1 Stripe 400/600 Removing and Installing Printhead Printhead Resistance Calibration Toggle Position Adjustment

2 Removing the Printhead 1.Turn the power switch off. 2.Disconnect the power cord. 3.Disconnect the printer communications cable. 4.Carefully open the right side cover first and then open the front cover. 5.Make sure you are appropriately grounded using proper anti-static procedures. Removin g the Printhea d Printer Communications Cable Anti-Static Device Right Side Cover Left Side Cover Front Cover Power Cord

3 1.Open the Printhead lever and raise. Printhead Assembly. 2.Remove media and ribbon (if applicable). Printhead Lever Media Printhead Assembly

4 Remove strip plate from the front of the Printhead Assembly by unscrewing the two Phillips head screws. Strip Plate

5 Using a 7/32 open-ended wrench, remove the two nuts fastening the Printhead to the Printhead Assembly. Remove the two fastening nuts.

6 1.Carefully lower Printhead bracket away from Printhead Assembly, detaching the guide pins from the alignment slots found in the Printhead Assembly. 2.Slowly pull Printhead forward to expose the Printhead Cable Assembly. Printhead Bracket Printhead Assembly Printhead Cable Assembly

7 1.Carefully disconnect the Printhead Assembly Cable from the Printhead Assembly. 2.Remove the Printhead. Printhead Cable Assembly Printhead Bracket Printhead Assembly

8 Installing the Printhead 1.Turn the power switch off and make sure both the power cord and the printer communications cable are disconnected. 2.Open the side cover first, then the front cover. 3.Open the Printhead lever. 4.Make sure to note the new Printhead resistance before installing. See calibration instructions. Resistance Print Line

9 Position the Printhead under the Printhead Assembly and connect the Printhead Assembly cable into the appropriate connector. Printhead Bracket Guide Pins

10 1.Attach the strip plate to the front of the Printhead Assembly by tightening the two Phillips head screws. 2.Install media and ribbon (if applicable). After confirming the Printhead Cable Assembly is properly positioned into the Printhead connector, attach the two 7/32 hex nuts onto the Printhead bracket guide pins.

11 1.Clean the Printheads print-line using an alcohol swab, removing oil or dirt that may have been deposited during installation. 2.Lower the Printhead Assembly and close Printhead lever, checking the media and ribbon for proper alignment. 3.Carefully close front cover first, then the side cover.

12 Printhead Resistance Calibration Printhead voltage should never be adjusted to affect print darkness. Changing Printhead voltage in this way will drastically reduce the life of the Printhead.

13 Disengage Printers left panel by removing three connecting screws Voltmeter/ Multimeter Three Panel Screws

14 1.Plug in power cord and printer communications cable. 2.With the printer turned off, attach the black probe of the voltmeter to Ground (GND) on the logic board, and the red probe to the top of point F2 (the bottom-left fuse). Red Probe (Positive) Touching F2 Power Switch Black Probe (Negative) Touching Ground (GND)

15 1.Turn the voltmeter/multimeter switch to VDC Without removing the probes, turn the power on and wait for the Power On Self-Test to be completed (usually takes between seconds). 3.Find RV2 at the very bottom of the Main Logic Board and adjust with a small Phillips-head screwdriver until the voltmeter displays the correct value from Table 1 (as defined by the resistance value for this particular Printhead). Ground RV2 F2 Table 1

16 Table 1 After voltage is Properly adjusted, Re-attach left panel with the three connecting screws.

17 Toggle Position Adjustment Toggle position adjustment 1.Before adjusting toggle pressure, perform a Pause Self-Test by holding the pause key while turning on power. If the print is not consistent across the width of the label, proceed to make toggle adjustments. 2.Turn the toggle adjusting nuts until appropriate pressure is achieved. a.Tighten (clockwise) to increase pressure. b.Loosen (counter-clockwise) to decrease pressure. Note that too much pressure applied to the toggles will shorten the life of the Printhead. Choose the lowest even pressure that produces the desired print quality in order to maximize Printhead life.

18 perfect and bad labels Examples of uneven toggle pressure versus even pressure Uneven PressureEven Pressure

19 Platen Roller Replacement Removing Control Panel Cover Main Logic Board Detachment Media Sensor Assembly Removal Tear-Off Plate Removal Platen Roller Removal & Installation

20 Removing Control Panel Cover 1.Turn power off and disconnect power cord and printer communications cable. 2.Remove media and ribbon (if applicable). 3.Remove the right, left, and front cover. 4.Make sure you are appropriately grounded using proper anti-static procedures.

21 1.Disconnect the Control Panel data connector from the Main Logic Board. Control Panel Data Connector

22 1.Detach the Control Panel Cover by removing the attachment screw. 2.Carefully lift the bottom of the control panel cover and pull cover away from the front of the printer. Attachment Screw Control Panel Cover

23 Note where the data connectors are attached to the Main Logic Board. 1. Disconnect all of the data connectors from the Main Logic Board. Removing the main logic board Removing the Main Logic Board

24 1.Remove Ground Strap and the three logic board fastening screws. Ground Strap

25 To detach Main Logic Board from the power supply connector below it, firmly grip board on both sides and pull it upward, carefully rocking it side to side in order to loosen it. Power Supply Connector

26 Media sensor assembly Detach the Upper Media Guide by sliding it away from the right side of the printer. Upper Media Guide

27 1.Unscrew the two attachment screws that hold the Media Sensor in place. 2.Remove the Media Sensor Assembly. Media Sensor Assembly Attachment Screws

28 Tear-Off Plate Removal 1.Remove the two Tear-Off Plate screws. 2.Grasping the bottom of the Tear-Off Plate, disengage it by pushing it up and pulling it away from the front of the printer.

29 Platen Roller Removal Platen Pulley Main Drive Belt Ground Chain Idler Pulley

30 1.Loosen the Idler Pulley bolt. 2.Gently side the Idler Pulley downward, releasing tension from the Main Drive Belt.

31 1.Disengage Main Drive Belt from the three pulleys. 2.Using a hex wrench, loosen the platen pulley hex screw that secures the platen pulley to the platen roller. 3.Remove the platen pulley. 4.Detach the ground chain from the platen roller bar.

32 1.Lift up the left end of the platen roller and carefully slide the platen bearing off of the metal platen roller bar. 2.Disengage the platen roller by lifting up the side with the platen pulley and shifting the right platen bearing to the left, removing it from the bearing opening. 3.Remove the platen roller. Left Platen Bearing and Spacer

33 Platen Roller Installation 1.Slide the platen bearing off the pulley side of the platen roller. 2.Insert the right side of the platen roller into the bearing opening.

34 *Make sure that the bearings are rotated correctly for either the S400 or the S600. For the S400, the bearing hole should be on top. The S600 rotates the bearings 180 degrees (the bearing hole is toward the bottom). * Make sure that the bearings are rotated correctly for either the S400 or the S600. For the S400, the bearing groove should be on the bottom. The S600 rotates the bearings 180 degrees (the bearing groove is toward the top). S600S400 Bearing Groove

35 Once the right side of the platen roller is correctly inserted into the right bearing opening, slide the left bearing onto the Platen roller bar and lower it into the left bearing dropout.

36 1.Attach the Ground Chain. 2.Attach the platen pulley to the Platen roller bar, tightening the platen pulley hex screw until it is snug. Platen Pulley Platen Roller Bar

37 1.Make sure that the Idler Pulley is loose and pulled downward. 2.Set up the Main Drive Belt around the three pulleys. 3.Increase Main Drive Belt tension by sliding the Idler Pulley up until tension is correct.

38 Tighten the hex bolt to secure Idler Pulley against printer. Idler Pulley Platen Pulley Ground Chain

39 Reinstall the Media Sensor Assembly by inserting it through the right side of the printer and securing with the two screws. Slide the media guide into the Media Sensor Assembly slot. Media Sensor Assembly Slot

40 Install the Main Logic Board, making sure all the power supply connector pins line up with the connector pins at the bottom of the board. Push the board down into place (rocking the board from side to side may be necessary). Logic Board Connector

41 Attach all of the data connectors to the Main Logic Board. Secure Logic board into place with the three screws (making sure the top screw also connects the grounding strap underneath). Grounding Strap and Screw

42 1.Attach the tear-off plate to the front of the printer by inserting the metal legs into the tear- off plate notches and push it down into place. Fasten it with two screws. 2.Reattach the control panel and fasten it with the two screws. Attach the Control Panel cable to the Main Logic Board. 3.Install the media and ribbon (if applicable).

43 1.Attach the right, left and front cover. 2.Connect the power cord and the printer communications cable.

44 Zebra is a registered trademark of ZIH Corp. All other trademarks are the property of their respective owners. (*) Contents Subject to Change Without Notice. Doc. No. S Instructions