S4m menu S4M printer - newbie to Zebra's. How do I enable hex mode on the printer. I can get to the option, but cannot toggle it to 'yes' ?!?!

Yes you can, the S4m and Z4m both use EPL, contact www.lancerlabels.co.uk for pricing and delivery of a Z4M printer.
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Use the following link to replace your roller:
http://support.scansource.com/images/TKP3XXX%20Articles/TKP3990/S4M%20Platen%20Replacement.pdf

It is the same loading procedure for an S4M or ZM400. Here's a link:
http://www.zebra.com/id/zebra/na/en/index/products/printers/industrial_commercial/s4m.html

You can try this: on the S4M, you can press the Menu key to go into setup mode. Under password level 3 parameters,there is a setting for ribbon which by default is set to Yes thermal trans. If you set it to No for direct thermal mode, this will in effect turn off the ribbon sensor. The printer won't stop now if it runs out of ribbon but usually you are there when printing to see that the ribbon is running out.

On other Zebras, you can turn down the sensitivity of the RIBBON LED sensor but the S4M doesn't have that setting.

See if that helps.

Should be able to order this:
http://www.barcodesinc.com/zebra/s4m-ribbons.htm

In the software printer driver- set it to direct thermal or no ribbon. It will override the printer setting.

Go to www.zebra.com and download the S4M pdf user manual. It guides you how to change configuration.

You can go from the setings (overigth mem - yes)
Reset to factory defult (dowload segull driver from www.seagullscientific.com)
other solution is to install new firmware (latest version) www.zebra.com

try looking at the bottom of the printer, it should have the detailed model in there

The S4M comes with either EPL or ZPL programming language installed. (installed at factory) The S600 is a ZPL only printer. Check that you have correctly specified the S4M as a ZPL printer. Print a config label to check. If it is set as an EPL printer contact your supplier and ask him to download the correct programming language. It should only take a competent engineer about ten minutes (If he knows what he is doing)