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Printhead Assembly Maintenance Kit

Installation Instructions

This procedure is for installing the Printhead Assembly. Maintenance Kit into the following printers:

• Z4M™/Z6M™

• Z4Mplus™/Z6Mplus™

• R4Mplus™

• S4M™

Read these instructions thoroughly before performing this procedure.

Prepare for Installation

Parts List

Before proceeding, verify that your kit contains the items for your printer listed below.

Figure 1 • Kit Contents

Table 1 • Kit Parts List

Item Qty Part Number Description1 1 G79056M Z4M, Z4Mplus, and R4M printhead kit 203 dpi1 1 G79057M Z4M and Z4Mplus printhead kit 300 dpi1 1 G41400M S4M printhead kit 203 dpi 1 1 G41401M S4M printhead kit 300 dpi2 1 G79058M Z6M and Z6Mplus printhead kit 203 dpi2 1 G79059M Z6M and Z6Mplus printhead kit 300 dpi

Bold = Part available for purchase.Italic = Part not available for purchase, listed and shown for reference only.

1 2

© 2006 ZIH Corp. All product names and numbers are Zebra trademarks, and Zebra and the Zebra logo are registered

trademarks of ZIH Corp. All rights reserved.

77000L-002 Rev. A8/23/06

Printed on chlorine-free recycled paper.

Printhead AssemblyPrepare for Installation

2

Reference Materials

The following manuals and CDs may be helpful references while performing this procedure.

• S4M User Guide

• S4M User Guide CD

• S4M Maintenance Manual

• S4M Maintenance Manual CD

• Z4M/Z6M User Guide

• Z4M/Z6M Maintenance Manual

• Z4Mplus/Z6Mplus User Guide

• Z4Mplus/Z6Mplus Maintenance Manual

• Z Series User CD

• Z Series Maintenance Manual CD

Tools Required

What type of printer do you have?

Tools • You need these tools to complete this procedure:

Phillips Screwdriver SetAntistatic Wriststrap and Mat

47362* Zebra Preventive Maintenance KitMetric Nutdriver Set

* In place of the Preventive Maintenance Kit, you may use clean swabs and a solution containing isopropyl alcohol (≥ 90%) with deionized water (≤10%).

If you have a… Then…

S4M or Z Series printer Continue with Remove the Z Series and S4M Printhead on page 3.

R4Mplus printer Go to Remove the R4Mplus Electronics Cover on page 6.

77000L-002 Rev. A Z Series® and S4M Installation Instruction 8/23/06

3Printhead AssemblyRemove the Z Series and S4M Printhead

Remove the Z Series and S4M Printhead1.

Connect yourself to an antistatic device.

2. Turn off (O) the printer and disconnect the AC power cord and data cables.

3.

4. See Figure 2. Note the current printhead pressure dial settings, and then rotate the two printhead pressure dials to position #1.

Figure 2 • Printhead Pressure Knobs

Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.

Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead.

Open the media door and remove media and ribbon.

Z4M/Z4Mplus/S4M Z4M/Z6Mplus1 Position #1 1 Position #12 Position #4 2 Position #83 Thumbscrew 3 Thumbscrew4 Printhead pressure dial (2) 4 Printhead pressure dial (2)

Front of Printer

Z4M/Z4Mplus/S4M Z4M/Z6Mplus

1 2 3

4

1 2 3

4

Front of Printer

8/23/06 Z Series® and S4M Installation Instruction 77000L-002 Rev. A

Printhead AssemblyRemove the Z Series and S4M Printhead

4

5. See Figure 3. Remove the printhead thumbscrew.

6.

Unlatch the print mechanism and lift and latch it in the open position.

Figure 3 • Printhead Assembly Mounting and Connections

7. Slide the printhead fork assembly out of the print mechanism.

8. With the cable connectors exposed, carefully disconnect the two printhead cables from the printhead assembly. Remove and discard the old printhead assembly.

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.

1 Thumbscrew2 Printhead pressure dials (2)3 Print mechanism assembly4 Printhead connectors (2)5 Printhead fork assembly6 Locating holes (2)7 Ribbon guide plate

1

2

3

4

56

7



Install the New Z Series and S4M Printhead1.

Connect the printhead cables to the new printhead fork assembly and then carefully slide the assembly into the print mechanism.

2. Ensure the two locating protrusions on the print mechanism mounting plate snap into the locating holes on the printhead fork assembly.

3. Try to move the printhead fork assembly back and forth to make sure that it is engaged; the assembly should not move. If the assembly moves, repeat step 2.

4. Secure the printhead to the mechanism with the previously removed thumbscrew and close the print mechanism.

5. Rotate the two printhead pressure dials to the desired position for your daily printing, as noted in step 4 on page 3.

6.

Clean the printhead and platen roller using Zebra Preventive Maintenance Kit (47362).

7. Reinstall media and ribbon and close the media door.

8. Reconnect the AC power cord and data cables.

9. Turn on (l) the printer.

Caution • An improperly connected 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.

Important • When mounting the printhead fork assembly onto the print mechanism, visually inspect and ensure the following:• the cables are in their channels at the back of their carrier assembly• the power cable is under data cable• they are not binding on the print mechanism

Important • The printhead must be properly engaged with the ribbon guide plate to ensure proper print quality.

Caution • Do not use sharp objects to clean the printhead or platen roller.



6

Remove the R4Mplus Electronics Cover1.

Connect yourself to an antistatic device.

2. Turn off (O) the printer and disconnect the AC power cord and data cables.

3. Open the media door and remove media and ribbon.

4. Refer to Figure 4. Remove the electronics cover mounting screw and lock washer.

Figure 4 • Remove Electronics Cover

Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.

1 Electronics cover2 Upper flange3 Media door4 Lock washer5 Mounting screw6 Lower flange

2 3

4 5

6

1



5. See Figure 5. Remove the electronics cover by pressing in on the electronics cover with the palm of your hand, then lifting up on the cover to remove it.

Figure 5 • Remove and Install the Electronics Cover



8

Remove the R4Mplus Old Printhead1. See Figure 6. Open the media door. Note the current printhead pressure dial settings, and

then rotate the two printhead pressure dials to position #1.

Figure 6 • Top View of Print Mechanism

1 Position #12 Position #43 Thumbscrew4 Printhead Pressure dial

(2)

Front of Printer

1 23

4



2.

See Figure 7. Remove the printhead thumbscrew.

Figure 7 • Remove and Install the Printhead

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.

1 Thumbscrew 6 Printhead lower guide2 Printhead pressure dial (2) 7 Lower guide release tab3 Print mechanism assembly 8 Antenna4 Printhead connectors (2) 9 Locating holes (2)5 Printhead fork assembly 10 Mounting plate

1

2

3

4

5

6

7

8

9

10



10

3.

Unlatch the print mechanism; lift and latch it in the open position.

4. Slide the printhead fork assembly out of the print mechanism.

5. With the cable connectors exposed, carefully disconnect the two printhead cables from the printhead assembly.

6. See Figure 8 on page 11. Disconnect the antenna assembly from the Reader PC board assembly. Feed the antenna wire through the deflector’s cable clamp, and through the hole in the frame. Remove and discard the old printhead.

7. See Figure 7 on page 9. Use a small flat blade screwdriver and gently pry out the release tab and then remove the printhead lower guide.

Caution • Be sure that the printhead is fully open and latched in the open position.



Install the New R4Mplus Printhead1. Remove the new printhead lower guide and snap the printhead lower guide with antenna

to the bottom of the new printhead.

2. See Figure 8. Place the antenna wire through the hole in the frame, through the deflector’s cable clamp, and connect the antenna lead into the reader board assembly.

Figure 8 • Connect the Antenna Lead

Note • Ensure that the antenna lead is plugged into the right side of the reader board. If the antenna lead is plugged into the wrong port, the unit will not work, and the reader board assembly will be damaged.

1 Main frame2 Reader PCB assembly3 Antenna lead4 Deflector5 Base

1

2

3

4

5

Reader Board Connection


Printhead AssemblyReinstall the R4Mplus Electronics Cover

12

3. Connect the printhead cables to the printhead fork assembly, and carefully slide the assembly into the print mechanism.

4. Ensure the two locating protrusions on the print mechanism mounting plate snap into the locating holes on the printhead fork assembly. Move the assembly back and forth to be sure that it is engaged. There should be little movement.

5. Secure the printhead to the mechanism with the previously removed thumbscrew and close the print mechanism.

6. Rotate the two printhead pressure dials to the desired position for your daily printing.

7.

Clean the printhead and platen roller using Zebra Preventive Maintenance Kit (47362).

Reinstall the R4Mplus Electronics Cover1. See Figure 5 on page 7. Reinstall the electronics cover by aligning it and sliding down,

ensuring the lower tabs are inside the base and the upper flange is between the main frame and the media door.

2. Install the four mounting screws on the back of the printer.

3. See Figure 4 on page 6. Reopen the media door and install the mounting screw and washer.

4. Reinstall media and ribbon and close the media door.

5. Reconnect AC power cord and data cables.

6. Turn on (l) the printer.

Important • When mounting the printhead fork assembly onto the print mechanism, visually inspect and ensure the following:• the cables are in their channels at the back of their carrier assembly• the power cable is under data cable• the antenna wire out to the side• they are not binding on the print mechanism

Caution • An improperly connected printhead data or power cable may cause the printhead to generate excessive heat and/or a false HEAD COLD message display while the printhead is hot enough to cause severe burns.

Caution • Do not use sharp objects to clean the printhead or platen roller.


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