Maintenance Manual Zebra Xi4;
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List of Figures
List of Tables
Advanced Printer Information
TROUBLESHOOTING
Troubleshooting Checklists
LCD Error Messages
Print Quality Problems
Calibration Problems
Communications Problems
Ribbon Problems
Miscellaneous Printer Problems
Printer Diagnostics
Power-On Self Test
CANCEL Self Test
PAUSE Self Test
FEED Self Test
FEED and PAUSE Self Test
Communications Diagnostics Test
Sensor Profile
DATA PORTS
Parallel Data Port
Parallel Cabling Requirements
Parallel Port Interconnections
Serial Data Port
Hardware Control Signal Descriptions
Pin Configuration
RS-232 Interface Connections
USB 2.0 Port
Applicator Interface Connector
Applicator Signals
Applicator Interface Connector Pin Configuration
Jumper Configurations and Pinouts for +5 V I/O Operation
Pinouts for +24-28 V I/O Operation
PREVENTIVE MAINTENANCE
Replacing Printer Components
Ordering Replacement Parts
Recycling Printer Components
Lubrication
Cleaning Schedule and Procedures
Clean the Exterior
Clean the Media Compartment
Clean the Printhead and Platen Roller
Clean the Sensors
Clean the Snap Plate
Clean the Cutter
Replace the Fuse
CORRECTIVE MAINTENANCE
PRINT SYSTEM
Printhead Assembly
Tools Required
Remove the Printhead
Install the Printhead
Adjust the Printhead
Printhead Parallelism
Adjust the Printhead Parallelism
Adjust the Wear Plate Position
Adjust the Printhead Position
Set the Darkness
Align the Strip Plate
Print Mechanism Hardware
Tools Required
Remove the Printhead
Remove the Electronics Cover
Remove the Printhead Test Board
Remove the Old Print Mechanism
Install the New Print Mechanism
Reinstall the Electronics Cover
Reinstall the Printhead
Adjust the Printhead
Printhead Cables
Tools Required
Remove the Printhead
Remove the Electronics Cover
Disconnect All Printhead Cables
Remove the Printhead Test Board
Remove the Old Printhead Cables
Install the New Printhead Cables
Reinstall the Electronics Cover
Ribbon Strip Plate and Static Brush
Tools Required
Remove the Old Static Brush
Install the New Static Brush
Remove the Old Ribbon Strip Plate
Install the New Ribbon Strip Plate
Adjust the Strip Plate
Toggle Assembly
Tools Required
Remove the Old Toggle Assembly
Install the New Toggle Assembly
Pivot Bar
Tools Required
Remove the Electronics Cover
Remove the Old Pivot Bar Assembly
Install the New Pivot Bar
Reinstall the Electronics Cover
Head Open Sensor Flag
Tools Required
Remove the Electronics Cover
Remove the Old Sensor Flag
Install the New Sensor Flag
Reinstall the Electronics Cover
SENSORS
Media Sensor Assemblies
Tools Required
Remove the Electronics Cover
Remove the Printhead Test Board
Remove the Mounting and Printhead Stop Spring Stud
Disconnect Media Sensor Cables
Remove the Upper Media Sensor
Install the New Upper Media Sensor Assembly
Remove the Old Lower Media Sensor Printed Circuit Board (PCB)
Install the New Lower Sensor PCB
Reinstall the Electronics Cover
Adjust the Upper Media Sensor
Adjust the Lower Media Sensor
Media Low Sensor
Tools Required
Remove the Electronics Cover
Remove the Old Media Low Sensor
Remove the Damper
Install the New Media Low Sensor
Reinstall the Electronics Cover
Calibrate the Media Low Sensor
Complete the Installation
Ribbon Sensor
Remove the Electronics Cover
Disconnect the Old Ribbon Sensor
Remove the Printhead Test Board
Access the Ribbon Out Sensor Cable
Remove the Printhead
Remove the Old Ribbon Out Sensor
Install the New Ribbon Out Sensor
Reinstall the Printhead
Reinstall the Electronics Cover
Ribbon Low Sensors
Tools Required
Remove the Electronics Cover
Remove the Old Ribbon Low Sensors
Install the New Ribbon Low Sensors
Reinstall the Electronics Cover
Head Open Sensor
Tools Required
Remove the Electronics Cover
Disconnect the Head Open Sensor
Remove the Printhead Test Board
Access the Head Open Sensor Cable
Remove the Old Printhead Open Sensor Assembly
Install the New Head Open Sensor Assembly
Reinstall the power supplyElectronics Cover
Take-Label Sensors
Tools Required
Remove the Electronics Cover
Disconnect the Old Take-Label Sensors
Install the New Take-Label Sensors
Reinstall the Electronics Cover
Cutter Sensor
Tools Required
Remove the Electronics Cover
Remove the DC Power Supply
Remove the AC/DC Power Supply
Remove the Old Cutter Sensor
Install the New Cutter Sensor
Reinstall the Power Supply
Reinstall the Electronics Cover
DRIVE SYSTEM
Platen Roller
Tools Required
Remove the Electronics Cover
Remove the Old Upper Platen Roller
Install the New Upper Platen Roller
Remove the Old Lower Platen Roller
Remove the 140Xi4, 170Xi4, and 220Xi4 DC Power Supply
Remove the 110Xi4 AC/DC Power Supply
Remove the Rewind Drive Belt
Install the New Lower Platen Roller
Reinstall the Rewind Drive Belt
Reinstall the Electronics Cover
Adjust the Lower Platen Roller
Main Drive System
Tools Required
Remove the Electronics Cover
Remove the Old Main Drive System
Install the New Main Drive System
Adjust the Main Drive Belt Tension
Reinstall the Electronics Cover
Main Drive Belt
Tools Required
Remove the Electronics Cover
Remove the Old Main Drive Belt
Install the New Main Drive belt
Adjust the Main Drive Belt Tension
Reinstall the Electronics Cover
Rewind Drive System
Tools Required
Remove the Electronics Cover
Remove the AC/DC Power Supply
Remove the DC Power Supply
Remove the Old Rewind Drive System
Install the New Rewind Drive System
Adjust the Rewind Belt Tension
Reinstall the Power Supply
Reinstall the Electronics Cover
Rewind Drive Belt
Tools Required
Remove the Electronics Cover
Remove the AC/DC Power Supply
Remove the DC Power Supply
Remove the Old Rewind Drive Belt
Install the New Rewind Drive Belt
Adjust the Rewind Belt Tension
Reinstall the Electronics Cover
110Xi4, 140Xi4, and 170Xi4 DC Stepper Motor w/Pulley
Tools Required
Remove the Electronics Cover
Remove the DC Power Supply
Remove the AC/DC Power Supply
Remove the Main Drive Belt
Remove the Rewind Drive Belt
Remove the Platen Roller
Remove the Rewind Platen Roller
Remove the Side Plate
Remove the Old Stepper Motor
Install the New Stepper Motor
Reinstall the Side Plate
Reinstall the Rewind Platen Roller Pulley
Reinstall the Platen Roller and Pulley
Reinstall the Tear Bar
Reinstall DC Power Supply
Reinstall AC/DC Power Supply
Adjust the Rewind Drive Belt Tension
Adjust the Main Drive belt Tension
Adjust the Printhead
Reinstall the Electronics Cover
220Xi4 DC Stepper Motor w/Pulley
Tools Required
Remove the Electronics Cover
Remove the DC Power Supply
Remove the Main Drive Belt
Remove the Rewind Drive Belt
Remove the Platen Roller
Remove the Rewind Platen Roller
Remove the Side Plate
Remove the Old Stepper Motor
Install the New Stepper Motor
Reinstall the Side Plate
Reinstall the Tear Bar
Reinstall the Rewind Platen Roller Pulley
Adjust the Rewind Drive Belt Tension
Reinstall the Platen Roller and Pulley
Adjust the Main Drive belt Tension
Reinstall DC Power Supply
Reinstall the Electronics Cover
110Xi4 Media Hanger
Tools Required
Remove the Electronics Cover
Move the Rear Panel
Remove the Old Media Hanger
Install the New media Hanger
Reinstall the Rear Panel
Reinstall the Electronics Cover
140Xi4, 170Xi4, and 220Xi4 Media Supply Hanger
Tools Required
Remove the Electronics Cover
Remove the Main Logic Board (MLB)
Move the Rear Panel
Remove the Old Media Supply Hanger
Install the New Media Hanger
Reinstall the Electronics Cover
Ribbon Supply Spindle
Tools Required
Remove the Electronics Cover
Remove the Ribbon Supply Spindle
Install the New Ribbon Supply Spindle
Reinstall the Electronics Cover
Ribbon Supply Spindle Hardware
Tools Required
Remove the Old RSS Parts
Install the New Ribbon Supply Spindle Parts
Adjust the Ribbon Supply Spindle
Ribbon Take-Up Spindle
Tools Required
Remove the Electronics Cover
Remove the Old Ribbon Take-Up Spindle
Install the Ribbon Take-up Assembly
Install the Spindle/Clutch Assembly
Adjust the Main Drive Belt Tension
Reinstall the Electronics Cover
Remove the End Cap/Release Bar Assembly
Adjust the Ribbon Take-Up Spindle Assembly Tension
Ribbon and Media Supply Pulley
Tools Required
Remove the Electronics Cover
Remove the Old RTU Pulley
Install the New RTU Pulley
Remove the Power Supply
Remove the Old MTU Pulley
Install the New MTU Pulley
Reinstall the Electronics Cover
Media Rewind Spindle
Remove the Electronics Cover
Remove AC/DC the Power Supply
Remove the DC Power Supply
Remove the Old Rewind Spindle Assembly
Install the New Media Rewind Spindle Assembly
Reinstall the Power Supply
Reinstall the Electronics Cover
Media Supply Spindle
Tools Required
Remove the Electronics Cover
Move the Rear Panel
Remove the Old Media Supply Hanger
Remove the Old Media Supply Spindle
Install the New Media Supply Spindle
Adjust the Spindle Tension
Reinstall the Electronics Cover
ROLLER SYSTEM
Dancer Assembly
Tools Required
Remove the Electronics Cover
Remove the Printhead Test Board
Remove the Old Dancer Assembly
Install the New Dancer Assembly
Reinstall the Electronics Cover
Rewind Platen Roller Adjustment Bracket
Tools Required
Remove the Rewind Platen Roller Adjustment Bracket
Install the Rewind Platen Roller Adjustment Bracket
Adjust the Rewind Platen Roller Adjustment Bracket
Ribbon Rollers
Tools Required
Remove the Electronics Cover
Remove the Top Ribbon Roller Assembly
Install the New Top Ribbon Roller Assembly
Remove the Lower Ribbon Roller Assembly
Install the New Lower Ribbon Roller
Remove the Ribbon Dancer Rollers
Install the Ribbon Dancer Rollers
Remove the Print Mechanism Roller Assembly
Install the New Print Mechanism Roller
Reinstall the Electronics Cover
Adjust the Print Mechanism Roller
PRINTED CIRCUIT BOARDS
Control Panel
Tools Required
Remove the Electronics Cover
Remove the Old Control Panel
Install the New Control Panel
Reinstall the Electronics Cover
Control Panel Cover
Remove the Old Control Panel Cover
Install the New Control Panel Cover
Main Logic Board
Tools Required
Remove the Electronics Cover
Remove the Applicator Board
Remove the Twinax/Coax Board
Remove the Internal Printer Server
Remove the External Antenna
Remove the Wireless Card
Remove the MLB
Remove the Wireless Board
Remove the Internal Ethernet Board
Install the New Main Logic Board
Reinstall Removed Components
Reinstall the Electronics Cover
Calibrate the Media Low Sensor
AC Power Supply
Tools Required
Remove the Electronics Cover
Remove the AC Power Supply
Install the New AC Power Supply
Install the New AC Power Supply Shield
Reinstall the MLB
Reinstall the Electronics Cover
110Xi4 AC/DC Power Supply Assembly
Tools Required
Remove the Electronics Cover
Remove the AC/DC Power Supply Assembly
Install the AC/DC Power Supply Assembly
Reinstall the Electronics Cover
DC Power Supply
Tools Required
Remove the Electronics Cover
Remove the Old DC Power Supply
Install the New DC Power Supply
Reinstall the Electronics Cover
Cutter Printed Circuit Board
Tools Required
Remove the Electronics Cover
Remove the AC/DC Power Supply
Remove the DC Power Supply
Remove the Old Cutter Control Board
Install the New Cutter Control Board
Reinstall the Electronics Cover
110Xi4 Power Entry
Tools Required
Remove the Electronics Cover
Remove the Power Entry Module
Remove and Install the On/Off Switch
Install the New Power Entry Module
Reinstall the AC/DC Power Supply Shield
Reinstall the Electronics Cover
140Xi4, 170Xi4, and 220Xi4 Power Entry
Tools Required
Remove the Electronics Cover
Remove the Power Entry Module
Remove and Install the On/Off Switch
Install the New Power Entry Module
Reinstall the AC Power Supply Shield
Reinstall the MLB
Reinstall the Electronics Cover
Electronics Cables
Tools Required
Remove the Electronics Cover
Remove and Install the Electronics Cables
Reinstall the Electronics Cover
Printhead Test Board Option
Tools Required
Remove the Electronics Cover
Install the Printhead Test Board Spacers
Remove the Old Printhead Test Board
Install the Printhead Test Board Shield
Install the Printhead Test Board
Connect the Printhead Test Board Cables
Reconnect the Printhead Test Board
Reinstall the Electronics Cover
Set Head Test Count
Twinax/Coax Option
Tools Required
Remove the Electronics Cover
Remove the Defective Twinax/Coax Board
Install the Twinax/Coax Board
Reinstall the Electronics Cover
Applicator Interface
Tools Required
Remove the Electronics Cover
Remove the Old Applicator Interface Board
Install the Applicator Interface Board
Reinstall the Electronics Cover
Applicator Port Pinouts
Input/Output Specifications
Wired Ethernet
Tools Required
Remove the Electronics Cover
Remove the Wired Ethernet Board
Install the Wired Ethernet Board
Reinstall the Electronics Cover
Wireless Plus PCMCIA Option/Maintenance Kit
Tools Required
Remove the Electronics Cover
Remove the Existing PCMCIA Option Board Assembly
Install the Wireless PCMCIA Board
Reinstall the Electronics Cover
Resume Operation
Compact Flash Adapter
Installation Instructions
ZebraNet® Internal Wireless Plus Print Server
Tools Required
Remove the Electronics Cover
Remove the Existing Print Server Board
Install the New Internal Wireless Plus
Install the Cover and External Antenna
Reinstall the Electronics Cover
Resume Printer Operation
After You Complete the Installation
Compliance Information
SEH PS102-Z IPv6 Internal Print Server
Tools Required
Remove Electronics Cover
Remove the Cover Plate
Remove the Existing Communication Hardware
Install the SEH PS102-Z Internal Print Server
After You Complete the Installation
OUTER CASTING COMPONENTS
Electronics Cover
Remove the Old Electronics Cover
Install the New Electronics Cover
Media Door
Tools Required
Remove the Old Media Door
Install the New Media Door
Media Door Window
Remove the Old Media Door Window
Install the New Media Door Window
Media Door Damper Assembly
Tools Required
Remove the Old Media Door Damper Assembly
Install the New Damper Assembly
TrimPanel and Nameplate
Tools Required
Remove the Old Lower Trim Panel
Install the New Lower Trim Panel
Remove the Nameplate
Tear Front Plate
Remove the Old Tear Front Plate
Install the New Tear Front Plate
Side Plate
Tools Required
Remove the Electronics Cover
Remove the Old Side Plate
Install the New Side Plate
Reinstall the Electronics Cover
Adjust the Rewind Platen Roller
Adjust the Printhead
Access Hole Covers and Media Low Bracket
Tools Required
Install Cutter Module Hole Cover Plate
Install the Take-Label Sensor Expansion Covers
Install the Lower Platen Plug
Install the Compliance Roller Hole Plug
Install the Rewind Spindle Hole Plug
Install the 220Xi4 Rewind Spindle Hole Cover Plate
Install the Cutter Motor Cover Plate
Install the Media Low Brackets
Slot and Wireless Covers
Tools Required
Install the Slot Covers
Install the RFID Covers
Complete the Installation
OPTIONS
Cutter Option
Remove the Electronics Cover
Remove the Power Supply
Install the Cutter Motor
Install the Cutter Module
Install the Cutter Circuit Board and Optical Sensor
Install the Drive Link Assembly
Align Lower Drive Arm Mechanical
Reinstall the Power Supply
Configure the Printer
Align the Upper Drive Arm
Reinstall the Electronics Cover
Cutter Module
Tools Required
Remove the Electronics Cover
Remove the Old Cutter Module
Install the New Cutter Module
Align the Upper Drive Arm
Reinstall the Electronics Cover
Cutter Brackets
Tools Required
Remove the Electronics Cover
Remove the Cutter Module
Install the Cutter Brackets
Reinstall the Cutter Module
Reinstall the Upper Linkage
Configure the Printer
Reinstall the Electronics Cover
Cutter Linkage
Tools Required
Remove the Electronics Cover
Remove the DC Power Supply
Remove the AC/DC Power Supply
Install the Cutter Linkage Maintenance Kit
Reinstall the Electronics Cover
Cutter Static Brush
Tools Required
Remove the Old Cutter Static Brush
Install the New Cutter Static Brush
Cutter Catch Tray
Tools Required
Install the Catch Tray
Adjust the Catch Tray
Install the Anti-Curl Shaft Assembly
Rewind Option
Tools Required
Remove the Electronics Cover
Remove the Power Supply
Install the Idler Pulley
Reinstall the Electronics Cover
Configure the Printer
Repacking Instructions
MAINTENANCE PARTS
Outer Casing Components
Media and Ribbon Path
Print Mechanism
Electronics
Drive System
Media Handling Options
Miscellaneous