Zebra Xi4 Maintenance Manual

Xi4™
Performance Printer
Maintenance Manual
P1011223-001 Rev. A
2
© 2009 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described
therein are owned by ZIH Corp. and Zebra’s 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®, and ZebraLink™ programs; Element Energy Equalizer™ Circuit; E3™;
and Monotype Imaging fonts. Software © ZIH Corp. All rights reserved worldwide.
ZebraLink, Element Energy Equalizer, E3 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.
FCC Radiation Exposure Statement (for printers with radios or RFID encoders) This equipment
complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be
installed and operated with minimum distance 20cm between the radiator and your body.
This transmitter must not be co-located or operating in conjunction with any other antenna or transmitter.
P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Advanced Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Sensor Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Parallel Cabling Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Parallel Port Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

4 Contents
Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Hardware Control Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
RS-232 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
USB 2.0 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Applicator Interface Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Applicator Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Applicator Interface Connector Pin Configuration . . . . . . . . . . . . . . . . . . .77
Jumper Configurations and Pinouts for +5 V I/O Operation. . . . . . . . . . . .80
Pinouts for +24-28 V I/O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Recycling Printer Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Clean the Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Clean the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Clean the Snap Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Clean the Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Replace the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Remove the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Install the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Adjust the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Printhead Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Adjust the Printhead Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Adjust the Wear Plate Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Adjust the Printhead Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Set the Darkness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Align the Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Contents 5
Print Mechanism Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Remove the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Remove the Printhead Test Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Remove the Old Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Install the New Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Reinstall the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Disconnect All Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Remove the Old Printhead Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Install the New Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Ribbon Strip Plate and Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Remove the Old Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Install the New Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Remove the Old Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Install the New Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Adjust the Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Remove the Old Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Install the New Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Pivot Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Remove the Old Pivot Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Install the New Pivot Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Head Open Sensor Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Remove the Old Sensor Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Install the New Sensor Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172

6 Contents
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Media Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Remove the Mounting and Printhead Stop Spring Stud . . . . . . . . . . . . . .179
Disconnect Media Sensor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Remove the Upper Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Install the New Upper Media Sensor Assembly . . . . . . . . . . . . . . . . . . . .185
Remove the Old Lower Media Sensor Printed Circuit Board (PCB) . . . .187
Install the New Lower Sensor PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Adjust the Upper Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Adjust the Lower Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Media Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Remove the Old Media Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Remove the Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Install the New Media Low Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Calibrate the Media Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Disconnect the Old Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Access the Ribbon Out Sensor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Remove the Old Ribbon Out Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Install the New Ribbon Out Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Reinstall the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Ribbon Low Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Remove the Old Ribbon Low Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Install the New Ribbon Low Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . .217

Contents 7
Head Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Disconnect the Head Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Access the Head Open Sensor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Remove the Old Printhead Open Sensor Assembly . . . . . . . . . . . . . . . .225
Install the New Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . .226
Reinstall the power supplyElectronics Cover . . . . . . . . . . . . . . . . . . . . . .227
Take-Label Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Disconnect the Old Take-Label Sensors . . . . . . . . . . . . . . . . . . . . . . . . .230
Install the New Take-Label Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Cutter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
Remove the DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
Remove the AC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Remove the Old Cutter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Install the New Cutter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
Reinstall the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Remove the Old Upper Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Install the New Upper Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Remove the Old Lower Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . .253
Remove the 140Xi4, 170Xi4, and 220Xi4 DC Power Supply. . . . . . . . . .254
Remove the 110Xi4 AC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . .256
Remove the Rewind Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Install the New Lower Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Reinstall the Rewind Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Adjust the Lower Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266

8 Contents
Main Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
Remove the Old Main Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
Install the New Main Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
Adjust the Main Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Remove the Old Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Install the New Main Drive belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
Rewind Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Remove the Old Rewind Drive System . . . . . . . . . . . . . . . . . . . . . . . . . .291
Install the New Rewind Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Adjust the Rewind Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Rewind Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
Remove the Old Rewind Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
Install the New Rewind Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
Adjust the Rewind Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308

Contents 9
110Xi4, 140Xi4, and 170Xi4 DC Stepper Motor w/Pulley. . . . . . . . . . . . . . . .309

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
Remove the Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318
Remove the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Remove the Rewind Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321
Remove the Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
Remove the Old Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324
Install the New Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
Reinstall the Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
Reinstall the Rewind Platen Roller Pulley . . . . . . . . . . . . . . . . . . . . . . . .325
Reinstall the Platen Roller and Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . .326
Reinstall the Tear Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Reinstall DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Reinstall AC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Adjust the Rewind Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Adjust the Main Drive belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
220Xi4 DC Stepper Motor w/Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332
Remove the Main Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337
Remove the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
Remove the Rewind Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
Remove the Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
Remove the Old Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
Install the New Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
Reinstall the Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
Reinstall the Tear Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
Reinstall the Rewind Platen Roller Pulley . . . . . . . . . . . . . . . . . . . . . . . .344
Adjust the Rewind Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . .345
Reinstall the Platen Roller and Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . .346
Adjust the Main Drive belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
Reinstall DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349

10 Contents
110Xi4 Media Hanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350
Move the Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Remove the Old Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Install the New media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354
Reinstall the Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354
140Xi4, 170Xi4, and 220Xi4 Media Supply Hanger . . . . . . . . . . . . . . . . . . . .356
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
Remove the Main Logic Board (MLB) . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Remove the Old Media Supply Hanger . . . . . . . . . . . . . . . . . . . . . . . . . .361
Install the New Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362
Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
Remove the Ribbon Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
Install the New Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . .366
Ribbon Supply Spindle Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
Remove the Old RSS Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
Install the New Ribbon Supply Spindle Parts . . . . . . . . . . . . . . . . . . . . . .372
Adjust the Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373
Ribbon Take-Up Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375
Remove the Old Ribbon Take-Up Spindle . . . . . . . . . . . . . . . . . . . . . . . .378
Install the Ribbon Take-up Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .380
Install the Spindle/Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380
Remove the End Cap/Release Bar Assembly . . . . . . . . . . . . . . . . . . . . .383
Adjust the Ribbon Take-Up Spindle Assembly Tension . . . . . . . . . . . . . .384

Contents 11
Ribbon and Media Supply Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
Remove the Old RTU Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
Install the New RTU Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
Remove the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
Remove the Old MTU Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398
Install the New MTU Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
Media Rewind Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Remove AC/DC the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
Remove the Old Rewind Spindle Assembly. . . . . . . . . . . . . . . . . . . . . . .408
Install the New Media Rewind Spindle Assembly . . . . . . . . . . . . . . . . . .411
Media Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413
Remove the Old Media Supply Hanger . . . . . . . . . . . . . . . . . . . . . . . . . .417
Remove the Old Media Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . .418
Install the New Media Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . .419
Adjust the Spindle Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420
Roller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Dancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424
Remove the Old Dancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .428
Install the New Dancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431
Rewind Platen Roller Adjustment Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .433
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
Remove the Rewind Platen Roller Adjustment Bracket . . . . . . . . . . . . . .433
Install the Rewind Platen Roller Adjustment Bracket . . . . . . . . . . . . . . . .434
Adjust the Rewind Platen Roller Adjustment Bracket . . . . . . . . . . . . . . .435

12 Contents
Ribbon Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436
Remove the Top Ribbon Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . .438
Install the New Top Ribbon Roller Assembly . . . . . . . . . . . . . . . . . . . . . .439
Remove the Lower Ribbon Roller Assembly . . . . . . . . . . . . . . . . . . . . . .440
Install the New Lower Ribbon Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .444
Remove the Ribbon Dancer Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . .446
Install the Ribbon Dancer Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448
Remove the Print Mechanism Roller Assembly . . . . . . . . . . . . . . . . . . . .449
Install the New Print Mechanism Roller . . . . . . . . . . . . . . . . . . . . . . . . . .450
Adjust the Print Mechanism Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454
Remove the Old Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456
Install the New Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461
Control Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
Remove the Old Control Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . .464
Install the New Control Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .465
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466
Remove the Applicator Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468
Remove the Twinax/Coax Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470
Remove the Internal Printer Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Remove the External Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472
Remove the Wireless Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473
Remove the MLB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474
Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479
Remove the Internal Ethernet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .480
Install the New Main Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480
Reinstall Removed Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481
Calibrate the Media Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482

Contents 13
AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485
Remove the AC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486
Install the New AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491
Install the New AC Power Supply Shield . . . . . . . . . . . . . . . . . . . . . . . . .492
Reinstall the MLB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .493
110Xi4 AC/DC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .495
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495
Remove the AC/DC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . .497
Install the AC/DC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . .501
DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
Remove the Old DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504
Install the New DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505
Cutter Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .506
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .506
Remove the Old Cutter Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . .514
Install the New Cutter Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .515
110Xi4 Power Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516
Remove the Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518
Remove and Install the On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .521
Install the New Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .521
Reinstall the AC/DC Power Supply Shield . . . . . . . . . . . . . . . . . . . . . . . .522

14 Contents
140Xi4, 170Xi4, and 220Xi4 Power Entry . . . . . . . . . . . . . . . . . . . . . . . . . . .523

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523
Remove the Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .524
Remove and Install the On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .529
Install the New Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .529
Reinstall the AC Power Supply Shield . . . . . . . . . . . . . . . . . . . . . . . . . . .530
Reinstall the MLB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .531
Electronics Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532
Remove and Install the Electronics Cables . . . . . . . . . . . . . . . . . . . . . . .533
Printhead Test Board Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
Install the Printhead Test Board Spacers . . . . . . . . . . . . . . . . . . . . . . . . .536
Remove the Old Printhead Test Board. . . . . . . . . . . . . . . . . . . . . . . . . . .538
Install the Printhead Test Board Shield . . . . . . . . . . . . . . . . . . . . . . . . . .540
Install the Printhead Test Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541
Connect the Printhead Test Board Cables . . . . . . . . . . . . . . . . . . . . . . . .542
Reconnect the Printhead Test Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .545
Set Head Test Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
Twinax/Coax Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547
Remove the Defective Twinax/Coax Board . . . . . . . . . . . . . . . . . . . . . . .549
Install the Twinax/Coax Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549
Applicator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .551
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .551
Remove the Old Applicator Interface Board. . . . . . . . . . . . . . . . . . . . . . .554
Install the Applicator Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .558
Applicator Port Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .560
Input/Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567

Contents 15
Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .568

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .568
Remove the Wired Ethernet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .570
Install the Wired Ethernet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .571
Wireless Plus PCMCIA Option/Maintenance Kit . . . . . . . . . . . . . . . . . . . . . .576
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576
Remove the Existing PCMCIA Option Board Assembly . . . . . . . . . . . . .578
Install the Wireless PCMCIA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .579
Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .582
Compact Flash Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .583
Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .583
ZebraNet® Internal Wireless Plus Print Server . . . . . . . . . . . . . . . . . . . . . . .584
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584
Remove the Existing Print Server Board . . . . . . . . . . . . . . . . . . . . . . . . .586
Install the New Internal Wireless Plus . . . . . . . . . . . . . . . . . . . . . . . . . . .587
Install the Cover and External Antenna . . . . . . . . . . . . . . . . . . . . . . . . . .588
Resume Printer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .590
After You Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .590
Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592
SEH PS102-Z IPv6 Internal Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
Remove Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
Remove the Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .594
Remove the Existing Communication Hardware . . . . . . . . . . . . . . . . . . .596
Install the SEH PS102-Z Internal Print Server . . . . . . . . . . . . . . . . . . . . .597
After You Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
Outer Casting Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600
Remove the Old Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600
Install the New Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
Remove the Old Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
Install the New Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605

16 Contents
Media Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .606

Remove the Old Media Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . .606
Install the New Media Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . .608
Media Door Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .609
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .609
Remove the Old Media Door Damper Assembly . . . . . . . . . . . . . . . . . . .610
Install the New Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .612
TrimPanel and Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614
Remove the Old Lower Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614
Install the New Lower Trim Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .617
Remove the Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618
Tear Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619
Remove the Old Tear Front Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619
Install the New Tear Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619
Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620
Remove the Old Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .622
Install the New Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627
Adjust the Rewind Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631
Access Hole Covers and Media Low Bracket . . . . . . . . . . . . . . . . . . . . . . . .639
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .639
Install Cutter Module Hole Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . .639
Install the Take-Label Sensor Expansion Covers. . . . . . . . . . . . . . . . . . .640
Install the Lower Platen Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641
Install the Compliance Roller Hole Plug. . . . . . . . . . . . . . . . . . . . . . . . . .641
Install the Rewind Spindle Hole Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .642
Install the 220Xi4 Rewind Spindle Hole Cover Plate . . . . . . . . . . . . . . . .643
Install the Cutter Motor Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .643
Install the Media Low Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .649
Slot and Wireless Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652
Install the Slot Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .653
Install the RFID Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .654
Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .654

Contents 17
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .656
Install the Cutter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .664
Install the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .666
Install the Cutter Circuit Board and Optical Sensor . . . . . . . . . . . . . . . . .670
Install the Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .676
Align Lower Drive Arm Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . .677
Configure the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .679
Align the Upper Drive Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680
Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .682
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .682
Remove the Old Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .684
Install the New Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .686
Align the Upper Drive Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .689
Cutter Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690
Remove the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .692
Install the Cutter Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695
Reinstall the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .697
Reinstall the Upper Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .699
Cutter Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
Install the Cutter Linkage Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . .708
Cutter Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717
Remove the Old Cutter Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . .717
Install the New Cutter Static Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .719

18 Contents
Cutter Catch Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721
Install the Catch Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
Adjust the Catch Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724
Install the Anti-Curl Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .725
Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .726
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .726
Install the Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .734
Repacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .751
Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753

Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755
Media and Ribbon Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763
Print Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781
Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797
Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811

List of Figures
Advanced Printer Information .............................................................. 39

Troubleshooting .......................................................................................... 41
Figure 1 • Ribbon-Out Threshold Too High .....................................................54
Figure 2 • Sample Configuration Label ...........................................................58
Figure 3 • PAUSE Test Label ..........................................................................59
Figure 4 • FEED Test Label ............................................................................60
Figure 5 • Bar Code Darkness Comparison ....................................................61
Figure 6 • Communications Diagnostics Test Label ........................................64
Figure 7 • Sensor Profile (Ribbon Section) .....................................................65
Figure 8 • Sensor Profile (Media Section) .......................................................65
Data Ports ..................................................................................................... 67
Figure 9 • RS-232 DB9 MLB Connections ......................................................72
Figure 10 • DB-9 to DB-25 Cable Connections ...............................................73
Figure 11 • RS-232 Cable Connections ..........................................................73
Figure 12 • USB Connectors ...........................................................................74
Figure 13 • Applicator Signals (Mode 1) ..........................................................75
Preventive Maintenance ....................................................................... 83
Figure 17 • Sensor Locations ..........................................................................89
Figure 18 • Upper Media Sensor .....................................................................90
Figure 19 • Lower Media Sensor .....................................................................90
Figure 20 • Media Out Sensor .........................................................................91
Figure 21 • Snap Plate Location ......................................................................92
Figure 22 • AC Power Entry Module ...............................................................94
Figure 23 • Fuse Locations .............................................................................95

20 List of Figures
Corrective Maintenance ........................................................................ 97

Print System ................................................................................................. 99
Figure 24 • Open the Media Door .................................................................101
Figure 25 • Turn the Lever to Open the Printhead ........................................102
Figure 26 • Replace Printhead ......................................................................103
Figure 27 • Adjust Toggle ..............................................................................105
Figure 28 • Printhead Parallelism Adjustment ...............................................107
Figure 29 • Adjust the Printhead Pressure ....................................................110
Figure 33 • Disconnect the Printhead Ground ...............................................116
Figure 34 • Remove the Printhead Cable Cover ...........................................117
Figure 35 • Remove the Ribbon Sensor ........................................................117
Figure 36 • Remove the Electronics Cover ...................................................118
Figure 37 • Remove the Printhead Test Board Shield ..................................119
Figure 38 • Remove the Printhead Test Board .............................................120
Figure 39 • Remove the Printhead Lift Spring and E-ring .............................121
Figure 40 • Remove the Wear Plate ..............................................................122
Figure 41 • Remove the Print Mechanism .....................................................123
Figure 42 • Install the C-ring and Printhead Lift Spring .................................124
Figure 43 • Move the Printhead Cables ........................................................126
Figure 44 • Set the Initial Toggle ...................................................................128
Figure 45 • Adjust the Wear Plate .................................................................129
Figure 46 • Adjust the Printhead ...................................................................131
Figure 47 • Adjust the Ribbon Strip Plate ......................................................133
Figure 51 • Remove the Printhead Ground ...................................................138
Figure 53 • Disconnect the Printhead Data Cable .........................................140
Figure 54 • Disconnect AC/DC Power Input Cable .......................................141
Figure 55 • Remove the AC/DC Power Supply Shield ..................................141
Figure 56 • Remove the Printhead Power Cable 110Xi4 ..............................142
Figure 57 • Disconnect the Printhead Power Cable
140Xi4, 170Xi4, and 220Xi4 ..........................................................................142
Figure 60 • Remove the Printhead Cables 110Xi4 w/o printhead test board 146
Figure 61 • Remove the Printhead Cables 110Xi4 w/printhead test board ...147
Figure 62 • Remove the Printhead Cables 140Xi4 and 170Xi4 ....................148

List of Figures 21
Figure 63 • Remove the Printhead Cables 220Xi4 ........................................149

Figure 64 • Move the Printhead Cables ........................................................153
Figure 65 • Remove the Static Brush ............................................................156
Figure 66 • Remove the Old Ribbon Strip Plate ............................................157
Figure 67 • Remove the Head Open Handle .................................................160
Figure 68 • Remove the Toggle Assembly ....................................................161
Figure 69 • Slide the Toggles Off the Pivot Bar .............................................162
Figure 72 • Replace Head Handle .................................................................167
Figure 75 • Remove and Install the Sensor Flag ...........................................172
Sensors ...................................................................................................... 175
Figure 79 • Remove the Mounting and Spring Tensioner Stud .....................180
Figure 80 • Disconnect the Upper and Lower Media Sensor Connectors .....181
Figure 81 • Access the Media Sensor Cables ...............................................182
Figure 82 • Remove the Upper Media Sensor Assembly ..............................183
Figure 83 • Remove the Upper Media Sensor Assembly ..............................184
Figure 84 • Install the Upper Media Sensor Assembly ..................................185
Figure 85 • Install the Two Thumbscrews .....................................................186
Figure 86 • Remove the Lower Media Sensor PCB ......................................187
Figure 87 • Install the Printhead Test Board Shield ......................................188
Figure 88 • Upper Media Sensor Location ....................................................190
Figure 89 • Lower Media Sensor Location ....................................................191
Figure 91 • Disconnect the Media Low Sensor .............................................194
Figure 92 • Remove the Media Low Sensor (110Xi4, 140Xi4, and 170Xi4) ..195
Figure 93 • Remove the Media Low Sensor (220Xi4) ...................................195
Figure 94 • Remove the Media Cover Damper .............................................196
Figure 95 • Route the Media Low Sensor Cable ...........................................198
Figure 96 • Media Low Calibration Tool ........................................................199
Figure 97 • Full Roll .......................................................................................200
Figure 98 • Roll Empty ..................................................................................201
Figure 100 • Disconnect the Ribbon Sensor .................................................204
Figure 101 • Remove the Printhead Test Board Shield ................................205
Figure 102 • Remove the Printhead Test Board ...........................................206
Figure 103 • Access the Ribbon Out Sensor Cable ......................................207

22 List of Figures
Figure 104 • Turn the Lever to Open the Printhead ......................................208

Figure 105 • Remove the Printhead ..............................................................209
Figure 106 • Remove the Ribbon Out Sensor ...............................................210
Figure 107 • Install the Printhead Test Board Shield ....................................212
Figure 108 • Remove the Electronics Cover .................................................215
Figure 109 • Disconnect the Ribbon Low Sensors ........................................216
Figure 110 • Remove the Ribbon Low Sensors ............................................217
Figure 112 • Disconnect the Head Open Sensor ..........................................221
Figure 115 • Access the Head Open Sensor Cable ......................................224
Figure 116 • Remove the Head Open Sensor Assembly ..............................225
Figure 119 • Disconnect the Take-Label Sensors .........................................230
Figure 120 • Remove the Take-Label Sensor Mounting Screws ..................231
Figure 121 • Remove the Take-Label Sensors .............................................231
Figure 122 • Install the Take-Label Sensors .................................................232
Figure 125 • Remove all Cables ....................................................................236
Figure 126 • Remove the DC Power Supply .................................................237
Figure 127 • Disconnect the AC Power Input Cable .....................................238
Figure 128 • Remove the AC/DC Power Supply Shield ................................239
Figure 129 • Remove All Cables ...................................................................240
Figure 130 • Remove the AC/DC Power Supply ...........................................241
Figure 132 • Remove the Old Cutter Sensor .................................................242
Figure 133 • Disconnect the Cutter Sensor ...................................................243
Figure 134 • Routing Cable ...........................................................................243
Drive System .............................................................................................. 245
Figure 137 • Main Drive Belt .........................................................................249
Figure 138 • Remove the Tear Bar and Platen Roller ...................................250
Figure 139 • Install the Drive Belt ..................................................................252
Figure 140 • Rewind Plate Removal and Installation ....................................253

List of Figures 23

Figure 148 • Locate the Print Mechanism Lower Access Hole .....................260
Figure 149 • Rewind Belt ...............................................................................261
Figure 150 • Lower Platen Roller Removal and Installation ..........................262
Figure 151 • Adjust the Rewind Drive Belt Tension ......................................264
Figure 153 • Loosen the Idler Pulley .............................................................269
Figure 154 • Remove the Drive Belt ..............................................................269
Figure 155 • Remove the Old Ribbon Take-up Pulley ..................................270
Figure 156 • Choose the Proper Ribbon Take-up Pulley ..............................271
Figure 157 • Choose the Proper Platen Pulley ..............................................272
Figure 158 • Install the New Idler Pulley .......................................................273
Figure 159 • Adjust the Main Drive Belt Tension (220Xi4) ............................275
Figure 160 • Adjust the Main Drive Belt Tension
(110Xi4, 140Xi4, and 170Xi4) .......................................................................276
Figure 162 • Remove the Main Drive Belt, 110Xi4 ........................................279
Figure 163 • Remove the Main Drive Belt, 140Xi4 ........................................280
Figure 164 • Adjust the Main Drive Belt Tension (220Xi4 shown) .................281
Figure 174 • Remove the Idler Pulley ............................................................291
Figure 175 • Remove the Drive Belts ............................................................292
Figure 176 • Remove the Rewind Drive Pulleys ...........................................293
Figure 177 • Choose the Proper Ribbon Take-up Pulley ..............................294
Figure 178 • Choose the Proper Rewind Platen Pulley .................................295
Figure 179 • Adjust the Belt Tension .............................................................296

24 List of Figures

Figure 188 • Remove the Idler Pulley ............................................................306
Figure 189 • Remove the Drive Belts ............................................................307
Figure 190 • Adjust the Belt Tension .............................................................308
Figure 192 • Disconnect the DC Power Supply (early 105SL shown) ...........312
Figure 199 • Remove the Main Drive Belt and Platen Pulley ........................318
Figure 200 • Remove the Rewind Drive Belt and Pulley ...............................319
Figure 201 • Remove the Platen Roller (XiIIIPlus shown) .............................320
Figure 202 • Remove the Rewind Platen Roller (105SL shown) ...................321
Figure 203 • Remove the Side Plate (105SL shown) ....................................323
Figure 204 • Remove the DC Stepper Motor (105SL shown) .......................324
Figure 205 • Remove the Lower Access Hole Cover ....................................328
Figure 209 • Interconnections .......................................................................335
Figure 210 • DC Power Supply Removal and Installation .............................336
Figure 211 • Remove the Main Drive Belt .....................................................337
Figure 212 • Rewind Drive Belt Removal and Installation .............................338
Figure 213 • Remove the Upper Platen Roller ..............................................339
Figure 214 • Print Mechanism View with Lower Platen Roller ......................340
Figure 215 • Side Plate Removal and Installation .........................................341
Figure 216 • Remove and Install DC Stepper Motor .....................................342
Figure 217 • Remove the Lower Access Hole Cover ....................................345
Figure 221 • Remove the Rear Panel ...........................................................352
Figure 222 • Gain Access to the Mounting Hooks .........................................353
Figure 223 • Bend the Media Hanger Hooks .................................................353
Figure 224 • Remove and Install the Media Hanger .....................................354
Figure 227 • Remove the Radio Card ...........................................................359

List of Figures 25
Figure 228 • Remove the Rear Pane ............................................................360

Figure 229 • Access the Mounting Screw .....................................................361
Figure 230 • Remove the Media Supply Hanger ...........................................361
Figure 232 • Disconnect the Ribbon Low Sensors ........................................365
Figure 233 • Remove the Ribbon Supply Spindle .........................................366
Figure 234 • Install the Ribbon Supply Spindle .............................................366
Figure 235 • Remove the Old Ribbon Supply Spindle Parts 110Xi4 .............369
Figure 239 • Adjust the Ribbon Supply Spindle Tension ...............................373
Figure 243 • Remove the Ribbon Take-up Spindle .......................................379
Figure 244 • Adjust the Main Drive Belt Tension (220Xi4 shown) .................381
Figure 246 • Remove the End Cap/Release Bars .........................................383
Figure 247 • Adjust the RTU Spindle Tension ...............................................384
Figure 250 • Remove the RTU Pulley ...........................................................389
Figure 251 • Remove and Install the DC Power Supply ................................391
Figure 259 • Remove the MTU Pulley ...........................................................398
Figure 269 • Remove the Rewind Spindle Assembly ....................................409

26 List of Figures
Figure 270 • Remove the Old Bearing Housing

(all models except 220Xi4) ............................................................................410
Figure 271 • Remove the Old Bearing Housing (220Xi4) ..............................410
Figure 274 • Remove the Rear Pane ............................................................415
Figure 275 • Gain Access to the Mounting Hooks (110Xi4 only) ..................416
Figure 276 • Gain Access to the Mounting Screw
(all models except 110Xi4) ............................................................................416
Figure 277 • Bend the Media Supply Hanger Hooks .....................................417
Figure 278 • Remove Media Supply Hanger .................................................417
Figure 279 • Remove the Media Supply Hanger (all models except 110Xi4) 418
Figure 280 • Remove the Old Media Spindle ................................................418
Figure 281 • Install the Media Spindle ...........................................................419
Figure 282 • Adjust the Spindle Tension .......................................................420
Roller System ............................................................................................. 423
Figure 286 • Remove the Mounting Screw (110XiIIIPlus shown) ..................428
Figure 287 • Remove the Mounting Screw and Lock Washer .......................429
Figure 288 • Remove the Dancer Assembly .................................................430
Figure 289 • Prepare the Dancer Assembly ..................................................431
Figure 290 • Remove and Install the Rewind Platen Roller
Adjustment Bracket .......................................................................................434
Figure 291 • Adjust the Rewind Platen Roller Adjustment Bracket ...............435
Figure 293 • Remove the Top Ribbon Roller Assembly ................................438
Figure 294 • Assemble the Top Roller, Shaft, and Bearings Assembly ........439
Figure 297 • Remove the Head Lift Spring Stop ...........................................441
Figure 298 • Disconnect the Upper Reflective Media Sensor .......................442
Figure 299 • Remove the Brass Screws .......................................................442
Figure 300 • Remove the Upper Media Sensor Assembly ............................443
Figure 301 • Assemble and Disassemble the Lower Ribbon Roller ..............444
Figure 302 • Remove the Old Ribbon Dancer Rollers ...................................446
Figure 303 • Remove the Large Ribbon Dancer Roller .................................447
Figure 304 • Install the Small Ribbon Dancer Roller .....................................448
Figure 305 • Remove the Inside Mounting Screw .........................................449
Figure 306 • Remove the Outside Mounting Screw ......................................449
Figure 307 • Remove the Print Mechanism Roller ........................................450

List of Figures 27
Printed Circuit Boards .............................................................................. 453

Figure 309 • Disconnect the Control Panel (110Xi4) .....................................456
Figure 310 • Disconnect the Control Panel (140Xi4, 170Xi4, and 220Xi4) ...457
Figure 312 • Remove the Standoff ................................................................458
Figure 313 • Open the Ferrite Block ..............................................................459
Figure 314 • Remove the Control Panel Cable .............................................459
Figure 315 • Remove the Control Panel ........................................................460
Figure 316 • Remove the Ferrite Block .........................................................460
Figure 317 • Install the Cable Tie on the Ferrite Block ..................................461
Figure 318 • Open the Ferrite Block ..............................................................461
Figure 319 • Align the Control Panel .............................................................462
Figure 320 • Remove and Install the Control Panel Cover ............................464
Figure 322 • Disconnect the Applicator Board Cables ..................................468
Figure 323 • Remove the Applicator Interface Board ....................................469
Figure 324 • Remove the Twinax/Coax Board and Cable .............................470
Figure 325 • Remove the Internal Print Server .............................................471
Figure 326 • Remove the External Antenna ..................................................472
Figure 327 • Remove the Wireless Radio Card ............................................473
Figure 328 • Disconnect all Cables ...............................................................474
Figure 329 • Remove the 110Xi4 MLB ..........................................................475
Figure 330 • Remove the 110Xi4 MLB with Wireless Board .........................476
Figure 331 • Remove the 140Xi4, 170Xi4, and 220Xi4 MLB ........................477
Figure 332 • Remove the 140Xi4, 170Xi4, and 220Xi4 MLB
and Wireless Assembly .................................................................................478
Figure 333 • Remove the Wireless Board .....................................................479
Figure 334 • Remove the Ethernet Board .....................................................480
Figure 335 • Media Low Calibration Tool ......................................................482
Figure 336 • Full Roll .....................................................................................483
Figure 337 • Roll Empty ................................................................................484
Figure 339 • Disconnect Main Logic Board Cables .......................................487
Figure 340 • Remove the Main Logic Board .................................................488
Figure 341 • Remove the AC Power Supply Shield ......................................489
Figure 342 • Disconnect all Cables ...............................................................489
Figure 343 • Remove the AC Power Supply .................................................490
Figure 344 • Slide the AC Power Supply Out ................................................491
Figure 345 • Form the New AC Power Supply Shield ...................................492
Figure 346 • Install the AC Power Supply Shield ..........................................493

28 List of Figures

Figure 364 • Disconnect all Cables from the Cutter Control Board ...............514
Figure 365 • Remove the Old Cutter Control Board ......................................514
Figure 369 • Remove the AC Ground ...........................................................520
Figure 370 • Disconnect the AC Cables ........................................................520
Figure 371 • Remove the Power Entry Module and AC Power Switch .........521
Figure 373 • Disconnect Main Logic Board Cables .......................................525
Figure 374 • Remove the Main Logic Board .................................................526
Figure 375 • Remove the AC Power Supply Shield ......................................527
Figure 376 • Remove the AC Ground ...........................................................527
Figure 377 • Disconnect the AC Cables ........................................................528
Figure 378 • Remove the Power Entry Module and AC Power Switch .........529
Figure 379 • Install the AC Power Supply Shield ..........................................530
Figure 382 • Remove the Three Mounting Nuts ............................................536
Figure 383 • Install the Three Spacers ..........................................................537
Figure 386 • Form the Printhead Test Board Shield .....................................540
Figure 388 • Remove the AC/DC Power Input Connector ............................542

List of Figures 29
Figure 390 • Connect the Printhead Test Board Cables ...............................543

Figure 391 • Insert Data Cable ......................................................................544
Figure 392 • Reconnect the Printhead Test Board ........................................545
Figure 394 • Remove the Rear Panel Blank Cover .......................................548
Figure 395 • Remove the Twinax/Coax Board and Cable .............................549
Figure 397 • Remove the No Option Board Slot Cover .................................553
Figure 398 • Remove the AC Power Input Cable (110Xi4) ...........................554
Figure 400 • Remove the Applicator Cables (110Xi4) ...................................555
Figure 401 • Disconnect the Data Cable .......................................................556
Figure 402 • Remove the Applicator Cables (140Xi4, 170Xi4, and 220Xi4) .556
Figure 403 • Remove and Install the 5V Applicator Board ............................557
Figure 404 • Remove and Install the 24-28V Applicator Board .....................558
Figure 405 • Connect the Applicator Data and Power Cables ......................559
Figure 406 • 5V Applicator Board Pinouts .....................................................560
Figure 407 • Isolated and Non-isolated Applicator Operation .......................563
Figure 408 • 24-28V Applicator Board Pinouts ..............................................564
Figure 409 • Typical Input Circuit ..................................................................567
Figure 410 • Typical Output Circuit ...............................................................567
Figure 412 • Remove the Wired Ethernet Board ...........................................570
Figure 413 • Remove the Blank Cover and Screw ........................................571
Figure 414 • Clean the J4 Pads ....................................................................572
Figure 415 • Install the Mounting Standoffs ..................................................573
Figure 416 • Install the Wired Ethernet Board ...............................................574
Figure 418 • RF Card ....................................................................................578
Figure 419 • Install New Spacers ..................................................................580
Figure 420 • Install the New Wireless PCMCIA Board ..................................581
Figure 421 • Wireless Compact Flash Card and Adapter Placement ...........583
Figure 423 • RF Card and Cover ...................................................................586
Figure 424 • Install New Spacers ..................................................................588
Figure 425 • Closeup of Antenna Installation ................................................589
Figure 426 • Sample Label ............................................................................590
Figure 427 • Label Location ..........................................................................591
Figure 429 • Cover Plate ...............................................................................595
Figure 430 • Remove/Install the SEH PS102-Z Internal Print Server ...........596
Figure 431 • SEH PS102-Z Internal Print Server ..........................................597

30 List of Figures
Outer Casting Components ...................................................................... 599

Figure 433 • Remove and Install the Media Door (except 220Xi4) ...............603
Figure 434 • Remove and Install the Media Door (220Xi4) ...........................604
Figure 435 • Install the Nameplate (110Xi4 shown) ......................................605
Figure 436 • Remove the Old Media Door Window ......................................606
Figure 437 • Remove the Old Window ..........................................................607
Figure 438 • Lift the Window Out ..................................................................607
Figure 439 • Install the New Window ............................................................608
Figure 440 • Removing the Media Cover Damper ........................................610
Figure 441 • Remove the Damper Mounting Bracket ....................................611
Figure 442 • Route the Media Low Sensor Cable .........................................612
Figure 443 • Remove the Front Plate ............................................................614
Figure 444 • Loosen the Mounting Screws ...................................................615
Figure 445 • Remove the Lower Trim Panel .................................................616
Figure 446 • Install the New Lower Trim Panel .............................................617
Figure 447 • Remove and Install the Nameplate ...........................................618
Figure 448 • Remove and Install the Tear Printer Front Plate ......................619
Figure 450 • Remove the Toggle Bar Lever ..................................................622
Figure 451 • Remove the Rewind Platen Roller Support Bracket .................623
Figure 452 • Remove the Hex Key Mounting Screws ...................................624
Figure 453 • Remove the Cutter Option Mounting Screws ...........................624
Figure 454 • Remove the Hex Head Mounting Screws
(140Xi4 and 220Xi4) .....................................................................................625
Figure 455 • Remove the Hex Head Mounting Screws
(110Xi4 and 170Xi4) .....................................................................................625
Figure 456 • Remove the Side Plate .............................................................626
Figure 457 • Remove the Wear Plate and Access Hole Cover(s) .................626
Figure 458 • Align the Side Plate ..................................................................627
Figure 459 • Install the Hex Head Screws .....................................................628
Figure 460 • Reinstall the Wear Plate ...........................................................630
Figure 461 • Adjust the Rewind Platen Roller Support Bracket ....................631
Figure 462 • Adjust the Toggles ....................................................................632
Figure 463 • Printhead Parallelism Adjustment .............................................634
Figure 464 • Adjust the Printhead Pressure ..................................................636
Figure 465 • Install the Cutter Module Hole Cover Plate ...............................639
Figure 466 • Install the Take-Label Covers ...................................................640
Figure 467 • Install the Lower Platen Plug ....................................................641
Figure 468 • Install the Compliance Roller Hole Plug ...................................641
Figure 469 • Install the Rewind Spindle Hole Plug ........................................642
Figure 470 • Align the Rewind Spindle Hole Cover Plate ..............................643

List of Figures 31

Figure 473 • Disconnect the AC Connector to the Power Supply .................646
Figure 476 • Install the Cutter Motor Hole Cover Plate .................................648
Figure 477 • Remove the Media Low Sensor
(110Xi4, 140Xi4, and 170Xi4) .......................................................................649
Figure 478 • Remove the Media Low Sensor (220Xi4) .................................650
Figure 479 • Route the Media Low Sensor Cable .........................................651
Figure 480 • Install the Slot Covers ...............................................................653
Figure 481 • Install Wireless Covers .............................................................654
Options ....................................................................................................... 655
Figure 490 • Remove the Access Hole Cover Plate ......................................664
Figure 491 • Install the Cutter Motor .............................................................665
Figure 492 • Remove the Cutter Module Access Cover Plate ......................666
Figure 493 • Prepare the Cutter Module .......................................................667
Figure 494 • Install the Cutter Module ...........................................................668
Figure 495 • Cutter Mechanical Assembly Positioning ..................................669
Figure 496 • Install the Cutter Circuit Board ..................................................670
Figure 497 • Cutter Option Circuit Board Connectors ...................................671
Figure 498 • Install the Ferrite on the Data Cable (110Xi4) ..........................672
Figure 499 • Install the Ferrite on the Data Cable
(140Xi4, 170Xi4, and 220Xi4) .......................................................................673
Figure 500 • Cutter Motor Leads ...................................................................674
Figure 501 • Install the Cutter Sensor ...........................................................675
Figure 502 • Install the Cutter Drive Link .......................................................676
Figure 503 • Connect the Drive Link to the Cutter System ............................677
Figure 504 • Connect to the Main Logic Board (MLB) ...................................678
Figure 506 • Loosen the Upper Cutter Arm ...................................................684
Figure 507 • Remove the Cutter Module .......................................................685
Figure 508 • Remove the Cutter Module Mounting Brackets ........................686

32 List of Figures

Figure 512 • Remove the Cutter Linkage ......................................................692
Figure 513 • Remove the Cutter Module .......................................................692
Figure 514 • Remove the Lower Cutter Bracket ............................................693
Figure 515 • Remove the Cutter Support Bracket and Static Brush .............694
Figure 516 • Remove the Upper Cutter Bracket and Guide ..........................695
Figure 517 • Install the Cutter Static Brush ...................................................696
Figure 528 • Remove the Pivot Post Mounting Screw ..................................708
Figure 529 • Remove the Upper Linkage ......................................................708
Figure 530 • Remove the Lower Linkage ......................................................709
Figure 531 • Remove the Drive Linkage .......................................................710
Figure 532 • Remove the Upper Drive Arm ...................................................711
Figure 533 • Assembly Drawing ....................................................................712
Figure 534 • Cutter Mechanical Position .......................................................713
Figure 535 • Cutter Option Circuit Board Connectors ...................................714
Figure 536 • Position the Cutter Blade ..........................................................715
Figure 537 • Remove the Mounting Screws ..................................................718
Figure 538 • Remove the Cutter Static Brush ...............................................719
Figure 539 • Install the New Cutter Static Brush ...........................................719
Figure 540 • Install the Cutter Plate Assembly ..............................................722
Figure 541 • Install the Cutter Tray ...............................................................723
Figure 542 • Install the Cutter Catch Tray Assembly ....................................724
Figure 543 • Anti-Curl Shaft Assembly ..........................................................725
Figure 552 • Remove the Plastic Plug ...........................................................734

List of Figures 33
Figure 553 • Install the Idler Pulley Shaft ......................................................734

Figure 554 • Remove the Front and Cover Plates ........................................735
Figure 555 • Install the Rewind Bearing Housing ..........................................736
Figure 556 • Install the Rewind Spindle ........................................................737
Figure 557 • Install the Rewind Platen Roller Support Bracket .....................738
Figure 558 • Install the Rewind Platen Roller, Media Side ............................739
Figure 559 • Install the Rewind Platen Pulley ...............................................740
Figure 560 • Platen Pulley and Set Screws ...................................................740
Figure 562 • Install the Rewind Drive Belt .....................................................742
Figure 563 • Ribbon Take-Up Pulley .............................................................743
Figure 564 • Adjust the Rewind Drive Belt ....................................................744
Figure 565 • Install the Take-Label Sensors .................................................745
Figure 566 • Connect the Take Label Sensor Cables ...................................746
Figure 567 • Adjust Rewind Spindle Position ................................................747
Figure 568 • Adjust the Spindle Tension .......................................................748
Figure 569 • Adjust Platen Support Bracket ..................................................749
Maintenance Parts ............................................................................... 753
Outer Casing Components ....................................................................... 755
Figure A • Outer Casing Components Overview ...........................................756
Figure B • Media door ...................................................................................758
Figure C • Electronics Cover, Trim, and Name Plates ..................................760
Media and Ribbon Path ............................................................................. 763
Figure D • Media and Ribbon Path Overview ................................................764
Figure E • Hangers and Spindles ..................................................................766
Figure F • Media Supply Spindle Options .....................................................768
Figure G • Dancer, Media Guide, and Ribbon Rollers ..................................770
Print Mechanism ........................................................................................ 773
Figure H • Print Mechanism Overview ..........................................................774
Figure I • Print Mechanism and Printhead Cables ........................................776
Figure J • Pivot Bar, Platen, and Peel/Tear Bar ............................................778
Electronics ................................................................................................. 781
Figure K • 110Xi4 Specific Electronics Overview ..........................................782
Figure L • 110Xi4 Specific Electronics ..........................................................784
Figure M • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics Overview ........786
Figure N • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics ........................787
Figure O • Xi4 Series Common Electronics Overview ..................................788
Figure P • Main Logic Board .........................................................................789
Figure Q • Optional Electronics .....................................................................790
Figure R • Sensors Overview ........................................................................792
Figure S • Sensors ........................................................................................794

34 List of Figures
Drive System .............................................................................................. 797

Figure T • Drive Systems Overview ..............................................................798
Figure U • Drive Systems ..............................................................................800
Media Handling Options ........................................................................... 801
Figure V • Media Handling Options Overview ...............................................802
Figure W • Cutter Option ...............................................................................804
Figure X • Cutter Static Brush and Brackets .................................................806
Figure Y • Media Rewind Option ...................................................................808
Miscellaneous ............................................................................................ 811
Figure Z • Sensor Brackets and Hole Covers ...............................................812
Figure AA • Slot Covers ................................................................................814

List of Tables
Advanced Printer Information.............................................................. 39

Troubleshooting ......................................................................................... 41
Table 1 • LCD Error Messages ........................................................................43
Table 2 • Print Quality Problems ......................................................................48
Table 3 • Calibration Problems.........................................................................52
Table 4 • Communications Problems ...............................................................53
Table 5 • Ribbon Problems ..............................................................................54
Table 6 • Miscellaneous Printer Problems .......................................................55
Table 7 • Judging Bar Code Quality .................................................................62
Data Ports ................................................................................................... 67
Table 8 • Parallel Cable Pin Configuration .......................................................68
Table 9 • Serial Connector Pin Configuration...................................................71
Table 10 • Applicator Interface Connector Pin Configuration ...........................77
Table 11 • Non-Isolated and Isolated Modes for +5V Operation......................80
Table 12 • Non-Isolated and Isolated Modes for +24–28V Operation..............81
Preventive Maintenance ....................................................................... 83
Table 13 • Recommended Printer Cleaning Schedule .....................................85
Corrective Maintenance........................................................................ 97
Drive System............................................................................................. 245
Table 14 • DC Power Supply Connections.....................................................335
Table 15 • Ribbon Supply Spindle Tensions ..................................................373
Table 16 • Spindle Force Values for Full Width Media ...................................385

36 List of Tables
Printed Circuit Boards ............................................................................. 453

Table 17 • 5V Applicator Interface Connector Pin Configuration ...................560
Table 18 • 24-28V Applicator Interface Connector Pin Configuration ............564
Table 19 • Input User Specifications ..............................................................567
Table 20 • Output User Specifications ...........................................................567
Maintenance Parts............................................................................... 753
Outer Casing Components ...................................................................... 755
Table A • Outer Casing Components Overview .............................................757
Table B • Media Door .....................................................................................759
Table C • Electronics Cover, Trim, and Name Plates ....................................761
Media and Ribbon Path............................................................................ 763
Table D • Media and Ribbon Path Overview ..................................................765
Table E • Hangers and Spindles ....................................................................767
Table F • Media Supply Spindle Options........................................................769
Table G • Dancer, Media Guide, and Ribbon Rollers.....................................771
Print Mechanism....................................................................................... 773
Table H • Print Mechanism Overview.............................................................775
Table I • Print Mechanism ..............................................................................777
Table J • Pivot Bar, Platen, and Peel/Tear Bar ..............................................779
Electronics ................................................................................................ 781
Table K • 110Xi4 Specific Electronics Overview ............................................782
Table L • AC/DC Power Supply and Power Entry, 110Xi4 .............................785
Table M • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics Overview ..........786
Table N • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics...........................787
Table O • Common Electronics Overview ......................................................788
Table P • Main Logic Board............................................................................789
Table Q • Optional Electronics .......................................................................791
Table R • Sensors Overview ..........................................................................793
Table S • Sensors ..........................................................................................795
Drive System............................................................................................. 797
Table T • Drive Systems Overview.................................................................799
Table U • Drive Systems ................................................................................800
Media Handling Options .......................................................................... 801
Table V • Media Handling Options Overview .................................................803
Table W • Cutter Option .................................................................................805
Table X • Cutter Static Brush and Brackets ...................................................807
Table Y • Media Rewind Option .....................................................................809
Miscellaneous........................................................................................... 811
Table Z • Sensor Brackets and Hole Covers..................................................813
Table AA • Slot Covers...................................................................................814

1
Advanced Printer
Information
This section contains advanced information designed for technicians or others who need to
service or troubleshoot an Xi4 printer.
For basic printer information, refer to the User Guide. A copy of the guide in English is
available on the Maintenance Manual CD. To check for an updated version of the guide or to
find the guide in other languages, go to http://www.zebra.com/manuals.
Contents
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

38 Advanced Printer Information
Contents
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Troubleshooting
This section provides information about errors that you might need to troubleshoot. Assorted
diagnostic tests are included.
Contents
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Troubleshooting Checklists
Troubleshooting Checklists
If an error condition exists with the printer, review this checklist:
Is there an error message on the LCD? If yes, see LCD Error Messages on page 41.
Did you receive a memory error? If yes, see Memory Errors on page 15.
Are noncontinuous labels being treated as continuous labels? If yes, perform a media and
ribbon sensor calibration. For instructions, refer to the User Guide.
Is the CHECK RIBBON light on when ribbon is loaded properly? If yes, perform a media
and ribbon sensor calibration. For instructions, refer to the User Guide.
Are you experiencing problems with print quality? If yes, see Print Quality Problems
on page 46.
Are you experiencing communications problems? If yes, see Communications Problems
on page 51.
Are you experiencing other unexpected behavior? If yes, see Firmware Issues on page 25.

Advanced Printer Information 41
LCD Error Messages
LCD Error Messages

The LCD displays messages when there is an error. See Table 1 for LCD errors, the possible
causes, and the recommended solutions. For instructions on modifying printer parameters or
calibrating the printer, refer to the User Guide.
Table 1 • LCD Error Messages
LCD Display/
Possible Cause Recommended Solution
Printer Condition
The printhead was replaced with Install a genuine Zebra™ printhead.
one that is not a genuine Zebra™
printhead.
The ERROR light flashes.

In thermal transfer mode, ribbon is Load ribbon correctly.
not loaded or incorrectly loaded.
In thermal transfer mode, the 1. Load ribbon correctly.
ribbon sensor is not detecting 2. Calibrate the sensors.
ribbon.
In thermal transfer mode, media is 1. Load media correctly.
The printer stops; the blocking the ribbon sensor. 2. Calibrate the sensors.
RIBBON light is on; the
ERROR light flashes. In thermal transfer mode, the 1. Print a sensor profile. The ribbon
printer did not detect the ribbon out threshold (1) is likely too high,
even though it is loaded correctly. above the black area that indicates
where the ribbon is detected (2).
1
2
2. Calibrate the sensors or load

printer defaults.
Ribbon is loaded, but the printer is Ribbon is not required with direct
set for direct thermal mode. thermal media. If you are using direct
thermal media, remove the ribbon. This
error message will not affect printing.
If you are using thermal transfer media,
which requires ribbon, set the printer
The RIBBON light is on; the for Thermal Transfer mode.
ERROR light flashes.

LCD Error Messages
Table 1 • LCD Error Messages (Continued)
LCD Display/
Printer Condition
The media is not loaded or is Load media correctly.
loaded incorrectly.
Misaligned media sensor. Check position of the media sensor.
The printer is set for Install proper media type, or reset
noncontinuous media, but printer for current media type and
continuous media is loaded. perform calibration.
The printer stops; the
MEDIA light is on; the
The printhead is not fully closed. Close printhead completely.
The head open sensor is not Replace the sensor.
working properly.

The printhead has a faulty Replace the printhead. See Printhead
thermistor. Assembly on page 98.
The ERROR light flashes.

LCD Error Messages
LCD Display/
Printer Condition
Caution • An improperly connected printhead data or power cable

can cause these error messages. The printhead may be hot
enough to cause severe burns. Allow the printhead to cool.
The printhead data cable is not

Caution • Turn off (O) the printer
properly connected. before performing this procedure.
Failure to do so can damage the
printhead.
1. Turn off (O) the printer.
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 printer.


ERROR light is on; the
printer cycles through these
three messages.

LCD Error Messages
LCD Display/
Printer Condition
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.
The printhead temperature is Continue printing while the printhead

approaching its lower operating reaches the correct operating
limit. temperature. If the error remains, the
The printer prints while the environment may be too cold for
ERROR light flashes. proper printing. Relocate the printer to
a warmer area.
The printhead data cable is not
Caution • Turn off (O) the printer
properly connected. before performing this procedure.
Failure to do so can damage the
printhead.
2. Disconnect and reconnect the data
cable to the printhead.
3. Ensure that the cable connector is
fully inserted into the printhead
connector.

Caution • The printhead may be hot enough to cause severe

burns. Allow the printhead to cool.
The printhead is over temperature. Allow the printer to cool. Printing

automatically resumes when the
printhead elements cool to an
The printer stops; the acceptable operating temperature.

LCD Error Messages
LCD Display/
Printer Condition
The printer is defragmenting
Caution • Do NOT turn off the printer
memory. power during defragmenting. Doing so
can damage the printer.
Allow the printer to finish

defragmenting. If you get this error
message frequently, check your label
The printer stops.
formats. Formats that write to and erase
memory frequently may cause the
printer to defragment often. Using
properly coded label formats usually
minimizes the need for defragmenting.
If this error message does not go away,
contact Technical Support. The printer
requires service.
Caution • The cutter blade is sharp. Do not touch or rub the blade
with your fingers.
The cutter blade is in the media Turn off the printer power and unplug
path. the printer. Inspect the cutter module
for debris and clean as needed
The printer stops; the following the cleaning instructions in
ERROR light flashes. Clean the Cutter on page 91.

Print Quality Problems

Table 2 identifies problems with print quality, the possible causes, and the recommended
solutions. For instructions on modifying printer parameters, calibrating the printer, or loading
ribbon and media, refer to the User Guide.
Table 2 • Print Quality Problems
Problem Possible Cause Recommended Solution

General print quality The printer is set at the For optimal print quality, set the print speed to
issues incorrect print speed. the lowest possible setting for your application
via control panel, the driver, or the software. You
may want to perform the FEED Self Test
on page 58.
You are using an incorrect 1. Switch to a different type of media or ribbon
combination of labels and to try to find a compatible combination.
ribbon for your application. 2. If necessary, consult your authorized Zebra
reseller or distributor for information and
advice.
The printer is set at an incorrect For optimal print quality, set the darkness to the
darkness level. lowest possible setting for your application via
the control panel, the driver, or the software. You
may want to perform the FEED Self Test
on page 58 to determine the ideal darkness
setting.
The printhead is dirty. Clean the printhead. See Clean the Printhead
and Platen Roller on page 84.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality. See Adjust the
Printhead on page 102.
The printhead is improperly See Adjust the Printhead on page 102.
balanced.
Long tracks of Print element damaged. Replace the printhead. See Printhead Assembly
missing print on on page 98.
several labels
Wrinkled ribbon. See wrinkled ribbon causes and solutions in this
table.

Table 2 • Print Quality Problems (Continued)

Wrinkled ribbon Ribbon was fed through the Load the ribbon correctly.
ribbon system incorrectly.
Incorrect burn temperature. Set the darkness to the lowest possible setting for
good print quality. See.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality.See Adjust the
Printhead on page 102.
Media not feeding properly; Make sure that media is snug by adjusting the
“walking” from side to side. media guide, or call a service technician.
The strip plate needs adjusting. See Adjust the Printhead on page 102.
The printhead needs vertical See Adjust the Printhead on page 102.
adjustment.
The printhead is improperly See Adjust the Printhead on page 102.
balanced.
The printhead and platen roller See Adjust the Printhead on page 102 and Adjust
need to be realigned. the Lower Platen Roller on page 264.
Printing too light or The media or ribbon is not Replace supplies with those recommended for
too dark over the designed for high-speed high-speed operation.
entire label operation.
You are using an incorrect 1. Switch to a different type of media or ribbon
combination of media and to try to find a compatible combination.
ribbon for your application. 2. If necessary, consult your authorized Zebra
reseller or distributor for information and
advice.
You are using ribbon with Direct thermal media does not require ribbon. To
direct thermal media. check if you are using direct thermal media,
perform the label scratch test in When to Use
Ribbon on page 34.
Incorrect or uneven printhead Set the pressure to the minimum needed. See
pressure. Adjust the Printhead on page 102.
Smudge marks on The media or ribbon is not Replace supplies with those recommended for
labels designed for high-speed high-speed operation.
operation.
Misregistration/skips The printer is not calibrated. Recalibrate the printer.
labels The media sensor is not Place the media sensor in the proper position.
positioned correctly. See Adjust Transmissive Media Sensors
on page 67.
Improper label format. Use correct label format.


Misregistration and The platen roller is dirty. See Clean the Printhead and Platen Roller
misprint of one to on page 84.
three labels The media sensor is not Place the media sensor in the proper position.
positioned correctly. See Adjust Transmissive Media Sensors
on page 67.
Media does not meet Use media that meets specifications.
specifications.
Vertical drift in The printer is out of calibration. Recalibrate the printer.
top-of-form position Normal tolerances of 1. Calibrate the printer.
mechanical parts and printer 2. Adjust the label top position setting.
modes.
Note • A vertical drift of
± 4 to 6 dot rows
(approximately 0.5 mm)
is within normal
tolerances.
Vertical drift occurs during Calibrate the printer.
normal printer operation.
Note • A vertical drift of
± 4 to 6 dot rows
(approximately 0.5 mm)
is within normal
tolerances.
The platen roller is dirty. Clean the platen roller. See Clean the Printhead


Vertical image or The printer is using Configure the printer for non-continuous and run
label drift non-continuous labels but is calibration routine, if necessary.
configured in continuous mode.
The media sensor is positioned Ensure that the media sensor is properly
incorrectly. positioned to read a single/consistent interlabel
gap. See Adjust Transmissive Media Sensors
on page 67.
The media sensor is calibrated Refer to the User Guide for the procedure.
improperly.
The platen roller is dirty. Clean the platen roller. See Clean the Printhead
Improper printhead pressure Adjust the printhead pressure to ensure proper
settings (toggles). functionality.
Improperly loaded ribbon or Verify that the printer is loaded properly.
media.
Incompatible media. Ensure that the interlabel gaps or notches are 2 to
4 mm and consistently placed. Media must not
exceed minimum specifications for mode of
operation.
The bar code printed The bar code is not within Perform the FEED Self Test on page 58. Adjust
on a label does not specifications because the print the darkness or print speed settings as necessary.
scan. is too light or too dark.
Not enough blank space around Leave at least 1/8 in. (3.2 mm) between the bar
the bar code. code and other printed areas on the label and
between the bar code and the edge of the label.

Calibration Problems
Calibration Problems
Table 3 identifies problems with calibration, the possible causes, and the recommended
solutions. For instructions on modifying printer parameters or calibrating the printer, refer to
the User Guide.
Table 3 • Calibration Problems

Loss of printing The platen roller is dirty. Clean the platen roller according to the
registration on labels. instructions in Clean the Printhead and Platen
Excessive vertical Roller on page 84.
drift in top-of-form Media guides are positioned Ensure that the media guides are properly
registration. improperly. positioned.
The media type is set Set the printer for the correct media type
incorrectly. (non-continuous or continuous).
An incorrect sensor is being Manually select the correct sensor to use.
used for the media type.
Auto Calibrate failed. Media or ribbon is loaded Ensure that media and ribbon are loaded
incorrectly. correctly.
The sensors could not detect the Manually calibrate the printer.
media or ribbon.
The sensors are dirty or Ensure that the sensors are clean and properly
positioned improperly. positioned.

Communications Problems
Communications Problems
Table 4 identifies problems with communications, the possible causes, and the recommended
solutions. For instructions on modifying printer parameters or calibrating the printer, refer to
the User Guide.
Table 4 • Communications Problems

A label format was sent to The communication Check the printer driver or software
the printer but was not parameters are incorrect. communications settings (if applicable).
recognized. The DATA If you are using serial communication, check
light does not flash. the serial port setting in the control panel
menu.
If you are using serial communication, make
sure that you are using a null modem cable or a
null modem adapter.
Using the control panel menu, check the
protocol setting. It should be set to NONE.
If a driver is used, check the driver
communication settings for your connection.
A label format was sent to The serial communication Ensure that the flow control settings match.
the printer. Several labels settings are incorrect. Check the communication cable length. See
print, then the printer Table 5 on page 27 for requirements.
skips, misplaces, misses, or
distorts the image on the Check the printer driver or software
label. communications settings (if applicable).
A label format was sent to The prefix and delimiter Verify the prefix and delimiter characters..
the printer but was not characters set in the printer
recognized. The DATA do not match the ones in the
light flashes but no label format.
printing occurs. Incorrect data is being sent Check the communication settings on the
to the printer. computer. Ensure that they match the printer
settings.
Ensure that ZPL II is being used.
If the problem continues, check the ZPL II

format for changes to ^CC, ^CT, and ^CD.

Ribbon Problems
Ribbon Problems
Table 5 identifies problems that may occur with ribbon, the possible causes, and the
recommended solutions. For instructions on modifying printer parameters or calibrating the
printer, refer to the User Guide.
Table 5 • Ribbon Problems

Broken or melted Darkness setting too high. 1. Reduce the darkness setting.
ribbon 2. Clean the printhead thoroughly.
The printer does not The ribbon-out threshold is set 1. Print a sensor profile.
detect when the too high to detect the ribbon. 2. Calibrate the printer, this time using ribbon,
ribbon runs out. On a sensor profile, the or load printer defaults.
In thermal transfer ribbon-out threshold (circled in
Important • Loading defaults resets
mode, the printer did Figure 1) appears above the
all printer parameters back to factory
not detect the ribbon black bars that indicate the
defaults.
even though it is ribbon. This happens if you
calibrate the printer without 3. Print another sensor profile, and compare it
loaded correctly. to the first one.
ribbon and later insert ribbon
without recalibrating the printer 4. If the ribbon-out threshold is still too high,
or loading printer defaults. you may manually change the value.
Figure 1 • Ribbon-Out
Threshold Too High
The ribbon light is on The printer was not calibrated Calibrate the sensors.
even though ribbon is for the label and ribbon being
loaded correctly. used.

Miscellaneous Printer Problems

Table 6 identifies miscellaneous problems with the printer, the possible causes, and the
recommended solutions. For instructions on modifying printer parameters or calibrating the
printer, refer to the User Guide.
Table 6 • Miscellaneous Printer Problems

The LCD displays a The language parameter was 1. Press SETUP/EXIT to enter configuration
language that I changed through the control mode.
cannot read panel or a firmware command. 2. Press MINUS (-).
The printer displays the LANGUAGE
parameter in the current language. Even if
you cannot recognize the characters
displayed, you can still scroll to another
language.
3. Press PLUS (+) or MINUS (-) to scroll
through the choices until you find a language
that you can read.
4. Press SETUP/EXIT.
The LCD displays SAVE CHANGES in the
original language.
5. Press NEXT/SAVE to exit configuration
mode and save the changes (if the language
does not change, you may need to scroll to a
different save option by pressing PLUS (+)
or MINUS (-) in the previous step).
6. Repeat this process, if necessary, until you
reach the desired language.
The LCD is missing The LCD may need replacing. Run the Power-On Self Test on page 55 and
characters or parts of check that the LCD display shows all characters.
characters If not, replace the control panel. See Control
Panel on page 452.
Changes in Parameters are set incorrectly. 1. Set parameters and save permanently.
parameter settings 2. Turn the printer off (O) and then on (I).
did not take effect
A firmware command turned Refer to the Programming Guide for the printer
off the ability to change the language being used.
parameter.
A firmware command changed Refer to the Programming Guide for the printer
the parameter back to the language being used.
previous setting.
If the problem continues, there Replace the main logic board. See Main Logic
may be a problem with the Board on page 464.
main logic board.

Table 6 • Miscellaneous Printer Problems (Continued)

The printer fails to The printer was not calibrated Calibrate the printer.
calibrate or detect the for the label being used.
top of the label. The printer is configured for Set the media type to noncontinuous media.
continuous media.
The driver or software Driver or software settings produce commands
configuration is not set that can overwrite the printer configuration.
correctly. Check the driver or software media-related
setting.
Non-continuous The printer was not calibrated Calibrate the printer.
labels are being for the media being used.
treated as continuous The printer is configured for Set the media type to noncontinuous media.
labels. continuous media.
All lights are on, but Internal electronic or firmware Turn the printer power off (O) and then on (I). If
nothing displays on failure. the printer locks up again, replace the main logic
the LCD, and the board.
printer locks up. Turn the printer power off (O) and then on (I). If
the printer locks up again, replace the main logic
board. Replace the main logic board. See Main
Logic Board on page 464.
The printer locks up Main logic board failure. Replace the main logic board. See Main Logic
while running the Board on page 464.
Power-On Self Test.

Printer Diagnostics
Printer Diagnostics
Self tests and other diagnostics provide specific information about the condition of the printer.
The self tests produce sample printouts and provide specific information that helps determine
the operating conditions for the printer. The most commonly used are the Power-On and the
CANCEL self tests.
Important • Use full-width media when performing self tests. If your media is not wide
enough, the test labels may print on the platen roller. To prevent this from happening, check
the print width, and ensure that the width is correct for the media that you are using.
Each self test is enabled by pressing a specific control panel key or combination of keys while
turning on (I) the printer power. 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.
Note •
• When performing these self tests, do not send data to the printer 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 printer by turning
it off (O) and then on (l).
• If printer 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.
Power-On Self Test

A Power-On Self Test (POST) is performed each time the printer is turned on (l). During this
test, the control 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, complete these steps:

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.

Printer Diagnostics
CANCEL Self Test

The CANCEL self test prints a configuration label (Figure 2).
To perform the CANCEL Self Test, complete these steps:
2. Press and hold CANCEL while turning on (I) the printer. Hold CANCEL until the first
control panel light turns off.
A printer configuration label prints (Figure 2).
Figure 2 • Sample Configuration Label

Printer Diagnostics
PAUSE Self Test

This self test can be used to provide the test labels required when making adjustments to the
printer’s mechanical assemblies or to determine if any printhead elements are not working.
Figure 3 shows a sample printout.
To perform a PAUSE self test, complete these steps:
2. Press and hold PAUSE while turning on (I) the printer. Hold PAUSE until the first control
panel light turns off.
• The initial self test prints 15 labels at the printer’s slowest speed, and then
automatically pauses the printer. Each time PAUSE is pressed, an additional 15 labels
print. Figure 3 shows a sample of the labels.
Figure 3 • PAUSE Test Label
• While the printer is paused, pressing CANCEL alters the self test. Each time PAUSE is
pressed, 15 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a second time.
Each time PAUSE is pressed, 50 labels print at the printer’s slowest speed
• While the printer is paused, pressing CANCEL again alters the self test a third time.
Each time PAUSE is pressed, 50 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a fourth time.
Each time PAUSE is pressed, 15 labels print at the printer’s maximum speed.
• To exit this self test at any time, press and hold CANCEL.

Printer Diagnostics
FEED Self Test

Different types of media may require different darkness settings. This section contains a
simple but effective method for determining the ideal darkness for printing bar codes that are
within specifications.
During the FEED self test, labels are printed at different darkness settings at two different print
speeds. The relative darkness and the print speed are printed on each label. The bar codes on
these labels may be ANSI-graded to check print quality.
The darkness value starts at three settings lower than the printer’s current darkness value
(relative darkness of –3) and increase until the darkness is three settings higher than the current
darkness value (relative darkness of +3).
Depending on the dot density of the printhead, seven labels are printed at each of the following
speeds:
• 203 dpi printers: 2 ips, 6 ips, and 10 ips
• 300 dpi printers: 2 ips, 6 ips, 8 ips
• 600 dpi printers: 2 ips, 4 ips
To perform a FEED self test, complete these steps:
1. Print a configuration label to show the printer’s current settings.
3. Press and hold FEED while turning on (I) the printer. Hold FEED until the first control
panel light turns off.
The printer prints a series of labels (Figure 4) at various speeds and at darkness settings
higher and lower than the darkness value shown on the configuration label.
Figure 4 • FEED Test Label

Printer Diagnostics
4. See Figure 5 and Table 7. Inspect the test labels and determine which one has the best
print quality for your application. If you have a bar code verifier, use it to measure bars/
spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes
or the system scanner to choose the optimal darkness setting based on the labels printed in
this self test.
Figure 5 • Bar Code Darkness Comparison

Printer Diagnostics
Table 7 • Judging Bar Code Quality
Print Quality Description

Too dark Labels that are too dark are fairly obvious. They may be
readable but not “in-spec.”
• The normal bar code bars increase in size.
• The openings in small alphanumeric characters may fill in
with ink.
• Rotated bar code bars and spaces run together.
Slightly dark Slightly dark labels are not as obvious.
• The normal bar code will be “in-spec.”
• Small character alpha numerics will be bold and could be
slightly filled in.
• The rotated bar code spaces are small when compared to
the “in-spec” code, possibly making the code unreadable.
“In-spec” The “in-spec” bar code can only be confirmed by a verifier,
but it should exhibit some visible characteristics.
• The normal bar code will have complete, even bars and
clear, distinct spaces.
• The rotated bar code will have complete, even bars and
clear, distinct spaces. Although it may not look as good as
a slightly dark bar code, the bar code will be “in-spec.”
• In both normal and rotated styles, small alphanumeric
characters look complete.
Slightly light Slightly light labels are, in some cases, preferred to slightly
dark ones for “in-spec” bar codes.
• Both normal and rotated bar codes will be in spec, but
small alphanumeric characters may not be complete.
Too light Labels that are too light are obvious.
• Both normal and rotated bar codes have incomplete bars
and spaces.
• Small alphanumeric characters are unreadable.
5. Note the relative darkness value and the print speed printed on the best test label.
6. Add or subtract the relative darkness value from the darkness value specified on the
configuration label. The resulting numeric value is the best darkness value for that specific
label/ribbon combination and print speed.
7. If necessary, change the darkness value to the darkness value on the best test label.
8. If necessary, change the print speed to the same speed as on the best test label.

Printer Diagnostics
FEED and PAUSE Self Test

Performing this self test temporarily resets the printer 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.
To perform a FEED and PAUSE self test, complete these steps:
2. Press and hold FEED and PAUSE while turning on (I) the printer.
3. Hold FEED and PAUSE until the first control panel light turns off.
The printer configuration is temporarily reset to the factory default values. No labels print
at the end of this test.

Printer Diagnostics
Communications Diagnostics Test

The communication diagnostics test is a troubleshooting tool for checking the interconnection
between the printer and the host computer.
When the printer is in diagnostics mode, it prints all data received from the host computer as
straight ASCII characters with the hex values below the ASCII text. The printer prints all
characters received, including control codes such as CR (carriage return). Figure 6 shows a
typical test label from this test.
Note • The test label prints upside-down.
Figure 6 • Communications Diagnostics Test Label
To use communications diagnostics mode, complete these steps:
1. Set the printer to DIAGNOSTICS. For instructions, refer to the User Guide.
The printer enters diagnostics mode and prints any data received from the host computer
on a test label
2. Check the test label for error codes. For any errors, check that your communication
parameters are correct.
Errors show on the test label as follows:
• FE indicates a framing error.
• OE indicates an overrun error.
• PE indicates a parity error.
• NE indicates noise.
3. Turn the printer off (O) and then back on (I) to exit this self test and return to normal
operation.

Printer Diagnostics
Sensor Profile
Use the sensor profile label to troubleshoot the following types of problems:
• If the media sensor experiences difficulty in determining gaps (web) between labels.
• If the media sensor incorrectly identifies preprinted areas on a label as gaps (web).
• If the ribbon sensor cannot detect ribbon.
Print a sensor profile and compare your results to the examples shown in this section. If the
sensitivity of the sensors must be adjusted, calibrate the printer. For instructions on printing a
sensor profile or for calibrating the printer, refer to the User Guide.
Ribbon Sensor Profile (Figure 7) The bars (1) on the sensor profile indicate the ribbon
sensor readings. The ribbon sensor threshold setting is indicated by the word RIBBON (2). If
the ribbon readings are below the threshold value, the printer does not acknowledge that
ribbon is loaded.
Figure 7 • Sensor Profile (Ribbon Section)
Media Sensor Profile (Figure 8) The media sensor readings are shown as bars and flat
areas on the sensor profile. The bars (1) indicate gaps between labels (the web), and the low
areas (2) indicate where labels are located. If you compare the sensor profile printout to a
blank length of your media, the bars should be the same distance apart as the gaps on the
media. If the distances are not the same, the printer may be having difficulty determining
where the gaps are located.
The media sensor threshold settings are shown by the words MEDIA (3) for the media
threshold and WEB (4) for the web threshold. Use the numbers to the left of the sensor
readings to compare the numeric readings to the sensor settings.
Figure 8 • Sensor Profile (Media Section)
1 2
3 4

Printer Diagnostics
Notes • ___________________________________________________________________
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Data Ports
This section describes the standard communication ports available to connect the printer to
your computer or network.
Contents
Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parallel Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parallel Port Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hardware Control Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
RS-232 Interface Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
USB 2.0 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Applicator Interface Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Applicator Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Applicator Interface Connector Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Jumper Configurations and Pinouts for +5 V I/O Operation. . . . . . . . . . . . . . . . . . . . . 78
Pinouts for +24-28 V I/O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Parallel Data Port
Parallel Data Port

The parallel data interface supports IEEE 1284 bidirectional parallel communications in nibble
mode. The parallel interface provides a means of communication that typically is faster than
the serial interface methods. In this method, the bits of data that make up a character are sent
all at one time over several wires in the cable, one bit per wire.
When communicating via the parallel port, the values selected on the printer must be the same
as those used by the host equipment connected to the printer. 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.
Parallel Cabling Requirements

A standard 36-pin parallel connector is available on the back of the printer for connection to
the data source. An IEEE-1284 compatible bidirectional parallel data cable is required when
this communication method is used. The required cable must have a standard 36-pin parallel
connector on one end that is plugged into the mating connector located at the rear of the
printer. The other end of the cable connects to the printer connector at the host computer. Port
selection for status information is determined each time the printer is turned on.
Parallel Port Interconnections

Table 8 shows the pin configuration and function of a standard computer-to-printer parallel
cable.
Table 8 • Parallel Cable Pin Configuration
36-Pin Connectors Description

1 nStrobe/HostClk
2–9 Data Bits 1–8
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.
To enable this capability, a qualified service technician
must install a jumper on the printer’s main logic board on
JP1, pins 2 and 3.
19–30 Ground

Parallel Data Port
Table 8 • Parallel Cable Pin Configuration (Continued)
36-Pin Connectors Description

31 nInit
32 nFault/NDataAvail
33, 34 Not used
35 +5 V through a 1.8 KΩ Resistor
36 NSelectin/1284 active

Serial Data Port
Serial Data Port

To communicate using the serial data port of the printer, you must choose the number of data
bits, parity, and handshaking. Parity applies only to data transmitted by the printer 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
printer. Default printer settings are 9600 baud, 8 data bits, no parity, and XON/XOFF. The
printer will accept any host setting for stop bits.
Hardware Control Signal Descriptions

For all RS-232 input and output signals, the printer follows both the Electronics Industries
Association (EIA) RS-232 and the Consultative Committee for International Telegraph and
Telephone (CCITT) V.24 standard signal level specifications.
When DTR/DSR handshaking is selected, the Data Terminal Ready (DTR) control signal
output from the printer controls when the host computer may send data. DTR ACTIVE
(positive voltage) permits the host to send data. When the printer places DTR in the
INACTIVE (negative voltage) state, the host must not send data.
Note • When XON/XOFF handshaking is selected, data flow is controlled by the ASCII
Control Codes DC1 (XON) and DC3 (XOFF). The DTR Control lead has no effect.
Request To Send (RTS) is a control signal from the printer that is connected to the Clear To
Send (CTS) input at the host computer.

Serial Data Port
Pin Configuration
Connect the serial data cable to the female DB-9 connector on the back of the printer. For all
RS-232 connections through a DB-25 cable, use a DB-9 to DB-25 interface module (see DB-9
to DB-25 Connections on page 71).
Table 9 shows the pin configuration of the serial data connector.
Table 9 • Serial Connector Pin Configuration
Pin No. Name Description

1 – Unused and unterminated
2 RXD Receive data—data input to printer
3 TXD Transmit data—data output from printer
4 DTR Data terminal ready—output from printer
5 SG Signal ground
6 DSR Data set ready—input to printer
7 RTS Request to send—output from printer
8 CTS Clear to send—input to printer
9 +5 VDC +5 VDC at 750 mA
The maximum current draw may be limited by option
configuration.
Important • To enable this capability, a qualified
service technician must install a jumper on the printer’s
main logic board on JP1, pins 2 and 3.

Serial Data Port
RS-232 Interface Connections

The printer is configured as Data Terminal Equipment (DTE). Figure 9 shows the internal
connections of the printer’s RS-232 connector.
Note • Use a null modem (crossover) cable to connect the printer to a computer or any other
DTE device.
Figure 9 • RS-232 DB9 MLB Connections
1 +5VDC signal source
2 RXD (receive data) input
3 TXD (transmit data) output
4 DTR (data terminal ready) output
5 SG (signal ground)
6 DSR (data set ready) input
7 RTS (request to send) output
8 CTS (clear to send) input

+5VDC
R1
9 +5VDC signal source
1K
Pin 9 is also available as a +5 VDC signal source at 750 mA. The maximum current draw may
be limited by option configuration.
Important • To enable this capability, a qualified service technician must install a jumper on
the printer’s main logic board on JP1, pins 2 and 3.

Serial Data Port
DB-9 to DB-25 Connections
To connect the printer’s RS-232 DB-9 interface to a DB-25 connector, an interface adapter is
required. A generic DB-25 adapter can be used, although the +5 VDC signal source would not
be passed through the adapter. Figure 10 shows the connections required for the DB-9 to
DB-25 interface.
Figure 10 • DB-9 to DB-25 Cable Connections
2 RXD FG 1
3 TXD TXD 2
4 DTR RXD 3
SG RTS 4
5
DSR CTS 5
6
DSR 6
7 RTS
SG 7
8 CTS +5 VDC
9
+5 VDC SIGNAL
9 DTR
SIGNAL 20
Modem Connection
When the printer 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. Figure 11
shows the connections required for this cable.
Figure 11 • RS-232 Cable Connections

DTE DCE
(Printer) (Modem, etc.)
RXD (receive data)
2 2
TXD (transmit data)
3 3
DTR (data terminal ready)
4 4
SG (signal ground)
5 5
DSR (data set ready)
6 6
RTS (request to send)
7 7
CTS (clear to send)
8 8
+5 VDC signal source
9 9
NOTE: Pin 1 is unused and unterminated at the printer.

USB 2.0 Port
USB 2.0 Port

A USB 2.0 port (which is USB 1.1 and 1.0 compatible) is available to connect your printer to
the host equipment. The industry-standard USB cable has an A-male connector on one end and
a B-male connector on the other end as shown in Figure 12.
Figure 12 • USB Connectors

Printer Computer
=
2
5 4
1 “B” male connector, attaching to printer

2 “B” male connector, detail
3 “A” male connector, attaching to computer
4 “A” male connector, detail
5 Maximum cable length = 16.4 ft. (5 m)
Note • Use a USB 2.0-certified compliant cable no longer than 16.4 ft (5 m) long. A cable
that meets these requirements is available from Zebra (part number 33011).

Advanced Printer Info 73
Applicator Interface Connector

An external DB-15 connector is present on the rear panel of the printer for communication
with a customer applicator. An optional DB-15 to DB-9 adapter cable (Zebra part number
49609) is available to accommodate existing DB-9 interfaces.
Applicator Signals
The printer communicates with a customer applicator through a series of signals on the pins in
the DB-15 connector. Each pin causes different things to happen when the signal is active
(asserted) or not active (deasserted). Applicator Interface Connector Pin Configuration
on page 75 provides additional information about each pin and signal.
Figure 13 • Applicator Signals (Mode 1)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

74 Advanced Printer Info

not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

Applicator Interface Connector Pin Configuration

The Applicator Interface Assembly is available in two versions: a +5 V I/O and a +24–28 V I/
O. Table 10 lists the pin configurations and functions of the applicator interface connector for
both +5 V and +24–28 V operation.
Table 10 • Applicator Interface Connector Pin Configuration
Pin
Signal Name Signal Type Description
No.
1 I/O SIGNAL I/O Signal Using jumper JP2, this pin can be configured as isolated
GROUND Ground or non-isolated from the printer signal ground. See
(+5V Return) Jumper Configurations and Pinouts for +5 V I/O
Operation on page 78 for more information.
1 I/O SIGNAL I/O Signal No jumpers to configure.
GROUND Ground Important • Customer must provide this external
(+24-28V Return) ground. (This ground can come from pin 8 when
operating at 28V for all printers except the
110Xi4.) See Pinouts for +24-28 V I/O Operation
on page 79 for more information.
2 +5V I/O Power Using jumper JP1, this pin can be configured as isolated
(Fused at 1 A) or non-isolated from the Applicator Interface Circuit
+5 V Supply. See Jumper Configurations and Pinouts for
Caution • Replace
the fuse only with +5 V I/O Operation on page 78 for more information.
one of the same
type and rating.
2 +24-28V I/O Power No jumpers to configure. This +24-28V power source
also supplies voltage for output signal pull-up resistors.
Important • Customer must provide this external
power. (This power can come from pin 7 when
110Xi4.) See Pinouts for +24-28 V I/O Operation
on page 79 for more information.
3 START PRINT Input See Applicator Signals on page 73 for more information
about the start and end print signals.
• 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 of
a new label.
• Level Mode—Assert LOW to enable the printer to
print if a label format is ready. When deasserted HIGH,
the printer completes the label that is printing then
stops and waits for this input to be reasserted LOW.
4 FEED Input When the printer is idle or has been paused, assert this
input LOW to trigger repeated feeding of blank labels.
Deassert HIGH to stop feeding blank labels and register
to the top of the next label.

Table 10 • Applicator Interface Connector Pin Configuration (Continued)
Pin
No.
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 printer to reprint the last
label.
• If the Reprint feature is disabled, this input is ignored.
7 +28 V Power The Interface Power Supply. Supplies power to external
(For the 5V board, sensors as required.
+28V is fused at 2 A. Note • If operating with 28V signals only, pin 7
For the 24–28V may be used to supply power to pin 2, which
board, +28V is fused creates a non-isolated mode of operation. (This is
at 500 mA.) not applicable to the 110Xi4.)
Caution • Replace
the fuse only with
one of the same
type and rating.
8 POWER GROUND Ground The Interface Power Ground.
(+28 V DC Return) Note • If pin 7 is used to supply power to pin 2,
use this pin to ground pin 1. (This is not
applicable to the 110Xi4.)
9 — — No function.
10 SERVICE Output Asserted LOW in the following circumstances:

REQUIRED • the printhead is open
• the ribbon or media is out
• the printer is paused
• an operational fault occurs
• a Resynch error occurs while the applicator Resynch
mode is set to Error mode

Table 10 • Applicator Interface Connector Pin Configuration (Continued)
Pin
No.
11 END PRINT Output See Applicator Signals on page 73 for more information
about the start and end print signals.
• MODE 0—The applicator port is OFF.
• MODE 1—Asserted LOW only while the printer is
moving the label forward; otherwise deasserted HIGH.
• MODE 2—Asserted HIGH only while the printer is
moving the label forward; otherwise deasserted LOW.
• MODE 3—(Default) Asserted LOW for 20
milliseconds when a label is completed and positioned.
Not asserted during continuous printing.
• MODE 4—Asserted HIGH for 20 milliseconds when a
label is completed and positioned. Not asserted during
continuous printing.
12 MEDIA OUT Output Asserted LOW while there is no media in the printer.
13 RIBBON OUT Output Asserted LOW while there is no ribbon in the printer.
14 DATA READY Output See Applicator Signals on page 73 for more information
about this signal.
• 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.

Jumper Configurations and Pinouts for +5 V I/O Operation

Jumpers JP1 and JP2 are used together to produce isolated or non-isolated modes of operation
for applicator input and output control signals. JP1 configures the +5 V source for the
optoisolator circuits, and JP2 configures the ground. For proper operation, when JP1 is
installed, JP2 must be installed, and when JP1 is removed, JP2 must be removed.
Table 11 describes the pin and jumper configurations for +5 V I/O operation.
Table 11 • Non-Isolated and Isolated Modes for +5V Operation
Non-Isolated (Jumpers In) Isolated (Jumpers Out)

Pin 1 Ground +5V, Jumper JP2 In External Ground +5V, Jumper JP2 Out
I/O ground is connected to the printer signal I/O ground is disconnected from the printer
ground. signal ground. Ground must be provided
externally to this pin.
Pin 2 +5V Output, Jumper JP1 In External +5V Input, Jumper JP1 Out
+5 V I/O is connected to the applicator +5 V I/O is disconnected from the applicator
interface circuit +5 V Supply. interface circuit +5 V Supply. The +5 V for the
applicator interface optoisolator circuits must be
provided externally. This input also supplies
voltage for output signal pull-up resistors.

Pinouts for +24-28 V I/O Operation

Table 12 describes the pin configurations for +24–28 V I/O operation. There are no jumpers to
configure for this mode.
Table 12 • Non-Isolated and Isolated Modes for +24–28V Operation
Isolated (External Power) Non-Isolated (Internal Printer Power)

Pin 1 External Ground +24-28V Ground +28V from Pin 8
I/O ground must be connected to an external If pin 7 is used to supply power to pin 2, use
ground. pin 8 to ground pin 1.
(Required for the 110Xi4.) (Does not apply to the 110Xi4.)
Pin 2 +24-28V External Input +28V Input from Pin 7
+24-28 V I/O must be connected to an external If operating with 28V signals only, pin 7 may
power supply. This input also supplies voltage be shorted to pin 2, which creates a
for output signal pull-up resistors. non-isolated mode of operation. This input
(Required for the 110Xi4.) also supplies voltage for output signal pull-up
resistors.
(Does not apply to the 110Xi4.)
Pinouts
1 1
+24-28V +24-28V +28V +28V
2 2
3 3
4 4
5 5
+28V 6 +28V 6
+28V +28V
7 7
500 mA 500 mA
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

2
Preventive Maintenance
This section provides routine cleaning and maintenance procedures.
Contents
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Replace the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

82 Preventitive Maintenance
Replacing Printer Components
Replacing Printer Components

Some printer components, such as the printhead and platen roller, may wear out over time and
can be replaced easily. Regular cleaning may extend the life of some of these components. See
Cleaning Schedule and Procedures on page 83 for the recommended cleaning intervals.
Ordering Replacement Parts

For optimal printing quality and proper printer performance across our product line, Zebra
strongly recommends the use of genuine Zebra™ supplies as part of the total solution.
Contact your authorized Zebra reseller for part ordering information, or see Contacts
on page 11 for contact addresses and telephone numbers.
Recycling Printer Components

The majority of this printer’s components are recyclable. The printer’s main logic board
includes a battery that you should dispose of properly.
Do not dispose of any printer components in unsorted municipal waste. Please dispose of the
battery according to your local regulations, and recycle the other printer components
according to your local standards. For more information, see http://www.zebra.com/
environment.
Lubrication
Other than lubricating the cutter blade after approximately 60,000 cuts, no lubrication is
needed for this printer.
Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.
Caution • Some commercially available lubricants will damage the finish and the
mechanical parts if used inappropriately on this printer.

Preventitive Maintenance 83
Cleaning Schedule and Procedures

Cleaning your printer regularly maintains print quality and may extend the life of the printer.
The recommended cleaning schedule is shown in Table 13. See the following pages for
specific procedures.
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. You are not required to turn off the printer power when working near an open
printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose
all temporary settings, such as label formats, and you must reload them before you resume
printing.
Caution • Use only the cleaning agents indicated. Zebra is not responsible for damage
caused by any other fluids being used on this printer.
Table 13 • Recommended Printer Cleaning Schedule
Area Method Interval

Printhead Solvent* Perform these procedures at the following times:
Platen roller Solvent* • When CLEAN HEAD NOW appears.
Transmissive (media) sensor Air blow† • Direct Thermal Print Mode: After every roll of
labels or 500 ft (150 m) of fanfold labels.
Black mark sensor Air blow†
• Thermal Transfer Print Mode: After every roll
Media path Solvent* (1500 ft or 450 m) of ribbon.
Ribbon sensor Air blow
Label-available sensors Air blow Every 6 months, or as needed
Tear-off/peel-off bar Solvent*
Snap plate Solvent* As needed
Cutter Solvent*
* Zebra recommends using Preventive Maintenance Kit (part number 47362). In place of this kit, you may use a clean swab
dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%).
† If using canned air, it is recommended that you turn off the printer before cleaning.
Clean the Exterior

Clean the outside surfaces of the printer with a lint-free cloth. Use a mild detergent solution or
desktop cleaner sparingly, as needed.
Caution • Do not use harsh or abrasive cleaning agents or solvents.

Clean the Media Compartment

After every four rolls of media, inspect the media compartment. Use a soft bristle brush or a
vacuum cleaner to remove any dirt and lint from the interior of the printer.
Clean the Printhead and Platen Roller

If print quality does not improve after you perform this procedure, clean the printhead with
Save-a-Printhead cleaning film. This specially coated material removes contamination
buildup without damaging the printhead. Call your authorized Zebra reseller or distributor for
more information.
Cleaning intervals are as follows, based on the printhead resolution:
For 203 and 300 dpi printers Clean the printhead after every roll (1500 feet or 450 m) of
thermal transfer ribbon or after every roll (500 feet or 150 m) of direct thermal labels or when
CLEAN HEAD NOW appears on the LCD. Clean the printhead more often if you see
inconsistent print quality, such as voids in the bar code or graphics.
For 600 dpi printers Clean the printhead after each roll (500 feet or 150 m) of labels or
when CLEAN HEAD NOW appears on the LCD. Clean the printhead more often if you see
inconsistent print quality, such as voids in the bar code or graphics.
If power is removed from a 600 dpi printer when cleaning the printhead, the
CLEAN HEAD NOW warning shown on the LCD will not disappear.

Caution • The printhead may be hot and can cause severe burns. Allow the printhead to
cool.
Caution • Before touching the printhead assembly, discharge any built-up static electricity
by touching the metal printer frame or by using an anti-static wriststrap and mat.
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. You are not required to turn off the printer power when working near an open
printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose
all temporary settings, such as label formats, and you must reload them before you resume
printing.
To clean the printhead and platen roller, complete these steps:
1. Open the printhead assembly by rotating the printhead-open lever (1) counter-clockwise.
2. Remove the media and ribbon (if loaded).

3. Using the swab from the Preventive Maintenance Kit (part number 47362), wipe along the
brown strip on the printhead assembly from end to end. In place of the Preventive
Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol
(minimum 90%) and deionized water (maximum 10%). Allow the solvent to evaporate.
3
4
1 Swab
2 Platen roller
3 Printhead print elements
4 Printhead-open lever
4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the
solvent to evaporate.
5. Reload the media and the ribbon (if required).
6. Push down the printhead assembly (1), and then rotate the printhead-open lever (2)
clockwise until it locks into place.
2 1

Clean the Sensors

Brush or vacuum any accumulated paper lint and dust off the sensors. Clean the sensors
according to the recommendations in Cleaning Schedule and Procedures on page 83.
Ribbon and Label-Available Sensor Locations

The ribbon sensor and optional label-available sensor are shown in Figure 17.
Figure 17 • Sensor Locations
2 3
1 Label-available sensors
2 Black mark sensor
3 Ribbon sensor

Transmissive Media Sensor

The uppper and lower transmissive media sensors are show in Figure 18 and Figure 19.
Figure 18 • Upper Media Sensor
Y
Z
X
1 Upper media sensor adjustment screw
Figure 19 • Lower Media Sensor

Media Out Sensor Location

The location of the media out sensor is shown in Figure 20.
Figure 20 • Media Out Sensor

Clean the Snap Plate

Clean the snap plate when label adhesive or a label is stuck to the underside.
Figure 21 • Snap Plate Location
1 2
3
1 Left loop
2 Snap plate
3 Right loop
To clean the snap plate, complete these steps:
1. See Figure 21. Insert a small-blade screwdriver or similar tool into the loop on the left side
of the snap plate.
2. Gently lift the left side of the snap plate.
3. Insert a small-blade screwdriver or similar tool into the loop on the right side of the snap
plate.
4. Gently lift the right side of the snap plate.
5. Remove the snap plate from the printer.
6. Using the swab from the Preventive Maintenance Kit (part number 47362), clean the snap
plate. In place of the Preventive Maintenance Kit, you may use a clean swab or soft cloth
dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum
10%). Allow the solvent to evaporate.

7. To reinstall the snap plate, insert the two tabs on the bottom of the snap plate into the two
slots of the media path.
8. Slide the snap plate toward you.
9. Press down on the loops to lock the snap plate into place.
Clean the Cutter

If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter.
To clean the cutter, complete these steps:
2. Unplug the power cord.
3. Using the swab from the Preventive Maintenance Kit (part number 47362), clean the
stationary cutter blade. In place of the Preventive Maintenance Kit, you may use a clean
swab dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water
(maximum 10%). Allow the solvent to evaporate.
4. If cleaning does not remove label fragments and adhesive, contact an authorized service
technician.

Replace the Fuse
Replace the Fuse

The instructions that follow are for the 140Xi4, 170Xi4, and 220Xi4 printers only. Fuses are
not user-replaceable in the 110Xi4.
Caution • Turn the AC power switch off (O) and remove the power cord before performing
this procedure.
The printer uses a metric-style fuse (5 × 20 mm IEC) rated at F5A, 250 V. The AC power entry
module comes with two approved fuses in the fuse holder: one is in-circuit, and the second is
provided as a spare. The end caps of the fuse must bear the certification mark of a known
international safety organization (see Figure 7 on page 31).
To replace a faulty fuse, complete these steps:
1. Use a small-blade screwdriver or similar tool to remove the fuse holder.

The fuse holder is part of the AC power entry module at the rear of the printer (Figure 22).
Figure 22 • AC Power Entry Module
1 Power switch
2 Fuse holder
3 AC power entry module
4 Small-blade screwdriver
2. Remove the faulty fuse and install a new fuse in the in-circuit position (Figure 23).
Important • If you use the spare fuse, be sure to order a replacement fuse from an
authorized Zebra distributor. The spare fuse should be the exact type and rating as the
original in-circuit fuse.

Replace the Fuse
Figure 23 • Fuse Locations
1 In-circuit fuse
2 Fuse holder
3 Spare fuse
3. Snap the fuse holder back into the AC power entry module.
4. Reconnect the power cord, and turn the printer on (I).
Note • If the printer does not power on, an internal component failure may have occurred,
and the printer requires servicing by an authorized service technician.

Replace the Fuse
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

3
Corrective Maintenance
This section shows you how to replace parts.
Contents
Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Roller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Outer Casing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
RFID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453

96 Corrective Maintenance
Contents
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Print System
This section contains information on changing the printhead, ribbon strip plate, pivot bar,
toggle, and head open flag.
Contents
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Print Mechanism Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Ribbon Strip Plate and Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Head Open Sensor Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Printhead Assembly
Printhead Assembly
This kit includes the parts and documentation necessary to install a printhead into the
following Xi4™ printers.
Read these instructions thoroughly before attempting to install this kit.
Note • For optimal printing quality and proper printer performance across our product line,
Zebra strongly recommends the use of genuine Zebra™ supplies as part of the total solution.
Specifically, the Xi4 are designed to work only with genuine Zebra™ printheads, thus
maximizing safety and print quality.
Tools Required
Tools • You need these tools to complete this procedure:
Flatblade Screwdriver Set SAE Hex Key (Allen Wrench) Set

Antistatic Mat and Wrist Strap 47362* Zebra Preventive Maintenance
Kit
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol
(minimum 90%) and deionized water (maximum 10%).
Note • For best print quality replaced the platen roller.
Remove the Printhead

1.
Caution • Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2. See Figure 24. Open the media door.

Corrective Maintenance 99
Printhead Assembly
Figure 24 • Open the Media Door
1 Media door
2 Lever

Printhead Assembly
3.
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.
See Figure 25. Open the printhead assembly by rotating the head control lever to the
open position. Remove the media and ribbon, and then close the printhead assembly by
rotating the head control lever to the close position.
Figure 25 • Turn the Lever to Open the Printhead

1
1 Lever in open position.
4.
Caution • Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
Connect yourself to an antistatic device.

Printhead Assembly
5. See Figure 26. Locate the mounting screw on top of the printhead assembly. Loosen the
mounting screw until the printhead comes loose.
6.
Caution • The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
Slowly open the printhead assembly. The printhead will be resting on the platen while the
rest of the assembly pivots out of the way.
Figure 26 • Replace Printhead

1
2
3
7
4
6 5
110Xi4, 140Xi4 and 170Xi4

220Xi4 Printhead Printhead
1 Printhead mechanism assembly

2 Printhead mounting screw
3 Printhead alignment posts
4 Power cable locking tab
5 Printhead power connector
6 Printhead alignment slots
7 Printhead data connector
7. Spread the holding tabs on the sides of the printhead data connector to release the data
cables and then disconnect the data cable.
8. Grasp the outside edges of the printhead power cable connector and press down on the
power cable locking tab.
Note • There are two power connectors on the 220Xi4.
9. While maintaining pressure on the locking tab(s), disconnect the printhead power cable(s).
10. Remove the printhead.

Printhead Assembly
Install the Printhead

1.
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.
Spread the holding tab(s) on the top of the power connector(s) and connect the printhead
data cable(s) to the proper connectors. The holding tab(s) must snap into place.
2. Carefully position the alignment slots of the new printhead with the alignment posts on the
mounting bracket.
3. Make sure the cables are in their proper channels and are not binding.
4. The two locating posts on either side of the mounting plate slip into the locating holes of
the printhead assembly.
5. Make sure the printhead mounting screw is properly aligned, and then tighten it.
6. Clean the new printhead elements using Zebra’s Preventive Maintenance Kit, part number
47362 or you may use a clean swab dipped in a solution of isopropyl alcohol (minimum
90%) and deionized water (maximum 10%).
7.
Caution • When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Reinstall the media and ribbon.
8. Reconnect the AC power cord and data cables.
9. Press and hold PAUSE while turning on (l) the printer.
10. When the printer begins printing labels, refer to Set the Darkness on page 108.
11. Press PAUSE to pause the printer and check the labels for proper print quality. If the print
quality not correct continue with Adjust the Printhead.
Adjust the Printhead

Five interrelated adjustments lead to optimum print quality with increased printhead life:
• Printhead Parallelism
• Wear Plate (Balance) Position
• Printhead Position
• Printhead Pressure
• Strip Plate Position
Note • To achieve optimum results with print quality adjustments, install full-width media
and ribbon. Verify the media and ribbon are properly matched, and that darkness and print
speed configurations are correct for the application before performing any mechanical
adjustments.

Printhead Assembly
Prior to Performing Printhead Adjustments
Figure 27 • Adjust Toggle
Position the toggle(s) as follows:
1. See Figure 27.

110/140/170/220Xi4 and R110Xi4: Position each
toggle over the width of the media.
2. Adjust the toggle spring while the head is closed and

locked by turning the lower knurled nut until the
30mm distance from the top of the toggle foot to the bottom
of the lower knurled nut equals 1.18 in. (30mm).
3. Press PAUSE to continue the Pause Self Test.
4. Press PAUSE to pause the Pause Seft Test.
Printhead Parallelism
Important • Excessive toggle pressure will increase printhead wear and decrease printhead
life. Increase printhead life by combining minimum toggle pressure and optimum printhead
position over the platen roller.
The order in which the adjustments are performed depends on the print quality of the labels
printed during the Pause Self Test.
Complete the first two printhead adjustments (Parallelism and Wear Plate) prior to locating
the optimum print position. As with the other adjustments, parallelism and wear plate
adjustments are interrelated. Adjusting one may have an effect on the position of the other.
This adjustment is performed in conjunction with the wear plate position, printhead position,
and printhead pressure adjustments.
Adjusting the printhead parallelism squares the printhead to the platen roller.
Test the Printhead Parallelism

See Figure 28. Prior to starting this test, ensure the installed media is square with the tear-off
bar and that the toggle is set to 30 mm.
2. The uppermost line on the test label should be parallel to the top edge of the label.
3. Are the print lines parallel to the top of the label?
If… Then…
No Continue to Adjust the Printhead Parallelism.
Yes Go to Adjust the Wear Plate Position on page 105.

Printhead Assembly
Adjust the Printhead Parallelism

1. Ensure that the printhead is seated properly.
3. Press PAUSE to pause the Pause Self Test to adjust is necessary.
4. See Figure 28. Loosen the four screws at the top rear of the print mechanism.
5. Adjust the parallel location of the uppermost lines by turning one of the two screws
located at the back of the print mechanism. Only small adjustments are required.
6. To move the printhead forward, turn the adjustment screw clockwise as viewed from the
rear of the printer.
7. To move the printhead backward, turn the adjustment screw counter-clockwise as viewed
from the rear of the printer.
8. Adjust each side as necessary to align the uppermost line of the test label parallel with the
top edge of the label.
9. Press PAUSE to run additional Pause Self Test labels to check for proper parallelism.
10. Tighten the four top screws, and then run additional Pause Self Test labels to verify proper
positioning.
11. Press PAUSE to pause the Pause Self Test.

Printhead Assembly
Figure 28 • Printhead Parallelism Adjustment

Loosen these screws before
adjusting the printhead.
1
2
3
1 Toggle knurled adjusting nut
2 Parallelism adjustment screws (2)
3 Eccentric
4 Wear plate screws (2)
5 Strip plate
6 Tear-off bar
Adjust the Wear Plate Position

Adjusting the wear plate position produces even pressure across the full width of the printhead
and platen roller.
2. See Figure 29 on page 108. Loosen the two screws on the front of the strip plate.
4. After printing a few labels, press PAUSE and reduce the darkness value until the test
labels are a charcoal gray color (see Set the Darkness on page 108).
5. Press PAUSE to run additional Pause Self Test labels and observe the print quality.
6. If printing is evenly dark, the wear plate position is good. If lighter or no printing is
observed on one side of the label, continue with this adjustment.
7. Loosen the two screws securing the wear plate.
8. Continue to print pause test labels while adjusting the wear plate eccentric.
9. Adjust the wear plate eccentric by turning it by hand, a wrench, or a pair of utility pliers.

Printhead Assembly
10. Adjust the wear plate eccentric clockwise to increase pressure on the main frame side of
the label, or adjust it counter-clockwise to increase pressure on the outboard side of the
printer.
11. When even print quality is achieved, hold the wear plate in position and retighten the two
wear plate screws.
13. Is parallelism out of tolerance?
If… Then…
No Align the strip plate. Go to Align the Strip Plate on page 109.
Yes Go to Adjust the Printhead Parallelism on page 104.
Adjust the Printhead Position

This adjustment is performed in conjunction with the printhead parallelism, wear plate
position, and printhead pressure adjustments.
Adjusting the printhead position aligns the printhead for optimum print quality.
1. See Figure 28 on page 105. The thermal elements of the printhead should be aligned just
behind the crest of the platen roller.
3. Set the darkness to achieve as close to optimum print quality as possible (see Set the
Darkness on page 108).
4. If the position is incorrect press PAUSE to pause the Pause Self Test and then loosen the
four screws at the top rear of the print mechanism.
Caution • To prevent printhead damage, loosen the four top screws before turning the
two adjustment screws.
5. Adjust the printhead position for optimum print quality by equally turning the two screws
located at the back of the print mechanism.
Note • Adjustments are made in very small increments.

Due to spring pressure, there may be a dead spot in the actual printhead movement when
switching adjustments from one direction to the other.
6. Turn both screws 1/8 turn clockwise and observe the changes in print quality. Turn both
screws 1/8 turn counter-clockwise and observe the changes in print quality.
7. Press PAUSE and check the test labels for streaks, flouring, and other print quality
problems.
8. Adjust the screws while observing print quality.

Printhead Assembly
9. Since printhead parallelism, wear plate position, and printhead positions are interrelated,
look at the test labels for changes in these settings and adjust if necessary.
Adjust the Printhead Pressure

Printhead pressure is the fourth of the five interrelated adjustments. Using lower printhead
pressure and darkness settings can extend printhead life. If printing is too light on one side, or
if thick media is used, printhead pressure may require adjustment.
See Figure 29. Locate the pressure toggles. The Xi4 printers have two toggles. These toggles
are typically positioned at the 1/4 and 3/4 positions across the width of the media. If the media
is sufficiently narrow that both toggles will not fit within its edges, the inside toggle should be
centered above the media.
2. See Figure 27 on page 103. To increase printhead pressure, loosen the upper knurled nut
on the toggle and adjust the lower toggle adjusting nut downwards.
3. To decrease printhead pressure, loosen the upper knurled nut and adjust the lower toggle
adjusting nut upwards.
4. Adjust printhead pressure for optimum print quality.
5. To lock the toggle pressure, tighten the upper knurled nut against the lower toggle
adjusting nut.
6. Though different media and ribbon combinations may require different toggle settings, a
suggested initial distance between the top of the toggle foot to the bottom of the lower
knurled nut equals 1.18 in. (30 mm).
7. Continue to Set the Darkness on page 108.

Printhead Assembly
Figure 29 • Adjust the Printhead Pressure
Toggle Adjusting
Nuts
Strip Plate
Positioning Screw
Set the Darkness

Darkness settings depend on a variety of factors, including ribbon type, labels, 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.
Press PAUSE to continue the Pause Self Test to determine the best darkness setting. Because
the darkness setting takes effect immediately, you can see the results on labels that are
currently printing.
Note • Turning off (O) the printer is not required for the new setting to take effect.
Set the darkness to the lowest setting that provides good print quality. If the darkness is set
too high, the ink may smear, or the ribbon may burn through.
Begin printing a batch of labels, using the Pause Self Test labels. Adjust the darkness setting to
obtain the desired print quality. the Darkness does not need saved until the correct darkness is
found. The darkness settings can be adjusted while the Pause Self Test is running.
• Decreasing the value in the display causes a lighter (less black) image.
• Increasing the value causes a darker (blacker) image.
1. Press SETUP/EXIT to enter the Configuration Mode. DARKNESS is displayed.
2. Press the left oval to decrease the value or right oval to increase the value.
3. Press SETUP/EXIT and then NEXT/SAVE to permanently save the darkness setting.

Printhead Assembly
Align the Strip Plate

The strip plate adjustment is a very important part of the printhead adjustment procedure, and
can be adjusted for proper tracking and separation of the ribbon from the media.
See Adjust the Printhead Pressure on page 108.
2. Press PAUSE to pause the Pause Self Test and observe the ribbon for possible problems
such as wrinkling.
3. Press PAUSE to continue the Pause Self Test, lower the strip plate until the ribbon is an
inverted V ( ), smooth and tracks properly when fed to the ribbon take-up spindle.
4. Tighten the strip plate screws and print a minimum of 25 labels while checking for ribbon
wrinkle, tracking, and media/ribbon separation problems. If ribbon problems persist,
check the torque settings of the ribbon supply spindle and adjust tension if required.

Print Mechanism Hardware
Tools Required
Phillips Screwdriver Set Needle-nose Pliers

Flat-blade Screwdriver Set Antistatic Wriststrap and Mat
Safety Glasses 47362* Zebra Preventive Maintenance
Kit
* In place of the Preventive Maintenance Kit, you may use clean swabs and a solution containing
isopropyl alcohol (≥ 90%) with deionized water (≤10%).

1.

1 Media door
2 Lever

3.

1
4.

6.
printhead to cool.

1
2
3
7
4
6 5
110Xi4, 140Xi4 and 170Xi4



11. See Figure 33. Close the print mechanism and remove the two mounting screws and lock
washers that secure the pressure plate to the print mechanism.
Figure 33 • Disconnect the Printhead Ground
1 Print mechanism pressure plate

2 Lock washers (2)
3 Ground cable
4 Mounting screws (2)
12. Slide the ground cable under the print mechanism pressure plate and then open the print
mechanism.
13. Pull the ground cable out of the print mechanism.

14. See Figure 34. Remove the printhead cable cover by removing the two mounting screws.
Figure 34 • Remove the Printhead Cable Cover
1 Printhead cable cover

15. See Figure 35. Remove the ribbon sensor from the print mechanism removing the
mounting screw and rubber washer.
Figure 35 • Remove the Ribbon Sensor
1 3
2
1 Ribbon sensor
2 Mounting screw
3 Washer

Remove the Electronics Cover
Note • Retain all parts removed during disassembly, unless otherwise directed.
1.
2.
Open the media door and remove the media and ribbon.
3. See Figure 36. Remove the electronics cover by removing the three mounting screws
securing it.
Figure 36 • Remove the Electronics Cover
Lift up at rear 1
corner.
1 Electronics cover
4. Lift up on the rear of the electronics cover and then lift the electronics cover off the
printer.

5. Which model of Xi4 are you working on?
If you have a… Then…

110Xi4 w/printhead test board Continue with Remove the Printhead Test Board.
• 110Xi4 Go to Remove the Old Print Mechanism on page 119.
w/o printhead test board
• 140Xi4
• 170Xi4
• 220Xi4
Remove the Printhead Test Board

1. Take note of all cable connections and then disconnect all cables.
2. See Figure 37. Remove and discard the mounting screw securing the printhead test board
shield.
Figure 37 • Remove the Printhead Test Board Shield

1
1 Printhead test board shield

2 Mounting screw
3.

4. See Figure 38. Disconnect all cables connected to the printhead test board.
5. Lift the printhead test board shield and then remove the two mounting screws and the
printhead test board.
Figure 38 • Remove the Printhead Test Board
5
1
2 6
3
4

2 Top mounting spacer
3 Right mounting spacer
4 Left mounting spacer
5 Printhead test board

Remove the Old Print Mechanism

1.
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.
See Figure 39. With a pair of needle nose pliers remove the printhead lift spring from the
printhead lift spring stop.
Figure 39 • Remove the Printhead Lift Spring and E-ring
1 2 3
4
1 Printhead lift spring stop

2 C-ring
3 E-ring
4 Printhead lift spring
5 Print mech shaft
2. Remove the e-ring and then slide the printhead lift spring off the print mech shaft.
3. Remove the c-ring from the print mech shaft.

4. See Figure 40. On the media side turn the head open handle to open and the remove and
discard the two mounting screws, flat washers, lock washer, eccentric pin, and wear plate.
Figure 40 • Remove the Wear Plate

1
2
3
7 5
3 4
6
1 Print mechanism
2 Eccentric pin
3 Flat washer
4 Long mounting screw
5 Lock washer
6 Short mounting screw
7 Wear plate
8 Head open handle

5. See Figure 41. Slide the print mechanism out of the printer.
Figure 41 • Remove the Print Mechanism
1 Print mechanism
2 Access hole
Install the New Print Mechanism

1. See Figure 41. Slide the new crescent washer onto the print mechanism shaft and then
slide the print mechanism into the print mechanism mounting hole, ensuring the printhead
cables do not snag on the print mechanism.
2. See Figure 40 on page 120. Install the new wear plate using the new screws, flat washers,
lock washer, and eccentric pin. Snug the screws but do not tighten at this time you will
have to adjust the wear plate.
3. Close the print mechanism.

4.
See Figure 42. On the electronics side install the new c-ring.
Figure 42 • Install the C-ring and Printhead Lift Spring

2
3 4
1 Printhead lift spring stop

2 C-ring
3 Printhead lift spring
4 E-ring
5 Print mechanism shaft
5. Slide the new printhead lift spring onto the print mechanism shaft shown and then install
the e-ring.
6. With a needle-nose pliers turn the printhead lift spring counter clockwise and hook it to
the printhead lift spring stop.

7. Which model Xi4 are you working on?

110Xi4 w/printhead test board a. See Figure 38 on page 118. Align the printhead test
board, with J1 and J2 at the bottom and facing out,
with the mounting spacers and then install the top
and right mounting screws.
b. See Figure 37 on page 117. Bend the printhead test
board shield down until the mounting hole aligns
with the left mounting hole in the printhead test
board and then reinstall the printhead mounting
board shield mounting screw.
• 110Xi4 Continue with Reinstall the Electronics Cover.
w/o printhead test board
• 140Xi4
• 170Xi4
• 220Xi4
Reinstall the Electronics Cover

1. See Figure 36 on page 116. Reinstall the electronics cover by aligning the cover so that it
slips over the main frame.
2. Reinstall the mounting screws to secure the electronics cover.
Reinstall the Printhead

1. See Figure 33 on page 114. Remove the two print mechanism pressure plate mounting
screws and lock washers.
2. Open the print mechanism slide the printhead ground cable through the left hole in the
print mechanism and then under the print mechanism pressure plate.
4. Slide the left print mechanism pressure plate mounting screw through the printhead
ground cable’s eyelet, lock washer, and then reinstall the screw into the print mechanism
and tighten.
5. Reinstall and tighten the right mounting screw and lock washer.
6. Open the print mechanism.

7.
Caution • Do not over tighten the ribbon sensor mounting screw, damage will occur to
the ribbon sensor.
See Figure 35 on page 115. Reinstall the ribbon sensor into the print mechanism by
sliding the mounting screw through the mounting hole in the ribbon sensor, rubber
washer, and then into the print mechanism and slightly tighten.
8. See Figure 43. Push the printhead cables behind and above the print mechanism roller.
Figure 43 • Move the Printhead Cables
1 3
2
1 Printhead data cable

2 Print mechanism roller
3 Printhead power cable
9. See Figure 34 on page 115. Reinstall the printhead cable cover plate by aligning the plate
with mounting holes in the print mechanism shaft and then reinstall the two mounting
screws.
10.
See Figure 32 on page 113. Spread the holding tab(s) on the top of the power connector(s)
and connect the printhead data cable(s) to the proper connectors. The holding tab(s) must
snap into place.
mounting bracket.

16.
19. Press PAUSE to pause the printer and check the labels for proper print quality. If the print
quality not correct continue with .
Caution • Other than printhead pressure, printhead adjustments rarely need to be

performed, even after replacing the printhead. These adjustments should be performed
only by a qualified technician who has been specifically trained. Do not perform these
adjustments unless you have been trained to do so.
There are four printhead adjustments that affect print quality. The adjustments must be
performed in the following order:
Note • The following adjustments are interrelated and may have to be performed more than
once to achieve desired results.
Note • To achieve optimum results with print quality adjustments, install full width media
and ribbon. Verify that media and ribbon are properly matched and darkness/print speed
configurations are correct for the application before performing any mechanical adjustments.

Toggle Pressure
1. Ensure that the power switch is in the off (O) position.
2. See Figure 44. Measure the distance from the top of the toggle foot to the bottom of the
lower knurled nut. If the measurement is not 1-3/16 in. (30 mm), loosen the upper knurled
nut and adjust the lower knurled nut until the distance is correct.
Figure 44 • Set the Initial Toggle
1
2
3
6 4
1 Toggle assembly
2 Lock nut
3 Upper knurled nut
4 Set to 1–3/16 inch (30 mm)
5 Toggle foot
6 Spring
7 Lower knurled nut
3. Tighten the upper knurled nut against the lower knurled nut to lock that position.
4. Repeat step 2 and step 3 on the other toggle.
5.
Reinstall the media and ribbon, and reposition the toggles for printing.
6. Perform the Pause Key Self Test by pressing and holding PAUSE while turning the printer
on (l).
Note • To increase printhead pressure, loosen the upper knurled nut on the toggle and
adjust the lower toggle knurled nut downward. To decrease printhead pressure, loosen
the upper knurled nut and adjust the lower knurled nut upward.
7. Adjust printhead pressure for the lowest pressure that produces acceptable print quality.
Lock the toggle pressure by tightening the upper knurled nut against the lower knurled
nut.

Adjust the Wear Plate

1. Press and hold PAUSE while turning on the printer. Pause Key Test labels will start
printing.
2. Press PAUSE to pause the printer.
3. Press SETUP/EXIT to enter the configuration mode, DARKNESS will be displayed.
4. Press Minus (–) to decrease the darkness setting.
5. Press PAUSE to restart the printer and then continue pressing Minus (–) until the Pause
Key Self Test labels are a charcoal-gray color.
6. Press PAUSE to stop the printer.
7. Slightly loosen the two screws on the wear plate.
Figure 45 • Adjust the Wear Plate

1 2
1 Wear plate
2 Eccentric
Note • Print Pause Key Test labels while adjusting the wear plate eccentric and check for
even printing.
Adjust the wear plate eccentric by turning it by hand or with an open-end wrench or
pliers. Make very small adjustments and check the results.
Wear plate adjustments can adversely affect all adjustments. Additional adjustments may
be necessary.
the label or adjust it counterclockwise to increase pressure on the outboard side of the
printer.

9. When even print quality is achieved, hold the wear plate eccentric in position and tighten
the two wear plate screws.
10. Press Plus (+) to increase the darkness setting until the Pause Key Self Test labels are at
optimum resolution and contrast.
11. Continue to print Pause Key Self Test labels and verify even printing and parallelism.
12. If parallelism is out of tolerance, perform the Adjust Printhead Parallelism on page 130.
13. If no other adjustment is required, tighten the two screws to lock the adjustment.
Printhead Position
Caution • Other than printhead pressure, printhead adjustments rarely need to be

performed, even after replacing the printhead. These adjustments should be performed
only by a qualified technician who has been specifically trained. Do not perform these
adjustments unless you have been trained to do so.
Adjusting the printhead position moves the printhead with respect to the platen for optimum
print quality. If satisfactory print quality cannot be achieved or can be achieved only with
higher than normal darkness settings or higher than normal printhead pressure, the printhead
may not be in the proper position.
Note • The thermal elements of the printhead should be aligned just behind top dead center
of the platen roller.

1. Print test labels using the Pause Key Self Test.
Figure 46 • Adjust the Printhead

1
1 Loosen these screws before adjusting the printhead

(4)
2 Position and parallelism adjustment screws (2)
Note • Make very small adjustments and check the results. Turn the screws clockwise to
move the printhead toward the front of the printer. Turn the screws counterclockwise to
move the printhead toward the back of the printer.
A special hex key wrench allows adjustment of the printhead location screws while the
printer is running.
3. Adjust the printhead position by turning equally the two screws located at the back of the
print mechanism. Turn both screws one-eighth of a turn clockwise and observe the
changes in print quality. Turn both screws one-sixteenth of a turn counterclockwise and
observe the changes in print quality. Due to spring pressure, there may be a dead spot in
the actual printhead movement when changing adjustment direction.
4. Continue to make small adjustments until the best quality is achieved.
5. Decrease the darkness setting until the Pause Key Self Test labels are a charcoal-gray
color.
6. Inspect the test labels for streaks and other print quality problems.
7. If required, adjust the printhead position until print quality problems are corrected.
8. Increase the darkness until the Pause Key Self Test labels are printed at optimum
resolution and contrast.

9. When acceptable print quality is achieved, tighten the four screws at the top of the
printhead.
10. Run additional Pause Key Self Test labels to verify proper positioning.
Adjust Printhead Parallelism
Caution • Printhead parallelism adjustment rarely needs to be performed. Do not perform

this adjustment unless you have been trained to do so. If the procedure is not done
correctly, print quality will be adversely affected.
The printhead parallelism adjustment corrects for printing skew. If the lines at the top of the
Pause Key Self Test labels are not parallel to the media, this adjustment should be performed.
1. See Figure 46 on page 129. Loosen the four screws at the top rear of the print mechanism.
Note • Make very small adjustments and check the results. Turn the screws clockwise to
move the printhead toward the front of the printer. Turn the screws counterclockwise to
move the printhead toward the back of the printer.
A special hex key wrench allows adjustment of the printhead location screws while the
printer is running.
2. Adjust the parallel location of the uppermost lines by turning one of the screws located at
the back of the print mechanism.
3. Adjust one side as necessary to align the uppermost line of the test label parallel with the
4. To check the results of your adjustments, run additional Pause Key Self Test labels and
check for proper parallelism.
5. When parallelism is achieved, tighten the four screws at the top of the printhead.
6. Run additional Pause Key Self Test labels to verify proper positioning.
Adjust the Strip Plate

The strip plate can be adjusted to achieve proper tracking and separation of the ribbon from the
media after printing.
1. Print Pause Key Self Test labels.
2. Press PAUSE, wait until the printer pauses, then observe the ribbon for problems such as
wrinkling.

3. See Figure 47. Loosen but do not remove the two screws securing the strip plate to the
front of the printhead assembly.
Figure 47 • Adjust the Ribbon Strip Plate

1
1 Ribbon strip plate

4. While running the Pause Key Self Test, raise the strip plate all the way up and then lower
the strip plate until the ribbon tracks flat and smoothly when fed to the ribbon take-up
spindle.
5. Tighten the strip plate screws. Print a minimum of 25 labels and check for ribbon wrinkle,
tracking, and media and ribbon separation problems.
6. Press SETUP/EXIT and then press NEXT/SAVE.

Printhead Cables
Printhead Cables
This kit includes the parts and documentation necessary to install the Printhead Cable maintenance
kit in the Xi4™ printers. Read these instructions thoroughly before installing this kit.
Tools Required
Phillips Screwdriver Set SAE Nutdriver Set

SAE Hex Key (Allen wrench) Set 47362* Zebra Preventive Maintenance
Wire Cutters Kit
* In place of the Preventive Maintenance Kit, you may use clean swabs and a solution containing
isopropyl alcohol (≥ 90%) with deionized water (≤10%).

Printhead Cables

1.
1 Media door
2 Lever

Printhead Cables
3.

1
4.

Printhead Cables
6.
printhead to cool.

1
2
3
7
4
6 5
110Xi4, 140Xi4 and 170Xi4



Printhead Cables
10.
Caution • Before touching the printhead assembly, discharge any built-up static
electricity by touching the metal printer frame or by using an anti-static wriststrap and
mat.
Remove the printhead.
11. See Figure 51. Close the print mechanism and the remove the two screws securing the
print mechanism pressure plate.
Figure 51 • Remove the Printhead Ground
1 Print mechanism pressure plate

2 Lock washers (2)
3 Ground cable
12. Slide the ground cable under the print mechanism pressure plate and then open the print
mechanism.
13. Pull the ground cable out of the print mechanism.

Printhead Cables
1.
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Printhead Cables
Disconnect All Printhead Cables

1.
2. See Figure 53. Unplug the printhead data cable connected to P19 on the main logic board
(MLB).
Figure 53 • Disconnect the Printhead Data Cable
P19

110Xi4 w/ Go to Remove the Printhead Test Board on page 141.
printhead test
board
110Xi4 a. See Figure 54 on page 139. Unplug the AC power input cable
w/o printhead from the AC/DC power supply.
test board b. See Figure 55 on page 139. Remove the two AC/DC power
supply shield mounting screws and then remove the shield.
c. See Figure 56 on page 140. Unplug the printhead power cable
from J3 on the AC/DC power supply.
d. Go to Remove the Old Printhead Cables on page 143.
• 140Xi4 e. See Figure 57 on page 140. Disconnect the printhead power
cable(s) from J2 and/or J3 on the DC power supply.
• 170Xi4
f. Go to Remove the Old Printhead Cables on page 143.
• 220Xi4*
*.The 220Xi4 has two power cables for the printhead.

Printhead Cables
Figure 54 • Disconnect AC/DC Power Input Cable

1 2
1 AC power input cable

2 AC power input cable connector
3 White beaded cable tie
Figure 55 • Remove the AC/DC Power Supply Shield
1
2
1 AC/DC power supply shield


Printhead Cables
Figure 56 • Remove the Printhead Power Cable 110Xi4
J3
Figure 57 • Disconnect the Printhead Power Cable 140Xi4, 170Xi4, and 220Xi4
J3
J2

Printhead Cables

shield.

1
J3
J1 J2

2 Mounting screw
3.

Printhead Cables
4. See Figure 59. Lift the printhead test board shield and the remove and discard the two
mounting screws, printhead test board, and shield.
4
1
2 5
3


Printhead Cables
Remove the Old Printhead Cables


110Xi4 a. See Figure 60 on page 144. Remove the mounting nut securing
w/o printhead the cable clamp and printhead ground cable and then open the
test board cable clamp and remove the printhead ground.
b. Remove the mounting nut securing the cable containing the
printhead power cable and then open the clamp and remove the
printhead power cable.
c. Remove the two mounting nuts securing the two cable clamps
containing the printhead data cable and then open the clamps and
remove the printhead data cable.
d. Go to step 2 on page 147.
110Xi4 w/ a. See Figure 61 on page 145. Remove the mounting nut securing
printhead test the cable clamp and printhead ground cable and then open the
board cable clamp and remove the printhead ground.
c. Remove the printhead test board spacer securing the cable clamp
containing the printhead data cable and then open the cable
clamp and remove the printhead data cable.
d. Cut cable tie securing the printhead data cable to the printhead
test board spacer and the remove the lock washer.
e. Go to step 2 on page 147.
170Xi4 the cable clamp and printhead ground cable and then open the
cable clamp and remove the printhead ground.
the cable clamp and printhead ground cable and then open the
cable clamp and remove the printhead ground.
b. Remove the mounting nut securing the cable clamp containing
the printhead power cables and then open the clamp and remove
the printhead power cables.

Printhead Cables
Figure 60 • Remove the Printhead Cables 110Xi4 w/o printhead test board
1
2
2
2
2
5
4 3
1 Printhead ground cable

2 Cable clamp mounting nut
4 Ferrite

Printhead Cables
Figure 61 • Remove the Printhead Cables 110Xi4 w/printhead test board
1
2
7
6
2
5
4 3

4 Ferrite
6 Cable tie
7 Printhead test board spacer and lock washer

Printhead Cables
Figure 62 • Remove the Printhead Cables 140Xi4 and 170Xi4
1
2
2 2
5
4
3

4 Ferrite

Printhead Cables
Figure 63 • Remove the Printhead Cables 220Xi4
1
2
2 2
2 3
5
4

3 Printhead power cable (2)
4 Ferrite
2. From the electronics side pull the printhead cables out of the printer and discard them.

Printhead Cables
Install the New Printhead Cables

1. From the electronics side feed the printhead power, data and ground cables through the
main frame and into the print mechanism.

110Xi4 a. See Figure 60 on page 144. Slide the printhead ground cable
w/o printhead onto the mounting stud and then slide the cable clamp onto the
test board mounting stud.
b. Reinstall the mounting nut, tighten and then install the cable tie
around the head open sensor cable, ribbon sensor cable and
ground.
c. Route the printhead power cable under the drive belt and then
open the cable clamp that you remove the old printhead power
cable from and insert the new printhead power cable into it.
d. Slide the cable clamp onto the mounting stud, reinstall the
mounting nut and tighten.
e. Route the printhead data cable under the drive belt and then
insert the printhead data cable into the two cable clamps.
f. Slide the two cable clamps onto the two mounting studs, reinstall
the mounting nuts and tighten.
g. See Figure 56 on page 140. Connect the printhead power cable to
J3 on the AC/DC power supply.
h. See Figure 55 on page 139. Reinstall the AC/DC power supply
shield and secure it. Ensure the shield flaps are tucked in
between the power supply and the aluminum mounting plate.
i. See Figure 54 on page 139. Connect the AC power input cable
and then reinstall the white plastic beaded cable tie.
j. See Figure 53 on page 138. Connect the printhead data cable to
P19 on the main logic board.

Printhead Cables

110Xi4 w/ a. See Figure 61 on page 145. Slide the printhead ground cable
printhead test onto the mounting stud and then slide the cable clamp onto the
board mounting stud.
ground.
insert the printhead data cable into the cable clamp.
f. Slide the cable clamp onto the mounting stud, reinstall the lock
washer and printhead test board spacer and tighten.
g. Route the cable tie through the cable clamp above the left
printhead spacer, around the spacer and around the printhead
data cable and then tighten the cable tie.
h. See Figure 56 on page 140. Connect the printhead power cable to
J3 on the AC/DC power supply.
i. See Figure 55 on page 139. Reinstall the AC/DC power supply
j. SeeFigure 54 on page 139. Connect the AC power input cable
k. See Figure 53 on page 138. Connect the printhead data cable to
170Xi4 onto the mounting stud and then slide the cable clamp onto the
mounting stud.
ground.
g. See Figure 57 on page 140. Reconnect the printhead power cable
to J3 on the DC power supply.
h. See Figure 53 on page 138. Connect the printhead data cable to

Printhead Cables

onto the mounting stud and then slide the cable clamp onto the
mounting stud.
ground.
c. Route the printhead power cables under the drive belt and then
cable from and insert the new printhead power cables into it.
g. See Figure 57 on page 140. Reconnect the printhead power
cables to J2 and J3 on the DC power supply.
h. See Figure 53 on page 138. Connect the printhead data cable to
3. See Figure 51 on page 136. On the media side, feed the other end of the printhead ground
cable through the left side of the print mechanism and under the print mechanism pressure
plate.
5. Slide the left print mechanism pressure plate mounting screw through the printhead
ground cables eyelet, lock washer, and then reinstall the screw into the print mechanism
and tighten.
6. Reinstall and tighten the right mounting screw and lock washer.
7. Open the print mechanism.

Printhead Cables
8. See Figure 64. Push the printhead cables behind and above the print mechanism roller.
Figure 64 • Move the Printhead Cables
1 3
2

9.
See Figure 50 on page 135. Spread the holding tab(s) on the top of the power connector(s)
and connect the printhead data cable(s) to the proper connectors. The holding tab(s) must
snap into place.
mounting bracket.

Printhead Cables
15.

5. Press PAUSE to pause the printer and check the labels for proper print quality.

Ribbon Strip Plate and Static Brush

This kit includes the parts and documentation necessary to install the Ribbon Strip Plate and Static
Brush in the Xi4 printers. Read these instructions thoroughly before installing this kit.
Tools Required
Phillips Screwdriver Set Metric Hex Key (Allen wrench) Set
Remove the Old Static Brush

1.
Caution • Turn Off (O) the printer and disconnect it from the power source before
2.

3. See Figure 65. Remove and discard the two static brush mounting screws.
Figure 65 • Remove the Static Brush
2
1
Rear
1 Static brush
4. Remove and discard the old static brush.

Install the New Static Brush

1. Remove the new static brush from the kit.
2. See Figure 65 on page 154. Align the new static brush with the mounting holes, brush
angled toward the rear of the printer, and then install the new mounting screws.
Remove the Old Ribbon Strip Plate

1. See Figure 66. Remove and discard the two ribbon strip plate mounting screws.
Figure 66 • Remove the Old Ribbon Strip Plate
1 Ribbon strip plate

2. Remove and discard the old ribbon strip plate.

Install the New Ribbon Strip Plate

1. Align the new ribbon strip plate with the print mechanism and install the two mounting
screws supplied in the kit.
2. Slightly tighten the mounting screws.
3. Align the strip plate with the screw heads in the center of the slots in the ribbon strip plate.
4.
5. Reinstall the AC power cord and data cables.
6. Press and hold PAUSE and turn then on (l) the printer.
7. After the Power On Self Test (POST), the printer will start to print the Pause test labels.
8. Press PAUSE. After the printer pauses, observe the ribbon for possible problems such as
wrinkling.
9. Does the ribbon wrinkle or track incorrectly?
If… Then…
No a. Tighten the mounting screws.
b. Installation is complete.
Yes Continue with Adjust the Strip Plate.
Adjust the Strip Plate

1. The strip plate can be adjusted for proper tracking and separation of the ribbon from the
media after printing.
2. Loosen the two mounting screws securing the strip plate to the front of the print
mechanism assembly.
3. Press PAUSE to restart the printing.
4. While the printer is running adjust the strip plate so that the ribbon is flat, smooth and
tracks properly when fed to the ribbon take-up spindle.
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.
6. If problem persists repeat step 4.

Toggle Assembly
Toggle Assembly
This kit includes the parts and documentation necessary to install the Toggle Assembly in the Xi4
printers.
Read these instructions thoroughly before installing this kit.
Tools Required
SAE Hex Key (Allen wrench) Set
Remove the Old Toggle Assembly

1.
2.
Open the media door and remove the ribbon and media.

Toggle Assembly
3. See Figure 67. Take note of the location of the toggle(s). With the head open remove the
head handle mounting screw and then slide the handle and washer(s) off the pivot bar.
Figure 67 • Remove the Head Open Handle

3 4
1 2
1 Pivot bar
2 Handle mounting screw
3 Wave washer (may have flat washer also)
4 Head handle

Toggle Assembly
4. See Figure 68. Slide the pivot bar toward the main frame.
Figure 68 • Remove the Toggle Assembly
2
1
1 Pivot bar
2 Toggles (2)

Toggle Assembly
5. See Figure 69. Loosen the top knurled locking nut on the toggles and then slide them off
the pivot bar.
Figure 69 • Slide the Toggles Off the Pivot Bar

2
1
1 Pivot bar
2 Toggle(s)
3 Top knurled locking nut
4 Locating marks
Install the New Toggle Assembly

1. Remove the new toggle(s) from the kit(s).
2. See Figure 69. Loosen the top knurled locking nut and then slide the toggle(s) onto the
pivot bar ensuring that the locating marks can be seen.
3. See Figure 68 on page 159 and Figure 67 on page 158. Align the pivot bar with the
mounting hole in the side plate and slide the pivot bar through it.
4. Holding the pivot bar, slide the washer(s) onto it and then slide the handle onto the pivot
bar as shown in Figure 67 on page 158.
5. Insert the handle mounting screw into the handle and then tighten the mounting screw.

Toggle Assembly
6.
7. Set the toggles in the proper location on the pivot bar.
9. Turn on (l) the printer.
10. See the printer’s User Guide for toggle pressure adjustment procedure.

Pivot Bar
Pivot Bar
This kit includes the parts and documentation necessary to install the Pivot Bar maintenance
kit in the Xi4 printers.
Tools Required
Phillips Screwdriver Set SAE Hex Key (Allen Wrench) Set
Caution • A qualified service technician must perform this installation.
1.

Pivot Bar
2. See Figure 70. Remove the electronics cover by removing the two mounting screws
securing it and then lifting up from the rear corner.
Lift up at rear
3 corner.
1 Electronics cover
2 Electronics cover mounting screws (2)
3 Channel
4 Lip of cover
3.

Pivot Bar
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Pivot Bar
Remove the Old Pivot Bar Assembly

1. See Figure 72. Locate the sensor flag in the upper right corner of the electronics cabinet.
Remove and discard the tri-mount and flag.
2. Remove the toggle pivot bar handle by removing and discarding the mounting screw and
then sliding and discarding the handle and wave washer.
3. Slide the toggle pivot bar further into the main frame until the other end comes out of the
side plate, and then remove and discard the toggle pivot bar assembly.
Figure 72 • Replace Head Handle

4
2
3
1 5
6
11
3
2
Can be seen on 10 9
electronics side.
1 Toggle pivot bar 7 Set screw

2 Tri-mount 8 Head handle
3 Sensor flag 9 Side plate
4 Main Frame 10 Head open sensor
5 Flat washer 11 Toggle assemblies (1) or (2)
6 Curved washer

Pivot Bar
Install the New Pivot Bar

1. See Figure 72. Install the toggle pivot bar by sliding the long round end into the main
frame and then the short round end into the side plate.
Note • The toggle assembly(s) are attached to the toggle pivot bar at the factory.
2. Install the flat washer, curved washer, and handle onto the short end of the toggle pivot
bar, and then tighten the set screw.
3. Install the sensor flag by aligning the flat in the sensor flag hole with the flat on the toggle
pivot bar.
4. Close the printhead assembly. The sensor flag must be centered in the slot of the head
open sensor assembly.
5. Push the tri-mount into the hole of the sensor flag and toggle pivot bar.

1.
4.
Open the media door and reinstall media and ribbon.

Head Open Sensor Flag

This kit includes the parts and documentation for installing the sensor flag.Read these
instructions thoroughly before attempting to install this kit.
Tools Required

Flat-Blade Screwdriver Set Safety Goggles
1.

Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover
3.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Remove the Old Sensor Flag

1.
Pry out and discard the trimount clip and the old sensor flag.
Figure 75 • Remove and Install the Sensor Flag
1
2
3 Align Flat
Surfaces
1 Sensor flag
2 Curved washer
3 Trimount clip
4 Toggle pivot bar
Install the New Sensor Flag

1. See Figure 75. Push in the new sensor flag, curved washer, and trimount clip onto the
toggle pivot bar.


3.

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Sensors
Contents
Media Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Media Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Ribbon Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Ribbon Low Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Head Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Take-Label Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Cutter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Media Sensor Assemblies

Tools Required
Phillips Screwdriver Set Antistatic Wriststrap and Mat

Flat-blade Screwdriver Set Safety Goggles
SAE Hex Key (Allen Wrench) Set SAE Nutdriver Set
Needle Nose Pliers
1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.
5. Do you have a 110Xi4 with a printhead test board?
If... Then...
No Go to Remove the Mounting and Printhead Stop Spring Stud on page 177.
Yes Continue to Remove the Printhead Test Board on page 176.


2. See Figure 77. Remove the mounting screw securing the printhead test board shield.

1

2 Mounting screw
3.

4. See Figure 78. Lift the printhead test board shield and the remove the two mounting
screws and then remove the printhead test board and shield.
4
1
2 5
3
J2
J3 J1

Remove the Mounting and Printhead Stop Spring Stud

1.
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.

2. See Figure 79. Using a needle nose pliers, remove the spring from the mounting and
spring tension stud.
Figure 79 • Remove the Mounting and Spring Tensioner Stud
1 Tensioning spring
2 Mounting and printhead stop spring stud
3. Remove the mounting and spring tension stud.

Disconnect Media Sensor Cables

1. See Figure 80. Disconnect the upper media sensor cable from P10 on the main logic board
(MLB).
Figure 80 • Disconnect the Upper and Lower Media Sensor Connectors
1
2
1 P10, Upper media sensor

2 P8, Lower media sensor
2. Disconnect the lower media sensor cable from P8 of the MLB.

3. Did you remove a printhead test board?
If… Then…
No See Figure 81. Remove the nuts securing the cable clamps.
Yes See Figure 81. Remove the printhead test board standoffs and lock washers.
Figure 81 • Access the Media Sensor Cables

Xi4 without Printhead Test Board 110Xi4 with Printhead Test Board
1 1
3
3
2
4
1 Cable clamps (3)

2 Mounting nuts (3)
3 Lock washers (3)
4 Mounting standoffs (3)
4. Remove only the media sensor wires from the cable clamps.

Remove the Upper Media Sensor

1. See Figure 82. Remove the two thumbscrews securing the upper media sensor bracket
assembly.
Figure 82 • Remove the Upper Media Sensor Assembly

1
1 Thumbscrew (2)
2 Mounting screw
2. Remove the mounting screw.
3. Lift the old upper media sensor assembly out of the printer while guiding the upper media
sensor cable through the access hole.

1 Upper media sensor assembly

2 Mounting screw
3 Upper media sensor cable
4 Access hole

Install the New Upper Media Sensor Assembly

1. Remove the upper media sensor assembly from the maintenance kit.
2. See Figure 84. Feed the sensor wires and connector through the access hole in the main
frame.
Figure 84 • Install the Upper Media Sensor Assembly
1 3 4
2

2 Upper media sensor connector
3 Main frame
4 Mounting and printhead stop spring stud
5 Access hole
6 Mounting screw
3. Slide the upper media assembly into the printer and align the two mounting holes.
4. Install the mounting screw and the mounting and spring tensioner.

5. See Figure 85. Install the two thumbscrews.
Figure 85 • Install the Two Thumbscrews
1
2
1 Thumbscrew (2)

Remove the Old Lower Media Sensor Printed Circuit Board (PCB)
1. See Figure 86. Slide the lower media sensor away from the printer main frame. Minimally
pry apart the sides of the bracket holding the sensor PCB. The sensor PCB should fall free
and dangle from its wires.
Figure 86 • Remove the Lower Media Sensor PCB
3
1
1 Lower media sensor bracket

2 Lower media sensor PCB
3 Lower media sensor wires
2. Remove the grommet from the access hole in the main frame. Gently pull on the sensor
while guiding the wires through the access hole in the main frame.
3. Remove the lower media sensor PCB.
Install the New Lower Sensor PCB

1. See Figure 86. Guide the wires of the new lower media sensor through the main frame and
reinstall the grommet.
2. Slightly spread the lower media bracket open and install the lower media sensor PCB with
the component side up.
3. Ensure the sensor PCB is properly seated in the bracket.
4. See Figure 80 on page 179. Connect the upper and lower media sensor connector to the
MLB.
5. Route the wires through the cable clamps and reinstall the grommet around the upper and
lower sensor cables.

6. Do you have a 110Xi4 with the printhead test board?
If... Then...
No a. Reinstall the nuts to secure cables clamps.
b. Go to Reinstall the Electronics Cover on page 187.
Yes a. See Figure 81 on page 180. Reinstall the three printhead test board
standoffs.
b. See Figure 87. Install the hook of the printhead test board shield around the
top mounting spacer.
c. See Figure 78 on page 177. Align the printhead test board, with J1 and J2
facing down and out, with the mounting spacers and then install the top and
right mounting screws.
d. See Figure 77 on page 176. Install the printhead mounting board shield
mounting screw.
e. Reinstall all cables removed from the printhead test board.
f. Continue with Reinstall the Electronics Cover.
Figure 87 • Install the Printhead Test Board Shield
2
3
4

3 Hook
4 Lower mounting spacers (2)


3.
4. Reconnect the data cables and the AC power cord.
Adjust the Upper Media Sensor
Note • There is an LED on the lower media sensor that shines through the media guide slot to
aid in the alignment of the media sensors.
Do you need to set the media sensor to the outside half of the media?
If... Then...
No Continue with Adjust to the Inside Half of Media.
Yes Go to Adjust to the Outside Half of Media on page 188.

Adjust to the Inside Half of Media

1. See Figure 88. Slightly loosen the upper media sensor adjustment screw.
Figure 88 • Upper Media Sensor Location
1 2
1 Upper media sensor adjustment screw

2 Upper media sensor
2. Using the tip of the screwdriver, slide the upper sensor along the slot to the desired
position for non-continuous media with a notch or hole in the media, the sensor must be
directly above the notch or hole.
3. Tighten the adjustment screw to secure the upper media sensor.
Adjust to the Outside Half of Media

1. See Figure 88. Remove the upper media sensor adjustment screw.
2. Lift the upper media sensor assembly from the slot, and move it and the wire cover to the
outside slot. Carefully pull the wires through the cable clamp. You may need to set aside
the sensor wire cover if the adjustment is too far to the outside.
3. Replace and slightly tighten the adjustment screw.
4. Slide the upper media sensor along the slot to the desired position (for noncontinuous
media with a notch or hole in the media, the sensor must be directly above the notch or
hole).
5. Tighten the adjustment screw.
6. Ensure that the wires are routed in the groove of the media sensor bracket.

Adjust the Lower Media Sensor

1. See Figure 89. Locate the lower media sensor assembly under the rear roller. The sensor is
a spring clip holding a circuit board.
Figure 89 • Lower Media Sensor Location
1 Lower media sensor

2 LED
2. Slide the lower sensor until it is under the upper media sensor. Gently pull wires out as
needed (wires should have a little slack).
3. If you move the sensor inward and a large loop of wire develops, remove the electronics
cover from the side of the printer, and gently pull the wires through. Secure the wires so
that they do not touch any drive belts.

Media Low Sensor
Media Low Sensor
Tools Required

1.

Media Low Sensor
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.
Open the media door and remove the media.

Media Low Sensor
Remove the Old Media Low Sensor

1. See Figure 91. Disconnect the media low sensor cable from J9 on the main logic board
(MLB).
Figure 91 • Disconnect the Media Low Sensor
J9
2. Which model of Xi4 printer are you working on?

110Xi4 a. See Figure 92. Remove the two media low sensor mounting
140Xi4 screws and then remove the media low sensor from the mounting
170Xi4 bracket.
b. Pull the media low sensor cable out of the printer while guiding
it through the access hole.
c. Go to Install the New Media Low Sensor on page 195.
220Xi4 a. See Figure 93. Remove the two media low sensor mounting
screws and then remove the media low sensor from the mounting
bracket.
b. Go to Remove the Damper on page 194.

Media Low Sensor
Figure 92 • Remove the Media Low Sensor (110Xi4, 140Xi4, and 170Xi4)
110Xi4
140Xi4
170Xi4
1
2
3
3
1 Media low sensor bracket

2 Media low sensor
Figure 93 • Remove the Media Low Sensor (220Xi4)
220Xi4
4
2
3
3
1 Media low sensor bracket

2 Media low sensor
4 Access hole

Media Low Sensor
Remove the Damper

1.
See Figure 94. Remove the e-ring and washer from the pivot pin on the media door.
2. Remove the pivot pin and washer to release the arm of the damper from the media door.
Figure 94 • Remove the Media Cover Damper

4
3
1
2 3
5
1 Media door
2 E-ring
3 Washers (2)
4 Pivot pin
5 Damper mounting screws (4)
6 Media low sensor mounting bracket
7 Media low sensor
8 Damper mounting bracket
3. Remove the four screws securing the damper assembly and media low bracket to the
damper mounting bracket.
4. Pull the media low sensor cable out of the printer while guiding it through the access hole
and through the damper mounting bracket.

Media Low Sensor
Install the New Media Low Sensor
Caution • Do not touch the media low sensor lens.

110Xi4 a. Guide the new media low sensor cable into the printer via the
140Xi4 access hole.
170Xi4 b. See Figure 92. Install the new media low sensor onto the media
low sensor bracket.
c. See Figure 91 on page 192. Connect the media low sensor cable
to J9 on the main logic board.
d. Go to Reinstall the Electronics Cover on page 196.
220Xi4 a. See Figure 94 on page 194. Guide the media low sensor cable
through the damper mounting bracket as shown.
b. Slide the new damper into the damper mounting bracket,
ensuring that the cable for the media low sensor is not pinched
between the damper and bracket as shown in Figure 95.
c. See Figure 93 on page 193. Slide the new media low sensor
mounting bracket into the damper mounting bracket, ensuring
that the cable for the media low sensor is not pinched between
the two brackets and then install the two front damper mounting
screws.
d. Guide the media low cable through the access hole.
e. See Figure 91 on page 192. Connect the media low sensor cable
to J9 on the main logic board.
f. Go to Reinstall the Electronics Cover on page 196.

Media Low Sensor
Figure 95 • Route the Media Low Sensor Cable
1 2
3
6
5 5

2 Damper assembly
3 Damper assembly mounting bracket
4 Rear damper assembly mounting screws (2)
5 Cable guide
6 Media low sensor cable
7 Front damper assembly mounting screws (2)

3.
4. Reconnect the AC power cord and all data cables.

Media Low Sensor
Calibrate the Media Low Sensor

1.
2. On the control panel press and hold MINUS (–) while turning on (l) the printer until
BBlock is displayed.
3. Press NEXT/SAVE until MEDIA LOW is displayed.
4. Press PLUS (+); LOAD FULL ROLL displays.
5. See Figure 96. Familiarize yourself with the media low sensor calibration tool.
Figure 96 • Media Low Calibration Tool
1 Media roll empty

posts
2 Media roll full posts

Media Low Sensor
Full Media Roll Calibration

1. See Figure 97. Slide media roll full posts of the calibration tool into the keyholes in the
media low sensor bracket and then slide the tool down to secure it in place.
Figure 97 • Full Roll
1
3
2
1 Calibration tool
2 Keyholes
3 Media low bracket
2. Press PLUS (+) to calibrate; CALIBRATING PLEASE WAIT displays.
3. After LOAD EMPTY ROLL is displayed, remove the calibration tool.
4. Continue with Empty Media Roll Callibration.

Media Low Sensor
Empty Media Roll Callibration

1. See Figure 98. Slide media roll empty posts of the calibration tool into the keyholes in the
media low sensor bracket and then slide the tool down to secure it in place.
Figure 98 • Roll Empty

2 3
1 Calibration tool
2 Keyholes
3 Media low bracket
2. Press PLUS (+) to calibrate, CALIBRATING PLEASE WAIT displays.
3. After MEDIA LOW is displayed, remove the calibration tool.
Complete the Installation

2.
Reinstall the media.
4. 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.

Ribbon Sensor
Ribbon Sensor
This kit includes the parts and documentation necessary to install the Ribbon Out Sensor
maintenance kit in the Xi4™ printers.
Tools Required

Phillips Screwdriver Long Set SAE Hex Key (Allen wrench) Set
Flat-blade Screwdriver Set Wire Cutters
Antistatic Wriststrap and Mat 47362* Zebra Preventive Maintenance
Kit
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl
alcohol (minimum 90%) and deionized water (maximum 10%).
1.

Ribbon Sensor
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.

Ribbon Sensor
Disconnect the Old Ribbon Sensor

1.
2. See Figure 100. Disconnect the ribbon sensor from P4 on the main logic board (MLB).
Figure 100 • Disconnect the Ribbon Sensor
P4
3. Are you working on a 110Xi4 with the printhead test board?
If… Then…
Yes Continue with Remove the Printhead Test Board.
No Go to Access the Ribbon Out Sensor Cable on page 205

Ribbon Sensor


1

2 Mounting screw
3.

Ribbon Sensor
4. See Figure 102. Lift the printhead test board shield and then remove the two mounting
screws, printhead test board, and shield.
4
1
2 5
3
J2
J3 J1


Ribbon Sensor
Access the Ribbon Out Sensor Cable

If… Then…
No a. See Figure 103. Remove the nut securing the cable clamp.
b. Open the cable clamp and then remove the ribbon out sensor cable.
Yes a. See Figure 103. Remove the printhead test board spacer and lock washer
securing the cable clamp.
b. Open the cable clamp and then remove the ribbon out sensor cable.
Figure 103 • Access the Ribbon Out Sensor Cable

1 4 1
2 3
1 Cable clamp
2 Mounting nut
3 Mounting spacer
4 Lock washer
2. Cut and discard any cable ties holding the ribbon out sensor cable to the other cables in the
printer.

Ribbon Sensor

1.

1
2.
Caution • Before touching the printhead assembly, discharge any built-up static
electricity by touching the metal printer frame or by using an anti-static wriststrap and
mat.

Ribbon Sensor
4.
printhead to cool.
Figure 105 • Remove the Printhead

1
2
3
7
4
6 5
220Xi4 Printhead 110Xi4, 140Xi4 and 170Xi4

Printhead


Ribbon Sensor
Remove the Old Ribbon Out Sensor

1. See Figure 106. With the print mechanism in the most vertical position, remove the guard
plate by removing the two mounting screws.
Figure 106 • Remove the Ribbon Out Sensor

1 1
2 6 8
7
1 Print mechanism
2 Guard plate
3 Mounting Screws (2)
4 Guard plate access hole
5 Mounting screw
6 Neoprene washer
7 Ribbon out sensor
2. Remove the ribbon out sensor by sliding a long phillips screw driver behind the print
mechanism roller and removing the mounting screw.
3. Slide the ribbon out sensor out of the printer.
4. Pull the ribbon out cable out of the printer and discard it.

Ribbon Sensor
Install the New Ribbon Out Sensor

1. See Figure 106. Install the new ribbon out sensor by sliding the neoprene washer and the
ribbon out sensor into the printer and then install but do not tighten the new mounting
screw.
2. Guide the ribbon out sensor cable through the access hole in the printer.
3. Reinstall the guard plate by aligning the ribbon out sensor with the access hole in the
guard plate and then align the mounting holes in the plate with the mounting holes in the
print mechanism and then reinstall the mounting screws.
4. Snug the ribbon out sensor mounting screw, over tightening the mounting screw will
damage the sensor.
5. Route the ribbon out cable through the cable clamp and then connect it to P4 on the MLB.
6. Install any cable ties previously removed.
If… Then…
No See Figure 103 on page 205. Reinstall the nut securing the cable clamp.
Yes a. See Figure 103 on page 205. Reinstall the printhead test board standoff and
lock washer securing the cable clamp.
b. See Figure 107. Install the hook around the top mounting spacer.
c. Align the printhead test board, with J1 and J2 facing down and out, with the
mounting spacers and then install the top and right mounting screws.
d. See Figure 102 on page 204. Reinstall the two mounting screws.
e. Fold the printhead test board shield over the printhead test board and then
install the shield mounting screw.
f. Reconnect all cables removed from the printhead test board.

Ribbon Sensor
2
3
4

3 Hook
Reinstall the Printhead

1.
2. See Figure 105 on page 207. Ensure that all the cables ar behind the guard plate and then
reinstall the printhead.
mounting bracket.
47362 or a solution of 90% isopropyl alcohol and 10% deionized water.
8.

Ribbon Sensor


Ribbon Low Sensors
Ribbon Low Sensors

This kit includes the parts and documentation necessary to install the Ribbon Low Sensors
Tools Required

Wire Cutters
1.

Ribbon Low Sensors
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Ribbon Low Sensors
Remove the Old Ribbon Low Sensors

1.
2. See Figure 109. Disconnect the ribbon low sensors from J8 and J10 on the main logic
board (MLB).
Figure 109 • Disconnect the Ribbon Low Sensors
J8
J10
3. Cut the cable tie securing the two ribbon low sensor cables to the other cables.

Ribbon Low Sensors
4. See Figure 110. Remove and discard the two ribbon low sensors from the printer by
removing the two screws securing them.
Figure 110 • Remove the Ribbon Low Sensors

2
1
3
5
1 Ribbon supply spindle

2 Upper ribbon low sensor, five pin connector, J8
4 Lower ribbon low sensor, six pin connector, J10
5 Main frame slots
Install the New Ribbon Low Sensors

1. See Figure 110. Choose the ribbon low sensor with the five pin connector, align it with the
upper mounting slot and mounting hole and then install the mounting screw.
2. Choose the ribbon low sensor with the six pin connector, and align it with the lower
mounting slot and mounting hole, and then install the mounting screw.
3. Figure 109 on page 214. Connect the five pin connector to J8 on the MLB.
4. Connect the six pin connector to J10 on the MLB.
5. Install the cable tie around all wires that previously cable tied together.

Ribbon Low Sensors

3.

Head Open Sensor
Head Open Sensor
Tools Required

Flat-blade Screwdriver Set Antistatic Wriststrap and Mat
1.

Head Open Sensor
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Head Open Sensor
Disconnect the Head Open Sensor

1.
2. See Figure 112. Disconnect the head open sensor cable from P5 on the main logic board
(MLB).
Figure 112 • Disconnect the Head Open Sensor
P5
3. Cut the cable tie securing the head open cable to the other cables.
4. Are you working on a 110Xi4 with the printhead test board installed?
If… Then…
No Continue with Remove the Printhead Test Board.
Yes Go to Access the Head Open Sensor Cable on page 222.

Head Open Sensor


1

2 Mounting screw
3.

Head Open Sensor
4. See Figure 114. Lift the printhead test board shield and then remove the two mounting
4
1
2 5
3


Head Open Sensor
Access the Head Open Sensor Cable

If… Then…
No a. See Figure 115. Remove the three nuts securing the three cable clamps.
b. Open the three clamps and remove only the head open sensor cable.
Yes a. See Figure 115. Remove the two printhead test board spacers and lock
washers.
b. Remove the one nut securing the last cable clamp.
c. Open the three clamps and remove only the head open sensor cable.
Figure 115 • Access the Head Open Sensor Cable

2 3 2
4
2 1
1 3
1 Cable clamp (3)

2 Mounting nut (3)
3 Mounting spacers (2)
4 Lock washer (2)

Head Open Sensor
Remove the Old Printhead Open Sensor Assembly

1. Open the printhead so that the head open flag is not within the head open sensor.
2. See Figure 116. Remove and discard the trimount clip securing the flag and then slide the
curved washer and flag out of the printer and discard them.
Figure 116 • Remove the Head Open Sensor Assembly

1 2
9 3
7 8
1 Flag
2 Curved washer
3 Trimount clip
4 Head open sensor assembly
5 Mounting nut
6 Tab
7 Slot
8 Mounting stud
9 Pivot shaft
3. Remove and discard the mounting nut securing the head open sensor assembly and then
slide the sensor assembly out of the printer and discard it.

Head Open Sensor
Install the New Head Open Sensor Assembly

1. See Figure 116. Align the new head open sensor assembly with the mounting stud and
then slide it onto the stud.
2. Install the mounting nut onto the stud, ensuring that the tab on the head open sensor
assembly is in the slot and then tighten the it.
3. Align the new flag with the pivot shaft and slide it onto it.
4. Slide the curved washer onto the pivot shaft and then push the trimount clip into the pivot
shaft hole to secure the flag.
5. Close the head.
6. See Figure 112 on page 219. Route the head open sensor cable behind the main drive belt
and connect it to P5 on the MLB.
7. Insert the head on cable into the three cable clamps and then slide the clips onto the
corresponding mounting studs.
8. Install any cable tie previously removed.
If… Then…
No See Figure 115 on page 222. Reinstall the three nuts onto the mounting studs to
secure the three cable clamps.
Yes a. See Figure 115 on page 222. Reinstall the printhead test board standoff and
lock washer securing the cable clamp.
b. See Figure 117. Install the hook around the top mounting spacer.
c. Align the printhead test board, with J1 and J2 facing down and out, with the
mounting spacers and then install the top and right mounting screws.
d. See Figure 114 on page 221. Reinstall the two mounting screws.
e. Fold the printhead test board shield over the printhead test board and then
install the shield mounting screw.
f. Reconnect all cables removed from the printhead board.

Head Open Sensor
2
3
4

3 Hook
Reinstall the power supplyElectronics Cover


Take-Label Sensors
Take-Label Sensors
This kit includes the parts and documentation necessary to install the take-label sensor maintenance
kit in the Xi4™ printers.
Tools Required
Phillips Screwdriver Set Antistatic Wristband and Pad

1.

Take-Label Sensors
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Take-Label Sensors
Disconnect the Old Take-Label Sensors

1.
2. See Figure 119. Disconnect the take-label connectors from J2 and J3 on the control panel.
Note • Do not remove the control panel from the printer.
Figure 119 • Disconnect the Take-Label Sensors
1 J2, upper sensor, black

and yellow wires
2 J3, lower sensor, black
and red wires

Take-Label Sensors
3. Remove and discard the mounting screws.
Figure 120 • Remove the Take-Label Sensor Mounting Screws

2 Sensors (2)
4. See Figure 121. While guiding the take-label sensor cables out of the printer, remove and
discard the upper and lower take-label sensors.
Figure 121 • Remove the Take-Label Sensors
1 Mounting holes (2)

2 Upper take-label sensor
3 Lower take-label sensor

Take-Label Sensors
Install the New Take-Label Sensors

1. See Figure 122. Feed the upper sensor cable through the upper mounting hole.
Figure 122 • Install the Take-Label Sensors

2
3
4
5
6
7

2 Two pin connector, black and yellow wires
4 Upper take-label sensor window
5 Three pin connector, black and red wires
6 Lower take-label sensor window
2. Position the sensor with the window facing down, and secure with a screw.
3. Feed the lower sensor cable through the lower mounting hole.
4. Position the sensor with the window facing up, and secure with screw.
5. See Figure 119 on page 228. Connect the upper take-label sensor to J2 on the control
panel.
6. Connect the lower take-label sensor to J3 on the control panel.

3. Reinstall the AC power cord and data cables and then turn on (l) the printer.

Cutter Sensor
Cutter Sensor
This kit includes the parts and documentation necessary to install the Cutter Sensor
maintenance kit in the XiIIIPlus™ and Xi4™ printers.
Tools Required

Flat-blade Screwdriver Set SAE Nutdriver Set
SAE Open-End Wrench Set
1.

Cutter Sensor
Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover
3.

Cutter Sensor
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
6. Which model printer are you working?

110Xi4 Go to Remove the AC/DC Power Supply on page 236.
All other Xi4 Continue with Remove the DC Power Supply.
Remove the DC Power Supply

1.
2. See Figure 125. Make note of all cables connected to the DC power supply and then
remove them..

Cutter Sensor
Figure 125 • Remove all Cables
1 2
4
6 5
1 J11 data cable from main logic board

2 J5—J10 DC output to options
3 J4 stepper motor
4 J1 AC input from AC power supply
5 J2 printhead power

Cutter Sensor
3. See Figure 126. Remove the mounting screw and then remove the two mounting nuts.
Figure 126 • Remove the DC Power Supply
1 Mounting screw
2 Mounting nuts (2)
4. Lift the DC power supply out of the printer.
5. Go to Remove the Old Cutter Sensor on page 240.

Cutter Sensor
Remove the AC/DC Power Supply

1. See Figure 127. Remove the AC power connector from the AC/DC power supply.
Figure 127 • Disconnect the AC Power Input Cable

1
1 AC input connector
2 White plastic beaded cable tie
2. Open and remove the white plastic beaded cable tie going through the left corner of the
AC/DC shield and around the AC power input cable. Save this tie for reinstallation.

Cutter Sensor
Caution • Certain components located under the insulation shield can store a residual
charge for as long as ten minutes after power has been removed. Use extreme care
when removing the power supply. Handle the board only by the outer edges.
3. See Figure 128. Remove the two mounting screws securing the AC/DC power supply
shield. Pull the shield flaps out from behind the AC/DC power supply and remove the
shield.

2 Shield mounting screws (2)

Cutter Sensor
4.
5. See Figure 129. Make note of all cables connected to the AC/DC power supply and then
remove them.
Figure 129 • Remove All Cables

J4 J3 J1 J5
J7
J6
J2
J1 Control connector to P26 on the Main Logic

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

Cutter Sensor
6. See Figure 130. Remove the mounting two screws and nuts securing the AC/DC power
supply assembly.
Figure 130 • Remove the AC/DC Power Supply
1 AC/DC power supply

2 Mounting nuts (2)
7. See Figure 131. Lift the AC/DC power supply assembly out of the printer.
AC/DC Power
Supply
Mounting
Studs

Cutter Sensor
Remove the Old Cutter Sensor

1. See Figure 132. Rotate the lower drive arm enough for the flag to clear the cutter sensor.
Figure 132 • Remove the Old Cutter Sensor
1
5
2
3
4 4
1 Mounting nut
2 Cutter sensor
3 Cable clamp
4 Mounting stud
5 Flag
6 Lower drive arm
2. Locate the old cutter sensor and then remove the mounting nut and cable clamp.
3. Slide the cutter sensor off the mounting stud.

Cutter Sensor
4. See Figure 133. Disconnect the cutter sensor from J3 on the cutter board.
Figure 133 • Disconnect the Cutter Sensor
J3
5. Remove and discard the old cutter sensor.
Install the New Cutter Sensor

I
1. See Figure 134. Slide the new cutter sensor onto the mounting stud.
2. Slide the cable clamp onto the mounting stud ensuring the cutter sensor cable routing is as
shown.
Figure 134 • Routing Cable
1
2
3
2
4
5 5
1 Mounting nut
2 Cable clamp
3 Cutter sensor
4 Mounting stud
5 Cutter sensor cable
3. See Figure 133. Connect the cutter cable to J3 on the cutter board.

Cutter Sensor
4. Rotate the lower drive arm to verify that the flag enters the cutter sensor freely.
Reinstall the Power Supply

1. Which model printer are you working?

110Xi4 a. See Figure 131 on page 239. Set the AC/DC power supply onto
the two mounting studs.
b. See Figure 130 on page 239. Reinstall the two mounting nuts
and mounting screws.
c. See Figure 129 on page 238. Reinstall all cables except the AC
power input cable.
d. See Figure 128 on page 237. Reinstall the AC/DC shield.
e. See Figure 127 on page 236. Reconnect the AC power input
cable.
All other Xi4 a. See Figure 126 on page 235. Set the DC power supply into the
printer and onto the two mounting studs
b. Reinstall the two mounting nuts and mounting screw.
c. See Figure 125 on page 234. Reconnect all cables.
d. Continue with Reinstall the Electronics Cover.


Drive System
Contents
Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Main Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Main Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Rewind Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Rewind Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
110Xi4, 140Xi4, and 170Xi4 DC Stepper Motor w/Pulley. . . . . . . . . . . . . . . . . . . . . . . . 307
220Xi4 DC Stepper Motor w/Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
110Xi4 Media Hanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
140Xi4, 170Xi4, and 220Xi4 Media Supply Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Ribbon Supply Spindle Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Ribbon Take-Up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Ribbon and Media Supply Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Media Rewind Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Media Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

Platen Roller
Platen Roller
Tools Required

Phillips Screwdriver Set Small Flat-blade Screwdriver Set
Standard Hex Key (Allen wrench) Set 0.020 in. Shim or Feeler Gauge
Metric Hex Key (Allen wrench) Set Torque Wrench – calibrated in inch-
pounds
Long Metric Hex Key (Allen wrench)
Set with a 25 cm (10 in.) minimum shaft 11303 Spring Gauge 2200g
length
1.

Platen Roller
Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover
3.

Platen Roller
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
6. Are you replacing the upper platen roller?
If… Then…
Yes Continue with Remove the Old Upper Platen Roller.
No Go to Remove the Old Lower Platen Roller on page 251.

Platen Roller
Remove the Old Upper Platen Roller

1. See Figure 137. Align the three access holes in the ribbon take-up pulley with the three
mounting screws.
2. Loosen, but do not remove, the three mounting screws.
3. Slide the ribbon take-up assembly toward the front of the printer to remove the tension on
the main drive belt.
4. Remove the drive belt.
5. Loosen, but do not remove, the two set screws in the platen pulley assembly.
Figure 137 • Main Drive Belt
5
4
1 Ribbon take-up pulley

2 Ribbon take-up access holes (3)
3 Inside peel/tear-off bar mounting screw
4 Upper platen roller pulley
5 Main drive belt
6. Remove the platen pulley from the platen roller shaft.
7. See Figure 138. Using a piece of a label (or masking tape), mark the peel/tear-off bar to
identify the top and right side for reinstallation.
8. Remove the peel/tear-off bar.

Platen Roller
9.
Remove the C-clip.
10. Slide the platen roller as far to the left as possible and remove the right bearing.
11. Slide the platen roller to the right and remove the roller.
12. Remove the left bearing.
Figure 138 • Remove the Tear Bar and Platen Roller

1 2
3
5 9
6
7
3
8
1 Platen roller pulley 6 Mark top right side with label or

tape.
2 Large spacer (all models) 7 Peel/tear-off bar outside mounting
screw
3 Flanged roller bearings (2) 8 Washer
4 Platen roller 9 C-clip
5 Peel/tear-off bar

Platen Roller
Install the New Upper Platen Roller

1. See Figure 138. Install a flanged bearing, flange facing out, into right side of the print
mechanism.
2. Insert the long end of the platen roller shaft through the hole in the main frame.
3. Slide the short end into the flanged bearing previously installed.
4. Install the washer included in the kit onto the right end of the platen roller shaft as shown.
5.
Install the C-clip onto the shaft.
6. From the electronics side, install the left flanged bearing, flange facing out, onto the long
end of the platen roller shaft.
7. Reinstall the peel/tear-off bar using the markings for top and right side.
8. Loosely install both of the peel/tear-off bar mounting screws.
9. Ensure that there is a gap between the platen roller and then peel/tear-off bar
approximately the thickness of a business card.
10. Tighten both peel/tear-off bar mounting screws.
Note • For upper platen roller replacement, the small spacer is not used and should be
discarded.
11. Slide the large spacer onto the left side of the platen roller shaft.
12. Slide rewind platen pulley onto the shaft and align the two set screws with the flat surfaces
of the shaft.
13. Leave approximately a 0.5 mm (0.020 in.) gap between the C-clip and washer on the
media side of the platen roller shaft.
14. Tighten the two set screws of the platen roller pulley.

Platen Roller
15. See Figure 139. Reinstall the main drive belt onto the outer most pulley of the stepper
motor pulley, onto the platen pulley, and then slide it onto the take-up spindle pulley.
Figure 139 • Install the Drive Belt

1
6 3
3
2
1 S
HE
22
NC
00
I
20
00
18
00
16
4
00
14
00

2 Belt
3 Platen pulley
4 Measuring device
5 Stepper motor pulley
6 Spring gauge
7 Access holes (3)
16. Hook a 2200-gram spring scale to the belt as shown in Figure 139, and carefully slide the
ribbon take-up spindle assembly to the left to increase belt tension.
17. When a scale reading of 2000 grams ±250 grams (4.5 lbs. ±0.5 lbs.) creates a deflection of
6 mm (1/4 in.), tighten the three mounting screws to a torque of 2.3 N•m
(20 inch-pounds).

Platen Roller
Remove the Old Lower Platen Roller

1. Turn the printer off (O) and remove the AC power cord. Remove the communications
cable.
2. Open the media cover and remove all media and ribbon.
3. See Figure 140. Remove the rewind plate by sliding it off of the print mechanism.
Figure 140 • Rewind Plate Removal and Installation
4 2
1 Rewind plate
2 Lip
3 Adjustable hook plate
4 Slot
4. What model printer are you working on?

110Xi4 a.
140Xi4 a. Select another user variable from the list.
170Xi4 b. Change the variable definition to a single space.
220Xi4 c. Repeat until all variables that need to be removed have been
changed.
d. Click Done.
e. Click Done again to exit.

Platen Roller
Remove the 140Xi4, 170Xi4, and 220Xi4 DC Power Supply

1.
remove them..
1 2
4
6 5

3 J4 stepper motor

Platen Roller
1 Mounting screw
2 Mounting nuts (2)

Platen Roller
Remove the 110Xi4 AC/DC Power Supply


1

Platen Roller
shield.


Platen Roller
4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

Platen Roller
supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs

Platen Roller
Remove the Rewind Drive Belt

1. See Figure 148. Locate and remove the access hole plug.
Figure 148 • Locate the Print Mechanism Lower Access Hole
1 Print mechanism side plate

2 Lower access hole
2. Using a hex key (Allen wrench) with a 25 cm (10 in.) minimum shaft length, reach
through the hole and loosen the idler pulley mounting screw.

Platen Roller
3. See Figure 149. Slide the idler pulley assembly toward the front of the printer to relieve
the tension on the rewind drive belt and then remove the belt.
Figure 149 • Rewind Belt
1 Rewind pulley
2 Rewind drive belt
3 Idler pulley
4 Lower platen pulley
4. Loosen, but do not remove, the two set screws in the rewind platen pulley.
5. Pull the rewind platen pulley off of the lower platen roller shaft.

Platen Roller
6. See Figure 150. Remove the two screws securing the roller adjust plate to the print
mechanism.
Figure 150 • Lower Platen Roller Removal and Installation

Small spacer for all
models except 220Xi4.
Large spacer for
220Xi4.
1
2
3
6 7
8
5
3
1 Lower platen roller pulley

2 Spacer
3 Flanged bearing
4 Lower platen roller
5 Lower platen roller adjust plate
6 Flat washers (2)
8 C-clip
7. Remove the roller adjust plate and lower platen roller.
8. Remove the old bearing from the printer main frame.
9.
Remove the C-clip from the end of the old platen roller.
10. Slide the roller adjust plate off of the old platen roller shaft and remove the bearing.
Note • Do not re-use the old bearings.

Platen Roller
Install the New Lower Platen Roller

1. Install a new flanged bearing on the roller adjust plate with the flange facing out.
2. Install a new flanged bearing into the main frame from the media side.
3. Insert the long of the shaft new platen roller through the bearing in the main frame.
4. Slide the flanged bearing and roller adjust plate onto the right end of the platen roller
shaft.
5. Reinstall the two washers and mounting screws to secure the roller adjust plate.
Note • For lower platen roller replacement (Peel/Rewind Option only), the washer is not
used and should be discarded.
6. Slide the c-clip into the groove on the right end of the platen roller shaft.
Note • For lower platen roller replacement, the small spacer is used for all models except
the 220Xi4.
7. On the electronics side, slide the spacer onto the shaft.
8. Slide the rewind platen pulley onto the platen roller and align the two set screws with the
flat surfaces of the platen roller.
9. Leave approximately 0.5 mm (0.020 in.) gap between c-clip and roller adjust plate on the
10. Tighten the two set screws on the rewind platen pulley. Both set screws must be on flat
portions of the shaft.

Platen Roller
Reinstall the Rewind Drive Belt

1. See Figure 151. Reinstall the rewind drive belt. Hook a 2200-gram spring scale to the belt
and carefully slide the idler gear assembly to the left to increase belt tension.
Figure 151 • Adjust the Rewind Drive Belt Tension
7 1400
2
1600
1800
2000
2200 3
INCHES
4
5
2
31
1 Rewind drive belt

3 Spring gauge
4 Idler pulley
5 Lower peel roller pulley
6 Measuring device
7 Rewind spindle pulley
2. When a scale reading of 2000 grams ± 250 grams (4.5 lbs. ± 0.5 lbs.) creates a deflection
of 1/4 inch (6 mm), tighten the idler pulley mounting screw to a torque of 2.3 N•m
(20 inch-pounds).
3. See Figure 148 on page 258. Reinstall the plug into the lower access hole.

Platen Roller
4. Which model printer are you working on?
If have a… Then…
110Xi4 a. See Figure 147 on page 257 and Figure 146 on page 257.
Set the AC/DC power supply into the printer and then
reinstall the two mounting nuts and mounting screws.
b. See Figure 145 on page 256. Reinstall all cables except the
AC input cable.
c. See Figure 144 on page 255. Reinstall the AC/DC power
supply shield and secure it. Ensure the shield flaps are
tucked in between the power supply and the aluminum
mounting plate.
d. See Figure 143 on page 254. Connect the AC power input
cable and then reinstall the white plastic beaded cable tie.
e. Go to Reinstall the Electronics Cover.
140Xi4 a. See Figure 142 on page 253. Set the DC power supply into
170Xi4 the printer and then reinstall the two mounting nuts and one
220Xi4 mounting screw.
b. See Figure 141 on page 252. Reconnect all cables to the DC
power supply.
c. Go to Reinstall the Electronics Cover.

4. Press and hold PAUSE while turning on (I) the printer. Observe the printer Power-On Self
Test and examine the test labels for proper print quality.
5. Is the liner material tracking off to one side?
If… Then…
No Installation is complete.
Yes Continue with Adjust the Lower Platen Roller.

Platen Roller
Adjust the Lower Platen Roller

1. See Figure 150. Loosen the two screws securing the roller adjust plate to the print
mechanism.
2. Move the roller adjust plate in the appropriate direction to compensate for the tracking and
tighten the screws.
Note • Moving the roller adjust plate toward the front of the printer moves the liner
material away from the roller adjust plate. Moving the roller adjust plate toward the rear of
the printer moves the liner material toward the roller adjust plate.
3. Repeat step 1 and step 2 until the required results are achieved.

Main Drive System
Main Drive System
Tools Required
Phillips Screwdriver Set SAE Hex Key (Allen wrench) Set

Flat-Blade Screwdriver Set Safety Glasses
11303 Spring Gauge 2200g Ruler
1.

Main Drive System
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
Remove the Old Main Drive System
Remove the Old Drive Belt


110Xi4 See Figure 154. Remove the old main drive belt by pulling out on
140Xi4 the belt while turning the ribbon take-up pulley.
170Xi4
220Xi4 a. See Figure 153. Loosen the idler pulley mounting screw and
slide the pulley up to loosen the belt tension.
b. Remove the drive belt.

Main Drive System
Figure 153 • Loosen the Idler Pulley

1
Loosen
Tighten
1 Idler pulley mounting screw
Figure 154 • Remove the Drive Belt

1
2

2 Main drive belt
3 Platen pulley

Main Drive System
Remove the Ribbon Take-up and Platen Pulleys
1.
See Figure 155. Remove the e-ring securing the ribbon take-up pulley.
Figure 155 • Remove the Old Ribbon Take-up Pulley

1 2 3 4
5
1 Wave washer
2 Flat washer
3 Spacer
4 Ribbon take-up (RTU) pulley
5 E-ring
6 Platen pulley set screws (2)
7 Platen pulley
2. Slide the pulley, spacer flat washer, and wave washer off the ribbon take-up spindle shaft.
3. See Figure 155. Loosen the two set screws and then slide the platen pulley off the platen
roller shaft.

Main Drive System
Install the New Main Drive System
Install the New Ribbon Take-up Pulley

1. See Figure 155 on page 268. Slide the wave washer, flat washer, and spacer onto the
ribbon take-up spindle shaft.
2. See Figure 156. Choose the proper ribbon take-up pulley from the maintenance kit and
then slide it onto the ribbon take-up spindle shaft.
Figure 156 • Choose the Proper Ribbon Take-up Pulley

1 2
1 600 dpi pulley

2 203/300 dpi pulley
3 Toward printer
3. See Figure 155 on page 268. Install the new e-ring to secure the ribbon take-up pulley.

Main Drive System
Install the New Platen Pulley

1. See Figure 157. Choose the proper platen pulley from the maintenance kit and then slide it
onto the platen roller shaft and align the two set screws with the flat surfaces of the shaft.
Figure 157 • Choose the Proper Platen Pulley

1
3
2
1 600 dpi platen pulley assembly

2 Toward the printer
3 203/300 dpi platen pulley

Main Drive System
Install the New Main Drive Belt


110Xi4 a. See Figure 154 on page 267. Install the main drive belt onto the
140Xi4 outer most pulley of the stepper motor pulley, onto the platen
170Xi4 pulley, and then slide it onto the take-up spindle pulley while
turning the take-up pulley.
b. Go to Adjust the Main Drive Belt Tension on page 272.
220Xi4 a. See Figure 158. From the electronics side, slide the idler pulley
from the idler pulley shaft.
b. See Figure 153 on page 267. From the media side, remove and
discard the idler pulley shaft mounting screw and washer.
c. Install the new idler pulley shaft by inserting the new mounting
screw and washer through the mounting hole and then from the
electronics side align the new idler pulley shaft with the
mounting screw and tighten.
d. See Figure 158. From the electronics side, slide the new idler
pulley onto the idler pulley shaft.
e. Reinstall the main drive belt onto the outer most pulley of the
stepper motor pulley, onto the platen pulley, and then slide it onto
the take-up spindle pulley.
f. Go to Adjust the Main Drive Belt Tension on page 272.
Figure 158 • Install the New Idler Pulley
1 2 3
1 Mounting screw
2 Idler pulley shaft
3 Idler pulley

Main Drive System
Adjust the Main Drive Belt Tension


220Xi4 a. See Figure 159. Hook a 2200-gram spring scale to the belt as
shown.
b. See Figure 153 on page 267 and Figure 159. Use a hex key
(Allen wrench) to loosen the idler pulley mounting screw and
carefully slide it to increase the belt tension. When a scale
reading of 2000 grams ±250 grams (4.5 lbs. ± 0.5 lbs.) creates a
deflection of 6 mm (1/4 in.), tighten the idler pulley mounting
screw.
110Xi4 a. See Figure 160. Hook a 2200-gram spring scale to the belt as
140Xi4 shown.
170Xi4 b. Loosen the three ribbon take-up spindle mounting screws by
accessing them through the three access holes in the ribbon take-
up pulley.
c. Slide the ribbon take-up pulley to the left to increase belt tension.
When a scale reading of 2000 grams ±250 grams (4.5 lbs. ±
0.5 lbs.) creates a deflection of 1/4 inch (6 mm), tighten the three
mounting screws.

Main Drive System
Figure 159 • Adjust the Main Drive Belt Tension (220Xi4)

1
8
2
4
5
7
6
1 Idler pulley
2 Decrease tension
3 Increase tension
4 Platen pulley
5 Ruler
7 Spring tension gauge

Main Drive System
Figure 160 • Adjust the Main Drive Belt Tension (110Xi4, 140Xi4, and 170Xi4)
Left Right
6
1
2
5 3

2 Ruler
3 Platen pulley
5 Spring tension gauge
6 Ribbon take-up spindle mounting screws access holes (3)


Main Drive Belt
Main Drive Belt

This kit includes the parts and documentation necessary to install the Main Drive Belt maintenance
Tools Required

11303 Spring Gauge 2200g
1.

Main Drive Belt
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Main Drive Belt
Remove the Old Main Drive Belt
1.
Connect yourself to the printer by using an antistatic device.
2. Remove the main drive belt by holding the belt and rotate it towards the ribbon take-up
pulley as you pull it off that pulley.
Figure 162 • Remove the Main Drive Belt, 110Xi4

2 Main drive belt

Main Drive Belt
Figure 163 • Remove the Main Drive Belt, 140Xi4

2 Main drive belt
Install the New Main Drive belt

1. See Figure 163. Install main drive belt by holding the belt and rotating it towards the
ribbon take-up pulley as you push it on that pulley.

Main Drive Belt

1. See Figure 164. Hook a 2200-gram spring scale to the belt as shown.
Figure 164 • Adjust the Main Drive Belt Tension (220Xi4 shown)
2
1
3
1 Ribbon take-up spindle mounting screw access holes (3)

2 Ribbon take-up spindle pulley
3 Idler wheel (only on 220Xi4)
4 Main drive belt
2. Are you working on a 220Xi4?
If… Then…
No See Figure 164. Slide the ribbon take-up pulley to the left to increase belt
tension. When a scale reading of 2000 grams ±250 grams (4.5 lbs. ± 0.5 lbs.)
creates a deflection of 1/4 inch (6 mm), tighten the three mounting screws.
Yes See Figure 164 and Figure 165. Use an hex key (Allen wrench) to loosen the
idler pulley mounting screw and carefully slide it to the right to increase belt
tension. When a scale reading of 2000 grams ±250 grams (4.5 lbs. ± 0.5 lbs.)
creates a deflection of 6 mm (1/4 in.), tighten the idler pulley mounting screw.

Main Drive Belt
2 1 3
1 Idler pulley adjustment screw

2 Increase belt tension
3 Decrease belt tension
3. Continue with Reinstall the Electronics Cover.


Rewind Drive System
Rewind Drive System
Tools Required
Phillips Screwdriver Set SAE Hex Key (Allen wrench) Long Set
SAE Nutdriver Set Antistatic Wriststrap and Mat
Safety Glasses Spring Gauge 2200g
Ruler Feeler Gauge, 0.020 inch (0.5 mm)
1.

Rewind Drive System
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4. .Which model of Xi4 printer are you working on?

140Xi4 Go to Remove the DC Power Supply on page 288.
170Xi4
220Xi4

Rewind Drive System


1

Rewind Drive System
shield.


Rewind Drive System
4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

Rewind Drive System
supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs
8. Go to Remove the Old Rewind Drive System on page 289.

Rewind Drive System

1.
remove them..
1 2
4
6 5

3 J4 stepper motor

Rewind Drive System
1 Mounting screw
2 Mounting nuts (2)
5. Continue with Remove the Old Rewind Drive System on page 289.

Rewind Drive System
Remove the Old Rewind Drive System
Remove the Old Rewind Drive Belt

1. See Figure 174. Remove the access hole cover and then with a long hex key remove and
discard the screw and washer securing the idler pulley shaft.
Figure 174 • Remove the Idler Pulley

3
4
2 5 6
1
1 Access hole
2 Access hole cover
3 Idler pulley
4 Idler pulley shaft
5 Idler pulley shaft mounting washer
6 Idler pulley shaft mounting screw
2. Remove and discard the idler pulley and shaft.

Rewind Drive System
3. See Figure 175. Remove the main drive belt by pulling it off while turning the ribbon
take-up pulley.
Figure 175 • Remove the Drive Belts

1
2 3 4
4 7 6 5

2 Main drive belt
3 Upper platen pulley
5 Rewind platen pulley
6 Rewind drive belt
4. Remove and discard the rewind drive belt.

Rewind Drive System
Remove the Old Rewind Drive Pulleys

1.
See Figure 176. Remove and discard the e-ring securing the rewind spindle pulley and
then slide the pulley, spacer, flat washer, and wave washer off the rewind spindle shaft
and discard.
Figure 176 • Remove the Rewind Drive Pulleys

2
1
9 8
6
7
1 Rewind spindle shaft

2 Rewind platen roller shaft
3 Rewind platen roller pulley set screws (2)
4 Rewind platen roller pulley
5 E-ring
6 Spacer
8 Flat washer
9 Wave washer
2. Loosen the two set screws in the rewind platen roller drive pulley and then slide the
rewind platen pulley off of the rewind platen roller shaft and discard.

Rewind Drive System
Install the New Rewind Drive System
Install the New Rewind Spindle Pulley

1. See Figure 176 on page 291. Slide the new wave washer and flat washer onto the rewind
spindle shaft.
2. See Figure 177. Choose the proper rewind spindle pulley from the maintenance kit and
then slide it onto the rewind spindle shaft.
Figure 177 • Choose the Proper Ribbon Take-up Pulley

1 2
1 600 dpi pulley

2 203/300 dpi pulley
3 Toward printer
3. Slide the new spacer onto the rewind spindle shaft.
4.
See Figure 176 on page 291. Install the new e-ring to secure the ribbon take-up pulley.

Rewind Drive System
Install the New Rewind Platen Pulley

1. See Figure 178. Choose the proper rewind platen pulley from the maintenance kit and then
slide it onto the rewind platen roller shaft and align the two set screws with the flat
surfaces of the shaft.
Figure 178 • Choose the Proper Rewind Platen Pulley

1
3
2
1 600 dpi rewind platen pulley

2 Away from the printer
3 203/300 dpi rewind platen pulley
3. Tighten the two set screws of the rewind platen roller pulley.
Install the New Rewind Drive Belt

1. See Figure 174 on page 289. Slide the new washer onto the new idler shaft mounting
screw and then align the new idler shaft with the mounting hole and install the mounting
screw and washer.
2. Slide the idler shaft to the left as far as possible and snug the mounting screw.
3. See Figure 176 on page 291. Choose the proper rewind drive belt from the maintenance
kit and then put the belt onto the inner pulley of the stepper motor pulley, rewind platen
pulley and rewind spindle pulley.
4. See Figure 174 on page 289. Loosen the idler pulley and slide to the right until the rewind
drive belt is snug.

Rewind Drive System
Reinstall the Main Drive Belt

1. See Figure 175 on page 290. Reinstall the main drive belt onto the outer most pulley of the
stepper motor pulley, onto the platen pulley, and then slide it onto the take-up spindle
pulley while turning the take-up pulley.
Adjust the Rewind Belt Tension

Figure 179 • Adjust the Belt Tension

2
1 3
4
6
5
1 Increase tension
3 Decrease tension
4 Idler pulley
2. See Figure 174 on page 289. Use a hex key (Allen wrench) to loosen the idler pulley
mounting screw and carefully slide it to increase the belt tension. When a scale reading of
2000 grams ±250 grams (4.5 lbs. ± 0.5 lbs.) creates a deflection of 6 mm (1/4 in.), tighten
the idler pulley mounting screw.

Rewind Drive System


140Xi4 a. See Figure 173 on page 288. Set the DC power supply into the
170Xi4 printer and then reinstall the two mounting nuts and one
power supply.
c. Continue with Reinstall the Electronics Cover.
110Xi4 a. See Figure 171 on page 286 and Figure 170 on page 286. Set the
AC/DC power supply into the printer and then reinstall the two
mounting nuts and mounting screws.
b. See Figure 169 on page 285. Reinstall all cables except the AC
input cable.
c. See Figure 168 on page 284. Reinstall the AC/DC power supply
d. See Figure 167 on page 283. Connect the AC power input cable
e. Continue with Reinstall the Electronics Cover.


Rewind Drive Belt
Rewind Drive Belt

This kit includes the parts and documentation necessary to install the Rewind Drive Belt
Tools Required

Safety Glasses 11303 Spring Gauge 2200g
Ruler Feeler Gauge, 0.020 inch (0.5 mm)
1.

Rewind Drive Belt
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4. Are you working on a 110Xi4 with printhead test board?
If… Then…
No Go to Remove the AC/DC Power Supply on page 298.
Yes Go to Remove the DC Power Supply on page 302.

Rewind Drive Belt


1

Rewind Drive Belt
shield.


Rewind Drive Belt
4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

Rewind Drive Belt
supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs
8. Go to Remove the Old Rewind Drive Belt on page 304.

Rewind Drive Belt

1.
remove them..
1 2
4
6 5

3 J4 stepper motor

Rewind Drive Belt
1 Mounting screw
2 Mounting nuts (2)
5. Continue with Remove the Old Rewind Drive Belt.

Rewind Drive Belt
Remove the Old Rewind Drive Belt

1. See Figure 188. Remove the access hole cover and then with a long hex key loosen the
screw and washer securing the idler pulley shaft.
Figure 188 • Remove the Idler Pulley
1 2 1
1 Access hole
2 Access hole cover
2. Slide the idler pulley and shaft to release the tension on the rewind drive belt and then
slightly tighten the screw to ensure that the idler pulley is not interfering with the rewind
drive belt removal.

Rewind Drive Belt
3. See Figure 189. Remove the main drive belt by pulling it off while turning the ribbon
take-up pulley.
Figure 189 • Remove the Drive Belts

1
2 3 4
4 7 6 5

2 Main drive belt
3 Upper platen pulley
6 Rewind drive belt
4. Remove and discard the rewind drive belt.
Install the New Rewind Drive Belt

1. Slide the idler shaft to the left as far as possible and snug the mounting screw.
2. See Figure 190 on page 306. Choose the proper rewind drive belt from the maintenance
kit and then put the belt onto the inner pulley of the stepper motor pulley, rewind platen
pulley, and rewind spindle pulley.
3. See Figure 188 on page 304. Loosen the idler pulley and slide it until the rewind drive belt
is snug and then slightly tighten the mounting screw.
4. See Figure 189 on page 305. Reinstall the main drive belt onto the outer most pulley of the
stepper motor pulley, onto the platen pulley, and then slide it onto the take-up spindle
pulley while turning the take-up pulley.

Rewind Drive Belt
Adjust the Rewind Belt Tension

Figure 190 • Adjust the Belt Tension

2
1 3
4
6
5
1 Increase tension
3 Decrease tension
4 Idler pulley
2. See Figure 188 on page 304. Use a hex key (Allen wrench) to loosen the idler pulley
mounting screw and carefully slide it to increase the belt tension. When a scale reading of
2000 grams ±250 grams (4.5 lbs. ± 0.5 lbs.) creates a deflection of 6 mm (1/4 in.), tighten
the idler pulley mounting screw.


110Xi4, 140Xi4, and 170Xi4 DC Stepper Motor w/Pulley

This kit includes the parts and documentation necessary to install the DC Stepper Motor and
Pulley maintenance kit into the following printers:
• 110Xi4™
• 140Xi4™
• 170Xi4™
Note • The 220Xi4 have different kit part numbers and installation instructions. See your
maintenance manual for the proper stepper motor and pulley maintenance kit part number.
Tools Required

Phillips Screwdriver Set Standard Nutdriver Set
SAE Hex Key (Allen wrench) Set Safety Glasses
Antistatic Wriststrap and Mat
Note • Please make absolutely sure that the DC stepper motor is isolated and identified as the
cause of printer non-conformance before starting this kit.
Note • Because this kit is so extensive and involved, users are asked to read all instructions
first until they have an understanding of all the steps involved. Work slowly and carefully,
taking notes and labeling parts as you go, as necessary, so you can get all the parts back
together as easily as possible.
Note • Even though the printer models referred to in these instructions are basically similar,
individual art will be shown for each model. Make sure you are looking at the correct
illustration and reading the instructions that apply to your model printer. If no printer models
are listed, the instructions apply to all printers.
1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.
Open the media door and remove the media into the printer.
5. Is there a rewind option installed?
If… Then…
No Go to Remove the Main Drive Belt on page 316.
Yes Continue with step 6.

If you have an… Then…

140Xi4 or 170Xi4 Continue with Remove the DC Power Supply
on page 310.
110Xi4 Go to Remove the AC/DC Power Supply
on page 312.


1.
2. See Figure 192. Note wire connector positions. Tag and label any connector you remove
from the DC power supply to ensure correct reassembly. Unplug ribbon cables and small
wire connectors as necessary to remove the DC power supply board.
Figure 192 • Disconnect the DC Power Supply (early 105SL shown)
4
6 3
5 2
7
1 J9 LCD display
2 J4 Stepper motor
3 J7 Cutter
4 J10 Option
5 J1 AC input
6 J11 Main logic board (MLB)
7 J3 Printhead

3. See Figure 193. Remove the mounting screw and two hex nuts holding the DC power
supply assembly to the printer chassis.
1 /SAVE
SETUP/EX
IT
NEXT
IOUS
PREV
ER
POW
LABEL
TAKE
R
ERRO
RIBBON
CHECK
OUT
PAPER
FEED
PAUSE
DATA
1 DC power supply
2 Mounting nuts (2)
3 Mounting screw
4. Remove the DC power supply assembly from the printer.
Important • The black heat conduction pad MUST NOT be removed.
5. Go to Remove the Main Drive Belt on page 316.



1

Caution • Certain component located under the insulation shield can store a residual
shield.


4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

supply assembly.

2 Mounting nuts (2)
7. Lift the AC/DC power supply assembly out of the printer.
AC/DC Power
Supply
Mounting
Studs

Remove the Main Drive Belt
Note • The ribbon take-up pulley has no lip on it and is designed to allow the main belt to
be pulled off as the pulley is rotated.
1. See Figure 199. Remove the main drive belt by holding the belt and rotate it towards the
ribbon take-up pulley as you pull it off that pulley.
Figure 199 • Remove the Main Drive Belt and Platen Pulley
1
.
4
3
1 Main drive belt

2 Platen roller pulley
4 Rewind drive belt
5 Platen pulley setscrews (2)
If… Then…
No Go to Remove the Platen Roller on page 318.
Yes Continue with Remove the Rewind Drive Belt.

Note • The media take-up pulley has no lip on it and is designed to allow the rewind belt
to be pulled off as the pulley is rotated.
1. See Figure 200. Remove the rewind drive belt by holding the belt and rotating it towards
the media take-up pulley as you pull it off that pulley.
Figure 200 • Remove the Rewind Drive Belt and Pulley
3
6
1 Rewind drive belt

3 Idler pulley
5 Rewind platen pulley setscrews (2)

Remove the Platen Roller

1. See Figure 199 on page 316. Using a hex key, loosen, but do not remove, the two set
screws in the platen pulley assembly.
2. See Figure 201. Pull the platen pulley and spacer off of the platen roller shaft.
Figure 201 • Remove the Platen Roller (XiIIIPlus shown)
1
2
3
6
7 4
3
8
1 Platen pulley
2 Spacer
3 Bearings (2)
4 Tear bar mounting screws (2)
5 Tear bar
6 Mark with label/tape top and right side
7 Platen roller
8 Washer (not on XiIIIPlus)
9 C-clip
3. Mark with label/tape top and right side of the tear bar.
4. Remove the two tear bar mounting screws and the remove the tear bar.

If… Then…
No Go to Remove the Side Plate on page 321.
Yes Continue with Remove the Rewind Platen Roller.
Remove the Rewind Platen Roller

1. See Figure 202. Using a hex key, loosen but do not remove, the two set screws in the
rewind platen pulley.
Figure 202 • Remove the Rewind Platen Roller (105SL shown)
1
2
5 6
3 7 8
1 Platen pulley set screws (2)

2 Spacer
3 Bearing (2)
5 Rewind platen roller
6 Bracket
7 C-clip
8 Bracket mounting screws (2)
9 Bracket mounting washers (2)
2. Slide the rewind platen pulley off the lower peel roller shaft.

3. Remove the small spacer and bearing.
Note • Do not remove the roller adjust bracket unless it is damaged, twisted, or bent. If the
adjust bracket is removed, the alignment is lost and an adjustment procedure must be
performed.
4.
On the media side remove the C-clip and bearing.
5. Slide the platen roller as far to the left as possible to free the right end from the adjust
plate. Remove the roller.

Remove the Side Plate

1. See Figure 203. Remove the head control handle mounting screw and then slide the head
control handle and wave washer off the pivot bar.
Figure 203 • Remove the Side Plate (105SL shown)

5 1
6 2
7
8
7
10
7 4
7 3
1 Head control handle

2 Mounting screw
3 Wave washer
4 Flat washer
5 Pivot bar
6 Printhead pivot shaft
7 Hex key side plate mounting screws (4 wo/dancer, 5 w/dancer)
8 Long hex key screw with lock washer for dancer
9 Phillips head side plate mounting screws (6)
10 Side plate
Note • To ensure that the side plate is reinstalled in the exact position, mark two thin lines
from the side plate to the stepper motor housing.
2. Remove the brass screw from the media guide into side plate and then release the dancer
spring from the side plate.
3. Remove and retain the side plate mounting screws and then remove the side plate.
Note • When removing the side plate, the dancer assembly, upper media sensor bracket,
and media guide plate will still be attached to the main frame.

Remove the Old Stepper Motor
Note • Due to the fact that there are different cable routings for the different printers
involved in this installation, during removal make a note of all cable clamps and cable ties
used.
1. Remove the nut securing the cable clamp(s) holding the stepper motor cable.
2. Open the clamp(s) and then remove the stepper motor cable.
3. Cut any cable ties holding the stepper motor cable.
4. See Figure 204. With a long hex key, reach into the motor housing and remove the four
mounting screws.
Figure 204 • Remove the DC Stepper Motor (105SL shown)
1 Grommet
2 Stepper motor
5. Pull out the old stepper motor, cable, and grommet and then discard.

Install the New Stepper Motor

1. See Figure 204 on page 322. Position the new stepper motor near the motor housing. Feed
the motor power cord through the grommet and the slot in the main frame. Turn the split in
the grommet away from the large opening.
2. Secure the new motor to the main frame with 4 screws, using the long hex key. The
mounting screws are to be torqued to 1.7-1.8 N•m (15-16 lbf. in.).
Reinstall the Side Plate

1. See Figure 203 on page 321. Realign the side plate using the two thin lines that were
drawn and the reinstall the side plate mounting screws.
2. Install the 11 screws removed previously to secure the side plate.
3. The head control lever must be installed in the same orientation as the toggle assembly. If
the toggle is pointing down, then the head control handle must point down.
a. You must compress the wave washer to install the head control lever and to get the
mounting screw to line up with pivot bar.
b. Install and tighten the mounting screw.
4. Route the stepper motor cable and connector over to and through the cable clamp(s)
removed previously.
5. Secure the cable clamp(s) with the nut(s) removed previously.
Reinstall the Rewind Platen Roller Pulley

1. From the electronics side, install the flange bearing, flange facing out, into the rewind
platen mounting hole and from the mechanical side, insert the long end of the rewind
platen roller shaft into the flange bearing.
2. From the mechanical side, insert the flange bearing into the platen support bracket, flange
facing out and onto the short end of the rewind platen roller.
3.
Reinstall the C-clip onto the right side of the platen roller shaft.
4. From the electronics side, slide the spacer and the rewind platen pulley onto the platen
roller shaft.
5. Align the two pulley set screws with the flat surfaces of the platen roller shaft and tighten.
The pulley should be positioned with approximately 5 mm (0.20 in.) between the C-clip
and the flange bearing on the media side.
to be pushed on as the pulley is rotated.

6. Install rewind drive belt by holding the belt and rotating it towards the rewind take-up
pulley as you push it onto the pulley.
Reinstall the Platen Roller and Pulley

1. See Figure 202 on page 319. Install a flanged bearing, flange facing out, into right side of
the print mechanism.
5.
of the shaft.
Note • The ribbon take-up pulley has no lip in it and is designed to allow the main belt to
be pushed on as the pulley is rotated.
11. Install main drive belt by holding the belt and rotate it towards the ribbon take-up pulley
as you push it on that pulley.

Reinstall the Tear Bar
Note • Reinstalling the motor housing cover (side plate) involves a lot of adjustment.
There are bearings that need to be inserted, shafts that need to be installed and several
supports that have to line up with screw holes. Be patient and work carefully. Don’t
tighten any screws until all of the screws are installed.
1. See Figure 201 on page 318. Reinstall the peel/tear-off bar using the markings for top and
right side.
3. Insert the 0.003 inch (0.075 mm) feeler gauge between the peel/tear bar and the platen
roller.
Ensure that the clearance is equal along the length of the platen roller.
5. Which model of printer are you working on?

Xi4 (except 110Xi4) Continue with Reinstall DC Power Supply.
110Xi4 Continue with Reinstall AC/DC Power Supply
Reinstall DC Power Supply

1. See Figure 193 on page 311. Ensure that the black heat conduction pad is in position and
then install the DC power supply securing it the two nuts and one screw.
2. See Figure 192 on page 310. Connect the stepper motor cable to connector J4 on DC
power supply.
3. Reconnect all other cables.
Reinstall AC/DC Power Supply

1. See Figure 198 on page 315. Position the cables out of the way while installing the AC/
DC power supply assembly over the two mounting studs.
2. See Figure 197 on page 315. Install the mounting screws and nuts securing the AC/DC
power supply assembly.
3. See Figure 196 on page 314. Connect all cables to their proper connectors.
4. See Figure 195 on page 313. Reinstall the AC/DC power supply shield and secure it.
Ensure the shield flaps are tucked in between the power supply and the aluminum
mounting plate.
5. Connect the AC power input cable and then reinstall the white plastic beaded cable tie.

Adjust the Rewind Drive Belt Tension

1. See Figure 205. Remove the cover on the lower access hole in the side plate.
Figure 205 • Remove the Lower Access Hole Cover
1 Side plate
2 Lower access hole cover
2. Using a hex key (Allen wrench) with a 10-inch minimum shaft length, reach through the
hole and loosen the idler pulley mounting screw.

3. See Figure 206. Hook a 2200-gram spring scale to the belt and carefully slide the idler
gear assembly to the left to increase belt tension.
7 1400
2
1600
1800
2000
2200 3
INCHES
5
2
31
1 Rewind drive belt

3 Spring gauge
4 Idler pulley
6 Measuring device
of 6 mm (1/4 in.), tighten the idler pulley mounting screw to a torque of 2.3 N•m
(20 lbf. in.).

Adjust the Main Drive belt Tension

1. See Figure 207. Loosen the three ribbon take-up mounting screws through the access
holes in the ribbon take-up pulley.
2. Hook a 2200-gram spring scale to the belt and carefully slide the ribbon take-up spindle
assembly to the left to increase belt tension.

1
6 3
3
2
1 S
HE
22
NC
00
I
20
00
18
00
16
4
00
14
00

2 Belt
3 Platen pulley
4 Measuring device
6 Spring gauge
7 Access holes (3)
1/4 in. (6 mm), tighten the three mounting screws to a torque of 2.3 N•m (20 lbf. in.).


To achieve optimum print quality, install full-width media and ribbon in the printer before
making the printhead adjustments. Perform the five printhead adjustments for optimum printer
performance after installation of a new stepper motor. See the printhead adjustment section in
your printer’s Maintenance Manual.

1. See Figure on page 307. Reinstall the electronics cover by aligning the cover so that it
4.
5. Reinstall the AC power cord and all data cables.

220Xi4 DC Stepper Motor w/Pulley

This kit includes the parts and documentation necessary to install the DC stepper motor into
the 220Xi4™ printer. Read these instructions thoroughly before installing this kit.
Tools Required
Phillips Screwdriver Set Standard Hex Key (Allen wrench) Set

Standard Nutdriver Set Metric Hex Key (Allen wrench) Set
Metric Nutdriver Set Safety Glasses
Antistatic Wriststap and Pad
Note • Please make absolutely sure that the DC stepper motor is isolated and identified as the
cause of printer non-conformance before starting this kit.
Note • Because this kit is so extensive and involved, users are asked to read the entire
instructions first until they have an understanding of all the steps involved. Work slowly and
carefully, taking notes and labeling parts as you go, as necessary, so you can get all the parts
back together as easily as possible.
Note • Even though the printer models referred to in these instructions are basically similar,
individual art will be shown for each model. Make sure you are looking at the correct
illustration and reading the instructions that apply to your model printer. If no printer models
are listed, the instructions apply to all printers.

1.
Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover

Remove the media and ribbon.
If… Then…
No Go to Remove the Main Drive Belt on page 335.
Yes Continue with Remove the Rewind Drive Belt on page 336.


1.
Connect yourself to the printer by using an antistatic device.
2. See Figure 209. Note wire connector positions. Label any connector you remove from the
DC power supply to ensure correct reassembly. Unplug ribbon cables and small wire
connectors as necessary to remove the DC power supply board.
Figure 209 • Interconnections
PCMCIA
Board
1
F3
Main Logic P2 7
Board P2 8
2
P1 7
P6 J2
J2 JP 3
P2 1 3 2 1
JP 5
P1 0
P3 6 JP 6
P5
3 2 1
P8
P3
P1 3
JP 1
1
2
3
P1 2 ELECTRICAL
P3 0 P3 1 P3 2 DANGER
P1
J1 P2
P3 3 P3 5
P3 4 P2 0
J1
J11 J10
J9
J7
J8
J5 3
AC Power PCB DC Power PCB
J6
J4
J1
1 Nut
2 Cable clamp
3 Stepper motor connector
Table 14 • DC Power Supply Connections

J2 Printhead power J9 LCD display power
J3 Printhead power J10 J20 Main logic board (MLB)
J4 Stepper motor J11 J11 MLB
J5 N/A

3. See Figure 210. Remove the mounting screw and nuts securing the DC power supply
assembly.
Figure 210 • DC Power Supply Removal and Installation

;
1 DC power supply
2 Mounting nuts (2)
3 Mounting screw
4. Remove the DC power supply assembly from the printer.
Note • The black heat conductor pad must remain with the printer.

Remove the Main Drive Belt

1. Remove the main drive belt by holding the belt and rotate it towards the ribbon take-up
Figure 211 • Remove the Main Drive Belt

2 Spindle assembly mounting screws access holes (3)
3 Main drive belt
4 Idler pulley


1. Remove the rewind drive belt by holding the belt and rotating it towards the media take-up
Figure 212 • Rewind Drive Belt Removal and Installation
2
5
1 Rewind drive belt

3 Idler pulley
5 Media take-up pulley

Remove the Platen Roller

1. Refer to Figure 213. Loosen, but do not remove, the set screws in the platen roller pulley.
Figure 213 • Remove the Upper Platen Roller
1
2
3
4
6
7
3
8

2 Large spacer (all models)
3 Bearing
4 Peel/Tear bar mounting screws (2)
5 Peel/Tear bar
6 Mark with label/tape top and right side
7 Platen roller
8 Washer
9 C-clip
2. Pull the platen roller pulley and spacer off the platen roller shaft.
3. Mark with label/tape top and right side
4.
Caution • Wear protective eye wear when installing or removing E-rings, C-clips, snap
While facing the front of the printer, slide the upper platen roller to the right. Remove the
c-clip, washer, and right bearing from the upper platen roller.

5. Slide the platen roller as far to the left as possible to free the right end from the side plate.
Remove the upper platen roller.
Remove the Rewind Platen Roller

1. See Figure 214. Using a hex key, loosen but do not remove the two set screws in the
rewind platen pulley.
Figure 214 • Print Mechanism View with Lower Platen Roller
1
2
OPEN
HEAD D
CLOSE
8
3 6 7
4
5
3

2 Large spacer for 220XiIIIPlus only
3 Bearing
4 Platen roller
5 Platen roller adjustment plate
6 Washers (2)
8 C-clip
2. Slide the rewind platen pulley off the lower platen roller shaft.
3. Remove the spacer and bearing.
4. Push the lower platen roller to the right.
Note • Do not remove the roller adjust plate unless it is damaged, twisted, or bent. If the
adjust plate is removed, the alignment is lost and an adjustment procedure must be
performed.
5.
Remove the C-clip.

6. Slide the platen roller as far to the left as possible to free the right end from the adjust
plate. Remove the roller.
Remove the Side Plate

1. See Figure 215. Loosen the printhead lever mounting screw and remove the printhead
lever and the wave washer, as shown in Detail A.
Figure 215 • Side Plate Removal and Installation

5
6 7
4
1 Detail A
3
2
8
1
Put marks here.
1 Side plate mounting screws (11)

2 Side plate
3 Stepper motor housing
4 Bearing
5 Pivot bar
6 Wave washer
7 Mounting screw
8 Printhead lever
Note • To ensure that the side plate is reinstalled in the exact position, mark two thin lines
from the side plate to the stepper motor housing.
2. Remove and retain the 11 side plate mounting screws and remove the side plate.
Note • When removing the side plate, the dancer assembly, upper media sensor bracket,
and media guide plate will still be attached to the main frame.

Remove the Old Stepper Motor
Note • Due to the fact that there are different cable routings for the different printers
involved in this installation, make a note of all cable clamps and cable ties used.
1. On the electronics side, remove the nut, open the cable clamp(s) securing the stepper
motor cable.
2. Open the clamp(s) then remove the stepper motor cable.
3. Cut any cable ties holding the stepper motor cable.
4. See Figure 216. With a long hex key, reach into the motor housing and remove the 4
mounting screws.
Figure 216 • Remove and Install DC Stepper Motor
1 2
6
4
5
1 Grommet
2 Stepper mother cable connector
3 Stepper motor cable
4 Stepper motor
5 Stepper motor mounting screws (4)
6 Side plate
7 Stepper motor housing
5. Pull out the old motor, cable and grommet.

Install the New Stepper Motor

I
1. See Figure 216 on page 340. Position the new stepper motor near the motor housing.
Feed the motor power cord through the grommet and the slot in the main frame. Turn the
split in the grommet away from the large opening.
2. See Figure 209 on page 333. Route the stepper motor wire leads through the cable clamp
and retighten the nut.
3. Secure the new motor to the main frame with 4 screws, using the long hex key. The
mounting screws are to be torqued to 1.7-1.8 N•m (15-16 lbf. in.).
Note • Reinstalling the motor housing cover (side plate) involves a lot of adjustment.
There are bearings that need to be inserted, shafts that need to be installed and several
supports that have to line up with screw holes. Be patient and work carefully. Don’t
tighten any screws until all of the screws are installed.
Reinstall the Side Plate

1. See Figure 215 on page 339. Realign the side plate using the two thin lines that were
drawn and replace the side plate using screws 1 through 11.
2. Slide the flat washer, wave washer, and head control lever onto the pivot bar.
3. The head control lever must be installed in the same orientation as the toggle assembly. If
the toggle is pointing down, then the head control handle must point down.
a. You must compress the wave washer to install the head control lever and to get the
mounting screw to line up with pivot bar.
b. Install and tighten the mounting screw.
4. Route the stepper motor cable and connector over to and through the cable clamp(s)
removed previously.
5. Secure the cable clamp(s) with the nut(s) removed previously.
Reinstall the Tear Bar

1. See Figure 213. Reinstall the peel/tear-off bar using the markings for top and right side.
3. Ensure that there is a gap between the platen roller and the peel/tear-off bar approximately
the thickness of a business card.

Reinstall the Rewind Platen Roller Pulley

1. See Figure 214 on page 338. Install the platen support bracket the side plate with two
washers and two screws. Do not tighten the screws at this time.
2. From the electronics side, install the flange bearing, flange facing out, into the rewind
platen mounting hole and from the mechanical side, insert the long end of the rewind
platen roller shaft into the flange bearing.
3. From the mechanical side, insert the flange bearing into the platen support bracket), flange
facing out and onto the short end of the rewind platen roller.
4. Tighten the mounting screws to secure the platen support bracket. The bracket may need
adjustment later.
5. Reinstall the C-clip onto the right side of the platen roller shaft.
6. From the electronics side, slide the spacer and the rewind platen pulley onto the platen
roller shaft.
Note • The platen support bracket will need adjustment later.
7. Align the two pulley set screws with the flat surfaces of the platen roller shaft and tighten.
The pulley should be positioned with approximately 5 mm (0.20 in.) between the C-clip
and the platen support bracket.
8. Install rewind drive belt by holding the belt and rotating it towards the media take-up
pulley as you push it on that pulley.

Adjust the Rewind Drive Belt Tension

1. See Figure 217. Remove the cover on the lower access hole in the side plate.
Figure 217 • Remove the Lower Access Hole Cover
1 Side plate
2. Using a hex key (Allen wrench) with a 10-inch minimum shaft length, reach through the
hole and loosen the idler pulley mounting screw.

7 1400
2
1600
1800
2000
2200 3
INCHES
5
2
31
1 Rewind drive belt

3 Spring gauge
4 Idler pulley
6 Measuring device
of 6 mm (1/4 in.), tighten the idler pulley mounting screw to a torque of 2.3 N•m
(20 lbf. in.).
Reinstall the Platen Roller and Pulley

1. See Figure 213 on page 337. Install a flanged bearing, flange facing out, into right side of
the print mechanism.

5.
of the shaft.
right-hand side of the platen roller shaft.
Note • The ribbon take-up pulley has no lip in it and is designed to allow the main belt to
11. Install main drive belt by holding the belt and rotating it towards the ribbon take-up pulley
as you push it on that pulley.

Adjust the Main Drive belt Tension

1. See Figure 219. Loosen the three ribbon take-up mounting screws through the access
holes in the ribbon take-up pulley.
2. Hook a 2200-gram spring scale to the belt and carefully slide the ribbon take-up spindle
assembly to the left to increase belt tension.

1
6 3
3
2
1 S
HE
22
NC
00
I
20
00
18
00
16
4
00
14
00

2 Belt
3 Platen pulley
4 Measuring device
6 Spring gauge
7 Access holes (3)
1/4 in. (6 mm), tighten the three mounting screws to a torque of 2.3 N•m (20 lbf. in.).

Reinstall DC Power Supply

1. See Figure 210 on page 334. Ensure that the black heat conduction pad is in position and
then install the DC power supply securing it the two nuts and one screw.
2. See Figure 209 on page 333. Connect the stepper motor cable to connector J4 on DC
power supply.
3. Reconnect all other cables.
4. Reinstall the plug into the lower access hole.

3.

110Xi4 Media Hanger
110Xi4 Media Hanger
Tools Required
Phillips Screwdriver Set Utility Pliers

1.

110Xi4 Media Hanger
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.
Open the media cover and remove the media and ribbon.

110Xi4 Media Hanger
Move the Rear Panel

1.
2. Do you have a wireless board installed?
If… Then…
No a. See Figure 221. Remove the two screws securing the main logic board to
the main frame.
b. Remove the five screws securing the rear panel to the main frame.
c. See Figure 222. Move the rear panel to gain access to the media hanger
hooks.
Yes a. See Figure 221. Remove the screw in the upper left corner of the wireless
board.
b. Remove the two screws securing the main logic board.
c. Remove the five screws securing the rear panel to the main frame.
d. See Figure 222. Move the rear panel to gain access to the media hanger
hooks.
Figure 221 • Remove the Rear Panel

1 2
5
4
1 Rear panel
2 Main frame
3 Wireless board mounting screw
4 Main logic board mounting screws (2)
5 Rear panel mounting screws (5)

110Xi4 Media Hanger
Figure 222 • Gain Access to the Mounting Hooks
1 Mounting hooks (4)
Remove the Old Media Hanger

1. See Figure 223. Remove the media by straightening the hanger hooks.
Figure 223 • Bend the Media Hanger Hooks
3 1
1 Main frame
3 Mounting slots (4)

110Xi4 Media Hanger
2. See Figure 224. Lift up on the hanger and then pull it out of the printer.
Figure 224 • Remove and Install the Media Hanger

2
1 3
4
1 Media hanger
2 Main frame
Install the New media Hanger

1. See Figure 224. Slide the new media hanger into the main frame mounting slots and then
slide it down until the hooks a resting on the main frame.
2. See Figure 223 on page 351. Bend the bottom of the hooks inward to secure the media
hanger.
Reinstall the Rear Panel

1. See Figure 221 on page 350. Align the rear panel with the five mounting holes and the
reinstall the five mounting screws.
2. Reinstall the two main logic board mounting screws.
3. If you have a wireless board installed, reinstall the mounting screw into the upper left
mounting hole.

110Xi4 Media Hanger

3.

140Xi4, 170Xi4, and 220Xi4 Media Supply Hanger

This Kit includes the parts and documentation necessary to install the Media Supply Hanger
maintenance kit into the Xi4 printers.
Read this document thoroughly before installing this kit.
Tools Required

Phillips Screwdriver Set Standard Hex Key (Allen Wrench) Set
Antistatic Mat and Wrist Strap
1.

Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover
3.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Remove the Main Logic Board (MLB)

1. See Figure 227. Remove the radio card cover by removing the screw securing it.
2. Remove the wireless radio card by pressing the eject button.
Figure 227 • Remove the Radio Card
3 4
2
1
1 Mounting screw
2 Radio card cover
3 Radio card
4 Eject button
3. Remove any optional interface boards installed in the printer.

Refer to the removal instructions in the maintenance manual for that board before
continuing with this procedure.

Move the Rear Panel

1.
If… Then…
the main frame.
hooks.
board.
hooks.
Figure 228 • Remove the Rear Pane

1 2
5
4
1 Rear panel
2 Main frame

Figure 229 • Access the Mounting Screw
1 Mounting screw
Remove the Old Media Supply Hanger

1. See Figure 230. Remove the mounting screw and washer from the media side, lift up on
the hanger, and then pull it out of the printer.
Figure 230 • Remove the Media Supply Hanger
2 1 3
2 3
1 Mounting screw
2 Hooks seated on the main frame
3 Hooks lifted off the main frame

2. Remove and discard the media hanger by lifting it straight up then out from the printer
frame.
Install the New Media Hanger

1. Install the media hanger by inserting it into the main frame and then pressing down.
2. Install the hanger mounting screw and washer.
3. Tighten the mounting screw.
If… Then…
No a. See Figure 228 on page 358. Align the rear panel with the mounting holes
and then reinstall the two screws securing the main logic board to the main
frame.
b. Reinstall the five screws securing the rear panel to the main frame.
Yes a. See Figure 228 on page 358. Align the rear panel with the mounting holes
and then reinstall the two screws securing the main logic board to the main
frame.
b. Reinstall the upper left mounting securing the wireless board.
c. Reinstall the five screws securing the rear panel to the main frame.

1.
4.

Ribbon Supply Spindle

This kit includes the parts and documentation necessary to install the Ribbon Supply Spindle
maintenance kit on the Xi4™ printers.
Tools Required

SAE Hex Key (Allen Wrench) Set Wire Cutters
1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.

Remove the Ribbon Supply Spindle

1.
2. See Figure 232. Disconnect the ribbon low sensors from J9 and J10 on the main logic
board (MLB).
Figure 232 • Disconnect the Ribbon Low Sensors
J9
J10
3. Cut the cable tie securing the ribbon low cables to the other cables.

4. See Figure 233. Remove and discard the three screws securing the ribbon supply
spindle and then remove the spindle from the printer.
Figure 233 • Remove the Ribbon Supply Spindle

1
1 Ribbon supply spindle mounting screws (3)

2 Ribbon low sensors (2)
Install the New Ribbon Supply Spindle

1. See Figure 234. Orient the new spindle so that the blades face up.
Figure 234 • Install the Ribbon Supply Spindle

Orient Spindle with Blades
Facing Up and Aligned

2. See Figure 233 on page 364. Orient the new ribbon spindle with the two access holes in
the main frame for the ribbon low sensors and the feed the rbbon sensors wires through the
access holes.
3. Align the three mounting holes in the spindle mount with the three holes in the main frame
and then install the three mounting screws.
4. See Figure 232 on page 363. Reconnect the ribbon low sensor cables to J 8 and J9 on the
MLB.
5. Install the cable tie to the same location it was cut from.

1. See Figure 231 on page 362. Reinstall the electronics cover and secure it with two screws.
2.
3. Reconnect the data cables and AC power cord.

Ribbon Supply Spindle Hardware

This kit includes the parts and documentation necessary to install the Ribbon Supply Spindle (RSS)
Hardware Kit in the Xi4™ printers. Read these instructions thoroughly before installing this kit.
Tools Required
Box-End Wrench Set Phillips Screwdriver Set

11303 Spring Gauge 2200g 01773 Spindle Torque Adjustment Kit
Remove the Old RSS Parts
1.
2.
Open the media door and remove the media and ribbon from the printer.


110Xi4 See Figure 235. Remove adjustment nut and then slide the old parts
off of the RSS shaft.
Figure 235 • Remove the Old Ribbon Supply Spindle Parts 110Xi4
4 5 410
6
3 11
1 9 7 12 91314 15 2 16 17
2 18
2 2 7 8 7 3
1 Ribbon supply shaft 10 Outer blade 30070-1

2 Thrust washer (4) 11 Outer housing
3 Thrust bearing* (2) 12 Friction clutch No. 1, black
4 Screws (4) 13 O-ring, 47439
5 Inner blade 14 Tension plate
6 Inner housing 15 Compression spring
7 O-ring (3) 16 Torsion spring
8 Friction clutch No. 3, white 17 Spring housing
9 Wear plate (2) 18 Adjustment nut
*. Add a small amount of grease before installing.

4 4 10
5 6 14
3 11
13 16 17
1 8 7 12 9 15 2 2 18
2 2 7 97 3
1 Ribbon supply shaft 10 Outer blade 40070-1

4 Screws (4) 13 O-ring, 47439
6 Inner housing 15 Compression spring
7 O-ring (3) 16 Torsion spring
8 Friction clutch No. 3, white 17 Spring housing
9 Wear plate (2) 18 Adjustment nut

3 4 5 4 11 12 13 7 11
6 4 16
8 9 10 9 18 2 19 20
2 2 7 9
1 7 7
15 17 21
3
14
1 Ribbon supply shaft 12 Middle housing

2 Thrust washer (4) 13 Friction clutch No. 2, gray
3 Thrust bearing* (2) 14 Outer housing
4 Screws (6) 15 Friction clutch No. 1, black
5 Inner blade 16 O-ring, 47439
6 Inner housing 17 Tension plate
7 O-ring (3) 18 Compression spring
8 Friction clutch No. 3 white 19 Torsion spring
9 Wear plate (3) 20 Spring housing
10 O-ring 47441 21 Adjustment nut
11 Outer blade 40070-1 (2)

4 5 4 6 4 6 7 4 6 11
9 12 15 16 17
3 10 14
8 2
1
2 2 8 8
3 18
10 13
1 Ribbon supply shaft 10 Wear plate (2)

4 Screws (8) 13 O-ring, 47439
6 Outer blade 40070-1 (3) 15 Compression spring
7 Inner housing 16 Torsion spring
8 O-ring (3) 17 Spring housing
9 Friction clutch No. 3, white 18 Adjustment nut
Install the New Ribbon Supply Spindle Parts


110Xi4 See Figure 235. Slide the new parts onto the RSS shaft as shown.
2. Install the new adjustment nut.

Adjust the Ribbon Supply Spindle

1. See Figure 239. Align the sections of the spindle and then install a 1 inch inside diameter
cardboard core on it.
Figure 239 • Adjust the Ribbon Supply Spindle Tension

2
3 4
1 Ribbon supply spindle

2 Align the plates
3 Core
4 Mylar strip
2. Push the cap in to increase the tension. Let the cap move out to decrease the tension.
3. Use adhesive tape to attach a 2 inch wide strip of polyester strip to the core. Wind the
polyester strip around the core about 5 times in the direction shown.
4. Slowly and evenly, at about 2 inches per second, pull the strip of polyester using a spring
scale. The rotation of the spindle should be smooth and should not cause the reading on
the spring scale to move excessively.
5. Compare the spring scale reading with the load values provided.
Table 15 • Ribbon Supply Spindle Tensions

Model 110Xi4 140Xi4 170Xi4 220Xi4
(Grams) (Grams) (Grams) (Grams)
Tension 450 ±50 450 ±50 500 ±50 600 ±50
6. Turn the adjustment nut clockwise to increase the tension or counter clockwise to decrease
it.

7.
8. Reconnect the AC power cord and turn on (l) the printer.

Ribbon Take-Up Spindle

This kit includes the parts and documentation necessary to install the Ribbon Take-Up Spindle
Assembly maintenance kit on the Xi4™ printers:
Tools Required
Phillips Screwdriver Set 47362* Zebra Preventive Maintenance

Flat-blade Screwdriver Set Kit
Standard Allen Key Set 2200-Gram Spring Scale (Zebra part #
11303
Standard Open-End Wrench Set
2-inch Wide Strip of Polyester Film
Adhesive Tape
Clean Lint-Free Cloth Safety Glasses
1.

Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover
3.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
6.
Open the media cover and remove all media and ribbon.
7. Close and latch the printhead.

Remove the Old Ribbon Take-Up Spindle

1. See Figure 242. Remove the main drive belt by turning the ribbon take-up pulley to the
right and pulling off the belt.

1
1 Main drive belt

2 E-ring

2.
See Figure 243. Using a flat-blade screwdriver, remove the E-ring securing the ribbon
take-up pulley on the shaft and remove the pulley.
Figure 243 • Remove the Ribbon Take-up Spindle
1 2
3 6
4 5 7
8
9
6
7
1 E-ring
3 Spacer
4 Flat washer
5 Wave washer
7 Mounting washers (3)
8 Bearing assembly
9 Spindle/Clutch assembly
3. Remove the spacer, flat washer, and wave washer.

Install the Ribbon Take-up Assembly

1. Clean the main frame on both sides with isopropyl alcohol.
2. See Figure 243. Mount the new bearing housing on the media side of main frame by using
the mounting screws previously removed. Lightly tighten each screw.
3. Install the new ribbon take-up spindle/clutch assembly by sliding its shaft through the
bearing housing.
4. Reinstall the wave washer, flat washer, spacer, and pulley. Secure the assembly with the
new E-ring.
5. See Figure 244 on page 379. Reinstall the main drive belt.
6. Continue with Adjust the Main Drive Belt Tension.
Install the Spindle/Clutch Assembly

1. Install the new ribbon take-up spindle/clutch assembly by sliding its shaft through the
bearing housing.
2. Reinstall the wave washer, flat washer, spacer, and pulley. Secure the assembly with the
new E-ring.
3. See Figure 244 on page 379. Reinstall the main drive belt.
4. Continue with Adjust the Main Drive Belt Tension.


Figure 244 • Adjust the Main Drive Belt Tension (220Xi4 shown)
2
1
3
1 Ribbon take-up spindle mounting screw access holes (3)

2 Ribbon take-up spindle pulley
3 Idler wheel (only on 220Xi4/XiIIIPlus)
4 Main drive belt
2. See Figure 244. Slide the ribbon take-up pulley to the left to increase belt tension. When a
scale reading of 2000 grams ±250 grams (4.5 lbs. ± 0.5 lbs.) creates a deflection of 1/
4 inch (6 mm), tighten the three mounting screws.

3. See Figure 244 and Figure 245. Use a hex key (Allen wrench) to loosen the idler pulley
mounting screw and carefully slide it to the right to increase belt tension. When a scale
reading of 2000 grams ±250 grams (4.5 lbs. ± 0.5 lbs.) creates a deflection of 6 mm (1/
4 in.), tighten the idler pulley mounting screw.
2 1 3
1 Idler pulley adjustment screw

2 Decrease belt tension
3 Increase belt tension


Remove the End Cap/Release Bar Assembly

1. See Figure 246. Remove the end cap/release bar assembly from the spindle/clutch
assembly by pressing in on the two buttons and pulling on the assembly.
Figure 246 • Remove the End Cap/Release Bars
3
1 4
5
2
3
4
Used for tension 6

adjustment. 7
8
2
3
1 Ribbon take-up (RTU) assembly

2 Release bars (2)
3 Release buttons (2)
4 End cap
5 Nut
6 Locking holes (2)
7 Spindle alignment hole
8 Spindle/Clutch assembly
2. Continue with Adjust the Ribbon Take-Up Spindle Assembly Tension.

Adjust the Ribbon Take-Up Spindle Assembly Tension

1. See Figure 246 on page 381. Remove the end cap/release bar assembly, if not already
removed, by pressing in on the two buttons and pulling on the assembly.
2. See Figure 247. Use adhesive tape to attach a 51 mm (2 in.) wide strip of polyester film to
the ribbon take-up spindle shaft. Wind the polyester film around the spindle about five
times.
Figure 247 • Adjust the RTU Spindle Tension
1 Polyester film
2 Adjustment nut
3. Measure the tension by slowly pulling the film with a spring scale. Pull only in the
direction shown in a smooth steady motion. The pull rate should typically be 51 mm
(2 in.) per second.
4. Compare the spring scale reading with the force values shown in Table 16. Perform the
spindle adjustment only if the reading is out of specification.
5. Insert a hex key (Allen wrench) through the hole on the spindle into the hole in the spindle
shaft to keep the spindle from spinning. Turn the adjustment nut clockwise to increase the
tension or counterclockwise to decrease tension. Remove the hex key (Allen wrench) from
the hole.

6. Measure the spindle tension as performed above. Compare the tension reading on the
spring scale with the appropriate force value found in Table 16. Repeat the adjustment
procedure until the correct tension is obtained.
Table 16 • Spindle Force Values for Full Width Media
Printer Force (Grams)

110Xi4 450 ±50
140Xi4 450 ±50
170Xi4 550 ±50
220Xi4 630 ±50
7. Reinstall the end cap/release bar assembly by pressing in on the two buttons and sliding it
into the spindle/clutch assembly.
Note • In Direct Thermal mode, slide the O-ring over the ribbon take-up spindle to silence
the release bars. Remove the O-ring when using a ribbon in thermal transfer mode.
8.
11. Run sample labels to ensure the printer is operating properly.

Ribbon and Media Supply Pulley
Tools Required

Phillips Screwdriver Set Flat-blade Screwdriver Set
1.

Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover
3.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
6. Which pulley are you replacing?
If… Then…
RTU Go to Remove the Old RTU Pulley on page 387
MTU Continue with step 7.
7. Which model Xi4 printer are you working on?

All other models Xi4 Go to Remove the DC Power Supply.

Remove the Old RTU Pulley
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.
Note • The media take-up pulley has no lip on it and is designed to allow the rewind belt to be
pulled off as the pulley is rotated.
1. Remove the main drive belt.
2. See Figure 250. Using a screwdriver or pliers, remove the E-ring securing the RTU pulley.
3. Slide the RTU pulley and spacer off the ribbon take-up spindle shaft.
Figure 250 • Remove the RTU Pulley

1 2
3
4
5
1 E-ring
2 RTU pulley assembly
3 Spacer
4 Flat washer
5 Wave washer

Install the New RTU Pulley
1. See Figure 250. Slide the new spacer and the new RTU pulley onto the ribbon take-up
spindle shaft.
2. Install the E-ring to secure it.
Note • The ribbon take-up pulley has no lip on it and is designed to allow the main belt to
3. Reinstall the main drive belt around the outer gear of the stepper motor pulley, the platen
pulley, and the ribbon take-up pulley.
4. Are you also replacing the MTU?
If… Then…
No Go to Reinstall the Electronics Cover on page 397.
Yes Continue with step 5.
5. Continue with Remove the Power Supply.

Remove the Power Supply

All other models of Continue with Remove the DC Power Supply.
Xi4
charge for as long as 10 minutes after power has been removed. Use extreme care when
removing the AC/DC power supply. Handle the board only around the outer edges.
1. Unplug all ribbon cables and small wire connectors from the DC power supply
2. See Figure 251. Remove the DC power supply by removing two hex nuts and one
mounting screw.
Figure 251 • Remove and Install the DC Power Supply
IT
SETUP/EX
/SAVE
NEXT
IOUS
PREV
ER
POW
LABEL
TAKE
R
ERRO
RIBBON
CHECK
OUT
PAPER
FEED
PAUSE
DATA
1
2
3
4
1 Screw
2 DC power supply assembly
3 Heat-conduction pad
4 Nut (2)


1.
remove them..
1 2
4
6 5

3 J4 stepper motor

1 Mounting screw
2 Mounting nuts (2)
5. Go to Install the New MTU Pulley on page 397.


1

shield.


9.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs
13. Continue with Remove the Old MTU Pulley.

Remove the Old MTU Pulley
Note • The media take-up pulley has no lip on it and is designed to allow the rewind belt to be
pulled off as the pulley is rotated.
1. See Figure 259. Remove the rewind drive belt.
2. Use a screwdriver or pliers to remove the E-ring securing the MTU pulley.
3. Slide the spacer and MTU pulley off the rewind spindle shaft.
Figure 259 • Remove the MTU Pulley

5
3 4
2
1
1 Wave washer
2 Flat washer
3 MTU Pulley
4 Spacer
5 E-ring
6 Rewind spindle

Install the New MTU Pulley
1. See Figure 259. Slide the new MTU pulley and spacer onto the rewind spindle shaft.
2. Install the E-ring to secure it.
3. Reinstall the rewind drive belt around the inner stepper motor pulley, inside the idler
pulley, around the lower peel roller pulley, and slide it around the rewind spindle pulley.

3.

Media Rewind Spindle

This kit includes the parts and documentation necessary to install the media rewind spindle
maintenance kit onto the Xi4™ printers.
Tools Required
Phillips Screwdriver Set SAE Hex Key (Allen wrench) minimum

Flat-blade Screwdriver Set 30 cm (12 in.) Long
N•m (Inch/pound) Torque Wrench Antistatic Wriststrap and Mat
11303 Spring Gauge 2200g Safety Glasses
1.

Lift up at rear
3 corner.
1 Electronics cover
3 Channel
4 Lip of cover
3.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
6.

110Xi4 Continue with Remove AC/DC the Power Supply, Remove AC/DC
the Power Supply.
All other models Go to Remove the DC Power Supply on page 405.
Xi4

Remove AC/DC the Power Supply


1

shield.


4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs
8. Go to Remove the Old Rewind Spindle Assembly on page 406.


1.
2. Note their positions and then disconnect all connectors from the DC power supply
assembly.
3. See Figure 267. Remove the mounting screw and two nuts securing the DC power supply
assembly to the printer and then remove the DC power supply assembly from the printer.
1 DC power supply
2 Mounting screw
3 Mounting nuts (2)
4. Got to Remove the Old Rewind Spindle Assembly on page 406.

Remove the Old Rewind Spindle Assembly

1. See Figure 268. Locate the lower access hole in the print mechanism side plate and
remove the plug.
1 Side plate
2 Lower access hole
2. Using a 7/64 in. hex key (Allen wrench) with a 12-inch minimum shaft length, reach
through the hole and loosen the idler pulley mounting screw.
3. Slide the idler pulley assembly toward the front of the printer to relieve the tension on the
rewind drive belt and then remove the belt.

4.
See Figure 269. Remove the media rewind spindle E-ring and the remove the spacer,
rewind pulley, flat washer, wave washer, and media rewind spindle assembly.
Figure 269 • Remove the Rewind Spindle Assembly
1
3 2
5 4
6
1 E-ring
2 Spacer
4 Flat washer
5 Wave washer
6 Spindle assembly

220Xi4 See Figure 271. Remove the three mounting screws and
washers securing the rewind bearing housing to the printer.
All other models See Figure 270. Remove the three mounting screws and
washers securing the rewind bearing housing to the printer.

Figure 270 • Remove the Old Bearing Housing

(all models except 220Xi4)
2
1
1 Rewind bearing housing

Figure 271 • Remove the Old Bearing Housing (220Xi4)
1 3

4 Flat spot

Install the New Media Rewind Spindle Assembly


220Xi4 See Figure 271. Align the new rewind bearing housing with
the mounting holes, flat side up, and then reinstall the three
mounting washers and screws.
All other models See Figure 270. Align the new rewind bearing housing with
the mounting holes and then reinstall the three mounting
washers and screws.
2. See Figure 269 on page 407. Slide the media rewind spindle assembly through the bearing
housing.
3. Reinstall the wave washer, flat washer, rewind pulley, and spacer and then reinstall the
E-ring.
4. Reinstall the rewind drive belt.

2
1
1 Rewind drive belt

2 Spring scale
3 Ruler

6. When a scale reading of 2000-grams ± 250 grams creates a deflection of 6 mm (1/4 in.),
tighten the idler pulley mounting screw to a torque of 2.3 N•m (20 inch-pounds).


110Xi4 a. See Figure 265 on page 404. Align the AC/DC power supply
with the mounting studs and then set it into the printer.
b. Reinstall the mounting nuts and screws.
c. See Figure 264 on page 403. Reinstall all cables except the AC
input cable.
d. See Figure 263 on page 402. Reinstall the AC/DC power supply
shield.
e. See Figure 262 on page 401. Install the AC power input to J4 on
the AC/DC power supply.
All other models a. See Figure 267 on page 405. Ensure the black heat-conduction
of Xi4 pad is in place.
b. Reinstall the DC power supply.
c. Set the DC power supply on the two mounting studs and then
secure the power supply with the two nuts and one screw
previously removed.
d. Connect all ribbon cables and small wire connectors to the DC
power supply.

3.

Media Supply Spindle
Tools Required

SAE Nutdriver Set Polyester Film
SAE Hex Key (Allen wrench) Set Spring Gauge
1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Move the Rear Panel

1.
If… Then…
the main frame.
hooks or mounting screw.
board.
hooks or mounting screw.
Figure 274 • Remove the Rear Pane

1 2
5
4
1 Rear panel
2 Main frame

Figure 275 • Gain Access to the Mounting Hooks (110Xi4 only)
Figure 276 • Gain Access to the Mounting Screw (all models except 110Xi4)
1 Mounting screw
3. Do you have a media hanger installed?
If… Then…
No Go to See Figure 280. Remove the mounting screw and washer and then
remove the old media supply spindle. on page 416.
Yes Continue with See Figure 277. Remove the media hanger by straightening the
hanger hooks..

Remove the Old Media Supply Hanger

1. See Figure 277. Remove the media hanger by straightening the hanger hooks.
2. See Figure 278. Lift up on the hanger and then pull it out of the printer.
Figure 277 • Bend the Media Supply Hanger Hooks
3 1
1 Main frame
Figure 278 • Remove Media Supply Hanger

2
1 3
4
1 Media hanger
2 Main frame

Figure 279 • Remove the Media Supply Hanger (all models except 110Xi4)
2 1 3
2 3
1 Mounting screw
2 Hooks seated on the main frame
3 Hooks lifted off the main frame
3. Go to Install the New Media Supply Spindle on page 417.
Remove the Old Media Supply Spindle

1. See Figure 280. Remove the mounting screw and washer and then remove the old media
supply spindle.
Figure 280 • Remove the Old Media Spindle

110Xi4, 140Xi4, and 170Xi4 220Xi4
2
1
1
2
1 Lock washer
2 Mounting screw
2. Remove the old media spindle from the printer.
3. Continue with Install the New Media Supply Spindle.

Install the New Media Supply Spindle

1. See Figure 281. Install the media supply spindle with the support between the shaft and
the printer frame align the mounting holes.
Figure 281 • Install the Media Spindle

1 3
2
1 Mounting screw
2 Lock washer
3 Support
4 Media spindle
2. Install the mounting screw and lock washer onto the spindle shaft and then tighten.
3. Reinstall any optional memory/font cards or radio cards.

Adjust the Spindle Tension

1. See Figure 282. Use adhesive tape to attach a 5 cm (2 in.) wide strip of polyester film to
the spindle shaft (or core where required).
2. Wind the polyester film around the spindle (or core) about five times in the direction
shown.
Figure 282 • Adjust the Spindle Tension

1
5
4
1 Media supply spindle

2 Direction
3 Polyester film
4 Core
5 Adjustment nut
3. Measure tension by slowly pulling the film with a spring scale. Pull only in the direction
shown. The pull rate should be 5 cm (2 in.) per second.
4. Is the spring tension reading 300 grams ±50?
If… Then…
No a. See Figure 282. Make adjustments using the tension adjustment nut.
• Clockwise increases tension.
• Counterclockwise decreases tension.
b. Recheck the tension after running a full roll of labels.
c. Continue with Reinstall the Electronics Cover on page 419.
Yes Continue with Reinstall the Electronics Cover on page 419.


3.
4. Reconnect the AC power cord and data cables

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Roller System
Contents
Dancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Rewind Platen Roller Adjustment Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Ribbon Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434

Dancer Assembly
Dancer Assembly
Tools Required

Antistatic Wriststrap and Pad
1.

Dancer Assembly
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.

• 140Xi4 Go to Remove the Old Dancer Assembly on page 426.
• 170Xi4
• 220Xi4
110Xi4 w/printhead Continue with continue with Remove the Printhead Test Board.
test board

Dancer Assembly

1.

1

2 Mounting screw

Dancer Assembly
4. See Figure 285. Lift the printhead test board shield and then remove and the two mounting
5. Move the printhead test board out of the way.
Note • There is no need to remove the cables from the printhead test board, unless you
need more room to access the dancer mounting screw.
4
1
2 5
3

6. Continue with Remove the Old Dancer Assembly.

Dancer Assembly
Remove the Old Dancer Assembly

1. See Figure 286. Locate the mounting screw on the electronics side between the two cable
clamps.
Figure 286 • Remove the Mounting Screw (110XiIIIPlus shown)
1 Mounting screw
2 Cable clamps (2)

Dancer Assembly
2.
On the media side remove and discard the mounting screw and lock washer in the side
plate.
Figure 287 • Remove the Mounting Screw and Lock Washer
2
1
3
4
1 Mounting screw
2 Lock washer
3 Side plate
4 Outer torsion spring
5 Inner torsion spring
6 Main frame

Dancer Assembly
3. See Figure 288. Slip the outer torsion springs through the hole in the side plate.
4. Slip the inner torsion spring out of the main frame.
5. Slide the dancer assembly out of the printer.
Figure 288 • Remove the Dancer Assembly

1
1 Dancer assembly

Dancer Assembly
Install the New Dancer Assembly

1. Remove the dancer assembly from the kit.
2. See Figure 289. Prepare the dancer assembly for installation.
Figure 289 • Prepare the Dancer Assembly
2
3
6
7
1 Dancer housing
2 Roller shaft
3 Roller
4 Bearings (2)
7 Preparation complete
3. Ensure that all components of the dancer assembly are in place.
4. See Figure 288 on page 428. Slide the dancer assembly into the printer.

Dancer Assembly
5. Insert the inner torsion spring into the main frame hole and then insert the outer into the
hole in the side plate.
6. See Figure 287 on page 427. Install the new screw and lock washer through the side plate
mounting hole, into the dancer assembly, and then tighten the mounting screw.
7. See Figure 286 on page 426. On the electronics side align the dancer assembly roller shaft
with the mounting hole.
8. Install the remaining new screw and lock washer through the mounting hole, into the
dancer roller shaft and then tighten the mounting screw.

110Xi4 w/printhead test board a. See Figure 285 on page 425. Align the printhead
test board, with J1 and J2 facing down and out, with
the mounting spacers and then install the top and
right mounting screws.
b. See Figure 284 on page 424. Bend the printhead
test board shield down until the mounting hole
aligns with the left mounting hole in the printhead
test board and then reinstall the printhead mounting
board shield mounting screw.
• 110Xi4 w/o printhead test Continue with Reinstall the Electronics Cover.
board
• 140Xi4
• 170Xi4
• 220Xi4

1. See Figure 283. Reinstall the electronics cover by aligning the cover so that it slips over
the main frame.
3.

Rewind Platen Roller Adjustment Bracket

This kit includes the parts and documentation necessary to install the Rewind Platen Adjustment
Bracket maintenance kit in the Xi4™ printers.
Tools Required
SAE Hex Key (Allen wrench) 47362* Zebra Preventive Maintenance

Kit
Remove the Rewind Platen Roller Adjustment Bracket

1.
2.
See Figure 290. Remove and discard the C-clip from the platen roller.

Figure 290 • Remove and Install the Rewind Platen Roller Adjustment Bracket
1 2
3
4
6 5
1 C-clip
2 Rewind adjustment bracket
3 Flat washers (2)
5 Flange bearing
3. Slide the flange bearing out of the rewind adjustment bracket.
4. Remove and discard the two mounting screws and washers, and then discard the old
rewind adjustment bracket.
Install the Rewind Platen Roller Adjustment Bracket

1. See Figure 290. Remove the two mounting screws and flat washers from the kit and then
slide one of the washers onto each of the screws.
2. Align the new rewind platen adjustment bracket with the two mounting holes on the
printer.
3. Install the two mounting screws and washers.
4. While holding the rewind platen, slide the new flange bearing, flange facing out, onto the
platen shaft and into the new rewind platen adjustment bracket.
5.
While still holding the rewind platen, install the new C-clip.
6.

7. Press and hold PAUSE while turning on (l) the printer and check for proper tracking of the
media onto the rewind spindle.
8. Is the media tracking properly?
If… Then…
Yes Installation complete.
No Continue with Adjust the Rewind Platen Roller Adjustment Bracket.
Adjust the Rewind Platen Roller Adjustment Bracket

1. See Figure 291. Loosen the two screws securing the rewind adjustment bracket to the print
mechanism.
Figure 291 • Adjust the Rewind Platen Roller Adjustment Bracket
1 Rewind platen roller adjustment bracket

tighten the screws.
Note • Moving the rewind adjustment bracket toward the front of the printer moves the
liner material away from the roller adjust plate. Moving the rewind adjustment bracket
toward the rear of the printer moves the liner material toward the rewind adjustment
bracket.
4. Turn off (O) the printer and reconnect all data cables.

Ribbon Rollers
Ribbon Rollers
This kit includes the parts and documentation necessary to install the Ribbon Rollers maintenance
Tools Required
Phillips Screwdriver Set Flatblade Screwdriver Set

SAE Hex Key (Allen wrench) Set SAE Nutdriver Set
1.

Ribbon Rollers
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.
5. Which ribbon roller assembly are you replacing?
If… Then…
Top Ribbon Roller Go to Remove the Top Ribbon Roller Assembly on page 436.
Lower Ribbon Roller Go to Are you working on a 110Xi4 with the printhead test
board installed? on page 438.
Ribbon Dancer Rollers Go to Remove the Ribbon Dancer Rollers on page 444.
Print Mechanism Go to .
Roller

Ribbon Rollers
Remove the Top Ribbon Roller Assembly

1. See Figure 293. Remove and discard the mounting screw on the electronics side.
Figure 293 • Remove the Top Ribbon Roller Assembly

1
2
3
1 Electronics side mounting screw

2 Roller, shaft, and bearings assembly
3 Media side mounting screw
2. Remove and discard the mounting screw on the media side and then slide the roller, shaft,
and bearings out of the printer and discard.

Ribbon Rollers
3. See Figure 294. Assemble the roller, shaft, and bearings assembly.
Figure 294 • Assemble the Top Roller, Shaft, and Bearings Assembly
1
2
3
1
1 Bearings (2)
2 Top ribbon roller
3 Top ribbon roller shaft
Install the New Top Ribbon Roller Assembly

1. See Figure 293 on page 436. Slide the top ribbon roller assembly into the printer and align
it with the mounting hole on the media side.
2. Start the media side mounting screw.
3. Align the top ribbon roller assembly with the electronics side mounting hole.
4. From the electronics side start the mounting screw and then tighten it.
5. Tighten the media side mounting screw.
6. Are you installing another ribbon roller assembly?
If… Then…
No Go to See Figure 292 on page 435. Reinstall the electronics cover by aligning
the cover so that it slips over the main frame. on page 449.
Yes a. For the lower ribbon roller continue with Are you working on a 110Xi4 with
the printhead test board installed? on page 438.
b. For the ribbon dancer rollers go to Remove the Ribbon Dancer Rollers
on page 444.
c. For the print mechanism roller assembly go to .

Ribbon Rollers
Remove the Lower Ribbon Roller Assembly

If… Then…
No Continue with step 295.
Yes a. See Figure 295. Remove the printhead test board shield by removing the
screw securing it.
b. See Figure 296. Remove the two mounting screws securing the printhead
test board.
c. See Figure 297. Move the printhead test board to gain access to the upper
reflective media sensor cable and head spring lift stop.
d. Continue with step 295.

1

2 Shield mounting screw

Ribbon Rollers

1

2 Printhead test board mounting screws (2)
Figure 297 • Remove the Head Lift Spring Stop

1
1 Head lift spring

2 Head lift spring stop
2.
See Figure 297. Open the printhead and then remove the head lift spring from the head
lift spring stop with a pair of needle nose pliers.

Ribbon Rollers
3. Remove the head lift spring stop.
4. Disconnect the black mark sensor cable from P9 on the main logic board. Do not remove
the cable from any cable ties or cable clamps.
Figure 298 • Disconnect the Upper Reflective Media Sensor
P9
5. See Figure 299. From the media side remove the mounting screw from the side plate.
Figure 299 • Remove the Brass Screws
1 Mounting screw
2 Brass screws (2)

Ribbon Rollers
6. See Figure 300. Pull the upper media sensor assembly out of the printer while ensuring
that the cable does not get damaged until you can remove the roller, shaft, and bearings.
7. Slide the upper media sensor assembly out of the printer
1 Lower ribbon roller

2 Black mark sensor assembly
3 Lower ribbon roller shaft
4 Bearings (2)

Ribbon Rollers
8. See Figure 301. Slide the shaft out of the roller and black mark sensor assembly and
discard it.
9. Remove and discard the roller and then remove and discard the two bearings.
Figure 301 • Assemble and Disassemble the Lower Ribbon Roller

1
1 Lower roller
2 Black mark sensor assembly
3 Lower roller shaft
4 Lower roller bearings (2)
Install the New Lower Ribbon Roller

1. See Figure 301. Insert the two new bearings into the black mark sensor assembly as
shown.
2. See Figure 300 on page 441. Slide the new lower ribbon roller between the two bearings
and then slide the lower ribbon roller shaft through the outside bearing, into the lower
ribbon roller and then through the inside bearing.
3. While pulling the black mark sensor cable back into the electronics side, slide the
assembly into the printer.
4. See Figure 299 on page 440. Align the upper media sensor assembly with the two
mounting holes for the brass screws and then reinstall the two brass screws.
5. Align the upper media sensor assembly with the media side mounting screw hole and then
install the mounting screw.mounting screw.
6. See Figure 297 on page 439. Align the upper media sensor assembly with the electronics
head lift mounting spring stop mounting hole.
7. Install the head lift spring stop.
8. Reinstall the head lift spring onto the head lift spring stop.

Ribbon Rollers
9. See Figure 298 on page 440. Reconnect the black mark sensor cable to P9 on the main
logic board.
10. Are you working on a 110Xi4 with the printhead test board install?
If… Then…
Yes a. Align the printhead test board with the mounting standoffs and then install
the two mounting screws.
b. Align the printhead test board shield with the mounting hole and then install
the mounting screw.
c. Reconnect any cables removed to gain access to the black head spring stop.
If… Then…
No Go to Reinstall the Electronics Cover on page 449.
Yes a. For the print mechanism roller assembly continue with Remove the Ribbon
Dancer Rollers.
b. For the top ribbon roller go to Remove the Top Ribbon Roller Assembly
on page 436.
c. For the ribbon dancer rollers go to .

Ribbon Rollers
Remove the Ribbon Dancer Rollers

1. See Figure 302. Remove and discard the two screws securing the small ribbon dancer
roller assembly and then remove and discard the small ribbon dancer assembly.
Figure 302 • Remove the Old Ribbon Dancer Rollers

1

3 Ribbon dancer small roller assembly

Ribbon Rollers
2. See Figure 303. Slide the outer washer of the ribbon dancer roller shaft and then slide the
large roller off the shaft. Slide the inside washer off the shaft.
Figure 303 • Remove the Large Ribbon Dancer Roller

1
1 Ribbon dancer roller shaft

2 Inside washer
3 Large roller
4 Outside washer

Ribbon Rollers
Install the Ribbon Dancer Rollers

1. See Figure 303. Slide the inside washer, new ribbon dancer large roller, and then the
outside washer onto the ribbon dancer roller shaft.
2. See Figure 304. Install the small roller assembly in the slot on the shaft with the large
roller inside and outside washers closest to the large roller, as shown.
Figure 304 • Install the Small Ribbon Dancer Roller
1 4
2 1
3
2
4
5 6

3 Large roller inside washer
4 Large roller
5 Small roller assembly
6 Large roller outside washer

Ribbon Rollers
Remove the Print Mechanism Roller Assembly

1. See Figure 305. Open the printhead and align the print mechanism roller mounting screw
with the printhead cable access hole in the main frame.
Figure 305 • Remove the Inside Mounting Screw
1 Access hole
2 Print mechanism roller inside mounting screw
2. See Figure 306. Remove the print mechanism roller outside mounting screw.
Figure 306 • Remove the Outside Mounting Screw

2 Print mechanism roller outside mounting screw
3. See Figure 307. Remove and discard the print mechanism roller and shaft.

Ribbon Rollers
Figure 307 • Remove the Print Mechanism Roller
1 Inside print mechanism roller mounting screw

2 Outside print mechanize roller mounting screw
3 Print mechanism roller and shaft
Install the New Print Mechanism Roller

1. Slide the print mechanism roller shaft into the print mechanism roller and then insert it
into the printer.
2. See Figure 306 on page 447. Align the print mechanism roller with outside mounting hole
and then start the outside mounting screw.
3. See Figure 305 on page 447. Align the inside mounting hole with the access hole and then
align the print mechanism roller with the inside mounting hole.
4. Install and tighten the inside mounting screw.
5. Tighten the outside mounting screw.
If… Then…
No Continue with See Figure 292 on page 435. Reinstall the electronics cover by
aligning the cover so that it slips over the main frame. on page 449.
Yes a. For the lower ribbon roller continue with Are you working on a 110Xi4 with
the printhead test board installed? on page 438.
b. For the top ribbon roller go to Remove the Top Ribbon Roller Assembly
on page 436.
c. For the ribbon dancer rollers go to Remove the Ribbon Dancer Rollers
on page 444.

Ribbon Rollers

3.
5. Press and hold PAUSE while turning on the printer.
6. After the Power On Self Test (POST), the printer will start to print the Pause test labels.
7. Press PAUSE. After the printer pauses, observe the ribbon for possible problems such as
wrinkling.
8. Does the ribbon wrinkle or track incorrectly?
If… Then…
No Installation is complete.
Yes Continue with .
Adjust the Print Mechanism Roller

1. The print mechanism roller can be adjusted for proper ribbon tracking and to eliminate
ribbon wrinkle.
2. Open the printhead and loosen the outside mounting screw.
3. Which way do you want to move the ribbon?
If you want to move the ribbon… Then…

Away from the main frame Slide the roller up and then retighten the outside
mounting screw.
Toward the main frame Slide the roller down and then retighten the
outside mounting screw.
4. Close the printhead and press PAUSE to restart the printing.
5. Repeat step 2 through step 4 until the tracking is correct and there is no ribbon wrinkle.

Ribbon Rollers
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Printed Circuit Boards
Contents
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Control Panel Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
110Xi4 AC/DC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
DC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Cutter Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
110Xi4 Power Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
140Xi4, 170Xi4, and 220Xi4 Power Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Electronics Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Printhead Test Board Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Twinax/Coax Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
Applicator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
Wireless Plus PCMCIA Option/Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
Compact Flash Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
ZebraNet® Internal Wireless Plus Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
SEH PS102-Z IPv6 Internal Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591

Control Panel
Control Panel
Tools Required

1.

Control Panel
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.

Control Panel
Remove the Old Control Panel

1.

110Xi4 See Figure 309. Disconnect the control panel cable from P29 on the
main logic board (MLB).
140Xi4, 170Xi4, See Figure 310. Disconnect the control panel cable from P29 on the
or 220Xi4 main logic board (MLB).
Figure 309 • Disconnect the Control Panel (110Xi4)

6
5
1 4
2 3
1 Main logic board (MLB)

2 MLB connector P29
3 Control panel cable
4 Cable clamps (3)
5 Cable clamp nuts and washers (3)
6 Control panel

Control Panel
Figure 310 • Disconnect the Control Panel (140Xi4, 170Xi4, and 220Xi4)
4 6
2 3 5
1

2 MLB connector P29
4 Cable clamps (3)
5 Cable clamp nuts and washers (3)
6 Control panel
3. Are working on a 110Xi4 with the printhead test board installed?
If… Then…
No a. See Figure 309 on page 454 or Figure 310. Remove the three nuts and
washers securing the three cable clamps.
b. Continue with step 4.
Yes a. See Figure 311. Remove mounting screw securing the printhead board
shield and then open lift it up to access the other two mounting screws.
b. Remove the two remaining mounting screws securing the printhead test
board.
c. Move the printhead test board to gain access to the standoffs.
d. Remove the right standoff and lock washer.
e. Remove the cable clamp mounting nut.
f. Cut the cable tie.
g. Continue with step 4.

Control Panel

1

2 Mounting screw
Figure 312 • Remove the Standoff

1
3 4
5 3 2
1 Standoff
2 Mounting nut
3 Cable clamp2 (2)
4 Lock washer
5 Cable tie
4. Open the cable clamps and then remove the control panel cable.

Control Panel
5. See Figure 313. Open the ferrite block by using a flat-blade screwdriver to raise the tabs
and then remove the control panel cable.
Figure 313 • Open the Ferrite Block
1 Ferrite block
2 Tabs (2)
Figure 314 • Remove the Control Panel Cable
1
2

2 Ferrite block

Control Panel
6. See Figure 315. Remove the control panel by removing and discarding the two lower
mounting screws, one on the electronics side and one on the media side.
Figure 315 • Remove the Control Panel
1 2 3
1 Lower mounting screw media side

2 Upper mounting screw
3 Control panel
4 Lower mounting screw electronics side
7. Remove and discard the upper mounting screw.
8. Slide the control panel out of the printer while guiding the control panel cable through the
access hole.
9. Remove and discard the old ferrite block by cutting the cable tie securing it to the printer.
Figure 316 • Remove the Ferrite Block
1 Cable tie

Control Panel
Install the New Control Panel

1. See Figure 317. Remove the ferrite block from the kit. Turn it so that the rear is facing you
and then slide a cable tie in one slot and out the other.
Figure 317 • Install the Cable Tie on the Ferrite Block

2
1
1 Cable tie
2 Ferrite block
3 Slots (2)
2. From the electronics side insert the cable tie through the main frame and then attach it.
3. Cut the excess cable tie.
4. Open the ferrite block.
Figure 318 • Open the Ferrite Block
1 Ferrite block
2 Tabs (2)

Control Panel
5. See Figure 319. Guide the new control panel cable through the access hole.
6. Slide the two mounting tabs into the two slots and then set the control panel into the main
frame so that the two guide posts are in the two guide holes.
Figure 319 • Align the Control Panel
1 Control panel
2 Main frame
3 Control panel cable access hole
4 Guide holes (2)
5 Guide posts (2)
6 Slots (2)
7 Mounting tabs (2)
7. See Figure 315 on page 458. Install the upper mounting screw.
8. Install the two lower mounting screws.
9. See Figure 314 on page 457. Thread the new control panel cable up through the ferrite
block and then close it, ensuring not to pinch the cable.
10. See Figure 309 on page 454 or Figure 310 on page 455. Thread the new control panel
cable behind the drive belt, through the cable clamps.

Control Panel
If… Then…
No a. See Figure 309 on page 454 or Figure 310 on page 455. Reinstall the three
mounting nuts to secure the cable clamps.
b. Connect the control panel cable to P29 on the MLB.
Yes a. See Figure 312 on page 456. Reinstall the mounting nut to secure the far
right cable clamp.
b. Reinstall the lock washer and standoff to secure the other cable clamp.
c. Install a new cable tie to secure the control panel cable to the left standoff.
d. Align the printhead test board with the three standoffs and then reinstall the
top and right mounting screws.
e. See Figure 311 on page 456. Reinstall the printhead mounting board shield
mounting screw.
f. Connect the control panel cable to P29 on the MLB.
12. Ensure that the control panel cable does not come contact with any moving parts.

3.

Control Panel Cover
Control Panel Cover
Remove the Old Control Panel Cover

1.
Turn off (O) the printer and disconnect the AC power cord.
2. See Figure 320. Choose a corner and peel the old control panel cover off of the control
panel.
Figure 320 • Remove and Install the Control Panel Cover
2 3
1 Control panel cover

2 Peel corner
3 New control panel cover
4 Align first
3. If there is any residual adhesive, remove it using isopropyl alcohol and a clean cloth.

Control Panel Cover
Install the New Control Panel Cover

1. See Figure 320. Peel the backing off of the new control panel cover.
2. Hold the new control panel cover in both hands and then align it with lower left and right
keys on the control panel, ensuring that the cover does not interfere with the buttons.
3. To ensure that the control panel cover adheres, press the cover onto the control panel
working from the center out to the edges.

Main Logic Board
Main Logic Board

This kit includes the parts and documentation necessary to install the Main Logic Board
(MLB) maintenance kit in the Xi4™ printers.
Tools Required
Phillips Screwdriver Set Standard Hex Key (Allen Wrench) Set

Standard Nutdriver Set Antistatic Mat and Wrist Strap
1.

Main Logic Board
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4. Which option do you have installed?

Applicator interface board Go to Remove the Applicator Board on page 466.
Twinax/Coax board Go to Remove the Twinax/Coax Board on page 468.
Internal print server Go to Remove the Internal Printer Server on page 469.
Wireless board w/external Go to Remove the External Antenna on page 470.
Antenna
Wireless board w/radio Go to Remove the Wireless Card on page 471.
card
Ethernet board Go to Disconnect all cables from the MLB. on page 472.
None Go to Disconnect all cables from the MLB. on page 472.

Main Logic Board
Remove the Applicator Board

1.
2. See Figure 322. Disconnect the DC power connector from the applicator board.
Figure 322 • Disconnect the Applicator Board Cables
1
2
1 Data cable connector

2 DC power connector
3. Disconnect the data cable from either connector P31 through P34 on the main logic board
(MLB).

Main Logic Board
4. See Figure 323. Remove the two mounting screws and then slide the applicator interface
board out of the printer.
Figure 323 • Remove the Applicator Interface Board
1 Applicator interface board

5. Go to Disconnect all cables from the MLB. on page 472.

Main Logic Board
Remove the Twinax/Coax Board

1. See Figure 324. Remove the two mounting screws.
Figure 324 • Remove the Twinax/Coax Board and Cable
4 3
1 Twinax/Coax board
3 Internal parallel port connector
2. Pull the Twinax/Coax board slightly out of the printer and then disconnect the internal
parallel cable from the MLB.
3. Remove the twinax/Coax board from the printer.
4. Go to Remove the Applicator Board on page 466.

Main Logic Board
Remove the Internal Printer Server

1. See Figure 325. Remove the two mounting screws and then pull the printer server out
slightly.
2. Disconnect the print server cable from the internal parallel port on the MLB and then
remove the print server.
Figure 325 • Remove the Internal Print Server

1
4 3 2
1 Print server
3 Internal parallel port connector
4 Print server cable

Main Logic Board
Remove the External Antenna

1. See Figure 326. Unscrew the external antenna and then remove the mounting screw.
2. Remove the nut and lock washer securing the mounting plate to the internal print server
board.
Figure 326 • Remove the External Antenna
2 1
5 4 3
1 Mounting plate
2 Lock washer
3 Nut
4 Antenna
5 Mounting screw
3. Remove the mounting plate mounting screw and then remove the mounting plate.

Main Logic Board
Remove the Wireless Card

1. See Figure 327. Remove the radio card cover by removing the mounting screw and then
removing the cover.
Figure 327 • Remove the Wireless Radio Card

4
1 2 3
1 Mounting screw
2 Radio card cover
3 Radio card
4 Eject button
2. Push the eject button in. After the radio card pops out, remove the radio card.
3. Continue with Disconnect all cables from the MLB..

Main Logic Board
Remove the MLB

1. Disconnect all cables from the MLB.
Figure 328 • Disconnect all Cables

P25
P24 P23
J9
J1 P27
P28
J2
P26
J3
P9
P36 P5
P4
P2
P7
J10
J5
P19
P21
P33 P34 P29 J8
P31 P32 P13
Conn Description Conn Description
J1 Serial port P23 Wireless board connector
J2 Internal Ethernet P24 Wireless board connector
J3 Media sensor receiver P25 DC power input
J5 Parallel port P26 Cutter/Rewind
J8 Ribbon low sensor P27 DC output
J9 Media low sensor P28 DC output
J10 Ribbon low quadrature P29 Control Panel Connector
P4 Ribbon sensor P31 SPI Connector *
P5 Head open sensor P32 SPI Connector
P7 Reflective media sensor P33 SPI Connector
P9 Media Sensor emitter P34 SPI Connector
P19 Printhead data cable P36 USB Port
P21 Internal parallel connector

*SPI—Serial Peripheral Interface

Main Logic Board

110Xi4 Continue with Remove the 110Xi4 MLB.
140Xi4, 170Xi4, and 220Xi4 Go to Remove the 140Xi4, 170Xi4, and 220Xi4 MLB
on page 475.
Remove the 110Xi4 MLB

1. Is there a wireless board installed?
If… Then…
No a. See Figure 329. Remove the two screws securing the 36-pin parallel port
connector.
b. Remove the two standoffs and washers securing the 9-pin serial port
connector.
c. Remove the two screws securing the MLB to the printer.
d. Pull out the MLB as you guide the connectors out of the openings in the rear
panel.
Yes a. See Figure 330. Remove the three mounting screws securing the wireless
and main logic boards.
b. Remove the two screws securing the 36-pin parallel port connector.
c. Remove the two standoffs and washers securing the 9-pin serial port
connector.
d. Pull out the MLB and wireless board assembly as you guide the connectors
out of the openings in the rear panel.
Figure 329 • Remove the 110Xi4 MLB
5
1
4

4 Mounting studs (2)

Main Logic Board
Figure 330 • Remove the 110Xi4 MLB with Wireless Board
1
5
3
2
1 Wireless board and MLB assembly

5 Washers (2)

Main Logic Board
Remove the 140Xi4, 170Xi4, and 220Xi4 MLB

If… Then…
No a. See Figure 331. Remove the two screws securing the 36-pin parallel port
connector.
b. Remove the two standoffs and washers securing the 9-pin serial port
connector.
c. Remove the two screws securing the MLB to the printer.
d. Pull out the MLB as you guide the connectors out of the openings in the rear
panel.
Yes a. See Figure 332. Remove the three mounting screws securing the wireless
and main logic boards.
b. Remove the two screws securing the 36-pin parallel port connector.
c. Remove the two standoffs and washers securing the 9-pin serial port
connector.
d. Pull out the MLB and wireless board assembly as you guide the connectors
out of the openings in the rear panel.
Figure 331 • Remove the 140Xi4, 170Xi4, and 220Xi4 MLB
5
1
4

Main Logic Board
Figure 332 • Remove the 140Xi4, 170Xi4, and 220Xi4 MLB and Wireless
Assembly
1
6
4
2
3
1 Wireless board
6 Washers (2)
If… Then…
Yes Go to Remove the Wireless Board on page 477.
3. Is there an internal Ethernet board installed?
If… Then…
No Go to Install the New Main Logic Board on page 478.
Yes Go to Remove the Internal Ethernet Board on page 478.

Main Logic Board
Remove the Wireless Board

1. See Figure 333. Set the MLB and wireless board assembly on the antistatic mat and then
remove the three mounting screws.
Figure 333 • Remove the Wireless Board

1 2
1 5 3

2 Wireless board
5 Wireless board w/external antenna
2. Remove the three standoffs from the MLB.

Main Logic Board
Remove the Internal Ethernet Board

1. See Figure 334. Set the MLB/Ethernet assembly on the antistatic mat and then remove the
three nuts securing the ethernet board to the MLB.
Figure 334 • Remove the Ethernet Board

1
1 MLB
2 Ethernet board
3 Mounting nuts (3)
2. Remove the ethernet board and then remove the three standoffs from the MLB.
Install the New Main Logic Board

If… Then…
Yes a. See Figure 333 on page 477. Set the new MLB on the antistatic mat and
then install the three standoffs for the wireless board mounting.
b. Align the two connectors on the wireless board with P23 and P24 on the
MLB and then push them together.
c. Install the three mounting screws to secure the wireless board.

Main Logic Board
2. Is there an internal Ethernet board installed?
If… Then…
No Go to step 3.
Yes a. See Figure 334 on page 478. Set the new MLB on the antistatic mat and
then install the three standoffs for the wireless board mounting.
b. Align the ethernet board, component side down, with the three standoffs and
then reinstall the three mounting nuts.
c. Continue with step .
3. See Figure 328 on page 472. Connect all cables to the MLB.
Reinstall Removed Components

1. Which option do you have installed?

Applicator interface board a. See Figure 323 on page 467. Reinstall the Applicator
interface board and tighten the two mounting screws.
b. See Figure 322 on page 466. Reconnect the data cable
from the MLB to J2 on the applicator board.
c. Reconnect the power connector to J5 on the applicator
board.
Twinax/Coax board a. See Figure 324 on page 468. Route the Twinax/Coax
cable through the mounting hole and then connect it to
P21 on the MLB.
b. Slide the Twinax/Coax board into the printer and then
reinstall the two mounting screws.
Internal print server a. See Figure 325 on page 469. Route the print server
cable through the mounting hole and then connect it to
P21 on the MLB.
b. Slide the print server board into the printer and then
reinstall the two mounting screws.

the main frame.

Main Logic Board
Calibrate the Media Low Sensor

1.
2. On the control panel press and hold Minus (–) while turning on (l) the printer until
BBlock is displayed.
3. Press NEXT/SAVE until Media Low is displayed.
4. Press Plus (+), Load Full Roll will be displayed.
5. See Figure 335. Familiarize yourself with the media low sensor calibration tool.
Figure 335 • Media Low Calibration Tool
1 Roll empty posts (2)

2 Roll full posts (2)

Main Logic Board
6. See Figure 336. Slide the posts of the calibration tool into the keyholes in the media low
sensor bracket and then slide the tool down to secure it in place.
Figure 336 • Full Roll
1
3
2
1 Calibration tool
2 Keyholes
3 Media low bracket
7. Press Plus (+) to calibrate, Load Empty Roll will be displayed.
8. Remove the calibration tool.

Main Logic Board
9. See Figure 337. Slide the posts of the calibration tool into the keyholes in the media low
sensor bracket and then slide the tool down to secure it in place.
Figure 337 • Roll Empty

2 3
1 Calibration tool
2 Keyholes
3 Media low bracket
10. Press Plus (+) to calibrate and then remove the calibration tool.
11. Press SETUP/EXIT to save the calibration.
12.
Reinstall the media.
13. 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.

AC Power Supply
AC Power Supply
This kit includes the parts and documentation necessary to install the AC Power Supply
maintenance kit in the following printers:
• 140Xi4™
• 170Xi4™
• 220Xi4™
Tools Required

SAE Nutdriver Set
1.

AC Power Supply
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
Remove the AC Power Supply

1.

AC Power Supply
2. See Figure 339. Disconnect all cables connected to the main logic board.
Figure 339 • Disconnect Main Logic Board Cables

P25
P24 P23
J9
J1 P27
P28
J2
P26
J3
P9
P36 P5
P4
P2
P7
J10
J5
P19
P21
P33 P34 P29 J8
P31 P32 P13


AC Power Supply
3. Do you have a wireless option board installed?
If… Then…
No a. See Figure 340. Remove the main logic board (MLB) by removing the two
serial port mounting studs and lock washers.
b. Remove the two parallel port mounting screws.
c. Remove the two MLB mounting screws and then remove MLB from the
printer.
Yes a. See Figure 340. Remove the main logic board (MLB) and wireless option
board assembly by removing the wireless board mounting screw.
b. Remove the two serial port mounting studs and lock washers.
c. Remove the two parallel port mounting screws.
d. Remove the two MLB mounting screws and then remove MLB from the
printer.
Figure 340 • Remove the Main Logic Board
7 1
2
4 3
1 Wireless option board

3 MLB mounting screws (2)
5 Parallel port mounting screws (2)
6 Serial port mounting screws (2)
7 Serial port lock washers (2)

AC Power Supply
4. See Figure 341. Slide the AC power supply shield out of the printer.
Figure 341 • Remove the AC Power Supply Shield
1 AC power supply shield

2 AC power supply
5. Disconnect all cables from the AC power supply.
Figure 342 • Disconnect all Cables

AC Input
DC Output

AC Power Supply
6. See Figure 343. Remove the three mounting nuts and two spacers securing the AC power
supply.
Figure 343 • Remove the AC Power Supply

1
1 AC power supply
2 Mounting nuts(3)
3 Spacers (2)
4 MLB standoff
7. Remove the MLB standoff securing the AC power supply.

AC Power Supply
8. See Figure 344. Slide the AC power supply off of the mounting studs and then out of the
printer.
Figure 344 • Slide the AC Power Supply Out
1 AC power supply
Install the New AC Power Supply

1. See Figure 343. Set the new AC power supply into the printer and align the mounting
holes with the corresponding mounting studs and then slide it onto the mounting studs.
2. Slide the new spacers onto the upper and lower left mounting studs and then install the
two mounting nuts.
3. Install the lower right mounting nut onto the lower right mounting stud.
4. Install the new standoff onto the upper right mounting stud.
5. See Figure 342 on page 487. Reconnect the AC input and output connectors.

AC Power Supply
Install the New AC Power Supply Shield

1. See Figure 345. Form the AC power supply shield for installation.
Figure 345 • Form the New AC Power Supply Shield
2
3
5 6 7
10
8 9
1 AC power supply shield unfolded

2 Fold at this score
3 Fold the mounting tab up
4 Fold tab up
9 AC power supply shield folded
10 Hooks

AC Power Supply
2. After forming the AC power supply shield, slide the hooks between the printed circuit
board (PCB) and the AC power supply bracket.
Figure 346 • Install the AC Power Supply Shield

2
1
3

2 PCB
3 AC power supply bracket
Reinstall the MLB

If… Then…
No a. See Figure 340 on page 486. Slide the serial and parallel ports of the MLB
into the rear panel and then align the mounting holes with the two mounting
standoffs, ensuring the shield mounting tab is on the outside of the MLB,
and then reinstall the two mounting screws.
b. Reinstall the two serial port mounting studs and lock washers.
c. Reinstall the two parallel port mounting screws.
Yes a. See Figure 340 on page 486. Slide the serial and parallel ports of the MLB
into the rear panel and then align the mounting holes of the MLB with the
two mounting standoffs and the wireless board standoff, ensuring the shield
mounting tab is on the outside of the MLB, and then reinstall the three
mounting screws.
2. See Figure 342 on page 487. Reconnect all cables to the MLB.

AC Power Supply

3.

110Xi4 AC/DC Power Supply Assembly

This kit includes the parts and documentation necessary to install the AC/DC Power Supply
Assembly maintenance kit in the 110Xi4™ printers.
Tools Required

1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Remove the AC/DC Power Supply Assembly


1

Caution • Certain components located under the insulation shield can store a
residual charge for as long as ten minutes after power has been removed. Use
extreme care when removing the power supply. Handle the board only by the outer
edges.
shield.


4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

supply assembly.

1

2 Mounting nuts (2)
7. Lift the AC/DC power supply assembly out of the printer.
AC/DC Power
Supply
Mounting
Studs

Install the AC/DC Power Supply Assembly

1. See Figure 352 on page 498. Position the cables out of the way while installing the AC/
DC power supply assembly over the two mounting studs.
2. See Figure 351 on page 498. Install the mounting screws and nuts securing the AC/DC
power supply assembly.
3. See Figure 350 on page 497. Connect all cables to their proper connectors.
mounting plate.
5. Connect the AC power input cable and then reinstall the white plastic beaded cable tie.


DC Power Supply
DC Power Supply
This kit includes the parts and documentation necessary to install the DC Power Supply
• 140Xi4™
• 170Xi4™
• 220Xi4™
Tools Required

1.

DC Power Supply
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

DC Power Supply
Remove the Old DC Power Supply

1.
2. See Figure 354. Remove all cables from the DC power supply.
1 2
4
6 5

3 J4 stepper motor

DC Power Supply
3. See Figure 355. Remove and discard the mounting screw and the two mounting nuts.
1 Mounting screw
2 Mounting spacer
3 Mounting nuts (2)
5. Remove and discard the mounting spacer.
Install the New DC Power Supply

1. See Figure 355. Install the new mounting spacer.
2. Set the DC power supply into the printer and then install the two mounting nuts and one
mounting screw.
3. See Figure 354 on page 502. Reconnect all cables to the DC power supply.


Cutter Printed Circuit Board
Tools Required

1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

140Xi4 Go to Remove the DC Power Supply on page 510.
170Xi4
220Xi4



1

shield.


4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs

8. Go to Make a note of all cable connections to the cutter control board and then remove
them. on page 512.

1.
remove them..
1 2
4
6 5

3 J4 stepper motor

1 Mounting screw
2 Mounting nuts (2)
5. Continue with Remove the Old Cutter Control Board.

Remove the Old Cutter Control Board

1. Make a note of all cable connections to the cutter control board and then remove them.
Figure 364 • Disconnect all Cables from the Cutter Control Board
J2
J1
J3 J4
J1 Cutter data cable connector

J2 DC power cable connector
J3 Cutter sensor cable connector
J4 Cutter motor cable connector
2. See Figure 365. Remove and discard the four cutter control board mounting screws and
then remove the cutter control board.
Figure 365 • Remove the Old Cutter Control Board
1 Cutter control board


Install the New Cutter Control Board

1. See Figure 365 on page 512. Align the cutter control board, component side out and J3
and J4 on the bottom, with the mounting studs and then install the four new mounting
screws.
2. See Figure 364 on page 512. Connect all cables to the cutter control board.

140Xi4 a. See Figure 363 on page 511. Set the DC power supply into the
170Xi4 printer and then reinstall the two mounting nuts and one
power supply.
110Xi4 a. See Figure 361 on page 509 and Figure 360 on page 509. Set the
AC/DC power supply into the printer and then reinstall the two
mounting nuts and mounting screws.
b. See Figure 359 on page 508. Reinstall all cables except the AC
input cable.
c. See Figure 358 on page 507. Reinstall the AC/DC power supply
d. See Figure 357 on page 506. Connect the AC power input cable


110Xi4 Power Entry
110Xi4 Power Entry

This kit includes the parts and documentation necessary to install the Power Entry maintenance kit
in the 110Xi4™ printers. Read these instructions thoroughly before installing this kit.
Tools Required

SAE Nutdriver Set
1.

110Xi4 Power Entry
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

110Xi4 Power Entry
Remove the Power Entry Module

1.

1

110Xi4 Power Entry
edges.
shield.


110Xi4 Power Entry
5. See Figure 369. Remove the AC ground nut, cable, and lock washer.
Figure 369 • Remove the AC Ground
1 Grounding nut
2 Ground cable lug
3 Lock washer
4 Ground stud
6. See Figure 370. Disconnect the AC power cables from the on/off switch.
Figure 370 • Disconnect the AC Cables

1
2
2
1
1 Brown cable
2 Blue cable

110Xi4 Power Entry
7. See Figure 371. Remove the power entry module by removing the two mounting screws
and then sliding the power entry module out of the printer.
Figure 371 • Remove the Power Entry Module and AC Power Switch
3 4
1
1 Power entry module

3 On/Off switch
4 Tabs (2 on top and bottom)
Remove and Install the On/Off Switch

1. Push out on the old on/off switch and remove it from the printer.
2. Orient the new on/off switch with the bar (l) at the top and then push it into the printer
mounting hole.
3. See Figure 370 on page 518. Connect the new AC power cable top terminals of the AC
power switch, brown on the left and blue on the right.
Install the New Power Entry Module

1. See Figure 371. Orient the new power entry module as shown.
2. Guide the cables through the mounting hole, align the mounting holes and the install the
two new mounting screws.
3. See Figure 370 on page 518. Connect the blue cable to the lower right connector on the
on/off switch.
4. Connect the brown cable to the lower left connector.
5. See Figure 369 on page 518. Remove the new external lock washer from the kit and slide
it onto the ground stud, and then slide the ground lug onto the ground stud.

110Xi4 Power Entry
6. Install the new mounting nut onto the ground lug and then tighten it.
Reinstall the AC/DC Power Supply Shield

mounting plate.
2. See Figure 367 on page 516. Connect the AC power input cable and then reinstall the
white plastic beaded cable tie.


140Xi4, 170Xi4, and 220Xi4 Power Entry
Tools Required

1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
Remove the Power Entry Module

1.

2. See Figure 373. Disconnect all cables connected to the main logic board.
Figure 373 • Disconnect Main Logic Board Cables

P25
P24 P23
J9
J1 P27
P28
J2
P26
J3
P9
P36 P5
P4
P2
P7
J10
J5
P19
P21
P33 P34 P29 J8
P31 P32 P13


If… Then…
No a. See Figure 374. Remove the main logic board (MLB) by removing the two
serial port mounting studs and lock washers.
b. Remove the two parallel port mounting screws.
c. Remove the two MLB mounting screws and then remove MLB from the
printer.
Yes a. See Figure 374. Remove the main logic board (MLB) and wireless option
board assembly by removing the wireless board mounting screw.
b. Remove the two serial port mounting studs and lock washers.
c. Remove the two parallel port mounting screws.
d. Remove the two MLB mounting screws and then remove MLB from the
printer.
Figure 374 • Remove the Main Logic Board
1
7 2
6
5
4 3
1 Wireless option board

3 MLB mounting screws (2)
5 Parallel port mounting screws (2)
6 Serial port mounting screws (2)
7 Serial port lock washers (2)

4. See Figure 375. Slide the AC power supply shield out of the printer.
Figure 375 • Remove the AC Power Supply Shield

2 AC power supply
5. See Figure 376. Remove the AC ground nut, cable, and lock washer.
Figure 376 • Remove the AC Ground
1 Grounding nut
2 Ground cable
3 Lock washer
4 Ground stud

6. See Figure 377. Disconnect the AC power cables from the on/off switch.
Figure 377 • Disconnect the AC Cables
3
1 1 2
1 Brown cable
2 Blue cable
3 Ground cable

7. See Figure 378. Remove the power entry module by removing the two mounting screws
and then sliding the power entry module out of the printer.
Figure 378 • Remove the Power Entry Module and AC Power Switch
3
5
3
1 4
1 Power entry module

3 On/Off switch
4 Tabs (2 on top and bottom)
5 Bar
Remove and Install the On/Off Switch

1. Push out on the old on/off switch and remove it from the printer.
2. Orient the new on/off switch with the bar (l) at the top and then push it into the printer
mounting hole.
3. See Figure 377 on page 526. Connect the new AC power cable top terminals of the AC
power switch, brown on the left and blue on the right.
Install the New Power Entry Module

1. See Figure 378. Orient the new power entry module as shown.
2. Guide the cables through the mounting hole, align the mounting holes and then install the
two new mounting screws.
3. See Figure 377 on page 526. Connect the blue cable to the lower right connector on the
on/off switch.
4. Connect the brown cable to the lower left connector.

5. See Figure 376 on page 525. Remove the new external lock washer from the kit and slide
it onto the ground stud, and then slide the ground lug onto the ground stud.
6. Install the new mounting nut onto the ground lug and then tighten it.
Reinstall the AC Power Supply Shield

1. Reinstall the AC power supply shield, slide the hooks between the printed circuit board
(PCB) and the AC power supply bracket.
Figure 379 • Install the AC Power Supply Shield

2
1
3

2 PCB
3 AC power supply bracket

Reinstall the MLB

If… Then…
No a. See Figure 374 on page 524. Slide the serial and parallel ports of the MLB
into the rear panel and then align the mounting holes with the two mounting
standoffs, ensuring the shield mounting tab is on the outside of the MLB,
and then reinstall the two mounting screws.
Yes a. See Figure 374 on page 524. Slide the serial and parallel ports of the MLB
into the rear panel and then align the mounting holes of the MLB with the
two mounting standoffs and the wireless board standoff, ensuring the shield
mounting tab is on the outside of the MLB, and then reinstall the three
mounting screws.
2. See Figure 373 on page 523. Reconnect all cables to the MLB.

3.

Electronics Cables
Electronics Cables
Tools Required
Phillips Screwdriver Set Wire Cutters
1.
securing it.
Lift up at rear 1
corner.
1 Electronics cover

Electronics Cables
printer.
Remove and Install the Electronics Cables

1.
2. Cut any cable ties.
3. Remove the defective cable from the printer.
4. Choose the proper replacement cable from the kit and then install the new cable.
5. If a 200 ohm ferrite block was installed on the cable, install the ferrite block.
6. Install any cable ties previously removed.

the main frame.

Printhead Test Board Option
Tools Required

SAE Nutdriver Set Antistatic Wriststrap and Pad
1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.
5. Are you installing the printhead test board for the first time?
If… Then…
No Go to Remove the Old Printhead Test Board on page 536.
Yes Continue with Install the Printhead Test Board Spacers.

Install the Printhead Test Board Spacers

1. See Figure 382. Remove the three mounting nuts securing the three cable clamps and the
remove the one cable clamp noted.
Figure 382 • Remove the Three Mounting Nuts
2
3
1 Cable clamps (3)

2 Mounting nuts (3)
3 Remove this cable clamp.

2. See Figure 383. Remove the three lock washers from the kit and then slide them onto the
three studs.
Figure 383 • Install the Three Spacers

1
1 Studs (3)
2 Lock washers (3)
3 Spacers (3)
3. Install the three spacers onto the studs.
4. Got to Install the Printhead Test Board Shield on page 538.

Remove the Old Printhead Test Board

1.
shield.

1

3 Mounting screw

4. See Figure 385. Lift the printhead test board shield and the remove and discard the two
mounting screws, printhead test board, and shield.
4
1
2 5
3
J2
J3 J1

5. Continue with Install the Printhead Test Board Shield.

Install the Printhead Test Board Shield

1. See Figure 386. Form the printhead test board shield by bending the sides and top away
from the shock symbol and then inserting the tabs into the corresponding slots.
Figure 386 • Form the Printhead Test Board Shield
5 1
3
2
4 8
6 7
1 Shock symbol
2 Tab and slot
3 Tab and slot
4 Tab and slot
5 Hook
6 Mounting tab
7 Cable tie holes
8 Cable tie
2. Insert a cable tie through the two cable tie holes and then tighten the cable tie.
3. Bend the mounting hole tab up as shown.

4. See Figure 387. Install the hook around the top mounting spacer.

1
2
3
4

3 Hook
Install the Printhead Test Board

1.
2. See Figure 385 on page 537. Align the printhead test board, with J1 and J2 facing down
and out, with the mounting spacers and then install the top and right mounting screws.
3. See Figure 384 on page 536. Bend the printhead test board shield down until the mounting
hole aligns with the left mounting hole in the printhead test board and then reinstall the
printhead mounting board shield mounting screw.
4. Is this a new installation of the printhead test board option?
If… Then…
No Go to Reconnect the Printhead Test Board on page 543.
Yes Continue with Connect the Printhead Test Board Cables.

Connect the Printhead Test Board Cables

1. See Figure 388. Disconnect the AC power input connector from the AC/DC power supply.
Figure 388 • Remove the AC/DC Power Input Connector
AC Power
Input
edges.
2. See Figure 389. Remove the AC/DC power supply shield by removing the two screws
securing it to the power supply.


3. See Figure 390. Disconnect the printhead power cable from the AC/DC power supply
connector J3 and then connect it to J2 on the printhead test board.
Figure 390 • Connect the Printhead Test Board Cables
1 4 6 8 4
2 3 5 7
3
13
12 11 10 9
1 Main logic board (MLB) 8 Printhead power cable

2 Data cable from J3 to MLB 9 J3 connector AC/DC power
supply
3 Cable ties (2) 10 J1 to J3 cable
4 Ferrite block 11 AC/DC power supply
5 Control cable 12 SPI connector
6 J1 connector printhead test 13 J3 connector printhead test
board board
7 J2 connector printhead test
board
4. Remove the new J1 to J3 cable from the and connect it to J1 on the printhead test board
and then to J3 on the AC/DC power supply.
5. Remove the ferrite block from the kit. Turn it so that the rear is facing you and then slide a
cable tie in one slot and out the other.
6. Mount the ferrite block onto the control cable in the position shown using the cable tie you
just inserted into the ferrite block.
7. Remove the data cable from the kit and connect on end to J3 on the printhead test board
and then to any one of the open SPI connectors, P30 to P34.

8. See Figure 391. Open the ferrite block, insert the data cable, and then close it around the
data cable.
Figure 391 • Insert Data Cable

1 2
1 Ferrite block
2 Data cable
9. Using a cable tie attach the data cable to the control cable to the left of the ferrite block.
10. Go to Reinstall the Electronics Cover on page 544.

Reconnect the Printhead Test Board

1. See Figure 392. Reconnect the data cable to J3 on the new printhead test board.
Figure 392 • Reconnect the Printhead Test Board
4 3
6 5
1 J3 to the data cable

3 J3 on the AC/DC power supply
4 Cable from J1 on the printead test board to J3
on the AC/DC power supply
5 J2 to the printhead power cable
6 J1 to J3 on the AC/DC power supply
7 Data cable
2. Reconnect the printhead power cable to J2 on the printhead test board.
3. Reconnect the cable from J3 on the AC/DC power supply to J1 on the printhead test
board.


3.
Set Head Test Count

1. Press SETUP/EXIT. Press PREVIOUS or NEXT/SAVE until HEAD TEST COUNT is
displayed.
2. Press the left or right oval and enter your password; the factory default password is 1234.
Use the left oval to move the cursor to the digit you want to change, and then use the right
oval to change the value. After your password is set, press NEXT/SAVE to enter the
password.
3. Use the left and right ovals as before to change the head test count, and then press NEXT/
SAVE to enter your value.
4. Press SETUP/EXIT, then NEXT/SAVE to permanently save the head test count.

Twinax/Coax Option
Twinax/Coax Option
Tools Required
1.
securing it.
Lift up at rear 1
corner.
1 Electronics cover

Twinax/Coax Option
printer.
4. Are your replacing a defective Twinax/Coax board?
If… Then…
No a. See Figure 394. Remove and discard the two blank cover plate mounting
screws and plate.
b. Go to Install the Twinax/Coax Board on page 547
Yes Continue with Remove the Defective Twinax/Coax Board.
Figure 394 • Remove the Rear Panel Blank Cover
1 Blank cover plate


Twinax/Coax Option
Remove the Defective Twinax/Coax Board

1.
2. See Figure 395. Remove the two mounting screws.
Figure 395 • Remove the Twinax/Coax Board and Cable
4 3
1 Twinax/Coax board
3 Internal parallel port connector, P21
3. Pull the Twinax/Coax board slightly out of the printer and then disconnect the internal
parallel cable from the MLB.
4. Remove the twinax/Coax board from the printer.
Install the Twinax/Coax Board

1. See Figure 395. Route the Twinax/Coax cable through the mounting hole and then
connect it to P21 on the MLB.
2. Slide the Twinax/Coax board into the printer and then install the two mounting screws.

Twinax/Coax Option

3. Reconnect the AC power cord.
4. Connect the communication cable from the kit and connect the printer to your
communication network.

Applicator Interface
Tools Required

Wire Cutters
1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

4. Are you replacing an existing applicator interface board?
If… Then…
No a. See Figure 397. Remove and discard the option board slot cover by
removing and discarding the two mounting screws.
b. Go to Install the Applicator Interface Board on page 556.
Yes Continue with Remove the Old Applicator Interface Board on page 552.
Figure 397 • Remove the No Option Board Slot Cover

1 2
1 No option board slot cover

2 Option board slot

Remove the Old Applicator Interface Board

If… Then…
Yes a. See Figure 398. Disconnect the AC power input cable to the AC/DC power
supply and then open the white beaded cable tie and remove the cables.
b. Cut the cable tie securing the applicator power cable to the AC/DC power
supply shield.
c. See Figure 399 on page 553. Remove the AC/DC power supply shield by
removing the two mounting screws and then lifting the shield out of the
printer.
d. See Figure 400 on page 553. Disconnect the applicator board cable from J6,
J7, or J8 on the AC/DC power supply.
e. See Figure 401 on page 554. Disconnect the applicator data cable from P31,
P32, P33, or P34 on the main logic board (MLB).
No a. See Figure 402 on page 554. Disconnect the applicator cable from the
output connector on the DC power supply, J5, J6, J7, J8, J9, or J10.
b. Open the white beaded cable tie and remove the applicator board power
cable.
c. See Figure 401 on page 554. Disconnect the applicator data cable from P31,
Figure 398 • Remove the AC Power Input Cable (110Xi4)
1
2
1 AC power input cable

3 Cable tie


Figure 400 • Remove the Applicator Cables (110Xi4)
1
4
2
3

2 J6, J7, and J8
3 P31, P32, P33, and P34

Figure 401 • Disconnect the Data Cable
P33 P34
P31 P32
Figure 402 • Remove the Applicator Cables (140Xi4, 170Xi4, and 220Xi4)
1
5
4
2
3
1 DC power supply
2 J5 through J10
4 P31, P32, P33, and P34

2. Which model of applicator board are you removing.

5V See Figure 403. Remove the two mounting screws and then slide the
applicator board out of the printer.
24-28V Figure 404. Remove the two mounting screws and then slide the
applicator board out of the printer.
Figure 403 • Remove and Install the 5V Applicator Board

1
1 Applicator board

Figure 404 • Remove and Install the 24-28V Applicator Board

1
1 Applicator board
Install the Applicator Interface Board

1. Which model of applicator board did you remove.

5V a. See Figure 403. Remove the applicator board from the
maintenance/option kit and then slide it into the mounting hole in
the rear panel
b. Install the two mounting screws.
c. See Figure 405. Connect the applicator data cable to J4 on the
applicator board.
d. Connect the applicator power cable to J5 on the applicator board.
24-28V a. See Figure 404. Remove the applicator board from the
maintenance/option kit and then slide it into the mounting hole in
the rear panel
b. Install the two mounting screws.
c. See Figure 405. Connect the applicator data cable to J1 on the
applicator board.
d. Connect the applicator power cable to J3 on the applicator board.

Figure 405 • Connect the Applicator Data and Power Cables

J3
5V Applicator 24-28V Applicator
Board J4 Board
J1
J5
2. See Figure 401 on page 554. Connect the other end of the applicator data cable to P31,
If… Then…
No a. See Figure 402 on page 554. Connect the other end of the power cable to
either of connectors J5 through J10 on the DC power supply.
b. Insert the applicator power cable into the white beaded cable and then close
the cable tie.
Yes a. See Figure 400 on page 553. Connect the other end of the applicator power
cable to J6, J7, or J8 on the AC/DC power supply.
b. See Figure 399 on page 553. Reinstall the AC/DC power supply shield and
secure it with the two mounting screws removed previously. Ensure the
shield flaps are tucked in between the power supply and the aluminum
mounting plate and that the applicator power cable comes out through the
access hole in the top of the AC/DC power supply shield.
c. Connect the AC power input cable and then reinstall the white plastic
beaded cable tie with all cables that were removed and add the applicator
board power cable.


Applicator Port Pinouts
5V Board
See Figure 406 and Table 17 to identify the pins, signals, and functions for the 5V applicator
board port.
Figure 406 • 5V Applicator Board Pinouts

Isolated Power Supply Non-isolated Power Supply
(no jumpers installed) (jumpers installed)
JP2 JP2
+5V +5V
JP1 1A JP1 I/O SIGNAL GROUND

1A I/O SIGNAL GROUND
1 1
+5V +5V I/O ISOLATED INPUT +5V +5V I/O NON-ISOLATED
2 2
START PRINT START PRINT
3 3
FEED FEED
4 4
PAUSE PAUSE
5 5
REPRINT REPRINT
+28V 6 +28V 6
+28V OUTPUT +28V OUTPUT
7 7
2A POWER GROUND 2A POWER GROUND
8 8
RIBBON LOW RIBBON LOW
9 9
SERVICE REQUIRED SERVICE REQUIRED
10 10
END PRINT END PRINT
11 11
MEDIA OUT MEDIA OUT
12 12
RIBBON OUT RIBBON OUT
13 13
DATA READY DATA READY
14 14
SPARE (Non-RFID) SPARE (Non-RFID)
15 15 VOID (RFID)
VOID (RFID)
Table 17 • 5V Applicator Interface Connector Pin Configuration
Pin
No.
1 I/O SIGNAL I/O Signal Using jumper JP2, this pin can be configured as isolated
GROUND Ground or non-isolated from the printer signal ground. See
(+5V Return) Figure 407 on page 561 for location of jumpers.
2 +5V I/O Power Using jumper JP1, this pin can be configured as isolated
(Fused at 1 A) or non-isolated from the Applicator Interface Circuit
+5 V Supply. See Figure 407 on page 561 for location of
Caution • Replace
the fuse only with jumpers.
one of the same
type and rating.

Table 17 • 5V Applicator Interface Connector Pin Configuration (Continued)
Pin
No.
3 START PRINT Input • Pulse Mode—The label printing process begins on the
ready. De-assert this signal HIGH to inhibit printing of
a new label.
print if a label format is ready. When de-asserted
HIGH, the printer completes the label that is printing
then stops and waits for this input to be reasserted
LOW.
De-assert HIGH to stop feeding blank labels and register
label.
(Fused at 2 A) sensors as required.
Replace the fuse Note • If operating with 28V signals only, pin 7
only with one of the may be used to supply power to pin 2, which
same type and creates a non-isolated mode of operation. (This is
rating. applicable for all printers except the 110Xi4.)
use this pin to ground pin 1. (This is applicable for
all printers except the 110Xi4.)
9 RIBBON LOW Output Asserted LOW if the Supplies Warning feature is enabled
and the amount of ribbon remaining on the supply spindle
is below the threshold level.

Table 17 • 5V Applicator Interface Connector Pin Configuration (Continued)
Pin
No.
11 END PRINT Output • MODE 0—The applicator port is OFF.
moving the label forward; otherwise de-asserted
HIGH.
moving the label forward; otherwise de-asserted LOW.
• MODE 3—(Default) Asserted LOW for
20 milliseconds when a label is completed and
positioned. Not asserted during continuous printing.
14 DATA READY Output • Asserted LOW when sufficient data has been received
(Non-
RFID)
15 VOID Output • Asserted LOW when the RFID transponder over the
(RFID) antenna is “voided.”
• De-asserted HIGH when the end print signal is
asserted.

Figure 407 • Isolated and Non-isolated Applicator Operation
Isolated Non-Isolated
Jumpers Installed
Jumpers Removed
24-28V Applicator Board

Which model of Xi4 printer are you working on?

110Xi4 Always use Isolated Mode of operation. There is no usable voltage
on Pin 7 with respect to Pin 8.
140Xi4 Can use either Isolated or Non-Isolated Modes.
170Xi4
220Xi4

See Figure 408 and Table 18 to identify the pins, signals, and functions for the 24-28V
applicator board port.
Figure 408 • 24-28V Applicator Board Pinouts

Isolated Power Supply Non-isolated Power Supply
I/O SIGNAL GROUND I/O SIGNAL GROUND

+24-28 I/O ISOLATED POWER INPUT +24-28 I/O ISOLATED POWER INPUT
START PRINT START PRINT
FEED FEED
PAUSE PAUSE
REPRINT REPRINT
+28V POWER OUTPUT +28V POWER OUTPUT
POWER GROUND POWER GROUND
RIBBON LOW RIBBON LOW

SERVICE REQUIRED SERVICE REQUIRED
END PRINT END PRINT
MEDIA OUT MEDIA OUT
RIBBON OUT RIBBON OUT
DATA READY DATA READY

SPARE (non-RFID) SPARE (non-RFID)
VOID (RFID) VOID (RFID)
Table 18 • 24-28V Applicator Interface Connector Pin Configuration
Pin
No.
1 I/O SIGNAL I/O Signal No jumpers to configure.
GROUND Ground Important • Customer must provide this external
(+24-28V Return) ground. (This ground can come from pin 8 when
110Xi4.)
2 +24-28V I/O Power No jumpers to configure. This +24-28V power source
(Fused at 2 A) also supplies voltage for output signal pull-up resistors.
Replace the fuse Important • Customer must provide this external
only with one of the power (This power can come from pin 7 when
same type and operating at 28V for all printers except the
rating. 110Xi4.)
3 START PRINT Input • Pulse Mode—The label printing process begins on the
ready. De-assert this signal HIGH to inhibit printing of
a new label.
print if a label format is ready. When de-asserted
HIGH, the printer completes the label that is printing
then stops and waits for this input to be reasserted
LOW.

Table 18 • 24-28V Applicator Interface Connector Pin Configuration (Continued)
Pin
No.
De-assert HIGH to stop feeding blank labels and register
label.
(Fused at 500mA) sensors as required.
Caution • Note • If operating with 28V signals only, pin 7
Replace the may be used to supply power to pin 2, which
fuse only creates a non-isolated mode of operation. (This is
with one of the same applicable for all printers except the 110Xi4.)
type and rating.
use this pin to ground pin 1. (This is applicable for
all printers except the 110Xi4.)
9 RIBBON LOW Output Asserts LOW if the Supplies Warning feature is enabled
and the amount of remaining ribbon remaining on the
supply spindle is below the threshold level.

Table 18 • 24-28V Applicator Interface Connector Pin Configuration (Continued)
Pin
No.
11 END PRINT Output • MODE 0—The applicator port is OFF.
moving the label forward; otherwise de-asserted
HIGH.
moving the label forward; otherwise de-asserted LOW.
• MODE 3—(Default) Asserted LOW for 20
milliseconds when a label is completed and positioned.
Not asserted during continuous printing.
14 DATA READY Output • Asserted LOW when sufficient data has been received
(Non-
RFID)
15 VOID Output • Asserted LOW when the RFID transponder over the
(RFID) antenna is “voided.”
• De-asserted HIGH when the end print signal is
asserted.

Input/Output Specifications
Figure 409 • Typical Input Circuit

Opto V_I/O
Isolator
LED
R
Input
Table 19 • Input User Specifications
Applicator Board Resistor at V_I/O Maximum Current Minimum Current
24-28V 4.7K Ohm 6mA at 28V 2mA
5V 220 Ohm 18mA at 5V 2mA
Figure 410 • Typical Output Circuit

Opto V_I/O
Isolator
Photo-transistor Present on 24-28V
Board Only
10K Ohm
Output
I/O Signal Ground
Table 20 • Output User Specifications
Output Current
a. Limited by 10K ohm pull-up resistor.
Ioh
b. Not actively driven high.
a. 7mA maximum.
Iol
b. Not intended to sink high current loads.

Wired Ethernet
Wired Ethernet
Tools Required

Metric Nutdriver Set 47362* Zebra Preventive Maintenance
Kit
Important • Do not use needle nose pliers in place of the nutdriver, as you can damage the
Ethernet board. Always use recommended tools.
1.

Wired Ethernet
securing it.

1
3
1 Electronics cover
3 Rear corner
3. Lift up on the rear corner of the electronics cover, and then lift the electronics cover off the
printer.

Wired Ethernet
4. Are you replacing an existing wired Ethernet board?
If… Then…
No Go to Install the Wired Ethernet Board on page 569.
Yes Continue with Remove the Wired Ethernet Board.
Remove the Wired Ethernet Board

1.
2. See Figure 412. Remove the three nuts securing the wired Ethernet board to the main logic
board (MLB).
Figure 412 • Remove the Wired Ethernet Board

1

2 Wired Ethernet board
3 Mounting nuts (3)
3. Remove the wired Ethernet board.
4. Go to step 4 on page 572.

Wired Ethernet
Install the Wired Ethernet Board

1. See Figure 413. Remove and discard the rear panel Ethernet access cover and screw.
Figure 413 • Remove the Blank Cover and Screw
1 Wired Ethernet access cover

2 Wired Ethernet access hole
3 Mounting screw

Wired Ethernet
2. See Figure 414. Clean the J4 pads using the Zebra Preventive Maintenance Kit part
number 47362.
Figure 414 • Clean the J4 Pads
1 2
J4
1 J4
2 Pads

Wired Ethernet
3. See Figure 415. Install the three mounting standoffs supplied in the kit into the three
threaded mounting holes on the main logic board (MLB).
Figure 415 • Install the Mounting Standoffs

1

3 Mounting nuts (3)

Wired Ethernet
4. See Figure 416 on page 572. Install the wired Ethernet board.
a. Insert the Ethernet connector into the back panel.
b. Rotate the board down onto the three mounting studs.
c. Secure the board with the three nuts supplied in the kit.
Figure 416 • Install the Wired Ethernet Board

1 2
4

3 Mounting nuts (3)
4 Back plate

Wired Ethernet

3.
6. See your ZebraNet® 10/100 Internal PrintServer User Guide to set up your Ethernet
board.

Wireless Plus PCMCIA Option/Maintenance Kit
Tools Required
1.

securing it.

1
3
1 Electronics cover
3 Rear corner
printer.

Remove the Existing PCMCIA Option Board Assembly
Caution • Observe proper electrostatic safety precautions when handling any

1. See Figure 418. Remove the screw securing the plastic cover located at the rear of the
printer.
2. Remove the RF card from the card slot by pressing the eject button.
Figure 418 • RF Card

5
3 4
1 2
1 RF card cover mounting screw

2 RF card cover
3 RF card
4 Notch
5 Card eject button

Remove the PCMCIA Standoffs

1. Are you replacing an existing PCMCIA board?
If… Then…
No, installing a Continue with Install the Wireless PCMCIA Board.
new print server
Yes, replacing an a. Remove the four mounting screws securing the PCMCIA
existing print board.
server b. Unsnap the two connectors from P23 and P24 on the MLB.
c. Remove and discard the old PCMCIA board.
Install the Wireless PCMCIA Board

1. Are you replacing an existing PCMCIA board?
If… Then…
No, installing a From the rear panel, remove and discard the screw and the blank
new print server option cover plate.
Yes, replacing an Continue with step 4.
existing print
server

2. See Figure 419. Screw the three short standoffs into the three holes along the top of the
MLB.
Figure 419 • Install New Spacers

1
1 Main logic board

2 Short standoffs (3)
3. Screw the long octagonal standoff into the threaded post on the main frame.

4. See Figure 420. Align the two connectors on the wireless PCMCIA board with P23 and
P24 on the MLB and then push them together.
Figure 420 • Install the New Wireless PCMCIA Board
1
2
1 Wireless PCMCIA board

2 Long standoff mounting screw
3 Short standoffs mounting screws (3)
5. Insert the top screw through the mounting hole in the top of the wireless PCMCIA board
and into the long standoff.
6. Insert the three screws through the wireless PCMCIA board and into the three short
standoffs.
7. Reinstall the RF card through into the card slot in wireless PCMCIA board.
The eject button will protrude from the rear panel.
8. Install the screw to secure the plastic cover over the rear opening, the RF card, and the
eject button.


3.
Resume Operation
Important • After you have completed this installation, you must download the latest
version of firmware for your printer from: www.zebra.com.
2. Look at the front panel. If the wireless PCMCIA board was installed correctly, the
wireless link status indicator displays an underscore “_” on the LCD, providing a real-time
display of the printer’s network status.
3. Refer to the Wireless Print Server User Guide to configure the Wireless Print Server for
operation.

Compact Flash Adapter
Compact Flash Adapter

Zebra now supports the Symbol® LA-4137-1020-WW Compact Flash Wireless Radio Card.
The Compact Flash Wireless Card (CF card) and adapter are a replacement for discontinued
Wireless cards and are inserted into the Wireless Print Server socket. When using this new
Symbol CF card, you must use this compact flash adapter.
Note • All other supported Wireless cards do not require this adapter.
The following firmware is required for the Xi4. V53.17.x or later
Installation Instructions

1. See Figure 421. Insert the card and adapter into the printer.
Figure 421 • Wireless Compact Flash Card and Adapter Placement

Maintenance Manual
Back of
Printer
Back of Back of Adapter

Wireless
CF Card
2. Using the cover shield mounting screw, install the clear plastic PCMCIA cover (included
with your printer or the kit) over the card slot.
3. To configure the wireless card, follow the setup instructions in the ZebraNet® Wireless
Print Server User Guide.

ZebraNet® Internal Wireless Plus Print Server
Tools Required

Standard Open-End Wrench Set
1.

securing it.

1
3
1 Electronics cover
3 Rear corner
printer.

Remove the Existing Print Server Board

1. Which print server (also called an option) board are you removing?
If you have a(n)… Then…

Wireless Plus a. See Figure 423. Check the rear panel for the RF card cover.
Remove the mounting screw and the cover.
b. Eject the wireless card.
c. Continue with step 2.
Internal Wireless Plus a. From the back of the printer, unscrew the RF antenna.
b. Remove the nut and washer from the RF connector.
c. Remove the top mounting screw securing the Internal
Wireless Plus cover.
d. Remove the cover and set aside.
e. Continue with step 2.
Figure 423 • RF Card and Cover

5
3 4
1 2
1 RF card cover mounting screw

2 RF card cover (plastic)
3 Wireless option card
4 Notch
5 Card eject button
2. Remove the four screws securing the print server board to the main frame and MLB of the
printer.

3. Unsnap the two connectors from P23 and P24 on the MLB.
4. Remove and discard the old print server board.
Install the New Internal Wireless Plus

1. Are you replacing an existing print server board?
If… Then…
Yes, replacing an Continue with step 3.
existing print server
No, installing a new a. From the rear panel, remove and discard the screw and the
print server blank option cover plate.
b. Install the long standoff in the threaded post on the main
frame.
c. See Figure 424. Screw the three short standoffs into the
three holes along the top of the MLB.

2. See Figure 424. Align the two connectors on the Internal Wireless Plus board with P23
and P24 on the MLB, and then push them together.
Ensure that the Internal Wireless Plus board is seated into the MLB connectors correctly.
Figure 424 • Install New Spacers
1 2 3
1 Main logic board

2 P24 Connector
3 P23 Connector
4 Short standoffs (3)
3. Insert one screw into the top mounting hole in the print server board and the long standoff.
4. Insert three screws into the three mounting holes in the print server board and the short
standoffs.
Install the Cover and External Antenna

1. From the back of the printer, remove the sticker located alongside of the option card slot.
2. Using isopropyl alcohol, remove all of the sticker’s glue.
3. Insert the bottom edge of the cover in the small slot below the option card slot.

4. See Figure 425. Fasten the top of the cover into place using one of the screws provided in
the kit.
5. From the back of the printer, place the lock washer and nut on the RF connector and hand
tighten.
Figure 425 • Closeup of Antenna Installation

1
2
1 Cover mounting screw

2 Right edge of the cover
3 RF connector
4 Lock washer
5 Nut
6 RF antenna
6. Using an open-end wrench, tighten the brass nut by turning it clockwise one quarter of a
turn.
7. To install the external antenna, screw the antenna onto the RF connector extending out
from the back plate of the printer.

1. See Figure 422 on page 583. Reinstall the electronics cover by lowering the cover so the
lip goes into the channel on the top of the printer.
2. Secure the cover by reinstalling the three screws on the bottom cover.
3. Reconnect the data cables and the AC power cord.

Resume Printer Operation

1. Refer to the Wireless User Guide to configure the Internal Wireless Plus Print Server for
operation.
After You Complete the Installation
Firmware
After you have completed this installation, you must download firmware version V53.17.x (or
later) from: www.zebra.com/firmware.
Attach Labels
1. See Figure 426. Examine the labels included with the kit.
There may be several labels included with your kit.
Figure 426 • Sample Label
39545-xxx 110Xi4
2 1
1 Printer model
2 Zebra part number
2. Locate your printer model in the lower right-hand corner of the label.

3. See Figure 427. If present, remove the old plastic label with part number 39545-xxx
affixed to the back of your printer.
Note • Do not remove the electrical ratings label, also known as the model plate. The
model plate contains essential user information.
Figure 427 • Label Location
1 Affix label to the lowest available open spot.

2 Model plate (Do not remove)
4. See Figure 426. Remove the backing from the new label (part number 39545-xxx included
in this kit) for your specific printer.
5. See Figure 427. Affix the new printer label in the area to the left of the model plate.
6. Discard any additional labels included in the kit.
7. The installation is complete.

Compliance Information
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.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies Corporation could void the user’s authority to operate the equipment. To ensure
compliance, this printer must be used with Shielded Communication Cables.
FCC Radiation Exposure Statement

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled
environment. This equipment should be installed and operated with minimum distance 20cm
between the radiator and your body.
This transmitter must not be co-located or operating in conjunction with any other antenna or
transmitter.
Canadian DOC Compliance Statement

This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

SEH PS102-Z IPv6 Internal Print Server
Tools Required

Standard Hex Key (Allen Wrench) Set
Remove Electronics Cover

1.
securing it.

1
3
1 Electronics cover
3 Rear corner

3. Lift up on the rear corner of the electronics cover and then lift the electronics cover off the
printer.
4. Is there an SEH PS102-Z Internal Print Server already installed on the printer?
Remove the Cover Plate
1.
2.

3. See Figure 429. On the back of the printer, remove the two cover plate mounting screws
and the cover plate (shaded).
Discard the cover plate and the screws.
Note • The parallel port on the back of the printer is not operational when the internal
SEH PS102-Z is installed. The hardware for the SEH PS102-Z mounting bracket covers
the parallel port.
Figure 429 • Cover Plate

a1
1 Cover plate mounting screws (2)

2 Cover plate
4. Continue with Install the SEH PS102-Z Internal Print Server on page 595.

Remove the Existing Communication Hardware

1. See Figure 430. Remove and discard the two screws securing the bracket for the internal
print server to the back of the printer.
2. See Figure 430. Disconnect the ribbon cable from the main logic board (MLB).
3. Remove the old internal print server through the parallel port slot on the back of the
printer.
Figure 430 • Remove/Install the SEH PS102-Z Internal Print Server

1
5 2
1 SEH PS102-Z Internal Print Server board

2 Bracket
4 Ribbon cable
5 Ribbon cable connector (attaches to MLB)
4. Continue with Install the SEH PS102-Z Internal Print Server on page 595.

Install the SEH PS102-Z Internal Print Server

1. See Figure 431. If necessary, attach the long end (distance from the cable tie to the
connector) to the SEH PS102-Z board.
2. From the back of the printer, partially insert the ribbon cable and the connector through
the mounting slot.
Figure 431 • SEH PS102-Z Internal Print Server
1
2
3
4
5
9 6
7
1 Ribbon cable connector

3 Status button
4 Status LED
5 Network Activity LED
6 Link LED
7 Ethernet connector
8 SEH PS102-Z mounting bracket
9 Ribbon cable
3. Plug the connector into the keyed interface data cable connector (P21) on the main logic
board.
4. Confirm that all small cable connectors are tight.
5. Pull the SEH PS102-Z completely though the mounting slot.
6. Secure the SEH PS102-Z board and bracket in place using the mounting screws provided
in this kit.


5. The installation is complete.
After You Complete the Installation
Firmware
1. After you have completed this installation, you must download firmware version V53.17.x
(or newer) from: www.zebra.com/firmware.
2. To confirm the upgrade was successful, verify the version of firmware on the control
panel’s LCD.

Outer Casting Components
Contents
Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Media Door Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Media Door Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
TrimPanel and Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Tear Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
Side Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Access Hole Covers and Media Low Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
Slot and Wireless Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650

Electronics Cover
Electronics Cover
This kit includes the parts and documentation necessary to install the Electronics Cover
maintenance kit on the Xi4™ printers. Read these instructions thoroughly before installing this kit.
Tools Required
Phillips Screwdriver Set
Remove the Old Electronics Cover
1.

Electronics Cover
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
Install the New Electronics Cover

the main frame.

Media Door
Media Door
These instructions are for the installation of the Media Door on Xi4™ printers. Read these
instructions thoroughly before attempting to install this assembly.
Tools Required

Allen Wrench Ball-end Safety Glasses
Remove the Old Media Door

Which model are you working on?
If have a… Then…
110Xi4 Continue with 110Xi4, 140Xi4, and 170Xi4.
140Xi4
170Xi4
220Xi4 Go to 220Xi4 on page 602.

Media Door
110Xi4, 140Xi4, and 170Xi4

1. See Figure 433. Raise the existing media door.
Figure 433 • Remove and Install the Media Door (except 220Xi4)
1 Media door
2. Remove and discard the four mounting screws.
Note • Be sure to hold the door firmly when removing the last screws.
3. Remove the old door.

Media Door
220Xi4
1. See Figure 434. Raise the existing media door.
2.
Remove the e-ring securing the damper arm to the media door.
Figure 434 • Remove and Install the Media Door (220Xi4)
4
3
1 E-ring
2 Pivot pin
3 Damper arm
4 Flat washers (2)
3. Remove the two washers and pivot pin from the media door and arm.
4. See Figure 433 on page 601. Remove and discard the four mounting screws.
Note • Be sure to hold the door firmly when removing the last screws.
5. Remove the old door.

Media Door
Install the New Media Door

1. See Figure 433. Align the holes in the door hinges with the mounting holes in the printer.
2. Install the four new mounting screws.
3. Choose the proper nameplate from the kit and feed it into the door panel opening.
Figure 435 • Install the Nameplate (110Xi4 shown)
2
1
1 Nameplate
2 Door panel opening
3 Mounting screw(s) (1 for 110Xi4 and 140Xi4 or 2 for 170Xi4 and 220Xi4)
4. Push the nameplate to the media door and then install the mounting screw(s).
If… Then…
Yes a. See Figure 434 on page 602. Reinstall the damper arm to the media door
using the pivot pin, flat washers, and e-ring removed previously.

Media Door Window
Media Door Window

This kit includes the parts and documentation necessary to install the Media Door Window
Tools Required
Flat-blade Screwdriver Set
Remove the Old Media Door Window

1. Open the media door.
Figure 436 • Remove the Old Media Door Window

1
Standard
Media Door
Bifold
Media Door
1 Standard media door window

2 Bifold media door window

Media Door Window
2. See Figure 437. Remove the window by pressing on the seven snap tabs until it is free on
three sides.
Figure 437 • Remove the Old Window

1
1 Window
2 Snap Tabs (7)
3 Stationary Tabs (3)
3. See Figure 438. Lift the window out of the door.
Figure 438 • Lift the Window Out

Media Door Window
Install the New Media Door Window

1. See Figure 439. Set the three stationary tabs onto the door.
Figure 439 • Install the New Window
1 1
1 Stationary tabs
2 Set the stationary tabs here
2. See Figure 437 on page 605. Push the new window into the door opening, ensuring that all
seven snap tabs snap into place.
3. Close the media door.

Media Door Damper Assembly

This kit includes the parts and documentation necessary to install the Media Door Damper
• 220Xi4™
Tools Required

SAE Hex Key (Allen wrench) Set Safety Glasses
Needle Nose Pliers

Remove the Old Media Door Damper Assembly

1. Turn off (O) the printer and disconnect the AC power cord and data cables.
2. Open the media door and ensure that it rests on the top of the printer.
3. Remove the media low sensor from the mounting bracket by removing the two screws
securing it. Let the sensor hang there for now.
4.
See Figure 440. Remove and discard the e-ring and washer from the pivot pin on the
media door.
5. Remove the pivot pin and washer to release the arm of the damper from the media door.
Figure 440 • Removing the Media Cover Damper

4
3
1
2 3
5
9 8
1 Media door
2 E-ring
3 Washer
4 Pivot pin
5 Damper mounting screws (4)
7 Media low sensor

6. Remove the two media low sensor mounting screws. The media low sensor will fall out of
the mounting bracket.
7. Remove the four screws securing the damper assembly and media low bracket to the
damper mounting bracket.
8. See Figure 441. Remove and discard the three screws and washers securing the damper
mounting bracket to the main frame.
9. Guide the media low sensor through the damper mounting bracket and then remove an
discard the damper mounting bracket.
Figure 441 • Remove the Damper Mounting Bracket

2 Lock washers (3)
4 Media low sensor

Install the New Damper Assembly

1. See Figure 441. Orient the new mounting bracket as shown.
2. Secure the mounting bracket to the main frame with the three screws and lock washers.
3. Guide the media low sensor through the mounting bracket as shown.
4. See Figure 440 on page 608. Slide the new damper into the damper mounting bracket,
ensuring that the cable for the media low sensor is not pinched between the damper and
bracket as shown in Figure 442.
5. Install, but do not tighten, the two rear damper mounting screws.
6. See Figure 442. Slide the new media low sensor mounting bracket into the damper
mounting bracket, ensuring that the cable for the media low sensor is not pinched between
the two brackets and then install the two front damper mounting screws.
1 2
3
6
5 5

2 Damper assembly
5 Cable guide
7. Tighten the four damper assembly mounting screws.
8. See Figure 441 on page 609. Reinstall the media low sensor into the media low sensor
mounting bracket using the two screws removed previously.

9. See Figure 440 on page 608. Attach the damper arm to the cover with the pivot pin,
washers, and E-ring.
10. Close the media cover and check the operation of the damper.

TrimPanel and Nameplate

This kit includes the parts and documentation necessary to install the Lower Trim Panel and
Nameplate in the Xi4™ printers.
Tools Required
Phillips Screwdriver Set Small SAE Socket Set
Remove the Old Lower Trim Panel
1.
2. Open the media cover.
3. See Figure 443. Remove the front plate by loosening the two knurled mounting nuts and
then sliding it up and out of the printer.
Figure 443 • Remove the Front Plate
1 Front plate
2 Knurled mounting nuts (2)

4. See Figure 444. Loosen the screws securing the lower trim panel to the printer by turning
them approximately 1½ turns each.
Figure 444 • Loosen the Mounting Screws
1 Lower trim panel

2 Mounting screws (2 for 110Xi4 and
140Xi4 or 3 for 170Xi4 and 220Xi4)

5. See Figure 445. Remove and discard the lower trim panel by lowering it until the screw
heads align with the larger hole in the base and then slide it out.
Figure 445 • Remove the Lower Trim Panel
4
3
1 Lower trim panel

2 Large holes (2 or 3)
3 Openings in base (2)
4 Ribs (2)

Install the New Lower Trim Panel

1. See Figure 445. Install the new mounting screws into the new lower trim panel by turning
them approximately 1½ turns each.
Figure 446 • Install the New Lower Trim Panel
1 Lower trim panel

2 Mounting screws (2 or 3)
3 Openings in base (2)
4 Ribs (2)
2. Align the large mounting holes in the base with the mounting screws and then slide the
lower trim panel into the printer.
3.
Caution • Over tightening the mounting screws will cause damage to the lower trim
panel.
Lift up on the lower trim panel until the ribs are in the holes in the base and then tighten
the mounting screws.
4. See Figure 443 on page 612. Reinstall the front plate by sliding it into the printer and then
behind the mounting screws.
5. Tighten the two knurled mounting nuts.

Remove the Nameplate

1.
2. Open the media cover.
3. See Figure 447. Remove the mounting screw(s) securing the old nameplate to the media
door and then slide it out of the door panel opening.
Figure 447 • Remove and Install the Nameplate
2
1
1 Nameplate
2 Door panel opening
3 Mounting screw (1 for 110Xi4 and 140Xi4 or 2 for 170Xi4 and 220Xi4)
4. Slide the new nameplate into the door panel opening and then install the mounting
screw(s).
5. Reinstall the AC power cord.

Tear Front Plate
Tear Front Plate

This kit includes the parts and documentation necessary to install the Tear Front Plate in the Xi4™
printers. Read these instructions thoroughly before installing this kit.
Remove the Old Tear Front Plate
1.
2. See Figure 448. Remove the old tear front plate by removing and discarding the two
knurled nuts securing it.
Figure 448 • Remove and Install the Tear Printer Front Plate
3. Lift the tear front plate out of the printer.
Install the New Tear Front Plate

1. See Figure 448. Slide the new tear front plate into the printer until it rests on the mounting
studs.
2. Install the new knurled nuts.

Side Plate
Side Plate
Tools Required

1.

Side Plate
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.

Side Plate
Remove the Old Side Plate

1. See Figure 450. Open the head and then remove the head open lever and wave washer by
removing the head open lever mounting screw and then sliding the lever and washer off
the toggle bar.
Figure 450 • Remove the Toggle Bar Lever
4
3
2
1
1 Toggle bar lever mounting screw

2 Toggle bar
3 Wave washer
4 Toggle bar lever

Side Plate
2.
3. Do you have a rewind platen roller installed?
If… Then…
Yes a. Remove the rewind platen roller support bracket by removing the c-clip and
then sliding the bearing out of the rewind platen roller support bracket.
b. Remove the two mounting screws and washers.
c. Continue with step 4.
Figure 451 • Remove the Rewind Platen Roller Support Bracket
8
7 6 5 4
3
1 Rewind platen roller support bracket

4 C-clip
5 Bearing
6 Upper platen roller c-clip
7 Upper platen washer
8 Upper platen bearing
4. Remove the c-clip from the upper platen roller and then slide the washer and bearing off
the upper platen roller.

Side Plate
5. See Figure 452. Remove all of the hex key mount screws.
Figure 452 • Remove the Hex Key Mounting Screws
1
2
1 Dancer mounting lock washer

2 Dancer mounting screw
3 Hex key mounting screws (4)
6. Is there a cutter option installed?
If… Then…
Yes See Figure 453. Remove the two cutter option mounting screws.
No Go to step 7.
Figure 453 • Remove the Cutter Option Mounting Screws
1 Cutter mounting screws (2)

Side Plate
7. See Figure 454 or Figure 455. Remove and discard the hex head mounting screws.
Figure 454 • Remove the Hex Head Mounting Screws (140Xi4 and 220Xi4)
1 hex head mounting screws (6)
Figure 455 • Remove the Hex Head Mounting Screws (110Xi4 and 170Xi4)
1 Hex head mounting screws (7)

Side Plate
8. See Figure 456. Remove the side plate by sliding it out of the printer.
Figure 456 • Remove the Side Plate

140Xi4 and 220Xi4 110Xi4 and 170Xi4
9. See Figure 457. Remove the access hole cover(s).
Figure 457 • Remove the Wear Plate and Access Hole Cover(s)
1 1
2 2 3
34 4 5
5 6
6
7 8 7 8
9
9
1 140Xi4 and 220Xi4 side plate

110Xi4 and 170Xi4 side plate
2 Wear plate
3 Cam
4 Flat washer
5 Lock washer
6 Cam mounting screw
7 Flat washer
8 Wear plate mounting screw
9 Access hole cover(s)

Side Plate
10. Remove the wear plate by removing the cam mounting screw, washers, and cam and then
remove the wear plate mounting screw and washer.
Install the New Side Plate

1. See Figure 458. Align the new side plate with the toggle bar and then the upper platen
roller shaft and side plate mounting holes.
Figure 458 • Align the Side Plate

1
1 Toggle pivot bar

2 Toggle bar bearing
3 Print mechanism pivot bar
4 Platen roller shaft
2. Side the toggle bar into the new side plate ensuring that the bearing is seated into the
mounting hole.
3. Ensure that the upper platen roller shaft is through the side plate mounting hole.

Side Plate

140Xi4 a. See Figure 459. Align the mounting holes and then install the
220Xi4 number one hex head mounting screw first then the number two.
b. Install the other four in any order.
110Xi4 See Figure 459. Align the mounting holes and the cover plate and
170Xi4 then install the hex head mounting screws as indicated by the
numbers in the graphic.
Figure 459 • Install the Hex Head Screws

110Xi4 and 170Xi4 140Xi4 and 220Xi4
3
4
1 1
2
2
5. See Figure 452 on page 622. Align the top ribbon roller and shaft and then install the hex
key mounting screw.
6. Align the lower ribbon guide with the mounting hole and then install the hex key
mounting screw.
7. Align the dancer shaft with the mounting hole and then install the long hex key mounting
screw and lock washer.
8. Align the media guide with the mounting hole and then install the hex key mounting
screw.
9. Align the tear bar with the mounting hole and then install the hex key mounting screw.
10. Is there a cutter option installed?
If… Then…
Yes a. See Figure 453 on page 622. Reinstall the two cutter option mounting
screws.
11. See Figure 457 on page 624. Install the access hole cover(s).

Side Plate

110Xi4 a. See Figure 455 on page 623. Install the cover plate.
170Xi4 b. Continue with step 13.
140Xi4 Continue with step 13.
220Xi4
13. See Figure 450 on page 620. Slide the wave washer and handle onto the toggle bar and
then reinstall the handle mounting screw.
14. Hold the upper platen roller from the electronics side while sliding the upper platen roller
bearing, flange facing out, onto the upper platen roller shaft and then into the new side
plate.
15.
Slide the flat washer onto the upper platen roller shaft and then reinstall the C-clip.

Side Plate
16. See Figure 460. Slide the wear plate onto the print mechanism shaft and then start the
mounting screw and flat washer.
Figure 460 • Reinstall the Wear Plate

1
2
3
4
5
6
8 7
1 Wear plate
2 Print mechanism shaft
3 Cam
4 Flat washer
5 Lock washer
6 Long mounting screw
7 Mounting screw
8 Flat washer
17. Slide the lock washer, flat washer, and cam onto the long mounting screw and then install
the screw into the new side plate ensuring the cam is inserted into elongated hole in the
wear plate.
18. Is the rewind option installed?
If… Then…
No Continue with Reinstall the Electronics Cover on page 629.
Yes a. Install the rewind platen roller support bracket.
b. Hold the rewind platen roller from the electronics side while sliding the
rewind platen roller bearing, flange facing out, onto the rewind platen roller
shaft and then into the rewind platen roller support bracket.
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.
c. Reinstall the C-clip.

Side Plate

3.
Open the media door and then reinstall the media and ribbon.
5. Did you reinstall a rewind platen roller support bracket.
If… Then…
Yes Continue with Adjust the Rewind Platen Roller.
No Go to Adjust the Printhead on page 630.
Adjust the Rewind Platen Roller

1. Press and hold PAUSE while turning on (l) the printer and check for proper tracking of the
media onto the rewind spindle.
2. See Figure 461. Loosen the two screws securing the roller adjust plate to the print
mechanism.
Figure 461 • Adjust the Rewind Platen Roller Support Bracket


Side Plate
tighten the screws.
Note • Moving the roller adjust plate toward the front of the printer moves the liner
material away from the roller adjust plate. Moving the roller adjust plate toward the rear of
the printer moves the liner material toward the roller adjust plate.

Five interrelated adjustments lead to optimum print quality with increased printhead life:
• Strip Plate Position
Note • To achieve optimum results with print quality adjustments, install full-width media
and ribbon. Verify the media and ribbon are properly matched, and that darkness and print
speed configurations are correct for the application before performing any mechanical
adjustments.
Prior to Performing Printhead Adjustments
Figure 462 • Adjust the Toggles
Position the toggles as follows:
1.See Figure 462.

110/140/170/220Xi4: Position each toggle over the
width of the media.
2.Adjust the toggle spring while the head is closed

and locked by turning the lower knurled nut until
30 mm the distance from the top of the toggle foot to the
bottom of the lower knurled nut equals 1.18 in.
(30 mm).
3.Perform the Pause Self Test by pressing and

holding PAUSE while turning on (l) the printer.

Side Plate
Printhead Parallelism
Important • Excessive toggle pressure will increase printhead wear and decrease printhead
life. Increase printhead life by combining minimum toggle pressure and optimum printhead
position over the platen roller.
The order in which the adjustments are performed depends on the print quality of the labels
printed during the Pause Self Test.
Complete the first two printhead adjustments (Parallelism and Wear Plate) prior to locating
the optimum print position. As with the other adjustments, parallelism and wear plate
adjustments are interrelated. Adjusting one may have an effect on the position of the other.
This adjustment is performed in conjunction with the wear plate position, printhead position,
and printhead pressure adjustments.
Adjusting the printhead parallelism squares the printhead to the platen roller.
Test the Printhead Parallelism

See Figure 463. Prior to starting this test, ensure the installed media is square with the tear-off
bar and that the toggle is set to 30 mm.
1. Perform the Pause Self Test by pressing and holding PAUSE while turning on (l) the
printer.
2. When the printer begins printing labels, refer to Set the Darkness on page 635.
3. The uppermost line on the test label should be parallel to the top edge of the label.
4. Are the print lines parallel to the top of the label?
If… Then…
No Continue to Adjust the Printhead Parallelism.
Yes Go to Adjust the Wear Plate on page 632.
Adjust the Printhead Parallelism

2. Perform a Pause Self Test by pressing and holding PAUSE while turning on (l) the printer.
4. Adjust the parallel location of the uppermost lines by turning one of the two screws
located at the back of the print mechanism. Only small adjustments are required.
5. To move the printhead forward, turn the adjustment screw clockwise as viewed from the
rear of the printer.
6. To move the printhead backward, turn the adjustment screw counter-clockwise as viewed
from the rear of the printer.

Side Plate
7. Adjust each side as necessary to align the uppermost line of the test label parallel with the
8. Run additional Pause Self Test labels to check for proper parallelism.
9. Tighten the four top screws, and then run additional Pause Self Test labels to verify proper
positioning.
Figure 463 • Printhead Parallelism Adjustment

Note • Loosen these screws before adjusting the printhead.
1
2
3
1 Toggle knurled adjusting nut
2 Parallelism adjustment screws (2)
3 Cam
Adjust the Wear Plate

Adjusting the wear plate position produces even pressure across the full width of the printhead
and platen roller.
2. See Figure 463. Loosen the two screws on the front of the strip plate.
4. After printing a few labels, press PAUSE and reduce the darkness value until the test
labels are a charcoal gray color (see Set the Darkness on page 635).
5. Print additional Pause Self Test labels and observe the print quality.
6. If printing is evenly dark, the wear plate position is good. If lighter or no printing is
observed on one side of the label, continue with this adjustment.

Side Plate
7. Loosen the two screws securing the wear plate.
8. Continue to print pause test labels while adjusting the wear plate eccentric.
9. Adjust the wear plate eccentric by turning it by hand, a wrench, or a pair of utility pliers.
the label, or adjust it counter-clockwise to increase pressure on the outboard side of the
printer.
11. When even print quality is achieved, hold the wear plate in position and retighten the two
wear plate screws.
12. Print Pause Self Test labels to verify parallelism is correct.
13. Is parallelism out of tolerance?
If… Then…
No Align the strip plate. Go to Align the Strip Plate on page 636.
Yes Go to Adjust the Printhead Parallelism on page 631.
Adjust the Printhead Position

This adjustment is performed in conjunction with the printhead parallelism, wear plate
position, and printhead pressure adjustments.
Adjusting the printhead position aligns the printhead for optimum print quality.
1. See Figure 463 on page 632. The thermal elements of the printhead should be aligned just
behind the crest of the platen roller.
2. Perform the Pause Self Test by pressing and holding PAUSE while turning on (l) the
printer.
3. Set the darkness to achieve as close to optimum print quality as possible (see Set the
Darkness on page 635).
4. Loosen the four screws at the top rear of the print mechanism.
Caution • To prevent printhead damage, loosen the four top screws before turning the
two adjustment screws.
5. Adjust the printhead position for optimum print quality by equally turning the two screws
located at the back of the print mechanism.
Note • Adjustments are made in very small increments.

Due to spring pressure, there may be a dead spot in the actual printhead movement when
switching adjustments from one direction to the other.
6. Turn both screws 1/8 turn clockwise and observe the changes in print quality. Turn both
screws 1/8 turn counter-clockwise and observe the changes in print quality.

Side Plate
7. Press PAUSE and check the test labels for streaks, flouring, and other print quality
problems.
8. Adjust the screws while observing print quality.
9. Since printhead parallelism, wear plate position, and printhead positions are interrelated,
look at the test labels for changes in these settings and adjust if necessary.
Adjust the Printhead Pressure

Printhead pressure is the fourth of the five interrelated adjustments. Using lower printhead
pressure and darkness settings can extend printhead life. If printing is too light on one side, or
if thick media is used, printhead pressure may require adjustment.
See Figure 464. Locate the pressure toggles. The Xi4 printers have two toggles. These toggles
are typically positioned at the 1/4 and 3/4 positions across the width of the media. If the media
is sufficiently narrow that both toggles will not fit within its edges, the inside toggle should be
centered above the media.
Figure 464 • Adjust the Printhead Pressure
Toggle Adjusting
Nuts
Strip Plate
Positioning Screw
1. To check print quality, perform a Pause Self Test by pressing and holding PAUSE while
turning on (l) the printer.
2. To increase printhead pressure, loosen the upper knurled nut on the toggle and adjust the
lower toggle adjusting nut downwards.
3. To decrease printhead pressure, loosen the upper knurled nut and adjust the lower toggle
adjusting nut upwards.
4. Adjust printhead pressure for optimum print quality.

Side Plate
5. To lock the toggle pressure, tighten the upper knurled nut against the lower toggle
adjusting nut.
6. Though different media and ribbon combinations may require different toggle settings, a
suggested initial distance between the top of the toggle foot to the bottom of the lower
knurled nut equals 1.18 in. (30 mm).
7. Continue with Set the Darkness.
Set the Darkness

Darkness settings depend on a variety of factors, including ribbon type, labels, 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 can also 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.
Note • Turning off (O) the printer is not required for the new setting to take effect.
Set the darkness to the lowest setting that provides good print quality. If the darkness is set
too high, the ink may smear, or the ribbon may burn through.
Begin printing a batch of labels, using the Pause Self Test labels. Adjust the darkness setting to
obtain the desired print quality. the Darkness does not need saved until the correct darkness is
found. The darkness settings can be adjusted while the Pause Self Test is running.
• Decreasing the value in the display causes a lighter (less black) image.
• Increasing the value causes a darker (blacker) image.
1. Press SETUP/EXIT to enter the Configuration Mode.
2. DARKNESS is displayed. Press the left oval to decrease the value or right oval to increase
the value.
3. Press SETUP/EXIT; then NEXT/SAVE to permanently save the darkness setting.
4. Turn off (O) the printer, perform the Feed Self Test, and check print quality.

Side Plate
Align the Strip Plate

The strip plate adjustment is a very important part of the printhead adjustment procedure, and
can be adjusted for proper tracking and separation of the ribbon from the media.
See Adjust the Printhead Pressure on page 634.
2. Press PAUSE and observe the ribbon for possible problems such as wrinkling.
3. Loosen the two screws securing the strip plate to the front of the printhead assembly.
4. While running the Pause Self Test, lower the strip plate until the ribbon is flat, smooth and
tracks properly when fed to the ribbon take-up spindle.
5. See the printer’s Maintenance Manual for spindle adjustment procedures.
6. Tighten the strip plate screws and print a minimum of 25 labels while checking for ribbon
wrinkle, tracking, and media/ribbon separation problems. If ribbon problems persist,
check the torque settings of the ribbon supply spindle and adjust tension if required.

Access Hole Covers and Media Low Bracket

This kit includes the parts and documentation necessary to install the Access Hole Covers and
Ribbon Low Brackets maintenance kit in the Xi4™ printers.
Tools Required

SAE Nutdriver Set Flatblade Screwdriver Set
Install Cutter Module Hole Cover Plate

1. See Figure 465. Slide the cover plate into the slot in the main frame, align the mounting
holes, and then install the two mounting screws.
Figure 465 • Install the Cutter Module Hole Cover Plate
110Xi4, 140Xi4, and 170Xi4 220Xi4

1 1
3
3
2
1 Cutter hole cover plate

3 Slot in main frame

Install the Take-Label Sensor Expansion Covers

1. See Figure 466. Push the take-label covers into the two mounting holes and then install the
two screws.
Figure 466 • Install the Take-Label Covers
1
2
3
1
2

2 Expansion nuts (2)
3 Screws (2)

Install the Lower Platen Plug

1. See Figure 467. Push the plug into the lower platen roller hole.
Figure 467 • Install the Lower Platen Plug
1 Lower platen roller hole

2 Plug
Install the Compliance Roller Hole Plug

1. See Figure 468. Push the plug into the compliance roller hole.
Figure 468 • Install the Compliance Roller Hole Plug
1
110Xi4 and 140Xi4
2
1 Compliance roller hole

2 Plug

Install the Rewind Spindle Hole Plug

1. See Figure 469. Align the rewind spindle metal plug with the hole and push it into the
hole.
Figure 469 • Install the Rewind Spindle Hole Plug

110Xi4, 140Xi4, and 170Xi4
1 Rewind spindle hole

2 Metal plug
2. To tighten the metal plug remove the electronics cover and then using a screwdriver bend
several of the tabs toward the main frame.

Install the 220Xi4 Rewind Spindle Hole Cover Plate

1. Go to Remove the Electronics Cover and remove the electronics cover.
2. See Figure 470. On the electronics side align the rewind spindle cover plate with the hole.
Figure 470 • Align the Rewind Spindle Hole Cover Plate

1
3. From the media side install and tighten the three mounting screws.
4. Go to Reinstall the Electronics Cover on page 646.
Install the Cutter Motor Cover Plate
1.

securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
If… Then…
No Continue with Remove the DC Power Supply on page 643.
Yes Go to Remove the AC/DC Power Supply on page 644.


1.
2. See Figure 472. Remove the two mounting nuts and the one mounting screw and then
move the power supply enough to gain access to the cutter motor hole.
1 DC power supply
2 Mounting screw
3 Mounting nuts (2)
3. Continue to Align the Cutter Motor Hole Cover Plate on page 646.


1.
2. See Figure 473. Disconnect the AC connector to the power supply by squeezing the tab
and then pulling the connector out of the power supply.
Figure 473 • Disconnect the AC Connector to the Power Supply

1 2
1 AC Connector
2 Tab

3. See Figure 474. Remove the two mounting screws and then remove the shield.
2
3

2 Shield
4. See Figure 475. Remove the two mounting nuts and then the two mounting screws.
1 Mounting nuts (2)

5. Move the AC/DC power supply enough to gain access to the cutter motor hole.

Align the Cutter Motor Hole Cover Plate

1. See Figure 476. Align the cutter motor hole cover plate with the two mounting holes and
then install and tighten the two mounting screws from the media side.
Figure 476 • Install the Cutter Motor Hole Cover Plate

1 2

3 Cutter motor hole cover plate

110Xi4 a. See Figure 475 on page 645. Reinstall the AC/DC power supply.
b. See Figure 474 on page 645. Reinstall the AC/DC power supply
shield.
All others a. See Figure 472 on page 643 and reinstall the DC power supply.
b. Continue with Reinstall the Electronics Cover.

3. Reconnect the AC power cord and data cables and turn on (l) the printer.

Install the Media Low Brackets
Remove the Old Media Low Mounting Bracket


110Xi4 a. See Figure 477. Remove the two screws securing the media low
140Xi4 sensor in the old bracket.
170Xi4 b. Remove and discard the three media low sensor mounting
bracket mounting screws.
220Xi4 a. See Figure 478 on page 648. Remove the two screws securing
the media low sensor in the old bracket.
b. Remove the two mounting screws securing the damper and the
media low bracket and the slide the media low bracket out of the
printer.
Figure 477 • Remove the Media Low Sensor (110Xi4, 140Xi4, and 170Xi4)
1 2
2 4
1 Media low sensor

3 Media low sensor mounting screws (2)
4 Media low sensor mounting bracket mounting screws (3)

Figure 478 • Remove the Media Low Sensor (220Xi4)

2 4 5
1
2
6
1 Media low sensor

3 Media low sensor mounting screws (2)
4 Damper
6 Damper/Media low mounting screws (2)
Install the New Media Low Mounting Bracket


110Xi4 a. See Figure 477 on page 647. Align the new media low mounting
140Xi4 bracket with the mounting hole in the printer and install the three
170Xi4 mounting screws.
b. Install the media low sensor into the media sensor mounting
bracket using the two screws previously removed.
220Xi4 a. See Figure 479 on page 649. Slide the new media low sensor
mounting bracket into the damper mounting bracket, ensuring
that the cable for the media low sensor is not pinched between
the two brackets and then install the two damper/media low
bracket mounting screws.
b. See Figure 478. Reinstall the media low sensor into the media
low sensor mounting bracket using the two screws removed
previously.

1 2
3
6
5 5

2 Damper assembly
5 Cable guide

Slot and Wireless Covers

This kit includes the parts and documentation necessary to install the Slot and Wireless Covers on
the Xi4™ printers.
Tools Required

Install the Slot Covers

1.
2. See Figure 480. Install the slot covers by aligning the mounting holes in the back cover
with the holes in the slot covers and then install the mounting screw(s).
Figure 480 • Install the Slot Covers

1
2
4
3
2
1 Rear panel
2 Screws (6)
3 Blank option slot cover
4 Blank ethernet cover
5 Blank Wireless cover

Install the RFID Covers
Wireless Card Cover

1. See Figure 481. Align the tab with the slot and then install the mounting screw.
Figure 481 • Install Wireless Covers
2 5
3 3
4 4
1 Mounting screw
2 Wireless card cover
3 Tab
4 Slot
5 Wireless shipping debris slot cover
Wireless Shipping Debris Slot Cover

1. See Figure 481. Align the tab with the slot and then install the mounting screw.
Complete the Installation


Options
Contents
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
Cutter Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688
Cutter Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
Cutter Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
Cutter Catch Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719
Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724
Repacking Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749

Cutter Option
Cutter Option
This kit includes the parts and documentation necessary to install the Cutter Option in the
Xi4™ printers.
Tools Required
Phillips Screwdriver Set Safety Glasses

Flat-blade Screwdriver Set SAE Hex Key (Allen wrench) Set
SAE Open-end Wrench Set Fine-Toothed File
Grease-cutting Cleaner Jumper Cable with Alligator Clips
1.

Cutter Option
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

1. Which model of the Xi4 are you working on?
If you have… Then…

110Xi4 Continue with Remove the AC/DC Power Supply.
All others Go to Remove the DC Power Supply on page 660.

Cutter Option


1

Cutter Option
shield.


Cutter Option
4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

Cutter Option
supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs
8. Go to Install the Cutter Motor on page 662.

Cutter Option

1.
2. See Figure 488. Remove all cables from the DC power supply.
1 2
4
6 5

3 J4 stepper motor

Cutter Option
5. Continue with Install the Cutter Motor.

Cutter Option
Install the Cutter Motor

1. See Figure 490. From the media side remove two access cover plate mounting screws.
Figure 490 • Remove the Access Hole Cover Plate

Media Side Electronics Side
110Xi4,140Xi4 and 170Xi4
2 220Xi4
1 Cutter motor access hole

3 Access hole cover plate
2. From the electronics side remove the access hole cover plate.

Cutter Option
3. See Figure 491. Position the cutter motor near the mounting hole on the media side. Pass
the cutter motor leads through the slit in the rubber grommet.
Figure 491 • Install the Cutter Motor

110Xi4,140Xi4 and 170Xi4
1
7
2 6
3
4
220Xi4
1 4
2 3
4 3
1 Access hole
2 Grommet slot
3 Grommet
4 Cutter motor
4. See. Insert the grommet into the slot located in the lower right area of the motor mounting
hole and slide it into the small slot.
a. The electrical connector must be positioned on the electronics side of the printer.
b. Rotate the grommet so the cut is facing away from the motor.
5. Install the motor by aligning the screw holes in the motor with the holes in the main frame,
and install the two mounting screws.

Cutter Option
Install the Cutter Module

1. Remove the cutter module access hole cover plate by removing the two screws securing it.
Figure 492 • Remove the Cutter Module Access Cover Plate

110Xi4, 140Xi4, and 170Xi4 220Xi4
2
1 1
1 Access hole cover plate


Cutter Option
2.
See Figure 493. Locate the pre-assembled cutter mechanism. The upper cutter bracket at
the right rear corner of the cutter is placed in a horizontal position for shipping. Loosen
the mounting screw, rotate the bracket to a vertical position, and snug the screw but do
not tighten.
Figure 493 • Prepare the Cutter Module
1 1
2
2
3 4 3
4
1 Cutter Module
2 Upper cutter bracket
3 Loosen these screws (2)
4 Lower cutter bracket
3. Loosen the two screws securing the lower cutter bracket to the cutter assembly.

Cutter Option
4. See Figure 494. Slide the cutter module into the opening of the main frame.
5. Align the slots in the lower cutter bracket with the threaded holes in the main frame and
loosely attach the bracket.
Note • The cutter mechanism should be positioned as far forward as possible while
staying parallel to the tear-off bar. This should prevent interference of the rear cutter blade
with the tear-off bar.
Figure 494 • Install the Cutter Module

1 1
2
2
3
5
1 Cutter module
5 Slots (2)

Cutter Option
6. See Figure 495. Open the printhead and observe the position of the tear-off bar (in front of
the platen roller) and the rear cutter blade. Position the cutter mechanism so that the rear
cutter blade is parallel with the outer edge of the tear-off bar across the entire width of the
media path. Tighten all mounting screws.
Figure 495 • Cutter Mechanical Assembly Positioning

Relative position of
the rotary cutter
blade when the
drive link assembly
is stopped by the
1
optical sensor when
8 the power is on in
7 the cutter mode.
Ensure the top of
the tear-off bar
2
is positioned above 6 3
or level with the
top of the rear
5
cutter blade.
1 Rotary cutter blade

2 Clearance 2.5 mm (0.100 in.)
3 Rear cutter blade
4 Adjustment screws (4)
For position of cutter module and squareness to media.
5 Clearance 75 mm (0.030 in.) between rear cutter blade and tear-off
bar.
6 Tear-off bar
7 Media guide
8 Upper cutter bracket mounting screw
Note • While tightening the upper cutter bracket mounting screw, be careful not to change
the position of the media guide. If the media guide moves out of position, set its height so
that the lower edge is flush with the rear opening in the cutter mechanism.
The lower cutter blade is held in position by two springs. If these springs touch the tear bar
or other printer parts, the lower cutter blade will not float properly and will cause
excessive wear and premature failure of the cutter blades.
7. Check the clearance between the back of the cutter mechanism and the tear bar by
inserting a screwdriver from the front of the cutter mechanism. Press the top of the lower
cutter blade toward the printer. The blade should move a minimum of 0.75 mm. (0.030 in).
If necessary, loosen the four screws on the bottom of the cutter module and reposition.

Cutter Option
Install the Cutter Circuit Board and Optical Sensor

1. See Figure 497. Route the cutter motor leads between the two right-hand standoffs and out
behind the bottom of the circuit board.
2. Align the cutter circuit board with the four standoffs on the main frame and then install the
four mounting screws.
Figure 496 • Install the Cutter Circuit Board
5 6
4 4
7

2 Cutter circuit board
4 Route cutter motor cable here.
5 Cutter data cable
6 Cutter circuit board power cable
7 Cutter sensor cable

Cutter Option
3. See Figure 497. Connect the power cable to J2 on the cutter circuit board.
Figure 497 • Cutter Option Circuit Board Connectors

2
4 3
5
1 DC power supply connector J2

2 Capacitor C1
3 Cutter motor connector J4
4 Test point TP1
5 Cutter optical sensor connector J3
6 Main logic board connector J1
4. Connect the data cable to J1 on the cutter circuit board.

Cutter Option

110Xi4 a. See Figure 498. Open the ferrite and close it around the cutter
data cable as shown.
b. With the ferrite block to the left, install a cable tie through the
hole in the lower right of the MLB and then around the cutter
data cable.
c. With the ferrite block to the right, install a cable tie around the
control panel cable and then around the cutter cable.
140Xi4 a. See Figure 499 on page 671. Insert a cable tie through the two
170Xi4 holes in the rear of the ferrite block.
220Xi4 b. Wrap the cable tie around the power cable going to the DC
power supply and tighten the cable tie.
c. Open the ferrite, insert the cutter data cable, and then close the
ferrite block around the cutter data cable as shown.
Figure 498 • Install the Ferrite on the Data Cable (110Xi4)

2
1
3 4
5

3 Cable tie
4 Cutter data cable
5 Ferrite block
6 Hole in MLB

Cutter Option
Figure 499 • Install the Ferrite on the Data Cable (140Xi4, 170Xi4, and 220Xi4)
1
2
6
5
7
4 8

2 Ferrite block
3 Power cable to the DC power supply
4 Cutter data cable
5 DC power supply
6 Cable tie
7 Rear of ferrite block
8 Holes in rear of ferrite block

Cutter Option
6. See Figure 500. Wind the motor leads around the ferrite ring as shown.
Figure 500 • Cutter Motor Leads

1
2
3
1 Ferrite ring
2 Cutter motor leads
3 Red
4 Black
7. Pass the cutter board power cable along the bottom of the printer frame toward the main
logic board. This will be connected to the power supply later.
8. See Figure 497 on page 669. Connect the cutter motor leads to J4 on the cutter circuit
board with the black lead to the left. To minimize interference between components,
wedge the top of the ferrite core under the cutter board relay.

Cutter Option
9. See Figure 501. Install the cutter sensor assembly on the sensor mounting post. The sensor
part of the assembly should be mounted toward the main frame.
Figure 501 • Install the Cutter Sensor

3
1 2
1 Sensor clamp
2 Mounting nut
3 Sensor assembly
4 Sensor mounting post
10. Place the sensor clamp over the sensor and start the nut on the post. Do not tighten the nut
at this time.
11. Route the sensor cable under the clamp and toward the rear of the printer, and lightly
tighten the nut to hold the wires in position. Ensure that no wires are pinched.
12. See Figure 497 on page 669. Connect the cutter sensor cable into J3 on the cutter circuit
board.
13. Check the installation and ensure that no wiring touches any moving parts.

Cutter Option
Install the Drive Link Assembly

1. See Figure 502. Remove the screw from the mounting post on the drive link assembly.
Figure 502 • Install the Cutter Drive Link

1 5
2
3
6
3
4
1 Drive link assembly

2 Drive link mounting post
3 Drive link mounting hole
4 Mounting screw
5 Upper drive arm mounting post
6 Cutter motor shaft
2. From the electronics side, align the post with the mounting hole in the main frame and
then from the media side, secure the assembly with the mounting screw.

Cutter Option
3.
See Figure 503. Slide the top of the top of the cutter drive link assembly onto the upper
drive link mounting post and then secure it with the e-ring.
Figure 503 • Connect the Drive Link to the Cutter System

1
1
4 3
1 Upper drive arm mounting post

2 E-ring
3 Lower drive arm
4 Cutter sensor
5 Cutter flag
4. Slide the lower drive arm onto the cutter motor shaft ensuring that the cutter flag is in the
center of the cutter sensor and then tighten it to the shaft.
Align Lower Drive Arm Mechanical

j
Note • To perform the lower drive arm mechanical alignment, some cables must be connected
between the power supply and cutter board, but access to the cutter board is still required. The
power supply assembly must not be installed inside the printer. The power supply assembly
must be carefully positioned so the cables are connected, allowing access to the cutter board.
Connect only the cables listed.

Cutter Option
1. See Figure 504. Connect the data ribbon cable from J1 on the cutter board to any available
P31–P35 connector on the main logic board.
Figure 504 • Connect to the Main Logic Board (MLB)
P25
P31 P32
P33 P34

110Xi4 a. See Figure 485 on page 658. Connect the cable from
P25 on the main logic board to J1 on the power supply.
b. Connect the power cable from J2 on the cutter board
to J5 on the power supply.
c. Connect the AC input cable to J4 on the power supply.
140Xi4, 170Xi4, or 220Xi4 a. See Figure 488 on page 660. Connect the cable from
P25 on the main logic board to J11 on the power
supply.
b. Connect the power cable from J2 on the cutter board
to J5 on the power supply.
c. Connect the AC input cable to J1 on the power supply.
Note • Do not connect any other cables or connectors at this time.

Cutter Option
3. Reconnect the AC power cord and turn on (l) the printer. If the cutter motor starts, wait for
it to stop.
Note • The cutter motor must be rotated until the two flat surfaces on the cutter motor
shaft are aligned with the set screws in the lower drive arm, while the lower drive arm is in
a vertical position (sensor flag down).
4. See Figure 497 on page 669. Attach a test clip at one end of a jumper cable to the lead on
the right end of capacitor C1 (+5 VDC source) on the cutter board.
5. Briefly touch the test clip at the other end of the jumper cable to test point TP1 on the
cutter board to jog the cutter motor to the desired position.
6. Activate the cutter motor, and make certain the sensor flag travels through the slot in the
optical sensor without touching it.


110Xi4 a. See Figure 484 on page 657. Install the AC/DC power
supply and tighten the mounting screw and nuts.
Ensure all wires are positioned away from any moving
mechanical parts and are not pinched or cut.
b. Figure 485 on page 658. Connect the remaining cables
and connectors to the AC/DC power supply.
140Xi4, 170Xi4, or 220Xi4 a. See Figure 487 on page 659 and Figure 486
on page 659. Install the DC power supply and tighten
the mounting screw and nuts. Ensure all wires are
positioned away from any moving mechanical parts
and are not pinched or cut.
b. See Figure 488 on page 660. Connect the remaining
cables and connectors to the DC power supply.
Configure the Printer

1. Refer to the User Guide to configure the printer to the cutter mode. Save as PERMANENT
and then turn off (O) the printer.
2.

Cutter Option
4. Did the media feed and cut through the label properly?
If… Then…
No Continue with Align the Upper Drive Arm.
Yes Go to Reinstall the Electronics Cover on page 679.
Align the Upper Drive Arm
Note • The upper drive arm is part of the cutter mechanical assembly and has been aligned at
the factory. If for some reason the position is altered, the following procedure may be used to
realign the upper drive arm. The printer must be programmed to operate in the cutter mode
prior to performing the following procedure. If it is not already programmed for cutter mode,
refer to the User Guide for assistance.
1.
Loosen the screw that clamps the upper drive arm to the rotary cutter blade shaft. The
drive arm may be snug on the shaft.
2. Apply power to the printer. The lower drive arm of the drive link assembly should rotate
once and stop when the sensor flag activates the optical sensor.
3. See Figure 495 on page 667. After the drive link assembly stops, hold the upper drive arm
in position and adjust the rotary cutter blade so the gap between its cutting edge on the left
end and the cutting edge of the rear cutter blade is approximately 2.5 mm (0.100 in.).
Note • If the gap between the cutting edges is too large, the cutter may not cut properly
across the entire media width. If the gap is too small, the media may catch on the rotary
cutter blade edge and cause a jam.
Overtightening the screw can damage the drive arm and can strip out the threads.
4. Position the upper drive arm out from the cutter frame so its flat surface is flush with the
end of the rotary cutter blade shaft.
5. Tighten the screw with a 5/32 in. hex key socket on a torque wrench until the slot closes or
until a torque of 100 in.-lbs. (11.3 N•m) is reached.
6. Test the cutter alignment by feeding maximum-width label stock through the printer and
ensuring the label is cut completely.
7. If necessary, repeat steps 4, 5, and 6 until the labels cut completely.
8. With a felt-tip pen, draw a line across the outer face of the upper drive arm and the end of
the cutter blade shaft. Should cutter operation problems ever occur, this witness mark will
show at a glance if the alignment of the clamp and the cutter blade shaft has changed.

Cutter Option


Cutter Module
Cutter Module
This kit includes the parts and documentation necessary to install the Cutter Module maintenance
Tools Required

Flat Blade Screwdriver Set 75 mm (0.030 in.) Feeler Gauge
Torque Wrench – calibrated in inch-
pounds
1.

Cutter Module
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.
4.

Cutter Module
Remove the Old Cutter Module

1. See Figure 506. Loosen the upper cutter and then insert a flat blade screwdriver into the
slot in the upper cutter arm and spread it open.
Figure 506 • Loosen the Upper Cutter Arm

1
-
1 Upper cutter arm

2 Screw
3 Upper arm slot
4 Flat blade screwdriver

Cutter Module
2.
See Figure 507. Remove the four screws securing the cutter module.
Figure 507 • Remove the Cutter Module

1
1
1 Cutter module assembly


Cutter Module
3. See Figure 508. Remove the cutter module upper and lower mounting brackets.
Figure 508 • Remove the Cutter Module Mounting Brackets

1 2 3
4 3
7
6 5
1 Cutter module
2 Upper cutter guide
3 Mounting screw (2)
4 Washer
5 Upper mounting bracket
6 Lower mounting bracket
7 Washers (2)
Install the New Cutter Module

1. See Figure 508 on page 684. Install the upper cutter guide and upper cutter bracket using
the screws and washer previously removed.
2. Loosely install the lower cutter bracket using the screws and washers previously removed.
3.
See Figure 509. Slide the cutter module into the opening of the main frame.

Cutter Module

1 1
2
2
3
5
1 Cutter module
5 Slots (2)

Cutter Module

the rotary cutter
blade when the
drive link assembly
is stopped by the
1
optical sensor when
7 the cutter mode.
Ensure the top of
the tear-off bar
2
or level with the
top of the rear
5
cutter blade.

3 Rear cutter blade
bar.
6 Tear-off bar
7 Media guide
7. Slide the upper cutter arm onto the cutter module shaft and then tighten.

Cutter Module
Align the Upper Drive Arm

1. Loosen the screw that clamps the upper drive arm to the rotary cutter blade shaft. The
drive arm may be snug on the shaft.
2. Apply power to the printer. The lower drive arm of the drive link assembly should rotate
once and stop when the sensor flag activates the optical sensor.
3. See Figure 510 on page 686. After the drive link assembly stops, hold the upper drive arm
in position and adjust the rotary cutter blade so the gap between its cutting edge on the left
end and the cutting edge of the rear cutter blade is approximately 2.5 mm (0.100 in.).
Overtightening the screw can damage the drive arm and can strip out the threads.
4. Position the upper drive arm out from the cutter frame so its flat surface is flush with the
end of the rotary cutter blade shaft.
5. Tighten the screw with a 5/32 in. hex key socket on a torque wrench until the slot closes or
until a torque of 100 in.-lbs. (11.3 N•m) is reached.
6. Test the cutter alignment by feeding maximum-width label stock through the printer and
ensuring the label is cut completely.
7. If necessary, repeat steps 4, 5, and 6 until the labels cut completely.
8. With a felt-tip pen, draw a line across the outer face of the upper drive arm and the end of
the cutter blade shaft. Should cutter operation problems ever occur, this witness mark will
show at a glance if the alignment of the clamp and the cutter blade shaft has changed.

3.

Cutter Brackets
Cutter Brackets
This kit includes the parts and documentation necessary to install the Cutter Brackets maintenance
kit on the Xi4™ printers.
Tools Required
Phillips Screwdriver Set Antistatic Wriststrap and Pad

SAE Nutdriver Set SAE Hex Key (Allen wrench) Set
Safety Glasses
1.

Cutter Brackets
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

Cutter Brackets
Remove the Cutter Module

1.
See Figure 512. Remove the cutter module upper linkage by removing the e-ring and
then sliding it off the upper drive arm.
Figure 512 • Remove the Cutter Linkage

1 2
1
1 Upper drive arm linkage

2 E-ring
2. See Figure 513. Remove the four cutter module mounting screws and then slide the cutter
module out of the printer.
Figure 513 • Remove the Cutter Module

2

2 Cutter module

Cutter Brackets
3. .
See Figure 514. Remove and discard the lower cutter bracket by removing the two
mounting screws and washers.
Figure 514 • Remove the Lower Cutter Bracket

.
1 Cutter Module

Cutter Brackets
4. See Figure 515. Remove and discard the cutter support bracket and static brush assembly
by removing the four mounting screws and then sliding it off the cutter module.
Figure 515 • Remove the Cutter Support Bracket and Static Brush
1 Cutter module
2 Cutter support bracket
4 Cutter static brush

Cutter Brackets
5. See Figure 516. Remove and discard the two mounting screws, one flat washer, upper
cutter bracket, and cutter guide.
Figure 516 • Remove the Upper Cutter Bracket and Guide

1
2
5 3
1 Cutter module
2 Cutter guide
4 Flat washer
Install the Cutter Brackets

1. See Figure 516. Align the cutter guide with the two mounting holes and then start
installing the screw on the right, but do not tighten.
2. Slide the flat washer onto the other mounting screw and then insert it through the
remaining hole in the cutter guide and into the cutter module.
3. Loosely tighten the mounting screws.
4. Slide the new upper cutter bracket between the flat washer and the cutter guide, holding it
at a right angle to the top of the cutter module, and then tighten the mounting screw.
5. Tighten the first mounting screw installed.

Cutter Brackets
6. See Figure 517. Align the new cutter static brush on the inside of the new cutter support
bracket, with the two holes positioned as shown.
Figure 517 • Install the Cutter Static Brush

2
1
3

3 Mounting nuts (2)
7. Insert one of the mounting screws through the cutter support bracket mounting holes,
through the corresponding mounting hole in the static brush, and then attach the mounting
nut.
8. Repeat step 7 for the remaining mounting screw and nut.
9. Tighten the two screws.
10. See Figure 515 on page 692. Slide the cutter support bracket and static brush onto the
cutter module and then install the four mounting screws.
11. Slide the two flat washers for the lower bracket onto mounting screws.
12. See Figure 514 on page 691. Align the cutter lower bracket with the mounting holes in the
cutter module and then loosely install the two mounting screws and washers.

Cutter Brackets
Reinstall the Cutter Module

1. See Figure 518. Slide the cutter module into the opening of the main frame.
3. Loosely install the two mounting screws for the upper cutter bracket.

1 1
2
2
3
5
1 Cutter module
5 Slots (2)

Cutter Brackets

the rotary cutter
blade when the
drive link assembly
is stopped by the
1
optical sensor when
7 the cutter mode.
Ensure the top of
the tear-off bar
2
or level with the
top of the rear
5
cutter blade.

3 Rear cutter blade
bar.
6 Tear-off bar
7 Media guide

Cutter Brackets
Reinstall the Upper Linkage

1. See Figure 512 on page 690. Slide the top of cutter drive link assembly onto the upper
drive link mounting post and then secure it with the e-ring.

1. Refer to the User Guide to configure the printer to the cutter mode. Save as PERMANENT
and then turn off (O) the printer.
2.
4. Did the media feed and cut through the label properly?
If… Then…
No Go to step 4 on page 696 and repeat the procedure.
Yes Continue with Reinstall the Electronics Cover.


Cutter Linkage
Cutter Linkage
This kit includes the parts and documentation necessary to install the Cutter Linkage maintenance
Tools Required
Antistatic Wriststrap and Pad Safety Glasses

Flat-blade Screwdriver Set Fine-Toothed File
SAE Open-end Wrench Set Jumper Cable with Alligator Clips
Grease Cutting Cleaner
1.

Cutter Linkage
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

140Xi4, 170Xi4, or 220Xi4 Continue with Remove the DC Power Supply.

Cutter Linkage

1.
remove them..
1 2
4
6 5

3 J4 stepper motor

Cutter Linkage
1 Mounting screw
2 Mounting nuts (2)
5. Go to Install the Cutter Linkage Maintenance Kit on page 706.

Cutter Linkage


1

Cutter Linkage
shield.


Cutter Linkage
4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

Cutter Linkage
supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs
8. Continue with Install the Cutter Linkage Maintenance Kit.

Cutter Linkage
Install the Cutter Linkage Maintenance Kit

1. See Figure 528. From the media side remove the pivot post mounting screw.
Figure 528 • Remove the Pivot Post Mounting Screw
Pivot Post
Mounting
Screw
2.
See Figure 529. Remove the e-ring securing drive linkage to the upper drive arm.
Figure 529 • Remove the Upper Linkage
1
2
1
1 Upper drive arm

2 E-ring

Cutter Linkage
3. See Figure 530. To make simplify the removal of the lower drive arm, remove the cutter
sensor mounting nut.
4. Remove the lower drive arm by loosening the two set screws and then carefully, ensuring
that the flag does not damage the cutter sensor, slide it off the cutter motor shaft.
Figure 530 • Remove the Lower Linkage
2 3
1 Lower drive arm

2 Cutter sensor mounting nut
3 Pivot post
4 Lower drive arm setscrews (2)

Cutter Linkage
5. See Figure 531. Carefully slide the drive linkage out of the printer.
Figure 531 • Remove the Drive Linkage
3 2
5
6
4
1 Upper drive arm

2 Drive linkage
3 Pivot post
4 Lower drive arm
5 Cutter sensor
6 Cutter motor shaft

Cutter Linkage
6. See Figure 532. Remove the upper drive arm by loosening the screw securing it and then
sliding it off the rotary cutter shaft.
Note • If the upper drive is difficult to remove, insert the blade of a small flat blade
screwdriver into the slot in the drive arm. While holding the drive arm, slightly twist the
screwdriver and then slide the arm off the rotary cutter shaft.
Figure 532 • Remove the Upper Drive Arm
2
3
1 Rotary cutter shaft

2 Screw
3 Upper drive arm
7. See Figure 533. Use a fine-toothed file to remove any burrs from the rotary cutter blade
shaft.
Note • Any burrs on the cutter blade shaft may adversely affect the performance of the
new drive arm and prevent it from fitting properly.

Cutter Linkage
Figure 533 • Assembly Drawing
4
6
3 5
2
1
1 E-ring
2 Long drive link
3 Upper drive arm
4 Mounting screw
6 Cutter module
8. Clean the rotary cutter blade shaft and the inside diameter of the new upper drive arm. Use
a household grease cutting cleaner to remove any grease and oil.
Important • To achieve the best performance from this part, the single most important
concern is to have the connection between the drive arm and the cutter shaft as clean and
free of grease, oil and dirt as possible. A small amount of grease will lessen the holding
strength of the drive arm much more than further tightening of the screw can compensate
for.
9. Install the mounting screw into the new upper drive arm.
10. See Figure 534. Place the new upper drive arm over the end of the cutter shaft until the
shaft is flush with the outside face of the new drive arm.
Note • If the drive arm is too tight (too small) to slide over the shaft, insert the blade of a
small flat blade screwdriver into the slot in the drive arm while holding the drive arm
against the cutter shaft. A very slight twist of the screwdriver should be enough to allow
the drive arm to slide onto the cutter shaft.

Cutter Linkage
Figure 534 • Cutter Mechanical Position

3
4
2
5
1 6
1 E-ring
2 Long drive link
3 Upper drive arm
5 Witness mark
6 Cutter assembly
11. Snug the mounting screw at this time.
12. See Figure 531 on page 708. Align the new drive linkage with the cutter motor shaft,
rotary cutter shaft, and pivot post mounting hole and then slide the new drive linkage into
the printer.
13. See Figure 528 on page 706. Install the new pivot post mounting screw.
14. See Figure 530 on page 707. Tighten the two set screws on the lower drive arm and then
reinstall the cutter sensor mounting nut.
15.
Install the new e-ring onto the upper drive mounting post to secure the drive linkage.

Cutter Linkage

110Xi4 a. See Figure 525 on page 704. Connect the power cable
from J2 on the cutter board to J5 on the power supply.
b. Connect the AC input cable to J4 on the power supply.
140Xi4, 170Xi4, or 220Xi4 a. See Figure 521 on page 700. Connect the power cable
from J2 on the cutter board to J5 on the power supply.
b. Connect the AC input cable to J1 on the power supply.
Note • Do not connect any other cables or connectors at this time.
17. Reconnect the AC power cord and turn on (l) the printer. If the cutter motor starts, wait for
it to stop.
Note • The cutter motor must be rotated until the two flat surfaces on the cutter motor
shaft are aligned with the set screws in the lower drive arm, while the lower drive arm is in
a vertical position (sensor flag down).
18. See Figure 535. Attach a test clip at one end of a jumper cable to the lead on the right end
of capacitor C1 (+5 VDC source) on the cutter board.
Figure 535 • Cutter Option Circuit Board Connectors

2
4 3
5
1 DC power supply connector J2

2 Capacitor C1
3 Cutter motor connector J4
4 Test point TP1
5 Cutter optical sensor connector J3
6 Main logic board connector J1

Cutter Linkage
19. Briefly touch the test clip at the other end of the jumper cable to test point TP1 on the
cutter board to jog the cutter motor to the desired position.
20. Activate the cutter motor, and make certain the sensor flag travels through the slot in the
optical sensor without touching it.
21.
Turn off (O) the printer.
22.
See Figure 536. Only after the preceding step, adjust the rotary cutter blade so that the
gap between its cutting edge on the left end and the cutting edge of the rear cutter blade
is approximately 2.5 mm (0.100 in.) as gauged by eye. (The upper drive arm should be
held in position while the rotary cutter blade position is adjusted).
Figure 536 • Position the Cutter Blade

1 2
7
6
3
5
4
Relative position of the rotary cutter blade when
the drive link assembly is stopped by the optical
sensor, when the power is on in the cutter.

2 2.5 mm (0.10 in.)
3 Rear cutter blade
4 Minimum clearance of (0.030 in.)between rear
cutter blade and tear bar.
5 Tear bar
6 Media guide

Cutter Linkage
23. Tighten the mounting screw with a hex key socket on a torque wrench until torque of
11.3 N•m (100 lbf. in.) is reached.
Note • Overtightening the screw can damage the drive arm and can strip out the threads.
24. Turn on (l) the printer and test the cutter alignment by feeding maximum width label stock
through the printer and insuring that complete cutting of the label occurs.
25. If necessary, repeat steps , 23, and 24 to get complete cutting of the labels.
26. See Figure 16 on page 712. With a felt tip pen, draw a line across the outer face of the new
drive arm and the end of the cutter shaft. Should cutter operation problems ever occur, this
witness mark will show at a glance if the alignment of the upper cutter arm and the cutter
blade shaft has changed.
27. Turn off (O) the printer and disconnect the AC power cord.

110Xi4 a. See Figure 527 on page 705. Reinstall the AC/DC
power supply
b. See Figure 526 on page 705. Reinstall the two
mounting nuts and screws
c. See Figure 525 on page 704. Reconnect all cables to
the AC/DC power supply.
d. See Figure 524 on page 703. Reinstall the AC/DC
power supply shield and secure it with the two screws
removed previously.
e. Reinstall the white beaded cable tie into the left corner
of the shield and then insert the AC input cable into it.
140Xi4, 170Xi4, or 220Xi4 a. See Figure 522 on page 701. Reinstall the DC power
supply and secure it with the two mounting nuts and
the one mounting screw removed previously.
b. See Figure 521 on page 700. Reconnect all cables to
the DC power supply.


Cutter Static Brush
Cutter Static Brush

This kit includes the parts and documentation necessary to install the Cutter Static Brush in the
Xi4™ printers. Read these instructions thoroughly before installing this kit.
Tools Required
Remove the Old Cutter Static Brush

1.
Caution • Turn Off (O) the printer and disconnect it from the power source before
2.
Open the media door and remove the media and ribbon

Cutter Static Brush
3. See Figure 537. Remove and discard the two static brush mounting screws.
Figure 537 • Remove the Mounting Screws

1
1 Cutter module
3 Cutter static brush mounting screws (2)

Cutter Static Brush
4. See Figure 538. Remove and discard the cutter static brush by sliding it up and out of the
cutter module.
Figure 538 • Remove the Cutter Static Brush

2 Cutter module
Install the New Cutter Static Brush

1. See Figure 539. Slide the new cutter static brush into the cutter module as shown.
Figure 539 • Install the New Cutter Static Brush

Cutter Static Brush
2. See Figure 537 on page 716. Install the two new screws from the kit.
3.

Cutter Catch Tray
Cutter Catch Tray

This kit includes parts and documentation necessary to install the cutter catch tray on the
Xi4™ printers.
Tools Required
Phillips Screwdriver Set Adjustable Wrench

Cutter Catch Tray
Install the Catch Tray

1. Turn off (O) the printer and remove the AC power cord and all data cables.
2.
Open the media door and remove media and ribbon.
3. See Figure 540. With the media door open, locate the two knurled nuts securing the front
cover plate against the inside wall of the printer’s lower front cover. Remove these two
knurled nuts and the front cover plate.
Figure 540 • Install the Cutter Plate Assembly
2
1
Open
Close
5
4
1 Cutter
2 Media
3 Side plate
4 Cutter plate
5 Knurled nuts (2)

Cutter Catch Tray
4. See Figure 541. Install the cutter catch tray assembly onto the mounting studs. Reinstall
the knurled nuts.
Note • The mounting tabs on the stationary and adjustable width guides must fit inside
the cutter mechanism, and should rest on the angled surface of the cutter support
bracket.
Figure 541 • Install the Cutter Tray
1
3
1 Cutter tray
3 Knurled nuts (2)
5. Close the media door.
6.
7. Reinstall the AC power cord and data cables.
9. Feed and cut one label and place it in the catch tray.

Cutter Catch Tray
Adjust the Catch Tray

See Figure 542. The catch tray can be disassembled and reassembled to accommodate various
label lengths and widths. The specific label length and width will determine which adjustment
is required.
Figure 542 • Install the Cutter Catch Tray Assembly
1
2
4
6

2 Cutter
3 Mounting tabs
4 Width guides
5 Catch tray
6 Label stop guides
1. Does the catch tray length need adjustment?
If the… Then…
tray is too long Position the two label stop guides where needed to hold the
labels.
label is longer than tray Remove the eight remaining knurled brass nuts, extend the
lower cutter tray as needed, and then reassemble the catch
tray.
label residual curl See Adjust the Catch Tray on page 722. Attach the anti-curl
shaft assembly.
labels are different lengths Adjust the catch tray for the longest label. When shorter
labels are printed, install the label stop guides.

Cutter Catch Tray
2. Adjust the positions of the left and right width guides so they are close to, but not touching
the labels.
Note • During reassembly of the catch tray, be sure the mounting tabs on the stationary
and adjustable width guides fit inside the cutter mechanism and rest on the angled surface
of the cutter support bracket. The width guides should also rest on the surface of the front
cover bracket as shown in Figure 540 on page 720.
3. Feed and cut several labels to insure proper stacking operation of the label catch tray.
Install the Anti-Curl Shaft Assembly

See Figure 543. The shaft assembly consists of a pivot shaft mounted horizontally on the catch
tray assembly and an anti-curl tube used as a weight to hold down the labels and remove any
residual curl.
Figure 543 • Anti-Curl Shaft Assembly
2
1
3
1 Pivot shaft
2 O-ring
3 E-ring
4 Nut
5 Anti-curl tube
1. Remove the nut from the threaded end of the pivot shaft.
2. See Figure 542 on page 722. Insert the opposite end of the pivot shaft in the opening at the
top of the stationary guide.
3. Insert the threaded end of the pivot shaft into the adjustable guide.
4. Reinstall the nut onto the threaded end of the pivot shaft and tighten.
5. Position the anti-curl tube so it rests on the center of the labels. Disassemble and
reassemble the catch tray as necessary to ensure the lower end of the anti-curl tube rests on
the labels as they are cut and stacked.

Rewind Option
Rewind Option
Tools Required
Phillips Screwdriver Set Metric/Inch Ruler

SAE Nutdriver Set Polyester Strip, Zebra Part Number
SAE Hex Key (Allen wrench) Set Metric/Inch Spring Scale
Utility Knife Antistatic Mat and Wriststrap
Utility Pliers
Safety Glasses
1.

Rewind Option
securing it.
Lift up at rear 1
corner.
1 Electronics cover
printer.

1. Which model of the Xi4 are you working on?
If you have… Then…

110Xi4 Continue with Remove the AC/DC Power Supply.
All others Go to Remove the DC Power Supply on page 730.

Rewind Option


1

Rewind Option
shield.


Rewind Option
4.
remove them.

J4 J3 J1 J5
J7
J6
J2

Board
J2 Stepper motor
J3 Head voltage
J4 AC power input
J5 DC output
J6 DC output
J7 DC output

Rewind Option
supply assembly.

2 Mounting nuts (2)
AC/DC Power
Supply
Mounting
Studs
8. Go to Install the Idler Pulley on page 732.

Rewind Option

1.
remove them..
1 2
4
6 5

3 J4 stepper motor

Rewind Option
1 Mounting screw
2 Mounting nuts (2)
5. Continue with Install the Idler Pulley.

Rewind Option
Install the Idler Pulley

1. See Figure 552. Remove the plastic plug in the lower access hole near the bottom of the
side plate.
Figure 552 • Remove the Plastic Plug
1 1
2. See Figure 553. Place a flat washer onto mounting screw. Place the mounting screw and
washer through the lower access hole and idler pulley mounting hole in the main frame.
On the electronics side, install the idler shaft onto the mounting screw.
Figure 553 • Install the Idler Pulley Shaft
2
3
1 Flat washer
2 Mounting screw
3 Idler shaft
4 Idler pulley

Rewind Option
3. Position the idler shaft in the middle of the mounting hole and tighten. Apply a small
amount of grease to the idler shaft, ensuring no grease is on other components.
4. Slide the idler pulley, flat side facing out, onto the idler shaft.
Install the Media Rewind Spindle

1. Remove and discard the cover plate and screws of the media rewind spindle mounting
hole in the lower center portion of the main frame.
Figure 554 • Remove the Front and Cover Plates
2 3 4
1 Front cover
2 Front cover thumbscrews
3 Rewind platen mounting hole cover
4 Rewind spindle mounting hole cover

Rewind Option
2. Install the bearing housing assembly using three screws and three flat washers. Do not
tighten the screws at this time.
Figure 555 • Install the Rewind Bearing Housing

1 2
2 4
5
5

3 Access hole
4 Flat washers (3)

Rewind Option
3.
See Figure 556. From the media side, slide the shaft of the media rewind spindle through
the bearing housing assembly.
Figure 556 • Install the Rewind Spindle

1 4 6 7 1
2
3 5
1 Rewind spindle shaft

2 Rewind spindle bearing housing
3 E-ring
5 Spacer
6 Flat washer
7 Wave washer
4.
Place the wave washer, flat washer, and pulley, counter-sunk side facing out, onto the
media rewind spindle shaft, then the spacer, and secure with the E-ring.

Rewind Option
Install the Rewind Platen Roller

1. See Figure 557. Install the rewind platen support bracket to the side plate using two
washers and two screws. Do not tighten the screws at this time.
Figure 557 • Install the Rewind Platen Roller Support Bracket
4
3

2 Flat washers (2)
4 Rewind platen roller access hole
2. From the media side, insert the long end of the platen roller shaft into the access hole.

Rewind Option
3. See Figure 558. While holding the rewind platen roller, slide a flange bearing, flange
facing out, onto the platen roller shaft and then into the support bracket.
Figure 558 • Install the Rewind Platen Roller, Media Side

2
5
3 4
2
5
1
1 Rewind platen roller access hole

4 Flange bearing
5 C-clip
4.
Slide the short end of the platen roller shaft through the flange bearing and the install the
E-ring to secure it.
5. Tighten the mounting screws securing the platen support bracket. The bracket may need
adjustment later.

Rewind Option
6. From the electronics side slide the flange bearing, flange facing out, onto the rewind
platen roller shaft and then into the mounting hole.
Figure 559 • Install the Rewind Platen Pulley
2 3 4

2 Flange bearing
3 Spacer
4 Rewind platen roller pulley
7. Slide the spacer and the platen roller pulley onto the rewind platen shaft.
8. Align the two pulley set screws with the flat surfaces of the rewind platen shaft and
tighten.
The pulley should be positioned with approximately 5 mm (0.20 in.) between the E-ring
and the platen support bracket on the media side.
Figure 560 • Platen Pulley and Set Screws

2
1
1 Platen roller flats

2 Setscrews (2)

Rewind Option
Install and Adjust the Rewind Drive Belt

1. See Figure 563. Remove the main drive belt by walking it off the ribbon take-up. Pull out
on the drive belt while turning the ribbon take-up pulley.
1 Main drive belt

2 Ribbon take-up

Rewind Option
Install the Rewind Drive Belt

1. See Figure 562. Route the media rewind belt around the inner most stepper motor pulley,
media rewind pulley, rewind platen pulley, and idler pulley.
Figure 562 • Install the Rewind Drive Belt

2
1
3
5
4
1 Rewind drive belt

3 Idler pulley
2. See Figure 553 on page 732 and Figure 562. Grasp the idler pulley and shaft assembly
while loosening the mounting screw. Slide the assembly toward the rear of the printer until
the belt tension is tight, and then retighten the idler pulley mounting screw.
3. See Figure 561 on page 739. Reinstall the main drive belt on the outer most pulley of the
stepper motor and around the platen roller pulley.
4. Walk the main drive belt onto the ribbon take-up pulley by pushing it onto the pulley
while turning the pulley.

Rewind Option
Adjust the Belt Tensions

1. See Figure 563. Check the belt tension by hooking a spring scale at the midpoint of the
lower section of the belt and pull down. The belt should deflect 6.35 mm (0.25 in.) with a
tension of 2000 grams (4.5 in. lbs).
Figure 563 • Ribbon Take-Up Pulley

More Less
Tension Tension
3
3
2
1 S
C HE
22
IN
00
20
00
18
00
16
0
14
0
00
1 Take-up pulley mounting screw access holes (3)

3 Main drive belt
2. Access the three ribbon take-up mounting screws through the three holes in the ribbon
take-up pulley. Loosen but do not remove the three ribbon take-up mounting screws.
3. Slide the media rewind assembly toward the rear of the printer until the belt tension is
correct. Tighten the rewind spindle mounting screws.

Rewind Option
4. See Figure 564. Check the belt tension by hooking a spring scale at the midpoint of the
lower section of the belt and pull up. The belt should deflect 6.35 mm (0.25 in.) with a
tension of 2000 grams (4.5 in. lbs).
Figure 564 • Adjust the Rewind Drive Belt

1
6
2
5
1 Rewind drive belt

3 Idler pulley
5 Rewind spindle mounting screw access holes (3)
5. Grasp the idler pulley and shaft assembly while loosening the mounting screw. Slide the
assembly toward the rear of the printer until the belt tension is correct, and then retighten
the mounting screw.
6. When adjustment is completed, reinstall the plastic plug in the lower access hole in the
print mechanism side plate.

Rewind Option
Install the Take-Label Sensors
Important • Do not install the take-label sensors on cutter units. The take-label sensors are
required in the peel-off mode of operation.
1. See Figure 565. Remove the upper and lower take-label cover plates by removing the
screws and pushing cover plate out of the mounting holes.
Figure 565 • Install the Take-Label Sensors

4
1
1 5
1 Cover plate mounting screws (2)

2 Upper take-label mounting hole
3 Lower take-label mounting hole
2. Feed the upper sensor cable through the upper mounting hole.
3. Position the sensor with the window facing down, and secure with the mounting screw.
4. Feed the lower sensor cable through the lower mounting hole.
5. Position the sensor with the window facing up, and secure it with the mounting screw.

Rewind Option
6. See Figure 566. Connect the upper sensor cable to J2 on the control panel and then
connect the lower sensor cable to J3 on the control panel.
Figure 566 • Connect the Take Label Sensor Cables
J2
J3

3. Reconnect the AC power cord and data cable.
4.

See the User Guide to configure the printer to the Rewind Mode. Rewind Mode rewinds a
printed roll of continuous media or a printed roll with liner and labels.
To use this option to dispense individual labels and rewind the media backing only, see the
User Guide to set the printer to the Peel-Off Mode.
The rewind option kit usually requires some adjustments to prevent printing problems such as
ribbon wrinkle, non-centered labels, and tearing media. Print a number of test labels to check
for problems. Use the following procedures to correct any problems.

Rewind Option
Adjust the Tracking

If the media walks from side to side or tears or wrinkles against the backing plate of the media
rewind spindle, it may be necessary to adjust the position of the rewind spindle assembly.
1. See Figure 567. If the media cannot be made to track correctly after making this
adjustment, check the distance from the backing plate to the main frame. The factory set
dimension is 14 mm (0.550 in.) ±0.5 mm (0.020 in.).
Figure 567 • Adjust Rewind Spindle Position
5
3
1 Hex key, 7/64 in.

2 Setscrews (2), located inside spindle
3 Rewind spindle
4 Collar, located inside the spindle
5 Tracking plate
2. Loosen the two set screws in the collar located inside the rewind spindle assembly near the
backing plate. The set screws are accessible through a single hole in the rewind spindle
assembly. Reposition the backing plate as required and retighten the set screws in the
collar.

Rewind Option
Adjust Tension
Media that is rewound too tightly can cause mis-registration of labels, tearing, or poor print
quality due to smudging. Media rewound too loosely can jam up the printer before completing
a roll or make it impossible to separate labels from liner in Peel-Off Mode.
See Figure 568 to adjust the tension.
1. Loosen the set screw in the adjusting nut at the end of the rewind spindle assembly.
Figure 568 • Adjust the Spindle Tension
4 3
1 Spring gauge
2 Polyester strip
3 Adjusting nut
4 Setscrews (2)
5 Reinforced hole
2. Insert a hex key through the access hole at the rear of the rewind spindle assembly into one
of the set screws in the collar to prevent the rewind spindle shaft from turning while
adjusting the tension.
3. Position the adjusting nut with fingers or pliers as required.

• in for more tension
• out for less tension

Rewind Option
4. Measure the spindle tension using a spring scale gauge. Place a media core on the spindle
and attach a 51 mm (2 in.) wide by 7.6 m (30 in.) long strip of polyester film to the core
with adhesive tape. Wind the film in the direction shown in Figure 568.
5. Insert the spring scale tip through the reinforced hole in the end of the strip and pull slowly
and evenly, 2 in. (51 mm) per second, in the direction shown. Make this measurement
several times to ensure an accurate reading. This tension should be approximately 1400–
1500 grams (1.22–1.3 in. lb.).
6. Readjust tension as required and recheck the tension setting. Retighten the adjusting nut
set screw.
7. Recheck the tension after running a full roll of labels.
Note • Depending on your application, it may be necessary to deviate slightly from the
recommended tension setting shown above.
Adjust the Lower Roller

The lower roller alignment has much the same effect on media tracking as the rewind spindle
does in Rewind Mode.
1. See Figure 569. Loosen the mounting screws securing the platen support bracket to the
side plate.
Figure 569 • Adjust Platen Support Bracket
3
4 2

2 Platen support bracket
3 Bearing (2)
4 Lower platen roller

Rewind Option
2. Adjust the bracket as required and tighten the mounting screws.

• Moving the bracket toward the rear of the printer forces the media to wind closer to
the large backing plate on the rewind spindle.
• Moving the bracket toward the front of the machine moves the media away from the
backing plate.
3. Perform this adjustment until the required results are achieved.
Adjust Tension
For liner and label combinations that are particularly difficult, it may be necessary to increase
the rewind tension in Peel-Off Mode. Follow the same procedure used for the Rewind Mode.

Repacking Instructions
Important • Before repacking, call 1.847.913.2259 for a Repair Order number (RO).
Standard
1. Open the media door and set the proper insert
Insert Door
into the door and against the window.
Insert
2. Slide the printer into the plastic bag on its side,
electronics side down.
Bi-Fold
3. Gather the bag, and tape it shut. Door
Insert
4. Slide the two lift-out straps over the printer, as
shown.
Note • BR=Bottom Right, BL=Bottom Left,

TR=Top Right, TL=Top Left, F=Front.
5. Place the top left (TL) and bottom left (BL)

inserts onto the printer, as shown. The front of
each insert is marked with a stamped “F”.
Printer in
plastic bag
and taped
Position of shut
lift-out straps
TL and BL
markings
Front

TL BL
6. Place the printer into the carton. (Top (Bottom
Left) Left)
7. If the printer has a bifold door, place
the bifold door insert inside the carton,
as shown.
8. Place the top right (TR) and bottom Location of

right (BR) inserts into the carton on top stamped
of the printer as shown. “F”
9. Close the flaps, and seal the box with
postal quality shipping tape.
10. Label and send insured to:

Zebra Technologies TR
BR
(Top
333 Corporate Woods Parkway (Bottom
Right)
Vernon Hills, Illinois Right)
60061-3109
RO #XXXXXX Insert for

bifold
Note • Write the RO number on the door only Location of
mailing label and in large letters and stamped
numbers on top of the box. “F”
Shipping Box

4
Maintenance Parts
Contents
Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
Media and Ribbon Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797
Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811

752 Maintenance Parts
Contents
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Outer Casing Components
This section contains the part number for the outer casings and related trim.
Contents
Outer Casing Components Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
Media door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756
Electronics Cover, Trim, and Name Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758

Outer Casing Components Overview
Figure A • Outer Casing Components Overview
3
2

Maintenance Parts 755
Outer Casing Components Overview
Table A • Outer Casing Components Overview
Item Part Number Description Qty

1 P1006034 Xi4 Electronics Cover Maintenance Cover, see Table C on page 759 1
2 P1006036 110Xi4 Standard Media Door Maintenance Kit, see Table B on page 757 1
P1006037 140Xi4 Standard Media Door Maintenance Kit, see Table B on page 757 1
3 P1006041 110Xi4 Bifold Media Door Maintenance Kit, see Table B on page 757 1
P1006042 140Xi4 Bifold Media Door Maintenance Kit, see Table B on page 757 1
4 P1007546 Xi4 Control Panel Covers Maintenance Kit 3
5 P1006033 Xi4 Control Panel Maintenance Kit 1
6 P1006046 110Xi4 Lower Trim Plate and Nameplate Maintenance Kit, see Table C 1
on page 759
P1006047 140Xi4 Lower Trim Plate and Nameplate Maintenance Kit, see Table C 1
on page 759
on page 759
on page 759
7 P1006051 110Xi4 Tear Front Plate 1
P1006052 140Xi4 Tear Front Plate 1
8 HW01815 Knurled nut, 6-32 (sold in quantize of 25) 2
Bold = Part available for purchase
Light italic = Part not available for individual purchase, listed and shown for reference only
Boxes = Parts contained in kits listed above

Media door
Figure B • Media door
1 2
4 4
3 3
5 6

Media door
Table B • Media Door

1 P1006036 110Xi4 Standard Media Door Maintenance Kit 1
P1006037 140Xi4 Standard Media Door Maintenance Kit 1
2 P1006041 110Xi4 Bi-fold Media Door Maintenance Kit 1
P1006042 140Xi4 Bi-fold Media Door Maintenance Kit 1
3 HW30407-008 Mounting Screw, 6-32 × 0.5 (sold in quantities of 25) 4
4 N/A Name Plate, See Table C on page 759. 1
5 P1006035 Xi4 Standard Media Door Window Maintenance Kit 1
6 P1006522 Xi4 Bifold Media Door Window Maintenance Kit 1

Electronics Cover, Trim, and Name Plates
Figure C • Electronics Cover, Trim, and Name Plates
3 5
6 7
4 4

Table C • Electronics Cover, Trim, and Name Plates

1 P1006034 Xi4 Electronics Cover Maintenance Kit 1
2 HW32413-006 Screw, 6-32 × 0.37 inch (sold in quantities of 25) 3
3 P1006046 110Xi4 Trim panel and Name plate Maintenance Kit 1
4 P1006567 Screw, 6-32 × 0.50, 110Xi4 and 140Xi4 (sold in quantities of 25) 3
Screw, 6-32 × 0.50, 170Xi4 and 220Xi4 (sold in quantities of 25) 4

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Media and Ribbon Path
This section contains the part numbers for the media path components.
Contents
Media and Ribbon Path Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762
Hangers and Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
Media Supply Spindle Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766
Dancer, Media Guide, and Ribbon Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768

Media and Ribbon Path Overview
Figure D • Media and Ribbon Path Overview

Media and Ribbon Path Overview
Table D • Media and Ribbon Path Overview

1 G41150M 110Xi4 Ribbon Take-up Spindle Maintenance Kit, see Table E on page 765 1
G48250 140Xi4 Ribbon Take-up Spindle Maintenance Kit, see Table E on page 765 1
2 G41155M 110Xi4 Rewind Spindle Maintenance Kit, Table E on page 765 1
G48155M 140Xi4 Rewind Spindle Maintenance Kit, Table E on page 765 1
3 P1006058 110Xi4 Ribbon Supply Spindle Maintenance Kit, see Table E on page 765 1
P1006059 140Xi4 Ribbon Supply Spindle Maintenance Kit, see Table E on page 765 1
4 P1006064 110Xi4 Media Hanger Maintenance Kit, see Table E on page 765 1
5 G48153-4M 140Xi4 Media Hanger Maintenance Kit, see Table E on page 765 1
G46153M 170Xi4 Media Hanger Maintenance Kit, see Table E on page 765 1
G22153M 220Xi4 Media Hanger Maintenance Kit, see Table E on page 765 1
6 G41254M 110Xi4 40 mm Media Supply Spindle Option/Maintenance Kit, see Table F 1
on page 767
G48044M 140Xi4 40 mm Media Supply Spindle Option/Maintenance Kit, see Table F 1
on page 767
G46044M 170Xi4 40 mm Media Supply Spindle Option/Maintenance Kit, see Table F 1
on page 767
7 G41253M 110Xi4 3 inch Media Supply Spindle Option/Maintenance Kit, see Table F 1
on page 767
G48253M 140Xi4 3 inch Media Supply Spindle Option/Maintenance Kit, see Table F 1
on page 767
on page 767
on page 767

Hangers and Spindles
Figure E • Hangers and Spindles

1 2
5 4
3

Hangers and Spindles
Table E • Hangers and Spindles

1 P1006064 110Xi4 Media Hanger Maintenance Kit 1
2 G481523-4M 140Xi4 Media Hanger Maintenance Kit 1
G46153M 170Xi4 Media Hanger Maintenance Kit 1
G22153M 220Xi4 Media Hanger Maintenance Kit 1
3 G41150M 110Xi4 Ribbon Take-up Maintenance Kit 1
G48250 140Xi4 Ribbon Take-up Maintenance Kit 1
4 P1006058 110Xi4 Ribbon Supply Spindle Maintenance Kit 1
P1006059 140Xi4 Ribbon Supply Spindle Maintenance Kit 1
5 P1006063 Xi4 Series Ribbon Supply Spindle Hardware Maintenance Kit 1
6 G41155M 110Xi4 Rewind Spindle Maintenance Kit 1
G48155M 140Xi4 Rewind Spindle Maintenance Kit 1

Media Supply Spindle Options
Figure F • Media Supply Spindle Options
1 2

Media Supply Spindle Options
Table F • Media Supply Spindle Options

6 G41254M 110Xi4 40 mm Media Supply Spindle Option/Maintenance Kit 1
G48044M 140Xi4 40 mm Media Supply Spindle Option/Maintenance Kit 1
G46044M 170Xi4 40 mm Media Supply Spindle Option/Maintenance Kit 1
7 G41253M 110Xi4 3 inch Media Supply Spindle Option/Maintenance Kit 1
G48253M 140Xi4 3 inch Media Supply Spindle Option/Maintenance Kit 1

Dancer, Media Guide, and Ribbon Rollers
Figure G • Dancer, Media Guide, and Ribbon Rollers

1
2
3
2
8
8
10
9

Table G • Dancer, Media Guide, and Ribbon Rollers

1 41691M 110Xi4 Dancer Assembly Maintenance Kit 1
46691-2M 140Xi4 Dancer Assembly Maintenance Kit 1
46691-3M 170Xi4 Dancer Assembly Maintenance Kit 1
22391M 220Xi4 Dancer Assembly Maintenance Kit 1
2 HW30392-006 Screw, 6-32 × 0.37 (sold in quantities of 25) 2
3 HW06268 Lock Washer, #6 (sold in quantities of 25) 2
4 P1006106 110Xi4 Media Guide Maintenance Kit 1
P1006107 140Xi4 Media Guide Maintenance Kit 1
6 P1006099 110Xi4 Ribbon Rollers Maintenance Kit 1
P1006101 140Xi4 Ribbon Rollers Maintenance Kit 1
7 P1006103 170Xi4 Ribbon Rollers Maintenance Kit 1
P1006104 220Xi4 Ribbon Rollers Maintenance Kit 1
8 HW30392-004 Screw, 6-32 × 0.25 inch (sold in quantities of 50) 110Xi4 3
140Xi4, 170Xi4 and 220Xi4 5
9 HW30266 Head Lift Spring Stop, except 220Xi4 1
(sold in quantities of 10)
10 HW46127 Flat Washer, 0.312 × 0.153 ×0.030 (170Xi4 and 220Xi4 only) (sold in 2
quantities of 25)

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Print Mechanism
This section contains the part number for the print mechanism and related components.
Contents
Print Mechanism Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772
Print Mechanism and Printhead Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774
Pivot Bar, Platen, and Peel/Tear Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776

Print Mechanism Overview
Figure H • Print Mechanism Overview
7 5

Print Mechanism Overview
Table H • Print Mechanism Overview

1 P1006111 110Xi4 Media Guide Plate Maintenance Kit 1
P1006112 140Xi4 Media Guide Plate Maintenance Kit 1
2 P1006140 Xi4 Printhead Cable Maintenance Kit, see Table I on page 775 1
3 P1006146 110Xi4 Print Mechanism Hardware Maintenance Kit, 1
see Table I on page 775
P1006151 140Xi4 Print Mechanism Hardware Maintenance Kit, 1
4 P1004230 110Xi4 203 dpi Printhead Maintenance Kit 1
P1004232 110Xi4 300 dpi Printhead Maintenance Kit 1
5 G41022M 110Xi4 Pivot Bar and Toggles Maintenance Kit, see Table J on page 777 1
G48202M 140Xi4 Pivot Bar and Toggles Maintenance Kit, see Table J on page 777 1
38202M 170Xi4 Pivot Bar and Toggles Maintenance Kit, see Table J on page 777 1
G22222M 220Xi4 Pivot Bar and Toggles Maintenance Kit, see Table J on page 777 1
6 P1006115 110Xi4 Peel Tear Bar Maintenance Kit, Table J on page 777 1
P1006116 140Xi4 Peel Tear Bar Maintenance Kit, Table J on page 777 1
7 G41011M 110Xi4 230/300 dpi Platen Roller Maintenance Kit, see Table J on page 777 1
P1004592 110Xi4 600 dpi Platen Roller Maintenance Kit, see Table J on page 777 1
G40038M 140Xi4 Platen Roller Maintenance Kit, see Table J on page 777 1
8 P1006119 Xi4 Sensor Brackets and Hole Covers Maintenance Kit, 1
see Table Z on page 813

Print Mechanism and Printhead Cables
Figure I • Print Mechanism and Printhead Cables

1
4
3
10
5 6 7 8
11 12
13

Print Mechanism and Printhead Cables
Table I • Print Mechanism

1 P1006146 110Xi4 Print Mechanism Hardware Maintenance Kit 1
P1006151 140Xi4 Print Mechanism Hardware Maintenance Kit 1
2 P1006095 110Xi4 Ribbon Strip Plate and Static Brush Maintenance Kit 1
P1006096 140Xi4 Ribbon Strip Plate and Static Brush Maintenance Kit 1
5 HW06250 E-Ring, 0.312 (sold in quantities of 25) 1
6 N/A 220Xi4 Torsion Spring 1
HW40027 110Xi4, 140Xi4, and 170Xi4 Torsion Spring (sold in quantities of 25) 1
7 HW32373 C-Ring, 0.312 (sold in quantities of 25) 1
8 HW30239 Crescent Washer, 0.414 × 0.323 × 0.062 (sold in quantities of 25) 1
9 HW30956 Flat Washer, 0.207 × 0.146 × 0.030 (sold in quantities of 10) 2
11 HW06268 Lock Washer, #6 (sold in quantities of 25) 1
13 P1006140 Xi4 Printhead Cable Maintenance Kit 1

Pivot Bar, Platen, and Peel/Tear Bar
Figure J • Pivot Bar, Platen, and Peel/Tear Bar

Table J • Pivot Bar, Platen, and Peel/Tear Bar

1 G41022M 110Xi4 Pivot Bar Maintenance Kit 1
G48202M 140Xi4 Pivot Bar Maintenance Kit 1
38202M 170Xi4 Pivot Bar Maintenance Kit 1
G22222M 220Xi4 Pivot Bar Maintenance Kit 1
2 G46352M Sensor Flag 1
3 35099M All, except 220Xi4 Toggle Assembly Maintenance Kit (one toggle per kit) 1
22099M 220Xi4 Toggle Assembly Maintenance Kit (one toggle per kit) 1
4 HW07229 Washer, Curved 0.344 × 0.172 × 0.006 (sold in quantities of 25) 1
5 HW30391-006 Screw, 4-40 × 0.37 in. (sold in quantities of 25) 1
6 G41011M 110Xi4 200/300 dpi Platen Roller Maintenance Kit 1
P1004592 110Xi4 600 dpi Platen Roller Maintenance Kit 1
G40038M 140Xi4 Platen Roller Maintenance Kit 1
7 P1006115 110Xi4 Peel/Tear Bar Maintenance Kit 1
P1006116 140Xi4 Peel/Tear Bar Maintenance Kit 1

Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Electronics
This section contains the part numbers for the printed circuit boards and sensors.
Contents
110Xi4 Specific Electronics Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780
110Xi4 Specific Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 782
140Xi4, 170Xi4, and 220Xi4 Specific Electronics Overview. . . . . . . . . . . . . . . . . . . . . . 784
140Xi4, 170Xi4, and 220Xi4 Specific Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
Xi4 Series Common Electronics Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788
.................................................................. 789
Sensors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794

Electronics
Figure K • 110Xi4 Specific Electronics Overview

1
2
Table K • 110Xi4 Specific Electronics Overview

1 P1006158 110Xi4 Printhead Test Board Option/Maintenance Kit, see Table L 1
on page 783
2 P1007556 110Xi4 AC/DC Power Supply Maintenance Kit, see Table L on page 783 1
3 P1007559 110Xi4 Power Entry Maintenance Kit, see Table L on page 783 1
N/S 23812 110Xi4 AC/DC Power Supply Shield 1
N/S = Not shown

110Xi4 Specific Electronics Overview
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Figure L • 110Xi4 Specific Electronics
4 3
6 7
10
8 11

Table L • AC/DC Power Supply and Power Entry, 110Xi4

1 P1007556 110Xi4 AC/DC Power Supply Maintenance Kit 1
3 HW33809 Nut, 6-32 (sold in quantities of 25) 2
4 HW32413-006 Shield Screw, 6-32 × 0.37 (sold in quantities of 25) 2
5 P1007559 110Xi4 Power Entry Maintenance Kit 1
8 HW45946 External Lock Washer #6 (sold in quantities of 100) 1
9 P1006158 110Xi4 Printhead Test Board Option/Maintenance Kit 1
11 HW06020 Cable Ties, (sold in quantities of 20) 4

140Xi4, 170Xi4, and 220Xi4 Specific Electronics
Figure M • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics Overview
2 3
1
Table M • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics Overview

1 P1007560 140Xi4, 170Xi4, and 220Xi4 Power Entry Maintenance Kit, 1
see Table N on page 785
2 P1007557 140Xi4, 170Xi4, and 220Xi4 AC Power Supply Maintenance Kit, 1
3 P1007558 140Xi4, 170Xi4, and 220Xi4 DC Power Supply Maintenance Kit, 1

140Xi4, 170Xi4, and 220Xi4 Specific Electronics
Figure N • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics

1
3 8
4
7
10
9
Table N • 140Xi4, 170Xi4, and 220Xi4 Specific Electronics

1 P1007557 Xi4 AC Power Supply Maintenance Kit 1
2 HW49313 Spacer (sold in quantities of 25) 2
3 HW43968 Screw, M3 × 0.5 × 6 (sold in quantities of 25) 1
4 P1007560 140Xi4, 170Xi4, and 220Xi4 Power Entry Maintenance Kit 1
7 HW45946 External Lock Washer #6 (sold in quantities of 100) 1
8 P1007558 Xi4 DC Power Supply Maintenance Kit 1
10 HW33809 Flange Nut, 6-32 2

Common Electronics
Figure O • Xi4 Series Common Electronics Overview
2 3
1

Common Electronics
Table O • Common Electronics Overview

1 P1007561 Xi4 5V Applicator Interface Option/Maintenance Kit 1
P1011156 Xi4 24-28V Applicator Interface Option/Maintenance Kit 1
2 P1008550 Xi4 Internal Wireless Plus Option/Maintenance Kit 1
P1009634 Xi4 PCMCIA Wireless Plus Option/Maintenance Kit 1
3 P1004273 Xi4 8MB Main Logic Board Maintenance Kit 1
P1004274 Xi4 64MB Main Logic Board Maintenance Kit 1
4 P1007562 Xi4 Twinax Option/Maintenance Kit 1
P1007563 Xi4 Coax Option/Maintenance Kit 1
P1007564 Xi4 Internal Print Server IPv6 Option/Maintenance Kit 1
5 79823 Wired Ethernet Option/Maintenance IPv4 Kit 1
6 P1006160 Cutter Control Board Maintenance kit 1
7 P1006156 Xi4 Electronics Cables Maintenance Kit 1

Main Logic Board
Figure P • Main Logic Board

1
5 4 3 2
Table P • Main Logic Board

1 P1004273 Xi4 8MB Main Logic Board Maintenance Kit 1
P1004274 Xi4 64MB Main Logic Board Maintenance Kit 1
2 HW45945 Split Washer, #4 (sold in quantities of 100) 2
3 HW32406 Standoff, 4-40 × 0.50 (sold in quantities of 25) 2
4 HW78802 Screw, 4-40 × 0.03 (sold in quantities of 25) 2
6 P1006160 Cutter Control Board Maintenance Kit 1

Optional Electronics
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Figure Q • Optional Electronics

1
2 3
4 5
7
2 2
9
10
11

Table Q • Optional Electronics

1 P1007561 Xi4 5V Applicator Interface Option/Maintenance Kit 1
P1011156 Xi4 24-28V Applicator Interface Option/Maintenance Kit 1
2 HW43968 Screw, M3 × 0.5 × 6 (sold in quantities of 25) 2-5
3 HW06020 Cable Ties, (sold in quantities of 20) 2-4
4 P1008550 Xi4 Internal Wireless Plus 1
5 P1009634 Xi4 PCMCIA Wireless Plus Option/Maintenance Kit 1
6 P1007562 Xi4 Twinax Option Kit 1
7 P1007563 Xi4 Coax Option Kit 1
8 P1007564 Xi4 Internal Print Server IPv6 1
9 79823 Wired Ethernet Option/ Maintenance IPv4 Kit 1
10 HW10460 Nut, M3 × 2.4 × 5.5 (sold in quantities of 25) 3
11 HW79656 Standoff, M3 × 0.5 × 10 (sold in quantities of 12) 3

Sensors Overview
Figure R • Sensors Overview

1
3
4

Sensors Overview
Table R • Sensors Overview

1 P1006139 Ribbon Low Sensors Maintenance Kit, see Table S on page 795 1
2 P1006135 Xi4 Reflective Sensor Assembly Maintenance Kit, see Table S on page 795 1
3 P1006137 Xi4 Head Open Sensor Assembly Maintenance Kit, 1
see Table S on page 795
4 P1006138 Xi4 Media Low Sensors Maintenance Kit, see Table S on page 795 1
5 P1006134 Ribbon Out Sensor Maintenance Kit, see Table S on page 795 1
6 P1006029 110Xi4 Media Sensor Assembly Maintenance Kit, see Table S on page 795 1
P1006030 140Xi4 Media Sensor Assembly Maintenance Kit, see Table S on page 795 1
7 P1006136 Xi4 Take-Label Sensor Maintenance Kit, see Table S on page 795 1
8 G46618M Cutter Sensor Maintenance Kit, see Table S on page 795 1

Sensors
Figure S • Sensors
1
3
4 4
5 7
8
9
10
9
6 11
12
15 13
16 17
14
9 19 9
18
20

Sensors
Table S • Sensors

1 P1006029 110Xi4 Media Sensor Assembly Maintenance Kit 1
P1006030 140Xi4 Media Sensor Assembly Maintenance Kit 1
2 HW30392-004 Screw, 6-32 × 0.25 inch 1
3 HW30266 Stop Head Lift Spring (sold in quantities of 10) 1
4 HW48411 Knurled Screw, 6-32 × 0.25 inch (sold in quantities of 10) 2
5 P1006138 Xi4 Media Low Sensor Maintenance Kit 1
7 P1006135 Xi4 Reflective Sensor Assembly Maintenance Kit 1
9 HWQ06020 Cable Tie, 0.09 × 3.62 (sold in quantities of 20) 1 or 3
10 P1006134 Ribbon Out Sensor Maintenance Kit 1
11 HW30494 Neoprene Washer, 0.32 × 0.119 × 0.062 (sold in quantities of 25) 2
12 HW32332 Screw, 4-40 × 0.25 (sold in quantities of 25) 1
13 P1006137 Xi4 Head Open Sensor Assembly Maintenance Kit 1
14 HW40194 Curved Washer, 0.344 × 0.172 × 0.006 (sold in quantities of 25) 1
15 HW46352 Flag (sold in quantities of 50) 1
17 P1006139 Ribbon Low Sensors Maintenance Kit 1
19 P1006136 Xi4 Take-Label Sensor Maintenance Kit 1
20 HW45937 Screw, M4 × 10 (sold in quantities of 25) 2

Sensors
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Drive System
This section contains the drive systems part numbers .
Contents
Drive Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798
Drive Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800

Drive System Overview
Figure T • Drive Systems Overview

1
110Xi4, 140Xi4, and 170Xi4 220Xi4
2
3
6 7
4 5

Drive System Overview
Table T • Drive Systems Overview

1 P1006069 Xi4 Main Drive System Maintenance Kit 1
2 P1006066 110Xi4 (203/300 dpi), 140Xi4 (203dpi), and 170Xi4 (203/300 dpi), and 220Xi4 1
(203 dpi) Main Drive Belt
P1006067 110Xi4 600 dpi Main Drive Belt 1
3 P1006066 220Xi4 (203 dpi) Main Drive Belt 1
P1006068 220Xi4 300 dpi Main Drive Belt 1
4 G46198M 110Xi4 (203 dpi), 140Xi4 (203 dpi), and 170Xi4 (203 dpi) Drive Motor 1
G46199M 110Xi4 (300 dpi) and 170Xi4 (300 dpi) Dirve Motor 1
G33084M 110Xi4 (600 dpi) Drive Motor 1
5 G31197M 220Xi4 (203 dpi) Drive Motor 1
G31199M 220Xi4 (300 dpi) Drive Motor 1
6 P1006072 110Xi4 (203/300 dpi), 140Xi4 (203dpi), and 170Xi4 (203/300 dpi) 1
Rewind Drive Belt
P1006073 110Xi4 (600 dpi) Reind Drive Belt 1
7 P1006072 220Xi4 (203/300 dpi) Rewind Drive Belt 1
8 P1006071 Xi4 Rewind Drive System Maintenance Kit 1

Drive Systems
Figure U • Drive Systems
3 4
2
9 8 7
6 5
10
6 5
11 12
9 8 7
Table U • Drive Systems

1 P1006069 Main Drive System Maintenance Kit 1
2 P1006066 110Xi4 (203/300 dpi), 140Xi4 (203dpi), and 170Xi4 (203/300 dpi), and 220Xi4 1
(203 dpi) Main Drive Belt
3 P1006067 110Xi4 600 dpi Main Drive Belt 1
4 P1006068 220Xi4 300 dpi Main Drive Belt 1
5 HW40193 Washer, 0.406 × 0.172 × 0.048 (sold in quantities of 25) 1
7 HW30115 Wave Washer, 0.74 × 0.52 × 0.08 (sold in quantities of 25) 1
8 HW33804 Flat Washer, 0.76 × 0.51 × 0.03 (sold in quantities of 25) 1
9 HW33811 E-ring, 0.5 × 0.042, (sold in quantities of 25) 1
10 P1006071 Xi4 Rewind Drive System Maintenance Kit 1
11 P1006072 110Xi4, 140Xi4, 170Xi4, 220Xi4 203/300 Rewind Drive Belt Maintenance Kit 1
12 P1006073 110Xi4 600 dpi Rewind Drive Belt Maintenance Kit 1

Media Handling Options
This section contains the patr numbers of the media handling options and related components.
Contents
Media Handling Options Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Cutter Static Brush and Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Media Rewind Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808

Media Handling Options Overview
Figure V • Media Handling Options Overview

Media Handling Options Overview
Table V • Media Handling Options Overview

1 P1006075 110Xi4 Cutter Upgrade, see Table W on page 805 1
P1006077 140Xi4 Cutter Upgrade, see Table W on page 805 1
2 P1008479 110Xi4 Rewind Option Kit, 203 and 300 dpi, see Table Y on page 809 1
P1008480 110Xi4 Rewind Option Kit, 600 dpi, see Table Y on page 809 1
P1008481 140Xi4 Rewind Option Kit, see Table Y on page 809 1

Cutter Option
Figure W • Cutter Option

1
2
9
5
8 6

Cutter Option
Table W • Cutter Option

1 P1006075 110Xi4 Cutter Upgrade 1
P1006077 140Xi4 Cutter Upgrade 1
2 P1006081 Cutter Linkage Maintenance Kit 1
3 G46618M Cutter Sensor 1
4 P1006082 110Xi4 Cutter Module Maintenance Kit 1
P1006083 140Xi4 Cutter Module Maintenance Kit 1
5 P1006091 110Xi4 Upper Mounting Bracket, see Table X on page 807 1
P1006092 140Xi4 Upper Mounting Bracket, see Table X on page 807 1
6 G30374M Cutter Motor 1
7 P1006256 Xi4 Electronic Cables Maintenance Kit 1
8 G41387M 110Xi4 Cutter Catch Tray Option Kit 1
G48459 140Xi4 Cutter Catch Tray Option Kit 1
9 P1006160 Cutter Control Board 1

Cutter Brackets
Figure X • Cutter Static Brush and Brackets

1
4 5
2
6
9 8

Cutter Brackets
Table X • Cutter Static Brush and Brackets

1 P1006091 110Xi4 Cutter Brackets Maintenance Kit 1
P1006092 140Xi4 Cutter Brackets Maintenance Kit 1
2 P1006086 110Xi4 Cutter Static Brush Maintenance Kit 1
P1006088 140Xi4 Cutter Static Brush Maintenance Kit 1
4 HW32332 Screw, 4-40 × 0.25 inch (sold in quantities of 25) 2
5 HWQ10011 Screw, M4 × 0.7 × 10 (sold in quantities of 100) 2
6 HW33805 Flat Washer (sold in quantities of 25) 1
7 HW40193 Flat Washer (sold in quantities of 25) 2

Cutter Brackets
Figure Y • Media Rewind Option

1
2 3
5
4
6
7

Media Rewind Option
Table Y • Media Rewind Option

1 P1008479 110Xi4 Rewind Option Kit, 203 and 300 dpi 1
P1008480 110Xi4 Rewind Option Kit, 600 dpi 1
P1008481 140Xi4 Rewind Option Kit 1
2 P1006071 Xi4 Rewind Drive System Maintenance Kit, see Table U on page 800 1
3 P1006072 203/300 dpi Rewind Drive Belt Maintenance Kit, see Table U on page 800 1
P1006073 110Xi4 600 dpi Rewind Drive Belt Maintenance Kit, see Table U 1
on page 800
4 P1006105 Xi4 Rewind Platen Adjustment Bracket Maintenance Kit 1
5 G41155M 110Xi4 Rewind Spindle Maintenance Kit 1
6 G41011M 110Xi4 200/300 dpi Rewind Platen Roller Maintenance Kit 1
P1004592 110Xi4 600 dpi Rewind Platen Roller Maintenance Kit 1
G40038M 140Xi4 Rewind Platen Roller Maintenance Kit 1
7 G41383M 110Xi4 Rewind Plate Maintenance Kit 1
G48383M 140Xi4 Rewind Plate Maintenance Kit, non-cutter version 1

Media Rewind Option
Notes • ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Miscellaneous
This section contains the part numbers of miscellaneous components.
Contents
Sensor Brackets and Hole Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
Slot Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814

Sensor Brackets and Hole Covers
Figure Z • Sensor Brackets and Hole Covers

1
9 10
7 8
5 6
3 4
2
11
12
14
13
15
18
17 16

Sensor Brackets and Hole Covers
Table Z • Sensor Brackets and Hole Covers

1 P1006119 Xi4 Sensor Brackets and Hole Covers maintenance Kit 1
2 N/A 110Xi4, 140Xi4, and 170Xi4 Cutter Module Access Hole Cover 1
3 N/A 220Xi4 Cutter Module Access Hole Cover 1
5 N/A Expansion nut 2
7 N/A Rubber Grommet, 1.25 × 0.62 × 0.105 inch 2
8 N/A Hole Plug for lower platen roller hole (all models) and the compliance roller 2
hole (110Xi4 and 140Xi4).
9 N/A Hole plug for access holes in the side plate. 2
10 N/A 110Xi4, 140Xi4, and 170Xi4 Metal Hole Plug for the rewind hole. 1
11 N/A 220Xi4 Rewind Hole Cover Plate 1
12 HW30393-010 Screw, 6-32 × 0.62 for 220Xi4 rewind hole cover plate. 3
13 N/A Rubber grommet for lower media sensor. 2
14 N/A Cutter Motor Hole Cover Plate 1
15 HW47476 Screw, 8-32 × 0.37 for cutter motor hole cover plate. 2
16 N/A 220Xi4 Media Low Sensor Bracket 1
17 N/A 110Xi4, 140Xi4, and 170Xi4 Media Low Sensor Bracket 1

Slot Covers
Figure AA • Slot Covers

1
4
2
5 6
Table AA • Slot Covers

1 P1006120 Xi4 Slot Covers Maintenance Kit 1
2 N/A Blank Wireless Cover 1
3 N/A Blank Ethernet Cover 1
4 N/A Blank Option Board Cover 2
5 N/A Wireless Shipping Debris Slot Cover 1
6 N/A Wireless Card Cover 1

Index
A ribbon strip plate 158

AC power supply ribbon supply spindle tension 373
install 491 ribbon take-up spindle tension 384
AC power supply shield strip plate 158
install 492 upper media sensor 190
AC/DC power supply align
install 501 cutter upper drive arm 680
remove 497 applicator
access +24-28V isolated and non-isolated modes
head open sensor cable 224 81
ribbon out sensor cable 207 +5V isolated and non-isolated modes 80
adjustment bracket applicator interface connector 75
rewind platen roller interface pin configuration 77
install 434 signals during applicator modes 75
adjustments 107 applicator interface
cutter catch tray 724 inpu/output specifications 567
lower media sensor 191 install 558
main drive belt tension 281 pinouts
media supply spindle tension 420 24-28V board 563
print mechanism roller 451 5V board 560
printhead 104 remove 554
parallelism 105
position 108 B
pressure 109 bar codes
strip plate 111 darkness comparison during FEED self
rewind belt tension 308 test 60
rewind drive belt tension 296 battery disposal 84
rewind platen roller adjustment bracket black mark media
435 when to clean sensor 85
rewind spindle tracking 747

816 Index
C cutter circuit board

cable install 515, 670
head open sensor remove 514
access 224 cutter module
ribbon out sensor cable install 666, 686
access 207 remove 684
cables cutter module hole plate
printhead 134 install 639
calibrate cutter motor
media low sensor 199 install 664
calibration cutter motor hole cover plate
troubleshooting problems 52 install 643
Canadian DOC compliance 592 cutter optical sensor
CANCEL button install 670
CANCEL self test 58 cutter sensor
checklist install 243
troubleshooting 42 remove 242
cleaning cutter static brush
cutter 93 install 719
exterior of printer 85 remove 717
media compartment 86 cutter tray anti-curl shaft
printhead and platen roller 86 install 725
recommended schedule 85 cutter upper drive arm
sensors 89 align 680
snap plate 92
communications diagnostics test D
overview 64 damper
communications problems 53 media door
compact flash adapter installation 583 install 612
compliance roller hole plug remove 610
install 641 dancer assembly
configuration label install 431
printing using CANCEL self test 58 remove 428
connect data ports 67
printhead test board cables 542 data source
control panel communication interfaces 67
install 461 DB-9 to DB-25 connection 73
LCD error messages 43 DC power supply
remove 456 install 505
control panel cover remove 235, 504
install 465 defragmenting message 47
remove 464 diagnostics 57
cutter disconnect
cleaning 93 media sensor cables 181
when to clean 85 ribbon sensor 204
cutter brackets take-label sensors 230
install 695 disconnect all printhead cables 140
cutter catch tray display language
adjustments 724 changing from unreadable language 55
install 722 disposal of printer parts 84

Index 817
E cutter motor 664

electronics cables cutter motor hole cover plate 643
install 533 cutter optical sensor 670
remove 533 cutter sensor 243
electronics cover cutter static brush 719
install 198, 601 cutter tray anti-curl shaft 725
remove 600 dancer assembly 431
error messages 43 DC power supply 505
Ethernet 568 electronics cables 533
exterior cleaning 85 electronics cover 198, 601
head open sensor assembly 226
head open sensor flag 172
F internal wireless plus antenna and cover
FCC compliance 592 588
FCC radiation exposure limits 2, 592 internal wireless plus board 587
FEED button lower media sensor 187
FEED and PAUSE self test 63 lower platen hole plug 641
FEED self test 60 lower ribbon roller 444
lower trim plate 617
H main drive belt 280
main logic board 480
hardware control signal descriptions 70
media door 605
head open sensor assembly
media door damper 612
install 226
media door window 608
remove 225
media hanger, 140Xi4, 170Xi4, and
head open sensor cable
220Xi4 362
access 224
media hanger,110Xi4 354
head open sensor flag
media low brackets 650
install 172
media low sensor 197
remove 172
media supply spindle 419
head test count
media take-up pulley 399
setting 546
name plate 618
pivot bar 168
I power entry, 110Xi4 521
installations power entry, 140Xi4, 170Xi4, and 220Xi4
220Xi4 rewind spindle hole cover plate 529
643 print mechanism 123
AC power supply 491 print mechanism roller 450
AC power supply shield 492 printhead 104
AC/DC power supply 501 printhead cables 150
adjustment bracket printhead test board 541
rewind platen roller 434 printhead test board shield 540
applicator interface 558 printhead test board spacers 536
compact flash adapter 583 rear panel,110Xi4 354
compliance roller hole plug 641 rewind drive belt 295, 307
control panel 461 rewind idler pulley 734
control panel cover 465 rewind platen pulley 295
cutter brackets 695 rewind platen roller 738
cutter catch tray 722 rewind platen roller adjustment bracket
cutter circuit board 515, 670 434
cutter module 666, 686 rewind spindle 411, 735
cutter module hole plate 639 rewind spindle hole plug 642

818 Index
rewind spindle pulley 294 language

ribbon dancer rollers 448 changing from unreadable language 55
ribbon low sensors 217 LCD messages
ribbon strip plate 158 error messages 43
ribbon supply spindle 366 liability 2
ribbon supply spindle parts 372 lower media sensor
ribbon take-up pulley 390 adjust 191
ribbon take-up spindle 380 install 187
ribbon take-up spindle/clutch assembly remove 187
380 lower platen hole plug
SEH PS102-Z internal print server 597 install 641
side plate 325, 627 lower platen roller
side plate 220Xi4 343 remove 253
slot covers 653 lower ribbon roller
static brush 157 install 444
stepper motor, 110Xi4, 140Xi4, and remove 440
170Xi4 325 lower trim plate
stepper motor, 220Xi4 343 install 617
strip plate 158 remove 614
take-label sensor expansion covers 640 lubrication 84
take-label sensors 232, 745
tear front plate 619 M
toggle assembly 162
main drive belt
top ribbon roller 439
install 280
twinax/coax 549
remove 279
upper media sensor assembly 185
tension adjust 281
upper platen roller 251
main logic board
wired ethernet 571
install 480
wireless card cover 654
remove 359, 474
wireless PCMCIA board 579
maintenance kits
wireless shipping debris slot cover 654
110Xi4, 140Xi4, and 170Xi4 stepper
internal wireless plus antenna and cover
motor 309
installation 588
220Xi4 stepper motor 332
internal wireless plus board
AC power supply 485
install 587
AC/DC power supply 495
isolated mode for applicator control signals
access hole covers 639
+24-28V operation 81
adjustment bracket
+5V operation 80
rewind platen roller 433
applicator interface 551
J control panel 454
jumper configurations for +24-28V control panel cover 464
operation 81 cutter brackets 690
jumper configurations for +5V operation 80 cutter catch tray 721
cutter circuit board 506
L cutter linkage 700
cutter module 682
label top
cutter sensor 233
printer cannot detect 56
cutter static brush 717
label-available sensor
damper
location 89
media door 609
when to clean 85
dancer assembly 424
labels did not print 53
DC power supply 502

Index 819
electronics cables 532 wired ethernet 568

electronics cover 600 wireless covers 652
head open sensor flag 169 wireless plus PCMCIA 576
internal print server plus 584 media compartment cleaning 86
main drive belt 277 media door
main logic board 466 install 605
media door 602 remove 602
media door damper 609 media door damper
media door window 606 install 612
media hanger,110Xi4 350 remove 610
media hanger,140Xi4, 170Xi4, and media door window
220Xi4 356 install 608
media low bracket 639 remove 606
media low sensor 192 media hanger, 140Xi4, 170Xi4, and 220Xi4
media rewind spindle 400 install 362
media sensor assemblies 176 remove 361
media supply spindle 413 media hanger,110Xi4
name plate 614 install 354
pivot bar 164 remove 353
platen roller 246 media low brackets
power entry, 110Xi4 516 install 650
power entry, 140Xi4, 170Xi4, and 220Xi4 remove 649
523 media low sensor
print mechanism 112 calibrate 199
printhead cables 134 remove 194
printhead test board 534 media out sensor
rewind drive belt 298 location 91
rewind drive system 283 media path cleaning 85
rewind platen roller adjustment bracket media sensor cables
433 disconnect 181
ribbon and media supply spindle pulleys media supply spindle
386 install 419
ribbon low sensors 214 remove 418
ribbon rollers 436 tension adjust 420
ribbon sensor 202 media take-up pulley
ribbon strip plate 155 install 399
ribbon supply spindle 363 remove 398
ribbon supply spindle hardware 368 modem connection 73
ribbon take-up spindle 375
SEH PS102-Z IPv6 internal print server N
593
name plate
slot covers 652
install 618
static brush 155
remove 618
strip plate 155
non-isolated mode for applicator control
take-label sensors 228
signals
tear front plate 619
+28V operation 81
toggle assembly 159
+5V operation 80
trim plate 614
twinax/coax 547
window
media door 606

820 Index
O adjustments 104
options parallelism 105
applicator interface 551 position 108
cutter 656 pressure 109
cutter catch tray 721 strip plate 111
printhead test board 534 wear plate 107
rewind 726 cables 134
twinax/coax 547 cleaning 86
ordering replacement parts 84 install 104
remove 100
when to clean 85
P printhead cables
parallel port disconnect all 140
cabling requirements 68 install 150
pin configuration 68 remove 145
settings 68 printhead stop spring and stud
PAUSE button remove 179
FEED and PAUSE self test 63 printhead test board
PAUSE self test 59 install 541
pin configuration remove 538
applicator interface 77 printhead test board cables
parallel port 68 connect 542
serial port 71 printhead test board s 540
pivot bar printhead test board spacers
install 168 install 536
remove 167
platen roller
cleaning 86
R
when to clean 85 radiation exposure limits 2, 592
ports 67 rear panel
power entry, 110Xi4 110Xi4
install 521 move 352
remove 518 move 360
power entry, 140Xi4, 170Xi4, and 220Xi4 rear panel,110Xi4
remove 524 recycling printer parts 84
Power-On Self Test (POST) 57 registration problems 52
print configuration label removals
CANCEL self test 58 AC/DC power supply 497
print mechanism adjustment bracket
install 123 rewind platen roller 433
remove 121 applicator interface 554
print mechanism roller control panel 456
adjust 451 control panel cover 464
install 450 cutter circuit board 514
remove 449 cutter module 684
print quality cutter sensor 242
troubleshooting 48 cutter static brush 717
print server plus board dancer assembly 428
remove 586 DC power supply 235, 504
printer diagnostics 57 electronics cables 533
printhead electronics cover 600
head open sensor assembly 225

Index 821
head open sensor flag 172 toggle assembly 159

lower media sensor 187 top ribbon roller 438
lower platen roller 253 twinax/coax 549
lower ribbon roller 440 upper media sensor 183
lower trim plate 614 upper platen roller 249
main drive belt 279 wireless PCMCIA board 578
main logic board 359, 474 removals side plate 220Xi4 341
media door 602 repacking instructions 751
media door damper 610 replacement parts 84
media door window 606 rewind belt
media hanger, 140Xi4, 170Xi4, and tension adjust 308
220Xi4 361 rewind drive belt
media hanger,110Xi4 353 install 295, 307
media low brackets 649 remove 306
media low sensor 194 tension adjust 296
media supply spindle 418 rewind drive pulleys
media take-up pulley 398 remove 293
name plate 618 rewind idler pulley
pivot bar 167 install 734
power entry, 110Xi4 518 rewind platen pulley
power entry, 140Xi4, 170Xi4, and 220Xi4 install 295
524 rewind platen roller
print mechanism 121 install 738
print mechanism roller 449 rewind platen roller adjustment bracket
print server plus board 586 adjust 435
printhead cables 145 rewind spindle
printhead stop spring and stud 179 install 411, 735
printhead test board 538 remove 408
rewind drive belt 306 tracking adjust 747
rewind drive pulleys 293 rewind spindle 220Xi4 hole cover plate
rewind platen roller adjustment bracket install 643
433 rewind spindle hole plug
rewind spindle 408 install 642
ribbon dancer rollers 446 rewind spindle pulley
ribbon low sensors 216 install 294
ribbon out sensor 210 ribbon
ribbon strip plate 157 troubleshooting 54
ribbon supply spindle 365 ribbon dancer rollers
ribbon supply spindle parts 368 install 448
ribbon take-up pulley 389 remove 446
ribbon take-up spindle 378 ribbon low sensors
ribbon take-up spindle end cap/release bar install 217
assembly 383 remove 216
SEH PS102-Z internal print server 596 ribbon out sensor
side plate 323, 622 remove 210
static brush 155 ribbon out sensor cable
stepper motor, 220Xi4 342 access 207
stepper motor,110Xi4, 140Xi4, and
170Xi4 324
strip plate 157
tear front plate 619

822 Index
ribbon sensor S
cleaning 89 schedule for cleaning 85
disconnect 204 SEH PS102-Z internal print server
location 89 install 597
when to clean 85 remove 596
ribbon strip pate self tests 57
remove 157 CANCEL 58
ribbon strip plate communications diagnostics 64
adjust 158 FEED 60
install 158 FEED and PAUSE 63
ribbon supply spindle PAUSE 59
install 366 Power-On Self Test (POST) 57
remove 365 sensors
tension adjust 373 cleaning 89
ribbon supply spindle parts interpreting sensor profile 65
install 372 label-available sensor location 89
remove 368 media out sensor location 91
ribbon take-up pulley ribbon sensor location 89
install 390 serial port
remove 389 pin configuration 71
ribbon take-up spindle settings 70
install 380 setting
remove 378 head test count 546
tension adjust 384 side plate
ribbon take-up spindle end cap/release bar install 325, 627
assembly remove 323, 622
remove 383 side plate 220Xi4
ribbon take-up spindle/clutch assembly install 343
install 380 remove 341
rollers slot covers
lower platen install 653
remove 253 snap plate
lower ribbon roller cleaning 92
install 444 when to clean 85
remove 440 standard data ports 67
print mechanism roller static brush
remove 449 remove 155
ribbon dancer rollers stepper motor, 110Xi4, 140Xi4, and 170Xi4
remove 446 stepper motor, 220Xi4
top ribbon roller install 343
install 439 remove 342
remove 438 stepper motor,110Xi4, 140Xi4, and 170Xi4
upper platen remove 324
install 251 strip plate
remove 249 adjust 158
RS-232 serial interface install 158
connections 72 remove 157

Index 823
T W
take-label sensor expansion covers window
install 640 media door
take-label sensors install 608
disconnect 230 remove 606
install 232 wired ethernet
take-labl sensors install 571
install 745 wireless card cover
tear front plate install 654
install 619 wireless PCMCIA board
remove 619 install 579
Tear-Off mode remove 578
tear-off bar cleaning 85 wireless print server plus compliance info
timing diagrams for applicator signals 75 592
toggle assembly wireless shipping debris slot cover
remove 159
top of label
printer cannot detect 56
top ribbon roller
install 439
remove 438
transmissive (media) sensor
when to clean 85
troubleshooting
checklist 42
communications problems 53
diagnostic tests 57
LCD error messages 43
print quality problems 48
ribbon problems 54
twinax/coax
install 549
remove 549
U
upper media sensor
adjust 190
remove 183
upper media sensor assembly
install 185
upper platen roller
install 251
remove 249
USB port
settings 74

824 Index
Notes • ___________________________________________________________________
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__________________________________________________________________________

Zebra Technologies Corporation
Zebra Technologies Corporation
475 Half Day Road, Suite 500
Lincolnshire, IL 60069 USA
T: +1 847 634 6700
Toll-free +1 866 230 9494
F: +1 847 913 8766
Zebra Technologies Europe Limited

Dukes Meadow
Millboard Road
Bourne End
Buckinghamshire, SL8 5XF, UK
T: +44 (0)1628 556000
F: +44 (0)1628 556001
Zebra Technologies Asia Pacific, LLC

120 Robinson Road
#06-01 Parakou Building
Singapore 068913
T: +65 6858 0722
F: +65 6885 0838
http://www.zebra.com
© 2009 ZIH Corp.
P1011223-001 Rev. A

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Xi4™

Product Improvements Continuous improvement of products is a policy of Zebra Technologies Corporation.

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Advanced Printer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Serial Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Print Mechanism Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Head Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Main Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

110Xi4, 140Xi4, and 170Xi4 DC Stepper Motor w/Pulley. . . . . . . . . . . . . . . .309

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

110Xi4 Media Hanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Ribbon and Media Supply Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Ribbon Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

140Xi4, 170Xi4, and 220Xi4 Power Entry . . . . . . . . . . . . . . . . . . . . . . . . . . .523

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .568

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Media Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .606

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Cutter Catch Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721

Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Advanced Printer Information .............................................................. 39

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Corrective Maintenance ........................................................................ 97

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Figure 63 • Remove the Printhead Cables 220Xi4 ........................................149

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Figure 104 • Turn the Lever to Open the Printhead ......................................208

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Figure 145 • Remove All Cables ...................................................................258

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Figure 186 • Remove all Cables ....................................................................304

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Figure 228 • Remove the Rear Pane ............................................................360

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Figure 270 • Remove the Old Bearing Housing

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Printed Circuit Boards .............................................................................. 453

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Figure 348 • Disconnect the AC Power Input Cable .....................................497

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Figure 390 • Connect the Printhead Test Board Cables ...............................543

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A

Outer Casting Components ...................................................................... 599

P1011223-001 Rev. A Xi4 Maintenance Manual 8/12/2009

Figure 472 • Remove the DC Power Supply .................................................645

8/12/2009 Xi4 Maintenance Manual P1011223-001 Rev. A