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ZM400/ZM600

Industrial/Commercial Printer

Maintenance Manual

14207L-004 Rev. A
2 Copyright and Liability Disclaimer

2011 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described
therein are owned by ZIH Corp. and Zebras licensors. Unauthorized reproduction of this manual or the software
and/or firmware in the printer may result in imprisonment of up to one year and fines of up to $10,000
(17 U.S.C.506). Copyright violators may be subject to civil liability.

This product may contain ZPL, ZPL II, 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.

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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4 Table of Contents

Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Print Modes and Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Standard Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Additional Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Preventive and Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123


Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Cleaning Schedule and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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Table of Contents 5

Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Printhead Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Replace the Printhead Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Magnetic Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Drive Belt Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Stepper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Ribbon Take-up Spindle Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Sheet Metal Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Static Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Cutter Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Peel Maintenance Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Peel Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Outer Guard Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Roller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Linerless Media Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Platen Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Pinch Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Wireless Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
ZebraNet Internal Wireless Plus Print Server. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
ZebraNet b/g Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

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6 Table of Contents

Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467


Electronic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Media Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Lower Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
RFID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
RFID Upgrade Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
RFID Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
RFID Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
RZ400/RZ600 Media Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
RZ400 and RZ600 RFID Hardware Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

Drawings and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545

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List of Tables

System Description
Table 1 Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Table 2 Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Operations
Table 3 Storage Temperature and Humidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Table 4 Operating Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Table 5 Data Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Table 6 Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Table 7 Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Table 8 Media Paths for Print Modes with Various Printer Options . . . . . . . . . . . . . . . . . . . .52
Table 9 ZM400 and RZ400 Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Table 10 ZM600 and RZ600 Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Table 11 Printer Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Table 12 Print Width Ranges and Maximum Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Table 13 RFID Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Troubleshooting
Table 14 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Table 15 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Table 16 Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Table 17 Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Table 18 Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Table 19 Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Table 20 Judging Bar Code Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Preventive and Corrective Maintenance


Table 21 Recommended Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Table 22 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .544

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8 List of Tables

Drawings and Parts


Table A Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547
Table B Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .548
Table C Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549
Table D Media and Ribbon Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .551
Table E Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .552
Table F Media Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .553
Table G Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554
Table H Print Mechanism View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .555
Table I Print Mechanism View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .556
Table J Printhead Conversion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .557
Table K Platen Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559
Table L Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .560
Table M Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .561
Table N Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562
Table O Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
Table P Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .564
Table Q Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .565
Table R ZebraNet b/g Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .566
Table S Wired Ethernet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567
Table T Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .569
Table U Cutter Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .570
Table V Peel and Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .571
Table W Liner Take-up Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
Table X Inside Coated Ribbon Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .573
Table Y RFID Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .575
Table Z Reader and Coupler Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576
Table AA RZ400/RZ600 Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .577

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


List of Figures

Figure 1 Sample Figure with Callouts ........................................................... 23


System Description
Figure 2 Front of Printer................................................................................ 26
Figure 3 Rear of Printer ................................................................................ 27
Figure 4 Printer Components........................................................................ 28
Figure 5 Control Panel .................................................................................. 29
Operations
Figure 6 Power Cord Specifications.............................................................. 49
Figure 7 International Safety Organization Certifications.............................. 49
Figure 8 Tear-Off Mode Media Path ............................................................. 54
Figure 9 Ribbon Path .................................................................................... 59
Figure 10 Printhead Pressure Adjustment Dials ........................................... 65
Figure 11 Sample Configuration Label ......................................................... 70
Figure 12 Sample Network Configuration Label
(with a Wireless Print Server installed) .................................................................... 71
Figure 13 Tear-Off Position Adjustment........................................................ 74
Figure 14 Label Length ................................................................................. 78
Troubleshooting
Figure 15 Ribbon-Out Threshold Too High................................................. 112
Figure 16 Sample Configuration Label ....................................................... 116
Figure 17 PAUSE Test Label...................................................................... 117
Figure 18 FEED Test Label ........................................................................ 118
Figure 19 Bar Code Darkness Comparison ................................................ 119
Figure 20 Communications Diagnostics Test Label.................................... 121
Figure 21 Sensor Profile (Ribbon Section) ................................................. 122
Figure 22 Sensor Profile (Media Section) ................................................... 122

3/14/11 ZM400/ZM600 Maintenance Manual 14207L-004 Rev. A


10 List of Figures

Preventive and Corrective Maintenance


Figure 23 Location of the Printhead and Platen Roller ............................... 127
Figure 24 Cleaning the Cutter Module ........................................................ 131
Figure 25 Locate the Printhead Pressure Dials .......................................... 141
Figure 26 Remove the Thumbscrew........................................................... 142
Figure 27 Remove the Printhead Assembly ............................................... 143
Figure 28 Align the Forks and Bearings...................................................... 144
Figure 29 Install the Printhead Fork Assembly ........................................... 145
Figure 30 Remove the Cutter Assembly ..................................................... 147
Figure 31 Locate the Electronics Cover Mounting Screw ........................... 150
Figure 32 Remove the Electronics Cover Mounting Screws....................... 151
Figure 33 Remove the Electronics Cover ................................................... 151
Figure 34 Remove the Radio Card ............................................................. 152
Figure 35 Remove the Wireless Board ....................................................... 153
Figure 36 Remove the Antenna .................................................................. 154
Figure 37 Remove the SEH IPv6 Print Server Board ................................. 155
Figure 38 Remove the Wireless Board Mounting Standoffs ....................... 156
Figure 39 Remove the Standoff and Screw ................................................ 157
Figure 40 Gain Access the Power Supply .................................................. 158
Figure 41 Remove the Printhead Ribbon Cable Retaining Clip.................. 159
Figure 42 Printhead Grounding Strap ......................................................... 160
Figure 43 Remove the Cutter Assembly ..................................................... 161
Figure 44 Printhead Housing Mounting Screws.......................................... 162
Figure 45 Install the Printhead Data Cable Retaining Clip.......................... 163
Figure 46 Locate the Upper and Lower Flanges......................................... 165
Figure 47 Adjust the Print Mechanism ........................................................ 166
Figure 48 Install the Adjustment Cam......................................................... 167
Figure 49 Push Down on the Print Mechanism........................................... 168
Figure 50 Ribbon/Printhead Open Sensor.................................................. 169
Figure 51 Locate the Electronics Cover Mounting Screw ........................... 172
Figure 52 Remove the Electronics Cover Mounting Screws....................... 173
Figure 53 Remove the Electronics Cover ................................................... 173
Figure 54 Remove the Radio Card ............................................................. 174
Figure 55 Remove the Wireless Board ....................................................... 175
Figure 56 Remove the Antenna .................................................................. 176
Figure 57 Remove the SEH IPv6 Print Server............................................ 177
Figure 58 Remove the Standoff and Screw ................................................ 178
Figure 59 Gain Access the Power Supply .................................................. 179
Figure 60 Remove the Printhead Ribbon Cable Clip .................................. 180
Figure 61 Disconnect Printhead Cables ..................................................... 181
Figure 62 Top View of Printhead Housing .................................................. 181
Figure 63 Remove the Thumbscrew........................................................... 182
Figure 64 Printhead Removal and Installation ............................................ 183
Figure 65 Remove the Ground Cable Mounting Screw .............................. 184
Figure 66 Remove the Cables from the Print Mechanism .......................... 185
Figure 67 Install the New Cables ................................................................ 186

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


List of Figures 11

Figure 68 Align the Forks and Bearings...................................................... 187


Figure 69 Install the Printhead Fork Assembly ........................................... 188
Figure 70 Connect the Printhead Cables.................................................... 189
Figure 71 Install the Printhead Data Cable Retaining Clip.......................... 190
Figure 72 Remove the Cutter Assembly ..................................................... 192
Figure 73 Locate the Upper and Lower Flanges......................................... 193
Figure 74 Remove and Install the Ribbon Strip Plate ................................. 196
Figure 75 Open the Media Door ................................................................. 199
Figure 76 Remove the Latch Assembly ...................................................... 200
Figure 77 Adjustment Screw Location ........................................................ 201
Figure 78 Adjust the Print Mechanism ........................................................ 202
Figure 79 Print Mechanism Mounting Screws ............................................ 203
Figure 80 Locate the Printhead Pressure Dials .......................................... 206
Figure 81 Remove the Printhead and Cable Connections.......................... 207
Figure 82 Remove the Pressure Bracket and Roller .................................. 208
Figure 83 Remove the Pressure Dials ........................................................ 209
Figure 84 Install the Springs ....................................................................... 209
Figure 85 Align the Forks and Bearings...................................................... 210
Figure 86 Locate the Electronics Cover Mounting Screw ........................... 213
Figure 87 Remove the Electronics Cover Mounting Screws....................... 214
Figure 88 Remove the Electronics Cover ................................................... 214
Figure 89 Locate the Magnetic Latch.......................................................... 215
Figure 90 Remove the Old Magnetic Latch ................................................ 216
Figure 91 Install the New Magnetic Latch................................................... 217
Figure 92 Install Magnetic Latch Clamp...................................................... 218
Figure 93 Locate the Upper and Lower Flanges......................................... 219
Figure 94 Locate the Electronics Cover Mounting Screw ........................... 223
Figure 95 Remove the Electronics Cover Mounting Screws....................... 224
Figure 96 Remove the Electronics Cover ................................................... 224
Figure 97 Remove the Radio Card ............................................................. 225
Figure 98 Remove the Wireless Board ....................................................... 226
Figure 99 Remove the Standoff and Screw ................................................ 227
Figure 100 Gain Access the Power Supply ................................................ 228
Figure 101 Locate Drive System Components ........................................... 229
Figure 102 Disconnect the Media Sensor Cables....................................... 230
Figure 103 Remove the Upper Media Sensor Mounting Screw.................. 231
Figure 104 Release the Dancer Spring....................................................... 232
Figure 105 Remove the Media Sensor Assemblies.................................... 233
Figure 106 Remove the Protective Cap...................................................... 234
Figure 107 Locate the Access Hole ............................................................ 235
Figure 108 Remove the Protective Cap...................................................... 236
Figure 109 Install the Upper Media Sensor Assembly................................ 237
Figure 110 Adjust the ZM400 Upper Media Sensor.................................... 240
Figure 111 Adjust the ZM600 Upper Media Sensor.................................... 241
Figure 112 Locate the Electronics Cover Mounting Screw ......................... 243
Figure 113 Remove the Electronics Cover Mounting Screws..................... 244
Figure 114 Remove the Electronics Cover ................................................. 244

3/14/11 ZM400/ZM600 Maintenance Manual 14207L-004 Rev. A


12 List of Figures

Figure 115 Disconnect the Ribbon/Head Open Sensor.............................. 245


Figure 116 Ribbon Sensor Removal and Installation.................................. 246
Figure 117 Locate the Access Hole ............................................................ 247
Figure 118 Gap Measurement Between Print Mechanism and Sensor ...... 248
Figure 119 Locate the Upper and Lower Flanges....................................... 249
Figure 120 Locate the Electronics Cover Mounting Screw ......................... 253
Figure 121 Remove the Electronics Cover Mounting Screws..................... 254
Figure 122 Remove the Electronics Cover ................................................. 254
Figure 123 Lay the Printer on its Side......................................................... 255
Figure 124 Remove the Gear Cover........................................................... 256
Figure 125 Remove and Install Gears, Pulley, and Belt ............................. 257
Figure 126 Locate the Upper and Lower Flanges....................................... 259
Figure 127 Locate the Electronics Cover Mounting Screw ......................... 260
Figure 128 Remove the Electronics Cover Mounting Screws..................... 261
Figure 129 Remove the Electronics Cover ................................................. 261
Figure 130 Remove the Old Belt................................................................. 262
Figure 131 Locate the Upper and Lower Flanges....................................... 263
Figure 132 Locate the Electronics Cover Mounting Screw ......................... 265
Figure 133 Remove the Electronics Cover Mounting Screws..................... 266
Figure 134 Remove the Electronics Cover ................................................. 266
Figure 135 Remove the Radio Card ........................................................... 267
Figure 136 Remove the Wireless Board ..................................................... 268
Figure 137 Remove the Standoff and Screw .............................................. 269
Figure 138 Gain Access the Power Supply ................................................ 270
Figure 139 Locate Drive System Components ........................................... 271
Figure 140 Locate the Upper and Lower Flanges....................................... 273
Figure 141 Locate the Electronics Cover Mounting Screw ......................... 275
Figure 142 Remove the Electronics Cover Mounting Screws..................... 276
Figure 143 Remove the Electronics Cover ................................................. 276
Figure 144 Lay the Printer on its Side......................................................... 277
Figure 145 Remove the Gear Cover........................................................... 278
Figure 146 Loosen the Set Screws............................................................. 279
Figure 147 Remove the Clutch ................................................................... 280
Figure 148 Locate the Upper and Lower Flanges....................................... 281
Figure 149 Locate the Electronics Cover Mounting Screw ......................... 284
Figure 150 Remove the Electronics Cover ................................................. 284
Figure 151 Lay the Printer on its Side......................................................... 285
Figure 152 Remove the Gear Cover........................................................... 286
Figure 153 Loosen the Set Screws............................................................. 287
Figure 154 Remove the RTU Spindle ......................................................... 288
Figure 155 Locate the Upper and Lower Flanges....................................... 289
Figure 156 Locate the Electronics Cover Mounting Screw ......................... 291
Figure 157 Remove the Electronics Cover Mounting Screws..................... 292
Figure 158 Remove the Electronics Cover ................................................. 292
Figure 159 Remove the Drive Belt.............................................................. 293
Figure 160 Remove the Platen Pulley ........................................................ 294
Figure 161 Align the Screws ....................................................................... 294

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


List of Figures 13

Figure 162 Lay the Printer on its Side......................................................... 295


Figure 163 Remove the Gear Cover........................................................... 296
Figure 164 Remove the Compound Gear................................................... 297
Figure 165 Compound Gear DPI Location.................................................. 298
Figure 166 Locate the Upper and Lower Flanges....................................... 299
Figure 167 Locate the Printhead Pressure Dials ........................................ 300
Figure 168 Remove the Thumbscrew......................................................... 301
Figure 169 Remove the Printhead .............................................................. 302
Figure 170 Align the Forks and Bearings.................................................... 303
Figure 171 Install the Printhead Fork Assembly ......................................... 304
Figure 172 Remove the Cutter Assembly ................................................... 306
Figure 173 Locate the Electronics Cover Mounting Screw ......................... 309
Figure 174 Remove the Electronics Cover Mounting Screws..................... 310
Figure 175 Remove the Electronics Cover ................................................. 310
Figure 176 Lay the Printer on its Side......................................................... 311
Figure 177 Remove the Gear Cover........................................................... 312
Figure 178 Remove the Radio Card ........................................................... 313
Figure 179 Remove the Wireless Board ..................................................... 314
Figure 180 Locate the Drive Components .................................................. 315
Figure 181 Remove the Stepper Motor and Intermediate Gear.................. 316
Figure 182 Remove the Ribbon Supply Spindle ......................................... 317
Figure 183 Using the Remove Tool ............................................................ 318
Figure 184 Install the Thin Washer ............................................................. 318
Figure 185 Lubrication ................................................................................ 319
Figure 186 Spindle Installation.................................................................... 320
Figure 187 Locate the Upper and Lower Flanges....................................... 322
Figure 188 Remove and Install the Hanger Assembly................................ 324
Figure 189 Remove and Install the Hanger Assembly................................ 326
Figure 190 Remove the Front Cover .......................................................... 327
Figure 191 Remove and Install the Tear-Off Bar ........................................ 328
Figure 192 Install the New Tear-Off Bar ..................................................... 329
Figure 193 Locate the Pems....................................................................... 329
Figure 194 Remove and Install the Static Brush Assembly)....................... 331
Figure 195 Locate the Electronics Cover Mounting Screw ......................... 333
Figure 196 Remove the Electronics Cover Mounting Screws..................... 334
Figure 197 Remove the Electronics Cover ................................................. 334
Figure 198 Remove the Front Cover .......................................................... 335
Figure 199 Locate and Position the Mounting Brackets ............................. 336
Figure 200 Install the Cutter Assembly ....................................................... 337
Figure 201 Cutter Shield and Catch Tray ................................................... 338
Figure 202 Locate Cutter Connector on the Main Logic Board................... 339
Figure 203 Locate the Upper and Lower Flanges....................................... 340
Figure 204 Remove Old Peel Assembly ..................................................... 341
Figure 205 Install Peel Assembly................................................................ 342
Figure 206 Rear View of Peel Assembly .................................................... 343
Figure 207 Locate the Electronics Cover Mounting Screw ......................... 345
Figure 208 Remove the Electronics Cover Mounting Screws..................... 346

3/14/11 ZM400/ZM600 Maintenance Manual 14207L-004 Rev. A


14 List of Figures

Figure 209 Remove the Electronics Cover ................................................. 346


Figure 210 Remove the Front Cover .......................................................... 347
Figure 211 Remove the Old Base............................................................... 348
Figure 212 Install the Rewind Pan .............................................................. 349
Figure 213 Install the Rewind Spindle Assembly........................................ 351
Figure 214 Connect the Rewind Cable to the Main Logic Board ................ 352
Figure 215 Install the Motor and Spindle Assembly.................................... 353
Figure 216 Locate the Upper and Lower Flanges....................................... 354
Figure 217 Remove the Tear Bar ............................................................... 355
Figure 218 Remove the Peel Assembly...................................................... 356
Figure 219 Locate the Pems....................................................................... 357
Figure 220 Install the New Peel Assembly ................................................. 358
Figure 221 Load the Rewind Media ............................................................ 360
Figure 222 Load the Rewind Peel Media.................................................... 360
Figure 223 Align the Rewind Media ............................................................ 361
Figure 224 Remove the E-ring and Washers.............................................. 363
Figure 225 Remove the Rewind Spindle .................................................... 364
Figure 226 Remove the Rewind Back Plate ............................................... 365
Figure 227 Remove the Spindle ................................................................. 365
Figure 228 Remove the Outer Rewind Guide............................................. 366
Figure 229 Align the Outer Rewind Guide .................................................. 367
Figure 230 Slide the Platen Roller Assembly.............................................. 371
Figure 231 Remove the Platen Roller Assembly ........................................ 372
Figure 232 Bearing Keys ............................................................................ 373
Figure 233 Align the Drive Pin and Drive Shaft .......................................... 374
Figure 234 Install the Platen Roller Assembly ............................................ 375
Figure 235 Remove the Linerless Media Guide Assembly ......................... 377
Figure 236 Remove the Linerless Media Platen Roller Assembly .............. 378
Figure 237 Bearing Grooves....................................................................... 379
Figure 238 Install the Linerless Media Platen Roller Assembly .................. 380
Figure 239 Align the Drive Pin and Drive Shaft .......................................... 381
Figure 240 Verify the Take-Label Sensor Cable Routing ........................... 382
Figure 241 Locate the Electronics Cover Mounting Screw ......................... 384
Figure 242 Remove the Electronics Cover Mounting Screws..................... 385
Figure 243 Remove the Electronics Cover ................................................. 385
Figure 244 Slide the Platen Roller Assembly.............................................. 386
Figure 245 Remove the Platen Roller Assembly ........................................ 387
Figure 246 Remove the Drive Belt.............................................................. 388
Figure 247 Remove the Platen Pulley ........................................................ 389
Figure 248 Remove the E-ring and Washer ............................................... 390
Figure 249 Push the Drive Shaft Through .................................................. 391
Figure 250 Remove the Roller Bearings..................................................... 391
Figure 251 Align Flat Spots on the Shaft .................................................... 392
Figure 252 Locate the Upper and Lower Flanges....................................... 393
Figure 253 Bearing Keys ............................................................................ 394
Figure 254 Align the Drive Pin and Drive Shaft .......................................... 395
Figure 255 Install the Platen Roller Assembly ............................................ 396

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


List of Figures 15

Figure 256 Removing and Installing E-rings and Bearings......................... 398


Figure 257 Rear View of Peel Assembly .................................................... 399
Figure 258 Installing Peel Roller Assembly ................................................ 400
Figure 259 Locate the Electronics Cover Mounting Screw ......................... 404
Figure 260 Remove the Electronics Cover Mounting Screws..................... 405
Figure 261 Remove the Electronics Cover ................................................. 405
Figure 262 Open the Ferrite Block.............................................................. 406
Figure 263 Locate the Cable Clip ............................................................... 407
Figure 264 Remove the Control Panel........................................................ 408
Figure 265 Install the Ferrite Block ............................................................. 409
Figure 266 Locate the Upper and Lower Flanges....................................... 410
Figure 267 Locate the Electronics Cover Mounting Screw ......................... 413
Figure 268 Remove the Electronics Cover Mounting Screws..................... 414
Figure 269 Remove the Electronics Cover ................................................. 414
Figure 270 Remove the Radio Card ........................................................... 416
Figure 271 Remove the Wireless Board ..................................................... 417
Figure 272 Remove the Wireless Board Mounting Standoffs ..................... 418
Figure 273 Remove the Antenna ................................................................ 419
Figure 274 Remove the SEH IPv6 Print Server Board ............................... 420
Figure 275 Remove the Wireless Board Mounting Standoffs ..................... 421
Figure 276 Remove the Wired Ethernet Board........................................... 422
Figure 277 Remove the Wired Ethernet Board Standoffs........................... 422
Figure 278 Remove the Printhead Ribbon Cable Clip ................................ 423
Figure 279 Main Logic Board Assembly Connection Locations.................. 424
Figure 280 Remove the Old MLB ............................................................... 425
Figure 281 Install the Printhead Data Cable Retaining Clip........................ 426
Figure 282 Locate the Upper and Lower Flanges....................................... 428
Figure 283 Configuration Label................................................................... 429
Figure 284 Locate the Electronics Cover Mounting Screw ......................... 430
Figure 285 Remove the Electronics Cover Mounting Screws..................... 431
Figure 286 Remove the Electronics Cover ................................................. 431
Figure 287 Remove the Radio Card ........................................................... 432
Figure 288 Remove the Wireless Board ..................................................... 433
Figure 289 Remove the Blank Cover.......................................................... 434
Figure 290 Install the Standoffs .................................................................. 435
Figure 291 Install the Wireless Board ......................................................... 436
Figure 292 Locate the Upper and Lower Flanges....................................... 437
Figure 293 Locate the Electronics Cover Mounting Screw ......................... 439
Figure 294 Remove the Electronics Cover Mounting Screws..................... 440
Figure 295 Remove the Electronics Cover ................................................. 440
Figure 296 Remove the Old Print Server Board ......................................... 441
Figure 297 Install the Standoffs .................................................................. 442
Figure 298 Closeup of Antenna Installation ................................................ 443
Figure 299 Sample Label............................................................................ 445
Figure 300 Label Location .......................................................................... 446
Figure 301 Locate the Electronics Cover Mounting Screw ......................... 449
Figure 302 Remove the Electronics Cover Mounting Screws..................... 450

3/14/11 ZM400/ZM600 Maintenance Manual 14207L-004 Rev. A


16 List of Figures

Figure 303 Remove the Electronics Cover ................................................. 450


Figure 304 Remove the Old Print Server Board ......................................... 451
Figure 305 Install the Standoffs .................................................................. 452
Figure 306 Close up of Antenna Installation ............................................... 453
Figure 307 Sample Approvals Label........................................................... 455
Figure 308 Label Location .......................................................................... 456
Figure 309 Close-up of Antenna Installation............................................... 459
Figure 310 Locate the Electronics Cover Mounting Screw ......................... 461
Figure 311 Remove the Electronics Cover Mounting Screws..................... 462
Figure 312 Remove the Electronics Cover ................................................. 462
Figure 313 Remove the Ethernet Board ..................................................... 463
Figure 314 Remove the Blank Cover and Screw........................................ 464
Figure 315 Clean the J4 Pads .................................................................... 464
Figure 316 Install the Mounting Standoffs .................................................. 465
Figure 317 Locate the Upper and Lower Flanges....................................... 466
Figure 318 Locate the Electronics Cover Mounting Screw ......................... 469
Figure 319 Remove the Electronics Cover Mounting Screws..................... 470
Figure 320 Remove the Electronics Cover ................................................. 470
Figure 321 Locate the Upper and Lower Flanges....................................... 471
Figure 322 Media Door ............................................................................... 473
Figure 323 Remove the Old Window .......................................................... 475
Figure 324 Align the New Window.............................................................. 476
Figure 325 Position Tab.............................................................................. 477
Figure 326 Remove the Old Lower Front Panel ......................................... 478
Figure 327 Hook the Lower Tabs................................................................ 479
Figure 328 Snap to the Mounting Hooks .................................................... 480
Figure 329 Remove and Install the Rear End-Cap ..................................... 481
Figure 330 Locate the Electronics Cover Mounting Screw ......................... 485
Figure 331 Remove the Electronics Cover Mounting Screws..................... 486
Figure 332 Remove the Electronics Cover ................................................. 486
Figure 333 Remove the Old Mounting Screws ........................................... 487
Figure 334 Install the New Mounting Screws.............................................. 488
Figure 335 Install the RFID Reader Mounting Bracket ............................... 489
Figure 336 Install the RFID Reader Board Assembly ................................. 490
Figure 337 Install the Coupler Cable Guide Bracket................................... 491
Figure 338 Remove the Cutter Option ........................................................ 492
Figure 339 Remove Peel Assembly............................................................ 493
Figure 340 Remove the Front Cover .......................................................... 494
Figure 341 Remove and Install the Tear Bar .............................................. 495
Figure 342 Remove and Install the Media Shelf ......................................... 496
Figure 343 Install the Coupler Assembly .................................................... 497
Figure 344 Install the RFID Coupler Assembly........................................... 498
Figure 345 Connect Coupler Cable to the RFID Reader Board.................. 499
Figure 346 Remove the Front Media Door End Cap .................................. 500
Figure 347 Install the Tear Bar ................................................................... 501
Figure 348 Hook the Lower Tabs................................................................ 502
Figure 349 Snap to the Mounting Hooks .................................................... 503

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


List of Figures 17

Figure 350 Install Peel Assembly................................................................ 504


Figure 351 Rear View of Peel Assembly .................................................... 504
Figure 352 Locate the Upper and Lower Flanges....................................... 505
Figure 353 Sample Label............................................................................ 506
Figure 354 Attach Label.............................................................................. 507
Figure 355 Locate the Electronics Cover Mounting Screw ......................... 510
Figure 356 Remove the Electronics Cover Mounting Screws..................... 511
Figure 357 Remove the Electronics Cover ................................................. 511
Figure 358 RFID Reader Interconnect........................................................ 512
Figure 359 Remove the Old RFID Reader Assembly ................................. 513
Figure 360 Locate the Upper and Lower Flanges....................................... 514
Figure 361 Locate the Electronics Cover Mounting Screw ......................... 516
Figure 362 Remove the Electronics Cover Mounting Screws..................... 517
Figure 363 Remove the Electronics Cover ................................................. 517
Figure 364 Remove the Cutter Option ........................................................ 518
Figure 365 Remove Old Peel Assembly ..................................................... 519
Figure 366 Remove the Front Cover .......................................................... 520
Figure 367 Remove and Install the Tear Bar, RZM400 .............................. 521
Figure 368 Remove and Install the Tear Bar, RZM600 .............................. 522
Figure 369 Connect Coupler Cable to the RFID Reader Board.................. 523
Figure 370 Remove the Coupler Assembly ................................................ 524
Figure 371 Remove the Coupler Assembly ................................................ 524
Figure 372 Install the Media Shelf and Coupler Assembly ......................... 525
Figure 373 Hook the Lower Tabs................................................................ 527
Figure 374 Snap to the Mounting Hooks .................................................... 528
Figure 375 Install Peel Assembly................................................................ 529
Figure 376 Rear View of Peel Assembly .................................................... 530
Figure 377 Locate the Upper and Lower Flanges....................................... 531
Figure 378 Locate the Electronics Cover Mounting Screw ......................... 533
Figure 379 Remove the Electronics Cover Mounting Screws..................... 534
Figure 380 Remove the Electronics Cover ................................................. 534
Figure 381 RFID Reader Interconnect........................................................ 535
Figure 382 Remove the RFID Reader Assembly........................................ 536
Figure 383 Remove the RFID Reader Mounting Bracket ........................... 537
Figure 384 Remove the Media Door........................................................... 538
Figure 385 Locate the Upper and Lower Flanges....................................... 540
Figure 386 Remove the Front Cover .......................................................... 541
Figure 387 Remove and Install the Tear-Off Bar ........................................ 542
Figure 388 Hook the Lower Tabs................................................................ 543
Figure 389 Kit Contents .............................................................................. 544

3/14/11 ZM400/ZM600 Maintenance Manual 14207L-004 Rev. A


18 List of Figures

Drawings and Parts


Figure A Outer Casings .............................................................................. 546
Figure B Media Door................................................................................... 548
Figure C Rear End Cap .............................................................................. 549
Figure D Media and Ribbon Path................................................................ 550
Figure E Media Hanger............................................................................... 552
Figure F Media Sensors.............................................................................. 553
Figure G Ribbon Supply Spindle................................................................. 554
Figure H Print Mechanism View 1............................................................... 555
Figure I Print Mechanism View 2 ................................................................ 556
Figure J Printhead Conversion ................................................................... 557
Figure K Platen Housing ............................................................................. 558
Figure L Static Brush .................................................................................. 560
Figure M Ribbon Take-up Spindle .............................................................. 561
Figure N Drive System Components .......................................................... 562
Figure O Electronic Components................................................................ 563
Figure P Main Logic Board ......................................................................... 564
Figure Q Wireless Board............................................................................. 565
Figure R ZebraNet b/g Print Server ............................................................ 566
Figure S Wired Ethernet Board/Internal PrintServer................................... 567
Figure T Available Media Handling Options................................................ 568
Figure U Cutter Option................................................................................ 570
Figure V Peel and Rewind Option............................................................... 571
Figure W Liner Take-up Option................................................................... 572
Figure X Inside Coated Ribbon Supply Spindle.......................................... 573
Figure Y RFID Upgrade Kit ......................................................................... 574
Figure Z Reader and Coupler Maintenance Kit .......................................... 576
Figure AA RZ400/RZ600 Media Door......................................................... 577

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


About This Document

This section provides you with contact information, document structure and organization, and additional
reference documents.

Contents
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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20 About This Document
Who Should Use This Document

Who Should Use This Document


This Maintenance Manual is intended for use by any person who needs to operate or to troubleshoot problems
with the printer.

How This Document Is Organized


The Maintenance Manual is set up as follows:

Section Description
System Description on page 25 This section provides an overview of the printer. Included are
specifications of the printer and a brief explanation of each
component and its function.
Operations on page 39 This section assists the technician with out of the box installation,
initial setup, and printer operation.
Troubleshooting on page 101 This section provides information about LCD, print quality,
communications, and other errors that you might need to
troubleshoot. The tables provide symptoms, diagnoses of probable
causes, and recommended actions that should result in proper
printer operation. Working with these tables, the technician can
diagnose printer faults and determine the needed repair.
Preventive and Corrective This section provides various levels of printer maintenance required
Maintenance on page 123 for optimum performance. This section also provides information
on cleaning and general maintenance, replacement of major
assemblies, and mechanical adjustments.
Drawings and Parts on page 545 This section provides the technician with assembly drawings and
part number to maintain the printer.

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About This Document 21
Contacts

Contacts
Technical Support via the Internet is available 24 hours per day, 365 days per year.

Web Site: www.zebra.com


E-mail Back Technical Library:
E-mail address: emb@zebra.com
Subject line: Emaillist
Self Service Knowledge Base: www.zebra.com/knowledgebase
Online Case Registration: www.zebra.com/techrequest

Which Department Europe, Middle East, Asia Pacific


The Americas
Do You Need? and Africa and India

Regional Headquarters Zebra Technologies Corporation Zebra Technologies Europe Zebra Technologies Asia Pacific
475 Half Day Road, Suite 500 Limited Pte. Ltd.
Lincolnshire, IL 60069 USA Dukes Meadow 120 Robinson Road
T: +1 847 634 6700 Millboard Road #06-01 Parakou Building
Toll-free +1 866 230 9494 Bourne End Singapore 068913
F: +1 847 913 8766 Buckinghamshire, SL8 5XF T: + 65 6858 0722
United Kingdom F: +65 6885 0838
T: +44 (0) 1628 556000
F: +44 (0) 1628 556001
Technical Support T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1628 556039 T: +65 6858 0722
For questions on the F: +1 847 913 2578 F: +44 (0) 1628 556003 F: +65 6885 0838
operation of Zebra Hardware: ts1@zebra.com E: Tseurope@zebra.com E: China: tschina@zebra.com
equipment and software, Software: ts3@zebra.com All other areas:
please call your distributor. Kiosk printers: tsasiapacific@zebra.com
For additional assistance, T: +1 866 322 5202
contact us. E: kiosksupport@zebra.com
Please have your model and
serial numbers available.

Repair Service T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1772 693069 T: +65 6858 0722
Department F: +1 847 821 1797 F: +44 (0) 1772 693046 F: +65 6885 0838
For back-to-base service E: repair@zebra.com New requests: ukrma@zebra.com E: China: tschina@zebra.com
and repair. To request a repair in the U.S., Status updates: All other areas:
go to www.zebra.com/repair. repairupdate@zebra.com tsasiapacific@zebra.com

Technical Training T: +1 847 793 6868 T: +44 (0) 1628 556000 T: + 65 6858 0722
Department T: +1 847 793 6864 F: +44 (0) 1628 556001 F: +65 6885 0838
For Zebra product training F: +1 847 913 2578 E: Eurtraining@zebra.com E: China: tschina@zebra.com
courses. E: ttamerica@zebra.com All other areas:
tsasiapacific@zebra.com
Inquiry Department T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1628 556037 E: China:
For product literature and E: inquiry4@zebra.com F: +44 (0) 1628 556005 GCmarketing@zebra.com
distributor and dealer E: mseurope@zebra.com All other areas:
information. APACChannelmarketing@zebra.co
m
Customer Service T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1628 556032 T: +65 6858 0722
Department (US) E: clientcare@zebra.com F: +44 (0) 1628 556001 F: +65 6885 0836
Internal Sales E: cseurope@zebra.com E: China: order-csr@zebra.com
Department (UK) All other areas:
csasiapacific@zebra.com
For printers, parts, media,
and ribbon, please call your
distributor or contact us.
Key: T: Telephone
F: Facsimile
E: E-mail

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22 About This Document
Document Conventions

Document Conventions
The following conventions are used throughout this document to convey certain information.

Alternate Color (online only) Cross-references contain hot links to other sections in this
guide. If you are viewing this guide online in.pdf format, you can click the cross-reference
(blue text) to jump directly to its location.

LCD Display Examples Text from a printers Liquid Crystal Display (LCD) appears in
Bubbledot ICG font.

Command Line Examples Command line examples appear in Courier New font. For
example, type ZTools to get to the Post-Install scripts in the bin directory.

Files and Directories File names and directories appear in Courier New font. For
example, the Zebra<version number>.tar file and the /root directory.

Icons Used

Caution Warns you of the potential for electrostatic discharge.

Caution Warns you of a potential electric shock situation.

Caution Warns you of a situation where excessive heat could cause a burn.

Caution Advises you that failure to take or avoid a specific action could result in physical
harm to you.

Caution (No icon) Advises you that failure to take or avoid a specific action could result in
physical harm to the hardware.

Important Advises you of information that is essential to complete a task.

Note Indicates neutral or positive information that emphasizes or supplements important


points of the main text.

Example Provides an example, often a scenario, to better clarify a section of text.

Illustration Callouts Callouts are used when an illustration contains information that needs
to be labeled and described. A table that contains the labels and descriptions follows the
graphic.
Tools Figure
Tells 1 provides
you anyou
what tools example.
need to complete a given task.

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About This Document 23
Document Conventions

Figure 1 Sample Figure with Callouts

1 2

1 FEED button
2 CANCEL button

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24 About This Document
Document Conventions

Notes ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


1
System Description

This section provides an overview of the printer. Included are specifications of the printer and
a brief explanation of each component and its function.

Contents
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Printer Language Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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26 System Description
External View

External View
Figure 2 and Figure 3 show the components and connections on the outside of the printer.

Figure 2 Front of Printer

2
1

1 Control panel
2 Media door

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System Description 27
External View

Figure 3 Rear of Printer

(All Standard Connectors, Internal 10/100 Wired Print Server,


and Wireless Plus Print Server Shown)

6
1 7

2 8

(All Standard Connectors, Internal 10/100 Wired Print Server,


and Internal Wireless Plus Print Server Shown)

6
1 7

2 8

1 Power switch (O = off, I = on) 5 Serial port


2 AC power connector 6 Internal wired print server port
(Ethernet option)
3 Wireless card ejector button 7 USB port
8 Parallel port
4 Wireless Plus print server card slot 9 Internal Wireless Plus print server antenna
(Ethernet option) (Ethernet option)

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28 System Description
Printer Media Compartment

Printer Media Compartment


Figure 4 shows the components inside the media compartment of your printer. Depending on
installed options, your printer may look slightly different.

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 ZM400, ZM600, RZ400, and RZ600 are designed to work only with
genuine Zebra printheads, thus maximizing safety and print quality.

Figure 4 Printer Components

4
5

8
9

1 Printhead assembly 6 Ribbon take-up spindle


2 Control panel 7 Ribbon supply spindle
3 Media door 8 Dancer assembly
4 Media supply guide 9 Printhead release latch
5 Media supply hanger

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System Description 29
Control Panel

Control Panel
The control panel contains the lights that indicate basic operation and the buttons that you may
need to press during basic operation. The control panel buttons and lights are labeled in
Figure 5. Descriptions for each are located in Table 1 and Table 2.

Figure 5 Control Panel

1 2 3 4

12

11 6
10
9 7

1 Power LED
2 Pause LED
3 Error LED
4 Data LED
5 LCD
6 CANCEL button
7 PLUS (+) button
8 SETUP/EXIT button
9 MINUS () button
10 SELECT button
11 FEED button
12 PAUSE button

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30 System Description
Control Panel

Control Panel Buttons

Table 1 Control Panel Buttons

Button Function
FEED Forces the printer to feed one blank label each time the button is pressed.
Printer not printing: one blank label immediately feeds.
Printing: one blank label feeds after the current batch of labels is complete.
PAUSE Starts and stops the printing process.
Printer not printing: no printing occurs. (Press PAUSE again to resume printing.)
Printing: printing stops after the current label is complete.
CANCEL Cancels print jobs when the printer is paused.
Printer not printing: the next stored label format does not print.
Printing: current label completes printing, and the next label format is cancelled.
Press and hold for several seconds to cancel all print jobs in memory.
SETUP/EXIT Enters and exits the configuration mode.
SELECT Toggles the function of PLUS (+) and MINUS () between the Scroll and Change
Modes.
Press once to use PLUS (+) and MINUS () to change the values of the selection.
Press again to use PLUS (+) and MINUS () to scroll through the menu items.
PLUS (+) Scrolls to the next selection.
(scroll mode)
PLUS (+) Increases the value.
(change mode) Performs the action on the bottom right of the LCD.
MINUS () Scrolls to the previous selection.
(scroll mode)
MINUS () Decreases the value.
(change mode) Moves to the next available digit in a number.
Performs the action on the bottom left of the LCD.

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System Description 31
Control Panel

Control Panel Lights


Table 2 Control Panel Lights

Light Status Indication


POWER Off The printer is off, or no power is applied.
On The printer is on.
PAUSE Off Normal printer operation.
On The printer has stopped all printing operations.
Flashing The Pause light flashes when initializing FLASH memory and in
Peel-Off Mode when the label is available.
ERROR Off Normal printer operation (no errors).
On An error condition is preventing printing. This includes MEDIA
OUT and RIBBON OUT errors.
Flashing An error condition exists, but printing is allowed to continue. This
includes RIBBON IN warning, HEAD UNDER TEMP warning,
and HEAD OVER TEMP error.
DATA Off Normal printer operation (no data being received or processed).
One flash CANCEL was pressed and a format is successfully cancelled.
Slow flashing The printer cannot accept more data from the host.
Fast flashing The printer is receiving data.
On A partial format has been received and no subsequent data activity.

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32 System Description
Printer Language Modes

Printer Language Modes


Depending on how your printer was ordered, it came from the factory with firmware that
operates in or allows you to use certain commands for one of the following printer languages:
Zebra Programming Language (ZPL), which includes XML
Eltron Programming Language (EPL)
Datamax Programming Language (APL-D)
Intermec Printer Language (APL-I)

Note The following restrictions apply:


EPL, APL-D, and APL-I are supported only on 203 dpi printers.
RFID functionality is available only with R53.X firmware, which operates in ZPL mode
with XML. Other printer languages do not support RFID.

Firmware Downloads
You may download firmware to the printer at any time to change from one printer language to
another. For the latest firmware versions and instructions for downloading them, go to
http://www.zebra.com/firmware.

Note When the printer changes from one printer language to another, error messages may
appear on the LCD, and some control panel lights may activate in error mode. You may
ignore these error messages and lights. When the firmware download is complete, reboot the
printer and then load printer defaults to return the printer to Operating mode.

Additional Printer Language Information


The following manuals contain specific information about the different printer language
modes. Copies of these manuals are on the CD that came with your printer and at
http://www.zebra.com/manuals.

Zebra XML-Enabled Printer Reference Guide
EPL2 Programming Guide
APL-D Reference Guide
APL-I Reference Guide

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System Description 33
General Specifications

General Specifications

General Specifications ZM400/RZ400 ZM600/RZ600


Height 13.3 in. 338 mm 13.3 in. 338 mm
Width 10.9 in. 278 mm 13.4 in. 341 mm
Depth 18.7 in. 475 mm 18.7 in. 475 mm
Weight (without options) 32.4 lbs. 15 kg 34.7 lbs. 16 kg
Electrical 90-265 VAC, 48-62 Hz, 5 Amps 90-265 VAC, 48-62 Hz, 5 Amps
(fused) (fused)
Temperature Operating 40 to 104F 5 to 40C 40 to 104F 5 to 40 C
Storage 40 to 140F 40 to 60C 40 to 140F 40 to 60C
Relative Operating 20% to 85%, non-condensing 20% to 85%, non-condensing
Humidity Storage 5% to 85%, non-condensing 5% to 85%, non-condensing
Communication Interfaces USB 2.0
bi-directional parallel
serial data interface
RS-232C, with DB9F connector
Configurable baud rate (300 - 115,200 kB), parity, and data bits.
Stop bits can be set at 1 or 2
Software (XON/XOFF), hardware (DTR/DSR, or RTS/CTS)
communication handshake protocols
RS422/485 with optional adapter
ZebraNet Wireless Plus Print Server and Internal Wireless Plus Print
Server - 802.11b/g - compliant wireless print server
ZebraNet 10/100 Print Server - Ethernet network print server (10BASE-T,
100BASE-TX)
Memory 16 MB DRAM memory (12 MB user available)
8 MB flash memory (2 MB user available)
Label formats accepted by ZPL II
firmware XML-Enabled ZPL
EPL II (203 dpi ZM400 or ZM600 only)
APL-I (203 dpi ZM400 or ZM600 only)
APL-D (203 dpi ZM400 or ZM600 only)

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34 System Description
Printing Specifications

Printing Specifications

Printing Specifications ZM400/RZ400 ZM600/RZ600


Print resolution 203 dots/in. 8 dots/mm 203 dots/in. 8 dots/mm
300 dots/in. 12 dots/mm 300 dots/in. 12 dots/mm
600 dots/in. 24 dots/mm N/A N/A
Dot size 203 dots/in. 0.0049 in. x 0.125 mm x 0.0049 in. x 0.125 mm x
(width x length) 0.0049 in. 0.125 mm 0.0049 in. 0.125 mm
300 dots/in. 0.0033 in. x 0.084 mm x 0.0033 in. x 0.084 mm x
0.0039 in. 0.099 mm 0.0039 in. 0.099 mm
600 dots/in. 0.0016 in. x 0.042 mm x N/A N/A
0.0016 in. 0.042 mm
First dot location measured from 0.10 in. (2.5 mm 0.10 in. (2.5 mm
inside media backing edge 0.04 in. 1 mm) 0.04 in. 1 mm)
Maximum print 203 dots/in. 4.09 in. 104 mm 6.6 in. 168 mm
width
Minimum print length 1 dot row 1 dot row
Maximum 203 dots/in. 157 in. 3988 mm 102 in. 2590 mm
continuous print 300 dots/in. 73 in. 1854 mm 45 in. 1143 mm
length
600 dots/in. 20 in. 508 mm N/A N/A
Bar code Picket fence
modulus (non-rotated) orientation
(X) dimension 203 dots/in. 4.9 mil to 49 mil 4.9 mil to 49 mil
300 dots/in. 3.3 mil to 33 mil 3.3 mil to 33 mil
600 dots/in. 1.6 mil to 16 mil N/A
Ladder
(rotated) orientation
203 dots/in. 4.9 mil to 49 mil 4.9 mil to 49 mil
300 dots/in. 3.9 mil to 39 mil 3.3 mil to 33 mil
600 dots/in. 1.6 mil to 16 mil N/A

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System Description 35
Printing Specifications

Printing Specifications ZM400/RZ400 ZM600/RZ600


Programmable 203 dots/in. 2.4 in. (61 mm) per second 2.4 in. (61 mm) per second
constant print 3 in. through 10 in. per second in 3 in. through 10 in. per second in
speeds 1-in. increments (76 mm through 1-in. increments (76 mm through
254 mm per second in 25-mm 254 mm per second in 25-mm
increments) increments)
300 dots/in. 2.4 in. (61 mm) per second 2.4 in. (61 mm) per second
3 in. through 8 in. per second in 3 in. through 8 in. per second in
1-in. increments (76 mm through 1-in. increments (76 mm through
203 mm per second in 25-mm 203 mm per second in 25-mm
increments) increments)
600 dots/in. 1.5 in (38 mm) N/A
2 in. through 4 in. per second in
1-in. increments (51 mm through
102 mm per second in 25-mm
increments)
Thin film printhead with E3 Element Energy Control

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36 System Description
Media Specifications

Media Specifications

Media Specifications ZM400/RZ400 ZM600/RZ600


Label length Minimum Non-RFID
Tear-off 0.5 in. 13 mm 0.5 in. 13 mm
Peel-off 0.5 in. 13 mm 0.5 in. 13 mm
Rewind 0.5 in. 13 mm 0.5 in. 13 mm
Cutter 1 in. 25.4 mm 1.0 in. 25.4 mm
RFID Varies for each transponder type*
Maximum 200 or 39 in. 991 mm 39 in. 991 mm
300 DPI
600 DPI 20 in. 508 mm N/A N/A
Label width Minimum Non-RFID 1 in. 25.4 mm 2 in. 51 mm
RFID Varies for each transponder type*
Maximum Tear/Cutter 4.5 in. 114 mm 7.0 in. 178 mm
Peel/Rewind 4.25 in. 108 mm 6.75 in. 171 mm
Total thickness Minimum 0.0023 in. 0.058 mm 0.0023 in. 0.058 mm
(includes liner, if any) Maximum 0.010 in. 0.25 mm 0.010 in. 0.25 mm
Core size 3 in. 76 mm 3 in. 76 mm
Maximum roll diameter 8 in. 203 mm 8 in. 203 mm
Maximum fanfold pack size 8.0 in. 203 mm 8.0 in. 203 mm
(length x width x height) 4.5 in. 114 mm 7.0 in. 178 mm
6.2 in. 157 mm 6.2 in. 157 mm
Inter-label gap Minimum 0.079 in. 2 mm 0.079 in. 2 mm
Preferred 0.118 in. 3 mm 0.118 in. 3 mm
Maximum 0.157 in. 4 mm 0.157 in. 4 mm
Ticket/tag notch size (width x length) 0.25 in. 6 mm 0.25 in. 6 mm
0.12 in. 3 mm 0.12 in. 3 mm
Hole diameter 0.125 in. 3 mm 0.125 in. 3 mm
Notch or hole position (Centered Minimum 0.15 in. 3.8 mm 0.15 in. 3.8
from inner media edge) Maximum 2.25 in. 57 mm 3.5 in. 90 mm
Black mark Vertical length 0.098 in. to 2.5 to 0.098 in. to 2.5 to
dimensions 0.453 in. 11.5 mm 0.453 in. 11.5 mm
Horizontal width > 0.37 in. > 9.5 mm > 0.37 in. > 9.5 mm
Location Within 0.40 in. (1 mm) of inside media edge
Density, in Optical Density Units (ODU) > 1.0 ODU
Maximum media density 0.5 ODU
* See http://www.zebra.com/id/zebra/na/en/index/products/supplies/rfid_supplies/rfid_transponder_inlay.html for transponder
placement information.

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System Description 37
Ribbon Specifications

Ribbon Specifications
Ribbon can be wound with the coated side on the inside or outside. The ribbon used must
match the Thermal Transfer option installed. The standard Thermal Transfer option (black
ribbon spindle) uses ribbon coated on the outside, and the alternate Thermal Transfer option
(gray ribbon spindle) uses ribbon coated on the inside. For more information, see Ribbon
Overview on page 58.

Ribbon Specifications ZM400/RZ400 ZM600/RZ600


Ribbon width Minimum >2 in.* 51 mm* >2 in. 51 mm
(Zebra recommends using Maximum 4.3 in. 110 mm 6.85 in. 174 mm
ribbon at least as wide as the
media to protect the printhead
from wear.)
Standard lengths 2:1 media to 984 ft. 300 m 984 ft. 300 m
ribbon roll ratio
3:1 media to 1476 ft. 450 m 1476 ft. 450 m
ribbon roll ratio
Ribbon core inside diameter 1 in. 25.4 mm 1 in. 25.4 mm
Maximum ribbon roll size 3.2 in. 81.3 mm 3.2 in. 81.3 mm
* The narrowest width tested and approved for this printer is 2 in. (51 mm). You may be able to use narrower ribbon, as
long as the ribbon is wider than the media being used. To use a ribbon narrower than 2 in. (51 mm), test the ribbons
performance with your media to assure that you get the desired results.

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38 System Description
Printer Options

Printer Options

Option ZM400 ZM600 RZ400 RZ600


Cutter X X X X
Peel-off X X X X
Liner take-up X Not X Not
available available
Alternate Thermal Transfer option X Not X Not
(gray spindle), which uses ribbon coated on available available
the inside
Factory-installed 64 MB (58 MB user X X X X
available) Flash memory
300 dpi printhead X X X X
600 dpi printhead X Not Not Not
available available available
Rewind X X X X
External print server (10/100 or 10base-T) X X X X
Internal print server (10base-T) X X X X
Wireless print server X X X X
RFID reader/encoder Optional Optional Standard Standard

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2
Operations

This section assists the technician with out of the box installation, initial setup, and printer
operation.

Contents
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Select a Data Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Data Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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40 Operations

Contents (Continued)
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Enter and Use Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Print a Configuration Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Standard Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Additional Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
RFID Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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Operations 41
Before You Begin

Before You Begin


Review this checklist, and resolve any issues before you set up or use your printer.

Unpack and Inspect the Printer Have you unpacked the printer and inspected it for
damage? If you have not, see Unpack and Inspect the Printer on page 42.

Select a Site Have you selected an appropriate location for the printer? If you have not,
see Select a Site for the Printer on page 43.

Connect to a Data Source Have you determined how the printer will connect to a
data source (usually a computer)? For more information, see Select a Data
Communication Interface on page 44.

Attach a Power Cord Do you have the correct power cord for your printer? If you are
unsure, see Power Cord Specifications on page 49. To attach the power cord and connect
the printer to a power source, see Connect the Printer to a Power Source on page 48.

Select Media Do you have the correct media for your application? If you are unsure,
see Types of Media on page 50.

Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if
needed? If you are unsure, see Ribbon Overview on page 58.

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42 Operations
Handling the Printer

Handling the Printer


This section describes how to handle your printer.

Unpack and Inspect the Printer


When you receive the printer, immediately unpack it and inspect for shipping damage.
Save all packing materials.
Check all exterior surfaces for damage.
Raise the media door, and inspect the media compartment for damage to components.

If you discover shipping damage upon inspection:


Immediately notify the shipping company and file a damage report.
Keep all packaging material for shipping company inspection.

Important Zebra Technologies Corporation is not responsible for any damage incurred
during the shipment of the equipment and will not repair this damage under warranty.

Store the Printer


If you are not placing the printer into immediate operation, repackage it using the original
packing materials. You may store the printer under the conditions shown in Table 3.

Table 3 Storage Temperature and Humidity

Temperature Relative Humidity


40F to 140F (40 to 60C) 5% to 85% non-condensing

Ship the Printer


If you must ship the printer:
Turn off (O) the printer, and disconnect all cables.
Close the printhead.
Carefully pack the printer into the original container or a suitable alternate container to
avoid damage during transit. A shipping container can be purchased from Zebra if the
original packaging has been lost or destroyed.

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Operations 43
Select a Site for the Printer

Select a Site for the Printer


Consider the following when selecting an appropriate location for your printer.

Select a Surface
Select a solid, level surface of sufficient size and strength to accommodate the printer and
other equipment (such as a computer), if necessary. The choices include a table, countertop,
desk, or cart. For the printers weight and dimensions, see General Specifications on page 33.

Provide Proper Operating Conditions


This printer is designed to function in a wide range of environmental and electrical conditions,
including a warehouse or factory floor. For more information on the required conditions, see
General Specifications on page 33.

Table 4 shows the temperature and relative humidity requirements for the printer when it is
operating.

Table 4 Operating Temperature and Humidity

Mode Temperature Relative Humidity


Thermal Transfer 40 to 105F (5 to 40C) 20 to 85% non-condensing.
Direct Thermal 32 to 105F (0 to 40C) 20 to 85% non-condensing

Allow Proper Space


The printer should have enough space around it for you to be able to open the media door. To
allow for proper ventilation and cooling, leave open space on all sides of the printer.

Caution Do not place any padding or cushioning material behind or under the printer
because this restricts air flow and could cause the printer to overheat.

Provide a Data Source


If the printer will be located away from the data source (such as a computer), the selected site
must provide the appropriate connections to that data source. For more information on the
types of communication interfaces and their limitations, see Select a Data Communication
Interface on page 44.

Provide a Power Source


Place the printer within a short distance of a power outlet that is easily accessible.

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44 Operations
Select a Data Communication Interface

Select a Data Communication Interface


Table 5 provides basic information about data communication interfaces that you can use to
connect your printer to a computer. You may send label formats to the printer through any data
communication interface that is available. Select an interface that is supported by both your
printer and your computer or your Local Area Network (LAN).

Table 5 also shows how to connect the different types of data cables to your printer and
computer. The connectors on the back of your computer may be in different locations than on
the sample computer shown in this section.

Caution Ensure that the printer power is off (O) before connecting data communications
cables. Connecting a data communications cable while the power is on (I) may damage the
printer.

Table 5 Data Communication Interfaces

Standard or
Interface Description
Optional
RS-232 Serial Standard Limitations and Requirements
Maximum cable length of 50 ft (15.24 m).
You may need to change printer parameters to match the host
computer.
You need to use a null-modem adaptor to connect to the printer
if using a standard modem cable.
Connections and Configuration The baud rate, number of
data and stop bits, the parity, and the XON/XOFF or DTR control
must match those of the host computer. See Standard Control
Panel Parameters on page 72 to view or change these parameters.

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Operations 45
Select a Data Communication Interface

Table 5 Data Communication Interfaces (Continued)

Standard or
Interface Description
Optional
IEEE 1284 Standard Limitations and Requirements
Bidirectional Parallel Maximum cable length of 10 ft (3 m).
Recommended cable length of 6 ft (1.83 m).
No printer parameter changes required to match the host
computer.
Connections and Configuration No additional
configuration is necessary.

USB Standard Limitations and Requirements


Maximum cable length of 16.4 ft (5 m).
No printer parameter changes required to match the host
computer.
Connections and Configuration No additional
configuration is necessary.
Caution Be careful not to plug the USB cable into the wired
Ethernet print server connector on the printer because doing so
will damage the connector.

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46 Operations
Select a Data Communication Interface

Table 5 Data Communication Interfaces (Continued)

Standard or
Interface Description
Optional
Internal wired Limitations and Requirements
Ethernet print server Can print to the printer from any computer on your LAN.
Can communicate with the printer through the printers web
pages when in ZPL mode.
The printer must be configured to use your LAN.
Connections and Configuration Refer to the ZebraNet
10/100 Print Server User and Reference Guide for configuration
instructions. A copy of this manual is available at
http://www.zebra.com/manuals or on the user CD that came with
your printer.
Note To use this connection, you may need to remove a
factory-installed plug that is designed to keep someone
from accidentally plugging a USB connector into this port.

Wireless Ethernet Optional Limitations and Requirements


print server Can print to the printer from any computer on your Wireless
Local Area Network (WLAN).
Can communicate with the printer through the printers web
pages when in ZPL mode.
The printer must be configured to use your WLAN.
Configuration Refer to the ZebraNet Wireless User Guide for
configuration instructions. A copy of this manual is available at
http://www.zebra.com/manuals or on the user CD that came with
your printer.

Data Cables
You must supply all data cables for your application.

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Operations 47
Select a Data Communication Interface

Ethernet cables do not require shielding, but all other data cables must be fully shielded and
fitted with metal or metallized connector shells. Unshielded data cables may increase radiated
emissions above the regulated limits.

To minimize electrical noise pickup in the cable:


Keep data cables as short as possible.
Do not bundle the data cables tightly with the power cords.
Do not tie the data cables to power wire conduits.

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48 Operations
Connect the Printer to a Power Source

Connect the Printer to a Power Source


The AC power cord must have a three-prong female connector on one end that plugs into the
mating AC power connector at the rear of the printer. If a power cable was not included with
your printer, refer to Power Cord Specifications on page 49.

Caution For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific three-conductor grounded
plug configuration.

To connect the printer to a power source, complete these steps:

1. Toggle the printer power switch to the off (O) position.

2. Plug the power cord into the AC power connector (1) on the rear of the printer.

3. Plug the other end of the power cord into a power outlet near the printer.

4. Turn on (I) the printer.

The control panel LCD and lights activate, indicating that the printer is booting up.

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Operations 49
Connect the Printer to a Power Source

Power Cord Specifications

Caution For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific, three-conductor grounded
plug configuration.

Depending on how your printer was ordered, a power cord may or may not be included. If one
is not included or if the one included is not suitable for your requirements, see Figure 6 and
refer to the following guidelines:
The overall cord length must be less than 9.8 ft. (3 m).
The cord must be rated for at least 10 A, 250 V.
The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic
interference.

Figure 6 Power Cord Specifications

2 3
1

1 AC power plug for your countryThis should bear


the certification mark of at least one of the known
international safety organizations (Figure 7).
2 3-conductor HAR cable or other cable approved for
your country.
3 IEC 320 connectorThis should bear the
certification mark of at least one of the known
international safety organizations (Figure 7).
4 Length 9.8 ft. (3 m). Rating 10 Amp, 250 VAC.

Figure 7 International Safety Organization Certifications

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50 Operations
Types of Media

Types of Media
The printer can use various types of media (Table 6).

Table 6 Types of Media

Media Type How It Looks Description


Non-Continuous Labels have adhesive backing that sticks them to a liner, and
Roll Media they are separated by gaps, holes, notches, or black marks.
Tags are separated by perforations.

Continuous Roll media is wound on a 3-in. (76-mm) core.


Roll Media Continuous roll media does not have gaps, holes, notches, or
black marks to indicate label separations. This allows the
image to be printed anywhere on the label. Sometimes a cutter
is used to cut apart individual labels.

RFID Smart Radio frequency identification (RFID) smart labels are


Media made from the same materials and adhesives as non-RFID
(for use only with labels. Each label has an RFID transponder, made of a chip
printers that have and an antenna, embedded between the label and the liner
an RFID (sometimes called an inlay). The shape of the transponder
reader/encoder varies by manufacturer and is visible through the label.
installed) All smart labels have memory that can be read, and many
have memory that can be encoded.
Important Transponder placement within a label
depends on the transponder type and the printer model.
Make sure that you are using the correct smart media
for your printer.

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Operations 51
Print Modes and Printer Options

Print Modes and Printer Options


The printer can use different print modes and options for label removal (Table 7). Use a print
mode that matches the media being used and the printer options available. For more
information on the types of media, see Types of Media on page 50. To select a print mode, see
Select Print Mode on page 75.

Print Mode Descriptions and Printer Requirements

Table 7 Print Modes and Printer Options

Print Mode When to Use/Printer Options Required Printer Actions


Tear-Off Use for most applications. This mode can The printer prints label formats as it
(default setting) be used with any printer options and most receives them. The printer operator can tear
media types. off the printed labels any time after they
print.
Peel-Off Use only if the printer has the Peel-Off, The printer peels the label from the liner
Liner Take-Up, or Rewind option. during printing and then pauses until the
label is removed.
In Peel-Off mode, the liner exits the front of
the printer. In Peel-Off mode with Liner
Take-Up, the liner winds onto the liner
take-up spindle or the rewind spindle.
Cutter Use if the printer has a cutter option when The printer prints a label and then cuts it
you want the labels to be cut apart. free.
Delayed Cut Use if the printer has a cutter option when The printer prints a label, pauses, and cuts
you want the printer to cut the labels apart the label when it receives the ~JK (delayed
at a signal. cut) ZPL command.
Rewind Use if the printer has the Rewind option and The printer prints without pausing between
you want the labels to rewind on a core. labels. The media or liner is wound onto a
core after printing.
RFID Use when printing RFID labels with The printer increases throughput time when
RZ Series printers or with Z Series printers printing batches of RFID labels by
that have an optional RFID reader/encoder eliminating backfeed between labels
installed.
Linerless Peel Reserved for future options. Reserved for future options.
Linerless Reserved for future options. Reserved for future options.
Rewind
Linerless Tear Reserved for future options. Reserved for future options.

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52 Operations
Print Modes and Printer Options

Media Paths
Table 8 shows the media paths for print mode and printer option combinations using roll
media. Fanfold media uses the same print modes and printer options as roll media. RFID
printers can use all of these printer options and have the same media paths.

Table 8 Media Paths for Print Modes with Various Printer Options

Print Mode Printer Option Media Path


Tear-Off Printers with any
printer options can
use Tear-Off mode

Peel-Off Peel, Liner take-up,


or Rewind

Peel-Off (with Liner Liner take-up


Take-Up)

Rewind

Red solid lines = media, Blue dotted lines = backing only

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Operations 53
Print Modes and Printer Options

Table 8 Media Paths for Print Modes with Various Printer Options (Continued)

Print Mode Printer Option Media Path


Cutter or Cutter (shown with
Delayed Cut an optional catch
tray)

Rewind Rewind

Red solid lines = media, Blue dotted lines = backing only

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54 Operations
Load Media

Load Media
Use the instructions in this section to load media in Tear-Off mode (Figure 8). For instructions
for loading in other print modes, refer to the User Guide.

Figure 8 Tear-Off Mode Media Path

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.

To Load Roll Media in Tear-Off Mode, complete these steps:

1. Press the printhead release latch to open the printhead assembly. Lift the printhead until it
latches open.

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Operations 55
Load Media

2. Slide out the media guide.

3. Insert media into the printer. Follow the instructions for roll or fanfold media, as
appropriate.

Roll Media Fanfold Media

a. Remove and discard any tags or a. Flip down the media supply guide.
labels that are dirty or that are held
by adhesives or tape.

b. Flip down the media supply guide. b. Feed the media through the rear or
bottom access slot.
Rear Feed

c. Place the roll of media on the media


supply hanger. Push the roll as far
back as it will go.

Bottom Feed

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56 Operations
Load Media

Roll Media (Continued) Fanfold Media (Continued)

d. Flip up the media supply guide. c. Drape the media over the media
supply hanger.

e. Slide in the media supply guide until d. Flip up the media supply guide.
it touches the edge of the roll.

e. Slide in the media supply guide until


it touches the edge of the media.

4. Feed the media under the dancer assembly (1), the upper media sensor (2), and the ribbon
sensor (3). Slide the media back until it touches the inside back wall of the upper media
sensor.
3 2 1

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Operations 57
Load Media

5. Slide in the media guide until it touches the outer edge of the media.

6. Close the printhead assembly.

7. If the printer is paused (the Pause light is on), press PAUSE to enable printing.

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58 Operations
Ribbon Overview

Ribbon Overview
Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is
transferred to the media during the thermal transfer process.

When to Use Ribbon


Thermal transfer media requires ribbon for printing while direct thermal media does not.
To determine if ribbon must be used with a particular media, perform a media scratch test.

To perform a media scratch test, complete these steps:

1. Scratch the print surface of the media rapidly with your fingernail.

2. Did a black mark appear on the media?

If a black mark... Then the media is...


Does not appear on the media Thermal transfer. A ribbon is required.
Appears on the media Direct thermal. No ribbon is required.

Coated Side of Ribbon


Ribbon can be wound with the coated side on the inside or outside. The ribbon used must
match the Thermal Transfer option installed. The standard Thermal Transfer option (black
ribbon spindle) uses ribbon coated on the outside, and the alternate Thermal Transfer option
(gray ribbon spindle, available on the ZM400 and RZ400 only) uses ribbon coated on the
inside. If you are unsure which side of a particular roll of ribbon is coated, perform an adhesive
test or a ribbon scratch test to determine which side is coated.

1. Peel a label from its liner.

2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.

3. Peel the label off of the ribbon.

4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?

If ink from the ribbon... Then...


Adhered to the label The ribbon is coated on the outside and can be
used with the standard Thermal Transfer
option (black ribbon spindle). In the ribbon
loading procedure, instructions are marked
with this symbol.
Did not adhere to the label The ribbon is coated on the inside and can be
used with the alternate Thermal Transfer
option (gray ribbon spindle). In the ribbon
loading procedure, instructions are marked
with this symbol.

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Operations 59
Load Ribbon

Load Ribbon
Always use ribbon that is wider than the media to protect the printhead from wear. For direct
thermal printing, do not load ribbon in the printer.

The standard Thermal Transfer option (black ribbon spindle) uses ribbon coated on the
outside, and the alternate Thermal Transfer option (gray ribbon spindle) uses ribbon coated on
the inside. To avoid damaging your printer, follow the directions for the Thermal Transfer
option installed in your printer.

Figure 9 shows the ribbon paths for ribbon coated on the outside and ribbon coated on the
inside. The coated surfaces of the ribbon are shown in gray when they are visible. To
determine which side of a ribbon is printed, see Coated Side of Ribbon on page 58.

Figure 9 Ribbon Path

Ribbon Coated Outside Ribbon Coated Inside


(black ribbon spindle) (gray ribbon spindle)

1 1

2 2

3 3

4 4

5 5

1 Tension blade
2 Ribbon take-up spindle
3 Ribbon supply spindle
4 Printhead assembly
5 Printhead release latch

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60 Operations
Load Ribbon

To load ribbon, complete these steps:

1. Press the printhead release latch to open the printhead assembly. Lift the printhead until it
latches open.

2. Insert the ribbon into the printer. In this step, follow the instructions for the Thermal
Transfer option installed in your printer.
Ribbon Coated Outside Ribbon Coated Inside
(black ribbon spindle) (gray ribbon spindle)

a. Hold the ribbon with the loose end unrolling a. Hold the ribbon with the loose end unrolling
clockwise. counterclockwise.

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Operations 61
Load Ribbon

Ribbon Coated Outside Ribbon Coated Inside


(black ribbon spindle) (Continued) (gray ribbon spindle) (Continued)

b. Place the roll of ribbon on the ribbon supply b. Place the roll of ribbon on the ribbon supply
spindle (1) and push it all the way back. spindle (1) and push it all the way back.

1 1

c. Pull the end of the ribbon under the printhead c. Pull the end of the ribbon under the printhead
assembly (1) and out the front of the printer. assembly (1) and out the front of the printer.
Extend the ribbon approximately 24 in. Extend the ribbon approximately 24 in.
(610 mm) out of the printer. (610 mm) out of the printer.

1 1

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62 Operations
Load Ribbon

3. Close the printhead assembly.

4. Wind the ribbon clockwise onto the ribbon take-up spindle (1).

Ribbon Coated Outside Ribbon Coated Inside


(black ribbon spindle) (gray ribbon spindle)

1 1

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Operations 63
Load Ribbon

Remove Used Ribbon


To remove used ribbon, complete these steps:

1.
Caution Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may
damage the spindle.

If the ribbon has not run out, cut or break it before the ribbon take-up spindle (1).

2. To loosen the ribbon, squeeze it against the ribbon take-up spindle tension blades (1). At
the same time, turn the ribbon take-up spindle release knob counterclockwise (2).
The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.

3. Slide the used ribbon off of the ribbon take-up spindle and discard.

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64 Operations
Calibrate the Printer

Calibrate the Printer


The printer can be set to calibrate automatically, or you can calibrate it manually.

Auto Calibration
When the control panel setting for MEDIA POWER UP or HEAD CLOSE is set to
CALIBRATION, the printer automatically calibrates on power up or when the printhead is
closed. During auto calibration, the printer determines the label length and sensor settings. The
results of the auto calibration are stored in the printers memory and are retained even if printer
power is removed. These parameters remain in effect until the next calibration is performed.

Note If the control panel settings for MEDIA POWER UP or HEAD CLOSE are set to
LENGTH, NO MOTION, or FEED, the printer starts printing without auto calibrating. See
Select Media Power-Up Option on page 92 or Select Head Close Option on page 92.

Manual Calibration
Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the
media and ribbon are detected more accurately. If you change the type of ribbon or media,
your printer may operate better if you perform this calibration.

For instructions, refer to Calibrate Media and Ribbon Sensor Sensitivity on page 86.

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Operations 65
Adjust Printhead Pressure

Adjust Printhead Pressure


You may need to adjust printhead pressure if printing is too light on one side, if you use thick
media, or if the media drifts from side to side during printing.

See Figure 10. The ZM400 and RZ400 pressure adjustment dials have four possible settings
designated by blocks of increasing size embossed on the print mechanism. The smallest block
(fully counterclockwise) is considered position 1, and the largest block (fully clockwise) is
considered position 4. The ZM600 and RZ600 dials have seven settings instead of four.

Figure 10 Printhead Pressure Adjustment Dials

1 2

1 Outside dial
2 Inside dial

To set printhead pressure, complete these steps:

1. Use Table 9 or Table 10 to select the initial dial settings for your media, depending on
which printer you have.
Table 9 ZM400 and RZ400 Printhead Pressure

Media Width Inside Dial Outside Dial


1 in. (25.4 mm) 3 1
2 in. (51 mm) 4 1
3 in. (76 mm) 3 2
3.5 in. and up (89 mm and up) 3 3

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66 Operations
Adjust Printhead Pressure

Table 10 ZM600 and RZ600 Printhead Pressure

Media Width Inside Dial Outside Dial


2 in. (50 mm) 6 1
3 in. (75 mm) 6 2
4 in. (100 mm) 7 3
5 in. (125 mm) 7 4
5.5 in. and up (140 mm and up) 6 6

2. If necessary, adjust the pressure adjustment dials as follows:

If the media... Then...


Requires higher pressure to Increase both dials one position.
print well
Shifts left while printing Increase the outside dial setting one position, or
decrease the inside dial setting one position.
Shifts right while printing Increase the inside dial setting one position, or
decrease the outside dial setting one position.
Prints too lightly on the left side Increase the inside dial setting one position.
of the label.
Prints too lightly on the right Increase the outside dial setting one position.
side of the label.

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Operations 67
Setup Mode

Setup Mode
After you have installed the media and the Power-On Self Test (POST) is complete, the control
panel displays PRINTER READY. You may now set printer parameters for your application
using the control panel display and the buttons directly below it. If it becomes necessary to
restore the initial printer defaults, see FEED and PAUSE Self Test on page 120.
Important Certain printing conditions may require that you adjust printing parameters,
such as print speed, darkness, or print mode. These conditions include (but are not
limited to):
printing at high speeds
peeling the media
the use of extremely thin, small, synthetic, or coated labels

Because these and other factors affect print quality, run tests to determine the best
combination of printer settings and media for your application. A poor match may limit print
quality or print rate, or the printer may not function properly in the desired print mode.

Note If the printer is operating on an IP network and you have a ZebraNet wired or
wireless print server, you can change the printers parameters in these additional ways:
with ZebraLink WebView. For information, see the appropriate print server user guide.
with ZebraNet Bridge. For information, see the ZebraNet Bridge Enterprise Printer
Management User Guide.

Enter and Use Setup Mode


Use the LCD on the control panel to view and adjust printer settings through Setup mode.
When a parameter is changed, an asterisk (*) appears in the upper left corner of the display to
indicate that the value is different from the one currently active in the printer.

Press this key... To do the following...


SETUP/EXIT enter or exit Setup mode.
SELECT select or deselect a parameter.
PLUS (+) continue to the next parameter.
MINUS (-) return to the previous parameter in the cycle.

Exit Setup Mode


When you exit setup mode, you have several options for saving, changing, or not changing
parameters.

To leave Setup mode, complete these steps:

1. While in Setup mode, press SETUP/EXIT.


The LCD displays SAVE CHANGES.

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68 Operations
Setup Mode

2. Press PLUS (+) or MINUS (-) to display the save options:

LCD Description

PERMANENT Stores values in the printer even when power is turned off.
TEMPORARY Saves the changes until power is turned off.
CANCEL Cancels all changes made since you entered Setup mode,
except for changes made to the darkness and tear-off settings,
which go into effect as soon as they are made.
LOAD DEFAULTS Restores all parameters other than the network settings back to
the factory defaults. Use care when loading defaults because
you will need to reload all settings that you changed manually.
Note On non-RFID printers, loading factory defaults
causes the printer to auto-calibrate.

LOAD LAST SAVE Loads values from the last permanent save.
DEFAULT NET Restores the wired and wireless network settings back to
factory defaults.

3. Press SETUP/EXIT to select the displayed choice.


When the configuration and calibration sequence is done, PRINTER READY displays.

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Operations 69
Change Password-Protected Parameters

Change Password-Protected Parameters


Certain parameters, including the communication parameters, are password-protected by
factory default.

Caution Do not change password-protected parameters unless you have a complete


understanding of the parameters functions. If the parameters are set incorrectly, the printer
may function unpredictably.

The first time that you attempt to change a password-protected parameter, the printer displays
ENTER PASSWORD. Before you can change the parameter, you must enter the four-digit
numeric password. After you have entered the password correctly, you do not have to enter it
again unless you leave Setup mode by pressing SETUP/EXIT or by turning off (O) the printer.

To enter a password for a password-protected parameter, complete


these steps:

1. At the password prompt, use MINUS (-) to change the selected digit position.

2. When you have selected the digit that you wish to change, use PLUS (+) to increase the
selected digit value. Repeat these two steps for each digit of the password.

3. After entering the password, press SELECT.


The parameter you selected to change is displayed. If the password was entered correctly,
you can change the value.

Default Password Value


The default password value is 1234. The password can be changed using the Zebra
Programming Language (ZPL) command ^KP (Define Password) or using the printers web
pages (ZebraNet wired or wireless print server required).

Disable the Password Protection Feature


You can disable the password protection feature so that it no longer prompts you for a
password by setting the password to 0000 via the ^KP ZPL command. To re-enable the
password-protection feature, send the ZPL command ^KPx, where x can be any number from
1 to 9999.

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70 Operations
Print a Configuration Label

Print a Configuration Label


A configuration label lists the printer settings that are stored in configuration memory. After
you load the media, print a configuration label as a record of your printers current settings.
Keep the label to use when troubleshooting printing problems.

To print a configuration label, complete these steps:

1. On the control panel, press SETUP/EXIT.

2. Press PLUS (+) or MINUS (-) to scroll through the parameters until you reach
LIST SETUP.
3. Press SELECT to select the parameter.

4. Press PLUS (+) to confirm printing.


A configuration label prints (Figure 11).

Figure 11 Sample Configuration Label


Z Series RZ Series

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Operations 71
Print a Network Configuration Label

Print a Network Configuration Label


If you are using a print server, you can print a network configuration label after the printer is
connected to the network.

To print a network configuration label, complete these steps:

1. On the control panel, press SETUP/EXIT.

2. Press PLUS (+) or MINUS (-) to scroll through the parameters until you reach
LIST NETWORK.
3. Press SELECT to select the parameter.

4. Press PLUS (+) to confirm printing.


A network configuration label prints (Figure 12). An asterisk designates whether the
wired or wireless print server is active. If no wireless print server is installed, the wireless
portion of the label does not print.

Figure 12 Sample Network Configuration Label


(with a Wireless Print Server installed)

asterisk
indicating the
active print
server

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72 Operations
Standard Control Panel Parameters

Standard Control Panel Parameters


Table 11 shows parameters in the order in which they are displayed when you press PLUS (+)
after entering Setup mode. For parameters that do not appear in this table, see Additional
Control Panel Parameters on page 98.

Note Your label preparation software or the printer driver may override adjustments made
through the control panel. Refer to the software or driver documentation for more
information.

Table 11 Printer Parameters (Page 1 of 26)

Language/Parameter Action/Explanation
Adjust Print Darkness
Darkness (burn duration) settings depend on a variety of factors, including
ribbon type, media type, and the condition of the printhead. You may adjust
the darkness for consistent high-quality printing.
Important Set the darkness to the lowest setting that provides
good print quality. If the darkness is set too high, the ink may
smear, the ribbon may burn through, or the printhead may wear
prematurely.
If printing is too light or if there are voids in printed areas, increase the
darkness. If printing is too dark or if there is spreading or bleeding of
printed areas, decrease the darkness.
The FEED Self Test on page 118 can be used to determine the best darkness
setting. You may want to adjust darkness while performing the PAUSE Self
Test on page 117. Because the darkness setting takes effect immediately,
you can see the results on labels that are currently printing. Darkness
settings also may be changed by the driver or software settings.

Default Value (ZPL, APL-D, APL-I): +10


Range (ZPL, APL-D, APL-I): 00 to +30

Default Value (EPL): +7


Range (EPL): 00 to +15
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to increase darkness.
3. Press MINUS (-) to decrease darkness.
4. Press SELECT to accept any changes and deselect the parameter.

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Standard Control Panel Parameters

Table 11 Printer Parameters (Page 2 of 26)

Language/Parameter Action/Explanation
Adjust Print Speed
Adjusts the speed for printing a label (given in inches per second). Slower
print speeds typically yield better print quality. Print speed changes take
effect upon exiting Setup mode.

Default Value (ZPL, APL-I): 2 IPS


Default Value (EPL, APL-D): 6 IPS
Range:
200 dpi: 2 to 10 IPS
300 dpi: 2 to 8 IPS
600 dpi: 1 to 4 IPS
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to increase the value.
3. Press MINUS (-) to decrease the value.
4. Press SELECT to accept any changes and deselect the parameter.

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74 Operations
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Table 11 Printer Parameters (Page 3 of 26)

Language/Parameter Action/Explanation
Adjust the Tear-Off Position
This parameter establishes the position of the media over the
tear-off/peel-off bar after printing.
See Figure 13. Higher numbers move the media out (the tear line moves
closer to the leading edge of the next label), and lower numbers move the
media in (the tear line moves closer to the edge of the label just printed).

Figure 13 Tear-Off Position Adjustment

1
2

1 Media direction
2 Factory-set tear line location at position 00

Default Value (ZPL, EPL, APL-I): 0


Range (ZPL, EPL, APL-I): -120 to +120

Default Value (APL-D): +128i


Range (APL-D): +00i to +999i (inches), 0m to 2537m (metric)
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to increase the value. Each press adjusts the tear-off
position by four dot rows.
3. Press MINUS (-) to decrease the value. Each press adjusts the tear-off
position by four dot rows.
4. Press SELECT to accept any changes and deselect the parameter.

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Operations 75
Standard Control Panel Parameters

Table 11 Printer Parameters (Page 4 of 26)

Language/Parameter Action/Explanation
Select Print Mode
This parameter tells the printer how printed labels will be removed. Make
sure that you select a print mode that is compatible with your printer and
printer options. For information about how the print modes work with
different printer options, see Print Modes and Printer Options on page 51.

Default Value (non-RFID printers): TEAR-OFF


Selections (non-RFID printers): TEAR-OFF, PEEL-OFF, CUTTER,
DELAYED CUT, LINERLESS-P, LINERLESS-R, LINERLESS-T,
REWIND

Default Value (RFID printers): RFID MODE


Selections (RFID printers): TEAR-OFF, PEEL-OFF, CUTTER,
DELAYED CUT, LINERLESS-P, LINERLESS-R, RFID MODE,
LINERLESS-T, REWIND
Note The linerless selections apply only to printers that have the
Linerless option.

To change the value shown:


1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
APL-D only Set APL-D Compatibility Mode
Sets compatibility with DPL printers.

Default Value: OFF


Selections: ON, OFF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
APL-D only Set APL-D Control Codes

Default Value: STANDARD


Selections: STANDARD, MAINFRAME
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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76 Operations
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Table 11 Printer Parameters (Page 5 of 26)

Language/Parameter Action/Explanation
APL-D only Set Module A Storage Device for APL-D

Default Value: NONE


Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
APL-D only Set Module B Storage Device for APL-D

Default Value: NONE


Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
APL-I only Set Printer Resolution for APL-I
Sets the dot size for backward compatibility with some older APL-I
printers.

Default Value: 5 MIL


Selections: 5 MIL, 10 MIL, 15 MIL
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
Set Media Type
This parameter tells the printer the type of media that you are using (see
Types of Media on page 50 for more information). Selecting continuous
media requires that you include a label length instruction in your label
format (^LLxxxx if you are using ZPL or ZPL II).
When non-continuous media is selected, the printer feeds media to
calculate label length (the distance between two recognized registration
points of the inter-label gap, webbing, or alignment notch or hole).

Default Value: GAP/NOTCH


Selections: GAP/NOTCH, MARK, CONTINUOUS
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Operations 77
Standard Control Panel Parameters

Table 11 Printer Parameters (Page 6 of 26)

Language/Parameter Action/Explanation
Select Print Method
The print method parameter tells the printer the method of printing that you
want to use: direct thermal (no ribbon) or thermal transfer (using thermal
transfer media and ribbon).

Default Value: THERMAL TRANSFER


Selections: THERMAL TRANSFER, DIRECT THERMAL
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
Set Print Width
This parameter specifies the printable area across the width of the label.
Table 12 shows the ranges and default values for print width, which are
based on the printer model and the printhead resolution.

Table 12 Print Width Ranges and Maximum Values

Printhead
Printer
Resolution ZM400/RZ400 ZM600/RZ600
200 dpi Default Value: 832 Default Value: 1344
Range: 2 to 832 dots Range: 2 to 1344 dots
300 dpi Default Value: 1248 Default Value: 1984
Range: 2 to 1248 dots Range: 2 to 1984 dots
600 dpi Note 600 dpi is N/A
not available on the
RZ400.

Default Value: 2496


Range: 2 to 2496 dots

Note Setting the width too narrow can result in portions of a label
format not being printed on the media. Setting the width too wide
wastes formatting memory and can cause printing off of the label
and on the platen roller. This setting can affect the horizontal
position of the label format if the image was inverted using the
^POI ZPL II command.
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to change the value shown.
3. Press SELECT to accept any changes and deselect the parameter.

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78 Operations
Standard Control Panel Parameters

Table 11 Printer Parameters (Page 7 of 26)

Language/Parameter Action/Explanation
ZPL, EPL, APL-I Set Maximum Label Length
This parameter is used during the media portion of the calibration process.
Always set maximum label length to a value that is at least 1.0 in.
(25.4 mm) greater than the actual label length (Figure 14). If the value is set
to a smaller value than the label length, the printer assumes that continuous
media is loaded, and the printer cannot calibrate.
For example, if the label length is 5.0 inches (126 mm) including the
interlabel gap, set the parameter for 6.0 inches (152 mm). If the label length
APL-D only is 7.5 inches (190 mm), set the parameter for 9.0 inches (229 mm).

Figure 14 Label Length

}2

3
1

1 Label length (including interlabel gap)


2 Interlabel gap
3 Set maximum label length to approximately this value

Default Value (ZPL, EPL, APL-I): 39.0 inches (988 mm)


Selections (ZPL, EPL, APL-I): Values are adjustable in one-inch (25.4 mm)
increments

Default Value (APL-D): 1200i


Range (APL-D): 0000i to 9999i (o to 99.99 inches)
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to change the value shown.
3. Press SELECT to accept any changes and deselect the parameter.

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Operations 79
Standard Control Panel Parameters

Table 11 Printer Parameters (Page 8 of 26)

Language/Parameter Action/Explanation
Set Early Warning for Maintenance
When this feature is enabled, the printer provides warnings when the
printhead needs to be cleaned.

Default Value: MAINT. OFF


Selections: MAINT. OFF, MAINTENANCE ON
To change the Early Warning settings:
1. Press SELECT to select the parameter.
2. When the LCD displays EARLY WARNING MAINTENANCE, press
PLUS (+) or MINUS (-) to toggle between OFF and ON. (If you are
prompted for a password, enter your password using the instructions in
Change Password-Protected Parameters on page 69.)
3. Exit Setup mode and save changes to enable additional parameters
related to the early warning system.
4. Enter Setup mode again and go to the following parameters to enter the
printhead cleaning interval and the printhead life.
5. Press SELECT to accept any changes and deselect the parameter.
Set Printhead Cleaning Interval for Early Warning
This parameter appears only when Early Warning for Maintenance is
enabled. This value should correspond to the length of the media or ribbon
roll that you are using.

Default Value: 450 M/1476 FT


Selections: 100 M/328 FT to 450 M/1476 FT in 50 M increments
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to set the printhead cleaning interval to
the desired number of inches of media or ribbon.
When the printhead reaches the set length, WARNING CLEAN
PRINTHEAD appears on the LCD. If the alert function is enabled, the
printer generates an alert.
3. Press SELECT to accept any changes and deselect the parameter.
Reset Printhead Cleaning Counter for Early Warning
This parameter appears only when Early Warning for Maintenance is
enabled.
To reset the printhead cleaning counter:
1. Press SELECT to select the parameter.
2. Did you clean the printhead?
If you cleaned the printhead, press PLUS (+) to select YES.
If you did not clean the printhead, press MINUS (-) to select NO.
3. Press SELECT to accept any changes and deselect the parameter.

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80 Operations
Standard Control Panel Parameters

Table 11 Printer Parameters (Page 9 of 26)

Language/Parameter Action/Explanation
Set Printhead Life for Early Warning
This parameter appears only when Early Warning for Maintenance is
enabled. Set this value to the number of inches of media that the printhead
is expected to print.

Default Value: 1,000,000 inches


Range: 100 to 1,000,000 inches
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move the cursor.
3. Press PLUS (+) to increase the value of the digit.
When the printhead reaches the set length, WARNING REPLACE
HEAD appears on the LCD. If the alert function is enabled, the printer
generates an alert.
4. Press SELECT to accept any changes and deselect the parameter.
Reset Printhead Life Counter for Early Warning
This parameter appears only when Early Warning for Maintenance is
enabled.
To reset the printhead life counter:
1. Press SELECT to select the parameter.
2. Did you replace the printhead?
If you replaced the printhead, press PLUS (+) to select YES.
If you did not replace the printhead, press MINUS (-) to select NO.
3. Press SELECT to accept any changes and deselect the parameter.
View Non-Resettable Counter
This parameter displays the total length of media that the printer has
printed. You can use ZPL commands to change the unit of measure for this
counter. For the commands, refer to the ZPL Programming Guide.

View User-Controlled Counter 1


This parameter displays the total length of media that the printer has printed
since this parameter was last reset. You can use ZPL commands to change
the unit of measure and reset this counter. For the commands, refer to the
ZPL Programming Guide.

View User-Controlled Counter 2


This parameter displays the total length of media that the printer has printed
since this parameter was last reset. You can use ZPL commands to change
the unit of measure and reset this counter. For the commands, refer to the
ZPL Programming Guide.

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Operations 81
Standard Control Panel Parameters

Table 11 Printer Parameters (Page 10 of 26)

Language/Parameter Action/Explanation
Print Counter Readings
Prints a label that lists the odometer readings for the following:
the non-resettable counter
the two user-controlled counters
the Early Warning for Maintenance counters, which indicate when the
printhead was last cleaned and the printhead life
If the Early Warning for Maintenance feature is disabled, the counters
related to it do not print.
To print a list of the odometer readings:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to print the odometer readings.
3. Press SELECT to deselect the parameter.
ZPL, EPL, APL-D List Fonts
This option prints a label that lists the available fonts in the printer,
including standard printer fonts plus any optional fonts. Fonts may be
stored in RAM or Flash memory.
To print a list of the available fonts:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
ZPL only List Bar Codes
This option prints a label that lists the available bar codes in the printer. Bar
codes may be stored in RAM or Flash memory.
To print a list of the available bar codes:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
ZPL, EPL, APL-D List Images
This option prints a label that lists the available images stored in the
printers RAM, Flash memory, or optional memory card.
To print a list of the available images:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.

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82 Operations
Standard Control Panel Parameters

Table 11 Printer Parameters (Page 11 of 26)

Language/Parameter Action/Explanation
ZPL, EPL, APL-D List Formats
This option prints a label that lists the available formats stored in the
printers RAM, Flash memory, or optional memory card.
To print a list of the available formats:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
ZPL, EPL, APL-D List Setup
This option prints a configuration label (see Figure 11 on page 70), which
lists the current printer configuration.
To print a configuration label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
APL-I only

APL-I only Print Software Configuration Label


A software configuration label lists pages, formats, and bar codes that are
defined for the printer. Other printer settings also are included.
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
APL-I only Print Hardware Configuration Label
A hardware configuration label lists the memory options, printer metrics,
and printhead information.
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.

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Standard Control Panel Parameters

Table 11 Printer Parameters (Page 12 of 26)

Language/Parameter Action/Explanation
APL-I only Print Quality Test Label
A print quality test label contains test bar codes and relevant printer
settings.
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
APL-I only Print Pitch Test Label
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.

List Network Settings


This option prints a network configuration label (see Figure 12
on page 71), which lists the settings for any print server that is installed.
To print a network configuration label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
ZPL, EPL List All
This option prints labels that list the available fonts, bar codes, images,
formats, and the current printer and network configurations.
To print labels for all settings:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
APL-I only Print Stored APL-I Page
Up to 20 pages can be stored and printed.
Selections: 0 through 19

Default Value: 0
To modify this parameter:
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.

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Standard Control Panel Parameters

Table 11 Printer Parameters (Page 13 of 26)

Language/Parameter Action/Explanation
APL-I only Print Stored APL-I Format
Up to 100 formats can be stored and printed.
Selections: 0 through 99

Default Value: 0
To modify this parameter:
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
Format Memory Card
Note This parameter appears only when a Wireless Plus option
board with the flash chip populated is installed.

This option erases all previously stored information from the 64 MB flash
chip.
Caution This option completely erases the flash chip.
To format a memory card:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select A: or OPT:MEM (APL-D only).
If your printer is set to require a password, you are prompted to enter
the password.
3. Enter the password. For instructions, see Change Password-Protected
Parameters on page 69.
4. Press the appropriate button again to select the desired card.
The display shows ARE YOU SURE?.
5. Do you want to continue?
Press MINUS (-) to select NO to cancel the request and return to
FORMAT CARD prompt.
Press PLUS (+) to select YES and begin initialization.
When initialization is complete, the control panel displays
FORMATTING CARD COMPLETED.
Note Depending on the amount of memory in the memory card,
initialization may take up to 5 minutes to complete.

6. Press SELECT to deselect the parameter.

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Table 11 Printer Parameters (Page 14 of 26)

Language/Parameter Action/Explanation
Initialize Flash Memory
This option erases all previously stored information from Flash memory.
Caution This option completely erases the Flash memory.
To initialize Flash memory:
1. Press SELECT to select the parameter.
2. If prompted for a password, enter the printer password. For
instructions, see Change Password-Protected Parameters on page 69.
The display shows INITIALIZE FLASH?
3. Press PLUS (+) to select YES.
The display shows ARE YOU SURE?.
4. Do you want to continue?
Press MINUS (-) to select NO to cancel the request and return to the
INITIALIZE FLASH prompt.
Press PLUS (+) to select YES and begin initialization.
When initialization is complete, the control panel displays
INITIALIZING MEMORY COMPLETED.
Note Depending on the amount of free FLASH memory,
initialization may take up to 1 minute to complete.

5. Press SELECT to accept any changes and deselect the parameter.


Print Sensor Profile
A sensor profile shows sensor settings compared to actual sensor readings.
This label (which will extend across several actual labels or tags) can be
used to troubleshoot printing problems. To interpret the results of the
sensor profile, see Sensor Profile on page 122.

To print a sensor profile:


1. Press SELECT to select the parameter.
2. Press PLUS (+) to start this standard calibration procedure and print a
media sensor profile.
3. If the sensitivity of the sensors must be adjusted, perform Calibrate
Media and Ribbon Sensor Sensitivity on page 86.
4. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 15 of 26)

Language/Parameter Action/Explanation
Calibrate Media and Ribbon Sensor Sensitivity
Use this procedure to adjust sensitivity of media and ribbon sensors.
Important Follow this procedure exactly as presented. All of the
steps must be performed even if only one of the sensors requires
adjustment. You may press MINUS (-) at any step in this procedure
to cancel the process.
To perform a media and ribbon sensor calibration:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to start the calibration procedure.
The LOAD BACKING prompt displays.
3. Open the printhead.
4. Remove approximately 8 in. (203 mm) of labels from the backing, and
pull the media into the printer so that only the backing is between the
media sensors.
5. Leave the printhead open.
6. Press PLUS (+) to continue.
The REMOVE RIBBON prompt displays.
7. Remove the ribbon (if used).
8. Close the printhead.
9. Press PLUS (+) to continue.
The message CALIBRATING PLEASE WAIT displays.
The printer adjusts the scale (gain) of the signals that it receives from
the media and ribbon sensors based on the specific media and ribbon
combination being used. On the sensor profile, this essentially
corresponds to moving the peak of the graph up or down to optimize
the readings for your application.
When calibration is complete, RELOAD ALL displays.
10. Open the printhead and pull the media forward until a label is
positioned under the media sensor.
11. Reload the ribbon (if used).
12. Close the printhead.
13. Press PLUS (+) to continue.
The printer performs an auto-calibration. During this process, the
printer checks the readings for the media and ribbon based on the new
scale established, determines the label length, and determines the print
mode. To see the new readings on the new scale, print a sensor profile.
14. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 16 of 26)

Language/Parameter Action/Explanation
Set Parallel Communications
Select the communications port that matches the one being used by the host
computer.

Default Value: BIDIRECTIONAL


Selections: BIDIRECTIONAL, UNIDIRECTIONAL
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Serial Communications
Select the communications port that matches the one being used by the host
computer. This setting applies only when the serial port is used.
Note Select RS232 if you are using an external adapter to enable
RS422/485 operation.

Default Value: RS232


Selections: RS232, RS485 MULTIDROP
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
Set Baud
This setting applies only when the serial port is used. The baud setting of
the printer must match the baud setting of the host computer for accurate
communications to take place. Select the value that matches the one being
used by the host computer.

Default Value: 9600


Selections (ZPL, APL-I, APL-D): 300, 600, 1200, 2400, 4800, 9600, 14400,
19200, 28800, 38400, 57600, 115200
Selections (EPL): 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 17 of 26)

Language/Parameter Action/Explanation
Set Data Bits
This setting applies only when the serial port is used. The data bits of the
printer must match the data bits of the host computer for accurate
communications to take place. Set the data bits to match the setting being
used by the host computer.

Default Value: 8 BITS


Selections: 7 BITS, 8 BITS
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to toggle between the options.
3. Press SELECT to accept any changes and deselect the parameter.
Set Parity
This setting applies only when the serial port is used. The parity of the
printer must match the parity of the host computer for accurate
communications to take place. Select the parity that matches the one being
used by the host computer.

Default Value: NONE


Selections: EVEN, ODD, NONE
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
Set Host Handshake
This setting applies only when the serial port is used. The handshake
protocol of the printer must match the handshake protocol of the host
computer for communication to take place. Select the handshake protocol
that matches the one being used by the host computer.

Default Value (ZPL, APL-D): XON/XOFF


Selections (ZPL, APL-D): XON/XOFF, DSR/DTR, RTS/CTS

Default Value (APL-I): XON/XOFF


Selections (APL-I): XON/XOFF, DSR/DTR, RTS/CTS, APL-I

Default Value (EPL): DTR & XON/XOFF


Selections (EPL): DTR & XON/XOFF, DTR
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 18 of 26)

Language/Parameter Action/Explanation
APL-I only Send APL-I Status Response
Determines if a response is sent after inquiry commands.

Default Value: ON
Selections: ON, OFF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to toggle between the options.
3. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Protocol
Protocol is a type of error checking system. Depending on the selection, an
indicator may be sent from the printer to the host computer signifying that
data has been received. Select the protocol that is requested by the host
computer. Further details on protocol can be found in the ZPL
Programming Guide.

Default Value: NONE


Selections: NONE, ZEBRA, ACK_NAK
Note ZEBRA is the same as ACK_NAK, except that ZEBRA
response messages are sequenced. If ZEBRA is selected, the printer
must use DSR/DTR for host handshake protocol.
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Network ID
This parameter assigns a unique number to the printer when the printer is
operating in an RS422/485 multi-drop network environment (an external
RS422/485 adapter is required). This gives the host computer the means to
address a specific printer. This does not affect TCP/IP or IPX networks.

Default Value: 000


Range: 000 to 999
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to increase the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 19 of 26)

Language/Parameter Action/Explanation
Set Communications Mode
The communication diagnostics mode is a troubleshooting tool for
checking the interconnection between the printer and the host computer.
For more information, see Communications Diagnostics Test on page 121.

Default Value: NORMAL MODE


Selections: NORMAL MODE, DIAGNOSTICS
To select communication diagnostics mode:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to toggle between the options.
3. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Control Prefix Character
The printer looks for this two-digit hex character to indicate the start of a
ZPL/ZPL II control instruction.
Note Do not use the same hex value for the control, format, and
delimiter character. The printer must see different characters to
work properly.

Default Value: 7E ~
Range: 00 to FF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to increase the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Format Prefix Character
The format prefix is a two-digit hex value used as a parameter place marker
in ZPL/ZPL II format instructions. The printer looks for this hex character
to indicate the start of a ZPL/ZPL II format instruction. See the ZPL
Programming Guide for more information.
Note Do not use the same hex value for the control, format, and
delimiter character. The printer must see different characters to
work properly.

Default Value: 5E ^
Range: 00 to FF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to increase the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.

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Standard Control Panel Parameters

Table 11 Printer Parameters (Page 20 of 26)

Language/Parameter Action/Explanation
ZPL only Set Delimiter Character
The delimiter character is a two-digit hex value used as a parameter place
marker in ZPL/ZPL II format instructions. See the ZPL Programming
Guide for more information.
Note Do not use the same hex value for the control, format, and
delimiter character. The printer must see different characters to
work properly.

Default Value: 2C ,
Range: 00 to FF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to increase the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.
ZPL only Select ZPL Mode
The printer remains in the selected mode until it is changed by this
parameter or by using a ZPL/ZPL II command. The printer accepts label
formats written in either ZPL or ZPL II, eliminating the need to rewrite any
ZPL formats that already exist. See the ZPL Programming Guide for more
information on the differences between ZPL and ZPL II.

Default Value: ZPL II


Range: ZPL II, ZPL
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to toggle between the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 21 of 26)

Language/Parameter Action/Explanation
Select Media Power-Up Option
This parameter sets the action of the media when you turn on the printer.

Default Value (non-RFID printers): CALIBRATION


Default Value (RFID printers): FEED
Selections: CALIBRATION, SHORT CAL, LENGTH, NO MOTION,
FEED
Calibration adjusts sensor levels and thresholds, determines length,
and feeds the media to the next web.
Short Cal sets media and web thresholds without adjusting sensor
gain, determines length, and feeds the media to the next web.
Length determines label length using current sensor values, and feeds
the media to the next web.
No Motion tells the printer not to move the media. You must
manually ensure that the web is positioned correctly, or press feed to
position the next web.
Feedfeeds the labels to the first registration point.
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
Select Head Close Option
This parameter sets the action of the media when you close the printhead.

Default Value (non-RFID printers): CALIBRATION


Default Value (RFID printers): FEED
Selections: CALIBRATION, SHORT CAL, LENGTH, NO MOTION,
FEED
Calibration adjusts sensor levels and thresholds, determines length,
and feeds the media to the next web.
Short Cal sets media and web thresholds without adjusting sensor
gain, determines length, and feeds the media to the next web.
Length determines label length using current sensor values, and feeds
the media to the next web.
No Motion tells the printer not to move the media. You must
manually ensure that the web is positioned correctly, or press feed to
position the next web.
Feedfeeds the labels to the first registration point.
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Standard Control Panel Parameters

Table 11 Printer Parameters (Page 22 of 26)

Language/Parameter Action/Explanation
Select Backfeed Sequence
This parameter sets when label backfeed occurs after a label is removed in
some print modes. It has no effect in Rewind mode. This setting is
superseded by ~JS when received as part of a label format (see the ZPL
Programming Guide for more information).

Default Value: DEFAULT (90%)


Selections: DEFAULT, AFTER, OFF, BEFORE, 10%, 20%, 30%, 40%,
50%, 60%, 70%, 80%
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
ZPL, EPL, APL-D Adjust Label Top Position
This parameter adjusts the print position vertically on the label. Positive
numbers adjust the label top position farther down the label (away from the
printhead) by the specified number of dots. Negative numbers adjust the
position up the label (toward the printhead).

Default Value: +000


Range (ZPL, EPL): -120 to +120
APL-I only Range (APL-D): 0.64i to 0.64i (when printer is set to operate in inches)
Range (APL-I): 10 to 4000
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to increase the value.
3. Press MINUS (-) to decrease the value.
4. Press SELECT to accept any changes and deselect the parameter.
APL-I only Adjust Label Left Position
The label left position adjusts the print position horizontally on the label.
Positive numbers move the left edge of the image toward the center of the
label by the number of dots selected while negative numbers shift the left
edge of the image toward the left edge of the label.

Default Value: +0000


Range: 9999 to +9999
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to increase the value.
3. Press MINUS (-) to decrease the value.
4. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 23 of 26)

Language/Parameter Action/Explanation
Adjust Left Position
This parameter adjusts the print position horizontally on the label. Positive
numbers adjust printing to the left by the specified number of dots.
Negative numbers shift printing to the right.

Default Value: 0000


Range: 9999 to +9999 dots
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move the cursor.
3. Press PLUS (+) to change between +/- and to increase the value of the
digit. For a negative value, enter the value before changing to the
minus sign.
4. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Reprint Mode
When reprint mode is enabled, you can reprint the last label printed either
by issuing the ~PR ZPL command or by pressing MINUS (-) on the control
panel.

Default Value: DISABLED


Selections: ENABLED, DISABLED
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to toggle between the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Standard Control Panel Parameters

Table 11 Printer Parameters (Page 24 of 26)

Language/Parameter Action/Explanation
See next column View Sensor Settings
These parameters are automatically set during the calibration procedure
and should be changed only by a qualified service technician. Refer to the
ZPL II Programming Guide for information on these parameters.
To skip these parameters:
1. Press PLUS (+) to skip each of the following parameters:

ZPL only Select Format Convert


Selects the bitmap scaling factor. The first number is the original dots per
inch (dpi) value; the second, the dpi to which you would like to scale.

Default Value: NONE


Selections: NONE, 150 300, 150 600, 200 600, 300 600
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Table 11 Printer Parameters (Page 25 of 26)

Language/Parameter Action/Explanation
Select Idle Display
This parameter selects the LCD options for the real-time clock.
Note If the default value is not selected, pressing PLUS (+) or
MINUS (-) briefly displays the firmware version of the printer.

Default Value: FIRMWARE (FW) VERSION


Selections: MM/DD/YY (24HR), MM/DD/YY (12HR), DD/MM/YY
(24HR), DD/MM/YY (12HR), FW VERSION
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
Set Real-Time Clock (RTC) Date
This parameter allows you to set the date following the convention selected
in IDLE DISPLAY.
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to change the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.
Set RTC Time
This parameter allows you to set the time following the convention selected
in IDLE DISPLAY.
To change the value shown:
1. Press SELECT to select the parameter.
2. Press the left oval MINUS (-) to move to the next digit position.
3. Press the right oval PLUS (+) to change the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.
Specify Password Level
This parameter allows you to select whether certain factory-selected menu
items or all menu items are password protected.

Default Value: SELECTED ITEMS


Selections: SELECTED ITEMS, ALL ITEMS
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to toggle between the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Standard Control Panel Parameters

Table 11 Printer Parameters (Page 26 of 26)

Language/Parameter Action/Explanation
Select the Display Language
This parameter changes the language displayed on the LCD. Each language
selection is displayed in the language itself.

Default Value: ENGLISH


Selections: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN,
NORWEGIAN, PORTUGUESE, SWEDISH, DANISH, SPANISH 2,
DUTCH, FINNISH, JAPANESE, KOREAN, SIMPLIFIED CHINESE,
TRADITIONAL CHINESE

To change the value shown:


1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Additional Control Panel Parameters

Additional Control Panel Parameters


Additional parameters appear in the following situations.
When a Radio Frequency Identification (RFID) reader is installed. These parameters are
shown in Table 13 on page 99.
When a wired print server is installed in the printer. For more information, refer to the
ZebraNet 10/100 Print Server User and Reference Guide
When a wireless print server is installed in the printer. Refer to the ZebraNet Wireless
User Guide.

Copies of the print server manuals and the RFID Programming Guide are available at
http://www.zebra.com/manuals or on the user CD that came with your printer.

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Additional Control Panel Parameters

RFID Control Panel Parameters


The parameters shown in Table 13 display only if the printer has an RFID reader installed.

Table 13 RFID Parameters (Page 1 of 2)

Parameter Action/Explanation
Calibrate RFID Tag

RUN If the media being used does not conform to transponder placement
RFID TAG CALIB requirements for your printer, use the RUN option to have the printer
RESTORE RUN determine the optimum programming position for the non-standard labels.
Important Do not perform transponder calibration for RFID
media that meets the transponder placement specifications for your
printer. RFID tag calibration is necessary only if the transponder is
not in the ideal location for programming at the printers default
position.
The printer feeds an RFID label one millimeter at a time while taking
readings (via the READ TAG command and the WRITE TAG commands)
to profile the RFID transponder. Based on the results, the printer
determines the optimum programming position for the media and saves the
position to nonvolatile memory (the value is saved even if the power is
turned off). The calibrated value is used as the programming position for
the ^RS command unless the command specifies a different value.
Tag calibration takes into account the print mode, backfeed mode, and tear
off position. The ^HR ZPL command performs the same calibration and
returns a results table to the host. An auto-calibration occurs after the tag
calibration. This realigns the media to its proper rest position and updates
the media tracking values in the printer.
To restore the programming position to the default:
1. Press to select RESTORE.
To calibrate an RFID tag:
1. Load the printer with RFID media.
2. Close the printhead.
3. Press to select RUN.
4.
View or Change RFID Read Power
This parameter displays the current value for RFID read power.
Default: 16
RFID READ PWR Selections: 0 to 30
16
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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Table 13 RFID Parameters (Page 2 of 2)

Parameter Action/Explanation
View or Change RFID Write Power
This parameter displays the current value for RFID write power.
Default: 16
RFID WRITE PWR Selections: 0 to 30
16
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
RFID Error Status
During an error condition, an error message shows on the second line of the
display. This field cannot be modified. For more information on an error
RFID ERR STATUS message, refer to the RFID Programming Guide.

Specify RFID Tag Type


Select the RFID tag type that you are using.
Note RFID transponders operate on different frequencies. You
RFID TAG TYPE must use a frequency that complies with local regulations in your
GEN2 country.
Default: GEN 2 (EPC Class 1, Gen 2)
Selections: GEN 2 (EPC Class 1, Gen 2)
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.

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3
Troubleshooting

This section provides information about LCD, print quality, communications, and other errors
that you might need to troubleshoot. The tables provide symptoms, diagnoses of probable
causes, and recommended actions that should result in proper printer operation. Working with
these tables, the technician can diagnose printer faults and determine the needed repair.

Contents
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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102
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 103.
Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media
and Ribbon Sensor Sensitivity on page 86.
Is the printer reporting a ribbon error when ribbon is loaded properly? If yes, see Calibrate
Media and Ribbon Sensor Sensitivity on page 86.
Are you experiencing problems with print quality? If yes, see Print Quality Problems
on page 107.
Are you experiencing communications problems? If yes, see Communications Problems
on page 111.

If the labels are not printing or advancing correctly, review this checklist:
Are you using the correct type of labels? Review the types of label in Types of Media
on page 50.
Are you using a label that is narrower than the maximum print width? See Set Print Width
on page 77.
Review the label- and ribbon-loading illustrations in Load Media on page 43 and Load
Ribbon on page 59.
Does the printhead need to be adjusted? See Adjust Printhead Pressure on page 65 for
more information.
Do the sensors need to be calibrated? See Calibrate Media and Ribbon Sensor Sensitivity
on page 86 for more information.

If none of the above suggestions correct the problem, review this checklist:
Perform one or more of the self-tests given in Printer Diagnostics on page 115. Use the
results to help identify the problem.
If you are still having problems, see Contacts on page 21 for customer support
information.

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Troubleshooting 103
LCD Error Messages

LCD Error Messages


The LCD displays messages when there is an error. See Table 14 for LCD errors, the possible
causes, and the recommended solutions.

Table 14 LCD Error Messages

LCD Display/
Possible Cause Recommended Solution
Printer Condition
The printhead was replaced with Install a genuine Zebra printhead.
ERROR CONDITION one that is not a genuine Zebra
INVALID HEAD printhead.

The ERROR light flashes.


The printer stops; the In thermal transfer mode, ribbon is Load ribbon correctly. See Load
not loaded or incorrectly loaded. Ribbon on page 59.
ERROR CONDITION
RIBBON OUT In thermal transfer mode, the 1. Load ribbon correctly. See Load
ribbon sensor is not detecting Ribbon on page 59.
ERROR light flashes. ribbon. 2. Calibrate the sensors. See
Calibrate Media and Ribbon
Sensor Sensitivity on page 86.
In thermal transfer mode, media is 1. Load media correctly. See Load
blocking the ribbon sensor. Media on page 43.
2. Calibrate the sensors. See
Calibrate Media and Ribbon
Sensor Sensitivity on page 86.
In thermal transfer mode, the 1. Print a sensor profile. See Print
printer did not detect the ribbon Sensor Profile on page 85. The
even though it is loaded correctly. ribbon out threshold (1) is likely
too high, above the black area that
indicates where the ribbon is
detected (2).

1
2

2. Calibrate the sensors or load


printer defaults. See Calibrate
Media and Ribbon Sensor
Sensitivity on page 86 or LOAD
DEFAULTS on page 68.

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104 Troubleshooting
LCD Error Messages

Table 14 LCD Error Messages (Continued)

LCD Display/
Possible Cause Recommended Solution
Printer Condition
Ribbon is loaded, but the printer is Ribbon is not required with direct
WARNING set for direct thermal mode. thermal media. If you are using direct
RIBBON IN thermal media, remove the ribbon. This
error message will not affect printing.
The RIBBON light is on; the If you are using thermal transfer media,
ERROR light flashes. The which requires ribbon, set the printer
ERROR light flashes. for Thermal Transfer mode. See Select
Print Method on page 77.
The media is not loaded or is Load media correctly. See Load Media
ERROR CONDITION loaded incorrectly. on page 54.
PAPER OUT
Misaligned media sensor. Check position of the media sensor.
The printer stops; the The printer is set for Install proper media type, or reset
ERROR light flashes. noncontinuous media, but printer for current media type and
continuous media is loaded. perform calibration.
The printhead is not fully closed. Close printhead completely.
ERROR CONDITION
HEAD OPEN The head open sensor is not Replace the sensor.
working properly.
The printer stops; the
ERROR light flashes.
The printhead has a faulty Replace the printhead.
THERMISTOR thermistor.
FAULT

The ERROR light flashes.

WARNING Caution An improperly connected printhead data or power cable


HEAD COLD 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
THERMISTOR properly connected. before performing this procedure.
FAULT Failure to do so can damage the
printhead.
1. Turn off (O) the printer.
ERROR CONDITION
2. Disconnect and reconnect the data
HEAD ELEMENT BAD
cable to the printhead.
3. Ensure that the cable connector is
The printer stops; the fully inserted into the printhead
ERROR light is on; the connector.
printer cycles through these
4. Turn on (I) the printer.
three messages.
The printhead has a faulty Replace the printhead.
thermistor.

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Troubleshooting 105
LCD Error Messages

Table 14 LCD Error Messages (Continued)

LCD Display/
Possible Cause Recommended Solution
Printer Condition

WARNING Caution An improperly connected printhead data or power cable


HEAD COLD can cause this error message. The printhead may be hot enough to
cause severe burns. Allow the printhead to cool.

The printer prints while the The printhead temperature is Continue printing while the printhead
ERROR light flashes. approaching its lower operating reaches the correct operating
limit. temperature. If the error remains, the
environment may be too cold for
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.
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.

The printhead has a faulty Replace the printhead.


thermistor.

WARNING Caution The printhead may be hot enough to cause severe


HEAD TOO HOT burns. Allow the printhead to cool.

The printer stops; the The printhead is over temperature. Allow the printer to cool. Printing
ERROR light flashes. automatically resumes when the
printhead elements cool to an
acceptable operating temperature.

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106 Troubleshooting
LCD Error Messages

Table 14 LCD Error Messages (Continued)

LCD Display/
Possible Cause Recommended Solution
Printer Condition
The printer is defragmenting
DEFRAGMENTING Caution Do NOT turn off the printer
memory. power during defragmenting. Doing so
can damage the printer.

The printer stops. Allow the printer to finish


defragmenting. If you get this error
message frequently, check your label
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.

ERROR CONDITION Caution The cutter blade is sharp. Do not touch or rub the blade
CUTTER JAM with your fingers.

The cutter blade is in the media Turn off the printer power and unplug
The printer stops; the path. the printer. Inspect the cutter module
ERROR light flashes. for debris and clean as needed
following the cleaning instructions in
Clean the Cutter Module on page 130.

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Troubleshooting 107
Print Quality Problems

Print Quality Problems


Table 15 identifies problems with print quality, the possible causes, and the recommended
solutions.

Table 15 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. See
Adjust Print Speed on page 73. You may want to
perform the FEED Self Test on page 118.
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. See
Adjust Print Darkness on page 72. You may
want to perform the FEED Self Test on page 118
to determine the ideal darkness setting.
The printhead is dirty. Clean the printhead. See Clean the Printhead
and Platen Roller on page 127.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality.See Adjust
Printhead Pressure on page 65.
The printhead is improperly Adjust the printhead balance.
balanced.
Long tracks of Print element damaged. Replace the printhead.
missing print on
several labels

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108 Troubleshooting
Print Quality Problems

Table 15 Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution


Wrinkled ribbon Ribbon was fed through the Load the ribbon correctly. See Load Ribbon
ribbon system incorrectly. on page 59.
Incorrect burn temperature. Set the darkness to the lowest possible setting for
good print quality. See Adjust Print Darkness
on page 72.
Incorrect or uneven printhead Set the printhead pressure to the minimum
pressure. needed for good print quality. See Adjust
Printhead Pressure on page 65.
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.
The printhead needs vertical
adjustment.
The printhead is improperly Adjust the printhead balance.
balanced.
The printhead and platen roller
need to be realigned.
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 58.
Incorrect or uneven printhead Set the pressure to the minimum needed. See
pressure. Adjust Printhead Pressure on page 65.
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 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 127.
three labels Media does not meet Use media that meets specifications.
specifications.

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Troubleshooting 109
Print Quality Problems

Table 15 Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution


Vertical drift in The printer is out of calibration. Calibrate the printer. See Calibrate Media and
top-of-form position Ribbon Sensor Sensitivity on page 86.
Vertical drift occurs during Calibrate the printer. See Calibrate Media and
normal printer operation. Ribbon Sensor Sensitivity on page 86.
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
and Platen Roller on page 127.
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.
The media sensor is calibrated See Calibrate Media and Ribbon Sensor
improperly. Sensitivity on page 86.
The platen roller is dirty. Clean the platen roller. See Clean the Printhead
and Platen Roller on page 127.
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 118. 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.

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110 Troubleshooting
Calibration Problems

Calibration Problems
Table 16 identifies problems with calibration, the possible causes, and the recommended
solutions.

Table 16 Calibration Problems

Problem Possible Cause Recommended Solution


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 127.
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. (gap/notch, continuous, or mark). See Set Media
Type on page 76.
The media is loaded incorrectly. Load media correctly. See Load Media
on page 43.
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. See Calibrate
media or ribbon. Media and Ribbon Sensor Sensitivity on page 86.
The sensors are dirty or Ensure that the sensors are clean and that media
positioned improperly. The is positioned properly.
sensors are dirty, or media is
positioned improperly for the
sensors to detect.
The media type is set Set the printer for the correct media type
incorrectly. (gap/notch, continuous, or mark). See Set Media
Type on page 76.

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Troubleshooting 111
Communications Problems

Communications Problems
Table 17 identifies problems with communications, the possible causes, and the recommended
solutions.

Table 17 Communications Problems

Problem Possible Cause Recommended Solution


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. See Set Serial Communications
on page 87.
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. See
Set Protocol on page 89.
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 44 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. See
the printer but was not characters set in the printer Set Format Prefix Character on page 90 and
recognized. The DATA do not match the ones in the Set Delimiter Character on page 91 for the
light flashes but no label format. requirements.
printing occurs.
Incorrect data is being sent Check the communication settings on the
to the printer. computer. Ensure that they match the printer
settings.
If the problem continues, check the label
format.

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112 Troubleshooting
Ribbon Problems

Ribbon Problems
Table 18 identifies problems that may occur with ribbon, the possible causes, and the
recommended solutions.

Table 18 Ribbon Problems

Problem Possible Cause Recommended Solution


Broken or melted Darkness setting too high. 1. Reduce the darkness setting.
ribbon 2. Clean the printhead thoroughly.
The ribbon is coated on the Replace the ribbon with one coated on the
wrong side and cannot be used correct side. For more information, see Coated
in this printer. Side of Ribbon on page 58.
The printer does not The ribbon-out threshold is set 1. Print a sensor profile (see Print Sensor
detect when the too high to detect the ribbon. Profile on page 85), and note the location of
ribbon runs out. On a sensor profile, the the ribbon-out threshold (circled in
In thermal transfer ribbon-out threshold (circled in Figure 15).
mode, the printer did Figure 15) appears above the 2. Calibrate the printer, this time using ribbon,
not detect the ribbon black bars that indicate the or load printer defaults. See Calibrate Media
even though it is ribbon. This happens if you and Ribbon Sensor Sensitivity on page 86 or
loaded correctly. calibrate the printer without LOAD DEFAULTS on page 68.
ribbon and later insert ribbon
Important Loading defaults resets
without recalibrating the printer
all printer parameters back to factory
or loading printer defaults.
defaults.
3. Print another sensor profile, and compare it
Figure 15 Ribbon-Out to the first one.
Threshold Too High 4. If the ribbon-out threshold is still too high,
you may manually change the value.

The ribbon light is on The printer was not calibrated Perform the calibration procedure in Calibrate
even though ribbon is for the label and ribbon being Media and Ribbon Sensor Sensitivity on page 86.
loaded correctly. used.

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Troubleshooting 113
Miscellaneous Printer Problems

Miscellaneous Printer Problems


Table 19 identifies miscellaneous problems with the printer, the possible causes, and the
recommended solutions.

Table 19 Miscellaneous Printer Problems

Problem Possible Cause Recommended Solution


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.
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll
through the choices until you find a language
that you can read.
3. Press SETUP/EXIT.
The LCD displays SAVE CHANGES in the
original language.
4. Press SETUP/EXIT again 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).
5. 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 115 and
characters or parts of check that the LCD display shows all characters.
characters If not, replace the LCD.

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114 Troubleshooting
Miscellaneous Printer Problems

Table 19 Miscellaneous Printer Problems (Continued)

Problem Possible Cause Recommended Solution


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.
A ZPL command changed the
parameter back to the previous
setting.

If the problem continues, there Replace the main logic board.


may be a problem with the
main logic board.
The printer fails to The printer was not calibrated Perform the calibration procedure in Calibrate
calibrate or detect the for the label being used. Media and Ribbon Sensor Sensitivity on page 86.
top of the label.
The printer is configured for Set the media type to noncontinuous media. See
continuous media. Set Media Type on page 76.

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 Perform the calibration procedure in Calibrate
labels are being for the media being used. Media and Ribbon Sensor Sensitivity on page 86.
treated as continuous
labels.
The printer is configured for Set the media type to noncontinuous media. See
continuous media. Set Media Type on page 76.

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.
The printer locks up Main logic board failure. Replace the main logic board.
while running the
Power-On Self Test.

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Troubleshooting 115
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 using Set Print Width on page 77, 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).

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:

1. Turn on (I) the printer.


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.

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116 Troubleshooting
Printer Diagnostics

CANCEL Self Test


The CANCEL self test prints a configuration label (Figure 16).

To perform the CANCEL Self Test, complete these steps:

1. Turn off (O) the printer.

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 16).

Figure 16 Sample Configuration Label


Z Series RZ Series

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Troubleshooting 117
Printer Diagnostics

PAUSE Self Test


This self test can be used to provide the test labels required when making adjustments to the
printers mechanical assemblies or to determine if any printhead elements are not working.
Figure 17 shows a sample printout.

To perform a PAUSE self test, complete these steps:

1. Turn off (O) the printer.

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 printers slowest speed, and then
automatically pauses the printer. Each time PAUSE is pressed, an additional 15 labels
print. Figure 17 shows a sample of the labels.

Figure 17 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 printers 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 printers maximum speed.
To exit this self test at any time, press and hold CANCEL.

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118 Troubleshooting
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 printers 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 printers current settings.

2. Turn off (O) the printer.

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 18) at various speeds and at darkness settings
higher and lower than the darkness value shown on the configuration label.

Figure 18 FEED Test Label

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Troubleshooting 119
Printer Diagnostics

4. See Figure 19 and Table 20. 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 19 Bar Code Darkness Comparison

Table 20 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.

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120 Troubleshooting
Printer Diagnostics

Table 20 Judging Bar Code Quality (Continued)

Print Quality Description


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. See
Adjust Print Darkness on page 72.

8. If necessary, change the print speed to the same speed as on the best test label. See Adjust
Print Speed on page 73.

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:

1. Turn off (O) the printer.

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.

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Troubleshooting 121
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 20 shows a
typical test label from this test.

Note The test label prints upside-down.

Figure 20 Communications Diagnostics Test Label

To use communications diagnostics mode, complete these steps:

1. Set the print width equal to or less than the label width being used for the test. See Set
Print Width on page 77 for more information.

2. Set the printer to DIAGNOSTICS. For instructions, see Set Communications Mode
on page 90.
The printer enters diagnostics mode and prints any data received from the host computer
on a test label

3. 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.

4. Turn the printer off (O) and then back on (I) to exit this self test and return to normal
operation.

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122 Troubleshooting
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.

For instructions on printing a sensor profile, see Print Sensor Profile on page 85. If the
sensitivity of the sensors must be adjusted, perform Calibrate Media and Ribbon Sensor
Sensitivity on page 86.

Ribbon Sensor Profile (Figure 21) 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 21 Sensor Profile (Ribbon Section)

Media Sensor Profile (Figure 22) 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 22 Sensor Profile (Media Section)

1 2

3 4

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12
Preventive and Corrective
Maintenance

This section provides various levels of printer maintenance required for optimum
performance. This section also provides information on cleaning and general maintenance,
replacement of major assemblies, and mechanical adjustments.

Contents
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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124 Preventive and Corrective Maintenance

Notes ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Preventive Maintenance

This scection shows various levels of prventative maintenance including cleaning procedures
and schedules.

Contents
Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Clean the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . 132
Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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126 Preventive Maintenance
Cleaning Schedule and Procedures

Cleaning Schedule and Procedures

Important Zebra is not responsible for damage caused by the use of cleaning fluids on this
printer.

Specific cleaning procedures are provided on the following pages. Table 21 shows the
recommended cleaning schedule. These intervals are intended as guidelines only. You may
have to clean more often, depending upon your application and media.
.

Table 21 Recommended Cleaning Schedule

Area Method Interval


Printhead Solvent* Direct Thermal Mode: After every roll of
Platen roller Solvent* media (or 500 feet of fanfold media).
Thermal Transfer Mode: After every roll of
Media sensors Air blow
ribbon or three rolls of media.
Ribbon sensor Air blow
Media path Solvent*
Ribbon path Solvent*
Pinch roller (part of Peel-Off option) Solvent*
Cutter If cutting continuous, Solvent* After every roll of media (or more often,
module pressure-sensitive media depending upon your application and media).
If cutting tag stock or label Solvent* and After every two or three rolls of media.
liner material air blow
Tear-off/peel-off bar Solvent* Once a month.
Take-label sensor Air blow Once every six months.
* 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%).

Clean the Exterior


You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a
mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

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Preventive Maintenance 127
Cleaning Procedures

Clean the Printhead and Platen Roller


You can minimize printhead wear and maintain print quality with regular preventive measures.
Over time, the movement of media or ribbon across the printhead wears through the protective
ceramic coating, exposing and eventually damaging the print elements (dots). To avoid
abrasion:
Clean the printhead frequently, and use well-lubricated thermal transfer ribbons with
backings optimized to reduce friction.
Minimize printhead pressure and burn temperature settings by optimizing the balance
between the two.
Ensure that the thermal transfer ribbon is as wide or wider than the label media to prevent
exposing the elements to the more abrasive label material.

For best results, clean the printhead after changing every roll of ribbon. Inconsistent print
quality, such as voids in the bar code or graphics, may indicate a dirty printhead.
-

Note For printers with a peel assembly, keep the peel assembly closed while cleaning the
platen roller to reduce the risk of bending the tear-off/peel-off bar.

Figure 23 Location of the Printhead and Platen Roller

1 Printhead assembly
2 Platen roller

Caution The printhead may be hot and could 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 antistatic wriststrap and mat.

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128 Preventive Maintenance
Cleaning Procedures

To clean the printhead and platen roller, complete these steps:

1. Open the printhead assembly.

2. Remove the media and ribbon.

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.

4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the
solvent to evaporate.

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Preventive Maintenance 129
Cleaning Procedures

5. Reload media and ribbon, and close the printhead assembly.

Note If performing this procedure does not improve print quality, try cleaning the
printhead with Save-A-Printhead cleaning film. This specially coated material removes
contamination buildup without damaging the printhead. Call your authorized Zebra
reseller for more information.

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130 Routine Maintenance
Cleaning Procedures

Clean the Cutter Module


If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter.

Caution For personnel safety, always power off and unplug the printer before performing
this procedure.

To clean the cutter module, complete these steps:

1. Turn the printer off (O), and unplug the printer from its power source.

2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter shield (1) by removing the cutter shield thumbscrew and lock
washer (2).
1 2

3. To expose the V-shaped cutter blade, turn the cutter motor thumbscrew (1)
counterclockwise to lower the blade.

4. See Figure 24. Using the swab from the Preventive Maintenance Kit (part number 47362),
wipe along the upper cutting surface (1) and the cutter blade (2). 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.

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Routine Maintenance 131
Cleaning Procedures

Figure 24 Cleaning the Cutter Module


1

5. Replace the cutter shield.

6. Plug the printer into its power source, and then turn on (I) the printer.
The lower cutter blade returns to its correct operating position.

7. If the cutter continues to perform unsatisfactorily, contact an authorized service


technician.

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132 Preventive Maintenance
Routine Maintenance for the Rewind Option

Routine Maintenance for the Rewind Option


When you use the Rewind option, you will periodically need to remove printed labels or used
liner from the rewind spindle. You may also need to adjust the media alignment for the Rewind
option.

Remove Printed Labels or Liner from the Rewind Spindle


To remove printed labels or liner from the rewind spindle, complete these
steps:

1. Cut the liner between the media alignment spindle and the rewind spindle.

2. Rotate the take-up spindle counterclockwise until the rewind media guide is fully upright.

3. Loosen the thumbscrew on the rewind media guide.

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Preventive Maintenance 133
Routine Maintenance for the Rewind Option

4. Slide the rewind media guide all the way out, and then fold it down.

5. Slide the core with the liner from the take-up spindle.

Adjust Media Alignment for Rewind Option


The instructions below apply only if the printer has a Rewind option. The liner should be
installed flush against the backplate of the rewind spindle to prevent the media/backing from
winding too loosely.

Perform the adjustments in the order given. Do only what is needed to solve the problem.

To adjust the media alignment for printers with the Rewind option, complete
these steps:

1. Turn the adjustment dial (1) clockwise to move the media toward the backplate (2).

2. Turn the adjustment dial (1) counter clockwise to move the media away from the
backplate (2).

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134 Routine Maintenance
Replacing Printer Components

Replacing Printer Components

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 21 for contact addresses and telephone numbers.

Recycling Printer Components


The majority of this printers components are recyclable. The printers 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.

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Routine Maintenance 135
Lubrication

Lubrication
No lubrication is needed for this printer.

Caution Some commercially available lubricants will damage the finish and the
mechanical parts if used on this printer.

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136 Routine Maintenance
Lubrication

Notes ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Corrective Maintenance

This section shows you how to replace parts.

Contents
Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Roller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Outer Casing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
RFID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483

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138 Corrective Maintenance

Notes ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Print System

This section provides replacement, conversion and installation procedures for the
ZM400/ZM600 print system.

Contents
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Printhead Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Magnetic Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

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140 Corrective Maintenance
Printhead Assembly

Printhead Assembly
This procedure is for installing the Printhead Assembly. Read these ionstructions throughy
before performing this procedure.

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 ZM400 and ZM600 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:

47362* Zebra Preventive Maintenance Antistatic Wriststrap


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

Remove the Old Printhead


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

Open the media door and remove the media and ribbon.

2.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

3. See Figure 25. Take note of the position of the pressure dials and then rotate the printhead
pressure dials to the #1 position.

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Corrective Maintenance 141
Printhead Assembly

Figure 25 Locate the Printhead Pressure Dials


1 1
2 2 2 2
1 1

ZM400 ZM600

1 Position #1
2 Pressure dial

4. Do you have a cutter option installed?

If Then
No Continue with step 5.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Go to Remove the Cutter Assembly on page 146.

5. See Figure 26. Locate and remove the thumbscrew from the print mechanism.

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142 Corrective Maintenance
Printhead Assembly

Figure 26 Remove the Thumbscrew

1 Print mechanism
2 Thumbscrew

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Corrective Maintenance 143
Printhead Assembly

6.
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 27. Open the print mechanism and latch it in the vertical position.

7.
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

Disconnect the printhead data and power cables.

8. Remove the printhead assembly from the printer.

Figure 27 Remove the Printhead Assembly


4
2 3

1 Printhead assembly
2 Print mechanism
3 Printhead data cable connector
4 Printhead power cable connector
5 Latch assembly

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144 Corrective Maintenance
Printhead Assembly

Install the New Printhead Assembly


1. See Figure 28. Align the two forks with the bearings and set the printhead assembly onto
the platen housing. This is done for ease of connecting the printhead cables.

2.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or display HEAD COLD or other false error
messages.

Connect the power and data cables to the printhead.

Figure 28 Align the Forks and Bearings

8
3

5
6

1 Thumbscrew
2 Ribbon guide plate
3 Alignment holes (2)
4 Alignment pins (2)
5 Printhead ribbon guide
6 Platen housing
7 Forks (2)
8 Bearings (2)

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Corrective Maintenance 145
Printhead Assembly

3. See Figure 27 on page 143. Connect both printhead power and data cables to the printhead
connectors and carefully slide them into position. Ensure the cables are in their proper
channels and are not binding the printhead.

Note When mounting the printhead fork assembly onto the print mechanism, visually
inspect and ensure the cables are in their channels at the back of their carrier assembly,
power cable under data cable, and are not binding on the print mechanism.

4. See Figure 28 and Figure 29. Tip the printhead fork assembly slightly and insert the
printhead ribbon guide into the print mechanism as shown.

5. See Figure 28 and Figure 29. Tip the printhead fork assembly up and into the print
mechanism ensuing that the two locating protrusions on either side of the print printhead
snap into the locating holes of the ribbon guide plate. Move the assembly back and forth to
be sure that it is engaged. There should be little movement.

Figure 29 Install the Printhead Fork Assembly

1 1

2 2

3
3

4 4

5 5

1 Thumbscrew
2 Print mechanism
3 Printhead fork assembly
4 Ribbon guide plate
5 Printhead ribbon guide

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146 Corrective Maintenance
Printhead Assembly

6. While holding the printhead in place, install the thumb screw to secure the fork assembly.

7. Clean the printhead with the Zebra preventative maintenance kit.

8. See Figure 25 on page 141. Rotate the two printhead pressure dials to the desired position
for your daily printing.

9. Did you remove a cutter assembly?

If Then
No Continue with step 10.
Yes Got to Reinstall the Cutter Assembly on page 147.

10.
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.

11. Reconnect the AC power cord and data cables

12. Turn on (l) the printer.

Remove the Cutter Assembly


1. See Figure 30. Unlatch the printhead and turn the latch assembly clockwise to access the
cutter mounting screw.

2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter mounting screw.

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Corrective Maintenance 147
Printhead Assembly

Figure 30 Remove the Cutter Assembly

5 4 3 2

1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness

Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.

3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.

4. Go to step 5 on page 141.

Reinstall the Cutter Assembly


1. See Figure 30 on page 147. Reinstall the cutter assembly on the hooks of the platen
housing.
a. Hold the cutter assembly as far to the left as possible, and align the larger part of the
step slot with the hooks on the platen housing.
b. Slide the cutter assembly onto the hooks and then push down and slide the assembly
to the right.

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148 Corrective Maintenance
Printhead Assembly

2. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the
platen assembly.
The mounting tab on the cutter fits behind and attaches to the platen assembly.

3. Turn the latch assembly counterclockwise until it snaps in place.

4.
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.

5. Reconnect the AC power cord and data cables

6. Turn on (l) the printer.

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Corrective Maintenance 149
Print Mechanism

Print Mechanism

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Flat-blade Screwdriver Set Metric Nutdriver Set
Metric Hex key (Allen wrench) Set *47362 Zebra Preventative Maintenance
Kit
10 cm Adjustable Wrench
Feeler Gauge with 1.25 mm (0.050 in.)
* 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%).

Remove the Electronics Cover

Caution A qualified service technician must perform this installation.

1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media cover and remove the media and ribbon.

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150 Corrective Maintenance
Print Mechanism

3. See Figure 31. Remove the screw and washer securing the electronics cover.

Figure 31 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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Corrective Maintenance 151
Print Mechanism

5. See Figure 32. Remove the four mounting screws on the rear of the printer.

Figure 32 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 33. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 33 Remove the Electronics Cover

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152 Corrective Maintenance
Print Mechanism

7. Is there a wireless board installed?

If Then
No Go to Gain Access to the Power Supply on page 157.
Yes Continue with Remove the Zebra Wireless Board.

Remove the Wireless Board


Which wireless option do you have?

If you have a Then


SEH IPv6 Print Server Go to Remove the SEH IPv6 Print Server Board on page 154.
Wireless Continue with Remove the Zebra Wireless Board.

Remove the Zebra Wireless Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 34. Press in on the eject button to remove the radio card.

Figure 34 Remove the Radio Card


1

1 Eject button
2 Radio card

3. See Figure 35. Remove the screw from the upper left corner of the wireless board.

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Corrective Maintenance 153
Print Mechanism

4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).

Figure 35 Remove the Wireless Board


1

1 Wireless board
2 Mounting screws (4)

5. Go to Gain Access to the Power Supply on page 157.

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154 Corrective Maintenance
Print Mechanism

Remove the SEH IPv6 Print Server Board


1. See Figure 36. Remove the antenna by unscrewing it from the antenna connector and then
removing the mounting nut and lock washer securing the SEH IPv6 print server board to
the rear cover.

Figure 36 Remove the Antenna


1

2 3
4

1 Rear cover
2 Antenna connector
3 Lock washer
4 Mounting nut
5 Antenna

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Corrective Maintenance 155
Print Mechanism

2. See Figure 37. Remove the top left mounting screw securing the SEH IPv6 print server
board.

Figure 37 Remove the SEH IPv6 Print Server Board


1
\

5
4

1 SEH IPv6 print server board


2 SEH IPv6 print server board mounting screws (4)
3 MLB
4 Antenna connector mounting nut
5 Antenna connector mounting lock washer

3. Remove the three SEH IPv6 print server board mounting screws securing it to the MLB.

4. Remove the SEH IPv6 print server board from the printer.

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156 Corrective Maintenance
Print Mechanism

5. See Figure 38. Remove the three wireless mounting standoffs from the MLB.

Figure 38 Remove the Wireless Board Mounting Standoffs


1

1 MLB
2 Mounting standoffs (3)

6. Continue with Gain Access to the Power Supply.

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Gain Access to the Power Supply


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 39. Remove the standoff from the upper left of the power supply shield.

3. Remove the mounting screw from the upper right of the power supply shield.

Figure 39 Remove the Standoff and Screw

1 Mounting screw
2 Mounting standoff
3 Power supply shield

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158 Corrective Maintenance
Print Mechanism

4. See Figure 40. Pull the top of the shield away from the main frame and fold it down to
access the printhead power connector.

Figure 40 Gain Access the Power Supply

1 Shield

Disconnect the Print Mechanism


Do you have a retaining clip on the printhead data cable?

If Then
No Go to step 1 on page 160.
Yes Continue with step 1.

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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 41. Remove the printhead ribbon cable clip by lifting up on the tabs and then
pulling it away from the main logic board.

Note Some models have a ribbon cable retaining clip on the printhead data cable for
shipping purposes. It may be left off if you ensure that the printhead data cable is properly
seated into the main logic board MLB connector P19 upon reinstallation of the cable.

Figure 41 Remove the Printhead Ribbon Cable Retaining Clip


2

1 Printhead cable retaining clip


2 Tabs (2)

2. Drop it slightly out of the printhead connect and then remove it from the printer.

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160 Corrective Maintenance
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Disconnect the Print Mechanism


1. See Figure 42. Remove the printhead housing grounding strap mounting screw.

Figure 42 Printhead Grounding Strap

3 3
1 2 4

5
6

9 8 7

1 Power supply 6 Printhead housing ground


strap mounting screw
2 Printhead power cable 7 Main logic board (MLB)
connector J3 mounting bracket
3 Flat cable clips (5) 8 MLB
4 Stepper motor 9 MLB printhead data cable
5 Printhead housing ground connector P19
strap

2. Disconnect the printhead data cable from P19 on the MLB.

3. Disconnect the printhead power cable from J3 on the power supply.

4. Remove the printhead power cable from the flat cable clips securing it to the printer.

5. Guide the printhead power cable out from behind the stepper motor.

6. Guide the printhead data cable from behind the MLB mounting bracket.

7. Remove the printhead data cable from the flat cable clip on the base of the printer.

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Print Mechanism

8. Do you have a cutter option installed?

If Then
No Go to Remove the Print Mechanism on page 162.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Continue with Remove the Cutter Assembly.

Remove the Cutter Assembly


1. See Figure 43. Unlatch the printhead and turn the latch assembly clockwise to remove the
cutter mounting screw.

2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter mounting screw.

Figure 43 Remove the Cutter Assembly

5 4 3 2

1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness

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162 Corrective Maintenance
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Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.

3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.

Remove the Print Mechanism


1. See Figure 44. Remove the three mounting screws and two washers.

Figure 44 Printhead Housing Mounting Screws

1 Print mechanism
2 Washers (2)
3 Screws (3)

2. Remove the printhead housing assembly from the printer. Guide the print mechanism
cable out through the access hole after removing the print mechanism.

Install the New Print Mechanism


1. See Figure 44. Feed the new cables through the print mechanism mounting hole.

2. Install the three print mechanism mounting screws and two washers.

3. Close and latch the print mechanism.

4. See Figure 42 on page 160. Route the printhead power cable under the stepper motor and
up to the power supply.

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Print Mechanism

5. Connect the printhead power cable to J3 on the power supply board.

6. Install the printhead cable into the four flat cable clips.

7. Route the printhead data cable under the MLB mounting bracket and then connect it to
P19 on the MLB.

Reinstall the Printhead Ribbon Cable Retaining Clip

8. See Figure 45. Insert the bottom locating tab into the bottom hole in the main logic board
(MLB) connector and then lift up and around with the upper locating tab in the top hole of
the MLB connector.

Figure 45 Install the Printhead Data Cable Retaining Clip


5
4
2
3

1 Main logic board (MLB) connector


2 Top hole
3 Printhead cable
4 Top locating tab
5 Printhead ribbon cable retaining clip
6 Bottom hole
7 Bottom locating tab

9. Install the printhead data cable into the flat cable clip on the base of the printer.

10. Connect the ground strap from the print mechanism to the printer.

11. See Figure 40 on page 158. Close the shield on the power supply and then reinstall the
standoff and mounting screw.

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164 Corrective Maintenance
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12. Did you remove a wireless board?

If Then
No Go to Reinstall the Electronics Cover on page 165.
Yes Continue with the next step.

13. Which wireless board do you have?

If you have a Then


Wireless Ethernet a. See Figure 35 on page 153. Slide the wireless board into
the rear panel and then align the two connectors on the
MLB with the two connectors on the wireless board.
b. Press the wireless board into the MLB.
c. Reinstall the four mounting screws.
d. See Figure 34 on page 152. Reinstall the radio board.
e. Continue with Reinstall the Electronics Cover.
SEH IPv6 Print Server a. See Figure 37 on page 155. Slide the wireless board into
the rear panel and then align the two connectors on the
MLB with the two connectors on the wireless board.
b. Press the wireless board into the MLB.
c. Reinstall the four mounting screws.
d. Figure 36 on page 154. Reinstall the antenna mounting
washer and nut.
e. Reinstall the antenna.
f. Continue with Reinstall the Electronics Cover.

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Print Mechanism

Reinstall the Electronics Cover


1. See Figure 46. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 46 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 32 on page 151. Install the four mounting screws.

3. See Figure 31 on page 150. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

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166 Corrective Maintenance
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Adjust the Print Mechanism


1. See Figure 47. Remove the strike plate cap by gently prying up one snap tab with a small
flat-blade screwdriver. Loosen the strike plate mounting screws 1/2 turn.

Figure 47 Adjust the Print Mechanism


1

1 Strike plate cap


2 Adjustment screw
3 Strike plate
4 Strike plate mounting screws (2)
5 Print mechanism gap pin gauges (2)

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Print Mechanism

2. See Figure 48. Using the screw provided in the kit, install the print mechanism adjustment
cam on the printer main frame.

Note The cam should be in contact with print mechanism. Just snug the cam in place.

Figure 48 Install the Adjustment Cam

1 Cam mounting hole


2 Cam
3 Mounting screw

3. See Figure 47. Insert the print mechanism gap pin gauges through the holes that are
provided in the front of the ribbon guide plate.

4. See Figure 44 on page 162. Slightly loosen the three print mechanism mounting screws.

5. See Figure 47. Place a 10 cm adjustable wrench on the print mechanism adjustment cam.
While turning the wrench counterclockwise, push in and pull out the inside gap pin gauge
until a small amount of friction can be felt.

6. After aligning the inside pin gauge, use a screwdriver and turn the adjustment screw on
top of the latch plate strike.

7. Push in and pull out the outside gap pin gauge until a small amount of friction can be felt.
Double check both pin gauges for equal amount of friction.

8. Tighten the latch plate strike screws.

9. Tighten the print mechanism mounting screws when equal pressure is obtained.

10. Replace the strike plate cap.


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168 Corrective Maintenance
Print Mechanism

Adjust the Print Mechanism without Cam


1. See Figure 44 on page 162. Slightly loosen the three screws that secure the print
mechanism assembly to the mainframe.

2. See Figure 49. Push down on the print mechanism with a flat blade screw driver while
pushing in and pulling out the inside gap pin gauge until a small amount of friction can be
felt. Snug the two hex head screws.

Note On most printers, the print mechanism housing aligns with the mounting boss on
the main frame.

Figure 49 Push Down on the Print Mechanism

4
1
2
3

1 Screwdriver
2 Main frame
3 Print mechanism
4 Main frame mounting boss

3. See Figure 47 on page 166. After adjusting the inside pin gauge, use a screwdriver and
turn the adjustment screw on top of the latch plate strike.

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Print Mechanism

4. Push in and pull out the outside gap pin gauge until a small amount of friction can be felt.

Important Check both pin gauges for equal amount of friction.

5. Tighten the latch plate strike screws.

Adjust the Ribbon/Printhead Open Sensor


1. See Figure 50. Check the gap on the ribbon/printhead open sensor and adjust as necessary.

Figure 50 Ribbon/Printhead Open Sensor

5
4

1 Printhead housing
2 Gap, 1.25 mm (0.050 in.)
3 Ribbon/Printhead open sensor
4 Mounting screw
5 Ribbon guide plate

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170 Corrective Maintenance
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2. Use a 1.25 mm (0.050 in.) feeler gauge and check the distance between the ribbon/head
open sensor assembly and the ribbon guide plate.
If the distance is incorrect, loosen the mounting screw for the ribbon/head open sensor and
adjust for the proper distance. Once this distance is achieved, tighten the mounting screw.

3. Did you remove a cutter assembly?

If Then
No Continue with step 4.
Yes Go to Reinstall the Cutter Assembly on page 170.

4.
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.

5. Reconnect the AC power cord and data cables.

6. Turn on (l) the printer.

Reinstall the Cutter Assembly


1. See Figure 43 on page 161. Reinstall the cutter assembly on the hooks of the platen
housing.
a. Hold the cutter assembly as far to the left as possible, and align the larger part of the
step slot with the hooks on the platen housing.
b. Slide the cutter assembly onto the hooks and then push down and slide the assembly
to the right.

2. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the
platen assembly.
The mounting tab on the cutter fits behind and attaches to the platen assembly.

3. Turn the latch assembly counterclockwise until it snaps in place.

4.
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.

5. Reconnect the AC power cord and data cables

6. Turn on (l) the printer.

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Corrective Maintenance 171
Printhead Cables

Printhead Cables

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wrist Strap and Pad


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

Remove the Electronic Cover


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media door and remove the media and ribbon.

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172 Corrective Maintenance
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3. See Figure 51. Remove the screw and washer securing the electronics cover.

Figure 51 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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Printhead Cables

5. See Figure 52. Remove the four mounting screws on the rear of the printer.

Figure 52 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 53. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 53 Remove the Electronics Cover

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174 Corrective Maintenance
Printhead Cables

7. Is there a wireless board installed?

If Then
No Go to Gain Access to the Power Supply on page 178.
Yes Continue with Remove the Wireless Board.

Remove the Wireless Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 54. Press in on the eject button to remove the radio card.

Figure 54 Remove the Radio Card


1

1 Eject button
2 Radio card

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Corrective Maintenance 175
Printhead Cables

3. See Figure 55. Remove the screw from the upper left corner of the wireless board.

4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).

Figure 55 Remove the Wireless Board


1

1 Wireless board
2 Mounting screws (4)

5. Go to Gain Access to the Power Supply on page 178.

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176 Corrective Maintenance
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Remove the SEH Internal IPv6 Print Server


1. See Figure 56. Remove the antenna by unscrewing it from the antenna connector and then
removing the mounting nut and lock washer securing the board to the rear cover.

Figure 56 Remove the Antenna


1

2 3
4

1 Rear cover
2 Antenna connector
3 Lock washer
4 Mounting nut
5 Antenna

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Printhead Cables

2. See Figure 57. Remove the top left mounting screw securing the SEH IPv6 print server
board.

Figure 57 Remove the SEH IPv6 Print Server


1
\

5
4

1 SEH IPv6 print server board


2 SEH IPv6 print server board mounting screws (4)
3 MLB
4 Antenna connector mounting nut
5 Antenna connector mounting lock washer

3. Remove the three SEH IPv6 print server board mounting screws securing it to the MLB.

4. Remove the SEH IPv6 print server board from the printer.

5. Continue with Gain Access to the Power Supply.

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178 Corrective Maintenance
Printhead Cables

Gain Access to the Power Supply


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 58. Remove the standoff from the upper left of the power supply shield.

3. Remove the mounting screw from the upper right of the power supply shield.

Figure 58 Remove the Standoff and Screw

1 Mounting screw
2 Mounting standoff
3 Power supply shield

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Corrective Maintenance 179
Printhead Cables

4. See Figure 59. Pull the top of the shield away from the main frame and fold it down to
access the printhead connector.

Figure 59 Gain Access the Power Supply

1 Shield

5. See Figure 61 on page 181. Unplug the printhead power cable from J3 on the power
supply.

Do you have a retaining clip on the printhead data cable?

If Then
No Go to step 8 on page 180.
Yes Continue with step 6.

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180 Corrective Maintenance
Printhead Cables

6.
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 60. Remove the printhead ribbon cable clip by lifting up on the tabs and then
pulling it away from the main logic board.

Note Some models have a ribbon cable retaining clip on the printhead data cable for
shipping purposes. It may be left off if you ensure that the printhead data cable is properly
seated into the main logic board MLB connector P19 upon reinstallation of the cable.

7. Drop the clip slightly out of the printhead connect and then remove it from the printer.

Figure 60 Remove the Printhead Ribbon Cable Clip


3
1
2

1 Ribbon cable retaining clip


2 Tabs (2)
3 Printhead cable connector
4 Printhead cable

8. Unplug the printhead data cable from P19 on the main logic board (MLB).

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Printhead Cables

Figure 61 Disconnect Printhead Cables

2
3

1 Printhead power cable connected to J3 of the power supply


2 Printhead braided ground cable mounting screw
3 Printhead data cable connected to P19 on the MLB

9. Remove the printhead braided ground cable mounting screw.

10. Turn the printer around and open the media door.

Remove the Printhead


1. See Figure 62. Note the positions and then rotate the two printhead pressure knobs to the
#1 position.

Figure 62 Top View of Printhead Housing


1 1
2 2

Front Front
3 3 3 3
ZM400 ZM600

1 Position number one


2 Thumbscrew
3 Printhead Pressure Dials (2)

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182 Corrective Maintenance
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2.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

3. Do you have a cutter option installed?

If Then
No Continue with step 4.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Go to Remove the Cutter Assembly on page 192.

4. See Figure 63. Remove the thumbscrew to loosen the printhead fork assembly.

Figure 63 Remove the Thumbscrew

1 Thumb screw
2 Printhead fork assembly

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Printhead Cables

5. See Figure 64. Unlatch the print mechanism, and then lift and latch it in the open position.

Figure 64 Printhead Removal and Installation

1 Print mechanism
2 Printhead data cable
3 Printhead power cable
4 Printhead assembly
5 Platen housing

6. Set the printhead onto the bearings of the platen housing.

7. Disconnect the printhead data and power cables.

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184 Corrective Maintenance
Printhead Cables

8. See Figure 65. Disconnect the ground cable from the print mechanism by removing the
screw securing it.

Figure 65 Remove the Ground Cable Mounting Screw

1 Ground cable
2 Mounting screw

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Corrective Maintenance 185
Printhead Cables

9. See Figure 66. Guide the printhead cable connectors through the gap in the print
mechanism and discard them.

Figure 66 Remove the Cables from the Print Mechanism


1

1 Cable connector
2 Gap

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186 Corrective Maintenance
Printhead Cables

Install the New Printhead Cables


1. See Figure 67. From the electronics side, guide the new cables up through the gap in the
print mechanism.

Figure 67 Install the New Cables

1 2

1 Cable connector
2 Print mechanism
3 Ground cable

2. Tightly secure the ground cable to the printer with the screw previously removed.

3. See Figure 66 on page 185. Tightly secure the ground cable to the print mechanism.

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Corrective Maintenance 187
Printhead Cables

4. See Figure 68. Align the two forks with the bearings and set the printhead assembly onto
the platen housing.This is done for ease of connecting the printhead cables.

5.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or display HEAD COLD or other false error
messages.

Connect the power and data cables to the printhead.

Figure 68 Align the Forks and Bearings

7
2
3

1 Thumbscrew
2 Alignment holes (2)
3 Cable guide
4 Alignment pins (2)
5 Platen housing
6 Forks (2)
7 Bearings (2)

6. See Figure 64 on page 183. Connect both printhead power and data cables to the printhead
connectors.

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188 Corrective Maintenance
Printhead Cables

7. See Figure 69. Tip the printhead fork assembly slightly and insert the printhead ribbon
guide into the print mechanism as shown.

Note When mounting the printhead fork assembly onto the print mechanism, visually
inspect and ensure the cables are in their channels at the back of their carrier assembly,
power cable under data cable, and are not binding on the print mechanism.

8. Tip the printhead fork assembly up and into the print mechanism ensuing that the two
locating protrusions on either side of the print printhead snap into the locating holes of the
ribbon guide plate. Move the assembly back and forth to be sure that it is engaged. There
should be little movement.

9. While holding the printhead in place, install the thumb screw to secure the fork assembly.

Figure 69 Install the Printhead Fork Assembly

1 1

2 2

3
3

4 4

5 5

1 Thumbscrew
2 Print mechanism
3 Printhead fork assembly
4 Ribbon guide plate
5 Printhead ribbon guide

10. Clean the printhead with the Zebra preventative maintenance kit.

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Corrective Maintenance 189
Printhead Cables

11. See Figure 62 on page 181. Rotate the two printhead pressure dials to the desired position
for your daily printing.

12. See Figure 70. Route the printhead power cable as shown and then connect it to J3 on the
power supply board.

13. Insert the printhead power cable into the two cable clips shown.

14. Ensure that the printhead power cable is routed around the standoff as shown.

Figure 70 Connect the Printhead Cables


2 3 4 5 6
1

8
9

11 10

1 Power supply board 7 Cable clips (2)


2 J3 8 Cable tie
3 Standoff 9 Ground cable
4 Printhead power cable 10 Printhead data cable
5 Main logic board (MLB) 11 P19
6 MLB mounting bracket

15. Install the cable tie around all three printhead cables at the location shown in Figure 70.
Be sure to clip off the excess cable tie.

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190 Corrective Maintenance
Printhead Cables

16.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or a false HEAD COLD message to display
while the printhead is hot enough to cause severe burns. Allow the printhead to cool.

See Figure 70 on page 189. Route the printhead data cable connector under the main
logic board (MLB) mounting bracket and then connect it to P19 on MLB.

Reinstall the Printhead Ribbon Cable Retaining Clip

17. See Figure 71. Insert the bottom locating tab into the bottom hole in the main logic board
(MLB) connector and then lift up and around with the upper locating tab in the top hole of
the MLB connector.

Figure 71 Install the Printhead Data Cable Retaining Clip


5
4
2
3

1 Main logic board (MLB) connector


2 Top hole
3 Printhead cable
4 Top locating tab
5 Printhead ribbon cable retaining clip
6 Bottom hole
7 Bottom locating tab

18. Ensure that all connectors are properly seated into their connectors.

19. See Figure 59 on page 179. Lift the power supply shield back into place.

20. Replace the mounting screw and standoff.

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Printhead Cables

21. Which communication board do you have?

If you have Then


None Go to Reinstall the Electronics Cover on page 193.
Wired Ethernet Go to Reinstall the Electronics Cover on page 193.
Wireless Ethernet a. See Figure 55 on page 175. Slide the wireless board into
the rear panel and then align the two connectors on the
MLB with the two connectors on the wireless board.
b. Press the wireless board into the MLB.
c. Reinstall the four mounting screws.
d. See Figure 54 on page 174. Reinstall the radio board.
e. Go to Reinstall the Electronics Cover on page 193.
SEH IPv6 Print Server a. See Figure 57 on page 177. Slide the wireless board into
the rear panel and then align the two connectors on the
MLB with the two connectors on the wireless board.
b. Press the wireless board into the MLB.
c. Reinstall the four mounting screws.
d. Figure 56 on page 176. Reinstall the antenna mounting
washer and nut.
e. Reinstall the antenna.
f. Go to Reinstall the Electronics Cover on page 193.

22. Did you remove a cutter assembly?

If Then
No Go to Reinstall the Electronics Cover on page 193.
Yes Go to Reinstall the Electronics Cover on page 193.

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192 Corrective Maintenance
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Remove the Cutter Assembly


1. See Figure 72. Unlatch the printhead and turn the latch assembly clockwise to remove the
cutter mounting screw.

2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter mounting screw.

Figure 72 Remove the Cutter Assembly

5 4 3 2

1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness

Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.

3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.

4. Go to step 4 on page 182.

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Printhead Cables

Reinstall the Cutter Assembly


1. See Figure 72 on page 192. Reinstall the cutter assembly on the hooks of the platen
housing.
a. Hold the cutter assembly as far to the left as possible, and align the larger part of the
step slot with the hooks on the platen housing.
b. Slide the cutter assembly onto the hooks and then push down and slide the assembly
to the right.

2. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the
platen assembly.
The mounting tab on the cutter fits behind and attaches to the platen assembly.

3. Turn the latch assembly counterclockwise until it snaps in place.

Reinstall the Electronics Cover


1. See Figure 73. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 73 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 52 on page 173. Install the four mounting screws.

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194 Corrective Maintenance
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3. See Figure 51 on page 172. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5.
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.

6. Reconnect the AC power cord and data cables.

7. Turn on (l) the printer.

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Corrective Maintenance 195
Ribbon Strip Plate

Ribbon Strip Plate

Tools Required

Tools You need these tools to complete this procedure:

Metric Hex Key (Allen Wrench) Set

Remove the Old Ribbon Strip Plate

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

Open the media door and remove the media and ribbon.

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196 Corrective Maintenance
Ribbon Strip Plate

3. See Figure 74. Remove the two mounting screws securing the ribbon strip plate to the
print mechanism.

Figure 74 Remove and Install the Ribbon Strip Plate

1 Print mechanism
2 Ribbon strip plate
3 Mounting screws (2)

4. Remove the ribbon strip plate.

Install the New Ribbon Strip Plate


1. See Figure 74 on page 196. Align the ribbon strip plate and screws with the two mounting
holes.

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.

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Corrective Maintenance 197
Ribbon Strip Plate

4.
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.

5. Reinstall the AC power cord and data cables.

6. Press and hold PAUSE and turn 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.

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198 Corrective Maintenance
Printhead Latch

Printhead Latch

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Adjustable Wrench


Flat-blade Screwdriver Set Metric Nutdriver Set
Safety Glasses Metric Hex Key (Allen Wrench) Set

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Corrective Maintenance 199
Printhead Latch

Remove the Old Latch


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

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

Figure 75 Open the Media Door

1 Media door
2 Strike plate cap
3 Latch assembly

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200 Corrective Maintenance
Printhead Latch

3. See Figure 76. Remove the strike plate cap by placing a small screwdriver under the front
edge and lifting upward.

Figure 76 Remove the Latch Assembly


3
1 2

4
5

6
14

7 8
9 11
10

13 12

1 Print mechanism 8 Latch assembly


2 Adjustment screw 9 Wave washer
3 Strike plate cap 10 Shoulder screw
4 Strike plate 11 Plug
5 Washer 12 Washer plate
6 Strike plate mounting 13 Platen housing
screw (short)
7 Stabilizer 14 Ribbon strip plate

4. Remove the two screws and the washer securing the latch strike plate to the side of the
print mechanism.

5. Remove the adjustment screw from the print mechanism. You will have to pull out on the
bottom of the strike plate while removing the screw.

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Corrective Maintenance 201
Printhead Latch

6.
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.

Remove the plug.

7. Remove the shoulder screw and wave washer securing the latch assembly to the platen
housing and remove the latch assembly.

8. Remove the washer plate.

Install the New Latch Kit


1. See Figure 76 on page 200. Install the new latch assembly using the wave washer and
shoulder screw from the kit.

2. Ensure the latch assembly is locked in the vertical position.

3. See Figure 77. Install the adjustment screw into the strike plate by sliding it in the opening
with the shoulder below the top piece of sheet metal and above the bottom piece of sheet
metal.

4. Install the strike plate partially into print mechanism.

Figure 77 Adjustment Screw Location


1

1 Strike plate
2 Adjustment screw
3 Adjustment screw shoulder

5. See Figure 76 on page 200. Tighten the adjustment screw until the top of the strike plate is
just below the top of the print mechanism.

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202 Corrective Maintenance
Printhead Latch

6. Install the top mounting screw and washer through the strike plate and into the print
mechanism. Do not tighten at this time; leave them approximately turn loose. Latch the
print mechanism.

7. Insert the stabilizer into the print mechanism until it stops.

8. Install the lower strike plate mounting screw.

Adjust the Print Mechanism


1. See Figure 78. Insert the print mechanism gap pin gauges through the holes that are
provided in the front of the ribbon guide plate.

Figure 78 Adjust the Print Mechanism


1
2

1 Print mechanism adjustment cam location


2 Strike plate cap
3 Adjustment screw
4 Strike plate
5 Strike plate mounting screws (2)
6 Print mechanism gap pin gauges (2)

2. Turn the adjustment screw until a small amount of friction is felt on the gap pin gauge.

3. Snug the two strike plate mounting screws.

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Corrective Maintenance 203
Printhead Latch

4. Using the gap pin gauge, verify that the inside print mechanism adjustment is correct. A
slight friction should be felt when sliding the inside pin in and out of the inside hole.

5. Is the adjustment acceptable?

If Then
No Continue with step 6.
Yes Go to step 13.

6. Loosen the two strike plate screws.

7. See Figure 79. Install the print mechanism adjustment cam on the printer frame with the
screw provided in the kit.

Figure 79 Print Mechanism Mounting Screws


1
2

1 Print mechanism
2 Adjusting cam
3 Hex head mounting screws (2)
4 Large washer
5 Hex head mounting screw no washer

8. Slightly loosen the three screws that secure the print mechanism assembly to the
mainframe.

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204 Corrective Maintenance
Printhead Latch

9. Use an adjustable wrench on the print mechanism adjustment cam. While turning the
wrench counterclockwise, push in and pull out the inside gap pin gauge until a small
amount of friction can be felt. Snug the two hex head screws.

10. After aligning the inside gap pin gauge, verify that the outside adjustment is correct.
Double-check both gap pin gauges for equal amount of friction. Tighten the latch strike
plate screws.

11. See Figure 79. Tighten the three printhead mechanism mounting screws when equal
pressure is obtained.

12. Remove the print mechanism adjustment cam by removing the mounting screw.

13. See Figure 76 on page 200. Install the strike plate cap.

14.
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.

15. Close the media door.

16. Reconnect the AC power cord and data cables.

17. Turn on (l) the printer.

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Corrective Maintenance 205
Replace the Printhead Pressure Dials

Replace the Printhead Pressure Dials

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Flat-blade Screwdriver Set Masking Tape
Metric Nutdriver Set 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%).

Remove the Printhead

Note Retain all parts removed during disassembly, unless otherwise directed.

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

Open the media door, open the printhead, and remove media and ribbon.

3.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

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206 Corrective Maintenance
Replace the Printhead Pressure Dials

4. See Figure 80. Close the printhead and rotate the printhead pressure dials to the #1
position.

Figure 80 Locate the Printhead Pressure Dials


1 1
2 3 2 3 2 4 2 4
1 1

ZM400 ZM600

1 Postion #1
2 Pressure dial
3 Position #4
4 Position #8

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Corrective Maintenance 207
Replace the Printhead Pressure Dials

5.
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

See Figure 81. Remove the printhead thumbscrew.

Figure 81 Remove the Printhead and Cable Connections

2
1

4
5

7
6

6.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the print mechanism, and lift and latch it in the vertical position.

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

8. Disconnect the two printhead cables from the printhead assembly.

9. Remove the printhead assembly and set it aside on the antistatic mat.

To remove the pressure dials you must partially disassemble the print mechanism.

10. See . Place a soft pad down on your workbench and lay the printer on it with the
electronics cover side down.

11. Open the media door.

12. See Figure 82. Put a piece of masking tape over the pressure roller to secure it to the
pressure bracket.
This is being done for ease of reinstallation of the roller and bracket.

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208 Corrective Maintenance
Replace the Printhead Pressure Dials

Figure 82 Remove the Pressure Bracket and Roller

1
7

8
3

1 Print mechanism
2 Pressure bracket
3 Masking tape (2)
4 Pressure bracket mounting screw
5 Lifting spring
6 Lower print mechanism latch screw
7 Upper print mechanism latch screw

13. Remove the lower print mechanism latch screw and then remove the stabilizer.

14. Remove the pressure bracket mounting screw, and swing the bracket out of the way.

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Corrective Maintenance 209
Replace the Printhead Pressure Dials

15. See Figure 83. Remove and discard the dials and springs from the print mechanism.

Figure 83 Remove the Pressure Dials

1 Pressure dial and spring


2 Pressure bracket

Install the New Pressure Dials


1. See Figure 84. Install the new springs in to the new dials.

Figure 84 Install the Springs

1
2

1 Pressure dial
2 Spring

2. See Figure 83 on page 209. Insert the new dials and springs into the print mechanism.

3. See Figure 82 on page 208. Reinstall the pressure bracket and roller, and then remove the
masking tape.

4. Reinstall the stabilizer by inserting it into the print mechanism until it stops.

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210 Corrective Maintenance
Replace the Printhead Pressure Dials

5. Reinstall the lower latch screw.

6. See Figure 81 on page 207. Connect the printhead cables to the printhead fork assembly.
Lift the assembly and carefully slide the assembly into the print mechanism, ensuring the
data cable and power cable are kept away from the printhead lifting spring (see Figure 82
on page 208).

7. Route the printhead cables over the top of the wire guide.

8. See Figure 85. Align the two alignment pins on the printhead with the two alignment holes
in the print mechanism.

Figure 85 Align the Forks and Bearings

7
2

1 Thumbscrew
2 Alignment holes
3 Wire guide
4 Alignment pins
5 Platen housing
6 Forks (2)
7 Bearings (2)

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Corrective Maintenance 211
Replace the Printhead Pressure Dials

9. Lift and hold the printhead in position while securing it with the previously removed
thumbscrew and then close the print mechanism.

10. Set the printer up on the base.

11. Open the print mechanism and latch it in the open position.

12.
Caution Do not use sharp objects to clean the printhead or platen roller.

Using the Zebra Preventive Maintenance Kit, clean the printhead and platen roller.

13.
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.

14. See Figure 80 on page 206. Rotate the two printhead pressure dials to the desired position
for your daily printing.

15. Close the media door.

16. Reconnect the AC power cord and data cables.

17. Turn on (l) the printer.

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212 Corrective Maintenance
Magnetic Printhead Latch

Magnetic Printhead Latch

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Needle Nose Pliers


Flat Blade Screwdriver Set Antistatic Wriststrap and Mat

Remove the Electronics Cover


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.
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.

Remove the media and ribbon.

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Corrective Maintenance 213
Magnetic Printhead Latch

3. See Figure 86. Remove the screw and washer securing the electronics cover.

Figure 86 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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214 Corrective Maintenance
Magnetic Printhead Latch

5. See Figure 87. Remove the four mounting screws on the rear of the printer.

Figure 87 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 88. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 88 Remove the Electronics Cover

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Corrective Maintenance 215
Magnetic Printhead Latch

7.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Anytime you expose electronic printed circuit boards, connect yourself to an antistatic
device.

Remove the Old Magnetic Latch


1. See Figure 89. Reopen the media door and locate the magnetic latch and strike plate.

Figure 89 Locate the Magnetic Latch


1 2

1 Magnetic latch strike plate


2 Screw
3 Magnetic latch

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216 Corrective Maintenance
Magnetic Printhead Latch

2. See Figure 90. Remove and discard the old magnetic strike plate mounting screw.

3. Remove and discard the strike plate.

Figure 90 Remove the Old Magnetic Latch

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Corrective Maintenance 217
Magnetic Printhead Latch

1 Strike plate mounting screw


2 Strike plate
3 Magnetic latch clamp
4 Magnetic latch
5 Tabs

4. Facing the front of the printer, reach into the electronics side with your left hand and hold
the magnetic latch.

5. Using a long nose pliers in your right hand, squeeze the top and bottom tabs on the sides
of the magnetic latch together while pulling out slightly on the magnetic latch with your
left hand.

6. Repeat step five for the other two tabs.

7. Remove and discard the old magnetic latch.

Install the New Magnetic Latch


1. See Figure 91. From the electronics side, align the new magnetic latch with the mounting
hole, with the tabs facing the printer.

Figure 91 Install the New Magnetic Latch

1
2

1 Mounting hole
2 Tabs (4)
3 Magnetic latch

2. Push the magnetic latch into the mounting hole until all four tabs snap into the housing
and the magnetic latch is secure.

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218 Corrective Maintenance
Magnetic Printhead Latch

3. See Figure 92. Slide the tab of the magnetic latch clamp into the magnetic latch slot on the
right side of the latch and then press on the left side of the clamp to snap it into the slot on
the left side.

Figure 92 Install Magnetic Latch Clamp


1
2
4
3

1 Magnetic latch
2 Magnetic latch clamp
3 Tabs (2)
4 Slot (2)

4. See Figure 90 on page 216. Install the new magnetic latch strike plate.

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Corrective Maintenance 219
Magnetic Printhead Latch

Reinstall the Electronics Cover


1. See Figure 93. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 93 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 87 on page 214. Install the four mounting screws.

3. See Figure 86 on page 213. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5.
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.

6. Reconnect the AC power cord and data cables

7. Turn on (l) the printer.

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220 Corrective Maintenance
Magnetic Printhead Latch

Notes ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Sensors

This section provides replacement and installation procedures for the ZM400/ZM600 sensors.

Contents
Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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222 Corrective Maintenance
Sensor Assemblies

Sensor Assemblies

Caution A qualified service technician must perform this installation.

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Hex Key (Allen Wrench) Set


Flat-blade Screwdriver Set Antistatic Wriststrap and Pad
Safety Glasses Metric Nutdriver Set

Remove the Electronics Cover


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media door and remove the media and ribbon.

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Corrective Maintenance 223
Sensor Assemblies

3. See Figure 94. Remove the screw and washer securing the electronics cover.

Figure 94 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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224 Corrective Maintenance
Sensor Assemblies

5. See Figure 95. Remove the four mounting screws on the rear of the printer.

Figure 95 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 96. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 96 Remove the Electronics Cover

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Corrective Maintenance 225
Sensor Assemblies

7. Do you have a wireless board installed?

If Then
No Go to Access the Power Supply on page 227.
Yes Continue with Remove the Wireless Board.

Remove the Wireless Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 97. Press in on the eject button to remove the radio card.

Figure 97 Remove the Radio Card


1

1 Eject button
2 Radio card

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226 Corrective Maintenance
Sensor Assemblies

3. See Figure 98. Remove the screw from the upper left corner of the wireless board.

4. Remove the two lower mounting screws and then remove the wireless board from the
main logic board (MLB).

Figure 98 Remove the Wireless Board


1

2
3

1 Wireless board
2 Mounting screws (3)
3 Main logic board (MLB)

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Corrective Maintenance 227
Sensor Assemblies

Access the Power Supply


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 99. Remove the mounting stud from the upper left of the power supply shield.

3. Remove the mounting screw from the upper right of the power supply shield.

Figure 99 Remove the Standoff and Screw

1 Mounting screw
2 Mounting stud
3 Power supply shield

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228 Corrective Maintenance
Sensor Assemblies

4. See Figure 100. Pull the top of the power supply shield away from the main frame and
fold it down to access the stepper motor connector.

Figure 100 Gain Access the Power Supply

1 Power supply shield

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Corrective Maintenance 229
Sensor Assemblies

Remove the Stepper Motor


1. See Figure 101. Locate the stepper motor and drive belt.

Figure 101 Locate Drive System Components


1
2

7
4

6 5

1 Power supply, J2
2 Stepper motor cable routing
3 Stepper motor
4 Platen pulley
5 Drive belt
6 Locking screw
7 Pivot screw

5 Drive belt
6 Locking screw
7 Pivot screw

2. Disconnect the stepper motor cable from J2 on the power supply.

3. Remove the locking screw and nut.

4. Remove the pivot screw and then remove the stepper motor.

5. Set the stepper motor aside.

6. Continue with Remove the Media Sensor Connections.

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230 Corrective Maintenance
Sensor Assemblies

Remove the Media Sensor Connections


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 102. Disconnect the upper media sensor cables from J3 and P7 of the main
logic board (MLB).

Figure 102 Disconnect the Media Sensor Cables

3 2

1 Main logic board (MLB)


2 Wire wrap
3 Reflective media sensor connector (P7)
4 Lower media sensor connector (P9)
5 Media detector connector (J3)

3. Disconnect the lower media sensor cable from P9 of the main logic board (MLB).

4. Remove the wires from the wire wrap.

5. Continue with Remove the Sensor Assemblies.

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Corrective Maintenance 231
Sensor Assemblies

Remove the Sensor Assemblies


1. See Figure 103. Remove the mounting screw, split lock washer, and flat washer from the
upper media sensor assembly.

Figure 103 Remove the Upper Media Sensor Mounting Screw

1 2

5 4

1 Upper media sensor mounting screw


2 Upper media sensor mounting split lock washer
3 Upper media sensor mounting flat washer
4 Lower media sensor mounting split lock washer
5 Lower media sensor mounting screw

2. Remove the mounting screw and split washer from the lower media sensor assembly.

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232 Corrective Maintenance
Sensor Assemblies

3.
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 104. Release the dancer spring from the dancer spring stop

Figure 104 Release the Dancer Spring


1 2

1 Dancer spring stop


2 Dancer spring

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Corrective Maintenance 233
Sensor Assemblies

4. See Figure 105. Slowly slide the lower media sensor assembly out of the printer, while
guiding the sensor cable through the hole in the main frame.
The cable connector will need to be turned sideways.

Figure 105 Remove the Media Sensor Assemblies

1 Upper media sensor assembly


2 Lower media sensor assembly

5. Slowly slide the upper media sensor assembly out of the printer, while guiding the sensor
cables through the holes in the main frame.

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234 Corrective Maintenance
Sensor Assemblies

Install the New Upper Media Sensor Assembly


1. Remove the new lower sensor assembly from the maintenance kit.

2.
Caution The end of the shaft has barbs that are used for alignment. Use caution not to
damage the barbs.

See Figure 106. Remove the protective cap.

Figure 106 Remove the Protective Cap


1

2 1
3

1 Shaft
2 Protective cap
3 Barbs

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Corrective Maintenance 235
Sensor Assemblies

3. See Figure 107. Guide the cable of the lower media sensor through the access hole in the
main frame.

Figure 107 Locate the Access Hole

1 2

1 Cable connector access and locating hole


2 Locating pins
3 Mounting hole

4. Slide the lower media sensor assembly into the mounting hole while aligning the two
locating pins with the opening in the main frame until it stops.

5. Turn the shaft in the hole to ensure that the barbs are in the slots on the inside of the main
frame mounting hole.

6. See Figure 103 on page 231. While holding the lower media sensor in the slots, install the
mounting screw and washer.

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236 Corrective Maintenance
Sensor Assemblies

Install the New Upper Media Sensor Assembly


1. Remove the new upper sensor assembly from the maintenance kit.

2.
Caution The end of the shaft has barbs that are used for alignment. Use caution not to
damage the barbs.

See Figure 108. Remove the protective cap.

Figure 108 Remove the Protective Cap


1

2 1
3

1 Shaft
2 Protective cap
3 Barbs

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Corrective Maintenance 237
Sensor Assemblies

3. See Figure 109. Guide the cables of the upper media sensor through their proper access
holes in the main frame.

Figure 109 Install the Upper Media Sensor Assembly


1 2

1 Three wire connector access hole


2 Mounting hole
3 Four wire connector access hole

4. Slide the upper media sensor assembly into the mounting hole until it stops.

5. See Figure 104 on page 232. Relocate the arm of the dancer spring onto the dancer spring
stop.

6. Turn the shaft in the hole to ensure that the barbs are in the slots on the inside of the main
frame mounting hole.

7. See Figure 103 on page 231. While holding the upper media sensor in the slots, install the
mounting screw, lock washer, and flat washer.

Connect the Media Sensor Cables


1. See Figure 102 on page 230. Connect the upper media sensor cables to J3 and P7 on the
MLB.

2. Connect the lower media sensor cable to P9 on the MLB.

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238 Corrective Maintenance
Sensor Assemblies

3. Place the cables in the wire wrap.

Reinstall the Stepper Motor


1. See Figure 101 on page 229. Install the stepper motor by sliding the gear/pulley through
the drive belt. Secure in position with the pivot screw, but do not tighten at this time.

2. Reinstall the locking screw and nut, but do not tighten at this time.

Note The drive belt should deflect under finger pressure but no more than 6 mm
(1/4 in.).

3. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.

4. Route the stepper motor cable as shown and connect it to J2 on the power supply.

5. See Figure 99 on page 227 and lift the power supply shield back into place.

6. Replace the mounting stud.

7. Verify all cable routing.

8. Did you remove a wireless board?

If Then
No Continue with Reinstall the Electronics Cover.
Yes a. See Figure 98 on page 226 and replace the wireless board.
b. See Figure 97 on page 225 and replace the radio card.
c. Continue with Reinstall the Electronics Cover.

Reinstall the Electronics Cover


1. See Figure 96 on page 224. Install the electronics cover by aligning it and sliding down,
ensuring the lower flange is inside the base and the upper flange is between the main
frame and the media door.

2. See Figure 95 on page 224. Reinstall the four mounting screws.

3. Open the media door.

4. See Figure 94 on page 223. Reinstall the electronics cover mounting screw and lock
washer.

5.
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.

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Corrective Maintenance 239
Sensor Assemblies

Adjust the Sensor Gap


1. Which model printer are you working on?

If you have a Then


ZM400 a. See Figure 110. Using a hex key, loosen the mounting screw
securing the upper media sensor to the mounting shaft one full
turn.
b. Insert the gapping shim supplied in the kit between the upper and
lower media sensors at the notch.
c. Lightly squeeze the upper and lower sensors together and then
tighten the mounting screw.
d. Remove the gapping shim.
ZM600 a. See Figure 111. Using a hex key, loosen the two mounting
screws securing the upper media sensor to the mounting shaft
one full turn.
b. Insert the gapping shim supplied in the kit between the upper and
lower media sensors between the two notches.
c. Lightly squeeze the upper and lower sensors together and then
tighten the mounting screws.
d. Remove the gapping shim.

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240 Corrective Maintenance
Sensor Assemblies

Figure 110 Adjust the ZM400 Upper Media Sensor

Squeeze
Here
1

2 3
2

Squeeze
Here

1 Mounting screw
2 Gapping shim
3 Notch

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Corrective Maintenance 241
Sensor Assemblies

Figure 111 Adjust the ZM600 Upper Media Sensor


3 Squeeze
Here

2
2

Squeeze
Here

1 Mounting screws (2)


2 Gapping shim
3 Notches (2)

2. Turn on (l) the printer.

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242 Corrective Maintenance
Ribbon/Head Open Sensor Assembly

Ribbon/Head Open Sensor Assembly

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Metric Nutdriver Set Metric and inch Feeler Gauges; must
include: 1.5 mm (0.060 in.)

Remove the Electronics Cover


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media door and remove the media and ribbon.

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Corrective Maintenance 243
Ribbon/Head Open Sensor Assembly

3. See Figure 112. Remove the screw and washer securing the electronics cover.

Figure 112 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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244 Corrective Maintenance
Ribbon/Head Open Sensor Assembly

5. See Figure 113. Remove the four mounting screws on the rear of the printer.

Figure 113 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 114. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 114 Remove the Electronics Cover

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Corrective Maintenance 245
Ribbon/Head Open Sensor Assembly

Remove the Old Sensor


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 115. Unplug the ribbon/printhead open sensor cable from P4 on the main logic
board (MLB).

Figure 115 Disconnect the Ribbon/Head Open Sensor

1 2 3 4

1 Main logic board (MLB)


2 MLB connector (P4)
3 Ribbon/Head open sensor cable
4 Protective wrap

3. Remove the ribbon/head open cable from the protective wrap.

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246 Corrective Maintenance
Ribbon/Head Open Sensor Assembly

4. See Figure 116. Remove the screw securing the ribbon/head open sensor assembly.

Note You may find it easier to lay the printer on its side for easy access to the mounting
screw.

5. Pull the ribbon sensor cable and connector through the main frame.

Figure 116 Ribbon Sensor Removal and Installation

1 Ribbon/Head open sensor assembly


2 Mounting screw

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Corrective Maintenance 247
Ribbon/Head Open Sensor Assembly

Install the New Ribbon/Head Open Sensor Assembly


1. See Figure 117. Route the sensor wires, with connector, through the access hole in the
printer mainframe.

Figure 117 Locate the Access Hole

Access Hole

Mounting Hole

2. Place the sensor cable wires back into the protective wrap.

3. Connect the media sensor cable to P4 on the MLB.

4. Install the ribbon/head open sensor to the mainframe with the new screw. Do not tighten it
at this time.

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248 Corrective Maintenance
Ribbon/Head Open Sensor Assembly

5. See Figure 118. Check the gap on the ribbon/printhead open sensor and adjust as
necessary.

Figure 118 Gap Measurement Between Print Mechanism and Sensor

5
4

1 Printhead housing
2 Gap, 1.25 mm (0.050 in.)
3 Ribbon/Printhead open sensor
4 Mounting screw
5 Ribbon guide plate

6. Using a 1.25 mm (0.050 in.) feeler gauge, check the distance between the ribbon/head
open sensor assembly and the ribbon guide plate.
If the distance is incorrect, loosen the mounting screw for the ribbon/head open sensor and
adjust for the proper distance. Once this distance is achieved, tighten the mounting screw.

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Corrective Maintenance 249
Ribbon/Head Open Sensor Assembly

Reinstall the Electronics Cover


1. See Figure 119. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 119 Locate the Upper and Lower Flanges


1
2

1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)

2. See Figure 114 on page 244. Reinstall the electronics cover.

3. See Figure 113 on page 244. Install the four mounting screws.

4. See Figure 112 on page 243. Open the media door.

5. Install the electronics cover mounting screw and lock washer.

6.
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.

7. If the ribbon/head open sensor is not recognized by the main logic board see your User
Guide for calibration and setup procedures.

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250 Corrective Maintenance
Ribbon/Head Open Sensor Assembly

Notes ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Drive System

This section provides replacement and installation procedures for the ZM400/ZM600 drive
system.

Contents
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Drive Belt Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Stepper Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Ribbon Take-up Spindle Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Printhead Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Peel Maintenance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Media Hanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Sheet Metal Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Outer Guard Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Media Edge Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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252 Corrective Maintenance
Drive System

Drive System

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Flat-blade Screwdriver Set Metric Hex Key (Allen Wrench) Set

Remove the Electronics Cover


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.
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.

Remove the media and ribbon.

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Corrective Maintenance 253
Drive System

3. See Figure 120. Remove the screw and washer securing the electronics cover.

Figure 120 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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254 Corrective Maintenance
Drive System

5. See Figure 121. Remove the four mounting screws on the rear of the printer.

Figure 121 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 122. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 122 Remove the Electronics Cover

7. Remove the Gear Cover

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Corrective Maintenance 255
Drive System

8.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

9. See Figure 123. Lay the printer on its side, media door down on a mat.

Figure 123 Lay the Printer on its Side


2
1

1 Gear cover
2 Mounting screw

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256 Corrective Maintenance
Drive System

10. See Figure 124. Mark the proper mounting hole in the gear cover.
You will use this mark as areference when you reinstall the gear cover.

11. Remove and discard the gear cover mounting screw.

Figure 124 Remove the Gear Cover

1 Mounting screw
2 Gear cover
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.

12. Slide the cover off the drive assembly and discard.

13. Mark the outside facing side of the compound gear and remove it.
You will use this mark as areference when you reinstall the compound gear.

14. Turn the printer back up on its base.

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Corrective Maintenance 257
Drive System

Remove the Old Gears, Drive Belt, and Pulley


1. See Figure 125. Loosen the pivot screw and swing the stepper motor up to remove tension
from the belt, and then tighten the locking screw in this position. Remove the belt from the
stepper motor drive gear.

Note The pulley has two drive wheels that allow for 200 or 300 dpi operation. Note the
location and orientation of the drive belt on the pulley before removing.

2. Loosen the two set screws and remove the compound pulley. Note the orientation of the
pulley.

Figure 125 Remove and Install Gears, Pulley, and Belt

2
7
203 dpi

3
6
4 5

2 300 dpi
7
300/600 dpi 600 dpi

3
8
4
5

1 Gear cover
2 Compound gear mounting screw
3 Stepper motor pivot screw
4 Stepper motor locking screw
5 Platen pulley set screws (2)
6 Platen pulley (203 dpi)
7 Compound Gear
8 Platen pulley (300/600 dpi)

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258 Corrective Maintenance
Drive System

Install the New Gears, Drive Belt, and Compound Pulley


1. Match the size of the platen pulley with the one from the kit.

2. See Figure 125. Slide the new platen pulley onto the platen roller shaft in the proper
orientation to approximately 1/32 in. (0.80 mm) from the main frame and then tighten the
platen pulley set screws.

3. Install the new intermediate gear.

4. Install the stepper motor. Secure in the highest position with the pivot screw.

5. Match the size of the drive belt with the one from the kit.

6. Install the new drive belt.

Note The belt should deflect under finger pressure but no more than inch (6 mm).

7. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.

8. See Figure 124 on page 256. With the marked side facing out slide the compound gear
into the printer. Ensure that the gears mesh.

Note Look at the old compound gear to see what side you marked for facing out.

9. Ensure all gears mesh together.

10. Align the gear cover and slide it back into place.

11. Install the mounting screw in the proper hole in the gear cover, through the compound
gear, and then into the proper mounting hole in the main frame.

12. Tighten the mounting screw.

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Corrective Maintenance 259
Drive System

Reinstall the Electronics Cover


1. See Figure 126. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 126 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 121 on page 254. Install the four mounting screws.

3. See Figure 120 on page 253. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5.
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.

6. Reconnect the AC power cord and data cables.

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260 Drive Belt
Drive Belt Maintenance Kit

Drive Belt Maintenance Kit

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Flat-blade Screwdriver Set Metric Hex Key (Allen Wrench) Set

Remove the Electronics Cover

1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2. See Figure 127. Remove the screw and washer securing the electronics cover.

Figure 127 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

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Drive Belt 261
Drive Belt Maintenance Kit

3. Close the media door.

4. See Figure 128. Remove the four mounting screws on the rear of the printer.

Figure 128 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

5. See Figure 129. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 129 Remove the Electronics Cover

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262 Drive Belt
Drive Belt Maintenance Kit

Remove the Old Gears, Drive Belt, and Pulley


1. See Figure 130. Loosen the pivot screw and swing the stepper motor up to remove tension
from the belt, and then tighten the locking screw in this position.

2. Remove the drive belt from the stepper motor gear/pulley.

Figure 130 Remove the Old Belt

1 2
3

5 4

1 Stepper motor
2 Pivot screw
3 Drive belt
4 Platen pulley
5 Locking screw

3. Remove and discard the belt from the platen pulley.

Install the New Drive Bet


1. See Figure 130. Install the new belt on the platen pulley

2. Install the belt onto the drive gear/pulley.

3. Loosen the stepper motor locking screw.

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Drive Belt 263
Drive Belt Maintenance Kit

4. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.

Note The belt should deflect under finger pressure but no more than 6 mm (1/4 inch).

Reinstall the Electronics Cover


1. See Figure 131. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 131 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 128 on page 261. Install the four mounting screws.

3. See Figure 127 on page 260. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5. Reinstall the AC power cord and data cables.

6. Turn on (l) the printer.

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264 Corrective Maintenance
Stepper Motor Assembly

Stepper Motor Assembly

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Metric Hex Key (Allen Wrench) Set Metric Nutdriver Set

Remove the Electronics Cover

Note Retain all parts removed during disassembly, unless otherwise directed.

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

Open the media door and remove the media and ribbon.

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Corrective Maintenance 265
Stepper Motor Assembly

3. See Figure 4. Remove the screw and washer securing the electronics cover.

Figure 132 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door and turn the printer around.

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266 Corrective Maintenance
Stepper Motor Assembly

5. See Figure 133. Remove the four mounting screws on the rear of the printer.

Figure 133 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 134. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 134 Remove the Electronics Cover

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Corrective Maintenance 267
Stepper Motor Assembly

7. Which model of ZM400/ZM600 printer are you working on?

If you have a Then


ZM400/ZM600 Go to Gain Access to the Power Supply on page 269.
without wireless board
ZM400/ZM600 Continue with Remove the Wireless Board.
with wireless board

Remove the Wireless Board


1. See Figure 135. Press in on the eject button to remove the radio card.

Caution Observe proper electrostatic safety precautions when handling


static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

Figure 135 Remove the Radio Card


1

1 Eject button
2 Radio card

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268 Corrective Maintenance
Stepper Motor Assembly

2. See Figure 136. Remove the screw from the upper left corner of the wireless board.

Figure 136 Remove the Wireless Board


1

1 Wireless board
2 Mounting screws (4)

3. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).

4. Continue with Gain Access to the Power Supply.

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Corrective Maintenance 269
Stepper Motor Assembly

Gain Access to the Power Supply


1. See Figure 137. Remove the standoff from the upper left of the power supply shield.

2. Remove the mounting screw from the upper right of the power supply shield.

Figure 137 Remove the Standoff and Screw

1 Mounting screw
2 Standoff
3 Power supply shield

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270 Corrective Maintenance
Stepper Motor Assembly

3. See Figure 138. Pull the top of the shield away from the main frame and fold it down to
access the stepper motor connector.

4. Disconnect the stepper motor cable from J2 on the power supply.

Figure 138 Gain Access the Power Supply

1 Shield
2 Stepper motor cable
3 Stepper motor connector, J2

5. Continue to Remove the Old Stepper Motor and Gear.

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Corrective Maintenance 271
Stepper Motor Assembly

Remove the Old Stepper Motor and Gear


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 139. Locate the stepper motor and drive belt.

Figure 139 Locate Drive System Components


1
2

7
4

6 5

1 Power supply, J2
2 Stepper motor cable routing
3 Stepper motor
4 Platen pulley
5 Drive belt
6 Locking screw
7 Pivot screw

3. Remove the locking screw and nut.

4. Remove the pivot screw and then remove the stepper motor.

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272 Corrective Maintenance
Stepper Motor Assembly

Install the New Stepper Motor and Gear


1. See Figure 139 on page 271. Install the stepper motor by sliding the gear/pulley through
the drive belt. Secure in position with the pivot screw, but do not tighten at this time.

2. Reinstall the locking screw and nut, but do not tighten at this time.

Note Belt should deflect under finger pressure but no more than inch (6 mm).

3. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.

4. Route the stepper motor cable as shown and connect it to J2 on the power supply.

5. See Figure 137 on page 269 and lift the power supply shield back into place.

6. Replace the mounting screw and standoff.

7. Verify all cable routing.

8. See Figure 136 on page 268 and replace the wireless board.

9. See Figure 135 on page 267 and replace the radio card.

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Corrective Maintenance 273
Stepper Motor Assembly

Reinstall the Electronics Cover


1. See Figure 140. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 140 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 133 on page 266. Install the four mounting screws.

3. See Figure 132 on page 265. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5.
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.

6. Reconnect the AC power cord and data cables.

7. Turn on (l) the printer.

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274 Ribbon Take-up Spindle Clutch
Ribbon Take-up Spindle Clutch

Ribbon Take-up Spindle Clutch

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Feeler Gauges; must include:


0.50 mm
Metric Hex Key (Allen Wrench) Set
Safety Glasses
Metric Nutdriver Set
Antistatic Wrist Strap and Mat

Remove the Electronics Cover

Caution Observe proper electrostatic safety precautions when handling any


static-sensitive components such as circuit boards and printheads.

Note Retain all parts removed during disassembly, unless otherwise directed.

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Ribbon Take-up Spindle Clutch 275
Ribbon Take-up Spindle Clutch

1. See Figure 141. Remove the screw and washer securing the electronics cover.

Figure 141 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

2. Close the media door.

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276 Ribbon Take-up Spindle Clutch
Ribbon Take-up Spindle Clutch

3. See Figure 142. Remove the four mounting screws on the rear of the printer.

Figure 142 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

4. See Figure 143. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 143 Remove the Electronics Cover

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Ribbon Take-up Spindle Clutch 277
Ribbon Take-up Spindle Clutch

Remove the Gear Cover


1. See Figure 144. Lay the printer on its side, media door down on a mat.

Figure 144 Lay the Printer on its Side


2
1

1 Gear cover
2 Mounting screw

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278 Ribbon Take-up Spindle Clutch
Ribbon Take-up Spindle Clutch

2. See Figure 145. Mark the proper mounting hole in the gear cover.
This ensures correct installation when the ribbon take-up spindle installation is complete.

3. Remove the gear cover mounting screw.

Figure 145 Remove the Gear Cover

1 2

1 Gear cover
2 Mounting screw
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.

4. Slide the cover off the drive assembly.

5. Mark the outside facing side of the compound gear and remove it.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.

6. Turn the printer back up on its base.

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Ribbon Take-up Spindle Clutch 279
Ribbon Take-up Spindle Clutch

Remove the Old Ribbon Take-Up Clutch


1. See Figure 146. Mark the proper mounting hole in the main frame.

2.
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.

Loosen the two set screws on the ribbon take-up collar and slide the collar off of the shaft
and discard it.

Figure 146 Loosen the Set Screws


1
2

1 Ribbon take-up gear and clutch assembly


2 Set screws (2)
3 Collar
4 Main frame. Mark the proper mounting hole.

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280 Ribbon Take-up Spindle Clutch
Ribbon Take-up Spindle Clutch

3. See Figure 147. Remove and discard the plastic thrust washer, clutch bearing, hub, spring,
gear and washer or washers from the ribbon take-up (RTU) spindle shaft.

Figure 147 Remove the Clutch

4 5 7
1
3

2 9
8

1 Collar
2 Set screws (2)
3 Thrust washer
4 Bearing and hub
5 Spring
6 Clutch gear
7 Flat washers (2)
8 RTU spindle shaft
9 0.50 mm gap between the collar and thrust washer

Install the New RTU Clutch


1. See Figure 147. Holding the ribbon take-up (RTU) spindle slide the washer or washers
and new clutch gear onto the RTU spindle shaft.

2. Start the two set screws in the collar.

3. Slide the spring, thrust washer and collar onto the RTU spindle shaft.

4. Place a 0.50 mm feeler gauge between the thrust washer and the collar.

5. From the media side, push in on the RTU spindle and then tighten the two set screws in the
collar and ensure that the RTU spindle turns freely.

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Ribbon Take-up Spindle Clutch 281
Ribbon Take-up Spindle Clutch

Reinstall the Gear Cover


1. See Figure 145 on page 278. With the marked side facing out, slide the compound gear
into the printer. Ensure that the gears mesh.

2. Align the gear cover and slide it back into place.

3. Install the mounting screw in the proper hole in the gear cover, then through the
compound gear, and then into the proper mounting hole in the main frame.

4. Tighten the mounting screw.

Reinstall the Electronics Cover


1. See Figure 148. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 148 Locate the Upper and Lower Flanges


1
2

1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)

2. See Figure 142 on page 276. Install the four mounting screws.

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282 Ribbon Take-up Spindle Clutch
Ribbon Take-up Spindle Clutch

3. See Figure 141 on page 275. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5.
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.

6. Reconnect the AC power cord and data cables.

7. Turn on (l) the printer.

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Corrective Maintenance 283
Ribbon Take-up Spindle

Ribbon Take-up Spindle

Caution A qualified service technician must perform this installation.

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Metric Hex Key (Allen Wrench) Set Metric Feeler Gauges; must include:
0.5 mm
Metric Nutdriver Set

Remove the Electronic Cover

Note Retain all parts removed during disassembly, unless otherwise directed.

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

Open the media door and remove the media and ribbon.

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284 Corrective Maintenance
Ribbon Take-up Spindle

3. See Figure 149. Remove the screw and washer securing the electronics cover.

Figure 149 Locate the Electronics Cover Mounting Screw

1 2
3

5 4

1 Electronics cover
2 Media cover
3 Upper flange
4 Mounting screw
5 Lock washer
6 Lower flange

4. See Figure 150. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 150 Remove the Electronics Cover

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Corrective Maintenance 285
Ribbon Take-up Spindle

Remove the Gear Cover


1. See Figure 151. Lay the printer on its side, media door down on a mat.

Figure 151 Lay the Printer on its Side


2
1

1 Gear cover
2 Mounting screw

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286 Corrective Maintenance
Ribbon Take-up Spindle

2. See Figure 152. Mark the proper mounting hole in the gear cover.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.

3. Remove the gear cover mounting screw.

Figure 152 Remove the Gear Cover


1

1 Gear cover
2 Mounting screw
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.

4. Slide the cover off the drive assembly.

5. Mark the outside facing side of the compound gear and remove it.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.

6. Turn the printer back up on its base.

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Corrective Maintenance 287
Ribbon Take-up Spindle

Remove the Old RTU Spindle Assembly


1. See Figure 153. Mark the proper mounting hole in the main frame.

2. Loosen the two set screws on the ribbon take-up collar and slide the collar off of the shaft.

Figure 153 Loosen the Set Screws


1
2

1 Ribbon take-up gear and clutch assembly


2 Set screws (2)
3 Collar
4 Main frame. Mark the proper mounting hole.

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288 Corrective Maintenance
Ribbon Take-up Spindle

3. See Figure 154. Remove the plastic thrust washer, clutch gear assembly, and washer(s)
from the shaft of the ribbon take-up spindle assembly.

Figure 154 Remove the RTU Spindle

7 3

6 5
4
2
1

1 Ribbon take-up spindle assembly


2 Washer
3 Washer(s)
4 Clutch gear assembly
5 Thrust washer
6 Place a 0.500 mm feeler gauge between the thrust washer and
the collar.
7 Collar

4. From the media side, remove the ribbon take-up assembly and washer.

Install the New Ribbon Take-up Spindle Assembly


1. See Figure 154. Slide the washer onto the new ribbon take-up assembly.

2. From the media side, slide the ribbon take-up assembly and washer through the main
frame.

3. On the electronics side, place the washer(s), gear clutch assembly, plastic thrust washer,
and collar onto the end of the ribbon take-up assembly shaft.

4. Place a 0.500 mm feeler gauge between the thrust washer and the collar. From the media
side, push in on the ribbon take-up spindle. Tighten the two screws in the collar and ensure
the ribbon take-up spindle turns freely.

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Corrective Maintenance 289
Ribbon Take-up Spindle

Reinstall the Gear Cover


1. See Figure 152 on page 286. With the marked side facing out, slide the compound gear
into the printer. Ensure that the gears mesh.

2. Align the gear cover and slide it back into place.

3. Install the mounting screw in the proper hole in the gear cover, then through the
compound gear, and then into the proper mounting hole in the main frame.

4. Tighten the mounting screw.

Reinstall the Electronics Cover


1. See Figure 155. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 155 Locate the Upper and Lower Flanges


1
2

1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)

2. See Figure 149 on page 284. Open the media door.

3. Install the electronics cover mounting screw and lock washer.

4. Reconnect the AC power cord and data cables and then turn on (l) the printer.

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290 Corrective Maintenance
Printhead Conversion

Printhead Conversion

Caution A qualified service technician must perform this installation.

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 ZM400 and ZM600 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:

Phillips Screwdriver Set Metric Nutdriver Set


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

Remove the Electronics Cover

Note Retain all parts removed during disassembly, unless otherwise directed.

Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

1.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media cover and remove the media and ribbon.

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Corrective Maintenance 291
Printhead Conversion

2. See Figure 156. Remove the screw and washer securing the electronics cover.

Figure 156 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

3. Close the media door.

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292 Corrective Maintenance
Printhead Conversion

4. See Figure 157. Remove the four mounting screws on the rear of the printer.

Figure 157 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

5. See Figure 158. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 158 Remove the Electronics Cover

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Corrective Maintenance 293
Printhead Conversion

Remove the Old Drive Belt and Platen Pulley


1. See Figure 159. Loosen the stepper motor locking and pivot screws.

Figure 159 Remove the Drive Belt

1 2 3

1 Pivot screw
2 Stepper motor
3 Drive belt
4 Set screws (2)
5 Platen pulley
6 Locking screw

2. Swing the stepper motor to the right to loosen the drive belt and then tighten the locking
screw to snug the motor in place.

3. Remove the drive belt from the stepper motor and then from the platen pulley and discard
it.

4. Loosen the two set screws securing the platen pulley.

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294 Corrective Maintenance
Printhead Conversion

5. See Figure 160. Slide the platen pulley from the coupling assembly and discard it.

Figure 160 Remove the Platen Pulley

Install the New Drive Belt and Platen Pulley


1. See Figure 161. Slide the platen pulley all the way onto the coupling drive shaft in the
proper orientation and align the set screws with the flat spots on the drive shaft.

Figure 161 Align the Screws


1

2
2

1 Setscrews (2)
2 Flats on shaft

2. See Figure 159 on page 293. Install the drive belt onto the platen pulley and the stepper
motor pulley.

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Corrective Maintenance 295
Printhead Conversion

3.
Caution Do not over tighten the drive belt, or damage to the bearings and platen
roller will occur. The belt should deflect under finger pressure but no more than 6 mm
(1/4 inch).

Loosen the locking screw and then rotate the motor down until the drive belt is just taut.
Tighten the locking screw and then the pivot screw.

Remove the Gear Cover


1. See Figure 162. Lay the printer on its side, media door down on a mat.

Figure 162 Lay the Printer on its Side


2
1

1 Gear cover
2 Mounting screw

Caution A qualified service technician must perform this installation.

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296 Corrective Maintenance
Printhead Conversion

2. See Figure 163. Remove the gear cover mounting screw.

Figure 163 Remove the Gear Cover


1

1 Mounting screw
2 Gear cover
3 Compound gear

3. Slide the cover off the drive assembly.

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Corrective Maintenance 297
Printhead Conversion

4. See Figure 164. Remove the compound gear.

Figure 164 Remove the Compound Gear

1 2

1 Compound gear turned to 300/600 dpi


2 Compound gear turned to 200 dpi

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298 Corrective Maintenance
Printhead Conversion

5. See Figure 165. Turn the compound gear around to the proper dpi.

Note There is a statement on both sides of the compound pulley.


THIS SIDE OUT/200 dpi. and THIS SIDE OUT/300 DPI. THIS SIDE OUT/300 DPI is
also used for 600 dpi.

Figure 165 Compound Gear DPI Location


DPI Statement

Reinstall the Compound Gear and Gear Cover


1. See Figure 163 on page 296. With the proper side facing out slide the compound gear into
the printer. Ensure that the gears mesh.

2. Ensure all gears mesh together.

3. Align the gear cover and slide it back into place.

4. Install the mounting screw in the proper hole in the gear cover, through the compound
gear, and then into the proper mounting hole in the main frame.

5. Tighten the mounting screw.

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Corrective Maintenance 299
Printhead Conversion

Reinstall the Electronics Cover


1. See Figure 166. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 166 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 157 on page 292. Install the four mounting screws.

3. See Figure 156 on page 291. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

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300 Corrective Maintenance
Printhead Conversion

Remove the Old Printhead

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

1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 167. Rotate the printhead pressure dials to the #1 position.

Figure 167 Locate the Printhead Pressure Dials


1 1 2
2 2 2
1 1

ZM400 ZM600

1 Postion #1
2 Pressure dial

3. Do you have a cutter option installed?

If Then
No Continue with step 4.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Go to Remove the Cutter Assembly on page 306.

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Corrective Maintenance 301
Printhead Conversion

4. See Figure 168. Locate and remove the thumbscrew from the print mechanism.

Figure 168 Remove the Thumbscrew

1 Print mechanism
2 Thumbscrew

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302 Corrective Maintenance
Printhead Conversion

5. See Figure 169. Open the print mechanism and latch it in the vertical position.

6.
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.

Disconnect the printhead data and power cables.

7. Remove and discard the printhead assembly from the printer.

Figure 169 Remove the Printhead


4
2 3

1 Printhead assembly
2 Print mechanism
3 Printhead data cable connector
4 Printhead power cable connector
5 Latch assembly

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Corrective Maintenance 303
Printhead Conversion

Install the New Printhead


1. See Figure 170. Align the two forks with the bearings and set the printhead assembly onto
the platen housing. This is done for ease of connecting the printhead cables.

2.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or display HEAD COLD or other false error
messages.

Connect the power and data cables to the printhead.

Figure 170 Align the Forks and Bearings

7
2
3

1 Thumbscrew
2 Alignment holes (2)
3 Cable guide
4 Alignment pins (2)
5 Platen housing
6 Forks (2)
7 Bearings (2)

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304 Corrective Maintenance
Printhead Conversion

3. Connect both printhead power and data cables to the printhead connectors and carefully
slide them into position. Ensure the cables are in their proper channels and are not binding
the printhead.

Note When mounting the printhead fork assembly onto the print mechanism, visually
inspect and ensure the cables are in their channels at the back of their carrier assembly,
power cable under data cable, and are not binding on the print mechanism.

4. See Figure 171. Tip the printhead fork assembly slightly and insert the printhead ribbon
guide into the print mechanism as shown.

5. Tip the printhead fork assembly up and into the print mechamism ensuing that the two
locating protrusions on either side of the print printhead snap into the locating holes of the
ribbon guide plate. Move the assembly back and forth to be sure that it is engaged. There
should be little movement.

6. While holding the printhead in place, install the thumb screw to secure the fork assembly.

Figure 171 Install the Printhead Fork Assembly

1 1

2 2

3
3

4 4

5 5

1 Thumbscrew
2 Print mechanism
3 Printhead fork assembly
4 Ribbon guide plate
5 Printhead ribbon guide

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Corrective Maintenance 305
Printhead Conversion

7. Clean the printhead with the Zebra Preventative Maintenance kit.

8. See Figure 167 on page 300. Rotate the two printhead pressure dials to the desired
position for your daily printing.

9. Did you remove a cutter assembly?

If Then
No Continue with step 10.
Yes Got to Remove the Cutter Assembly on page 306.

10.
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.

11. Reconnect the AC power cord and data cables

12. Turn on (l) the printer.

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306 Corrective Maintenance
Printhead Conversion

Remove the Cutter Assembly


1. See Figure 172. Unlatch the printhead and turn the latch assembly clockwise to access the
cutter mounting screw.

2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter mounting screw.

Figure 172 Remove the Cutter Assembly

5 4 3 2

1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness

Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.

3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.

4. Go to step 4 on page 301.

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Corrective Maintenance 307
Printhead Conversion

Reinstall the Cutter Assembly


1. See Figure 172 on page 306. Reinstall the cutter assembly on the hooks of the platen
housing.
a. Hold the cutter assembly as far to the left as possible, and align the larger part of the
step slot with the hooks on the platen housing.
b. Slide the cutter assembly onto the hooks and then push down and slide the assembly
to the right.

2. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the
platen assembly.
The mounting tab on the cutter fits behind and attaches to the platen assembly.

3. Turn the latch assembly counterclockwise until it snaps in place.

4.
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.

5. Reconnect the AC power cord and data cables

6. Turn on (l) the printer.

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308 Corrective Maintenance
Ribbon Supply Spindle

Ribbon Supply Spindle

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Hex Key (Allen Wrench) Set


Antistatic Wrist Strap and Pad

Remove the Electronics Cover

Caution A qualified service technician must perform this installation.

1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media cover and remove the media and ribbon.

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Corrective Maintenance 309
Ribbon Supply Spindle

3. See Figure 173. Remove the screw and washer securing the electronics cover.

Figure 173 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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310 Corrective Maintenance
Ribbon Supply Spindle

5. See Figure 174. Remove the four mounting screws on the rear of the printer.

Figure 174 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 175. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 175 Remove the Electronics Cover

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Corrective Maintenance 311
Ribbon Supply Spindle

Remove the Old Ribbon Supply Spindle

Caution Observe proper electrostatic safety precautions when handling any


static-sensitive components such as circuit boards and printheads.

Remove the Gear Cover


1. See Figure 176. Lay the printer on its side, media door down on a mat.

Figure 176 Lay the Printer on its Side


2
1

1 Gear cover
2 Mounting screw

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312 Corrective Maintenance
Ribbon Supply Spindle

2. See Figure 177. Mark the proper mounting hole in the gear cover.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.

3. Remove the gear cover mounting screw.

Figure 177 Remove the Gear Cover


1

1 Gear cover
2 Mounting screw
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.

4. Slide the cover off the drive assembly.

5. Mark the outside facing side of the compound gear and remove it.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.

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Corrective Maintenance 313
Ribbon Supply Spindle

Remove the Stepper Motor


Do you have a wireless board installed?

If Then
No Go to step 6 on page 315.
Yes Continue to the next step.

1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 178. Press in on the eject button to remove the radio card.

Figure 178 Remove the Radio Card


1

1 Eject button
2 Radio card

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314 Corrective Maintenance
Ribbon Supply Spindle

3. See Figure 179. Remove the screw from the upper left corner of the wireless board.

4. Remove the two lower mounting screws and then remove the wireless board from the
main logic board (MLB).

Figure 179 Remove the Wireless Board


1

1 Wireless board
2 Mounting screws (3)

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Corrective Maintenance 315
Ribbon Supply Spindle

5.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

6. See Figure 180. Disconnect the stepper motor cable from the power supply.

7. Locate the stepper motor and drive belt.

Figure 180 Locate the Drive Components


1 3
2 4

1 Stepper motor power connector


2 Stepper motor
3 Stepper motor cable
4 Drive belt
5 Locking screw
6 Pivot screw
7 Intermediate gear

8. Loosen the pivot screw and the locking screw.

9. Swing the stepper motor to the right to loosen the drive belt.

10. Remove the drive belt from the stepper motor pulley.

11. Remove the locking screw and nut.

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316 Corrective Maintenance
Ribbon Supply Spindle

12. See Figure 181. Remove the pivot screw and then slide the stepper motor out of the
printer.

Figure 181 Remove the Stepper Motor and Intermediate Gear

3
1 2

4
5

1 Pivot screw
2 Stepper motor
3 Intermediate gear
4 Locking screw nut
5 Locking screw

13. Remove the intermediate gear.

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Corrective Maintenance 317
Ribbon Supply Spindle

14. See Figure 182. Remove the ribbon supply spindle (RSS) mounting screw and washer.

Figure 182 Remove the Ribbon Supply Spindle


4
3

2
1

1 Mounting screw
2 Mounting washer
3 Washer
4 RSS

15. Which model printer do you have?

If you have Then


ZM400 a. Push the spindle out of the main frame.
b. Go to Install the New Ribbon Supply Spindle on page 318.
ZM600 Continue with the next step.

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318 Corrective Maintenance
Ribbon Supply Spindle

16. See Figure 183. Slide the spindle remove tool over the ribbon supply spindle on the
printer.

17. Install the screw into the end of the spindle assembly until it bottoms out.

18. Slide the washer over the end of the screw until it is against the remove tool.

19. Install the nut until it rests against the washer.

Figure 183 Using the Remove Tool


1
2
3
4
5

1 Spindle assembly
2 Spindle remove tool
3 Washer
4 Screw
5 Nut

20. While holding the remove tool and using the nut driver, turn the nut clockwise to remove
the ribbon supply spindle from the printer.

21. Remove the nut, washer, and screw from the spindle.

22. Slide the remove tool from the spindle.

Install the New Ribbon Supply Spindle


1. See Figure 184. Install the thin washer onto the spindle shaft.

Figure 184 Install the Thin Washer

1 2

1 Thin washer
2 Ribbon supply spindle shaft

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Corrective Maintenance 319
Ribbon Supply Spindle

2. Which model of printer do you have?

If you have a Then


ZM400 a. Push the RSS into the main frame.
b. Go to step 9 on page 320.
ZM600 Continue to the next step.

3. See Figure 185. Place a small amount of grease on the tolerance rings of the ribbon supply
spindle shaft.

Figure 185 Lubrication

Put grease here.

4. See Figure 183 on page 318. Slide the remove tool onto the new spindle assembly, then
gently push the ribbon supply spindle assembly into the printer main frame.

Important In step 4, do not use force or pound on the ribbon supply spindle or the
remove tool.

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320 Corrective Maintenance
Ribbon Supply Spindle

5. See Figure 186. Install the tool screw into the spindle shaft until it bottoms out.

6. Slide the washer over the end of the screw until it is against the main frame.

7. Install the nut until it rests against the washer.

Figure 186 Spindle Installation

1 Nut
2 Screw

8. While holding the remove tool, turn the nut clockwise to draw the ribbon supply spindle
into the printer. Once the spindle is in the printer, turn the spindle nut turn
counterclockwise and remove the screw, nut, and washer.

9. See Figure 182 on page 317. Install the spindle mounting screw and washer.

10. See Figure 181 on page 316. Reinstall the intermediate gear, ensuring the gears mesh
properly.

11. Loosely reinstall the stepper motor using the pivot screw, locking screw, and adjustment
nut.

Note The belt should have some deflection, but no more than inch.

12. While lifting up on the stepper motor, reinstall the drive belt. Release the stepper motor to
provide tension on the belt.

13. Ensure the belt tension is correct and then tighten the locking screw to secure the motor.

14. Tighten the pivot screw.

15. Route the stepper motor cable up to the power supply connector stepper motor connector.

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Corrective Maintenance 321
Ribbon Supply Spindle

16. See Figure 180 on page 315. Reconnect the stepper motor to the power supply.

17. Fold the power supply shield back into place and reinstall the mounting screw and
mounting standoff.

Reinstall the Gear Cover


1. See Figure 177 on page 312. With the marked side facing out slide the compound gear
into the printer. Ensure that the gears mesh.

Note Look at the old compound gear to see what side you marked for facing out.

2. Ensure all gears mesh together.

3. Align the gear cover and slide it back into place.

4. Install the mounting screw in the proper hole in the gear cover, through the compound
gear, and then into the proper mounting hole in the main frame.

5. Tighten the mounting screw.

6. Did you remove the wireless board?

If Then
No Go to Reinstall the Electronics Cover on page 322.
Yes a. See Figure 179 on page 314. Reinstall the wireless board.
b. See Figure 178 on page 313. Reinstall the radio card.
c. Go to Reinstall the Electronics Cover on page 322.

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322 Corrective Maintenance
Ribbon Supply Spindle

Reinstall the Electronics Cover


1. See Figure 187. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 187 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 174 on page 310. Install the four mounting screws.

3. See Figure 173 on page 309. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5.
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.

6. Set the tension on the ribbon supply spindle.

Note If your ribbon is wide, use the high tension setting. If you experience ribbon
slippage, use the low tension setting.

7. Reconnect the AC power cord and data cables.

8. Turn on (l) the printer.

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Corrective Maintenance 323
Media Hanger

Media Hanger

Tools Required

Tools You need these tools to complete this procedure:

Metric Nutdriver Set

Replace the Old Hanger Assembly


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media cover and remove the media and ribbon.

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324 Corrective Maintenance
Media Hanger

3. See Figure 188. Locate the media hanger assembly.

4. Remove and discard the three mounting screws securing it.

Figure 188 Remove and Install the Hanger Assembly

1 Media hanger assembly


2 Mounting screws (3)

5. Remove the new media hanger assembly from the kit.

6. Align the media hanger assembly with the mounting holes and then install the three
mounting screws supplied in the kit.

Caution Use the screws supplied in the kit to avoid damaging the peinter.

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 and then turn on (l) the printer.

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Corrective Maintenance 325
Sheet Metal Media Hanger

Sheet Metal Media Hanger

Tools Required

Tools You need these tools to complete this procedure:

Metric Nutdriver Set

Replace the Old Hanger Assembly


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media cover and remove the media and ribbon.

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326 Corrective Maintenance
Sheet Metal Media Hanger

3. See Figure 189. Locate the media hanger assembly.

4. Remove and discard the two mounting screws securing it.

5. Discard the old hanger.

Figure 189 Remove and Install the Hanger Assembly

1 Media hanger assembly


2 Mounting screws (2)

6. Remove the new media hanger assembly from the kit.

7. Align the media hanger assembly with the mounting holes and then install the two
mounting screws supplied in the kit.

Caution Use the screws supplied in the kit to avoid damaging the printer.

8.
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.

9. Reconnect the AC power cord and data cables and then turn on (l) the printer.

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Corrective Maintenance 327
Tear-Off Bar

Tear-Off Bar

Tools Required

Tools You need these tools to complete this procedure:

2.5 mm Hex Key (Supplied) Flat Blade Screwdriver set

Remove the Front Cover


1. Turn off (O) the printer and remove the AC power cord and data cables.

2. See Figure 190. Remove the front cover by pulling out on the upper corners of the cover
and then lifting it out of the printer.

Figure 190 Remove the Front Cover

1 Front cover
2 Mounting hooks

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328 Corrective Maintenance
Tear-Off Bar

Remove the Old Tear-Off Bar


1. See Figure 191. Remove the two tear-off bar mounting screws.

Figure 191 Remove and Install the Tear-Off Bar

2
2

1 Tear-off bar
2 Tear-off bar mounting screws (2)

2. Lift the tear-off bar out of the platen housing.

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Corrective Maintenance 329
Tear-Off Bar

Install the New Tear-Off Bar


1. See Figure 192. Install the new tear-off bar into the platen housing. Do not tighten the
mounting screws at this time.

Figure 192 Install the New Tear-Off Bar

1
3

1 Tear-off bar
2 Platen housing
3 Horizontal mounting bar
4 Rest the pems on top of the horizontal mounting bar.
5 Mounting screws (2)

2. Lift the tear-off bar up slightly. See Figure 193. Push the tear-off bar back against the
horizontal mounting bar of the platen housing and then back down until the pems are
resting on the mounting bar.

Figure 193 Locate the Pems

Pems

3. Tighten the mounting screws while keeping pressure down on the tear-off bar.

4. See Figure 190 on page 327. Reinstall the front cover.

5. Reconnect the AC power cord and data cables

6. Turn on (l) the printer.

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330 Corrective Maintenance
Static Brush

Static Brush

Tools Required

Tools You need these tools to complete this procedure:

Metric Nutdriver Set

Remove the Old Static Brush Assembly

Note Retain all parts removed during disassembly, unless otherwise directed.

1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

Open the media cover and remove all media and ribbon.

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Corrective Maintenance 331
Static Brush

2. See Figure 194. Remove the two mounting screws securing the static brush assembly.

3. Remove the brush assembly from the printer.

Figure 194 Remove and Install the Static Brush Assembly)

1 Mounting screws (2)


2 Static brush assembly

Install the New Static Brush Assembly


1. See Figure 194. Secure the new static brush assembly to the printer frame with the two
mounting screws previously removed.

2. Reinstall the ribbon and media and close the media cover.

3. Reconnect the AC power cord and data cables.

4. Turn on (l) the printer.

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332 Corrective Maintenance
Cutter Option

Cutter Option

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Flat-blade Screwdriver Set Safety Goggles
Metric Hex Key (Allen Wrench) Set

Remove the Electronics Cover


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.
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.

Remove the media and ribbon.

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Corrective Maintenance 333
Cutter Option

3. See Figure 195. Remove the screw and washer securing the electronics cover.

Figure 195 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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334 Corrective Maintenance
Cutter Option

5. See Figure 196. Remove the four mounting screws on the rear of the printer.

Figure 196 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 197. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 197 Remove the Electronics Cover

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Corrective Maintenance 335
Cutter Option

Remove the Front Cover


1. See Figure 198. Remove the front cover by pulling out on the upper left and right corners.

Figure 198 Remove the Front Cover

1 Front cover
2 Mounting hooks

2. Lift the front cover to remove it.

3. Close the media door.

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336 Corrective Maintenance
Cutter Option

Install the Cutter Option


1. See Figure 199, Detail A. Locate the cutter assembly in the kit. Verify that the mounting
bracket is installed properly, with the M in the correct position. If it is not, loosen the
center screw and rotate the bracket until the M is in the proper position.

Figure 199 Locate and Position the Mounting Brackets


Detail A

M must be in this location.


M

M
M

Detail B

Cutter
Assembly

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Corrective Maintenance 337
Cutter Option

2. See Figure 200. While holding the cutter assembly, route the cutter assembly wire harness
through the mainframe access hole.

Figure 200 Install the Cutter Assembly


1

2
4

6 4
7 5

1 Tear bar
2 Latch assembly
3 Mounting screw
4 Platen assembly hook
5 Main frame access hole
6 Cutter cable
7 Cutter assembly

3. Install the cutter assembly on the hooks of the platen housing.


a. See Figure 199 on page 336. The ZM400 and ZM600 mounting brackets have step
slots.
b. Hold the cutter assembly as far to the left as possible, and align the larger part of the
slot with the hooks on the platen housing.
c. Set the cutter assembly onto the hooks, then push down and slide the assembly to the
right.

4. See Figure 200. Secure the cutter assembly onto the platen assembly. The mounting
bracket tab on the cutter fits behind and attaches to the platen assembly using the screw
provided.

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338 Corrective Maintenance
Cutter Option

5. See Figure 201. Place the catch tray in the slot or slots of the front cover of cutter
assembly. Place the cutter shield over the cutter assembly and secure in place using the
thumb screw provided.

Figure 201 Cutter Shield and Catch Tray


A B

1
1

2
2

3 4
4 3

A ZM400
B ZM600
1 Cutter shield
2 Thumbscrew
3 Cutter assembly
4 Cutter catch tray

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Corrective Maintenance 339
Cutter Option

6. See Figure 202. Locate the connector P26 on the main logic board (MLB) and plug in the
cutter assembly connector. Route the cable as shown and ensure that it is away from the
drive belt and gears.

Figure 202 Locate Cutter Connector on the Main Logic Board


1
2

1 Main logic board (MLB) connector, P26


2 Cutter cable connector
3 Access hole

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340 Corrective Maintenance
Cutter Option

Reinstall the Electronics Cover


1. See Figure 203. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 203 Locate the Upper and Lower Flanges


1
2

1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)

2. See Figure 196 on page 334. Install the four mounting screws.

3. See Figure 195 on page 333. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5. Reinstall media and ribbon.

6. Close the media cover.

7. Reconnect the AC power cord.

8. Turn on (l) the printer.

9. Place the printer into the Cutter Mode (see your User Guide for proper setup and media
loading instructions).

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Corrective Maintenance 341
Peel Maintenance Assembly

Peel Maintenance Assembly

Tools Required

Tools You need these tools to complete this procedure:

Metric Hex Key (Allen wrench) Set Antistatic Wrist Strap and Mat
Metric Nutdriver Set

Remove the Old Peel Assembly


1. See Figure 204. Remove the two mounting screws and remove the peel assembly.

Figure 204 Remove Old Peel Assembly

1 Peel Assembly
2 Mounting Screw (2)

2. Go to Install the New Peel Assembly on page 342.

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342 Corrective Maintenance
Peel Maintenance Assembly

Install the New Peel Assembly


1. See Figure 205. Install the two mounting screws from the kit, using the hex key (Allen
wrench) supplied, into the tear bar mounting screw holes. Tighten them to within 1/4 in. of
the platen housing.

Figure 205 Install Peel Assembly


2
1

1 Peel assembly
2 Mounting slots (2)
3 Mounting screws (2)
4 Platen housing
5 Rest pems on housing here.
6 Peel lever

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Corrective Maintenance 343
Peel Maintenance Assembly

2. See Figure 206. Notice the pems and the mounting slots.

Figure 206 Rear View of Peel Assembly


1

1 Mounting slots (2)


2 Pems (2)

3. See Figure 205 on page 342. Install the peel assembly with the pems to the rear and the
opening in the mounting slot to the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Now push the assembly back against the vertical surface of the platen housing then
down, so that the pems are resting on the horizontal surface of the platen housing.

4. Maintain a slight pressure downward on the peel assembly, to keep the pems on the
horizontal surface, and tighten the mounting screws.

5.
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.

6. Reinstall the AC power cord and data cables.

7. Turn on (l) the printer.

8. Refer to your User Guide for information on selecting the Peel Option Mode.

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344 Corrective Maintenance
Peel Rewind Option

Peel Rewind Option

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Nutdriver Set


Antistatic Mat and Wrist Strap

Remove the Electronics Cover

Note Retain all parts removed during disassembly, unless otherwise directed.

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

Open the media door and remove the media and ribbon.

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Corrective Maintenance 345
Peel Rewind Option

3. See Figure 207. Remove the screw and washer securing the electronics cover.

Figure 207 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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346 Corrective Maintenance
Peel Rewind Option

5. See Figure 208. Remove the four mounting screws on the rear of the printer.

Figure 208 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 209. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 209 Remove the Electronics Cover

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Corrective Maintenance 347
Peel Rewind Option

Remove the Base


1. See Figure 210. Remove the front cover by sliding it to the right and then lifting it up.

Figure 210 Remove the Front Cover

1 Front cover

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348 Corrective Maintenance
Peel Rewind Option

2. See Figure 211. Remove the two screws that attach the rear cover to the base.

Note Do not remove the screws attaching the platen housing to the main frame.

Figure 211 Remove the Old Base


2
1
5

1 Main frame 5 Main frame mounting screws (5)


2 Rear end cap mounting screws (2) 6 Base
3 Rear end cap 7 Platen housing
4 Mounting flat washers (3)

3. Remove the screw and flat washer securing the platen housing to the base.

4. Remove the four screws and two flat washers securing the main frame.

5. Lift the main frame off the base assembly.

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Corrective Maintenance 349
Peel Rewind Option

Install the Rewind Pan


Important Alignment is very important. The platen housing must be inside the mounting
tab of the rewind pan.

1. See Figure 212. Place the main frame onto the rewind pan assembly. Ensure the rear ledge
of the main frame rests completely on the rear support in the pan.

Figure 212 Install the Rewind Pan


1 3

7 6 5

1 Main frame
2 Main frame mounting screws (4)
3 Rear end cap mounting screws (2)
4 Rear end cap
5 Platen housing mounting screw
6 Flat washer
7 Rewind Pan

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350 Corrective Maintenance
Peel Rewind Option

Note The oversize mounting hole in the pan allows for adjustment of the front of the pan
to align with the door.

2. Install, but do not tighten, the main frame mounting screws provided in the kit.

3. Recheck the alignment from step 1 and then tighten the two screws on the rear of the main
frame.

4. Tighten the rest of the main frame mounting screws.

5. Reinstall the rear cover by sliding it under the screw loosened previously on the main
frame. Leave the screw loose.

6. Using the two screws supplied in the kit, attach the rear cover to the rewind pan.

7. Tighten the two screws install steps 5 and 6.

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Corrective Maintenance 351
Peel Rewind Option

Install the Rewind Spindle Assembly

Note Make sure the two holes on rewind support bracket face up and are in line with the
printer main frame.

1. See Figure 213. Place the rewind motor and spindle assembly in the rewind pan assembly.

Figure 213 Install the Rewind Spindle Assembly


1

1 Rewind spindle and motor assembly


2 Rewind support bracket (holes must be on top)
3 Rewind spindle back plate
4 Rewind pan
5 Mounting holes for rewind support bracket

2. Feed the media rewind cable through the hole in the bottom of the main frame.

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352 Corrective Maintenance
Peel Rewind Option

3.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

4. See Figure 214. Connect the rewind cable connector to P26 on the main logic board
(MLB).

Figure 214 Connect the Rewind Cable to the Main Logic Board
1
2

4
5

1 Main logic board


2 Connector P26
3 Rewind cable
4 Access hole
5 Cut away

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Corrective Maintenance 353
Peel Rewind Option

5. See Figure 215. Align one of the two access holes in the rewind back plate to one of the
mounting holes on the rewind support plate.

6. Using a nut driver, mount the rewind motor and spindle assembly to the printer main
frame using one of the two screws provided.

Note For ease of alignment, do not tighten the first screw until the second screw is
installed.

Figure 215 Install the Motor and Spindle Assembly

1 1
2
2

1 Access hole
2 Rewind back plate

7. Align the other access hole of the rewind back plate to the other mounting hole on the
rewind support plate.

8. Install the mounting screw and tighten.

9. Tighten the screw installed in step 6.

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354 Corrective Maintenance
Peel Rewind Option

Reinstall the Electronics Cover


1. See Figure 216. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 216 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 208 on page 346. Install the four mounting screws.

3. See Figure 207 on page 345. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5. Do you have an existing peel assembly?

If Then
No Continue with Remove the Tear Bar.
Yes Go to Remove the Existing Peel Assembly on page 356.

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Corrective Maintenance 355
Peel Rewind Option

Remove the Tear Bar

Note If there is an existing peel assembly, it must be removed. If a peel assembly in not
currently installed, the tear bar must be removed.
Retain all parts removed during disassembly, unless otherwise directed.

1. See Figure 217. Remove the two mounting screws and remove the tear bar.

Figure 217 Remove the Tear Bar

2 2

1 Tear bar
2 Mounting screws (2)

2. Go to Install the New Peel Assembly on page 357.

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356 Corrective Maintenance
Peel Rewind Option

Remove the Existing Peel Assembly


1. See Figure 218. Remove the two existing mounting screws.

Figure 218 Remove the Peel Assembly


2
1

1 Peel assembly
2 Platen housing
3 Peel assembly mounting screws

2. Remove the peel assembly.

3. Continue with Install the New Peel Assembly.

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Corrective Maintenance 357
Peel Rewind Option

Install the New Peel Assembly


1. Install the two mounting screws previously removed into the tear bar mounting screw
holes.
Tighten them to within 3.2 mm (1/8 in. ) of the platen housing.

2. See Figure 219. Take note of the pems and the mounting slots.

Figure 219 Locate the Pems


2
1

1 Peel assembly
2 Mounting slots (2)
3 Pems (2)

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358 Corrective Maintenance
Peel Rewind Option

3. See Figure 220. Install the peel assembly with the pems to the rear and the opening in the
mounting slot to the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Push the assembly back against the vertical surface of the platen assembly then down
so that the pems are resting on the horizontal surface of the platen housing.

4. Maintain a slight pressure downward on the peel assembly to keep the pems on the
horizontal surface, and tighten the mounting screws.

Figure 220 Install the New Peel Assembly


2
1
4

1 Peel assembly
2 Platen housing
3 Mounting screws (2)
4 Rest pems here.

Load the Media


See Figure 221 (Rewind) or Figure 222 (Peel) while loading media.

1.
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.

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Corrective Maintenance 359
Peel Rewind Option

2. Load media and pull about two feet of media through the front of the printer.
a. Slide the media supply guide to the outer edge of the media hanger.
b. Fold the media supply guide down.
c. Place the roll of media on the media supply hanger and push it on all the way.
d. Fold the media supply guide up.
e. Slide the media supply guide toward the outer edge of the media roll until it makes
light contact.
f. Press the printhead open lever and raise the printhead assembly.
g. Feed the media under the dancer, between the transmissive sensor, under the ribbon
sensor, and out the front of the printer.
h. Slide the media guide in until it is against the outer edge of the media.

3. Choose the method to continue loading the media.

If you are loading for Then


Rewind See Figure 221. Pass the media down over the front of the
peel assembly, through the printer housing, and under the
media alignment spindle.
Peel/Rewind a. See Figure 222. Open the peel assembly by rotating the
lever forward.
b. Remove labels, leaving approximately 24 in. (610 mm)
of liner.
c. Pass the liner over the peel bar, down behind the peel
assembly, through the printer housing, and under the
media alignment spindle.
d. Return the peel assembly to its operating position.

4. Loosen the thumbscrew on the rewind media guide.

5. Slide the rewind media guide to the end of the spindle and rotate it to its horizontal
position.

6. Place an empty media core on the rewind spindle. Wrap the media (or liner, if using Peel
Mode) around the core and turn the spindle counterclockwise to wind up the excess
material.

7. Rotate the rewind media guide to its vertical position.

8. Slide it in against the media and tighten the thumbscrew to lock it in position.

9. Close the media cover.

10. Reconnect the AC power cord.

11. Turn the power on (l). Place the printer into Rewind or Peel Mode.

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360 Corrective Maintenance
Peel Rewind Option

Figure 221 Load the Rewind Media

Figure 222 Load the Rewind Peel Media

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Corrective Maintenance 361
Peel Rewind Option

Align the Rewind/Peel Media

Note The media/liner should be installed flush against the back plate of the take-up spindle
to prevent the media/backing from winding too loosely.

Perform the following adjustment if the media does not track properly onto the take-up
spindle.

See Figure 223.

If you want to move the media Then


Toward the main frame Turn the dial clockwise
Away from the main frame Turn the dial counterclockwise

Figure 223 Align the Rewind Media

Dial

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362 Corrective Maintenance
Outer Guard Rewind

Outer Guard Rewind

Tools Required

Tools You need these tools to complete this procedure:

Flat-blade Screwdriver Set

Remove the Old Outer Rewind Guide

Note Retain all parts removed during disassembly, unless otherwise directed.

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

Open the media cover and remove the media and ribbon.

3. Open the rewind pan door.

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Corrective Maintenance 363
Outer Guard Rewind

4.
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 224. Remove the e-ring securing the rewind spindle.

5. Remove the flat and wave washers from the rewind spindle shaft.

Figure 224 Remove the E-ring and Washers


1

3 4

1 Rewind spindle
2 E-ring
3 Wave washer
4 Flat washer

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364 Corrective Maintenance
Outer Guard Rewind

6. See Figure 223. Remove the spindle by sliding it off the rewind spindle shaft.

Figure 225 Remove the Rewind Spindle

1 2

1 Rewind spindle shaft


2 Rewind spindle

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Corrective Maintenance 365
Outer Guard Rewind

7. See Figure 7 and Figure 227. Remove the rewind back plate from the spindle by pressing
in on the two tabs shown on the left and right sides of the spindle.

Figure 226 Remove the Rewind Back Plate

1 1

3
3

1 Rewind back plate


2 Spindle
3 Tabs (2)

Figure 227 Remove the Spindle

4
2

1 Rewind back plate 3 Mounting Holes (2)


2 Spindle 4 Tabs (2)

8. Remove the thumb screw from the outer rewind guide.

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366 Corrective Maintenance
Outer Guard Rewind

9. See Figure 228. Remove the outer rewind guide by sliding it off the rear of the spindle.

Figure 228 Remove the Outer Rewind Guide


Rear

1 Thumb screw
2 Outer rewind guide
3 Spindle

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Corrective Maintenance 367
Outer Guard Rewind

Install the New Outer Rewind Guide


1. See Figure 229. Align the new outer rewind guide with the rewind spindle.

Figure 229 Align the Outer Rewind Guide

Rear

1 Outer rewind guide


2 Rewind spindle

2. See Figure 228 on page 366. Slide the outer rewind guide onto the spindle and install the
thumb screw.

3. See Figure 227 on page 365 and Figure 7 on page 365. Align the rewind back plate with
the spindle and press it into the spindle until the tabs snap into the mounting holes.

4. See Figure 223 on page 355. Slide the rewind spindle assembly onto the rewind spindle
shaft.

5. See Figure 224 on page 363. Slide the wave washer onto the rewind spindle shaft.

6. Slide the flat washer onto the rewind spindle shaft and then install the e-ring.

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. Close the rewind pan door.

9. Close the media door.

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368 Corrective Maintenance
Outer Guard Rewind

10. Reconnect the AC power cord and data cables.

11. Turn on (l) the printer.

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Roller System

This section provides replacement and installation procedures for the ZM400/ZM600 roller
system.

Contents
Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Linerless Media Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Platen Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

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370 Corrective Maintenance
Platen Roller

Platen Roller

Tools Required

Tools You need these tools to complete this procedure:

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%).

Remove the Old Platen Roller


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

Open the media cover and remove the media and ribbon.

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Corrective Maintenance 371
Platen Roller

3. See Figure 230. Open and latch the print mechanism in the vertical position.

Figure 230 Slide the Platen Roller Assembly


1 2

1 Print mechanism
2 Platen roller assembly
3 Latch assembly

4. If you have a peel unit installed, you will have to open it.

5. Turn the latch assembly clockwise to gain access to the platen roller.

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372 Corrective Maintenance
Platen Roller

6. See Figure 231. Remove the platen roller assembly.


a. Platen roller in the printer.
b. Slide the platen roller assembly away from the printer until it disengages the platen
housing.
c. Lift the platen assembly out of the printer.
d. Platen is out of the printer.

Figure 231 Remove the Platen Roller Assembly

a c

b
d

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Corrective Maintenance 373
Platen Roller

Install the New Platen Roller Assembly

Important The grooves in the inner and outer bearings must be facing up.

1. See Figure 232. Verify that the bearings are oriented properly.

Figure 232 Bearing Keys

1
2

3
4

1 Inner bearing
2 Inner bearing grooves
3 Outer bearing grooves
4 Outer bearing

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374 Corrective Maintenance
Platen Roller

2. See Figure 233 and Figure 234. Slide the platen roller assembly into the platen housing,
while aligning the platen roller bearings with the platen housing and the drive pin with the
slot in the drive shaft.

Figure 233 Align the Drive Pin and Drive Shaft

1 Platen roller drive pin


2 Drive shaft slot

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Corrective Maintenance 375
Platen Roller

Figure 234 Install the Platen Roller Assembly

a c

b d

3. Turn the latch assembly to the vertical position to secure the platen roller assembly.

4. Clean the platen roller using the Zebra preventative maintenance kit or equivalent.

5.
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.

6. Reconnect the AC power cord and data cables.

7. Turn on (l) the printer.

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376 Corrective Maintenance
Linerless Media Platen Roller

Linerless Media Platen Roller

Tools Required

Tools You need these tools to complete this procedure:

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%).

Remove the Old Linerless Media Platen Roller Assembly


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

Open the media cover and remove the media.

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Corrective Maintenance 377
Linerless Media Platen Roller

3. See Figure 235. Being careful not to damage the sensor cable, loosen the three thumb
screws securing the linerless media guide assembly and then pull it out slightly and set it
down.

Figure 235 Remove the Linerless Media Guide Assembly


1

4
3

1 Print mechanism
2 Thumbscrews (3)
3 Latch assembly
4 Linerless media guide assembly

4. Open and latch the print mechanism in the vertical position.

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378 Corrective Maintenance
Linerless Media Platen Roller

5. See Figure 236. Turn the latch assembly clockwise 90 degrees to gain access to the platen
roller.

6. Remove the linerless media platen roller assembly.


a. Linerless media platen roller assembly in the printer.
b. Slide the linerless media platen roller assembly away from the printer until it
disengages the platen housing.
c. Lift the linerless media platen roller assembly out of the printer.
d. Linerless media platen roller assembly is out of the printer.

Figure 236 Remove the Linerless Media Platen Roller Assembly

a c

b d

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Corrective Maintenance 379
Linerless Media Platen Roller

Install the New Linerless Media Platen Roller Assembly

Important The grooves in the inner and outer bearings must be facing up.

1. See Figure 237. Verify that the bearings are oriented properly.

Figure 237 Bearing Grooves

1
2

3
4

1 Inner bearing
2 Inner bearing grooves
3 Outer bearing grooves
4 Outer bearing

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380 Corrective Maintenance
Linerless Media Platen Roller

2. See Figure 238. Install the linerless platen roller assembly.


a. Linerless media platen roller assembly is out of the printer.
b. Lower the linerless media platen roller assembly into the printer.
c. See Figure 239 on page 381. Slide the linerless media platen roller assembly into the
platen housing, while aligning the platen roller bearings with the platen housing and
the drive pin with the slot in the drive shaft.
d. See Figure 239. Linerless media platen roller assembly in the printer.

Figure 238 Install the Linerless Media Platen Roller Assembly

a c

b d

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Corrective Maintenance 381
Linerless Media Platen Roller

Figure 239 Align the Drive Pin and Drive Shaft

1 Platen roller drive pin


2 Drive shaft slot

3. Turn the latch assembly to the vertical position to secure the linerless media platen roller
assembly.

4. Clean the linerless media platen roller using the 47362 Zebra preventive maintenance kit.

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382 Corrective Maintenance
Linerless Media Platen Roller

5. See Figure 240. Verify that the take-label sensor cable is securely pushed into the cable
retention device.

Figure 240 Verify the Take-Label Sensor Cable Routing

1 2 3 4

1 Linerless media guide assembly


2 Take-label sensor board
3 Take-label sensor connector
4 Take-label sensor cable connector
5 Take-label cable
6 Take-label cable retention device

6. See Figure 235 on page 377. Reinstall the linerless media guide and tighten the three
thumbscrews.

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.

8. Reconnect the AC power cord and data cables.

9. Turn on (l) the printer.

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Corrective Maintenance 383
Platen Coupling

Platen Coupling

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Hex Key (Allen wrench) Set


Metric Nutdriver Set Safety Glasses
Flat-blade Screwdriver Set Needle Nose Pliers
Bent Tip Scribe or a tool with a small
hook

Remove the Electronics Cover


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

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384 Corrective Maintenance
Platen Coupling

2. See Figure 241. Open the media door and remove the screw and washer securing the
electronics cover.

Figure 241 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

3. Close the media door.

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Corrective Maintenance 385
Platen Coupling

4. See Figure 242. Remove the four mounting screws on the rear of the printer.

Figure 242 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

5. See Figure 243. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 243 Remove the Electronics Cover

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386 Corrective Maintenance
Platen Coupling

Remove the Platen Roller Assembly


1. See Figure 244.Open and latch the print mechanism in the vertical position.

Figure 244 Slide the Platen Roller Assembly


1 2

1 Print mechanism
2 Platen roller assembly
3 Latch assembly

2.
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.

Remove the media and ribbon.

3. If you have a peel unit installed, open it.

4. Turn the latch assembly clockwise to gain access to the platen roller.

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Corrective Maintenance 387
Platen Coupling

5. See Figure 245. Remove the platen roller assembly.


a. Platen roller in the printer.
b. Slide the platen roller assembly away from the printer until it disengages the platen
housing.
c. Lift the platen assembly out of the printer.
d. Platen is out of the printer.

Figure 245 Remove the Platen Roller Assembly

a c

b
d

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388 Corrective Maintenance
Platen Coupling

Remove the Drive Belt and Platen Pulley


1. See Figure 246. Loosen the stepper motor locking and pivot screws.

Figure 246 Remove the Drive Belt

1 2 3

1 Pivot screw
2 Stepper motor
3 Drive belt
4 Set screws (2)
5 Platen pulley
6 Locking screw

2. Swing the stepper motor to the right to loosen the drive belt and then tighten the locking
screw to snug it in place.

3. Remove the drive belt from the stepper motor and then from the platen pulley. Set the
drive belt aside for reuse.

4. Loosen the two set screws securing the platen pulley to the coupling assembly.

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Corrective Maintenance 389
Platen Coupling

5. See Figure 247. Slide the platen pulley from the coupling assembly and set it aside for
reuse.

Figure 247 Remove the Platen Pulley

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390 Corrective Maintenance
Platen Coupling

Remove the Drive Shaft


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 248. Using a flat-blade screwdriver or needle nose pliers, remove and discard
the e-ring and washer from the drive shaft.

Figure 248 Remove the E-ring and Washer

1 Drive shaft
2 Washer
3 E-ring

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Corrective Maintenance 391
Platen Coupling

2. See Figure 249. Push the drive shaft through to the media side of the printer and then
remove and discard it.

Figure 249 Push the Drive Shaft Through

Drive Shaft

3. See Figure 250. Using a bent tip scribe or small hooked tool, remove the roller bearing
from the media side of the platen housing.

4. Using a bent tip scribe or small hooked tool, remove the roller bearing from the
electronics side of the platen housing.

Figure 250 Remove the Roller Bearings


Roller Bearings (2)

5. See Figure 250. Install the new bearings.


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392 Corrective Maintenance
Platen Coupling

Install the New Drive Shaft


1. See Figure 249. Slide the new drive shaft through the bearing on the media side being
careful not to push the bearing on the electronics side out.

2. See Figure 248 on page 390. Install the new washer and e-ring onto the new drive shaft.

3. Ensure that the e-ring is in the slot on the drive shaft and that the drive shaft moves freely.

Reinstall the Platen Pulley


1. See Figure 251. Slide the pulley all the way onto the platen pulley shaft in the proper
orientation and align the set screws with the two flat spots on the drive shaft.

Figure 251 Align Flat Spots on the Shaft

1 Set screws (2)


2 Platen roller shaft flat spots

2. See Figure 246 on page 388. Reinstall the drive belt between the stepper motor and the
platen pulley.

3. Reinstall the drive belt onto the platen pulley and the stepper motor pulley.

4.
Caution Do not over tighten the drive belt, or damage to the bearings and platen
roller will occur. The belt should deflect under finger pressure but no more than 6 mm
( inch).

Loosen the locking screw and then rotate the motor down until the drive belt is just taut.
Tighten the locking screw and then the pivot screw.

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Corrective Maintenance 393
Platen Coupling

Reinstall the Electronics Cover


1. See Figure 252. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 252 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 243 on page 385. Reinstall the electronics cover.

3. See Figure 242 on page 385. Install the four mounting screws.

4. See Figure 241 on page 384. Open the media door.

5. Install the electronics cover mounting screw and lock washer.

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394 Corrective Maintenance
Platen Coupling

Reinstall the Platen Roller

Important The grooves in the inner and outer bearings must be facing up.

1. See Figure 253. Verify that the bearings are oriented properly.

Figure 253 Bearing Keys

1
2

3
4

1 Inner bearing
2 Inner bearing grooves
3 Outer bearing grooves
4 Outer bearing

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Corrective Maintenance 395
Platen Coupling

2. See Figure 254 and Figure 255. Slide the platen roller assembly into the platen housing,
while aligning the platen roller bearings with the platen housing and the drive pin with the
slot in the drive shaft.

Figure 254 Align the Drive Pin and Drive Shaft

1 Platen roller drive pin


2 Drive shaft slot

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396 Corrective Maintenance
Platen Coupling

Figure 255 Install the Platen Roller Assembly

a c

b d

3. Turn the latch assembly to the vertical position to secure the platen roller assembly.

4. Clean the platen roller using the Zebra preventative maintenance kit or equivalent.

5.
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.

6. Reconnect the AC power cord and data cables.

7. Turn on (l) the printer.

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Corrective Maintenance 397
Pinch Roller

Pinch Roller

Tools Required

Tools You need these tools to complete this procedure:

Flat-blade Screwdriver Set Safety Goggles


Metric Hex Key (Allen Wrench) Set

Remove the Pinch Roller


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

Open the media door and remove media and ribbon from the printer.

3. See Figure 258 on page 400. Lower the pinch roller holder assembly to the open position.

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398 Corrective Maintenance
Pinch Roller

4.
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 256. Using a small flat blade screwdriver or an awl, remove and discard the
two E-rings.

Note If you have trouble reaching the E-rings and have a peel assembly installed, you
may have to remove it to access the E-rings. See Figure 258 on page 400. Loosen the two
mounting screws, and then remove the peel assembly from the printer.

5. Remove and discard the bearings and old pinch roller.

Figure 256 Removing and Installing E-rings and Bearings


1
2 3
4

2
1

1 E-rings 4 Groove for E-ring


(2 used, 2 spares)
2 Roller bearings (2) 5 Pinch roller mounting
hole
3 Pinch roller 6 Pinch roller holder
assembly

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Corrective Maintenance 399
Pinch Roller

Install the Pinch Roller


1. See Figure 256. Install the new pinch roller in the notches in the pinch roller holder
assembly.

2. Install the two new bearings on the shaft of the pinch roller, flange facing out, as shown.

3. Install two new E-rings in the grooves on the roller shaft.

4. See Figure 257. Notice the pems and the mounting slots.

Figure 257 Rear View of Peel Assembly

1 Mounting slots (2)


2 Pems (2)

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400 Corrective Maintenance
Pinch Roller

5. See Figure 258. Remove the old tear bar by removing the two mounting screw. Reinstall
the them into the mounting holes, to within 3.175 mm of the platen housing.

Figure 258 Installing Peel Roller Assembly

2
3

4
6
5

1 Peel assembly
2 Tear bar
3 Mounting screw
4 Mounting holes
5 Pinch roller
6 Rest the pems on the housing here.

6. Install the peel assembly with the pems to the rear and the opening in the mounting slot to
the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Push the assembly back against the vertical surface of the platen housing then down,
so that the pems are resting on the horizontal surface of the platen housing.

7. Maintain a slight downward pressure on the peel assembly to keep the pems on the
horizontal surface, and tighten the mounting screws.

8. Raise the pinch roller assembly to the closed position. Ensure the pinch holder assembly
snaps into position and exerts force on the platen roller.

9.
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.

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Corrective Maintenance 401
Pinch Roller

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

11. Verify proper printer operation.

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402 Corrective Maintenance
Pinch Roller

Notes ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Printed Circuit Boards

This section provides replacement and installation procedures for the various printed circuit
boards in the ZM400/ZM600.

Contents
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Wireless Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

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404 Corrective Maintenance
Control Panel

Control Panel

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Nut Driver Set


Antistatic Pad and Wrist Strap Flat Blade Screwdriver Set

Remove the Electronics Cover


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2. See Figure 259. Remove the screw and washer securing the electronics cover.

Figure 259 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

3. Close the media door.

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Corrective Maintenance 405
Control Panel

4. See Figure 260. Remove the four mounting screws on the rear of the printer.

Figure 260 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

5. See Figure 261. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 261 Remove the Electronics Cover

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406 Corrective Maintenance
Control Panel

Remove the Old Control Panel


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 263 on page 407. Is there already a ferrite block installed?

If Then
No Continue to step 3.
Yes a. See Figure 262. Using a screwdriver carefully pry open the ferrite block and
remove the control panel cable from the ferrite block.
b. Continue to step 3.

Figure 262 Open the Ferrite Block

2
1

1 Ferrite block
2 Flat blade screwdriver
3 Plastic locking tabs (3)

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Corrective Maintenance 407
Control Panel

3. See Figure 263. Remove the control panel cable from the cable clip and the ferrite block.

Figure 263 Locate the Cable Clip

3
2

1 Cable clip
2 Ferrite block
3 Control panel cable

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408 Corrective Maintenance
Control Panel

4. See Figure 264. Disconnect the control panel cable from P29 on the main logic board
(MLB).

Figure 264 Remove the Control Panel


1

7 6 5 4 3 2

1 Control panel
2 Access hole
3 Star lock washer
4 Split lock washer
5 Mounting screw
6 Control panel cable
7 Main logic board (MLB)

5. Remove the mounting screw, split lock washer, and star lock washer securing the control
panel.

6. Remove the control panel while carefully guiding the control panel cable out of the
printer.

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Corrective Maintenance 409
Control Panel

7. See Figure 263 on page 407. Is there already a ferrite block installed?

If Then
No a. See Figure 265. Peel the backing off the tape on the ferrite block.
b. Position the ferrite block as shown and then press it to the main frame.
c. Continue to step 1.
Yes Continue to step 1.

Figure 265 Install the Ferrite Block

1 2

1 Main frame
2 Ferrite block

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410 Corrective Maintenance
Control Panel

Install the New Control Panel


1. Remove the new control panel from the antistatic bag.

2. See Figure 264 on page 408. Guide the control panel cable into the printer.

3. Align the new control panel and then install the star lock washer, split lock washer, and
mounting screw and tighten.

4. Connect the control panel cable to P29 on the MLB.

5. See Figure 262 on page 406. Open the ferrite block.

6. See Figure 263 on page 407. Ensure that the control panel cable is laying in the ferrite
block and then close and snap the ferrite block around it.

7. Fold the control panel cable over itself to take up the slack and then slide it under the cable
clip.

Reinstall the Electronics Cover


1. See Figure 266. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 266 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

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Corrective Maintenance 411
Control Panel

2. See Figure 260 on page 405. Install the four mounting screws.

3. See Figure 259 on page 404. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5. Reinstall the AC power cord and data cables.

6. Turn on (l) the printer.

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412 Corrective Maintenance
Main Logic Board

Main Logic Board

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Nutdriver Set


Antistatic Wrist Strap and Mat

Print a Configuration Label


1. Can the printer print a configuration label?

If Then
No Go to Remove the Electronics Cover.
Yes Continue with step 2.

2. Print a configuration label for reference. Set the label aside.


a. Press and hold CANCEL while turning on (l) the printer,
b. After the DATA light turns off (approximately five seconds), release CANCEL.
c. Continue with Remove the Electronics Cover.

Remove the Electronics Cover


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.
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.

Remove the media and ribbon.

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Main Logic Board

3. See Figure 267. Remove the screw and washer securing the electronics cover.

Figure 267 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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414 Corrective Maintenance
Main Logic Board

5. See Figure 268. Remove the four mounting screws on the rear of the printer.

Figure 268 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 269. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 269 Remove the Electronics Cover

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Corrective Maintenance 415
Main Logic Board

7. Which communication board do you have?

If you have Then


None Go to Remove the Old MLB on page 423.
Wired Go to Remove the Wired Ethernet Board on page 422.
Wireless Continue with Remove the Wireless Board.
SEH IPv6 Print Server Go to Remove the SEH IPv6 Print Server Board on page 419.

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416 Corrective Maintenance
Main Logic Board

Remove the Wireless Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 270. Press in on the eject button to remove the radio card.

Figure 270 Remove the Radio Card


1

1 Eject button
2 Radio card

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Corrective Maintenance 417
Main Logic Board

3. See Figure 271. Remove the screw from the upper left corner of the wireless board.

4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).

Figure 271 Remove the Wireless Board


1

1 Wireless board
2 Mounting screws (4)

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418 Corrective Maintenance
Main Logic Board

5. See Figure 272. Remove the three wireless mounting standoffs from the MLB.

Figure 272 Remove the Wireless Board Mounting Standoffs


1

1 MLB
2 Mounting standoffs (3)

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Corrective Maintenance 419
Main Logic Board

Remove the SEH IPv6 Print Server Board


1. See Figure 273. Remove the antenna by unscrewing it from the antenna connector and
then removing the mounting nut and lock washer securing the SEH IPv6 print server boar
to the rear cover.

Figure 273 Remove the Antenna


1

2 3
4

1 Rear cover
2 Antenna connector
3 Lock washer
4 Mounting nut
5 Antenna

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420 Corrective Maintenance
Main Logic Board

2. See Figure 274. Remove the top left mounting screw securing the SEH IPv6 print server
board.

Figure 274 Remove the SEH IPv6 Print Server Board


1
\

5
4

1 SEH IPv6 print server board


2 SEH IPv6 print server board mounting screws (4)
3 MLB
4 Antenna connector mounting nut
5 Antenna connector mounting lock washer

3. Remove the three SEH IPv6 print server board mountung screws securing it to the MLB.

4. Remove the SEH IPv6 print server board from the printer.

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Corrective Maintenance 421
Main Logic Board

5. See Figure 275. Remove the three SEH IPv6 print server board mounting standoffs from
the MLB.

Figure 275 Remove the Wireless Board Mounting Standoffs


1

1 MLB
2 Mounting standoffs (3)

6. Go to Remove the Old MLB on page 423.

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422 Corrective Maintenance
Main Logic Board

Remove the Wired Ethernet Board


1. See Figure 276. Remove the three mounting nuts.

Figure 276 Remove the Wired Ethernet Board

1 Wired ethernet board


2 Mounting nuts (3)

2. Slide the wired ethernet board off the three mounting standoffs and set aside for
reinstallation.

3. See Figure 277. Remove the three standoffs from the MLB.

Figure 277 Remove the Wired Ethernet Board Standoffs

Standoffs

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Corrective Maintenance 423
Main Logic Board

Remove the Old MLB


Do you have a retaining clip on the printhead data cable?

If Then
No Go to step 3 on page 424.
Yes Continue with step 1.

1. page 423

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 278. Remove the printhead ribbon cable clip by lifting up on the tabs and then
pulling it away from the main logic board.

Note Some models have a ribbon cable retaining clip on the printhead data cable for
shipping purposes. It may be left off if you ensure that the printhead data cable is properly
seated into the main logic board MLB connector P19 upon reinstallation of the cable.

2. Drop the cable clip slightly out of the printhead connect and then remove it from the
printer.

Figure 278 Remove the Printhead Ribbon Cable Clip


3
1
2

1 Ribbon cable retaining clip


2 Tabs (2)
3 Printhead cable connector
4 Printhead cable

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424 Corrective Maintenance
Main Logic Board

3. See Figure 279. Unplug all ribbon cables and small wire connections.

Figure 279 Main Logic Board Assembly Connection Locations

P24 P23 P25


J3
J1

J4

P26

J4
P4
P36
P9
J2 P7

P29 P19

J1 Serial port P23 PCMCIA


J2 Parallel port P24 PCMCIA
J4 Wired ethernet P25 Power
P4 Ribbon/Head open sensor P26 Liner Take-up/Cutter/Rewind
P7 Reflective sensor P29 Control panel
P9 Transmissive sensor P36 USB
P19 Printhead data

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Corrective Maintenance 425
Main Logic Board

4. See Figure 280. Remove and discard the two mounting studs and washers securing the
9-pin serial port connector.

5. Remove and discard the two screws securing the 36-pin parallel port connector.

Figure 280 Remove the Old MLB

2 1

1 MLB mounting screws (2)


2 Parallel port mounting screws (2)
3 Serial port mounting studs (2)
4 Serial port mounting lock washers (2)
5 Rear panel

6. Remove and discard the two mounting screws securing the MLB to the printer.

7. Pull out the front end of the board. As you do, guide its two connectors out of the rear
panel openings.

Install the New MLB Board


1. From the kit, remove the new MLB.

2. See Figure 280 on page 425. Align the new MLB with the rear panel and insert the two
connectors into the mounting holes.

3. Secure the MLB with the two mounting screws.

4. With two mounting studs, secure the serial port connector to the rear panel.

5. With two screws, secure the parallel port connector to the rear panel.

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426 Corrective Maintenance
Main Logic Board

6.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or a false HEAD COLD message to display
while the printhead is hot enough to cause severe burns. Allow the printhead to cool.

See Figure 279 on page 424. Reconnect the ribbon cables and small wire connections to
the MLB.

Reinstall the Printhead Ribbon Cable Retaining Clip

7. See Figure 281. Insert the bottom locating tab into the bottom hole in the main logic board
(MLB) connector and then lift up and around with the upper locating tab in the top hole of
the MLB connector.

Figure 281 Install the Printhead Data Cable Retaining Clip


5
4
2
3

1 Main logic board (MLB) connector


2 Top hole
3 Printhead cable
4 Top locating tab
5 Printhead ribbon cable retaining clip
6 Bottom hole
7 Bottom locating tab

8. Ensure that all connectors are properly seated into their connectors.

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Corrective Maintenance 427
Main Logic Board

9. Which communication board do you have?

If you have Then


None Go to Reinstall the Electronics Cover on page 428.
Wired Ethernet a. See Figure 277 on page 422 and reinstall the three
mounting standoffs onto the MLB.
b. See Figure 276 on page 422. Slide the connector on the
wired ethernet board into the mounting hole in the rear
panel and then align the mounting holes with the three
studs of the standoffs.
c. Slide the board onto the three studs and then reinstall the
three mounting nuts.
d. Go to Reinstall the Electronics Cover on page 428.
Wireless Ethernet a. See Figure 272 on page 418 and reinstall the three
standoffs onto the MLB.
b. See Figure 271 on page 417. Slide the wireless board into
the rear panel and then align the two connectors on the
MLB with the two connectors on the wireless board.
c. Press the wireless board into the MLB.
d. Reinstall the four mounting screws.
e. See Figure 270 on page 416. Reinstall the radio board.
f. Go to Reinstall the Electronics Cover on page 428.
SEH IPv6 Print Server a. See Figure 275 on page 421 and reinstall the three
standoffs onto the MLB.
b. See Figure 274 on page 420. Slide the wireless board into
the rear panel and then align the two connectors on the
MLB with the two connectors on the wireless board.
c. Press the wireless board into the MLB.
d. Reinstall the four mounting screws.
e. Figure 273 on page 419. Reinstall the antenna mounting
washer and nut.
f. Reinstall the antenna.
g. Go to Reinstall the Electronics Cover on page 428.

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428 Corrective Maintenance
Main Logic Board

Reinstall the Electronics Cover


1. See Figure 282. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 282 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 268 on page 414. Install the four mounting screws.

3. See Figure 267 on page 413. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5.
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.

Reinstall the media and ribbon.

6. Reconnect the AC power cord and data cables.

7. Turn on (l) the printer. The printer performs the POST, and then displays
PRINTER READY.

8. Press SETUP/EXIT two times.

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Corrective Maintenance 429
Main Logic Board

9. Press () or (+) until LOAD DEFAULTS is displayed. Press SETUP/EXIT.


This resets all settings to the factory default.

10. Turn off (O) the printer.

Important If the front panel is unable to communicate with the MLB, it will display
Internal Printer Error, Please contact your Zebra Service Representative. The
troubleshooting section of the maintenance manual should detail what conditions would
cause the front panel to display this message. Possibilities include but are not limited to
the cable between the MLB and the front panel not being connected properly or the MLB
not having a valid bootblock or firmware

Check Hardware ID and Firmware Version


1. See Figure 283. Print a configuration label.
a. Press and hold CANCEL while turning on (l) the printer.
b. Release CANCEL after the DATA light turns off (approximately five seconds).

Figure 283 Configuration Label

2. If you printed a configuration label at the beginning of these kit instructions, compare the
configuration label you just printed to that one.

3. Reconfigure the printer using your User Guide.

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430 Corrective Maintenance
Wireless Option

Wireless Option

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Metric Nutdriver Set

Remove the Electronics Cover


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

See Figure 284. Remove the screw and washer securing the electronics cover.

Figure 284 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

2. Close the media door.

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Corrective Maintenance 431
Wireless Option

3. See Figure 285. Remove the four mounting screws on the rear of the printer.

Figure 285 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

4. See Figure 286. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 286 Remove the Electronics Cover

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432 Corrective Maintenance
Wireless Option

5. Are you replacing an existing wireless board?

If Then
No Go to Install the Wireless Board on page 434.
Yes Continue with Remove the Wireless Board.

Remove the Wireless Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 287. Press in on the eject button to remove the radio card.

Figure 287 Remove the Radio Card


1

1 Eject button
2 Radio card

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Corrective Maintenance 433
Wireless Option

3. See Figure 288. Remove the screw from the upper left corner of the wireless board.

4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).

Figure 288 Remove the Wireless Board


1

1 Wireless board
2 Mounting screws (4)

5. Continue to step 4 on page 436.

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434 Corrective Maintenance
Wireless Option

Install the Wireless Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 289. Remove the blank cover from the rear panel of the printer.

Figure 289 Remove the Blank Cover

1 Blank cover plate


2 Mounting screw

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Corrective Maintenance 435
Wireless Option

3. See Figure 290. Install the three standoffs from the kit into the main logic board (MLB).

Figure 290 Install the Standoffs


1

1 Main logic board (MLB)


2 Wireless board mounting standoffs (3)
3 Standoff mounting holes (3)

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436 Corrective Maintenance
Wireless Option

4. See Figure 291. Align the mounting holes in the wireless board with the mounting
standoffs and then install the four mounting screws.

Figure 291 Install the Wireless Board


1

1 Existing standoff
2 Wireless board
3 Mounting screws (4)
4 Installed standoffs (3)

5. See Figure 287 on page 432. Install your radio card.

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Corrective Maintenance 437
Wireless Option

Reinstall the Electronics Cover


1. See Figure 292. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 292 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 285 on page 431. Install the four mounting screws.

3. See Figure 284 on page 430. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5. Reinstall the AC power cord and data cables.

6. Turn on (l) the printer.

Important After you have completed this installation, you must download the latest
version of firmware for your printer from: www.zebra.com.

7. 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 printers network status.

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438 Corrective Maintenance
ZebraNet Internal Wireless Plus Print Server

ZebraNet Internal Wireless Plus Print Server

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Standard Open-End Wrench Set


Flat-blade Screwdriver Set Antistatic Wriststrap and Mat

Before You Begin


Before starting this installation, you must download firmware versionV53.16.x (or later) from:
www.zebra.com/firmware.

Remove the Electronics Cover


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.
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.

Remove the media and ribbon.

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Corrective Maintenance 439
ZebraNet Internal Wireless Plus Print Server

3. See Figure 293. Remove the screw and washer securing the electronics cover.

Figure 293 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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440 Corrective Maintenance
ZebraNet Internal Wireless Plus Print Server

5. See Figure 294. Remove the four mounting screws on the rear of the printer.

Figure 294 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 295. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 295 Remove the Electronics Cover

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Corrective Maintenance 441
ZebraNet Internal Wireless Plus Print Server

7. Is there a ZebraNet Internal Wireless Plus Print Server or Wireless Plus Print Server
already installed on the printer?

If Then
No Go to Install the New Internal Wireless Plus Print Server Board
on page 442.
Yes Continue with Remove the Old Print Server Board on page 441.

Remove the Old Print Server Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 296. Depending on your wireless plus print server, your printer may have
either three or four mounting screws. Remove the mounting screws from the either Print
Server board.

3. Remove the print server board from the printer.

Figure 296 Remove the Old Print Server Board


1

1 Wireless print server board


2 Mounting screws (3)

4. Go to Install the New Internal Wireless Plus Print Server Board on page 442.

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442 Corrective Maintenance
ZebraNet Internal Wireless Plus Print Server

Install the New Internal Wireless Plus Print Server Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. Are you installing the Internal Wireless Plus Print Server for the first time?

If Then
No a. See Figure 297. If needed, install one standoff in between the two beige
connectors (P23 and P24) on the main logic board as shown.
b. Go to step 3.
Yes a. See Figure 297. Install the three studded standoffs on the main logic board
as shown.
b. Continue with step 3.

Figure 297 Install the Standoffs


1

1 Cast boss
2 Studded standoffs (3)
3 Main logic board

3. Insert the upper edge of the Internal Wireless Plus board into the electronics area and in
front of the main logic board.

4. Place the RF connector through the option board slot in the back of the printer.

5. Align the connectors along the bottom edge of the Internal Wireless Plus board with the
connectors on the main logic board.

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Corrective Maintenance 443
ZebraNet Internal Wireless Plus Print Server

6. While supporting the back of the MLB with your fingers, press the wireless plus print
server board into place.

7. Install the Internal Wireless Plus board by inserting the four mounting screws into the
standoffs.

Install the Cover and External Antenna


1. Insert the bottom edge of the cover in the small slot below the option board opening.

2. See Figure 298. Fasten the top of the cover into place using one of the screws provided in
the kit.

Figure 298 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

3. From the back of the printer, place the lock washer and nut on the RF connector and hand
tighten.

4. Using an open-end wrench, tighten the brass nut by turning it clockwise one quarter of a
turn.

5. To install the external antenna, screw the antenna onto the RF connector extending out
from the back plate of the printer.

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444 Corrective Maintenance
ZebraNet Internal Wireless Plus Print Server

Install the Electronics Cover


1. See Figure 294 on page 440. Install the cover by aligning it and sliding down, ensuring the
lower tabs are inside the base and the upper flanges are between the main frame and the
media door.

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

3. See Figure 293 on page 439. Open the media door and install the mounting screw and
washer to secure the electronics cover.

Resume Operations
1.
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.

2. Reconnect AC power cord and data cables.

3. Turn on (l) the printer.

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Corrective Maintenance 445
ZebraNet Internal Wireless Plus Print Server

After You Complete the Installation

Firmware
After you have completed this installation, you must download firmware version V53.16.x (or
later) a second time from: www.zebra.com/firmware.

Attach Labels
1. See Figure 299. Examine the labels included with the kit.
There may be several labels included with your kit.

Figure 299 Sample Label

39545-xxx ZM400

2 1

1 Printer model
2 Zebra part number

2. Locate your printer model in the lower right-hand corner of the label.

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446 Corrective Maintenance
ZebraNet Internal Wireless Plus Print Server

3. See Figure 300. If present, remove the old plastic label with part number 39545-xxx
affixed inside the media compartment 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 300 Label Location


1

1 Affix label here


2 Model plate (Do not remove)

4. See Figure 299. Remove the backing from the new label (part number 39545-xxx included
in this kit) for your specific printer.

5. See Figure 300. 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.

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Corrective Maintenance 447
ZebraNet Internal Wireless Plus Print Server

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 users 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 numrique de la classe B est conforme la norme NMB-003 du Canada.

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448 Corrective Maintenance
ZebraNet b/g Print Server

ZebraNet b/g Print Server

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Standard Open-End Wrench Set


Flat-blade Screwdriver Set Antistatic Wriststrap and Mat

Remove the Electronics Cover


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.
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.

Remove the media and ribbon.

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Corrective Maintenance 449
ZebraNet b/g Print Server

3. See Figure 301. Remove the screw and washer securing the electronics cover.

Figure 301 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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450 Corrective Maintenance
ZebraNet b/g Print Server

5. See Figure 302. Remove the four mounting screws on the rear of the printer.

Figure 302 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 303. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 303 Remove the Electronics Cover

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Corrective Maintenance 451
ZebraNet b/g Print Server

7. Is there a ZebraNet Wireless Plus Print Server, ZebraNet Internal Wireless Plus Print
Server, or ZebraNet b/g Print Server already installed?

If Then
No Go to Install the ZebraNet b/g Print Server Board on page 452.
Yes Continue with Remove the Old Print Server Board on page 5.

Remove the Old Print Server Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 304. Depending on your wireless print server, you may have either three or
four mounting screws. Remove all mounting screws from the print server board.

3. Remove the print server board from the printer.

Figure 304 Remove the Old Print Server Board


1

1 Wireless print server board


2 Mounting screws (3)

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452 Corrective Maintenance
ZebraNet b/g Print Server

Install the ZebraNet b/g Print Server Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. Did you remove an existing print server board?

If Then
Yes a. See Figure 305. If there is an empty mounting hole between the two
connectors (P23 and P24) on the main logic board, install one of the studded
standoffs.
b. Go to step 3.
No a. See Figure 305. Install the three studded standoffs on the main logic board
as shown.
b. Continue with step 3.

Figure 305 Install the Standoffs


1

1 Cast boss
2 Studded standoffs (3)
3 Main logic board

3. Insert the upper edge of the ZebraNet b/g Print Server board into the electronics area and
in front of the main logic board.

4. Place the RF connector through the option board slot in the back of the printer.

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Corrective Maintenance 453
ZebraNet b/g Print Server

5. Align the connectors along the bottom edge of the ZebraNet b/g Print Server board with
the connectors on the main logic board.

6. While supporting the back of the MLB with your fingers, press the wireless print server
board into place.

7. Install the ZebraNet b/g Print Server board by inserting the four mounting screws into the
standoffs.

Install the Cover and External Antenna


1. Insert the bottom edge of the cover in the small slot below the option board opening.

2. See Figure 306. Fasten the top of the cover into place using one of the screws provided in
the kit.

Figure 306 Close up of Antenna Installation


4

1
2 3

1 Cover
2 RF connector
3 Antenna nut
4 RF antenna

3. From the back of the printer, place the lock washer and nut on the RF connector and hand
tighten.

4. Using an open-end wrench, tighten the brass nut by turning it clockwise one quarter of a
turn.

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454 Corrective Maintenance
ZebraNet b/g Print Server

5. To install the external antenna, screw the antenna onto the RF connector extending out
from the back plate of the printer.

Install the Electronics Cover


1. See Figure 303 on page 450. Install the cover by aligning it and sliding down, ensuring the
lower tabs are inside the base and the upper flanges are between the main frame and the
media door.

2. See Figure 302 on page 450. Install the four mounting screws on the back of the printer.

3. See Figure 301 on page 449. Open the media door and install the mounting screw and
washer to secure the electronics cover.

Resume Operations
1.
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.

2. Reconnect AC power cord and data cables.

3. Turn on (l) the printer.

After You Complete the Installation

Firmware
After you have completed this installation, you must download firmware version V53.17.11Z
(or later) from: www.zebra.com.

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Corrective Maintenance 455
ZebraNet b/g Print Server

Attach Labels
1. See Figure 307. Examine the labels included with the kit.
There may be several labels included with your kit.

Figure 307 Sample Approvals Label

Zebra Technologies Corporation


333 Corporate Woods Parkway
Vernon Hills, IL 60061

Contains Zebra ZLANG-VH Complies With


FCC ID: XXX-ZLANGVH IDA Standards
IC ID: XXXXX-ZLANGVH XXXXXX
C
  


TRA
REGISTRED No:
C
XXXXXXXX
XXXXXXX/XX
DEALER No:
XXXXXXX/XX
CCAF08LP0410T0
CMII ID: XXXXXXXXXX
CNC: XXXXXXX
XXXXX-XXX ZM400

2 1

1 Printer model
2 Zebra part number

2. Locate your printer model in the lower right-hand corner of the label.

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456 Corrective Maintenance
ZebraNet b/g Print Server

3. See Figure 308. If present, remove the old plastic label affixed to the inside of the media
compartment 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 308 Label Location

Zebra Technologies Corporation Zebra Technologies Corporation


333 Corporate Woods Parkway 333 Corporate Woods Parkway
Vernon Hills, IL 60061 Vernon Hills, IL 60061

Contains Zebra ZLANG-VH Complies With ZM400


FCC ID: XXX-ZLANGVH IDA Standards
IC ID: XXXXX-ZLANGVH XXXXXX
Config. No.
C
  


TRA xxxxx-xxxx-xxxxx

REGISTRED No: Config. No.


C
XXXXXXXX
XXXXXXX/XX
xxxxx-xxxx-xxxxx
DEALER No:
XXXXXXX/XX
CCAF08LP0410T0
CMII ID: XXXXXXXXXX
CNC: XXXXXXX
XXXXX-XXX ZM400

1 2

1 Affix label here


2 Model plate (Do not remove)

4. See Figure 307. Remove the backing from the new approvals label for your specific
printer.

5. See Figure 308. Affix the new approvals 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.

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Corrective Maintenance 457
ZebraNet b/g Print Server

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 users 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 numrique de la classe B est conforme la norme NMB-003 du Canada.

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458 Corrective Maintenance
Communications

ZebraNet b/g Print Server Antenna

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Open End Wrench Set

Do you need to install the ZebraNet b/g Print Server PC Board Cover?

If Then
Yes Continue with Install the Board Cover.
No Go to Install the Antenna on page 459.

Install the Board Cover


1. From the back of the printer, insert the tab on the lower edge of the cover into the slot on
the back plate of the printer.

2. Secure the cover using the screw provided in this kit for your specific printer.

3. Continue with Install the Antenna on page 459.

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Corrective Maintenance 459
Communications

Install the Antenna


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

2. See Figure 309. From the back of the printer, place the lock washer and nut on the RF
connector and hand tighten.

Figure 309 Close-up of Antenna Installation


6

1
3 4
2 5

1 Cover
2 RF connector
3 Lock washer
4 Nut
5 Antenna nut
6 RF antenna

3. Using an open-end wrench, tighten the brass nut by turning it clockwise one quarter of a
turn.

4. To install the external antenna, screw the antenna onto the RF connector extending out
from the back plate of the printer.

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460 Corrective Maintenance
Wired Ethernet

Wired Ethernet

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Antistatic Wriststrap and Mat


Metric Nutdriver Set 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%).

Important Do not use needle nose pliers in place of the nutdriver, as you can damage the
Ethernet board. Always use recommended tools.

Remove the Electronics Cover

Note Retain all parts removed during disassembly, unless otherwise directed.

1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

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Corrective Maintenance 461
Wired Ethernet

See Figure 310. Remove the screw and washer securing the electronics cover.

Figure 310 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

2. Close the media door.

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462 Corrective Maintenance
Wired Ethernet

3. See Figure 311. Remove the four mounting screws on the rear of the printer.

Figure 311 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

4. See Figure 312. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 312 Remove the Electronics Cover

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Corrective Maintenance 463
Wired Ethernet

5. Are you replacing an existing wired Ethernet board?

If Then
No Go to Install the Wired Ethernet Board on page 464.
Yes Continue with Remove the Wired Ethernet Board.

Remove the Wired Ethernet Board


1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

2. See Figure 313. Remove and discard the three nuts securing the wired Ethernet board.

Figure 313 Remove the Ethernet Board

1 Main logic board (MLB)


2 Wired Ethernet board
3 Mounting nuts (3)
4 Mounting studs (3)

3. Remove the wired Ethernet board.

4. Go to step 4 on page 465.

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464 Corrective Maintenance
Wired Ethernet

Install the Wired Ethernet Board


1. See Figure 314. Remove and discard the rear panel Ethernet access cover and screw.

Figure 314 Remove the Blank Cover and Screw

2 3

1 Wired Ethernet access cover


2 Mounting hole
3 Wired Ethernet access hole
4 Mounting screw

2. See Figure 315. Clean the J4 pads using the Zebra Preventive Maintenance Kit part
number 47362.

Figure 315 Clean the J4 Pads

1 2

J4

1 J4
2 Pads

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Corrective Maintenance 465
Wired Ethernet

3. See Figure 316. Install the three mounting standoffs supplied in the kit into the three
threaded mounting holes on the main logic board (MLB).

Figure 316 Install the Mounting Standoffs

1 Main logic board (MLB)


2 Mounting studs (3)
3 Mounting holes (3)

4. See Figure 313 on page 463. 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.

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466 Corrective Maintenance
Wired Ethernet

Reinstall the Electronics Cover


1. See Figure 317. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 317 Locate the Upper and Lower Flanges


1
2

1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)

2. See Figure 311 on page 462. Install the four mounting screws.

3. See Figure 310 on page 461. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

5. Reconnect the AC power cord and data cables.

6. Turn on (l) the printer.

7. See your ZebraNet 10/100 Internal PrintServer User Guide to set up your Ethernet
board.

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Outer Casing Components

This section provides replacement and installation procedures for the various outer casing
components on the ZM400/ZM600.

Contents
Electronic Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Media Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Lower Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

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468 Corrective Maintenance
Electronic Cover

Electronic Cover

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Nutdriver Set

Remove the Old Electronics Cover


1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

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.
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.

Remove the media and ribbon.

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Corrective Maintenance 469
Electronic Cover

3. See Figure 318. Remove the screw and washer securing the electronics cover.

Figure 318 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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470 Corrective Maintenance
Electronic Cover

5. See Figure 319. Remove the four mounting screws on the rear of the printer.

Figure 319 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 320. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 320 Remove the Electronics Cover

7. Install the New Electronics Cover

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Corrective Maintenance 471
Electronic Cover

8. See Figure 321. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.

Figure 321 Locate the Upper and Lower Flanges


1
2

9. See Figure 319 on page 470. Open the media door.

10. See Figure 318 on page 469. Install the electronics cover mounting screw and lock
washer.

11. Reconnect the AC power cord and data cables.

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472 Corrective Maintenance
Media Door

Media Door

Tools Required

Tools You need these tools to complete this procedure:

Metric Nutdriver Set Phillips Screwdriver Set

Remove the Old Media Door


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

Open the media cover and remove the media and ribbon.

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Corrective Maintenance 473
Media Door

3. See Figure 322. Remove the four screws and lock washers securing the old door and lift
the door off of the printer.

Figure 322 Media Door

1 Media door
2 External lock washers (4)
3 Mounting screws (4)

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474 Corrective Maintenance
Media Door

Install the New Media Door

Note The front hole is a locating hole; install this screw and lock washer first.

1. See Figure 322 on page 473. Install the new door by aligning the front hinge with the front
hole and installing the mounting screw and lock washer.

2. Install the other three screws and lock washers supplied in the kit. Ensure the door is
aligned properly and reinstall media and ribbon.

3.
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.

4. Reinstall the AC power cord and all data cables.

5. Turn on (l) the printer.

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Corrective Maintenance 475
Media Window

Media Window

Tools Required

Tools You need these tools to complete this procedure:

Flat-blade Screwdriver Set Glass Cleaner

Remove the Defective Window

1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

Open the media door.

2. Remove the old media door window using your finger to press on the tabs and window.
Once the tab has been popped out of the door keep outward pressure on the window to
keep the tab from popping back in.

Figure 323 Remove the Old Window

A A
\

1
2
2

3
3

4
4

A Flexible tabs (7)


B Non-flexible tabs (3)
1 First tab to press
2 Second set of tabs to press
3 Third set of tabs to press
4 Fourth set of tabs to press

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476 Corrective Maintenance
Media Window

3. Lift the old window out of the door and discard it.

IInstall the New Window


1. See Figure 324 and Figure 325. Hold the new window with top away from the windowless
door and set the non-flexible tabs over the door edge.

Figure 324 Align the New Window


1 2

1 New window
2 Door edge
3 Non-flexible tabs (3)

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Corrective Maintenance 477
Media Window

Figure 325 Position Tab

1
2

1 Non-flexible tab
2 Inside door edge

2. Lift and press the window into place until all flexible tabs have snapped in place and the
window is secure.

3. Clean the new window.

4. Reconnect the AC power cord and data cables.

5. Turn on (l) the printer

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478 Corrective Maintenance
Lower Front Panel

Lower Front Panel

Tools Required

Tools You need these tools to complete this procedure:

Flat-blade Screwdriver Set

1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.

See Figure 326. Pull out on both sides of the lower front panel until it comes loose of the
mounting hooks and then lift it out of the printer. Use a small flat blade screwdriver if
you are having trouble.

Figure 326 Remove the Old Lower Front Panel

Hooks

Lower
Front
Panel

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Corrective Maintenance 479
Lower Front Panel

Install the New Lower Front Panel


1. See Figure 327. Hook the lower tabs of the new lower front panel over the front of the
base.

Figure 327 Hook the Lower Tabs

1 2

3 4

2
5

1 Notches (2)
2 Base
3 Upper tabs (2)
4 Guide posts (2)
5 Lower tabs (2)

2. Align the two notches in the new lower front panel with the two guideposts on the base.

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480 Corrective Maintenance
Lower Front Panel

3. See Figure 328. Tip the new lower front panel up and snap the upper tabs onto the two
mounting hooks.

Figure 328 Snap to the Mounting Hooks


2

1 Lower front panel


2 Mounting hooks

4. Reconnect the AC power cord and data cables.

5. Turn on (l) the printer.

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


Corrective Maintenance 481
Rear End Cap

Rear End Cap


This procedure is for replacing the Rear End Cap. Read these instructions thoroughly before
attempting to changeover the printhead and drive system.

Tools Required

Tools You need these tools to complete this procedure:

Metric Nutdriver Set

Remove the Old Rear End-Cap


1.
Caution Turn Off (O) the printer and disconnect it from the power source before
performing the following procedure.

2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.

Open the media cover and remove the media and ribbon.

3. See Figure 329. Remove the three screws securing the rear end-cap and then remove the
end-cap.

Figure 329 Remove and Install the Rear End-Cap

3 1

1 Rear end-cap
2 Mounting screws (3)
3 Mounting holes (3)

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482 Corrective Maintenance
Rear End Cap

Install the New End-Cap


1. See Figure 329. Start the three mounting screws into the mounting holes.

2. Slide the new end-cap under the mounting screws and then tighten the mounting screws.

3.
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.

4. Reinstall the AC power cord.

5. Turn on (l) the printer.

14207L-004 Rev. A ZM400/ZM600 Maintenance Manual 3/14/11


RFID

This section provides replacement and installation procedures for the ZM400/ZM600 roller
system.

Contents
RFID Upgrade Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
RFID Coupler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
RFID Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
RZ400/RZ600 Media Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
RZ400 and RZ600 RFID Hardware Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

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484 Corrective Maintenance
RFID Upgrade Kit

RFID Upgrade Kit

Caution A qualified service technician must perform this installation.

Important You must have the proper firmware loaded in your printer for the main logic
board (MLB) to recognize the RFID upgrade. Go to http://www.zebra.com and download the
latest firmware for the RZ400/RZ600 printer.

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Metric Nut Driver Set


Metric Hex Key (Allen wrench) Set Wire Cutters
Antistatic Wriststap and Pad

Remove the Electronics Cover


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.
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.

Remove the media and ribbon.

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Corrective Maintenance 485
RFID Upgrade Kit

3. See Figure 330. Remove the screw and washer securing the electronics cover.

Figure 330 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

4. Close the media door.

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486 Corrective Maintenance
RFID Upgrade Kit

5. See Figure 331. Remove the four mounting screws on the rear of the printer.

Figure 331 Remove the Electronics Cover Mounting Screws


1

1 Electronics cover
2 Mounting screws (4)

6. See Figure 332. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.

Figure 332 Remove the Electronics Cover

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Corrective Maintenance 487
RFID Upgrade Kit

Install the RFID Reader


1. See Figure 333. Remove and discard the two front media door mounting screws and lock
washers.

2. Remove and discard the two static brush mounting screws.

Figure 333 Remove the Old Mounting Screws


1

5
3

1 Media door
2 Lock washers (2)
3 Media door front mounting screws (2)
4 Antistatic brush assembly mounting screws (2)
5 Antistatic brush assembly

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488 Corrective Maintenance
RFID Upgrade Kit

3. See Figure 334. Install the new media door mounting screws and lock washers into the
two front mounting holes.

Figure 334 Install the New Mounting Screws

1 External lock washers (2)


2 Media door mounting screws(2)
3 Antistatic brush assembly mounting screws (2)

4. Align the antistatic brush assembly with the mounting holes and then install the two new
mounting screws.

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Corrective Maintenance 489
RFID Upgrade Kit

5. See Figure 335. Turn the printer around and then slide the four spacers onto the four
screws just installed.

Figure 335 Install the RFID Reader Mounting Bracket


1
2 3

1
3

1 Spacers (4)
2 RFID mounting bracket
3 Mounting nuts (4)

6.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

7. Align the RFID reader mounting bracket with the four mounting screws and the slide it
onto the four screws.

8. Install and tighten the four mounting nuts.

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490 Corrective Maintenance
RFID Upgrade Kit

9. See Figure 336. Install and tighten the three standoffs.

Figure 336 Install the RFID Reader Board Assembly


2
1 3

1 3 4

1 Standoffs (3)
2 RFID reader board assembly
3 Split washers (3)
4 Mounting screws (3)

10. Install one of the split lock washers onto one of the mounting screws.

11. Repeat step 10 for the remaining two mounting screws and split lock washers.

12. Align the RFID reader assembly mounting holes with the standoffs and then install, but do
not tighten, the mounting screw and split lock washer through one of the RFID assembly
mounting holes and into the corresponding standoff.

13. After all three mounting screws and split lock washers are started, tighten all three.

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Corrective Maintenance 491
RFID Upgrade Kit

Install the Coupler Cable Guide and Cables


1. See Figure 337. Slide the bracket behind the drive belt, align the mounting holes in the
bracket with the mounting holes in the printer and the install the two mounting screws.

Figure 337 Install the Coupler Cable Guide Bracket

8 9 10 1
7

5
4

3
2

1 Coupler cable guide 6 Data cable


2 Drive belt 7 P28
3 Cable tie 8 Power cable
4 Mounting screws (2) 9 P1 HOST
5 P13 RFID 10 J1 PWR

2. Connect one end of the data cable to P13 on the main logic board and the other end to
P1 HOST on the RFID reader assembly.

3. Connect one end of the power cable to P28 on the main logic board and the other end to
J1 PWR on the RFID reader assembly.

4. Wrap a cable tie around the data and power cables at mid-point between the main logic
board and the RFID reader assembly and pull it tight.

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492 Corrective Maintenance
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5. Which media handling option do you have installed?

If you have a Then


Cutter or Continue with .
Cutter/Rewind
Peel or Go to Remove the Peel Option on page 493.
Peel/Rewind
Tear Go to Remove the Front Cover on page 494.

Remove the Cutter Module


1.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.

See Figure 338. Turn the latch assembly 90 degrees to the left to gain access to the
mounting screw and then remove the mounting screw.

Figure 338 Remove the Cutter Option

4
3

1 Cutter assembly
2 Latch assembly
3 Mounting screw
4 Platen assembly hooks

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RFID Upgrade Kit

2. Slide the cutter assembly to the left and lift.

Note You may have to lift slightly higher on the left to clear the base.

3. Set the cutter assembly down.

4. Go to Remove the Old Tear-Off Bar on page 495.

Remove the Peel Option


1. See Figure 339. Loosen the two mounting screws and remove the peel assembly.

Figure 339 Remove Peel Assembly


1

1 Peel assembly
2 Mounting screws (2)

2. Go to Remove the Media Shelf on page 496.

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Remove the Front Cover


1. See Figure 340. Remove the front cover by prying out on the upper corners of the cover
and then lifting it out of the printer.

Figure 340 Remove the Front Cover

1 Front cover
2 Mounting hooks

2. Continue with Remove the Old Tear-Off Bar.

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RFID Upgrade Kit

Remove the Old Tear-Off Bar


1. See Figure 341. Remove the two tear bar mounting screws.

Figure 341 Remove and Install the Tear Bar


1

1 Tear bar
2 Tear bar mounting screws (2)

2. Lift the tear bar out of the platen housing and discard it.

3. Continue with Remove the Media Shelf.

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Remove the Media Shelf


1. See Figure 342. Remove and discard the two mounting screws.

Figure 342 Remove and Install the Media Shelf

1 Media shelf
2 Mounting screws (2)

2. Slide the media shelf out of the printer and discard.

3. Continue with Install the Coupler Assembly.

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RFID Upgrade Kit

Install the Coupler Assembly


1. See Figure 343. Slide the media guide out as far as possible.

2. Remove the coupler assembly from the kit.

3. See Figure 343. Turn the coupler assembly on its side as shown.

4. Guide the coupler cable through the access hole.

Figure 343 Install the Coupler Assembly

2 3
4 2

1 Coupler assembly
2 Media guide
3 Access hole
4 Coupler cable

5. Slide the coupler assembly into the printer.

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6. See Figure 344. Align the mounting holes and then install the two mounting screws.

Figure 344 Install the RFID Coupler Assembly

2
1

1 Mounting screws (2)


2 Coupler assembly

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RFID Upgrade Kit

7. See Figure 345. Connect the coupler cable to J1 on the RFID reader board.

Figure 345 Connect Coupler Cable to the RFID Reader Board

3
4

7
6

1 RFID reader assembly


2 J1
3 Coupler cable
4 Coupler cable guide
5 Washer
6 Mounting screw
7 Cable clamp

8. Slide the cable clamp over the coupler cable and install it on the coupler cable guide
bracket as shown with the flat washer and screw.

9. Continue with Install the New Media Door Front End Cap.

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Install the New Media Door Front End Cap


1. See Figure 346. Remove the front end cap on the media door by removing and discarding
the three mounting screws.

Figure 346 Remove the Front Media Door End Cap

2
1

1 Front media door end cap


2 Mounting screws (3)

2. Remove the new end cap and mounting screws from the kit.

3. See Figure 346. Align the new end cap with the media door and install the three mounting
screws.

4. Which media handling option do you have installed?

If you have a Then


Cutter or Go to Reinstall the Tear Bar on page 501.
Cutter/Rewind
Peel or Go to Reinstall the Peel Assembly on page 504.
Peel/Rewind
Tear Go to Reinstall the Tear Bar on page 501.

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RFID Upgrade Kit

Reinstall the Cutter Module


1. See Figure 338 on page 492. Reinstall the cutter assembly on the hooks of the platen
housing.

2. Hold the cutter assembly as far to the left as possible, and align the larger part of the step
slot with the hooks on the platen housing.

3. Slide the cutter assembly onto the hooks and then push down and slide the assembly to the
right.

4. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the
platen assembly.
The mounting tab on the cutter fits behind and attaches to the platen assembly.

5. Turn the latch assembly counterclockwise until it snaps in place.

6. Go to Reinstall the Electronics Cover on page 505.

Reinstall the Tear Bar


1. See Figure 347. Align the new tear-off bar with the platen housing mounting holes and
then install and tighten the two mounting screws removed previously.

Figure 347 Install the Tear Bar

1 Tear bar
2 Platen housing
3 Mounting screws (2)

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2. Which media handling option do you have installed?

If you have a Then


Cutter or Go to Reinstall the Cutter Module on page 501.
Cutter/Rewind
Tear Continue with Reinstall the Front Cover.

Reinstall the Front Cover


1. See Figure 348. Hook the lower tabs of the lower front panel over the front of the base.

2. Align the two notches in the lower front panel with the two guideposts on the base.

Figure 348 Hook the Lower Tabs

4 2

1 Notches (2)
2 Base
3 Upper tabs (2)
4 Guide posts (2)
5 Lower tabs (2)

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RFID Upgrade Kit

3. See Figure 349. Tip the lower front panel up and snap the upper tabs onto the two
mounting hooks.

Figure 349 Snap to the Mounting Hooks


2

1 Lower front panel


2 Mounting hooks

4. Go to Reinstall the Electronics Cover on page 505.

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RFID Upgrade Kit

Reinstall the Peel Assembly


1. See Figure 350. Using the hex key (Allen wrench) supplied, install the two mounting
screws from the kit, into the tear bar mounting screw holes. Tighten them to within 1/4 in.
of the platen housing.

Figure 350 Install Peel Assembly


2
1

1 Peel assembly
2 Mounting screws (2)
3 Rest pems on housing here.

2. See Figure 351. Notice the pems and the mounting slots.

Figure 351 Rear View of Peel Assembly


1

1 Mounting slots (2)


2 Pems (2)

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RFID Upgrade Kit

3. See Figure 350 on page 504. Install the peel assembly with the pems to the rear and the
opening in the mounting slot to the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Push the assembly back against the vertical surface of the platen housing then down,
so that the pems are resting on the horizontal surface of the platen housing.

4. Maintain a slight pressure downward on the peel assembly to keep the pems on the
horizontal surface, and tighten the mounting screws.

5. Continue with Reinstall the Electronics Cover.

Reinstall the Electronics Cover


1. See Figure 352. Install the electronics cover by aligning it and sliding down, ensuring the
lower flanges are inside the base and the upper flanges are between the main frame and the
media door.

Figure 352 Locate the Upper and Lower Flanges


1
2

1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)

2. See Figure 332 on page 486. Install the four mounting screws.

3. See Figure 330 on page 485. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

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Attach Labels
1. See Figure 353. Examine the labels included with the kit and choose the proper one for
your printer model.
There may be several labels included with your kit.

Figure 353 Sample Label

1 2

1 Zebra part number


2 Printer model number

2. Do you have the wireless option installed?

If Then
Yes Note Do not remove the plastic label with part number 39545-xxx affixed
inside the media compartment with the serial number of your printer.
Continue with step 3.
No Continue with step 3.

Note Do not remove the printer model or the configuration labels. The model plate and
configuration labels contain essential user information.

3. Remove the backing from the new agency label for your specific printer.

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RFID Upgrade Kit

4. See Figure 354. Affix the agency label in the area to the left of the model plate and
ensuring that it does not cover any other label that may be installed.

Figure 354 Attach Label

1 2

Configuration:
RZ4752511010R0

6 4
5 3

1 License label
2 Agency label (RZ400 shown)
3 Printer model plate (Do not remove)
4 Printer configuration label (Do not remove)
5 Locate the agency label here (RZ400 shown)
6 Locate the license label here

5. Remove the backing from the license label and affix it above the printhead as shown.

6. Discard any additional labels included in the kit.

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. Reinstall the data cables and AC power cord.

9. Turn on (l) the printer.

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Confirm RFID Upgrade


1. After the Power On Self Test (POST) is completed, press SETUP/EXIT and then press
PREVIOUS () twice.

2. RFID TAG DATA will be displayed on the first line of the LCD display if the upgrade was
installed properly. If it is not displayed check your installation.

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 users 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.

This Class B digital apparatus complies with Canadian ICES-003.

Cet appareil numrique de la classe B est conforme la norme NMB-003 du Canada.

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RFID Reader Assembly

RFID Reader Assembly

Tools Required

Tools You need these tools to complete this procedure:

Phillips Screwdriver Set Standard Hex Key (Allen wrench) Set


Metric Nut Driver Set Antistatic Wriststrap and Pad
Metric Hex Key (Allen wrench) Set

Remove the Electronics Cover

Caution A qualified service technician must perform this installation.

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.

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2. See Figure 355. Remove the screw and washer securing the electronics cover.

Figure 355 Locate the Electronics Cover Mounting Screw

3
4

1 Media door
2 Electronics cover
3 Washer
4 Mounting screw

3. Close the media door.

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