take-up DC
motor.
In a right-hand print engine, the motor is on the far right. In a left-hand print engine, the
motor is on the far left.
2. Remove the DC motor wires from the rear of the ribbon take-up DC motor.
Take note of the color of the electrical wires and the terminals they connected to: black to
the positive terminal (+), yellow to the negative terminal ().
Phillips Screwdriver Set Flat-Blade Screwdriver Set
Wire Cutters Metric Hex Key (Allen Wrench) Set
Figure 116 DC Motor Power Wires
3. See Figure117. Remove the three take-up DC motor bracket mounting screws.
Ribbon Take-Up
Motor
Ribbon Take-Up Motor
Right-Hand
Print Engine
DC Motor
Wires
DC Motor
Wires
Yellow
Wire
Black
Wire
Yellow
Wire
Cable
Clamp
Cable
Clamp
Black
Wire
Encoder Wires
Encoder Wires
Left-Hand
Print Engine
Figure 117 Remove the Mounting Screws
4. Remove the ribbon take-up DC motor bracket assembly from the print engine.
5. Cut the cable tie.
6. See Figure118 onpage189. Follow the ribbon take-up encoder wires to the cable clamp.
Remove the cable clamp and wires.
7. Follow the take-up encoder wires up to the DC motor control board.
Motor
Bracket
Mounting
Screw
Mounting
Screw
Mounting
Screw
Mounting
Screw
Motor
Bracket
Mounting
Screw
Mounting
Screw
Right-Hand
Print Engine
Left-Hand
Print Engine
Figure 118 Locate the DC Motor Control Board
DC
Motor
Control
Board
Corrugated
Tubing
Cable
Clamp
Cable Clamp
Left-Hand
Print Engine
Right-Hand
Print Engine
DC
Motor
Control
Board
Corrugated Tubing
8. See Figure119. Loosen the two screws in the mounting slots of the rear enclosure.
9. Remove the two other mounting screws from the rear enclosure.
This provides access to the DC motor control board.
Figure 119 Loosen the Motor Control Board Mounting Screws
Mounting
Screws
Enlarged
Holes
Mounting
Screws
Enlarged
Holes
Right-Hand
Print Engine
Left-Hand
Print Engine
10. Slide the motor control board to the side, align the two screws with the enlarged holes of
the mounting slots, and then pull the board out of the enclosure.
11. See Figure120. Remove the connectors, J 7 and J 8, from the motor control board.
Figure 120 Motor Control Board
12. See Figure118 onpage189. Remove the ribbon take-up encoder wires from the
corrugated tubing.
J3
J4
J10
J11
J9
J1
J2
J8
J7
J6
J5
J12
J7 Ribbon Take-Up
Encoder 1
(4-Pin Violet Wire)
J8 Ribbon Take-Up
Encoder 2
(4-Pin Yellow Wire)
J4 Ribbon
Take-Up Motor
(Yellow and Black)
Install the New DC Ribbon Take-Up Motor
1. See Figure117 onpage188. Install the new DC motor bracket assembly onto the
mainframe, aligning the three mounting holes with the three holes in the mounting
bracket.
2. Install, but do not tighten, the three motor bracket mounting screws.
3. Turn the ribbon take-up spindle three times in one direction, three times in the other
direction, and then tighten the three mounting screws.
4. Route the new ribbon take-up encoder wires to the location of the first cable clamp. Insert
the new wires into the cable clamp along with the wires from the ribbon supply dancer
assembly and the take-up encoder.
5. Route the new ribbon take-up encoder wires to the location of the second cable clamp.
Insert the new wires into the cable clamp along with the wires from the ribbon supply
dancer assembly and the take-up encoder
6. Insert the new wires through the opening into the corrugated tubing.
7. See Figure120 onpage191. Install the wire connectors into the corresponding connectors
on the motor control board, J 5 for the connector with the orange wire and J 6 for the
connector with the blue wire.
8. See Figure119 onpage190. Reinstall the motor control board using the screws previously
removed.
Tighten all four screws.
9. See Figure116 onpage187. Install the two power connectors to the rear of the ribbon
take-up DC motor.
The black wire connects to the positive (+) terminal on the right, the yellow wire goes to
the negative () terminal on the left.
10. Install the cable tie.
Drive SystemRibbon Supply Motor
Ribbon Supply Motor
Tools Required
Remove the Ribbon Supply DC Motor
1. See Figure121 onpage194. At the back of the print engine, locate the ribbon supply DC
motor.
In a RH print engine, the motor is on the far right. In a LH print engine, the motor is on the
far left.
2. Remove the DC motor wires from the rear of the ribbon supply DC motor.
Take note of the color of the electrical wires and the terminals they connected to: black to
the positive terminal (+), red to the negative terminal ().
Phillips Screwdriver Set Flat-Blade Screwdriver Set
Wire Cutters Metric Hex Key (Allen Wrench) Set
Figure 121 Ribbon Supply DC Motor and Power Wires
3. Follow the ribbon supply encoder wires to the first cable clamp.
Take note of the routing of the wires.
4. Remove the cable clamp and remove the wires.
5. Refer to Figure122. Remove the three DC motor bracket mounting screws.
Ribbon Supply
DC Motor
Ribbon Supply
DC Motor
DC Motor
Wires
DC Motor
Wires
Yellow
Wire
Black
Wire
Yellow
Wire
Cable
Clamp
Cable
Clamp
Black
Wire
Encoder Wires
Encoder Wires
Right-Hand
Print Engine
Left-Hand
Print Engine
Figure 122 Remove the Mounting Screws
6. Remove the ribbon supply DC motor bracket from the print engine.
7. See Figure123 onpage196. Cut the cable tie.
8. Follow the ribbon supply encoder wires to the cable clamp. Remove the cable clamp and
wires.
9. Follow the supply encoder wires up to the DC motor control board.
Motor
Bracket
Mounting
Screw
Mounting
Screws
Mounting
Screws
Mounting
Screw
Right-Hand
Print Engine
Left-Hand
Print Engine
Motor
Bracket
Figure 123 Locate the DC Motor Control Board
DC
Motor
Control
Board
Corrugated
Tubing
Cable
Clamp
Cable Clamp
Left-Hand
Print Engine
Right-Hand
Print Engine
DC
Motor
Control
Board
Corrugated Tubing
10. See Figure124. Loosen the two screws in the mounting slots of the rear enclosure.
11. Remove the two other mounting screws from the rear enclosure.
This provides access to the DC motor control board.
Figure 124 Loosen the DC Motor Control Board Mounting Screws
Mounting
Screws
Enlarged
Holes
Mounting
Screws
Enlarged
Holes
Right-Hand
Print Engine
Left-Hand
Print Engine
12. Slide the motor control board to the side, align the two screws with the enlarged holes of
the mounting slots, and then pull the board out of the enclosure.
13. See Figure125. Remove the connectors, J 5 and J 6, from the motor control board.
Figure 125 Motor Control Board
14. See Figure123 onpage196. Remove the ribbon supply encoder wires from the
corrugated tubing.
Install the New Ribbon Supply DC Motor
1. See Figure122 onpage195. Install the new DC motor bracket assembly onto the
mainframe, aligning the three mounting holes with the three holes in the mounting
bracket.
2. Install, but do not tighten, the three motor bracket mounting screws.
3. Turn the ribbon supply spindle three times in one direction, three times in the other
direction, and then tighten the three mounting screws.
4. Route the new ribbon supply encoder wires to the location of the first cable clamp. Insert
the new wires into the cable clamp along with the wires from the ribbon supply dancer
assembly and the take-up encoder.
5. Route the new ribbon supply encoder wires to the location of the second cable clamp.
Insert the new wires into the cable clamp along with the wires from the ribbon supply
dancer assembly and the take-up encoder
6. Insert the new wires through the opening into the corrugated tubing.
7. See Figure125 onpage198. Install the wire connectors into the corresponding connectors
on the motor control board, J 5 for the connector with the orange wire and J 6 for the
connector with the blue wire.
8. See Figure124 onpage197. Reinstall the motor control board using the screws
previously removed. Tighten all four screws.
J3
J4
J10
J11
J9
J1
J2
J8
J7
J6
J5
J12
J7 Ribbon Take-Up
Encoder 1
(4-Pin Violet Wire)
J8 Ribbon Take-Up
Encoder 2
(4-Pin Yellow Wire)
J4 Ribbon
Take-Up Motor
(Yellow and Black)
9. See Figure121 onpage194. Install the two power connectors to the rear of the ribbon
supply DC motor.
The black wire connects to the positive (+) terminal on the right, the yellow wire goes to
the negative () terminal on the left.
10. Install the cable tie.

Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Rol l er Syst em
Pinch Roller
Peel Roller
Auxiliary Roller
Contents
Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Peel Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Auxiliary Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Roller SystemPinch Roller
Pinch Roller
Tools Required
Remove Pinch Roller Assembly
1. Place the print engine on its back or on its side so the peel roller bracket can move.
2. See Figure126. Raise the peel roller latch so the peel roller bracket assembly pivots freely.
3. Remove the peel roller bracket assembly mounting screw, and then remove the peel roller
bracket assembly.
Figure 126 Peel Roller Latch and Roller Assembly
Phillips Screwdriver Set Anti-Static Wriststrap and Mat
Metric Open-End Wrench Set Standard Hex Key (Allen Wrench) Set
Peel
Roller
Latch
Peel Roller
Bracket Assembly
Mounting Screw
Peel Roller
Bracket Assembly
Open/Close
screw.
(Right-Hand Print Engine Shown)
Right-hand print engine See Figure127.
Left-hand print engine See Figure128.
Compound Pulley &
Mounting Screws
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
(Left-Hand Print Engine Shown)
9. Repeat step 6 for the other screw.
compound pulley.
12. See Figure129. Loosen and remove the four screws that secure the label guide shelf plate.
Remove the plate.
Note The cam plates should not be separated from the label guide shelf plate. If they are
removed separately, correct roller alignment may be lost. The pinch roller assembly and
the elastomer rollers hang free when the label guide shelf plate is removed.
Stepper Motor Belt
Tensioner Pulley &
Mounting Screws
& Mounting Screws
Compound Pulley &
Mounting Screws
Figure 129 Label Guide Shelf Plate Mounting Screws
13. Loosen and remove the screw and washer that retain the peel roller bearing.
14. While holding the pulley at the rear of the print engine, slowly pull the pinch roller until it
is free from the pulley and the main frame. Discard the old roller but save the two spacers.
These will be installed on the new roller.
Install the New Pinch Roller
1. Place the two spacers on the new roller.
2. Slide the new pinch roller with bearing into the inner main frame. Install the outer bearing
and secure it to the pinch roller assembly using the E-ring provided with the kit.
3. Reinstall the spacer and pulley into the inner main frame. Rotate the shaft of the pinch
roller assembly so the two flat areas align with the set screws in the pulley, and then
tighten the set screws.
4. Reinstall the screw and washer that retain the pinch roller bearing.
5. From the front of the print engine, align the label guide shelf plate so the bearings of the
elastomer roller and pinch roller extend through the oblong holes and into the holes in the
cam plates.
6. Reinstall and tighten the four label guide shelf plate mounting screws.
7. See Figure127 or Figure128. From the rear of the print engine, ensure the belt is still
routed around the pulleys correctly.
shown in Figure127 or Figure128.
Note As the roller is being removed, the rear spacer between the main frame and the
pulley is free to fall.
Mounting
Screw
Mounting
Screw
9. Reinstall the screw removed earlier from the slack side idler pulley and tighten both
screws. Ensure the pinch/peel belt rides on the top of the slack side idler pulley.
belt.
Roller SystemPeel Roller
Peel Roller
Tools Required
Remove Peel Roller Assembly
1. Place the print engine on its back or on its side so the peel roller bracket can move.
2. See Figure130. Raise the peel roller latch so the peel roller bracket assembly pivots freely.
3. Remove and retain the peel roller bracket assembly mounting screw, and then remove the
peel roller bracket assembly.
Phillips Screwdriver Set Standard Hex Key (Allen Wrench) Set
Small Flat-blade Screwdriver Set Anti-Static Wriststrap and Mat
Metric Hex Key (Allen Wrench) Set
Figure 130 Peel Roller Latch and Roller Assembly
4. See Figure131. Loosen, but do not remove, the belt tensioner pulley mounting screws,
and then relieve tension off the belts by tilting the pulley.
5. Loosen, but do not remove, the two set screws for the peel roller pulley.
Make sure the pulley can slide off the peel roller shaft.
Note The cam plates should not be separated from the label guide shelf plate. If they are
removed separately, correct roller alignment may be lost. The peel roller assembly and the
elastomer rollers hang free when the label guide shelf plate is removed.
Peel
Roller
Latch
Peel Roller
Bracket Assembly
Mounting Screw
Peel Roller
Bracket Assembly
Open/Close
Figure 131 Rear View of the Peel Roller Pulley
6. See Figure132. Loosen and remove the four screws that secure the label guide shelf plate.
Remove the plate.
Figure 132 Removing the Label Guide Shelf Plate Mounting Screws
7. Loosen and remove the screw and washer that retain the peel roller bearing.
8. While holding the pulley at the rear of the print engine, slowly pull the peel roller until it is
free from the pulley and the main frame. Discard the old roller.
Note As the roller is being removed, the rear spacer between the main frame and the
pulley is free to fall.
Peel Roller
Pulley
Mounting
Screw
Mounting
Screw
Install the New Peel Roller
1. See Figure133. Slide the new peel roller with bearing into the inner main frame. Install
the outer bearing and secure it to the peel roller assembly using the E-ring provided with
the kit.
Figure 133 Remove/Install/Adjust the Peel Roller Assembly
2. See Figure131. Reinstall the spacer and pulley into the inner main frame. Rotate the shaft
of the peel roller assembly, so the two flat areas align with the set screws in the pulley, and
then tighten the set screws.
3. Reinstall the screw and washer that retain the peel roller bearing.
4. From the front of the print engine, align the label guide shelf plate so the bearings of the
elastomer roller and peel roller extend through the oblong holes and into the holes in the
cam plates.
5. See Figure132. Reinstall and tighten the four label guide shelf plate mounting screws.
6. See Figure131. From the rear of the print engine, ensure the belt is still routed around the
pulleys correctly.
7. Place tension on the belts and tighten the belt tensioner pulley mounting screws.
8. To reinstall the print engine in the applicator and resume printer operation, complete
Peel
Roller
Test and Adjust the Peel Roller
1. Set up and run some labels through the print engine while watching to see if the labels run
parallel to the main frame of the print engine.
2. Determine which way the media needs to be adjusted based on observations in step 1
above.
3. See Figure133. Loosen the cam plate screw and then loosen the cam screw in the center
of the cam. Use a small, flat-blade screwdriver to make the peel roller adjustment
required, as determined in step 2 above.
4. Make small adjustments, run more test labels, and then make corrections until the media
runs parallel to the main frame. Ensure the cam screw and the cam plate screw are
tightened after the final adjustment is made.
Note The peel roller assembly can be adjusted through the use of the cam on the label
guide shelf plate.
Note For right-hand print engines, turning the cam counterclockwise adjusts the media
away from the main frame, and towards the front of the print engine. Turning the cam
clockwise adjusts the media towards the mainframe, and away from the front of the print
engine. For left-hand print engines, turning the cam counterclockwise adjust the media
towards the mainframe, and away from the front of the print engine. Turning the cam
clockwise adjust the media away from the mainframe, and towards the front of the print
engine.
Note This is a trial and error type of adjustment.
Roller SystemAuxiliary Roller
Auxiliary Roller
Tools Required
Remove the Auxiliary Roller Assembly
1. See Figure134. Remove the printhead locking lever mounting screw and remove the
locking lever.
Figure 134 Auxiliary Roller Remove/Install
Standard Allen Wrench Set Phillips Screwdrivers
Metric Open-End Wrench
Set
Anti-Static Wriststrap and Mat
Auxiliary
Roller
Adjustment Hub
Set Screw
Bearing
Retainer Clamp
Mounting Screw
Extrusion End Plate
Mounting Screw
Extrusion End
Plate Mounting
Screws (3)
Printhead
Locking Lever
Mounting
Screw
Printhead
Locking Lever
Extrusion
End Plate
Bearing
Retainer
Clamp
2. Remove the adjustment hub set screw (right-hand side set screw for left-hand print engine,
left-hand side set screw for right-hand print engine).
3. Remove the c-clip from the end of the pivot toggle bar.
4. Remove the bearing retainer clamp mounting screw and retainer clamp.
5. Remove the four end plate mounting screws. Remove the end plate.
6. Slide the auxiliary roller assembly out of the print engine.
7. Remove the two c-clips from the ends of the auxiliary roller assembly. Retain the two
bearings and discard the old roller and gear.
Install the Auxiliary Roller Assembly
1. Install the bearings that were removed from the old auxiliary roller assembly.
2. Reinstall the one c-clip at the one end of the auxiliary roller assembly.
3. See Figure134. Slide the new auxiliary roller into the print engine.
4. Reinstall the screw and bearing retainer clamp.
5. Reinstall the other c-clip at the other end of the auxiliary roller assembly.
6. Reinstall and tighten the four extrusion end plate mounting screws.
7. Reinstall the c-clip on the pivot toggle bar.
8. Reinstall, but do not tighten the two adjustment hub set screws.
9. Reinstall the printhead locking lever mounting screw.
Printhead Balance Adjustment
The adjustment hub produces an even pressure across the full width of the printhead and platen
roller.
1. Print a Pause self-test by pressing Pause while turning On (l) the print engine power.
2. After printing a few labels, pause the print engine and reduce the darkness configuration
parameter value until the test labels are a charcoal gray color.
3. Print more test labels and observe the print quality.
4. If the label printing is lighter or no printing is observed on one side of the label as
compared with the other, continue to step 8.
If printing is even, printhead balance does not need to be adjusted.
5. See Figure135. Loosen the balance adjustment locking screw.
Figure 135 Printhead Balance Adjustment
6. Balance the printhead pressure by turning the hub adjusting screw.
7. When an even print quality is achieved, tighten the hub locking set screw.
8. Print Pause test labels to verify that printhead balance is correct.
Locking
Screw
Locking
Screw
Adjustment
Screw
Adjustment
Screw
Compression
Spring
Full View of
Hub
Close-Up View
of Hub
Note Continue to print Pause test labels while adjusting the hub for even printing. If the
label is darker on the inside (closest to the mainframe), turn the top adjustment screw
clockwise to balance the pressure. If the printing is darker on the outside, turn the top
adjustment screw counterclockwise.
Pr i nt ed Ci r c ui t Boar ds
PCMCIA card and Compact Flash card, wireless PCMCIA board
print server
main logic board
applicator interface board and AC power supply board
Contents
PCMCIA Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Wireless PCMCIA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Compact Flash and PCMCIA Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Print Server Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Main Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Applicator Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
AC Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Printed Circuit BoardsPCMCIA Card
PCMCIA Card
Tools Required
1. Turn Off (O) the printer or print engine and disconnect the AC power cord and data
cables, if required.
2. See Figure136. Remove the option card shield.
Figure 136 Memory/Font Card Installation for the 110PAX4 Print Engine
Phillips Screwdriver Set Anti-Static Mat
Hex Key (Allen Wrench) Set Anti-Static Wrist Strap
Left-Hand
Model
PCMCIA
Card
Shield
Notch
Mounting
Screw
PCMCIA
Card
Right-Hand
Model
Mounting
Screw
PCMCIA
Card
Notch
PCMCIA
Card
Shield
Note See Figure137 to verify the notch is positioned correctly for your print engine.
Printed Circuit BoardsPCMCIA Card
Figure 137 Notch Location
3. Insert the PCMCIA card until it is fully seated into the interface.
The card-eject button will pop out.
4. Reinstall the option card shield with the mounting screw.
5. Reconnect the AC power cord and data cables, if required.
6. Press and hold CANCEL while turning On (l) the printer.
7. After the Power-On test, a configuration label will print.
8. Verify the new option card is recognized. If the configuration label shows:
xxxxB: Memory Card
(where xxxx =the amount of memory installed),
the installation is complete.
Note For the right-hand PAX print engine, install the PCMCIA card with the product label
facing to the left. The L-shaped notch will be facing down.
For the left-hand PAX print engine, install the PCMCIA card with the product label facing to
the right. The L-shaped notch will be facing up.
Label Side
Notch
Top
edge
Bottom edge
Bottom edge
Bottom guide
Flipped Side
of Label
Printed Circuit BoardsWireless PCMCIA Board
Wireless PCMCIA Board
Tools Required
Remove the PCMCIA Option Board
1. Remove the PCMCIA card shield and mounting screw.
2. See Figure138. Remove the PCMCIA card from the PCMCIA slot, if applicable.
Figure 138 Rear View of PCMCIA Card Removal and Installation
3. See Figure139. Remove the screws and star washers that hold the printed circuit board
(PCB) access panel in place.
Phillips Screwdriver Set Anti-Static Mat
Nutdriver Set Anti-Static Wrist Strap
PCMCIA
Card
PCMCIA
Card
Shield
Mounting
Screw
Figure 139 Removal and Installation of PCB Access Panel from Print Engine
4. Which model print engine do you have?
PCB
Access
Panel
PCB Access
Panel Screws
(6)
PCB Access
Panel Screws
(6)
PCB
Access
Panel
Right-Hand Model Left-Hand Model
If you have... Then...
A right-hand print engine Continue with For the Right-Hand Print
Engine onpage220.
A left-hand print engine Go to For the Left-Hand Print Engine
onpage223.
For the Right-Hand Print Engine
1. Disconnect the cables from J 1 and J 2 of the motor control board.
Note the orientation of the wires: yellow is J 1 and white is J 2.
2. See Figure140. Remove the six screws and star washers on the lower enclosure panel.
Figure 140 View of Lower Enclosure Panel on Right-Hand Model Only
3. Pull out the lower enclosure panel and swing the panel to the right to gain access to the
main logic board connectors.
The two cables, which were disconnected from J 1 and J 2 of the motor control board, will
remain attached to the lower enclosure panel.
Outside View of the
Lower Enclosure Panel
Inside View of the
J1 and J2 on
the Motor
Control Board
Figure 141 Main Logic Board Electrical Connections
Table 13 Main Logic Board Electrical Connections
Connector Description
P2 Door-Open Sensor
P3 Head-Open Sensor
P5 Ribbon Sensor
P6 Reflective Media Sensor
P8 Transmissive Media Sensor
P19 Printhead Data Cable
P21 Internal 10/100 PS Connector
P23 PCMCIA Option Board Interface
P27 Power Connector
P30 SPI Peripheral
P31 SPI Peripheral
P32 SPI Peripheral
P33 SPI Peripheral
P34 SPI Peripheral
P35 SPI Peripheral
P23 P24
P27
P6
P8
P10
P5
P3
P2
P30-P35
P19
P21
4. See Figure141. If you have a 10/100 PrintServer installed, you must remove the two
screws securing the 10/100 PS board and unplug the ribbon cable attached to P21 on the
main logic board.
Figure 142 Main Logic Board and Applicator Interface Board Electrical
Connections
5. Unplug all cables from the main logic board.
6. Unplug the cables connected to J 1 and J 3 on the applicator interface board.
Note the location of the main logic board connectors and cables.
7. Carefully pull the PCB access panel completely out of the rear enclosure along with the
main logic board still attached.
8. Go to Remove the Applicator Interface Boardon page223.
Applicator
Interface Board
PCB Access
Panel
Main Logic
Board
(MLB)
J3 Power
Connector
J1 SPI Port
Connector
Internal 10/100 Print
Server (optional)
For the Left-Hand Print Engine
1. See Figure141. If you have a 10/100 PrintServer installed, remove the two screws
securing the 10/100 PS board and unplug the ribbon cable attached to P21 on the main
logic board.
2. Unplug the 34-pin ribbon cable from P19 on the main logic board.
4. Remove the SPI cables, P30-P35, and then pull the PCB access panel partially out of the
opening.
5. Remove the remaining cables connected to the main logic board.
6. Continue with Remove the Applicator Interface Board.
Remove the Applicator Interface Board
1. See Figure143. Remove the two screws that hold the applicator interface board in place.
Figure 143 Removal and Installation of Applicator Interface Board
2. Slide the applicator interface board out.
3. See Figure144. Remove the two mounting studs and washers on either side of the serial
interface connector.
4. Remove the two mounting screws and washers on either side of the parallel interface
connector.
Applicator
Interface
Board
Applicator Port
Screw
PCB Access
Panel
Screw
Figure 144 Removing or Installing Main Logic Board
5. See Figure145. Carefully remove the three hex screws and spacers that secure the MLB
and the PCMCIA board to the PCB access panel.
6. Remove the two hex screws and spacers fastening the PCMCIA board to the main logic
board.
7. Separate the PCMCIA board from the MLB using the following technique:
a. Grasp the boards by their edges.
b. With a gentle rocking and pulling motion, separate the connectors.
Figure 145 Spacer Locations on PCB Access Panel
Note The longer screw and two spacers separate the PCMCIA option board from the
PCB access panel.
Note The circuit boards may withstand a small amount of flexing; however, they are not
designed to bend.
Parallel
Interface
Connector
Mounting
Screw
Mounting
Screw
Serial
Interface
Connector
Mounting
Screws
Main Logic
Board (MLB)
PCB
Access
Panel
PCMCIA Socket
Option Board
P2 Connector
on MLB
Hex
Screws
and
Spacers
Hex Screws
and Spacers
Hex
Screws
Hex
Screw
Spacer
Nuts
Nut
PCMCIA
Board
(Back
Side)
Main
Logic
Board
PCB
Access
Panel
PCB
Access
Panel
PCB
Access
Panel
Installation of the Wireless PCMCIA Board Assembly
1. See Figure146. Align the connectors on the PCMCIA board with the connectors on the
MLB. Support both boards (MLB and wireless PCMCIA) under the connectors, and
gently press the connectors together until fully seated.
Figure 146 Wireless PCMCIA Option Board Components
2. Reinstall the two hex screws, spacers, and nuts to secure the new PCMCIA board to the
main logic board.
3. Reattach the main logic board/PCMCIA board to the PCB access panel by reinstalling the
two hex screws, spacers, and nuts. Snug the screws, but do not tighten at this time.
4. Install the longer hex screw, two spacers, and nut that separate the PCB access panel and
the new wireless PCMCIA board. Snug the screw, but do not tighten at this time.
5. See Figure144 onpage224. Install the screws, studs, and washers for the parallel
interface and serial interface connectors and tighten.
6. Tighten the three hex screws that secure the boards to the PCB access panel.
7. See Figure143 onpage223. Reattach the applicator interface board to the PCB access
panel.
8. See Figure141 onpage221 and Table13. Reinsert the PCB access panel, and reconnect
all of the cables to the main logic board.
9. See Figure141 onpage221. Reconnect J 1 and J 3 cables to the applicator interface board.
Ensure that all logic board connector leads are tucked in without being pinched and the
access panels metal frame slides into the rear enclosures plastic guide.
10. See Figure139 onpage219. Secure the PCB access panel using the six screws with star
washers.
Compact Flash
Socket
PCMCIA
Socket
Card
Eject
Button
Main Logic Board
Connectors
Note The SPI connectors are all the same electrically, and the components that plug into
an SPI connector can plug into any of the SPI connectors, P30-P35.
11. See Figure141 onpage221 and Figure142 onpage222. If you had an internal 10/100
Print Server installed, complete the following steps:
a. Plug the ribbon cable into the main logic board connector, P21. The connector is
polarized with a center key. Ensure the center key aligns with the slot in the main
logic board connector.
b. Insert the 10/100 PS into the opening while guiding the ribbon cable into the printer.
c. Secure the new print server cover plate to the PCB access panel by reinstalling the
two cover plate mounting screws.
12. Replace the lower enclosure panel.
13. Reinstall the six screws with star washers to secure the lower enclosure cover.
14. Reconnect cables to J 1 and J 2 on the motor control board.
The cable with the yellow wire connects to J 1; the cable with the white wire
connects to J 2.
16. See Figure138 onpage218. Insert the wireless PCMCIA card into the card slot in the
back of the print engine.
17. Install the clear plastic PCMCIA cover using the cover shield mounting screw.
19. Turn On (l) the print engine.
Refer to the Wireless Print Server User Guide (PN 13422L-001) to configure and verify proper
operation of the wireless PCMCIA card.
Note Do not force the PCB access panel into position. If required, reroute wire leads to
ensure the PCB access panel is properly positioned.
Note The removable lower enclosure cover has two tabs that fit on top and inside of the
bottom stationary cover. Refer to Figure140 for the proper position of the panel in the
lower enclosure.
Note For the right-hand print engine, install the PCMCIA card with the product label
Note For the left-hand print engine, install the PCMCIA card with the product label
facing to the right. The L-shaped notch will be facing up.
Note If the wireless PCMCIA board is not installed properly, the wireless link status
indicator does not appear at the bottom left of the front panel LCD.
Note If the wireless PCMCIA card is not installed or operating properly, the wireless
link status indicator will appear as an underscore at the bottom left of the front panel LCD.
Printed Circuit BoardsCompact Flash and PCMCIA Cards
Compact Flash and PCMCIA Cards
Tools Required
3. From inside the electronics enclosure, insert the compact flash card into the compact flash
socket.
The compact flash socket is located on the upper portion for the right-hand version and on
the lower portion for the left-hand version of the option board. The card can only be
inserted one way, and should snap in place.
Phillips Screwdriver Set Anti-Static Wrist Mat
Metric Hex Key (Allen Wrench) Set Anti-Static Wrist Strap
Right-hand print engine See Figure147 onpage229.
Left-hand print engine See Figure148 onpage230.
Figure 147 Inside Electronics Enclosure View of Option Board
and Compact Flash Card (Right-Hand Model Shown)
Option Board
(shown shaded)
Compact Flash Card
Compact
Flash
Socket
Figure 148 Inside Electronics Enclosure View of Option Board
and Compact Flash Card (Left-Hand Model Shown)
Option Board
(shown shaded)
Compact Flash Card
Compact
Flash
Socket
Initialize Flash Memory
1. Press SETUP/EXIT to enter the Configuration Mode.
2. Press PLUS (+) until INIT FLASH MEM. is displayed.
3. Press SELECT and enter your password.
The factory default password is 1234.
4. Press NEXT/SAVE.
The LCD asks INIT FLASH MEM.
5. Press PLUS (+) YES.
The LCD asks ARE YOU SURE?
6. Press PLUS (+) to select YES and begin initialization.
or
Press MINUS () to cancel the request and return to the INIT FLASH MEM. prompt.
PCMCIA Card Installation
1. Turn Off (O) the print engine and disconnect the AC power cord and interface cables, if
required.
2. See Figure149. Remove the PCMCIA card shield.
Caution Perform this operation only when it is necessary to erase all previously stored
information from the flash memory. Press NEXT/SAVE to bypass this function.
Note For right-hand print engines, install the PCMCIA card with the product label
For left-hand print engines, install the PCMCIA card with the product label facing to the
right. The L-shaped notch will be facing up.
Figure 149 PCMCIA Card Installation for the 110PAX4 Print Engines
3. Insert the PCMCIA card until it is fully seated into the PCMCIA card socket.
The card-eject button will pop out, and a click can be heard.
4. Reinstall the PCMCIA card shield.
1. Open the media door and reinstall the media and ribbon.
2. Latch the printhead and close the media door.
4. Press and hold CANCEL while turning On (l) the printer.
A configuration label will print.
5. Verify the installed cards are recognized.
If the configuration label shows:
xxxxA: Compact Flash
or
xxxxB: Memory Card
(where xxxx =the amount of memory installed),
the installation is complete.
Left-Hand
Model
PCMCIA
Card
Shield
Notch
Mounting
Screw
PCMCIA
Card
Right-Hand
Model
Mounting
Screw
PCMCIA
Card
Notch
PCMCIA
Card
Shield
Printed Circuit BoardsPrint Server Board
Print Server Board
Tools Required
Install ZebraNet 10/100 Print Server
1. See Figure150. Remove the two mounting screws securing the blank cover plate.
Figure 150 Back View of PCB Access Panel with and without 10/100 PS
Phillips Screwdriver Set Metric Hex Key (Allen Wrench) Set
Anti-Static Wrist Strap Anti-Static Wrist Mat
With the
10/100 Print Server
Without the 10/100
Print Server
10/100 Print
Server Cover
Plate
Disabled
Parallel Port
(Cover Plate
Extension)
Blank Cover Plate
Parallel
Port
Cover Plate
Mounting
Screws
PCB
Access
Panel
PCB
Access
Panel
Printed Circuit BoardsPrint Server Board
2. See Figure151. Insert the 10/100 Print Server ribbon cable connector through the opening
in the Printed Circuit Board (PCB) access panel.
Figure 151 10/100 Print Server Details
3. Plug the ribbon cable into the main logic board connector, P21. The connector is polarized
with a center key. Ensure the center key aligns with the slot in the main logic board
connector.
4. Insert the 10/100 PS into the opening while guiding the ribbon cable into the printer.
5. Secure the new print server cover plate to the PCB access panel by reinstalling the two
cover plate mounting screws.
Configure the 10/100 Print Server
To configure the print server, refer to the ZebraNet 10/100 Print Server User and Reference
Guide (p/n 47619L-001).
Ribbon
Cable
Status
Indicators
Test
Button
Ethernet
Connector Ribbon
Cable
Connector
Parallel
Port
Cover
Center
Key
Printed Circuit BoardsMain Logic Board
Main Logic Board
Tools Required
Obtain the Printhead Resistor Value
At the end of this procedure, (see Configure the Printer after Installation onpage244), you
will need the printhead resistor value. You can obtain the resistor value by printing a
configuration label (printed method) or by reading a label located on the printhead (observed
method). The configuration label, if it prints, will also tell you what is plugged into the SPI
ports (P30-P35) on the main logic board.
Printed Method
2. Press and hold CANCEL while turning the power On (l). Hold CANCEL until the first
front panel light turns off.
3. A configuration label will print.
4. Locate the line that reads Head Resistor for the printhead resistor value.
Observed Method
1. Unlatch the printhead lever and remove the media and ribbon from the print engine.
2. Locate the sticker on the underside of the printhead.
The resistor value is shown on the right-side of the label and appears as R=xxxx, where
xxxx is the resistor value.
Phillips Screwdriver Set Standard Nutdriver Set
Small Flat-blade Screwdriver Set Anti-Static Wriststrap and Mat
Metric Hex Key (Allen Wrench) Set Small Needle Nose Pliers
Note If you were unable to print out a configuration label earlier, use the Observed
Method listed below.
printhead to cool.
3. If you are unable to see the sticker clearly, while the printhead is still installed in the print
engine, remove the center printhead screw. Carefully pull the printhead out of the print
engine, and look at the underside of the printhead.
The resistor value is shown on the right-side of the label and appears as R=xxxx, where
xxxx is the resistor value.
4. Reinstall the printhead, if necessary.
5. Close and latch the printhead lever.
Removing the Main Logic Board
1. Carefully swing open the rear enclosure, ensuring that no cables are causing any
obstructions.
2. See Figure152. Remove the six screws with star washers that hold the printed circuit
board (PCB) access panel in place.
Caution Turn OFF (O) the AC power switch and remove the power cord before
performing this procedure.
PCB
Access
Panel
PCB Access
Panel Screws (6)
PCB Access
Panel Screws (6)
PCB
Access
Panel
1. See Figure153. Disconnect the cables connected to J 1 and J 2 on the motor control board.
Note the location of the wires: yellow is J 1 and white is J 2.
2. Remove the six screws with star washers on the lower enclosure panel.
3. Pull out the lower enclosure panel and swing the panel to the right to gain access to the
Right-hand print engine Continue with For the Right-Hand Print Engine
onpage237.
Left-hand print engine Go to For the Left-Hand Print Engine onpage240.
Outside View of the
Inside View of the
Lower Enclosure
J1 and J2 on
the Motor
Control Board
P2 Door-Open Sensor
P3 Head-Open Sensor
P5 Ribbon Sensor
P27 Power Connector
P30 SPI Peripheral
P31 SPI Peripheral
P32 SPI Peripheral
P33 SPI Peripheral
P34 SPI Peripheral
P35 SPI Peripheral
P23 P24
P27
P6
P8
P10
P5
P3
P2
P30-P35
P19
P21
4. See Figure155. If you have an internal 10/100 Print Server (10/100 PS) installed, you
must remove the two screws securing the 10/100 PS board and unplug the ribbon cable
attached to P21 on the main logic board.
Connections
5. Unplug all cables from the main logic board. Unplug J 3, the black power connector, on the
applicator interface board.
6. Note the location of the main logic board connectors.
8. Go to Remove the Applicator Interface Board onpage223.
Applicator
Interface Board
PCB Access
Panel
Main Logic
Board
(MLB)
J3 Power
Connector
J1 SPI Port
Connector
Server (optional)
1. See Figure154. If you have an internal 10/100 Print Server installed, remove the two
screws securing the 10/100 PS board and unplug the ribbon cable attached to P21 on the
main logic board.
2. See Figure154. Unplug the 34-pin ribbon cable connector, P19, on the main logic board.
3. Unplug the J 1 and J 3 connectors on the applicator interface board.
4. Remove the SPI connectors, P30-P35, and then pull the PCB access panel partially out of
the opening.
5. Remove the remaining connectors on the main logic board.
6. Continue with Remove the Applicator Interface Board.
Remove the Applicator Interface Board
1. See Figure156. Remove the two screws that hold the applicator interface board in place.
Figure 156 Removal and Installation of Applicator Interface Board
2. Slide the applicator interface board out.
3. See Figure157. Remove the two mounting studs and washers on either side of the serial
interface connector.
4. Remove the two mounting screws and washers on either side of the parallel interface
connector.
Applicator
Interface
Board
Applicator Port
Screw
PCB Access
Panel
Screw
Figure 157 Removing or Installing Main Logic Board
5. See Figure158. Carefully remove the three hex screws and spacers that secure the MLB
and the PCMCIA board to the PCB access panel.
6. Separate the PCMCIA board from the main logic board by removing the two hex screws
and spacers.
7. Disconnect the PCMCIA board from the MLB using the following technique:
a. Grasp the boards by their edges.
b. With a gentle rocking and pulling motion, separate the two connectors.
Note The longer screw and two spacers separate the PCMCIA option board from the
PCB access panel.
Note The circuit boards may withstand a small amount of flexing; however, they are not
designed to bend.
Parallel
Interface
Connector
Mounting
Screw
Mounting
Screw
Serial
Interface
Connector
Mounting
Screws
Main Logic
Board (MLB)
PCB
Access
Panel
PCMCIA Socket
Option Board
P2 Connector
on MLB
Figure 158 Spacer Locations on PCB Access Panel
Installing the Replacement Main Logic Board
1. See Figure158. Align the two connectors, supporting both boards (MLB and PCMCIA)
under the connectors, and gently press the two connectors together until fully seated.
2. Reinstall the two hex screws, spacers, and nuts to secure the PCMCIA board to the new
main logic board.
3. Reattach the new main logic board/PCMCIA board to the PCB access panel by
reinstalling the two hex screws, spacers, and nuts. Snug the screws, but do not tighten at
this time.
4. Install the longer hex screw and two spacers that separate the PCB access panel and the
PCMCIA board. Snug the screw, but do not tighten at this time.
5. See Figure157 onpage241. Install the screws, studs, and washers for the parallel
interface and serial interface connectors and tighten.
6. Tighten the three hex screws that secure the boards to the PCB access panel.
7. See Figure156 onpage240. Reattach the applicator interface board to the PCB access
panel.
Hex
Screws
and
Spacers
Hex Screws
and Spacers
Hex
Screws
Hex
Screw
Spacer
Nuts
Nut
PCMCIA
Board
(Back
Side)
Main
Logic
Board
PCB
Access
Panel
PCB
Access
Panel
PCB
Access
Panel
8. See Figure154 onpage238. Reinsert the PCB access panel, and reconnect the connectors
to the new main logic board.
9. See Figure154 onpage238. Reconnect J 1 and J 3 connectors to the applicator interface
board.
Ensure that all logic board connector leads are tucked in without being pinched and the
access panels metal frame slides into the rear enclosures plastic guide.
10. See Figure152 onpage236. Secure the PCB access panel using the six screws with star
washers.
11. See Figure154 and Figure155. If you had an internal 10/100 Print Server installed,
complete the following steps:
a. Plug the ribbon cable into the main logic board connector, P21. The connector is
polarized with a center key. Ensure the center key aligns with the slot in the main
logic board connector.
b. Insert the 10/100 PS into the opening while guiding the ribbon cable into the printer.
c. Secure the new print server cover plate to the PCB access panel by reinstalling the
two cover plate mounting screws.
12. Replace the lower enclosure panel.
a. Reinstall the six screws with star washers to secure the lower enclosure cover.
b. Reconnect cables to J 1 and J 2 on the motor control board.
The cable with the yellow wire connects to J 1; the cable with the white wire connects to
J 2.
Note The SPI connectors are all the same electrically, and the components that plug into
an SPI connector can plug into any of the SPI connectors, P30-P35.
Note The removable lower enclosure cover has two tabs that fit on top and inside of the
bottom stationary cover. Refer to Figure153 onpage237 for the proper position of the
panel in the lower enclosure.
Configure the Printer after Installation
1. Press and hold on the front panel, while turning On (I) the printer.
2. When the DATA light turns off, release .
3. When the printer has completed the Power-On Self Test (POST) the LCD displays:
POWERUP TEST
<- CONFIG LABEL ->
4. Press PREVIOUS until the printer displays MODEL SELECT.
5. Scroll through the printer types using and until you find your printer type.
6. Press Next/Save until the printer displays LOAD DEFAULTS.
7. Press to select YES and load the defaults for this printer type.
The printer displays LOADING DEFAULTS and recalibrates.
8. When the calibration is complete, turn Off (O) the printer and then back On (I).
The printer performs the POST then displays PRINTER READY.
9. Enter the resistance value of the printhead, as was located in Obtain the Printhead
Resistor Value onpage235.
10. Press SETUP/EXIT to enter Setup Mode.
11. Press NEXT/SAVE until the printer displays HEAD RESISTOR.
12. Press ; the LCD displays ENTER PASSWORD.
13. Use and to enter the password for your printer. The default password is 1234.
14. Press NEXT/SAVE.
15. Use and to enter the printhead resistance value for your printer.
16. After you have entered the printhead resistance value, press SETUP/EXIT.
The LCD displays SAVE CHANGES.
17. Use or until the printer displays PERMANENT.
18. Press NEXT/SAVE.
19. Verify that the printer is operating correctly.
If you had previously made changes to the default configuration, you will need to make
those changes again and save them. See the User Guide for instructions.
Note To configure a 110PAX4 printer, refer to the configuration number on the model
plate on the rear of the printer. The first three digits will be either 112 or 113.
For digits 112 (200 dpi), select printer type 110-8RH or 110-8LH.
For digits 113 (300 dpi), select printer type 110-12RH or 110-12LH.
Printed Circuit BoardsApplicator Interface Board
Applicator Interface Board
Tools Required
Remove and Install the Applicator Interface Board
Removing the applicator interface board can be done in a two ways:
Remove the Applicator Interface Board from the Printed Circuit Board (PCB) Access
Panel onpage245.
Remove the Applicator Interface Board by Opening the Printer (Optional steps)
onpage247.
Remove the Applicator Interface Board from the Printed Circuit
Board (PCB) Access Panel
1. See Figure159 and Figure160. From the PCB access panel on the back of the printer,
remove the two mounting screws that secure the applicator board.
Phillips Screwdriver Anti-Static Mat/Wrist Strap
Long 2.5 mm Allen Wrench (Hex Key) Metric Allen Wrench (Hex Key)
Figure 159 Applicator Interface Board (Right-Hand Print Engine Shown)
2. Gently pull the applicator board out.
3. Disconnect the power connector J 3 and the main logic board connector J 1.
4. Were you able to successfully remove the applicator board?
Install the Applicator Interface Board to the PCB access Panel
1. Connect the power connectors, J 3 and the main logic board connector J 1, to the applicator
interface board.
2. Slide the applicator interface board into the slot in the PCB access panel.
3. Fasten the mounting screws to secure the applicator interface board.
4. Go to Resume Printer Operation onpage248.
If... Then...
Yes Continue with Install the Applicator Interface Board with the
Printer Open onpage248.
No Skip to Remove the Applicator Interface Board by Opening the
Printer (Optional steps) onpage247 and complete those steps.
This is an alternative procedure..
J3 Power Connector
J1 Main Logic Board
Connector
Mounting Screw
Mounting Screw
Applicator
Interface Board
Remove the Applicator Interface Board by Opening the Printer
(Optional steps)
1. See Figure159. With the printer open, disconnect the power connectors, J 3 and the main
logic board connector J 1, to the applicator interface board. On the left-hand print engines,
the applicator board is at the bottom of the rear enclosure, and connector J 3 is more
difficult to access.
2. See Figure160. Remove the screws mounting the applicator interface board to the printed
circuit board (PCB) access panel. Remove the applicator interface board from the access
panel.
Figure 160 Rear View of PCB Access Panel and Applicator Interface Board
Removal and Installation
Left-Hand
Model
Mounting
Screws (2)
Applicator
Interface
Board
Mounting
Screws (2)
Applicator
Interface
Board
Right-Hand
Model
PCB Access Panel
AC Outlet
AC Outlet
Install the Applicator Interface Board with the Printer Open
1. See Figure160. Install the new applicator interface board into the PCB access panel using
the two screws previously removed. Ensure that the component side of the board faces the
AC outlet on the back of the print engine.
2. See Figure159. Reconnect the J 1 and J 3 connectors to the new applicator interface board.
Printed Circuit BoardsAC Power Supply Board
AC Power Supply Board
Tools Required
Remove AC Power Supply
1. See Figure161. Remove the six screws with star washers that hold the printed circuit
board (PCB) access panel in place.
Standard Allen Wrench (Hex Key)
Set
Phillips Screwdriver Set
Metric Open-End Wrench Set Anti-Static Wriststrap and Mat
PCB
Access
Panel
PCB Access
Panel Screws (6)
PCB Access Panel
Screws (6)
PCB
Access
Panel
1. See Figure162. Disconnect the cables connected to J 1 and J 2 on the motor control board.
Note the location of the wires: yellow is J 1 and white is J 2.
2. Remove the six screws with star washers on the lower enclosure panel.
3. Pull out the lower enclosure panel and slide the panel to the right to gain access to the
Right-hand print engine Continue with For the Right-Hand Print Engine on
page250.
Left-hand print engine Go to For the Left-Hand Print Engine on page253.
Outside View of the
Inside View of the
J1 and J2 on
the Motor
Control Board
P2 Door-Open Sensor
P3 Head-Open Sensor
P5 Ribbon Sensor
P27 Power Connector
P30 SPI Peripheral
P31 SPI Peripheral
P32 SPI Peripheral
P33 SPI Peripheral
P34 SPI Peripheral
P35 SPI Peripheral
P23 P24
P27
P6
P8
P10
P5
P3
P2
P30-P35
P19
P21
Connections
4. Unplug all cables from the main logic board.
See Figure163. Note the location of the main logic board connectors and cables.
7. See Figure166. Disconnect the two cables from the AC power supply assembly.
8. See Figure165. Remove the two AC power supply assembly mounting screws and star
washers.
Applicator
Interface Board
PCB Access
Panel
Main Logic
Board
(MLB)
J3 Power
Connector
J1 SPI Port
Connector
Server (optional)
Figure 165 AC Power Supply Remove/Install
9. Remove the AC power supply assembly through the PC board access panel opening.
1. Unplug the 34-pin ribbon cable from P19 on the main logic board.
2. Remove the SPI cables, P30-P35, and then pull the PCB access panel partially out of the
opening.
3. Remove the remaining cables on the main logic board.
See Figure163. Note the location of the main logic board connectors and cables.
6. See Figure166. Disconnect the two cables from the AC power supply assembly.
7. See Figure165. Remove the two AC power supply assembly mounting screws and star
washers.
AC Power
Supply
Star Washers
(2)
AC Power
Supply
Mounting
Screws
(2)
Install the New AC Power Supply Assembly
1. See to Figure166. Install the new AC power supply assembly.
2. Reconnect the two cables to J 1 and J 2.
Figure 166 AC Power Supply Assembly Connector Locations
3. See Figure165. Reinstall the two mounting screws and star washers and mount the new
AC power supply assembly.
4. See Figure163. Reconnect all cables to the main logic board.
5. See Figure164. Reconnect J 1 and J 3 cables to the applicator interface board.
Ensure that all logic board cables are tucked in without being pinched and the access
panels metal frame slides into the rear enclosures plastic guide.
6. See Figure161. Reinstall the PC board access panel using the six screws with star
washers.
J1
J2
7. Reinstall the lower enclosure panel.
8. See Figure162. Replace the lower enclosure panel and secure it to the print engine with
the six screws with star washers previously removed.
9. Reconnect the two cables, J 1 and J 2, back to the motor control board.
The cable with the yellow wire connects to J 1; the cable with the white wire connects to
J 2.
Note The removable lower enclosure cover has two lips that fit on top and inside of the
stationary cover. See Figure162 for the proper position of the panel in the lower
enclosure.

Notes ___________________________________________________________________
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__________________________________________________________________________
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__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Ex t er i or Component s
Front Cover
Door-Open Switch
Contents
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Door-Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Exterior ComponentsFront Cover
Front Cover
Tools Required
Removing the Front Cover
1. Turn Off (O) the print engine, remove the AC power cord, and disconnect all interface
cables.
3. Lift the front cover and locate the control panel mounting bracket, directly beneath the
clear plastic viewing window.
Phillips Screwdriver Set Flat-blade Screwdriver Set
Metric Nut Driver Set Safety Glasses
Right-hand print engine See Figure167 onpage259.
Left-hand print engine See Figure168 onpage259.
Figure 167 Control Panel Location and Removal (Right-Hand Model Shown)
Figure 168 Control Panel Location and Removal (Left-Hand Model)
Front Cover
(shown in open position)
Control Panel
Mounting
Bracket
(gray area)
Control Panel
Mounting Screw
Ground
Strap
Control Panel
Mounting Screw
Ground Strap
Screw
Hinge
Viewing Window
Front Cover
(shown in open position)
Control Panel
Mounting
Bracket
(gray area)
Control Panel
Mounting Screw
Control Panel
Mounting Screw
Hinge
Viewing Window
Ground
Strap
Ground Strap
Screw
4. Using a 6 mm nut driver, remove the two small nuts and star washers that secure the
control panel to the front cover.
5. See Figure169. Lower the front cover to the closed position.
Using a small flat-blade screwdriver, carefully pry off the black hinge covers located on
top of the hinges.
6. See Figure167 for the right-hand model. See Figure168 for the left-hand model.
Using a Phillips screwdriver, remove the Phillips screw, nut, and split ring lock washer
from the control panel mounting tab on the bottom of the front cover to fully release the
control panel.
7. To detach the ground strap, remove the nut, ground lug, and star washer located on the
bottom of the front cover.
8. See Figure169. Using a Phillips screwdriver, remove the remaining three Phillips screws,
lock washers, and nuts from the hinges, and remove the front cover. If necessary, use an 8
mm nut driver to clamp the nut.
Figure 169 Top and Front Views of Front Cover Hinges
Note Each hinge cover will come off in one piece and must be replaced when the new
front cover is assembled.
Note The Phillips screw secures the control panel mounting bracket as well as the hinge.
If necessary, use an 8 mm nut driver to clamp the nut while removing the Phillips screw.
Note Store the four hinge screws, lock washers, and nuts in a safe place as you will need
them to reattach the new front cover to the hinges.
Top View Front View
Hinges Hinges
Front Cover
Phillips Hinge Screws
Replacing the Front Cover
1. Attach the viewing window to the front cover with the four star washers and nuts included
with the replacement kit. Ensure the bottom edge of the window is seated in the front
cover flange.
2. Replace the Zebra logo in the lower left corner of the viewing window.
3. See Figure169. Align the new front cover with the hinge holes. Reattach the hinges to the
front cover by replacing three Phillips screws that were removed in step 8.
4. See Figure167 for the right-hand model. See Figure168 for the left-hand model.
Open the front cover.
5. To re-assemble the ground strap, place the star washer, ground lug, and nut onto the
ground strap screw protruding from the front cover.
6. To secure the control panel mounting bracket to the front cover, align the mounting
bracket with the studs in the front cover and hold it in place.
7. Insert the last Phillips screw through the hinge and the mounting bracket tab.
Secure the screw with the split ring lock washer and nut.
8. Place a star washer and nut on both of the mounting bracket studs located directly below
the viewing window.
The control panel mounting bracket should be securely attached to the front cover.
9. See Figure169. Close the front cover and carefully snap the hinge covers back into place
over the screws.
10. Reconnect the AC power cord and all interface cables, and then turn On (I) the print
engine.
Note The star washer, ground lug, and nut must be replaced in the exact order described
in step 4.
Exterior ComponentsDoor-Open Switch
Door-Open Switch
Tools Required
Remove the Old Door-Open Switch from the 110PAX4
1. See Figure170. Open the front cover and locate the door-open switch.
The door-open switch is on the right side of right-hand print engine and on the left side of
left-hand print engine.
Long #1 Phillips Screwdriver Anti-Static Wrist Strap
Metric Allen Wrench (Hex Key) Set
Figure 170 Front View of Door-Open Switch (Right-Hand Model Shown)
2. See Figure171. Remove and discard the two switch mounting screws and the nut bar that
secure the door-open switch to the side of the print engine.
Door-Open
Switch
Figure 171 Cable Route and Door Switch Location
3. See Figure171. To remove the On/Off switch cover plate, remove the two screws in the
On/Off switch cover plate.
Once the On/Off switch cover plate is off, the door-open switch cable is accessible.
4. See Figure172. Follow the door-open switch cable out through the On/Off switch cover
plate opening down to P2 on the main logic board and disconnect it.
Nut Bar
Door-Open
Switch
Switch
Mounting
Screws
Detail View
On/Off
Switch
Cover Plate
Front View
Door-Open
Switch Cable
Cover Plate
Screws
Important The door-open switch wires are partially covered by a heatshrink tubing near
the switch. Once the heatshrink ends, the wires are green and yellow and plug into main
logic board connector P2.
Figure 172 P2 Connector on Main Logic Board
5. See Figure173. Cut the cable tie at the upper edge of the cable channel and carefully
remove the door-open switch wires.
Figure 173 Top View of Cable Channel
6. Completely remove the door-open switch by threading it out the rear enclosure, through
the cover plate opening, and out the front of the print engine.
P2 Connector
Main Logic
Board
Printer
Main
Frame
Cable Tie
Cable
Channel
Wires
Install and Adjust the New Door-Open Switch in the 110PAX4
1. See Figure174. Place the new door-open switch against the side of the print engine so that
the switch actuator, located behind the switch actuation lever, is at the top of the switch
and faces out or toward the front, as shown.
2. See Figure171. Insert the two new mounting screws through the cover and through the
door-open switch. Position the nut bar and install the screws at the back of the slots. Snug
up the screws, but do not tighten.
3. See Figure174. Starting with the screws positioned at the back of the slots, close the front
cover, and listen for the trip of the actuator switch.
a. If the switch does not trip, slide the two screws forward and repeat the switch
adjustment.
b. If the switch does trip, tighten both of the screws to secure the door-open switch.
Figure 174 Side View of Door-Open Switch and Actuator
4. Carefully lower the front cover to the closed position.
Connect Switch to Main Logic Board
1. Pull the green and yellow wires through the cover plate opening.
2. Thread the green and yellow wires through the cable channel and reconnect to the main
logic board at P2.
3. See Figure173. Replace the cable tie that was previously cut at the cable channel.
4. See Figure171. Reinstall the two screws to secure the On/Off switch cover plate to the
mainframe.
Note Ensure that both screws are vertically aligned (parallel to the front of the shroud).
Note If you receive a Cover Open error during power up, repeat the switch adjustment.
Mounting Screws
(shown
inside of slots)
Switch
Lever
Actuator
(orange)
Direction of
Adjustment
5
Mai nt enanc e and Assembl y
Dr aw i ngs
This section contains mechanical assembly drawings and parts lists. Included are illustrations
of parts and assemblies common to all 110PAX4 models, as well as their part numbers.
Maintenance kits and their contents are also listed.
Contents
Front Print Engine Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Rear Print Engine Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Control Panel Maintenance Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Print Mechanism Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Printhead Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Toggle Assembly and Pivot Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Upper Dancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Lower Dancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Ribbon Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Upper Pinch Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Pinch Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Peel Roller Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Platen Peel Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Peel Bracket Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Auxiliary Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Idler Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Rear Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Stepper Motor and Belt Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Ribbon Supply DC Motor Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Ribbon Take-Up DC Motor Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Communications Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Memory Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Mai nt enance and Assembl y Drawi ngs

Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
General Information
General Information
This section identifies parts and assemblies in the 110PAX4 print engine using parts tables and
figures. Both assemblies and parts are listed in the table, and the individual parts are identified
in the associated figure.
In each of the tables, parts shown in bold face can be purchased. Parts shown italicized are not
purchasable, but may be available as a maintenance kit. (This information appears in the key at
the bottom of each parts table.)
Hardware items with an HW preceding the part number are not available as individual parts.
You can purchase an item as part of a hardware kit in quantities listed in the parts table.
The parts tables list part numbers for both right-hand (RH) and left-hand (LH) print engines.
All graphics shown in this section are for the right-hand 110PAX4 print engine only.
General Information
Table 16 Front Print Engine Assemblies
Item Part Number Description Qty
1 57101 Mainframe Assembly, RH 1
1 57102 Mainframe Assembly, LH 1
2 57235M Front Cover Maintenance Kit, RH (see Figure177 onpage275) 1
2 57236M Front Cover Maintenance Kit, LH (see Figure177 onpage275) 1
3 N/A Control Panel, RH & LH (see Figure178 onpage277) 1
4 57200 Print Mechanism Assembly, 203 dpi, RH (see Figure179 onpage279) 1
4 57230 Print Mechanism Assembly, 203 dpi, LH (see Figure179 onpage279) 1
4 57210 Print Mechanism Assembly, 300 dpi, RH (see Figure179 onpage279) 1
4 57240 Print Mechanism Assembly, 300 dpi, LH (see Figure179 onpage279) 1
5 57201 Printhead Support Assembly, 203 dpi, RH (see Figure180 onpage281) 1
5 57231 Printhead Support Assembly, 203 dpi, LH (see Figure180 onpage281) 1
5 57211 Printhead Support Assembly, 300 dpi, RH (see Figure180 onpage281) 1
5 57241 Printhead Support Assembly, 300 dpi, LH (see Figure180 onpage281) 1
6 57187M Toggle Assembly and Pivot Bar Maintenance Kit, RH
(see Figure181 onpage283)
1
6 57189M Toggle Assembly and Pivot Bar Maintenance Kit, LH
1
7 N/A Upper Dancer Assembly , RH (see Figure182 onpage285) 1
7 N/A Upper Dancer Assembly , LH (see Figure182 onpage285) 1
8 57531 Lower Dancer Assembly , RH (see Figure183 onpage287) 1
8 57529 Lower Dancer Assembly , LH (see Figure183 onpage287) 1
9 N/A Ribbon Spindle , RH & LH (see Figure184 onpage289) 1
10 57130 Upper Pinch Roller Assembly, RH (see Figure185 onpage291) 1
10 57282 Upper Pinch Roller Assembly, LH (see Figure185 onpage291) 1
11 N/A Segment Roller , RH & LH 1
12 57130M Pinch Roller Assembly Maintenance Kit, RH (see Figure186 onpage293) 1
12 57282M Pinch Roller Assembly Maintenance Kit, LH (see Figure186 onpage293) 1
13 43125 Peel Roller Latch Assembly, RH (see Figure187 onpage295) 1
13 43260 Peel Roller Latch Assembly, LH (see Figure187 onpage295) 1
14 57131M Peel Roller Maintenance Kit, RH & LH (see Figure187 onpage295) 1
15 57058 Platen Peel Bar Assembly, RH (see Figure188 onpage297) 1
15 57185 Platen Peel Bar Assembly, LH (see Figure188 onpage297) 1
16 N/A Peel Bracket , RH & LH (see Figure189 onpage298) 1
17 57167M Auxiliary Roller Assembly Maintenance Kit, RH & LH
18 57275 Idler Roller Assembly, RH (see Figure191 onpage301) 1
Bold =Part available for purchase
Italic =Part not available for purchase, listed and shown for reference only
General Information
Figure 175 Front Main Print Engine Assemblies
18 57278 Idler Roller Assembly, LH (see Figure191 onpage301) 1
19 57600M 300 to 203 dpi Conversion Maintenance Kit, RH & LH (not illustrated) 1
19 57601M 203 to 300 dpi Conversion Maintenance Kit, RH (not illustrated) 1
19 57602M 203 to 300 dpi Conversion Maintenance Kit, LH (not illustrated) 1
Table 16 Front Print Engine Assemblies (Continued)
1
15
2
3
9
7
4,5,6
16
8
13
14
10,11
12
17
18
General Information
Table 17 Rear Print Engine Assemblies
1 57087 Rear Enclosure Assembly, RH (see Figure192 onpage303) 1
1 57088 Rear Enclosure Assembly, LH (see Figure192 onpage303) 1
2 57272M AC Power Supply Maintenance Kit, RH & LH 1
3 57330M Main Logic Board Maintenance Kit, RH & LH 1
4 57056M Applicator Interface Board Maintenance Kit, 5V I/O 1
4 57389M Applicator Interface Board Maintenance Kit, 24-28V I/O 1
5 57527M Stepper Motor Assembly Maintenance Kit, (see Figure193 onpage305) 1
6 57604M Stepper Motor Pulley and Belt Maintenance Kit, (203 dpi) 1
6 57464M Stepper Motor Pulley and Belt Maintenance Kit, (300 dpi) 1
7 57069M Compound Pulley and Belt Maintenance Kit, RH & LH 1
8 57603M Replacement Belts Maintenance Kit, RH & LH 1
9 57466M Ribbon Supply DC Motor Maintenance Kit, RH
1
9 57468M Ribbon Supply DC Motor Maintenance Kit, LH
1
10 57467M Ribbon Take-Up DC Motor Maintenance Kit, RH
1
10 57469M Ribbon Take-Up DC Motor Maintenance Kit, LH
1
11 43238M N/A DC Power Supply, RH 1
11 43240M N/A DC Power Supply, LH 1
12 43210M N/A Motor Control Board, RH & LH 1
13
57546
Internal ZebraLink/Print Server 10/100 Option
(see Figure196 onpage310) (not illustrated)
1
14
47490
External ZebraLink/Print Server 10/100 Option
(see Figure196 onpage310) (not illustrated)
1
15 33193-032 Compact Flash Card (Blank) - 32 MB (see Figure197 onpage311)
(not illustrated)
1
(not illustrated)
1
(not illustrated)
1
(not illustrated)
1
16 46999-0008 8 MB PC (Blank) Memory Card (see Figure197 onpage311)
(not illustrated)
1
16 46999-0032 32 MB PC (Blank) Memory Card (see Figure197 onpage311)
(not illustrated)
1
General Information
Figure 176 Rear Print Engine Assemblies
1
2 3 4
5
7
11
8
10
12
6
9
General Information
Table 18 Cover Assembly
Ref 57235M Cover Assembly Maintenance Kit, RH 1
Ref 57236M Cover Assembly Maintenance Kit, LH 1
1 57382 Shroud, Rear, RH 1
1 57383 Shroud, Rear, LH 1
2 49512 Switch, Rocker 1
3 43373 Cable, AC Power 1
4 43374 Cable, AC Power 1
5 57339M Door-Open Switch Maintenance Kit 1
6 44192 Screw, 2-56 0.50 2
7 49858 Nutbar 1
8 HW43676 Screw, M5 0.8 (Sold in qty of 25) 8
9 49244 Hinge, Door 2
10 43364 Clamp, Cable 2
12 43495 Screw, M3 0.5 4
13 57338 Cable, Control Panel, RH 1
13 57319 Cable, Control Panel, LH 1
14 N/A Control Panel Assembly Maintenance Kit 1
15 57525 Label, Media Ribbon, RH 1
15 57526 Label, Media Ribbon, LH 1
16 57235M Cover, Front RH 1
16 57236M Cover, Front LH 1
17 57500 Label, Logo, 110PAX 1
18 43094 Cover, Window 1
19 HW01159 Washer, Lock External (Sold in qty of 100) 6
20 44055 Nut, M5 9
21 43497 Screw, M4 0.7 4
22 HW10477 Washer, Split, M5 (Sold in qty of 10) 4
23 HW01152 Washer, Flat 0.375 (Sold in qty of 100) 6
24 43197 Grommet, 3/8 Inch 1
25 43573 Cable, Ground 1
26 49069 Bumper (not shown) 1
27 43299 Nut, M3.5 0.6 6
General Information
Figure 177 Cover Assembly
1
2
3,4
5
6
7
8
9
14
9
15
16
18
17
10
12
23
25
11
11
13
26
20
20
20
24
19 &
27
19,27
21,22
19,27
23
23
General Information
Table 19 Control Panel Maintenance Kit Assembly
Ref N/A Control Panel Assembly 1
Ref 49398 Control Panel Assembly 1
1 49098 Switch Panel Membrane Route 1
2 HW49059 Screw, 2-56 0.187 (Sold in qty of 25) 4
3 57233 Bracket, Control Panel Mounting 1
4 49486 Enclosure, Control Panel 1
5 32043 Assembly, Backlit Display 1
6 HW10460 Nut, Hex M3 (Sold in qty of 25) 1
7 HW01153 Washer, Flat 0.250 0.125 0.028 (Sold in qty of 100) 2
8 43481 Washer, Lock External 1
General Information
Figure 178 Control Panel Maintenance Kit Assembly
1
3
2
4
5
6
7
8
General Information
Table 20 Print Mechanism Assembly
Ref 57200 Print Mechanism Assembly, 203 dpi, RH 1
Ref 57230 Print Mechanism Assembly, 203 dpi, LH 1
Ref 57210 Print Mechanism Assembly, 300 dpi, RH 1
Ref 57240 Print Mechanism Assembly, 300 dpi, LH 1
1 57578 Lever Locking Assembly, RH 1
2 HW10432 Screw, M4 0.7 12 (Sold in qty of 25) 1
3 HW44001 Screw, M3.5 0.5 0.11 (Sold in qty of 25) 6
4 57164 Plate, End Extrusion 1
5 57165 Extrusion, Print Mechanism, RH 1
5 57582 Extrusion, Print Mechanism, LH 1
7 46203 Trimounts, Shoulder 1
8 N/A Flag, Sensor 1
9 44423 Bearing, Ball 1
10 HW02252 Ring, Crescent, 0.250 (Sold in qty of 100) 3
11 57187M Toggle Assembly and Pivot Bar Maintenance Kit, RH 1
11 57189M Toggle Assembly and Pivot Bar Maintenance Kit, LH 1
12 N/A Toggle Assembly (see Figure 5-15 for assembly breakdown) 1
13 HW30105 Bearing (Sold in qty of 25) 1
14 57201 Printhead Support Assembly, 203 dpi RH (see Figure180) 1
14 57231 Printhead Support Assembly, 203 dpi LH (see Figure179) 1
14 57211 Printhead Support Assembly, 300 dpi RH (see Figure179) 1
14 57241 Printhead Support Assembly, 300 dpi LH (see Figure179) 1
15 57150 Tensioner, GT2 Belt Auxiliary Roller 1
16 HW02256 Ring, Erng External (Sold in qty of 100) 2
17 57540 Pin Coiled Sprint 0.13 0.63 LG 4
18 57481 Bearing, Bronze Flange 0.252 0.377 0.375 1
19 57167M Auxiliary Roller Assembly 1
General Information
Figure 179 Printhead Mechanism Assembly
1
2
3
4
17
5
16
9
19
9
16
17
6
7
8
10
15
18
10
12
11
10
10
13
14
General Information
Table 21 Printhead Support Assembly
Ref 57201 Printhead Support Assembly, 203 dpi, RH 1
Ref 57231 Printhead Support Assembly, 203 dpi, LH 1
Ref 57211 Printhead Support Assembly, 300 dpi, RH 1
Ref 57241 Printhead Support Assembly, 300 dpi, LH 1
2 57342 Cable, Double Ground Braid 1
3 HW01159 Washer, Lock (Sold in qty of 100) 1
4 HW48182 Rivet, Snap (Sold in qty of 10) 2
5 57205 Bar, CR Pressure 1
6 57206 Bar, Pressure 1
7 HW06250 Ring, E External (Sold in qty of 25) 2
8 49370 Spring, Torsion, RH 1
8 49413 Spring, Torsion, LH 1
9 77427 Screw, M4 0.10 2
10 43052 Plate, Washer 1
11 43048 Screw, Adjustment, M3 0.5 2
12 57204 Bracket, Printhead, (203300 dpi, RH) 1
12 57232 Bracket, Printhead, (203300 dpi, LH) 1
13 HW30402-
006
Screw, 6-32 0.37 (Sold in qty of 25) 2
15 43049 Plate, Strip 1
16 43055 Shaft, Roller 1
17 43056 Roller 1
18 57321 Cable, Printhead Power 1
19 57316 Cable, Printhead Data, RH 1
19 57317 Cable, Printhead Data, LH 1
20 57202M Printhead Assembly 203 dpi, RH & LH 1
20 57212M Printhead Assembly 300 dpi, RH 1
20 57242M Printhead Assembly 300 dpi, LH 1
21 HW01153 Washer, Flat (Sold in qty of 100) 1
22 30494 Washer, 0.32 1
23 N/A Ribbon Sensor, RH 1
23 N/A Ribbon Sensor, LH 1
24 43044 Bar, Head Pivot 1
25 HW49228 Ring, Retaining, External (Sold in qty of 25) 1
26 HW49227 Washer, Wavy Spring (Sold in qty of 5) 5
General Information
Figure 180 Printhead Support Assembly
27 49220 Bearing, Adjustment 1
28 57381 Hub, Adjusting, RH 1
28 57384 Hub, Adjusting, LH 1
29 HW46166 Spring, Compression (Sold in qty of 25) 1
31 HW49223 Washer, Adjustment (Sold in qty of 5) 5
32 49200 Plate, Clamp 1
33 49064 Bar, Adjustment 2
Table 21 Printhead Support Assembly (Continued)
1
2
3
4
5
1
4
6
1
33
33
11
11
9
10
12
13
15
14
17
16
7
8
18
20
19
14
23
22
21
25
26
27
28
32
31
31
29
30
30
24
7
13
General Information
Table 22 Toggle Assembly and Pivot Bar
Item Part Number Description
Qty
Ref 57187M Toggle Assembly Maintenance Kit, RH 1
Ref 57189M Toggle Assembly Maintenance Kit, LH 1
Ref 43053 Assembly, Movable Toggle 1
1 57187 Toggle and Pivot Bar, RH 1
1 57189 Toggle and Pivot Bar, LH 1
2 43072 Nut, Locking Toggle 1
3 43076 Shaft, Toggle 1
4 43078 Cylinder, Toggle 1
5 40046 Knob, Adjustment 2
6 43077 Spring, Compression 1
7 38046 Button, Toggle 1
9 46203 Shield, Trimnt (not shown) 1
10 46352 Flag, Sensor (not shown) 1
General Information
Figure 181 Toggle Assembly and Pivot Bar
2
3
4
5
6
7
8
1
General Information
Table 23 Upper Dancer Assembly
Item Part Number Description
Qty
Ref 57532 Upper Dancer Assembly Maintenance Kit, RH 1
Ref 57530 Upper Dancer Assembly Maintenance Kit, LH 1
1 43708 Dancer, Ribbon Tension 1
2 43477 Hall Effect Magnet Assembly 1
3 43256 Rivet, Push 2
4 43601 Dancer, Extension 1
5 43176 Roller 1
6 HW02256 E-Ring, External (Sold in qty of 100) 2
7 43454 Shaft, Collar 2
8 43446 Shaft, Bushing 1
9 43182 Bracket, Sensor Mounting 1
11 43186 Plate, Dancer Mounting, RH 1
11 43187 Plate, Dancer Mounting, LH 1
12 43064 Roller 2
13 43065 Cavity, Channel 1
15 43066 Plate, Cover 1
16 43178 Cavity, Channel 1
17 43527 Plate, Top Cavity 1
18 10461 Nut, M4 1
19 HW10474 Washer, Split M4 (Sold in qty of 25) 1
20 43525 Shaft, Dancer 1
21 HW44147 Screw, Set M3 (Sold in qty of 25) 2
22 43199 Spring, Torsion 1
23 43174 Bearing 6
24 48408 Bearing 2
25 43612 Shaft 1
26 57324 Hall Effect Sensor Upper Route, RH 1
26 57337 Hall Effect Sensor Upper Route, LH 1
27 43712 Vinyl Cap (0.125 0.250) 1
General Information
Figure 182 Upper Dancer Assembly
1
2
3
4
5
6
7
8
9
23
24
6
21
17
22
23
12
23
14
10
10
19
18
27
20
16 13
15
23
10
10
11
7
21
25
10
26
General Information
Table 24 Lower Dancer Assembly
Ref 57531 Lower Dancer Assembly Maintenance Kit, RH 1
Ref 57529 Lower Dancer Assembly Maintenance Kit, LH 1
1 43256 Rivet, Push 2
2 43477 Hall Effect Magnet Assembly 1
3 43601 Dancer, Extension 1
4 43254 Dancer, Ribbon Tension 1
5 48408 Bearing 2
6 43612 Shaft 1
7 43176 Roller 1
8 HW02256 Ring, External (Sold in qty of 100) 2
9 43446 Shaft, Bushing 1
10 HW44147 Screw, Set M3 (Sold in qty of 25) 2
13 10461 Nut, M4 0.7 1
14 43527 Plate, Top Cavity 1
15 43178 Channel, Cavity Sm 1
16 43066 Cover Plate 1
17 43174 Bearing 6
18 43065 Channel, Cavity Lg 1
19 43064 Roller 2
22 43187 Plate, Dancer Mounting, RH 1
22 43186 Plate, Dancer Mounting, LH 1
23 43182 Bracket, Mounting Sensor 1
24 43454 Shaft, Collar 5 mm 2
25 43525 Shaft, Dancer 1
26 57322 Hall Effect Sensor Upper Route, RH 1
26 57336 Hall Effect Sensor Upper Route, LH 1
27 43712 Vinyl Cap (0.125 0.250) 1
General Information
Figure 183 Lower Dancer Assembly
1
2
3
4
5
8
17
8
10
17
26
21
22
24
21
21
21
17
16
18 19
19
20
12
13
27
14
10
11
24
17
15
25
9
7
6
23
General Information
Table 25 Ribbon Spindle Assembly
Ref N/A Ribbon Spindle Assembly 1
Ref 43569 Ribbon Spindle Assembly 1
1 *49441 Washer, 0.75 0.506 0.010 2
2 *49445 Washer, 0.75 0.506 0.005 (not shown) 1
4 49379 Spindle, Outer Ribbon 1
5 43414 Blade, Spindle 2
6 49394 Assembly, Spindle Gear 67T 1
7 HW10188 E-Ring, 12 mm 1.1 mm (Sold in qty of 5) 2
8 43063 Shaft, Ribbon Spindle 1
10 49225 Nut, M6 1
Note *Items 1 and 2 are as needed for an end play of 0.010 in. (0.25 mm) or less.
General Information
Figure 184 Ribbon Spindle Assembly
9
1
3
4
5
7
8
7
10
5
6
1
General Information
Table 26 Upper Pinch Roller Assembly
Ref N/A Upper Pinch Roller Maintenance Kit, RH 1
Ref N/A Upper Pinch Roller Maintenance Kit, LH 1
2 HW10470 Washer, Flat M3 (Sold in qty of 50) 4
3 43015 Channel, Pinch Roller, RH 1
3 43082 Channel, Pinch Roller, LH 1
4 43021 Spring, Compression, 0.24 2
5 43276 Channel, Segment Roller 1
6 HW30485 Ring, E, External (Sold in qty of 25) 3
7 43277 Shaft, Segment Roller 1
8 49754 Roller, Segment 5
9 HW07309 Ring, E, External (Sold in qty of 25) 2
10 43018 Pin, Segment Pinch Roller Bracket 1
11 43029 Bracket, Pinch Pivot Roller 1
13 43613 Cam 1
15 43017 Channel, Upper Transmissive Sensor, RH 1
15 43083 Channel, Upper Transmissive Sensor, LH 1
16 N/A Upper Media Sensor Assembly, RH 1
16 N/A Upper Media Sensor Assembly, LH 1
17 43014 Slide, Transmissive Sensor, RH 1
17 43084 Slide, Transmissive Sensor, LH 1
18 43034 Spring, Flat Slide 2
19 43023 Spring, Compression, 0.30 1
20 43025 Latch 1
21 43026 Post, Spring Latch 1
22 57130M Pinch Roller Maintenance Kit, RH 1
22 57282M Pinch Roller Maintenance Kit, LH 1
General Information
Figure 185 Upper Pinch Roller Assembly
21
20
13
4
5
6
7
8,22
19
1
12
14
14
2
3
1
2
1
2
19
8,22
17
16
9
10
9
11
18
15
6
General Information
Table 27 Pinch Roller Assembly
Ref 57130 Pinch Roller Assembly Maintenance Kit, RH 1
Ref 57282 Pinch Roller Assembly Maintenance Kit, LH 1
1 HW02256 E-Ring, External (Sold in qty of 100) 1
3 49959 Spacer, Pinch Peel 1
5 57066 Spacer, Pinch Peel Roller 1
6 43614 Lens, Transmissive Sensor 1
7 43263 Assembly, Pulley 1
8 43032 Assembly, Reflective Ribbon Sensor, RH 1
8 N/A Assembly, Reflective Ribbon Sensor, LH 1
10 67665 Label, Reflective 1
11 N/A Lower Media Sensor Assembly, RH 1
11 N/A Lower Media Sensor Assembly, LH 1
12 43035 Guide, Inboard 1
14 43003 Shelf, Label Guide, RH 1
14 43004 Shelf, Label Guide, LH 1
15 43007 Guide, Outboard 1
16 HW46128 Washer, Flat (Sold in qty of 25) 1
17 HW40194 Washer, Curved (Sold in qty of 25) 2
18 10473 Washer, Flat M4 2
21 49819 Screw, M3 Special (Sold in qty of 25) 1
22 43613 Cam 2
23 43010 Plate, Cam 1
26 HW10470 Washer, Flat M3 (Sold in qty of 50) 2
27 43011 Plate, Cam 1
28 43009 Plate, Shelf Pin 1
29 43668 Spring Clip 1
30 43212 PCB Media Sensor, RH 1
30 43250 PCB Media Sensor, LH 1
General Information
Figure 186 Pinch Roller Assembly
31 N/A Elastomer Roller 1
Table 27 Pinch Roller Assembly (Continued)
1
2
31
3
4
7
5
8
9
10
11,30
13
14
16
18
17
18
17
19
29
28
20
20
21
23
22
24
24
25
26
22
27
15
6
12
25
General Information
Table 28 Peel Roller Maintenance Kit
Ref 57131M Peel Roller Maintenance Kit, RH & LH 1
1 HW02256 Ring, E External (Sold in qty of 100) 1
3 43118 Roller, Elastomer Peel 1
6 43263 Assembly, 28G 0.080 Pulley 1
General Information
Figure 187 Peel Roller Maintenance Kit
2
3
4
5
6
7
1
General Information
Table 29 Platen Peel Bar Assembly
Ref 57058 Platen Peel Bar Assembly, RH 1
Ref 57185 Platen Peel Bar Assembly, LH 1
1 49037 Post, Lock 1
3 HW10474 Washer, Split M4 6
4 49688 Bearing, Ball Flanged Sealed (Sold in qty of 25) 2
5 57062 Plate, Platen Support, RH 1
5 57063 Plate, Platen Support, LH 1
6 N/A Platen Shaft 1
7 43334 Assembly, Platen Extr with Pin 1
11 N/A Stepper Pulley Assembly 1
12 43116 Roller, Lower Media Liner 1
13 43114 Bar, Peel 1
15 43157 Cam, Peel Bar Lower 2
16 43115 Plate, Peel Bar Mounting 2
17 43117 Shaft, Roller Lower Media 1
18 HW02252 Ring, External Crescent (Sold in qty of 100) 1
19 57299 Assembly, Platen Pulley 1
20 HW44147 Screw, Set Cut M3 0.5 4 Patch (Sold in qty of 25) 2
21 HW77231 Screw, M3 8 Flng (Sold in qty of 25) 2
General Information
Figure 188 Platen Peel Bar Assembly
1
2
4
5
7
8
9
3
3
11,19
20
10
16
16
15
15
10
10
21
21
13
12
17
6
10
14
4
18
General Information
Figure 189 Peel Bracket Maintenance Kit
Table 30 Peel Bracket Maintenance Kit
Ref 43310 Peel Bracket Assembly 1
1 43120 Bracket, Peel 1
2 43146 Roller, Bracket 1
3 43119 Roller, Knurled 1
5 43123 Bar, Nut 1
7 49934 Pin 2
1
2
3
4
5
6
7
General Information
Figure 190 Auxiliary Roller Assembly
Table 31 Auxiliary Roller Assembly
Ref 57167M Auxiliary Roller Assembly 1
1 57183 Auxiliary Roller 1
2 57190 Gear, 32T 1
1 2
General Information
Table 32 Idler Roller Assembly
Ref 57275 Idler Roller Ribbon Assembly 1
1 57276 Post, Idler Support 1
2 49845 Screw, M6 1.0 12 mm 1
3 57505 Screw, M3 0.5 12 2
4 57507 Bracket, Static Brush Mounting 1
5 57508 Brush, Static 1
6 57277 Bracket, Idler Roller 1
7 57178 Shaft, Roller, Grvd. 1
8 43064 Roller 1
9 43174 Bearing 2
10 49837 C-Ring 2
General Information
Figure 191 Idler Roller Assembly
1
2
7
3
8
9
10
6
4
5
General Information
Table 33 Rear Enclosure Assembly
Ref 57087 Assembly, Rear Enclosure, RH 1
Ref 57088 Assembly, Rear Enclosure, LH 1
1 57085 Base, Back Assembly, RH 1
1 57086 Base, Back Assembly, LH 1
2 57156 Cover, Base Back, RH 1
2 57197 Cover, Base Back, LH 1
3 43519 Screw, M3 0.5 11
4 43654 Guide, Circuit Card .02 Deep 1
5 49673 Assembly, Power Entry with Ground and Fuse Holder 1
6 HW10460 Nut, Hex M3 (Sold in qty of 25) 4
7 HW10472 Washer, Star M3 (Sold in qty of 25) 2
9 57347 Clamp, Cable Twist (90 degree) 1
10 57362 Clamp, Cable Twist 0.51 (45 degree) 1
11 57480 Assembly, Motor Control Bracket 1
12 43210 Motor Control Board 1
13 Q15043 Label, Ground Symbol 1
14 57155 Base, Back Bottom, RH 1
14 57196 Base Back Bottom, LH 1
15 57154 Base, Back Side Plate, RH 1
15 57195 Base, Back Side Plate, LH 1
16 57082 Base, Back Plate, RH 1
16 57083 Base, Back Plate, LH 1
17 43652 Rivet, #42 1/8 in. 4
18 43495 Screw, M3 0.5 6 with Ext. T Lock Washer 6
19 57519 Gasket, ESD 2
20 57544 Shield, Bottom Electronics Enclosure, RH 1
20 57545 Shield, Bottom Electronics Enclosure, LH 1
General Information
Figure 192 Rear Enclosure Assembly
2 3
4
3
6
6
7
11
8
5
1
9
13
10
12
14
15
16
17
18
18
19
19
20
3
6
General Information
Table 34 Stepper Motor and Belt Maintenance Kit
1 57504 Screw, M4 0.7 4
2 77427 Screw, M4 0.10 5
4 57527M Stepper Motor Maintenance Kit, RH 1
4 57528M Stepper Motor Maintenance Kit, LH 1
6 43261 Pad, Stepper Clamp 2
7 43103 Clamp, Heatsink Motor 1
8 57475 Heatsink, Stepper Motor 2
9 57604M Stepper Pulley and Belt Maintenance Kit (203 dpi) 1
9 57464M Stepper Pulley and Belt Maintenance Kit (300 dpi) 1
10 30265 Pulley, Idler 1
11 57297 Standoff, Stepper Motor 2
12 43420 Motor, DC Stepper 1.8, RH 1
General Information
Figure 193 Stepper Motor and Belt Maintenance Kit, 203300 DPI

11
1
8
7
12
9
10
10
2
3
5
6
4
Cutaway
View
General Information
Table 35 Ribbon Supply DC Motor Maintenance Kit
Ref 57466M Ribbon Supply DC Motor Maintenance Kit, RH 1
Ref 57468M Ribbon Supply DC Motor Maintenance Kit, LH 1
1 43436 Tape, Glass Cloth A/R
2 49310 Assembly, Motor and 12T Gear 1
4 43482 Washer, Lock Eternal 3
5 57460 Assembly, Motor Mounting Plate, RH 1
5 57465 Assembly, Motor Mounting Plate, LH 1
6 43495 Screw, M3 0.5 6 2
7 43016 Washer, Nylon, 0.255 1
8 43061 Bracket, Sensor Mounting RH 1
8 43086 Bracket, Sensor Mounting LH 1
9 77207 Screw, M3 0.4 6
10 57367 Sensor, Encoder Supply #1, RH 1
10 57325 Sensor, Encoder Supply #1, LH 1
11 57326 Sensor, Encoder Supply #2, RH 1
11 57333 Sensor, Encoder Supply #2, LH 1
12 43062 Gear, Compound, 60T 1
13 HW30208 Washer, Flat, 0.500 (Sold in qty of 25) 1
14 HW49195 Ring, Retaining (Sold in qty of 10) 1
General Information
Figure 194 Ribbon Supply DC Motor Maintenance Kit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3
4
9
9
General Information
Table 36 Ribbon Take-Up DC Motor Maintenance Kit
Ref 57467M Ribbon Take-Up DC Motor Maintenance Kit, RH 1
Ref 57469M Ribbon Take-Up DC Motor Maintenance Kit, LH 1
Ref 57467 Ribbon Take-Up DC Motor Assembly, RH 1
Ref 57469 Ribbon Take-Up DC Motor Assembly, LH 1
1 43436 Tape, Glass Cloth A/R
2 49310 Assembly, Motor & 12T Gear 1
4 43482 Washer, Lock Eternal 2
5 57460 Assembly, Motor Mounting Plate, RH 1
5 57465 Assembly, Motor Mounting Plate, LH 1
6 77427 Screw, M4 0.10 1
7 43473 Clamp, Cable 0.25 1
8 43495 Screw, M3 0.5 6 2
9 43016 Washer, Nylon, 0.255 1
10 43061 Bracket, Sensor Mounting, RH 1
10 43086 Bracket, Sensor Mounting, LH 1
11 77207 Screw, M3 0.4 6
12 57323 Sensor, Encoder Take-Up #1, RH 1
12 57334 Sensor, Encoder Take-Up #1, LH 1
13 57366 Sensor, Encoder Take-Up #2, RH 1
13 57335 Sensor, Encoder Take-Up #2, LH 1
14 43062 Gear, Compound, 60T 1
15 HW30208 Washer, Flat, 0.500 (Sold in qty of 25) 1
16 HW49195 Ring, Retaining (Sold in qty of 10) 1
General Information
Figure 195 Ribbon Take-Up DC Motor Maintenance Kit
1
2
5
6
7
12
11
13
10
14
9
16
4
8
11
3
15
11
General Information
Figure 196 Communications Options
Table 37 Communications Options
1 57546 Internal ZebraLink/Print Server 10/100 Option 1
2 47490 External ZebraLink/Print Server 10/100 Option 1
1
2
General Information
Figure 197 Memory Options
Table 38 Memory Options
1 33193-032 Compact Flash Card (Blank) - 32 MB 1
2 46999-0008 8 MB (Blank) PC Memory Card 1
2 46999-0032 32 MB (Blank) PC Memory Card 1
1 2
General Information

Notes ___________________________________________________________________
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A
Dat a Por t s
This appendix describes the standard communication ports available to connect the print
engine to your computer or network.
Contents
Parallel Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Serial Pin Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
RS-232 Interface Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Applicator Interface Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Applicator Interface Connector Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
J umper Configurations for +5 V I/O Applicator Interface Board. . . . . . . . . . . . . . . . . 320
Data Ports
Parallel Port
Parallel Port
When communicating via the parallel port, the values selected must be the same as those used
by the host equipment connected to the print engine. Port selection for status information is
determined by the channel sending the request. The parallel port can be set for bidirectional or
unidirectional communication. The default setting is bidirectional.
A standard 36-pin parallel connector is available on the back of the print engine for connection
to the data source.
Table39 shows the pin configuration and function of a standard computer-to-printer parallel
cable.
Table 39 Parallel Cable Pin Configuration
36-Pin Connectors Description
1 nStrobe/HostClk
29 Data Bits 18
10 nACK/PtrClk
11 Busy/PtrBusy
12 PError/ACKDataReq
13 Select/Xflag
14 nAutoFd/HostBusy
15 Not used
16, 17 Ground
18 +5 V at 750 mA
The maximum current draw may be limited by option
configuration.
1930 Ground
31 ninit
32 nFault/NDataAvail
33, 34 Not used
35 +5 V through a 1.8 K Resistor
36 NSelectin/1284 active
Data Ports
Serial Port
Serial Port
To communicate using the serial data port of the print engine, you must choose the number of
data bits, parity, and handshaking. Parity applies only to data transmitted by the print engine
because the parity of received data is ignored.
The values selected must be the same as those used by the host equipment connected to the
print engine. Default print engine settings are 9600 baud, 8 data bits, no parity, and
XON/XOFF. The print engine will accept any host setting for stop bits.
Connect the serial data cable to the female DB-9 connector on the back panel of the print
engine. Use a DB-9 to DB-25 interface module for all RS-232 connections through a DB-25
cable.
Serial Pin Configuration
Table40 shows the pin configuration and function of the rear panel serial data connector on
theprint engine.
\
Note For all RS-232 input and output signals, the print engine follows the specifications of
the Electronics Industries Association (EIA) RS-232 and the Consultative Committee for
International Telegraph and Telephone (CCITT) V.24.
Table 40 Serial Connector Pin Configuration
Pin No. Name Description
1 Not connected
2 RXD Receive datadata input to print engine
3 TXD Transmit datadata output from print engine
4 DTR Data terminal readyoutput from print engine
5 SG Signal ground
6 DSR Data set readyinput to print engine
7 RTS Request to sendoutput from print engine
8 CTS Clear to sendinput to print engine
9 +5 VDC +5 VDC at 750 mA
The maximum current draw may be limited by option
configuration.
Data Ports
Serial Port
RS-232 Interface Connections
Direct Connection to a Computer
The print engine is configured as Data Terminal Equipment (DTE).
Figure198 shows the internal connections of the print engines RS-232 connector.
Figure 198 RS-232 Connections
Pin 9 is also available as a +5 VDC signal source at 750 mA. The maximum current draw may
be limited by option configuration.
DB-9 to DB-25 Connections
An interface adapter is required (Zebra part number 33109M) to connect the print engines
DB-9 interface to a DB-25 connector. A generic DB-25 adapter CAN be used, although the
+5VDC signal source would not be passed through the adapter.
Figure199 shows the connections required for the DB-9 to DB-25 interface.
Note Adapters are available from Zebra Technologies LLC.
RS-422/RS-485 adapter, Zebra part number 33114M
RS-232 DB-9 to DB-25 adapter, Zebra part number 33109M
Note Use a null modem (crossover) cable to connect the print engine to a computer or any
other DTE device.
Note To enable this capability, a qualified service technician must install a jumper on the
print engines main logic board on J P1, pins2 and3.
NOTE: Pin 1 is unused and unterminated.
RS-232 Connector (DTE)
Rear Panel Female DB-9
RXD (receive data) input
TXD (transmit data) output
DTR (data terminal ready) output
SG (signal ground)
DSR (data set ready) input
RTS (request to send) output
CTS (clear to send) input
+5 VDC signal source
2
3
4
5
6
7
8
9
R1
+5 VDC
1 K
Data Ports
Serial Port
Figure 199 DB-9 to DB-25 Connections
Modem Connection
When the print engine is connected via its RS-232 interface to Data Communication
Equipment (DCE) such as a modem, use a standard RS-232 (straight-through) interface cable.
Figure200 shows the connections required for this cable.
Figure 200 RS-232 Connections
Male DB-9 Adapter
Connector
(plugs into printer)
Female DB-25 Adapter
Connector
(plugs into cable)
NOTE: Pin 1 of DB-9 connector is unused and unterminated.
FG
TXD
RXD
RTS
DSR
SG
DTR
RXD
TXD
DTR
SG
DSR
RTS
CTS
+5 VDC
SIGNAL
2
3
4
5
6
7
8
9
1
2
3
4
6
7
9
20
+5 VDC
SIGNAL
5
CTS
DTE
(Printer)
DCE
(Modem, etc.)
RXD (receive data)
TXD (transmit data)
DTR (data terminal ready)
SG (signal ground)
DSR (data set ready)
RTS (request to send)
CTS (clear to send)
+5 VDC signal source
NOTE: Pin 1 is unused and unterminated at the printer.
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
Data Ports
Applicator Interface Connector
An external DB-15 connector is present on the rear panel of the print engine for
communication with the applicator. An optional DB-15 to DB-9 adapter cable (Zebra part
number 49609) is available to accommodate existing DB-9 interfaces.
Applicator Interface Connector Pin Configuration
The Applicator Interface Assembly is available in two versions: a +5V I/O and a +24V (24
28V) I/O. Table41 lists the pin configurations and functions of the applicator interface
connector for both +5V and 2428V operation.
Table 41 Applicator Interface Connector Pin Configuration
Pin No. Signal Name Signal Type Description
1 I/O SIGNAL
GROUND
I/O Signal
Ground
+5 V Version Using jumper J 5, this pin can be
configured as isolated or non-isolated from the Applicator
Interface Circuit Ground. See Table42 onpage320 for
more information.
2428 V Version Isolated I/O operation only. No
jumpers to configure.
2 +V I/O
(Fused at 1 A for
+5V operation.
SeeFigure201
onpage321 for fuse
location.)
Caution Replace
the fuse only with
one of the same
type and rating.
Power +5 V Version Using jumper J 4, this pin can be
configured as isolated or non-isolated from the Applicator
Interface Circuit +5V Supply. See Table42 onpage320
for more information.
2428 V Version Isolated I/O operation only. No
jumpers to configure.
3 START PRINT Input Pulse Mode The label printing process begins on the
HIGH to LOW transition of this signal if a format is
ready. De-assert this signal HIGH to inhibit printing of a
new label.
Level Mode Assert LOW to enable the print engine to
begin printing if a format is ready. The print engine prints
new labels as long as the signal is asserted. When de-
asserted, the currently printing label is completed and the
print engine stops and waits for this input to be reasserted
LOW.
4 FEED Input When the print engine is in an idle state or has been
paused, assert this input LOW to trigger repeated feeding
of blank labels. De-assert HIGH to stop feeding blank
labels and register to the top of the next label.
Data Ports
5 PAUSE Input To toggle the current pause state, this input must be
asserted LOW for 200 milliseconds, or until the
SERVICE REQUIRED output (pin 10) changes state.
6 REPRINT Input If the Reprint feature is enabled, this input must be
asserted LOW to cause the print engine to reprint the last
label. See Set Reprint Mode onpage77 for more
information.
If the Reprint feature is disabled, this input is ignored.
7 +28V
(Fused at 500mA.
See Figure201
onpage321 for fuse
location.)
Caution Replace
the fuse only with
one of the same
type and rating.
Power Interface Power Supply supplies power to external
sensors as required.
8 POWER GROUND
(+28V Return)
Ground Interface Power Ground.
9 RIBBON LOW Output Asserted HIGH if the Ribbon Low feature is enabled and
the amount of ribbon remaining on the supply spool is
below a specific threshold level. See Set Ribbon Low
Mode onpage77 for more information.
If the Ribbon Low feature is disabled, this output lead is
disabled.
10 SERVICE
REQUIRED
Output Asserted LOW if the media cover is open, the printhead
is open, the ribbon is out, the media is out, the print
engine is paused, or an operational fault occurs.
If the applicator Resynch mode is set to Error mode, this
signal also asserts LOW for a Resynch error.
11 END PRINT Output MODE 0: The Applicator Port is OFF.
MODE 1: Asserted LOW only while the print engine is
moving the label forward; otherwise de-asserted HIGH.
MODE 2: Asserted HIGH only while the print engine is
moving the label forward; otherwise de-asserted LOW.
MODE 3: (Default) Asserted LOW for 20 milliseconds
when a label has been completed and positioned. Not
asserted during continuous printing.
MODE 4: Asserted HIGH for 20 milliseconds when a
label has been completed and positioned. Not asserted
during continuous printing.
Table 41 Applicator Interface Connector Pin Configuration (Continued)
Data Ports
Jumper Configurations for +5 V I/O Applicator Interface Board
Table42 shows the pin and jumper configurations for pins 1 and 2 in +5V I/O operation.
J umpers J 4 and J 5 are used together to produce isolated or non-isolated modes of operation for
applicator input and output control signals. J 4 configures the +5V source for the optoisolator
circuits, and J 5 configures the ground. For proper operation, when J 4 is installed, J 5 must be
installed, and when J 4 is removed, J 5 must be removed.
Figure201 illustrates the location of the fuses and the location of jumpers J 4 and J 5 for the
+5V I/O applicator interface board.
12 MEDIA OUT Output Asserted LOW while there is no media in the print
engine.
13 RIBBON OUT Output Asserted LOW while there is no ribbon in the print
engine.
14 DATA READY Output Asserted LOW when sufficient data has been received to
begin printing the next label.
De-asserted HIGH whenever printing stops after the
current label, due to either a pause condition or the
absence of a label format.
15 SPARE Output To be determined.De-asserted HIGH when the end print
signal is asserted.
Table 41 Applicator Interface Connector Pin Configuration (Continued)
Table 42 Pin 1 and Pin 2 Jumper Configurations
Pin No. Non-Isolated Isolated
1 J5 In
I/O ground is connected to the
Applicator Interface Circuit
Ground.
J5 Out
I/O ground is disconnected from the Applicator Interface
Circuit Ground. Ground for the applicator interface
optoisolator circuits is provided externally to this pin.
2 J4 In
+5V I/O is connected to the
Applicator Interface Circuit +5V
Supply.
J4 Out
+5V I/O is disconnected from the Applicator Interface
Circuit +5V Supply. The +5V for the applicator
interface optoisolator circuits is provided externally to
this pin.
Data Ports
Figure 201 Applicator Interface Board
1 Fuse F2 for +28V at pin 7
2 Fuse F3 for +5V at pin 2 (+5V I/O only)
3 J umper J 4
4 J umper J 5
1
2
3 4
Data Ports

Notes ___________________________________________________________________
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Pr opr i et ar y St at ement
This manual contains proprietary information of Zebra Technologies Corporation and its
subsidiaries (Zebra Technologies). It is intended solely for the information and use of parties
operating and maintaining the equipment described herein. Such proprietary information may
not be used, reproduced, or disclosed to any other parties for any other purpose without the
expressed written permission of Zebra Technologies.
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
This device complies with Part 15 rules. Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may cause
undesired operation.
This equipment has been tested and found to comply with the limits for Class A Digital
Devices, 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.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies could void the users authority to operate the equipment. To ensure compliance,
this print engine must be used with Shielded Communication Cables.
Propri etary Stat ement
Canadian DOC Compliance Statement
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numrique de la classe A est conforme la norme NMB-003 du Canada.
Liability Disclaimer
Zebra Technologies takes steps to ensure 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.
Limitation of Liability
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, consequential damages including loss of
business profits, business interruption, or loss of business information) arising out of the use
of, the results of use of, or inability to use such product, even if Zebra Technologies has been
advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation or exclusion may
not apply to you.
War r ant y I nf or mat i on
Effective December 30, 2002
All new Zebra products are warranted by the manufacturer to be free from defect in material
and workmanship.
Printers and Related Hardware Products
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.
Products returned must be packaged in the original or comparable packing and shipping
container. 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.
Printers
All printers (excluding printheads) are warranted against defect in material or workmanship
for twelve (12) months from the purchase date.
Warrant y Inf ormat i on
Printheads
Because printhead wear is part of normal operation, the original printhead is covered by a
limited warranty as indicated below. Warranty period begins on purchase date.
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 Genuine Zebra Supplies (media and/or
ribbons) for warranty qualification.
However, if it is determined that the use of inappropriate or inferior supplies has caused any
defect in the printhead for which a warranty claim is made, the user is responsible for Zebras
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 the User Guide has caused defect in the thermal
printhead for which a warranty claim is made.
Related Hardware Items
Products are warranted to be free of defects in material and workmanship from the date of
purchase according to this chart:
Defective product must be returned to Zebra for evaluation. In the event of notification of
defect within the warranty period, Zebra will replace the defective item provided there had not
been damage resulting from user abuse, modification, improper installation or use, or damage
in shipping or by accident or neglect.
Printhead Warranty Period
Bar code label and receipt printer printheads 6 months
Plastic card printer printheads 12 months
Product Warranty Period
Accessories 1 month
Batteries 3 months
Cables 1 month
Chargers/Power Supplies 1 year
Hardware Keys 1 year
Keyboard Display Units 6 months
Parts 3 months
Pocket Eye
1 year
Software 1 month
ZebraNet

Print Servers 3 years
Warranty Information
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.
Zebras sole obligation under these warranties is to furnish parts and labor for the repair or
possible replacement of products 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.
Repair Services
Zebra repairs are warranted against defects in material and workmanship for 90 days from the
date of repair by Zebra. This excludes printheads, which are warranted separately. This
warranty does not cover normal wear and tear. This warranty becomes void if the item is
modified, improperly installed or used, or damaged by accident, neglect, or abuse.
Warranty Exclusions & Conditions Statement
The warranties given above are the only warranties given to you. No other warranties, express
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 Zebras
desire is to be responsive to your 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 on tests believed to be reliable, but do
not constitute a guaranty or warranty.
Zebras maximum liability for warranty claims is limited to the invoice price of the Product
claimed defective. Zebra does not assume responsibility for delays in replacement or repair of
products. Zebra shall not under any circumstances whatsoever be liable to you or any other
party for loss or profits, lost data, diminution of goodwill, or any other special or consequential
damages whatsoever with respect to any warranty claim made by you. Specifically for
software, Zebra is not liable for any incidental or consequential damages 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.
Zebra Technologies
Vernon Hills, IL 60061-3109 U.S.A.
Phone +1 847.634.6700 or +1 800.423.0442
Fax +1 847.913.8766 www.zebra.com
Warrant y Inf ormat i on

Notes ___________________________________________________________________
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__________________________________________________________________________
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Pr i nt er Sof t w ar e
and Fi r mw ar e
Li c ense Agr eement
YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS OF
THIS ZEBRA TECHNOLOGIES PRINTER SOFTWARE AND FIRMWARE LICENSE
AGREEMENT (PSFLA) BEFORE USING THE PRINTER WHICH IS ENCLOSED OR
OTHERWISE ASSOCIATED WITH THIS AGREEMENT. IF YOU DO NOT AGREE
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PLEASE PROMPTLY RETURN THE PRINTER, ENCLOSURES AND ALL PACKAGING
FOR A FULL REFUND.
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FIRMWARE on a storage device, such as a network server, used only to RUN the
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Pri nt er Soft ware and Fi rmware Li cense Agreement
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You must maintain all copyright notices on all copies of the SOFTWARE and
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6. U.S. GOVERNMENT RESTRICTED RIGHTS. All SOFTWARE and/or FIRMWARE
provided to the U.S. Government pursuant to solicitations issued on or after December 1,
1995 is provided with the commercial rights and restrictions described elsewhere herein.
All SOFTWARE and/or FIRMWARE provided to the U.S. Government pursuant to
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SOFTWARE and/or FIRMWARE, any part thereof, or any process or service that is the
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HEREBY DISCLAIM ALL OTHER WARRANTIES AND CONDITIONS, EITHER
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To the extent that the SOFTWARE and/or FIRMWARE covered by this PSFLA
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provide any warranty associated with the emulation libraries.
The emulation library does not work 100% correctly or cover 100% of the
functionality of the printer language being emulated. Modifications may be required
for each target application. If such modification is necessary, prior to making any such
modification, you are required to contact ZEBRA to obtain express written consent to
make such modification.
If the emulation library is sold separately by an authorized party other than ZEBRA
(RESELLERA party other than ZEBRA which is authorized by ZEBRA to
distribute the SOFTWARE and/or FIRMWARE with its application so long as the
SOFTWARE and/or FIRMWARE is used with a ZEBRA printer) or is sold bundled
with a printer to an end-user by a RESELLER, and if claims are made by the
RESELLER that the emulation library performs as a 100% emulation solution,
ZEBRA is not responsible if the emulation library does not work as advertised by the
RESELLER. Furthermore, ZEBRA is not liable for any damages directly or indirectly
relating to such emulation library which is sold separately by the RESELLER or
which is sold bundled with a printer to an end-user by the RESELLER.
The SOFTWARE and FIRMWARE was provided to you at no additional charge and
ZEBRA has included in this PSFLA terms that disclaim all warranties and liability for
the SOFTWARE and FIRMWARE. To the full extent allowed by law, YOU HEREBY
Printer Software and Firmware License Agreement
RELEASE ZEBRA AND ITS SUPPLIERS FROM ANY AND ALL LIABILITY
ARISING FROM OR RELATED TO ALL CLAIMS CONCERNING THE
SOFTWARE AND/OR FIRMWARE OR ITS USE. If you do not wish to accept the
SOFTWARE OR FIRMWARE under the terms of this PSFLA, do not use the
PRINTER enclosed with or otherwise associated with this PSFLA.
11. GOVERNING LAW. If you acquired the SOFTWARE and/or FIRMWARE in the United
States of America, the laws of the State of Illinois, U.S.A. will apply to this contract. If
you acquired this SOFTWARE and/or FIRMWARE outside of the United States of
America, then local law may apply. If any provision of this PSFLA is held invalid, the
remainder of this PSFLA shall continue in full force and effect.
12. QUESTIONS. Should you have any questions, or if you desire to contact ZEBRA for any
reason, please contact the ZEBRA subsidiary serving your country, or write:
Vernon Hills, IL 60061

Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Gl ossar y
Alphanumeric Indicating letters, numerals, and characters such as punctuation marks.
Backfeed When the print engine pulls the media and ribbon (if used) backward into the
print engine so that the beginning of the label to be printed is properly positioned behind the
printhead. Backfeed occurs when operating the print engine in Tear-Off and Applicator modes.
Bar code A code by which alphanumeric characters can be represented by a series of
adjacent stripes of different widths. Many different code schemes exist, such as the universal
product code (UPC) or Code 39.
Black mark A registration mark found on the underside of the print media that acts as a
start-of-label indication for the print engine. (See continuous media.)
Calibration (of a print engine) A process in which the print engine determines some basic
information needed to print accurately with a particular media and ribbon combination. To do
this, the print engine feeds some media and ribbon (if used) through the print engine and
senses whether to use the direct thermal or thermal transfer print method, and (if using
non-continuous media) the length of individual labels or tags.
Character set The set of all letters, numerals, punctuation marks, and other characters that
can be expressed by a particular font or bar code.
Check digit A character added to a bar code symbol that indicates to the scanner that it has
read the symbol correctly.
Configuration The print engine configuration is a group of operating parameters specific
to the print engine application. Some parameters are user selectable, while others are
dependent on the installed options and mode of operation. Parameters may be switch
selectable, front panel programmable or downloaded as ZPL II commands. A configuration
label listing all the current print engine parameters may be printed for reference.
Continuous media Label or tag-stock media that has no notch, gap, or web (media liner
only) to separate the labels or tags. The media is one long piece of material.
Gl ossary
Core diameter The inside diameter of the cardboard core at the center of a roll of media or
ribbon.
Diagnostics Information about which print engine functions are not working that is used
for troubleshooting print engine problems.
Die-cut media A type of label stock that has individual labels stuck to a media liner. The
labels may be either lined up against each other or separated by a small distance. Typically the
material surrounding the labels has been removed. (See non-continuous media.)
Direct thermal A printing method in which the printhead presses directly against the
media. Heating the printhead elements causes a discoloration of the heat-sensitive coating on
the media. By selectively heating the printhead elements as the media moves past, an image is
printed onto the media. No ribbon is used with this printing method. Contrast this with thermal
transfer.
Direct thermal media Media that is coated with a substance that reacts to the application
of direct heat from the printhead to produce an image.
Dynamic RAM The memory devices used to store the label formats in electronic form
while they are being printed. The amount of DRAM memory available in the print engine
determines the maximum size and number of label formats that can be printed. This is volatile
memory that loses the stored information when power is turned off.
Fanfold media Media that comes folded in a rectangular stack. Contrast this with roll
media.
Firmware This is the term used to specify the print engines operating program. This
program is downloaded to the print engine from a host computer and stored in FLASH
memory. Each time the print engine power is turned on, this operating program starts. This
program controls when to feed the media forward or backward and when to print a dot on the
label stock.
FLASH memory FLASH memory is non-volatile and maintains the stored information
intact when power is off. This memory area is used to store the print engines operating
program. In addition, this memory can be used to store optional print engine fonts, graphic
formats, and complete label formats.
Font A complete set of alphanumeric characters in one style of type. Examples include
CGTimes, CG Triumvirate Bold Condensed.
Ips inches-per-second The speed at which the label or tag is printed. Zebra offers print
engines that can print from 1 ips to 12 ips.
Label An adhesive-backed piece of paper, plastic, or other material on which information is
printed.
Label backing (label liner) The material on which labels are affixed during manufacture
and which is discarded or recycled by the end-users.
Liquid crystal display The LCD is a back-lit display that provides the user with either
operating status during normal operation or option menus when configuring the print engine to
a specific application.
Glossary
Light emitting diode (LED) Indicators of specific print engine status conditions. Each
LED is either off, on, or blinking depending on the feature being monitored.
Lock-up This is the term generally used to describe a fault condition that, for apparently no
reason, causes the print engine to stop working.
Media Material onto which data is printed by the print engine. Types of media include: tag-
stock, die-cut labels, continuous (with and without media liner), fanfold, and roll.
Media sensor This sensor is located behind the printhead to detect the presence of media
and, for non-continuous media, the position of the web, hole, or notch used to indicate the start
of each label.
Non-continuous media Consumable printing stock that contains an indication of where
one label/printed format ends and the next one begins. Examples are die-cut labels, notched
tag-stock, and stock with black mark registration marks.
Non-volatile memory Electronic memory that retains data even when the power to the
print engine is turned off.
Notched media A type of tag stock containing a cutout area that can be sensed as a start-of-
label indicator by the print engine. This is typically a heavier, cardboard-like material that is
either cut or torn away from the next tag. (See non-continuous media.)
Print speed The speed at which printing occurs. For thermal transfer print engines, this
speed is expressed in terms of ips (inches per second). Zebra offers print engines that can print
from 1 ips to 12 ips.
Printhead wear The degradation of the surface of the printhead and/or the print elements
over time. Heat and abrasion can cause printhead wear. Therefore, to maximize the life of the
printhead, use the lowest print darkness setting (sometimes called burn temperature or head
temperature) and the lowest printhead pressure necessary to produce good print quality. In the
thermal transfer printing method, use ribbon that is as wide or wider than the media to protect
the printhead from the rough media surface.
Registration Alignment of printing with respect to the top of a label or tag.
Ribbon A band of material consisting of a base film coated with wax or resin ink. The
inked side of the material is pressed by the printhead against the media. The ribbon transfers
ink onto the media when heated by the small elements within the printhead. Zebra ribbons
have a coating on the back that protects the printhead from wear.
Ribbon wrinkle A wrinkling of the ribbon caused by improper alignment or improper
printhead pressure. This wrinkle can cause voids in the print and/or the used ribbon to rewind
unevenly. This condition should be corrected by performing adjustment procedures.
Roll media Media that comes supplied rolled onto a core (usually cardboard). Contrast this
with fanfold media.
Supplies A general term for media and ribbon.
Symbology The term generally used when referring to a bar code.
Tag A type of media having no adhesive backing but featuring a hole or notch by which the
tag can be hung on something. Tags are usually made of cardboard or other durable material.
Gl ossary
Tear-off A mode of operation in which the user tears the label or tag stock away from the
remaining media by hand.
Thermal transfer A printing method in which the printhead presses an ink or resin coated
ribbon against the media. H eating the printhead elements causes the ink or resin to transfer
onto the media. By selectively heating the printhead elements as the media and ribbon move
past, an image is printed onto the media. Contrast this with direct thermal.
Void A space on which printing should have occurred, but did not due to an error condition
such as wrinkled ribbon or faulty print elements. A void can cause a printed bar code symbol
to be read incorrectly or not at all.
I ndex
A
AC power supply board replacement, 249
adhesive test for ribbon coating, 51
adjustments
elastomer pinch roller, 134
LCD, 78
left position, 75
media sensors, 130
media tracking, 132
media tracking cam, 136
print darkness, 129
print engine darkness, 61
print quality, 121
printhead balance, 124
printhead parallelism, 122
printhead position, 125
printhead pressure, 86, 127
strip plate, 128
tear-off position, 129
toggle positioning, 85
upper pinch roller, 132
applicator
install print engine, 36
reinstall print engine, 141
remove print engine, 138
applicator interface board replacement, 245
applicator interface connector, 318
applicator port setting, 76
authentication type, 81
auto-calibration, 82
auxiliary roller replacement procedure, 212
B
backfeed setting, 74
balance adjustment, 124
bar codes
list available codes, 66
specifications, 11
baud setting, 70
before you begin setup, 29
belt replacement procedure, 160
bitmap scaling factor, 78
black mark media
described, 42
setting sensor type, 63
black oval button descriptions, 5
buttons on front panel, 5
C
cable requirements, 41
calibration
CALIBRATE button description, 6
media and ribbon sensor, 69
methods, 82
setting for head close, 74
setting for media power up, 74
CANCEL button description, 6
CANCEL self test, 101
checklist
before you begin, 29
troubleshooting, 90
Index
cleaning
peel bar and media path, 117
print engine exterior, 115
print engine interior, 115
printhead and rollers, 115
close the rear enclosure, 141
communication interfaces
overview and location, 39
types of connections, 313
communications diagnostics test
overview, 106
selecting, 72
communications problems, 97
CompactFlash
card initialization, 67
card installation, 228
compound pulley replacement, 171
configuration
changing parameters, 61
enter Setup mode, 58
exit Setup mode, 59
configuration label
printing using CANCEL self test, 101
printing using List Setup command, 66
connect print engine to power source, 37
contact information, xi
continuous media
described, 43
setting media type, 62
control prefix setting, 72
corrective maintenance procedures, 119
customer support, xi
D
darkness adjustment, 129
darkness setting, 61
data bits setting, 70
data cable requirements, 41
data ports, 313
data source
communication interfaces, 313
connections, 39
date setting, 79
DB-9 to DB-25 connection, 316
default gateway, 80
default password, 60
delimiter character setting, 73
diagnostics, 100
direct connection to a computer, 316
direct thermal mode
media scratch test, 50
setting, 63
disable password protection, 60
display language selection, 79
door-open switch replacement, 262
dpi format conversion, 78
E
elastomer pinch roller, 134
electrical noise, 41
electrical specifications, 10
encryption settings, 81
environmental conditions, 9
equipment safety tips, 110
error messages, 91
ESSID setting, 81
exit Setup mode, 59
F
fanfold media, 43
FEED and PAUSE self test, 104
FEED button description, 6
FEED self test, 103
Flash memory, initialize, 67
font list, 66
format convert setting, 78
format list, 66
format prefix setting, 73
front cover replacement, 258
front panel
buttons, 5
exit Setup mode, 59
indicator lights, 6
LCD error messages, 91
LCD parameters, 61
fuses
replacement, 87
specifications, 10
G
gleaning, 80
H
HEAD COLD message, 92
host handshake setting, 70
humidity requirements, 9
Index
I
idle display setting, 79
images list, 66
initialize
Flash memory, 67
memory card, 67
inspect the print engine, 30
installation
procedure, 36
requirements, 31
interfaces
IEEE 1284 bi-directional parallel, 40
RS-232 serial, 40
international safety organization marks, 38
IP settings
default gateway, 80
IP address, 80
protocol, 80
subnet mask, 80
L
label length maximum setting, 64
label top
printer cannot detect, 98
setting, 75
label-available sensor
when to clean, 114
labels did not print, 97
language selection, 79
LCD messages
adjust LCD settings, 78
error messages, 91
language selection, 79
Setup mode, 61
lights on front panel, 6
list settings
all settings, 66
bar codes, 66
fonts, 66
formats, 66
images, 66
network, 66
setup, 66
loading
media, 44
ribbon, 52
long calibration, 82
M
MAC address, 81
main logic board replacement, 235
maintenance procedures, 107
mark LED setting, 78
Mark Med S. setting, 78
maximum label length setting, 64
media
continuous roll media, 43
fanfold, 43
loading, 44
media LED setting, 78
non-continuous roll media, 42
RFID smart labels, 43
specifications, 13
types of media, 42
media and ribbon sensor calibration procedure, 69
media path cleaning, 114, 117
media power up setting, 74
Media S. setting, 78
media sensor
adjustments, 130
print media sensor profile, 68
sensor sensitivity calibration, 83
media tracking
adjustments, 132
cam adjustment, 136
memory specifications, 10
modem connection, 317
N
network configuration label
printing using List Network command, 66
network ID setting, 71
NEXT button description, 5
non-continuous media
described, 42
O
open the rear enclosure, 139
P
parallel port
pin configuration, 314
setting parallel communications, 69
settings, 314
Index
parity setting, 70
passwords
default, 60
disable, 60
entering, 60
Pause mode
PAUSE button, 5
PAUSE LED, 6
PAUSE self test, 102
PCMCIA card
initialization, 67
installation, 216
peel bar cleaning, 117
peel roller
cleaning, 116
replacement procedure, 207
peel-off bar cleaning, 114
personal safety tips, 112
pin configuration
parallel port, 314
serial port, 315
pinch roller
adjustment of elastomer pinch roller, 134
adjustment of upper roller, 132
how to clean, 116
platen roller
how to clean, 116
when to clean, 114
ports, 313
power
connect to power source, 37
electrical specifications, 10
on/off switch location, 8
power cord specifications, 38
Power-On Self Test (POST), 100
preventive maintenance
cleaning the exterior, 115
cleaning the interior, 115
cleaning the peel bar and media path, 117
cleaning the printhead and rollers, 115
recommended schedule, 114
tools required, 114
PREVIOUS button description, 5
print configuration label
CANCEL self test, 101
List Setup command, 66
print darkness setting, 61
print engine setup
before you begin, 29
installation, 31
unpack the print engine, 30
print modes, 62
print network configuration label, 66
print quality adjustments
overview, 121
print darkness adjustment, 129
printhead balance adjustment, 124
printhead parallelism adjustment, 122
printhead position adjustment, 125
printhead pressure adjustment, 127
strip plate adjustment, 128
print quality troubleshooting, 94
print server board installation, 233
print server settings
default gateway, 80
IP address, 80
IP protocol, 80
subnet mask, 80
print width setting, 63
printer settings
applicator port, 76
backfeed, 74
baud, 70
calibration methods, 82
control prefix, 72
data bits, 70
date, 79
delimiter character, 73
format convert, 78
format prefix, 73
head resistor, 75
host handshake, 70
idle display, 79
IP settings, 79
label top, 75
language, 79
LCD, 78
left position, 75
maximum label length, 64
media type, 62
network ID, 71
parallel communications, 69
parity, 70
print darkness, 61
print method, 63
print server settings, 79
print width, 63
protocol, 71
resynch mode, 77
saving, 59
sensor type, 63
serial communications, 70
Index
printer settings (continued)
setting through front panel, 58
start print signal, 76
time, 79
ZPL mode, 73
printhead
balance adjustment, 124
dpi conversion, 148
head close setting, 74
head resistor value setting, 75
how to clean, 115
parallelism adjustment, 122
position adjustment, 125
pressure adjustment, 86, 127
when to clean, 114
printing specifications, 12
proprietary statement, 323
protocol setting, 71
pulley
compound pulley replacement, 171
stepper motor pulley replacement, 178
R
rear enclosure
closing, 141
opening, 139
reflective media sensor, 131
reinstall print engine in applicator, 141
related documents, xiii
remove print engine from applicator, 138
remove used ribbon, 57
report shipping damage, 30
reprint mode, 77
requirements for installation, 31
reset network option, 81
resynch mode setting, 77
RFID
smart labels, 43
ribbon
adhesive test, 51
determining coated side, 50
loading, 52
low ribbon warning, 77
removal, 57
ribbon LED setting, 78
ribbon tensioning system parameters, 78
scratch test, 51
specifications, 14
when to use, 50
Ribbon S. setting, 78
ribbon sensor
adjusting, 131
calibration procedure, 69
sensitivity calibration, 83
when to clean, 114
ribbon supply motor replacement, 193
ribbon take-up motor replacement, 186
Routine Referral Procedures (RRPs), 138
RS-232 interface
connections, 316
considerations, 40
RTC (Real-time clock) setting
date, 79
idle display, 79
time, 79
S
safety
equipment safety tips, 110
personal safety tips, 112
scratch test
media type, 50
ribbon coated side, 51
self tests
CANCEL, 101
communications diagnostics, 106
FEED, 103
FEED and PAUSE, 104
PAUSE, 102
Power-On Self Test (POST), 100
Sensor Profile calibration
description, 83
procedure, 68
sensors
adjustment, 130
calibration methods, 82
serial port
pin configuration, 315
setting serial communications, 70
settings, 315
setup checklist, 29
Setup mode
exit Setup mode, 59
LCD messages, 61
passwords, 60
SETUP/EXIT button description, 5
shipping
report damage, 30
reshipping the print engine, 30
Index
short calibration, 82
smart labels, 43
specifications
bar codes, 11
communications options, 10
electrical, 10
environmental conditions, 9
fuses, 10
media, 13
memory, 10
physical, 9
power cord, 38
printing, 12
ribbon, 14
Zebra Programming Language (ZPL), 11
standard data ports, 313
start print signal setting, 76
stepper motor pulley replacement, 178
stepper motor replacement, 182
storing the print engine, 30
strip plate adjustment, 128
subnet mask, 80
support, xi
system considerations
communication specifications, 40
communications code, 40
interfaces, 40
T
Tear-Off Mode
tear-off bar cleaning, 114
Tear-Off mode
tear-off position adjustment, 129
tear-off position front panel option, 62
temperature requirements, 9
thermal transfer mode
setting, 63
time setting, 79
toggle assembly replacement, 154
toggle positioning, 85
top of label
printer cannot detect, 98
setting, 75
transmissive (media) sensor
adjusting, 130
when to clean, 114
troubleshooting
checklist, 90
communications problems, 97
diagnostic tests, 100
LCD error messages, 91
print quality problems, 94
types of media
continuous roll media, 43
fanfold media, 43
non-continuous roll media, 42
RFID smart labels, 43
U
unpack the print engine, 30
W
web media, 42
Web S. setting, 78
wireless PCMCIA board installation, 218
Wireless Print Server settings
authentication type, 81
default gateway, 80
encryption, 81
ESSID, 81
IP address, 80
IP protocol, 80
MAC address, 81
reset network, 81
subnet mask, 80
Z
Zebra Programming Language (ZPL II)
specifications, 11
ZPL mode setting, 73
Zebra support, xi

Vernon Hills, Illinois 60061.3109 U.S.A.
Telephone: +1 847.634.6700
Facsimile: +1 847.913.8766
Zebra Technologies Europe Limited
Zebra House
The Valley Centre, Gordon Road
High Wycombe
Buckinghamshire HP13 6EQ, UK
Telephone: +44 (0) 1494 472872
Facsimile: +44 (0) 1494 450103
Customer Order #57515L-001
Manufacturer Part #57515L-001 Rev. 1
2005 ZIH Corp.

110PAX4 Maint Manual

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Print Server LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Print Server LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

10/100 PrintServer or ZebraNet Wireless Print

Print Server LCD Displays

Applicator Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

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