Professional Documents
Culture Documents
A
Xi4 and R110Xi4
Performance Printer
Maintenance Manual
2
P1011223-002 Rev. A Xi4 Maintenance Manual 7/15/2010
2010 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described
therein are owned by ZIH Corp. and Zebras licensors. Unauthorized reproduction of this manual or the software
and/or firmware in the printer may result in imprisonment of up to one year and fines of up to $10,000
(17 U.S.C.506). Copyright violators may be subject to civil liability.
This product may contain ZPL
, ZPL II
Circuit; E
3
;
and Monotype Imaging fonts. Software ZIH Corp. All rights reserved worldwide.
ZebraLink, Element Energy Equalizer, E
3
and all product names and numbers are trademarks, and Zebra, the Zebra
head graphic, ZPL and ZPL II are registered trademarks of ZIH Corp. All rights reserved worldwide.
All other brand names, product names, or trademarks belong to their respective holders. For additional trademark
information, please see Trademarks on the product CD.
Proprietary Statement 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 express, written permission of Zebra Technologies Corporation.
Product Improvements Continuous improvement of products is a policy of Zebra Technologies Corporation.
All specifications and designs are subject to change without notice.
Liability Disclaimer Zebra Technologies Corporation takes steps to ensure that its published Engineering
specifications and manuals are correct; however, errors do occur. Zebra Technologies Corporation reserves the right
to correct any such errors and disclaims liability resulting therefrom.
Limitation of Liability In no event shall Zebra Technologies Corporation 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 Corporation 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.
7/15/2010 Xi4 Maintenance Manual P1011223-002 Rev. A
Tabl e of Cont ent s
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Advanced Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
USB 2.0 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Applicator Interface Connector Pin Configuration . . . . . . . . . . . . . . . . . . . . . .67
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Replace the Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Table of Contents
4
P1011223-002 Rev. A Xi4 Maintenance Manual 7/15/2010
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Print Mechanism Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Ribbon Strip Plate and Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Pivot Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Head Open Sensor Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Media Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Media Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Ribbon Low Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Head Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Take-Label Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
Early Xi4 Cutter Design Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Main Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
Rewind Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Rewind Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
110Xi4, 140Xi4, and 170Xi4 DC Stepper Motor w/Pulley. . . . . . . . . . . . . . . .300
220Xi4 DC Stepper Motor w/Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
Current Xi4 Cutter Design Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
110Xi4 Media Hanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355
140Xi4, 170Xi4, and 220Xi4 Media Supply Hanger . . . . . . . . . . . . . . . . . . . .361
Ribbon Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367
Ribbon Supply Spindle Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372
Ribbon Take-Up Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
Ribbon and Media Supply Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
Media Rewind Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
Media Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414
Roller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Dancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424
Rewind Platen Roller Adjustment Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .433
Ribbon Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436
5
Table of Contents
7/15/2010 Xi4 Maintenance Manual P1011223-002 Rev. A
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454
Control Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466
AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485
110Xi4 AC/DC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .495
DC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
Early Xi4 Cutter Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .506
Current Xi4 Cutter Design Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . .517
110Xi4 Power Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .531
140Xi4, 170Xi4, and 220Xi4 Power Entry . . . . . . . . . . . . . . . . . . . . . . . . . . .538
Electronics Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547
Printhead Test Board Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549
Twinax/Coax Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562
Applicator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .566
Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .583
Wireless Plus PCMCIA Option/Maintenance Kit . . . . . . . . . . . . . . . . . . . . . .591
Compact Flash Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
ZebraNet
Wireless
Print Server User Guide.
Note All other supported Wireless cards do not require this adapter.
Caution Observe proper electrostatic safety precautions when handling any
static-sensitive components such as circuit boards and printheads.
Back of
Wireless
CF Card
Back of Adapter
Back of
Printer
597
Corrective Maintenance
ZebraNet