Zebra ZM400-ZM600 Maint Man

ZM400/ZM600
Industrial/Commercial Printer
Maintenance Manual
2007 ZIH Corp. The copyrights in this manual and the software and/or firmware in the label printer described
therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the label 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 and all product names and numbers are trademarks, and Zebra, the Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit 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.
Part Number: 14207L-001 A
Contents
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Americas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Europe, Africa, Middle East, and India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 24 25 25 25 25 25 26
1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 31 32 33 34 35 35 35 36 37 39 40 41
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2 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Cables and Wireless Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to the Computer or Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Modes and Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Used Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 46 46 46 46 47 47 47 47 47 47 48 49 49 52 53 54 55 55 56 58 62 62 62 64 68 69 69 69 70 72 72 73 74 74 74 75 76
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Control Panel Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to View or Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Printer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77 77 77 78
3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 FEED and PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4 Preventive and Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Cleaning Schedule and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Media Compartment and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 130 131 134 135 137 137 139 140 140 140 140
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gain Access to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnect the Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Print Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust the Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gain Access to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust the Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Latch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust the Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
144 144 145 148 151 152 153 153 153 156 158 160 161 162 162 163 164 167 168 168 171 171 173 176 181 186 187 187 189 189 189 191 191 192 192 192 195 196
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Printhead Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Remove the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Remove the Old Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Install the New Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Magnetic Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Remove the Old Magnetic Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Install the New Magnetic Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211 Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Stepper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Media Sensor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Sensor Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Upper Media Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Upper Media Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Media Sensor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust the Sensor Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 214 214 217 219 221 222 223 226 228 230 230 231 232 235 235 235 238 240 242
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Gears, Drive Belt, and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Gears, Drive Belt, and Compound Pulley . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 244 247 249 249 251
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Drive Belt Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Gears, Drive Belt, and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Drive Bet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gain Access to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Stepper Motor and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Stepper Motor and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Ribbon Take-Up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New RTU Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old RTU Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Ribbon Take-up Spindle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Drive Belt and Platen Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Drive Belt and Platen Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Compound Gear and Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
252 252 254 254 255 256 256 256 259 261 263 264 265 266 266 269 271 272 273 273 275 275 278 280 281 282 282 283 283 283 286 287 291 292 293 296 299 300
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Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Remove the Old Ribbon Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Remove the Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Remove the Stepper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Install the New Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311 Reinstall the Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Replace the Old Hanger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Remove the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Remove the Old Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Install the New Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Static Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Remove the Old Static Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Install the New Static Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Cutter Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Remove the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Install the Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 Peel Maintenance Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Remove the Old Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Install the New Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
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Peel Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Rewind Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Rewind Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Existing Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Align the Rewind/Peel Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer Guard Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Outer Rewind Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Outer Rewind Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
337 337 337 340 342 344 347 348 349 350 351 354 355 355 355 359
Roller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Platen Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platen Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Platen Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Drive Belt and Platen Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Platen Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinch Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362 362 362 365 368 368 368 371 373 375 377 377 378 379 382 382 382
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 388 389 391 392 393
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Contents
11
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wired Ethernet Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old MLB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New MLB Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Hardware ID and Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Electronics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Wired Ethernet Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Wired Ethernet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstall the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
394 394 394 395 397 400 401 402 404 405 406 406 406 408 410 413 414 414 415 417 418 420
Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 Electronic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Defective Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IInstall the New Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New Lower Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Old Rear End-Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the New End-Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 422 422 426 426 426 428 429 429 429 430 432 432 433 435 435 435 436
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12
Contents
5 Drawings and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

Outer Casings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media and Ribbon Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platen Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wired Ethernet Board/Internal PrintServer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Available Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peel and Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner Take-up Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Coated Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 442 443 444 446 447 448 449 450 451 452 454 455 456 457 458 459 460 462 464 465 466 467
14207L-001 A
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List of Tables
1 System Description
Table 1 Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Table 2 Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2 Operations
Table 3 Storage Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Table 4 Operating Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Table 5 Characteristics of the Data Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Table 6 Connecting the Printer to a Computer or Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Table 7 Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Table 8 Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Table 9 Media Paths for Print Modes with Various Printer Options . . . . . . . . . . . . . . . . . . . . . . . . .56 Table 10 ZM400 Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Table 11 ZM600 Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Table 12 Printer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Table 13 Print Width Ranges and Maximum Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
3 Troubleshooting
Table 14 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Table 15 Print Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Table 16 Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Table 17 Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Table 18 Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Table 19 Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Table 20 Judging Bar Code Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
4 Preventive and Corrective Maintenance

Table 21 Recommended Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Table 22 Kit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321 Table 23 Kit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
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List of Tables
5 Drawings and Parts

Table A Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441 Table B Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442 Table C Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .443 Table D Media and Ribbon Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445 Table E Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446 Table F Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447 Table G Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448 Table H Print Mechanism View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449 Table I Print Mechanism View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 Table J Printhead Conversion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451 Table K Platen Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453 Table L Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454 Table M Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455 Table N Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456 Table O Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457 Table P Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458 Table Q Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459 Table R Wired Ethernet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460 Table S Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 Table T Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464 Table U Peel and Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465 Table V Liner Take-up Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466 Table W Inside Coated Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
14207L-001 A
8/9/07
List of Figures
Figure 1 Sample Figure with Callouts ..............................................................................................27
1 System Description
Figure 2 Front of Printer ..................................................................................................................30 Figure 3 Rear of Printer ...................................................................................................................30 Figure 4 Printer Components ..........................................................................................................31 Figure 5 Control Panel .....................................................................................................................32
2 Operations
Figure 6 Power Cord Specifications ................................................................................................53 Figure 7 International Safety Organization Certifications ................................................................53 Figure 8 Tear-Off Mode Media Path ................................................................................................58 Figure 9 Ribbon Path .......................................................................................................................64 Figure 10 Printhead Pressure Adjustment Dials ..............................................................................70 Figure 11 Configuration Label .........................................................................................................75 Figure 12 Network Configuration Label (With a Wireless Print Server Installed) ............................76 Figure 13 Tear-Off Position Adjustment ..........................................................................................80 Figure 14 Label Length ....................................................................................................................83
3 Troubleshooting
Figure 15 Ribbon-Out Threshold Too High ...................................................................................114 Figure 16 Configuration Label .......................................................................................................118 Figure 17 PAUSE Test Label ........................................................................................................119 Figure 18 FEED Test Label ...........................................................................................................120 Figure 19 Bar Code Darkness Comparison ...................................................................................121 Figure 20 Communications Diagnostics Test Label ......................................................................124 Figure 21 Sensor Profile (Ribbon Section) ....................................................................................125 Figure 22 Sensor Profile (Media Section) ......................................................................................125
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List of Figures
4 Preventive and Corrective Maintenance

Figure 23 Location of the Printhead and Platen Roller ..................................................................131 Figure 24 Cleaning the Sensors ....................................................................................................134 Figure 25 Cleaning the Cutter Module ...........................................................................................136 Figure 26 Locate the Printhead Pressure Dials .............................................................................145 Figure 27 Remove the Thumbscrew .............................................................................................146 Figure 28 Remove the Printhead Assembly ..................................................................................147 Figure 29 Align the Forks and Bearings ........................................................................................148 Figure 30 Install the Printhead Fork Assembly ..............................................................................149 Figure 31 Remove the Cutter Assembly ........................................................................................151 Figure 32 Locate the Electronics Cover Mounting Screw ..............................................................154 Figure 33 Remove the Electronics Cover Mounting Screws .........................................................155 Figure 34 Remove the Electronics Cover ......................................................................................155 Figure 35 Remove the Radio Card ................................................................................................156 Figure 36 Remove the Wireless Board ..........................................................................................157 Figure 37 Remove the Standoff and Screw ...................................................................................158 Figure 38 Gain Access the Power Supply .....................................................................................159 Figure 39 Printhead Grounding Strap ............................................................................................160 Figure 40 Remove the Cutter Assembly ........................................................................................161 Figure 41 Printhead Housing Mounting Screws ............................................................................162 Figure 42 Locate the Upper and Lower Flanges ...........................................................................163 Figure 43 Adjust the Print Mechanism ...........................................................................................164 Figure 44 Install the Adjustment Cam ...........................................................................................165 Figure 45 Ribbon/Printhead Open Sensor ....................................................................................166 Figure 46 Locate the Electronics Cover Mounting Screw ..............................................................169 Figure 47 Remove the Electronics Cover Mounting Screws .........................................................170 Figure 48 Remove the Electronics Cover ......................................................................................170 Figure 49 Remove the Radio Card ................................................................................................171 Figure 50 Remove the Wireless Board ..........................................................................................172 Figure 51 Remove the Standoff and Screw ...................................................................................173 Figure 52 Gain Access the Power Supply .....................................................................................174 Figure 53 Disconnect Printhead Cables ........................................................................................175 Figure 54 Top View of Printhead Housing .....................................................................................176 Figure 55 Remove the Thumbscrew .............................................................................................177 Figure 56 Printhead Removal and Installation ...............................................................................178 Figure 57 Remove the Ground Cable Mounting Screw .................................................................179 Figure 58 Remove the Cables from the Print Mechanism .............................................................180 Figure 59 Install the New Cables ...................................................................................................181 Figure 60 Align the Forks and Bearings ........................................................................................182 Figure 61 Install the Printhead Fork Assembly ..............................................................................183 Figure 62 Connect the Printhead Cables ......................................................................................184 Figure 63 Remove the Cutter Assembly ........................................................................................186 Figure 64 Locate the Upper and Lower Flanges ...........................................................................187 Figure 65 Remove and Install the Ribbon Strip Plate ....................................................................190 Figure 66 Open the Media Door ....................................................................................................193 Figure 67 Remove the Latch Assembly .........................................................................................194 Figure 68 Adjustment Screw Location ...........................................................................................195 Figure 69 Adjust the Print Mechanism ...........................................................................................196 Figure 70 Print Mechanism Mounting Screws ...............................................................................197 Figure 71 Locate the Printhead Pressure Dials .............................................................................200 Figure 72 Remove the Printhead and Cable Connections ............................................................201
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List of Figures
17
Figure 73 Remove the Pressure Bracket and Roller .....................................................................202 Figure 74 Remove the Pressure Dials ...........................................................................................203 Figure 75 Install the Springs ..........................................................................................................203 Figure 76 Align the Forks and Bearings ........................................................................................204 Figure 77 Locate the Electronics Cover Mounting Screw ..............................................................207 Figure 78 Remove the Electronics Cover Mounting Screws .........................................................208 Figure 79 Remove the Electronics Cover ......................................................................................208 Figure 80 Locate the Magnetic Latch ............................................................................................209 Figure 81 Remove the Old Magnetic Latch ...................................................................................210 Figure 82 Install the New Magnetic Latch .....................................................................................211 Figure 83 Locate the Upper and Lower Flanges ...........................................................................212 Figure 84 Locate the Electronics Cover Mounting Screw ..............................................................215 Figure 85 Remove the Electronics Cover Mounting Screws .........................................................216 Figure 86 Remove the Electronics Cover ......................................................................................216 Figure 87 Remove the Radio Card ................................................................................................217 Figure 88 Remove the Wireless Board ..........................................................................................218 Figure 89 Remove the Standoff and Screw ...................................................................................219 Figure 90 Gain Access the Power Supply .....................................................................................220 Figure 91 Locate Drive System Components ................................................................................221 Figure 92 Disconnect the Media Sensor Cables ...........................................................................222 Figure 93 Remove the Upper Media Sensor Mounting Screw ......................................................223 Figure 94 Release the Dancer Spring ...........................................................................................224 Figure 95 Remove the Media Sensor Assemblies ........................................................................225 Figure 96 Remove the Protective Cap ..........................................................................................226 Figure 97 Locate the Access Hole .................................................................................................227 Figure 98 Remove the Protective Cap ..........................................................................................228 Figure 99 Install the Upper Media Sensor Assembly ....................................................................229 Figure 100 Adjust the ZM400 Upper Media Sensor ......................................................................233 Figure 101 Adjust the ZM600 Upper Media Sensor ......................................................................234 Figure 102 Locate the Electronics Cover Mounting Screw ............................................................236 Figure 103 Remove the Electronics Cover Mounting Screws .......................................................237 Figure 104 Remove the Electronics Cover ....................................................................................237 Figure 105 Disconnect the Ribbon/Head Open Sensor ................................................................238 Figure 106 Ribbon Sensor Removal and Installation ....................................................................239 Figure 107 Locate the Access Hole ...............................................................................................240 Figure 108 Gap Measurement Between Print Mechanism and Sensor ........................................241 Figure 109 Locate the Upper and Lower Flanges .........................................................................242 Figure 110 Locate the Electronics Cover Mounting Screw ............................................................245 Figure 111 Remove the Electronics Cover Mounting Screws .......................................................246 Figure 112 Remove the Electronics Cover ....................................................................................246 Figure 113 Lay the Printer on its Side ...........................................................................................247 Figure 114 Remove the Gear Cover .............................................................................................248 Figure 115 Remove and Install Gears, Pulley, and Belt ................................................................249 Figure 116 Locate the Upper and Lower Flanges .........................................................................251 Figure 117 Locate the Electronics Cover Mounting Screw ............................................................252 Figure 118 Remove the Electronics Cover Mounting Screws .......................................................253 Figure 119 Remove the Electronics Cover ....................................................................................253 Figure 120 Remove the Old Belt ...................................................................................................254 Figure 121 Locate the Upper and Lower Flanges .........................................................................255 Figure 122 Locate the Electronics Cover Mounting Screw ............................................................257 Figure 123 Remove the Electronics Cover Mounting Screws .......................................................258 Figure 124 Remove the Electronics Cover ....................................................................................258
8/9/07
14207L-001 A
18
List of Figures
Figure 125 Remove the Radio Card ..............................................................................................259 Figure 126 Remove the Wireless Board ........................................................................................260 Figure 127 Remove the Standoff and Screw .................................................................................261 Figure 128 Gain Access the Power Supply ...................................................................................262 Figure 129 Locate Drive System Components ..............................................................................263 Figure 130 Locate the Upper and Lower Flanges .........................................................................265 Figure 131 Locate the Electronics Cover Mounting Screw ............................................................267 Figure 132 Remove the Electronics Cover Mounting Screws .......................................................268 Figure 133 Remove the Electronics Cover ....................................................................................268 Figure 134 Lay the Printer on its Side ...........................................................................................269 Figure 135 Remove the Gear Cover .............................................................................................270 Figure 136 Loosen the Set Screws ...............................................................................................271 Figure 137 Remove the Clutch ......................................................................................................272 Figure 138 Locate the Upper and Lower Flanges .........................................................................273 Figure 139 Locate the Electronics Cover Mounting Screw ............................................................276 Figure 140 Remove the Electronics Cover Mounting Screws .......................................................277 Figure 141 Remove the Electronics Cover ....................................................................................277 Figure 142 Lay the Printer on its Side ...........................................................................................278 Figure 143 Remove the Gear Cover .............................................................................................279 Figure 144 Loosen the Set Screws ...............................................................................................280 Figure 145 Remove the RTU Spindle ............................................................................................281 Figure 146 Locate the Upper and Lower Flanges .........................................................................282 Figure 147 Locate the Electronics Cover Mounting Screw ............................................................284 Figure 148 Remove the Electronics Cover Mounting Screws .......................................................285 Figure 149 Remove the Electronics Cover ....................................................................................285 Figure 150 Remove the Drive Belt ................................................................................................286 Figure 151 Remove the Platen Pulley ...........................................................................................287 Figure 152 Align the Screws ..........................................................................................................287 Figure 153 Lay the Printer on its Side ...........................................................................................288 Figure 154 Remove the Gear Cover .............................................................................................289 Figure 155 Remove the Compound Gear .....................................................................................290 Figure 156 Compound Gear DPI Location ....................................................................................291 Figure 157 Locate the Upper and Lower Flanges .........................................................................292 Figure 158 Locate the Printhead Pressure Dials ...........................................................................293 Figure 159 Remove the Thumbscrew ...........................................................................................294 Figure 160 Remove the Printhead .................................................................................................295 Figure 161 Align the Forks and Bearings ......................................................................................296 Figure 162 Install the Printhead Fork Assembly ............................................................................297 Figure 163 Remove the Cutter Assembly ......................................................................................299 Figure 164 Locate the Electronics Cover Mounting Screw ............................................................302 Figure 165 Remove the Electronics Cover Mounting Screws .......................................................303 Figure 166 Remove the Electronics Cover ....................................................................................303 Figure 167 Lay the Printer on its Side ...........................................................................................304 Figure 168 Remove the Gear Cover .............................................................................................305 Figure 169 Remove the Radio Card ..............................................................................................306 Figure 170 Remove the Wireless Board ........................................................................................307 Figure 171 Locate the Drive Components .....................................................................................308 Figure 172 Remove the Stepper Motor and Intermediate Gear ....................................................309 Figure 173 Remove the Ribbon Supply Spindle ............................................................................310 Figure 174 Using the Remove Tool ...............................................................................................311 Figure 175 Install the Thin Washer ................................................................................................311 Figure 176 Lubrication ...................................................................................................................312
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Figure 177 Spindle Installation ......................................................................................................313 Figure 178 Locate the Upper and Lower Flanges .........................................................................315 Figure 179 Remove and Install the Hanger Assembly ..................................................................317 Figure 180 Remove the Front Cover .............................................................................................318 Figure 181 Remove and Install the Tear-Off Bar ...........................................................................319 Figure 182 Install the New Tear-Off Bar ........................................................................................320 Figure 183 Locate the Pems .........................................................................................................320 Figure 184 Kit Contents .................................................................................................................321 Figure 185 Kit Contents .................................................................................................................322 Figure 186 Remove and Install the Static Brush Assembly) .........................................................324 Figure 187 Locate the Electronics Cover Mounting Screw ............................................................326 Figure 188 Remove the Electronics Cover Mounting Screws .......................................................327 Figure 189 Remove the Electronics Cover ....................................................................................327 Figure 190 Remove the Front Cover .............................................................................................328 Figure 191 Locate and Position the Mounting Brackets ................................................................329 Figure 192 Install the Cutter Assembly ..........................................................................................330 Figure 193 Cutter Shield and Catch Tray ......................................................................................331 Figure 194 Locate Cutter Connector on the Main Logic Board .....................................................332 Figure 195 Locate the Upper and Lower Flanges .........................................................................333 Figure 196 Remove Old Peel Assembly ........................................................................................334 Figure 197 Install Peel Assembly ..................................................................................................335 Figure 198 Rear View of Peel Assembly .......................................................................................336 Figure 199 Locate the Electronics Cover Mounting Screw ............................................................338 Figure 200 Remove the Electronics Cover Mounting Screws .......................................................339 Figure 201 Remove the Electronics Cover ....................................................................................339 Figure 202 Remove the Front Cover .............................................................................................340 Figure 203 Remove the Old Base .................................................................................................341 Figure 204 Install the Rewind Pan .................................................................................................342 Figure 205 Install the Rewind Spindle Assembly ..........................................................................344 Figure 206 Connect the Rewind Cable to the Main Logic Board ...................................................345 Figure 207 Install the Motor and Spindle Assembly ......................................................................346 Figure 208 Locate the Upper and Lower Flanges .........................................................................347 Figure 209 Remove the Tear Bar ..................................................................................................348 Figure 210 Remove the Peel Assembly ........................................................................................349 Figure 211 Locate the Pems .........................................................................................................350 Figure 212 Install the New Peel Assembly ....................................................................................351 Figure 213 Load the Rewind Media ...............................................................................................353 Figure 214 Load the Rewind Peel Media ......................................................................................353 Figure 215 Align the Rewind Media ...............................................................................................354 Figure 216 Remove the E-ring and Washers ................................................................................356 Figure 217 Remove the Rewind Spindle .......................................................................................357 Figure 218 Remove the Rewind Back Plate ..................................................................................357 Figure 219 Remove the Spindle ....................................................................................................358 Figure 220 Remove the Outer Rewind Guide ...............................................................................358 Figure 221 Align the Outer Rewind Guide .....................................................................................359 Figure 222 Slide the Platen Roller Assembly ................................................................................363 Figure 223 Remove the Platen Roller Assembly ...........................................................................364 Figure 224 Bearing Keys ...............................................................................................................365 Figure 225 Align the Drive Pin and Drive Shaft .............................................................................366 Figure 226 Install the Platen Roller Assembly ...............................................................................367 Figure 227 Locate the Electronics Cover Mounting Screw ............................................................369 Figure 228 Remove the Electronics Cover Mounting Screws .......................................................370
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List of Figures
Figure 229 Remove the Electronics Cover ....................................................................................370 Figure 230 Slide the Platen Roller Assembly ................................................................................371 Figure 231 Remove the Platen Roller Assembly ...........................................................................372 Figure 232 Remove the Drive Belt ................................................................................................373 Figure 233 Remove the Platen Pulley ...........................................................................................374 Figure 234 Remove the E-ring and Washer ..................................................................................375 Figure 235 Push the Drive Shaft Through .....................................................................................376 Figure 236 Remove the Roller Bearings .......................................................................................376 Figure 237 Align Flat Spots on the Shaft .......................................................................................377 Figure 238 Locate the Upper and Lower Flanges .........................................................................378 Figure 239 Bearing Keys ...............................................................................................................379 Figure 240 Align the Drive Pin and Drive Shaft .............................................................................380 Figure 241 Install the Platen Roller Assembly ...............................................................................381 Figure 242 Removing and Installing E-rings and Bearings ...........................................................383 Figure 243 Rear View of Peel Assembly .......................................................................................384 Figure 244 Installing Peel Roller Assembly ...................................................................................385 Figure 245 Locate the Electronics Cover Mounting Screw ............................................................389 Figure 246 Remove the Electronics Cover Mounting Screws .......................................................390 Figure 247 Remove the Electronics Cover ....................................................................................390 Figure 248 Locate the Cable Clip ..................................................................................................391 Figure 249 Remove the Control Panel ..........................................................................................392 Figure 250 Locate the Upper and Lower Flanges .........................................................................393 Figure 251 Locate the Electronics Cover Mounting Screw ............................................................395 Figure 252 Remove the Electronics Cover Mounting Screws .......................................................396 Figure 253 Remove the Electronics Cover ....................................................................................396 Figure 254 Remove the Radio Card ..............................................................................................397 Figure 255 Remove the Wireless Board ........................................................................................398 Figure 256 Remove the Wireless Board Mounting Standoffs ........................................................399 Figure 257 Remove the Wired Ethernet Board .............................................................................400 Figure 258 Remove the Wired Ethernet Board Standoffs .............................................................400 Figure 259 Main Logic Board Assembly Connection Locations ....................................................401 Figure 260 Remove the Old MLB ..................................................................................................402 Figure 261 Locate the Upper and Lower Flanges .........................................................................404 Figure 262 Configuration Label .....................................................................................................405 Figure 263 Locate the Electronics Cover Mounting Screw ............................................................406 Figure 264 Remove the Electronics Cover Mounting Screws .......................................................407 Figure 265 Remove the Electronics Cover ....................................................................................407 Figure 266 Remove the Radio Card ..............................................................................................408 Figure 267 Remove the Wireless Board ........................................................................................409 Figure 268 Remove the Blank Cover ............................................................................................410 Figure 269 Install the Standoffs .....................................................................................................411 Figure 270 Install the Wireless Board ............................................................................................412 Figure 271 Locate the Upper and Lower Flanges .........................................................................413 Figure 272 Locate the Electronics Cover Mounting Screw ............................................................415 Figure 273 Remove the Electronics Cover Mounting Screws .......................................................416 Figure 274 Remove the Electronics Cover ....................................................................................416 Figure 275 Remove the Ethernet Board ........................................................................................417 Figure 276 Remove the Blank Cover and Screw ..........................................................................418 Figure 277 Clean the J4 Pads .......................................................................................................418 Figure 278 Install the Mounting Standoffs .....................................................................................419 Figure 279 Locate the Upper and Lower Flanges .........................................................................420 Figure 280 Locate the Electronics Cover Mounting Screw ............................................................423
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21
Figure 281 Remove the Electronics Cover Mounting Screws .......................................................424 Figure 282 Remove the Electronics Cover ....................................................................................424 Figure 283 Locate the Upper and Lower Flanges .........................................................................425 Figure 284 Media Door ..................................................................................................................427 Figure 285 Remove the Old Window .............................................................................................429 Figure 286 Align the New Window ................................................................................................430 Figure 287 Position Tab ................................................................................................................431 Figure 288 Remove the Old Lower Front Panel ............................................................................432 Figure 289 Hook the Lower Tabs ..................................................................................................433 Figure 290 Snap to the Mounting Hooks .......................................................................................434 Figure 291 Remove and Install the Rear End-Cap ........................................................................435
5 Drawings and Parts

Figure A Outer Casings .................................................................................................................440 Figure B Media Door .....................................................................................................................442 Figure C Rear End Cap .................................................................................................................443 Figure D Media and Ribbon Path ..................................................................................................444 Figure E Media Hanger .................................................................................................................446 Figure F Media Sensors ................................................................................................................447 Figure G Ribbon Supply Spindle ...................................................................................................448 Figure H Print Mechanism View 1 .................................................................................................449 Figure I Print Mechanism View 2 ...................................................................................................450 Figure J Printhead Conversion ......................................................................................................451 Figure K Platen Housing ................................................................................................................452 Figure L Static Brush .....................................................................................................................454 Figure M Ribbon Take-up Spindle .................................................................................................455 Figure N Drive System Components .............................................................................................456 Figure O Electronic Components ..................................................................................................457 Figure P Main Logic Board ............................................................................................................458 Figure Q Wireless Board ...............................................................................................................459 Figure R Wired Ethernet Board/Internal PrintServer .....................................................................460 Figure S Available Media Handling Options ..................................................................................462 Figure T Cutter Option ...................................................................................................................464 Figure U Peel and Rewind Option .................................................................................................465 Figure V Liner Take-up Option ......................................................................................................466 Figure W Inside Coated Ribbon Supply Spindle ...........................................................................467
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List of Figures
Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
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About This Document
This section provides you with contact information, document structure and organization, and additional reference documents.
Contents
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Americas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Europe, Africa, Middle East, and India. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 24 25 25 25 25 25 26
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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 29
This section provides an overview of the printer. Included are specifications of the printer and a brief explanation of each component and its function. This section assists the technician with out of the box installation, initial setup, and printer operation. 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. 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. This section provides the technician with assembly drawings and part number to maintain the printer.
Operations on page 43 Troubleshooting on page 103
Preventive and Corrective Maintenance on page 127
Drawings and Parts on page 437
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About This Document Contacts
25
Contacts
You can contact Zebra Technologies Corporation at the following:
Web Site
http://www.zebra.com Technical Support via the Internet is available 24 hours per day, 365 days per year. Go to http://www.zebra.com/support.
The Americas
Regional Headquarters Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A T: +1 847 793 2600 Toll-free +1 800 423 0422 F: +1 847 913 8766 Technical Support T: +1 877 ASK ZEBRA (275 9327) F: +1 847 913 2578 Hardware: ts1@zebra.com Software: ts3@zebra.com Customer Service Dept. For printers, parts, media, and ribbon, please call your distributor, or contact us. T: +1 877 ASK ZEBRA (275 9327) E: clientcare@zebra.com
Europe, Africa, Middle East, and India

Regional Headquarters Zebra Technologies Europe Limited Zebra House The Valley Centre, Gordon Road High Wycombe Buckinghamshire, HP13 6EQ, UK T: +44 (0)1494 472872 F: +44 (0) 1494 450103 Technical Support T: +44 (0) 1494 768298 F: +44 (0) 1494 768210 Germany: Tsgermany@zebra.com France: Tsfrance@zebra.com Spain/Portugal: Tsspain@zebra.com All other areas: Tseurope@zebra.com Internal Sales Dept. For printers, parts, media, and ribbon, please call your distributor, or contact us. T: +44 (0) 1494 768316 F: +44 (0) 1494 768244 E: cseurope@zebra.com
Asia Pacific
Regional Headquarters Zebra Technologies Asia Pacific, LLC 120 Robinson Road #06-01 Parakou Building Singapore 068913 T: +65 6858 0722 F: +65 6885 0838 Technical Support T: +65 6858 0722 F: +65 6885 0838 E: China: tschina@zebra.com All other areas: tsasiapacific@zebra.com Customer Service For printers, parts, media, and ribbon, please call your distributor, or contact us. T: +65 6858 0722 F: +65 6858 0836
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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.
Tools Tells you what tools you need to complete a given task.
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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. Figure 1 provides an example. Figure 1 Sample Figure with Callouts
1 2
FEED button CANCEL button
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Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Language Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 31 32 33 34 35 35 35 36 37 39 40 41
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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 2
Control panel Media door Figure 3 Rear of Printer
3 4 5 6 7 8
1 2
1 2 3 4
Power switch (O = off, I = on) AC power connector Wireless print server card slot (Ethernet) Wireless card ejector button
5 6 7 8
Serial port Internal wired print server port (Ethernet) USB port Parallel port
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System Description Printer Media Compartment
31
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 and ZM600 are designed to work only with genuine Zebra printheads, thus maximizing safety and print quality. Figure 4 Printer Components
7 9 1 2 3 4 5 8
Printhead assembly Control panel Media door Media supply guide Media supply hanger
6 7 8 9
Ribbon take-up spindle Ribbon supply spindle Dancer assembly Printhead release latch
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System Description 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
5 12 11 10 9 7 8 1 2 3 4 5 6 7 8 9 10 11 12 6
Power LED Pause LED Error LED Data LED LCD CANCEL button PLUS (+) button SETUP/EXIT button MINUS () button SELECT button FEED button PAUSE button
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Control Panel Buttons

Table 1 Control Panel Buttons
Button FEED Function
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. 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. 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. Enters and exits the configuration mode. 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. Scrolls to the next selection. Increases the value. Performs the action on the bottom right of the LCD. Scrolls to the previous selection. Decreases the value. Moves to the next available digit in a number. Performs the action on the bottom left of the LCD.
PAUSE
CANCEL
SETUP/EXIT SELECT
PLUS (+) (scroll mode) PLUS (+) (change mode) MINUS ()
(scroll mode)
MINUS ()
(change mode)
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Control Panel Lights

Table 2 Control Panel Lights
Light Status Indication
POWER PAUSE
Off On Off On Flashing
The printer is off, or no power is applied. The printer is on. Normal printer operation. The printer has stopped all printing operations. The Pause light flashes when initializing FLASH memory and in Peel-Off Mode when the label is available. Normal printer operation (no errors). An error condition is preventing printing. This includes MEDIA
ERROR
Off On Flashing
OUT and RIBBON OUT errors.
An error condition exists, but printing is allowed to continue. This includes RIBBON IN warning, HEAD UNDER TEMP warning, and HEAD OVER TEMP error. Normal printer operation (no data being received or processed).
CANCEL was pressed and a format is successfully cancelled.
DATA
Off One flash Slow flashing Fast flashing On
The printer cannot accept more data from the host. The printer is receiving data. A partial format has been received and no subsequent data activity.
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System Description Printer Language Modes
35
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) Eltron Programming Language (EPL)
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. ZPL II Programming Guide EPL2 Programming Guide
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System Description General Specifications
General Specifications
General Specifications ZM400 ZM600
Height Width Depth Weight (without options) Electrical Temperature Relative Humidity Operating Storage Operating Storage
13.3 in. 10.9 in. 18.7 in. 32.4 lbs.
338 mm 278 mm 475 mm 15 kg
13.3 in. 13.4 in. 18.7 in. 34.7 lbs.
338 mm 341 mm 475 mm 16 kg
90-265 VAC, 48-62 Hz, 5 Amps (fused) 40 to 104F 40 to 140F 5 to 40C 40 to 60C
90-265 VAC, 48-62 Hz, 5 Amps (fused) 40 to 104F 40 to 140F 5 to 40 C 40 to 60C
20% to 85%, non-condensing 5% to 85%, non-condensing
20% 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 - 802.11b/g - compliant wireless print server ZebraNet 10/100 Print Server - Ethernet network print server (10BASE-T, 100BASE-TX) 16 MB DRAM memory 8 MB flash memory (2 MB user available) ZPL II XML-Enabled ZPL EPL II APL-I APL-D
Memory Label formats accepted by firmware
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System Description Printing Specifications
37
Printing Specifications
Printing Specifications ZM400 ZM600
Print resolution
203 dots/in. 300 dots/in. 600 dots/in.
8 dots/mm 12 dots/mm 24 dots/mm 0.125 mm x 0.125 mm 0.084 mm x 0.099 mm 0.042 mm x 0.042 mm (2.5 mm 1 mm) 104 mm
203 dots/in. 300 dots/in. N/A 0.0049 in. x 0.0049 in. 0.0033 in. x 0.0039 in. N/A 0.10 in. 0.04 in. 6.6 in. 1 dot row
8 dots/mm 12 dots/mm N/A 0.125 mm x 0.125 mm 0.084 mm x 0.099 mm N/A (2.5 mm 1 mm) 168 mm
Dot size (width x length)
203 dots/in. 300 dots/in. 600 dots/in.
0.0049 in. x 0.0049 in. 0.0033 in. x 0.0039 in. 0.0016 in. x 0.0016 in. 0.10 in. 0.04 in. 4.09 in. 1 dot row 157 in. 73 in. 20 in.
First dot location measured from inside media backing edge Maximum print width Maximum continuous print length Bar code modulus (X) dimension 203 dots/in.
Minimum print length 203 dots/in. 300 dots/in. 600 dots/in.
3988 mm 1854 mm 508 mm
102 in. 45 in. N/A
2590 mm 1143 mm N/A
Picket fence (non-rotated) orientation 203 dots/in. 300 dots/in. 600 dots/in. 4.9 mil to 49 mil 3.3 mil to 33 mil 1.6 mil to 16 mil 4.9 mil to 49 mil 3.3 mil to 33 mil N/A Ladder (rotated) orientation 203 dots/in. 300 dots/in. 600 dots/in. 4.9 mil to 49 mil 3.9 mil to 39 mil 1.6 mil to 16 mil 4.9 mil to 49 mil 3.3 mil to 33 mil N/A
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System Description Printing Specifications
Printing Specifications
ZM400
ZM600
Programmable constant print speeds
203 dots/in.
2.4 in. (61 mm) per second 3 in. through 10 in. per second in 1-in. increments (76 mm through 254 mm per second in 25-mm increments) 2.4 in. (61 mm) per second 3 in. through 8 in. per second in 1-in. increments (76 mm through 203 mm per second in 25-mm increments) 1.5 in (38 mm) 2 in. through 4 in. per second in 1-in. increments (51 mm through 102 mm per second in 25-mm increments)
2.4 in. (61 mm) per second 3 in. through 10 in. per second in 1-in. increments (76 mm through 254 mm per second in 25-mm increments) 2.4 in. (61 mm) per second 3 in. through 8 in. per second in 1-in. increments (76 mm through 203 mm per second in 25-mm increments) N/A
300 dots/in.
600 dots/in.
Thin film printhead with E3 Element Energy Control
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System Description Media Specifications
39
Media Specifications
Media Specifications ZM400 ZM600
Label length
Minimum
Tear-off Peel-off Rewind Cutter
0.5 in. 0.5 in. 0.5 in. 1 in. 39 in. 20 in. 1 in. 4.5 in. 4.25 in. 0.0023 in. 0.010 in. 3 in. 8 in. 8.0 in. 4.5 in. 6.2 in.
13 mm 13 mm 13 mm 25.4 mm 991 mm 508 mm 25.4 mm 114 mm 108 mm 0.058 mm 0.25 mm 76 mm 203 mm 203 mm 114 mm 157 mm 2 mm 3 mm 4 mm 6 mm 3 mm 3 mm 3.8 mm 57 mm 2.5 to 11.5 mm > 9.5 mm
0.5 in. 0.5 in. 0.5 in. 1.0 in. 39 in. N/A 2 in. 7.0 in. 6.75 in. 0.0023 in. 0.010 in. 3 in. 8 in. 8.0 in. 7.0 in. 6.2 in. 0.079 in. 0.118 in. 0.157 in. 0.25 in. 0.12 in. 0.125 in. 0.15 in. 3.5 in. 0.98 in. to 0.453 in. > 0.37 in.
13 mm 13 mm 13 mm 25.4 mm 991 mm N/A 51 mm 178 mm 171 mm 0.058 mm 0.25 mm 76 mm 203 mm 203 mm 178 mm 157 mm 2 mm 3 mm 4 mm 6 mm 3 mm 3 mm 3.8 90 mm 2.5 to 11.5 mm > 9.5 mm
Maximum
200 or 300 dots/in. 600 dots/in.
Label width
Minimum Maximum Tear/Cutter Peel/Rewind Minimum Maximum
Total thickness (includes liner, if any) Core size Maximum roll diameter Maximum fanfold pack size (length x width x height) Inter-label gap
Minimum Preferred Maximum
0.079 in. 0.118 in. 0.157 in. 0.25 in. 0.12 in. 0.125 in. 0.15 in. 2.25 in. 0.98 in. to 0.453 in. > 0.37 in. > 1.0 ODU 0.5 ODU
Ticket/tag notch size (width x length) Hole diameter Notch or hole position (Centered from inner media edge) Black mark dimensions Minimum Maximum
Vertical length Horizontal width Location
Within 0.40 in. (1 mm) of inside media edge
Density, in Optical Density Units (ODU) Maximum media density
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System Description 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 62.
Ribbon Specifications ZM400 ZM600
Ribbon width (Zebra recommends using ribbon at least as wide as the media to protect the printhead from wear.) Standard lengths
Minimum Maximum
>2 in.* 4.3 in.
51 mm* 110 mm
>2 in. 6.85 in.
51 mm 174 mm
2:1 media to ribbon roll ratio 3:1 media to ribbon roll ratio
984 ft. 1476 ft. 1 in. 3.2 in.
300 m 450 m 25.4 mm 81.3 mm
984 ft. 1476 ft. 1 in. 3.2 in.
300 m 450 m 25.4 mm 81.3 mm
Ribbon core inside diameter Maximum ribbon roll size
* 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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System Description Printer Options
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Printer Options
Option ZM400 ZM600
Cutter Peel-off Liner take-up Factory-installed 64 MB (58 MB user available) Flash memory 300 dpi printhead 600 dpi printhead Rewind External print server (10/100 or 10base-T) Internal print server (10base-T) Wireless print server
X X X X X X X X X X
X X Not available X X Not available X X X X
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System Description Printer Options
Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
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Operations
This section assists the technician with out of the box installation, initial setup, and printer operation.
Contents
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select a Data Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Cables and Wireless Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to the Computer or Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 46 46 46 46 47 47 47 47 47 47 48 49 49 52 53 54 55 55 56 58 62 64 69 69 69
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Operations
Contents (Continued)
Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print a Configuration Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to View or Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Printer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 72 72 73 74 74 74 75 76 77 77 77 78
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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 46. 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 47. 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 48. Attach a Power Cord Do you have the correct power cord for your printer? If you are unsure, see Power Cord Specifications on page 53. To attach the power cord and connect the printer to a power source, see Connect the Printer to a Power Source on page 52. Select Media Do you have the correct media for your application? If you are unsure, see Types of Media on page 54. 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 62.
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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. Notify your authorized Zebra reseller
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. Remove any media, ribbon, or loose objects from the printer interior. 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 Select a Site for the Printer
47
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 36.
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 36. 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 Direct Thermal
40 to 104F (5 to 40C) 32 to 104F (0 to 40C)
20 to 85% non-condensing. 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 48.
Provide a Power Source

Place the printer within a short distance of a power outlet that is easily accessible.
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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 Characteristics of the Data Communication Interfaces
Interface Standard or Optional on Printer Characteristics
RS-232 Serial
Standard
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. 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. Maximum cable length of 16.4 ft (5 m). No printer parameter changes required to match the host computer. Can print to the printer from any computer on your LAN. Can communicate with the printer through the printers web pages. Computer must be equipped with an Ethernet board. The printer must be configured to use your LAN. 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. Computer must be equipped with an Ethernet board. The printer must be configured to use your WLAN.
IEEE 1284 Bidirectional Parallel
Standard
USB
Standard
Internal wired Ethernet print server
Optional
Wireless Ethernet print server
Optional
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Data Cables and Wireless Cards

You must supply all data cables or wireless cards for your application. Data Cables 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. Wireless Cards For supported wireless cards, refer to the ZebraNet Wireless Print Server and Wireless Plus Print Server User Guide. A copy of the manual is available at http://www.zebra.com/manuals or on the user CD that came with your printer.
Connect the Printer to the Computer or Network

Table 6 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. For another view of the connectors on the printer, see Figure 3 on page 30.
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 6 Connecting the Printer to a Computer or Network

Interface Connection and Configuration
RS-232 Serial
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 Control Panel Parameters on page 77 to view or change these parameters.
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Table 6 Connecting the Printer to a Computer or Network (Continued)

IEEE 1284 Bidirectional Parallel
No additional configuration is necessary.
USB
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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Table 6 Connecting the Printer to a Computer or Network (Continued)

Internal wired Ethernet print server
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.
Wireless Ethernet print server
Refer to the ZebraNet Wireless Print Server and Wireless Plus Print Server 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.
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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 53.
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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53
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 1 4 1 2 3 4 3
AC power plug for your countryThis should bear the certification mark of at least one of the known international safety organizations (Figure 7). 3-conductor HAR cable or other cable approved for your country. IEC 320 connectorThis should bear the certification mark of at least one of the known international safety organizations (Figure 7). Length 9.8 ft. (3 m). Rating 10 Amp, 250 VAC.
Figure 7 International Safety Organization Certifications
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Operations Types of Media
Types of Media
The printer can use various types of media (Table 7). Table 7 Types of Media
Media Type How It Looks Description
Non-Continuous Roll Media
Roll media is wound on a 3-in. (76-mm) core. Labels have adhesive backing that sticks them to a liner, and they are separated by gaps, holes, notches, or black marks. Tags are separated by perforations.
Non-Continuous Fanfold Media
Fanfold media is folded in a zigzag pattern. Fanfold media can have the same label separations as non-continuous roll media. The separations would fall on or near the folds.
Continuous Roll Media
Roll media is wound on a 3-in. (76-mm) core. 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. Radio frequency identification (RFID) smart labels are made from the same materials and adhesives as non-RFID labels. Each label has an RFID transponder, made of a chip and an antenna, embedded between the label and the liner (sometimes called an inlay). The shape of the transponder varies by manufacturer and is visible through the label. 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.
RFID Smart Media (for use only with printers that have an RFID reader/encoder installed)
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Operations Print Modes and Printer Options
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Print Modes and Printer Options

The printer can use different print modes and options for label removal (Table 8). 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 54. To select a print mode, see Select Print Mode on page 80.
Print Mode Descriptions and Printer Requirements

Table 8 Print Modes and Printer Options
Print Mode When to Use/Printer Options Required Printer Actions
Tear-Off (default setting)
Use for most applications. This mode can be used with any printer options and most media types. Use only if the printer has the Peel-Off, Liner Take-Up, or Rewind option.
The printer prints label formats as it receives them. The printer operator can tear off the printed labels any time after they print. The printer peels the label from the liner 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. The printer prints a label and then cuts it free. The printer prints a label, pauses, and cuts the label when it receives the ~JK (delayed cut) ZPL command. The printer prints without pausing between labels. The media or liner is wound onto a core after printing. Reserved for future options. Reserved for future options.
Peel-Off
Cutter Delayed Cut
Use if the printer has a cutter option when you want the labels to be cut apart. Use if the printer has a cutter option when you want the printer to cut the labels apart at a signal. Use if the printer has the Rewind option and you want the labels to rewind on a core. Reserved for future options. Reserved for future options.
Rewind
Linerless Peel Linerless Rewind
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Media Paths
Table 9 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. Table 9 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 Take-Up)
Liner take-up
Rewind
Red solid lines = media, Blue dotted lines = backing only
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Table 9 Media Paths for Print Modes with Various Printer Options (Continued)
Print Mode Printer Option
Media Path
Cutter or Delayed Cut
Cutter (shown with an optional catch tray)
Rewind
Rewind
Red solid lines = media, Blue dotted lines = backing only
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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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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 labels that are dirty or that are held by adhesives or tape.
a.
Flip down the media supply guide.
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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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 it touches the edge of the roll.
d.
Flip up the media supply guide.
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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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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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. The media determines whether you need to use ribbon and how wide the ribbon must be. When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.
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 Appears on the media
Thermal transfer. A ribbon is required. 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) 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.
Adhesive Test
If you have labels available, perform the adhesive test to determine which side of a ribbon is coated. This method works well for ribbon that is already installed.
To perform an adhesive test, complete these steps:

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.
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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. 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.
Did not adhere to the label
Ribbon Scratch Test

Perform the ribbon scratch test when labels are unavailable.
To perform a ribbon scratch test, complete these steps:

1. Unroll a short length of ribbon. 2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the
ribbon in contact with the paper.

3. Scratch the inner surface of the unrolled ribbon with your fingernail. 4. Lift the ribbon from the paper. 5. Observe the results. Did the ribbon leave a mark on the paper?
If the ribbon...
Then...
Left a mark on the paper
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. 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.
Did not leave a mark on the paper
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Operations 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 62. Figure 9 Ribbon Path
Ribbon Coated Outside (black ribbon spindle) Ribbon Coated Inside (gray ribbon spindle)
1 2 3 4 5 1 2 3 4 5
1 2 3 4 5
Tension blade Ribbon take-up spindle Ribbon supply spindle Printhead assembly Printhead release latch
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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 (black ribbon spindle) Ribbon Coated Inside (gray ribbon spindle)
a.
a.
Hold the ribbon with the loose end unrolling clockwise.
Hold the ribbon with the loose end unrolling counterclockwise.
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Ribbon Coated Outside (black ribbon spindle) (Continued)
Ribbon Coated Inside (gray ribbon spindle) (Continued)

b.
b.
Place the roll of ribbon on the ribbon supply spindle (1) and push it all the way back.
Place the roll of ribbon on the ribbon supply spindle (1) and push it all the way back.
c.
Pull the end of the ribbon under the printhead assembly (1) and out the front of the printer. Extend the ribbon approximately 24 in. (610 mm) out of the printer.
c.
Pull the end of the ribbon under the printhead assembly (1) and out the front of the printer. Extend the ribbon approximately 24 in. (610 mm) out of the printer.
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3. Close the printhead assembly.
4. Wind the ribbon clockwise onto the ribbon take-up spindle (1).
Ribbon Coated Outside (black ribbon spindle)
Ribbon Coated Inside (gray ribbon spindle)
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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.
1
3. Slide the used ribbon off of the ribbon take-up spindle and discard.
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Operations Calibrate the Printer
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Calibrate the Printer

Auto Calibration
By default, 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 96 or Select Head Close Option on page 96.
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 90.
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Operations 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 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 dials have seven settings instead of four. Figure 10 Printhead Pressure Adjustment Dials
1 2
1 2
Outside dial Inside dial
To set printhead pressure, complete these steps:

1. Use Table 10 or Table 11 to select the initial dial settings for your media, depending on
which printer you have. Table 10 ZM400 Printhead Pressure

Media Width
Inside Dial
Outside Dial
1 in. (25.4 mm) 2 in. (51 mm) 3 in. (76 mm) 3.5 in. and up (89 mm and up)
3 4 3 3
1 1 2 3
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Table 11 ZM600 Printhead Pressure

Media Width
Inside Dial
Outside Dial
2 in. (50 mm) 3 in. (75 mm) 4 in. (100 mm) 5 in. (125 mm) 5.5 in. and up (140 mm and up)
6 6 7 7 6
1 2 3 4 6
2. If necessary, adjust the pressure adjustment dials as follows:
If the media...
Then...
Requires higher pressure to print well Shifts left while printing Shifts right while printing Prints too lightly on the left side of the label. Prints too lightly on the right side of the label.
Increase both dials one position. Increase the outside dial setting one position, or decrease the inside dial setting one position. Increase the inside dial setting one position, or decrease the outside dial setting one position. Increase the inside dial setting one position. Increase the outside dial setting one position.
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Operations Setup Mode
Setup Mode
After you have installed the media and ribbon 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 123.
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 10/100
PrintServer or Wireless Plus 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 Setup Mode

To enter Setup Mode, complete these steps:
1. Press SETUP/EXIT. 2. Press PLUS (+) or MINUS () to scroll through the parameters. 3. Press SELECT to select and deselect the parameters.
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Operations Setup Mode
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Exit Setup Mode

To leave Setup mode, complete these steps:
1. Press SETUP/EXIT.
The LCD displays SAVE CHANGES.

2. Press PLUS (+) or MINUS (-) to display the save options:
LCD
Description
PERMANENT TEMPORARY CANCEL
Stores values in the printer even when power is turned off. Saves the changes until power is turned off. 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. 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 Loading factory defaults causes the printer to auto-calibrate. Loads values from the last permanent save. Restores the wired and wireless network settings back to factory defaults.
LOAD DEFAULTS
LOAD LAST SAVE DEFAULT NET
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 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 10/100 Print Server, or Wireless Plus 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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Operations Print a Configuration Label
75
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 Configuration Label
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Operations 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 Network Configuration Label (With a Wireless Print Server Installed)
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Operations Control Panel Parameters
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Control Panel Parameters

Use the LCD on the control panel to view and adjust printer settings.
How to View or Modify Parameters

While viewing parameters, press PLUS (+) to continue to the next parameter, or press MINUS (-) to return to the previous parameter in the cycle. Press SELECT when you want to modify a parameter or view its options. 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.
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.
Additional Parameters
Additional parameters appear in the following situations. 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 Print Server and Wireless Plus Print Server User Guide. When a Radio Frequency Identification (RFID) reader is installed. Refer to the RFID Programming Guide for more information. Copies of these manuals are available at http://www.zebra.com/manuals or on the user CD that came with your printer.
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Standard Printer Parameters

Table 12 shows parameters in the order in which they are displayed when you press PLUS (+) after entering Setup mode. Table 12 Printer Parameters (Page 1 of 24)
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 120 can be used to determine the best darkness setting. You may want to adjust darkness while performing the PAUSE Self Test on page 119. 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, XML): +10 Range (ZPL, XML): 00 to +30 Default Value (EPL): +7 Range (EPL): 00 to +15
To change the value shown:
1. 2. 3. 4.
Press SELECT to select the parameter. Press PLUS (+) to increase darkness. Press MINUS (-) to decrease darkness. Press SELECT to accept any changes and deselect the parameter.
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Table 12 Printer Parameters (Page 2 of 24)

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: 2 IPS Range: 200 dpi: 2 to 10 IPS 300 dpi: 2 to 8 IPS 600 dpi: 1 to 4 IPS
1. 2. 3. 4.
Press SELECT to select the parameter. Press PLUS (+) to increase the value. Press MINUS (-) to decrease the value. Press SELECT to accept any changes and deselect the parameter.
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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
Media direction Factory-set tear line location at position 00
Default Value: +0 Range: 120 to +120

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. 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 55. Default Value: TEAR-OFF Selections: TEAR-OFF, PEEL-OFF, CUTTER, DELAYED CUT, LINERLESS-P, LINERLESS-R, REWIND
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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Parameter
Action/Explanation
Set Media Type This parameter tells the printer the type of media that you are using (see Types of Media on page 54 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
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. 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 Range: THERMAL TRANSFER, DIRECT THERMAL
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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Parameter
Action/Explanation
Set Print Width This parameter specifies the printable area across the width of the label. Table 13 shows the ranges and default values for print width, which are based on the printer model and the printhead resolution. Table 13 Print Width Ranges and Maximum Values
Printhead Resolution
Printer ZM400 ZM600
200 dpi 300 dpi 600 dpi
Default Value: 832 Range: 2 to 832 dots Default Value: 1248 Range: 2 to 1248 dots Default Value: 2496 Range: 2 to 2496 dots
Default Value: 1344 Range: 2 to 1344 dots Default Value: 1984 Range: 2 to 1984 dots N/A
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.
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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Parameter
Action/Explanation
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 is 7.5 inches (190 mm), set the parameter for 9.0 inches (229 mm). Figure 14 Label Length
}2
3 1
1 2 3
Label length (including interlabel gap) Interlabel gap Set maximum label length to approximately this value
Default Value: 39.0 inches (988 mm). Selections: Values are adjustable in one-inch (25.4 mm) increments.
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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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 74.) 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
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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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
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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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. 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 and XML 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. 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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Parameter
Action/Explanation
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. List Setup This option prints a configuration label (see Figure 11 on page 75), 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. List Network Settings This option prints a network configuration label (see Figure 12 on page 76), 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. 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.
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Parameter
Action/Explanation
ZPL and XML only
Format Memory Card This option erases all previously stored information from the optional 64 MB flash chip on the Wireless Plus option board. This parameter appears only when a Wireless Plus option board with the flash chip populated is installed.
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:. 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 74. 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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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 74. 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 125.
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 90. 4. Press SELECT to accept any changes and deselect the parameter.
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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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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
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 and XML 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
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, XML): 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600, 115200 Selections (EPL): 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200
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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
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
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, XML): XON/XOFF Selections (ZPL, XML):XON/XOFF, DSR/DTR, RTS/CTS Default Value (EPL): DTR & XON/XOFF Selections (EPL): DTR & XON/XOFF, DTR
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Parameter
Action/Explanation
ZPL and XML 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.
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 and XML 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
1. 2. 3. 4.
Press SELECT to select the parameter. Press MINUS (-) to move to the next digit position. Press PLUS (+) to increase the value of the digit. Press SELECT to accept any changes and deselect the parameter.
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 124. Default Value: NORMAL MODE Selections: NORMAL MODE, DIAGNOSTICS
To select communication diagnostics mode:
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Parameter
Action/Explanation
ZPL and XML 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
1. 2. 3. 4. ZPL and XML 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
1. 2. 3. 4.
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Parameter
Action/Explanation
ZPL and XML 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
1. 2. 3. 4. ZPL and XML 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
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Parameter
Action/Explanation
Select Media Power-Up Option This parameter sets the action of the media when you turn on the printer. Default Value: CALIBRATION 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.
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: CALIBRATION 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.
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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%
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. 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: 120 to +120 dots
1. 2. 3. 4.
Press SELECT to select the parameter. Press PLUS (+) to increase the value. Press MINUS (-) to decrease the value. Press SELECT to accept any changes and deselect the parameter.
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
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.
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Parameter
Action/Explanation
ZPL and XML 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
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. 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:
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Parameter
Action/Explanation
ZPL and XML 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
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 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
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Parameter
Action/Explanation
Set Real-Time Clock (RTC) Date This parameter allows you to set the date following the convention selected in IDLE DISPLAY.
1. 2. 3. 4.
Press SELECT to select the parameter. Press MINUS (-) to move to the next digit position. Press PLUS (+) to change the value of the digit. 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.
1. 2. 3. 4.
Press SELECT to select the parameter. Press the left oval MINUS (-) to move to the next digit position. Press the right oval PLUS (+) to change the value of the digit. 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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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
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Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 105 109 112 113 114 115 117 117 118 119 120 123 124 125
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Troubleshooting 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 105. Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 90. Is the printer reporting a ribbon error when ribbon is loaded properly? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 90. Are you experiencing problems with print quality? If yes, see Print Quality Problems on page 109. Are you experiencing communications problems? If yes, see Communications Problems on page 113.
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 54. Are you using a label that is narrower than the maximum print width? See Set Print Width on page 82. Review the label- and ribbon-loading illustrations in Load Media on page 58 and Load Ribbon on page 64. Does the printhead need to be adjusted? See Adjust Printhead Pressure on page 70 for more information. Do the sensors need to be calibrated? See Calibrate Media and Ribbon Sensor Sensitivity on page 90 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 117. Use the results to help identify the problem. If you are still having problems, see Contacts on page 25 for customer support information.
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Troubleshooting LCD Error Messages
105
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/ Printer Condition Possible Cause Recommended Solution
ERROR CONDITION INVALID HEAD

The ERROR light flashes.
The printhead was replaced with one that is not a genuine Zebra printhead..
Install a genuine Zebra printhead.
ERROR CONDITION RIBBON OUT

The printer stops; the ERROR light flashes.
In thermal transfer mode, ribbon is not loaded or incorrectly loaded. In thermal transfer mode, the ribbon sensor is not detecting ribbon that is loaded incorrectly.
Load ribbon correctly. See Load Ribbon on page 64. 1. Load ribbon correctly. See Load Ribbon on page 64. 2. Calibrate the sensors. See Calibrate Media and Ribbon Sensor Sensitivity on page 90. 1. Load media correctly. See Load Media on page 58. 2. Calibrate the sensors. See Calibrate Media and Ribbon Sensor Sensitivity on page 90. 1. Print a sensor profile. See Print Sensor Profile on page 89. The ribbon out threshold (marked by the word RIBBON) is likely too high, above the black area that indicates where the ribbon is detected.
In thermal transfer mode, media is blocking the ribbon sensor.
In thermal transfer mode, the printer did not detect the ribbon even though it is loaded correctly.
2. Calibrate the sensors or load printer defaults. See Calibrate Media and Ribbon Sensor Sensitivity on page 90 or LOAD DEFAULTS on page 73.
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Table 14 LCD Error Messages (Continued)

WARNING RIBBON IN
Ribbon is loaded, but the printer is set for direct thermal mode.
Ribbon is not required with direct thermal media. If you are using direct thermal media, remove the ribbon. This error message will not affect printing. If you are using thermal transfer media, which requires ribbon, set the printer for Thermal Transfer mode. See Select Print Method on page 81.
ERROR CONDITION PAPER OUT

The media is not loaded or is loaded incorrectly. Misaligned media sensor. The printer is set for noncontinuous media, but continuous media is loaded. The printhead is not fully closed. The head open sensor is not working properly.
Load media correctly. See Load Media on page 58. Check position of the media sensor. Install proper media type, or reset printer for current media type and perform calibration. Close printhead completely. Replace the sensor.
ERROR CONDITION HEAD OPEN

THERMISTOR FAULT
The printhead has a faulty thermistor.
Replace the printhead.
WARNING HEAD COLD THERMISTOR FAULT ERROR CONDITION HEAD ELEMENT BAD
The printer stops; the ERROR light is on; the printer cycles through these three messages.
Caution An improperly connected printhead data or power cable can cause these error messages. The printhead may be hot enough to cause severe burns. Allow the printhead to cool.
The printhead data cable is not properly connected.
Caution Turn off (O) the printer 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 thermistor. Replace the printhead.
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WARNING HEAD COLD

The printer prints while the ERROR light flashes.
Caution An improperly connected printhead data or power cable can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool.
The printhead temperature is approaching its lower operating limit.
Continue printing while the printhead reaches the correct operating temperature. If the error remains, the environment may be too cold for proper printing. Relocate the printer to a warmer area.
Caution Turn off (O) the printer before performing this procedure. Failure to do so can damage the printhead.
The printhead data cable is not properly connected.
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 thermistor. Replace the printhead.
WARNING HEAD TOO HOT

Caution The printhead may be hot enough to cause severe burns. Allow the printhead to cool.
The printhead is over temperature.
Allow the printer to cool. Printing automatically resumes when the printhead elements cool to an acceptable operating temperature.
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DEFRAGMENTING
The printer is defragmenting memory.
Caution Do NOT turn off the printer 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.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.
ERROR CONDITION CUTTER JAM

The cutter blade is in the media path.
Turn off the printer power and unplug the printer. Inspect the cutter module for debris and clean as needed following the cleaning instructions in Clean the Cutter Module on page 135.
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Troubleshooting Print Quality Problems
109
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 issues
The printer is set at the incorrect print speed.
For optimal print quality, set the print speed to the lowest possible setting for your application via control panel, the driver, or the software. See Adjust Print Speed on page 79. You may want to perform the FEED Self Test on page 120. 1. Switch to a different type of media or ribbon to try to find a compatible combination. 2. If necessary, consult your authorized Zebra reseller or distributor for information and advice. For optimal print quality, set the darkness to the lowest possible setting for your application via the control panel, the driver, or the software. See Adjust Print Darkness on page 78. You may want to perform the FEED Self Test on page 120 to determine the ideal darkness setting. Clean the printhead. See Clean the Printhead and Platen Roller on page 131. Set the printhead pressure to the minimum needed for good print quality. See Adjust Printhead Pressure on page 70. Adjust the printhead balance. Replace the printhead.
You are using an incorrect combination of labels and ribbon for your application.
The printer is set at an incorrect darkness level.
The printhead is dirty. Incorrect or uneven printhead pressure. The printhead is improperly balanced. Long tracks of missing print on several labels Print element damaged.
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Table 15 Print Quality Problems (Continued)

Wrinkled ribbon
Ribbon fed through the machine incorrectly. Incorrect burn temperature.
See Load Ribbon on page 64. Set the darkness to the lowest possible setting for good print quality. See Adjust Print Darkness on page 78. Set the printhead pressure to the minimum needed for good print quality. See Adjust Printhead Pressure on page 70. Make sure that media is snug by adjusting the media guide, or call a service technician.
Incorrect or uneven printhead pressure. Media not feeding properly; walking from side to side. The strip plate needs adjusting. The printhead needs vertical adjustment. The printhead is improperly balanced. The printhead and platen roller need to be realigned. Printing too light or too dark over the entire label The media or ribbon is not designed for high-speed operation. You are using an incorrect combination of media and ribbon for your application.
Adjust the printhead balance.
Replace supplies with those recommended for high-speed operation. 1. Switch to a different type of media or ribbon to try to find a compatible combination. 2. If necessary, consult your authorized Zebra reseller or distributor for information and advice. Direct thermal media does not require ribbon. To check if you are using direct thermal media, perform the label scratch test in When to Use Ribbon on page 62. Set the pressure to the minimum needed. See Adjust Printhead Pressure on page 70. Replace supplies with those recommended for high-speed operation. Recalibrate the printer. Use correct label format. See Clean the Printhead and Platen Roller on page 131. Use media that meets specifications.
You are using ribbon with direct thermal media.
Incorrect or uneven printhead pressure. Smudge marks on labels Misregistration/skips labels Misregistration and misprint of one to three labels The media or ribbon is not designed for high-speed operation. The printer is not calibrated. Improper label format. The platen roller is dirty. Media does not meet specifications.
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Table 15 Print Quality Problems (Continued)

Vertical drift in top-of-form position
The printer is out of calibration. Recalibrate the printer. Vertical drift occurs during normal printer operation. Note A vertical drift of 4 to 6 dot rows (approximately 0.5 mm) is within normal tolerances. The platen roller is dirty. Calibrate the printer.
Clean the platen roller. See Clean the Printhead and Platen Roller on page 131.
Vertical image or label drift
The printer is using Configure the printer for non-continuous and run non-continuous labels but is calibration routine, if necessary. configured in continuous mode. The media sensor is positioned incorrectly. The media sensor is calibrated improperly. The platen roller is dirty. Improper printhead pressure settings (toggles). Improperly loaded ribbon or media. Incompatible media. Ensure that the media sensor is properly positioned to read a single/consistent interlabel gap. See Calibrate Media and Ribbon Sensor Sensitivity on page 90. Clean the platen roller. See Clean the Printhead and Platen Roller on page 131. Adjust the printhead pressure to ensure proper functionality. Verify that the printer is loaded properly. 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. Perform the FEED Self Test on page 120. Adjust the darkness or print speed settings as necessary. Leave at least 1/8 in. (3.2 mm) between the bar code and other printed areas on the label and between the bar code and the edge of the label.
The bar code printed on a label does not scan.
The bar code is not within specifications because the print is too light or too dark. Not enough blank space around the bar code.
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Troubleshooting Calibration Problems
Calibration Problems
Table 16 identifies problems with calibration, the possible causes, and the recommended solutions. Table 16 Calibration Problems
Loss of printing registration on labels. Excessive vertical drift in top-of-form registration.
The platen roller is dirty.
Clean the platen roller according to the instructions in Clean the Printhead and Platen Roller on page 131. Ensure that the media guides are properly positioned. Set the printer for the correct media type (gap/notch, continuous, or mark). See Set Media Type on page 81.
Media guides are positioned improperly. The media type is set incorrectly.
The media is loaded incorrectly. Load media correctly. See Load Media on page 58. Auto Calibrate failed. Media or ribbon is loaded incorrectly. The sensors could not detect the media or ribbon. The sensors are dirty or positioned improperly. The sensors are dirty, or media is positioned improperly for the sensors to detect. The media type is set incorrectly. Ensure that media and ribbon are loaded correctly. Manually calibrate the printer. See Calibrate Media and Ribbon Sensor Sensitivity on page 90. Ensure that the sensors are clean and that media is positioned properly.
Set the printer for the correct media type (gap/notch, continuous, or mark). See Set Media Type on page 81.
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Communications Problems
Table 17 identifies problems with communications, the possible causes, and the recommended solutions. Table 17 Communications Problems
A label format was sent to the printer but was not recognized. The DATA light does not flash.
The communication parameters are incorrect.
Check the printer driver or software communications settings (if applicable). If you are using serial communication, check the serial port setting in the control panel menu. See Set Serial Communications on page 91. If you are using serial communication, make sure you are using a null modem cable or a null modem adapter. Using the control panel controls, check the protocol setting. It should be set to NONE. See Set Protocol on page 93. If a driver is used, check the driver communication settings for your connection.
A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or distorts the image on the label. A label format was sent to the printer but was not recognized. The DATA light flashes but no printing occurs.
The serial communication settings are incorrect.
Ensure that the flow control settings match. Check the communication cable length. See Table 5 on page 48 for requirements. Check the printer driver or software communications settings (if applicable).
The prefix and delimiter characters set in the printer do not match the ones in the label format. Incorrect data is being sent to the printer.
Verify the prefix and delimiter characters. See Set Format Prefix Character on page 94 and Set Delimiter Character on page 95 for the requirements. Check the communication settings on the computer. Ensure that they match the printer settings. If the problem continues, check the label format.
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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
Broken or melted ribbon The printer does not detect when the ribbon runs out. In thermal transfer mode, the printer did not detect the ribbon even though it is loaded correctly.
Darkness setting too high. The ribbon-out threshold is set too high to detect the ribbon. On a sensor profile, the ribbon-out threshold (circled in Figure 15) appears above the black bars that indicate the ribbon. This happens if you calibrate the printer without ribbon and later insert ribbon without recalibrating the printer or loading printer defaults. Figure 15 Ribbon-Out Threshold Too High
1. Reduce the darkness setting. 2. Clean the printhead thoroughly. 1. Print a sensor profile (see Print Sensor Profile on page 89), and note the location of the ribbon-out threshold (circled in Figure 15). 2. Calibrate the printer, this time using ribbon, or load printer defaults. See Calibrate Media and Ribbon Sensor Sensitivity on page 90 or LOAD DEFAULTS on page 73. Important Loading defaults resets all printer parameters back to factory defaults. 3. Print another sensor profile, and compare it to the first one. 4. If the ribbon-out threshold is still too high, you may manually change the value.
The ribbon light is on even though ribbon is loaded correctly.
The printer was not calibrated for the label and ribbon being used.
Perform the calibration procedure in Calibrate Media and Ribbon Sensor Sensitivity on page 90.
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Troubleshooting Miscellaneous Printer Problems
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Miscellaneous Printer Problems

Table 19 identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions. Table 19 Miscellaneous Printer Problems
The LCD displays a language that I cannot read
The language parameter was changed through the control panel or a firmware command.
1. Press SETUP/EXIT to enter configuration mode. 2. Press MINUS (-). The printer displays the LANGUAGE parameter in the current language. Even if you cannot recognize the characters displayed, you can still scroll to another language. 3. Press SELECT to select the parameter. 4. Press PLUS (+) or MINUS (-) to scroll through the choices until you find a language that you can read. 5. Press SETUP/EXIT. The LCD displays SAVE CHANGES in the original language. 6. 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). 7. Repeat this process, if necessary, until you reach the desired language.
The LCD is missing characters or parts of characters Changes in parameter settings did not take effect
The LCD may need replacing.
Run the Power-On Self Test on page 117 and check that the LCD display shows all characters. If not, replace the LCD. 1. Set parameters and save permanently. 2. Turn the printer off (O) and then on (I). Refer to the ZPL Programming Guide. Refer to the ZPL Programming Guide.
Parameters are set incorrectly. A command turned off the ability to change the parameter. A command changed the parameter back to the previous setting. If the problem continues, there may be a problem with the main logic board.
Replace the main logic board.
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Troubleshooting Miscellaneous Printer Problems
Table 19 Miscellaneous Printer Problems (Continued)

The printer fails to calibrate or detect the top of the label.
The printer was not calibrated for the label being used. The printer is configured for continuous media. The driver or software configuration is not set correctly.
Perform the calibration procedure in Calibrate Media and Ribbon Sensor Sensitivity on page 90. Set the media type to noncontinuous media. See Set Media Type on page 81. Driver or software settings produce commands that can overwrite the printer configuration. Check the driver or software media-related setting. Perform the calibration procedure in Calibrate Media and Ribbon Sensor Sensitivity on page 90. Set the media type to noncontinuous media. See Set Media Type on page 81. Turn the printer power off (O) and then on (I). If the printer locks up again, replace the main logic board. Replace the main logic board.
Non-continuous labels are being treated as continuous labels. All lights are on, but nothing displays on the LCD, and the printer locks up. The printer locks up while running the Power-On Self Test.
The printer was not calibrated for the media being used. The printer is configured for continuous media. Internal electronic or firmware failure.
Main logic board failure.
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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 82, 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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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 Configuration Label
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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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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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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
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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 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. 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 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. Labels that are too light are obvious. Both normal and rotated bar codes have incomplete bars and spaces. Small alphanumeric characters are unreadable.
Slightly dark
In-spec
Slightly light
Too light
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 78.

8. If necessary, change the print speed to the same speed as on the best test label. See Adjust
Print Speed on page 79.
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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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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 82 for more information.

2. Set the printer to DIAGNOSTICS. For instructions, see Set Communications Mode
on page 93. 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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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 89. If the sensitivity of the sensors must be adjusted, perform Calibrate Media and Ribbon Sensor Sensitivity on page 90. 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)
1 2
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
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Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
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4
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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Preventive and Corrective Maintenance
Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
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Preventive Maintenance
This scection shows various levels of prventative maintenance including cleaning procedures and schedules.
Contents
Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Media Compartment and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 130 131 134 135 137 137 139 140 140 140 140
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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 Platen roller Media sensors Ribbon sensor Media path Ribbon path Pinch roller (part of Peel-Off option) Cutter module If cutting continuous, pressure-sensitive media If cutting tag stock or label liner material Tear-off/peel-off bar Take-label sensor
Solvent* Solvent* Air blow Air blow Solvent* Solvent* Solvent* Solvent* Solvent* and air blow Solvent* Air blow
Direct Thermal Mode: After every roll of media (or 500 feet of fanfold media). Thermal Transfer Mode: After every roll of ribbon or three rolls of media.
After every roll of media (or more often, depending upon your application and media). After every two or three rolls of media. Once a month. 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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131
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 2
Printhead assembly Platen roller
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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.
To clean the printhead and platen roller, complete these steps:

1. Open the printhead assembly. 2.
Open the media door and 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.
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4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the
solvent to evaporate.
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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Clean the Media Compartment and Sensors

To clean the media compartment and sensors, complete these steps:
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. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as label formats, and you must reload them before you resume printing.
2. Brush or vacuum any accumulated paper lint and dust away from the media and ribbon
paths.
3. Brush or vacuum any paper lint and dust away from the sensors (see Figure 24).
Figure 24 Cleaning the Sensors
1 2
1 2 3
4.
Take-label sensor Ribbon sensor Media sensor
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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Routine Maintenance Cleaning Procedures
135
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.
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.

1
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Routine Maintenance Cleaning Procedures
4. See Figure 25. 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. Figure 25 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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Preventive Maintenance Routine Maintenance for the Rewind Option
137
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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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.
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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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Preventive Maintenance Replacing Printer Components
Replacing Printer Components

Some printer components, such as the printhead and platen roller, may wear out over time and can be replaced easily. Regular cleaning may extend the life of some of these components. See Cleaning Schedule and Procedures on page 130 for the recommended cleaning intervals.
Ordering Replacement Parts

For optimal printing quality and proper printer performance across our product line, Zebra strongly recommends the use of genuine Zebra supplies as part of the total solution. Specifically, the ZM400 and ZM600 are designed to work only with genuine Zebra printheads, thus maximizing safety and print quality. Contact your authorized Zebra reseller for part ordering information, or see Contacts on page 25 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.
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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Corrective Maintenance
This section shows you how to replace parts.
Contents
Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer Casing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 213 243 361 387 421
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Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
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Print System
This section provides replacement, conversion and installation procedures for the ZM400/ZM600 print system.
Contents
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 153 168 189 192 199 206
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Corrective Maintenance Printhead Assembly
Printhead Assembly
This procedure is for installing the Printhead Assembly. Read these ionstructions throughy before performing this procedure.
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 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%).
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Remove the Old Printhead

1.
Caution Turn off (O) the printer and disconnect it from the power source before performing the following procedure.
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 26. Take note of the position of the pressure dials and then rotate the printhead
pressure dials to the #1 position. Figure 26 Locate the Printhead Pressure Dials
1 2 1 2 1 2 1 2
ZM400 1 2
ZM600
Position #1 Pressure dial
4. Do you have a cutter option installed?
If
Then
No Yes
Continue with step 5. You may find it easier to replace the printhead with the cutter assembly removed. Go to Remove the Cutter Assembly on page 151.
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5. See Figure 27. Locate and remove the thumbscrew from the print mechanism.
Figure 27 Remove the Thumbscrew

2 1
1 2
Print mechanism Thumbscrew
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6.
See Figure 28. Open the print mechanism and latch it in the vertical position.
7.
Disconnect the printhead data and power cables.

8. Remove the printhead assembly from the printer.
Figure 28 Remove the Printhead Assembly

2 1 3 4
5 1 2 3 4 5
Printhead assembly Print mechanism Printhead data cable connector Printhead power cable connector Latch assembly
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Install the New Printhead Assembly

1. See Figure 29. 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 29 Align the Forks and Bearings
1
2 8
7 5
1 2 3 4 5 6 7 8
Thumbscrew Ribbon guide plate Alignment holes (2) Alignment pins (2) Printhead ribbon guide Platen housing Forks (2) Bearings (2)
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3. See Figure 28 on page 147. 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 29 and Figure 30. Tip the printhead fork assembly slightly and insert the
printhead ribbon guide into the print mechanism as shown.

5. See Figure 29 and Figure 30. 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 30 Install the Printhead Fork Assembly
1 2 1 2
1 2 3 4 5
Thumbscrew Print mechanism Printhead fork assembly Ribbon guide plate Printhead ribbon guide
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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 26 on page 145. Rotate the two printhead pressure dials to the desired position
for your daily printing.

9. Did you remove a cutter assembly?
If
Then
No Yes
10.
Continue with step 10. Got to Reinstall the Cutter Assembly on page 152.

11. Reconnect the AC power cord and data cables 12. Turn on (l) the printer.
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Remove the Cutter Assembly

1. See Figure 31. Unlatch the printhead and turn the latch assembly clockwise to access the
cutter mounting screw.

2.
Remove the cutter mounting screw. Figure 31 Remove the Cutter Assembly
5 1 2 3 4 5
Cutter assembly Mounting screw Printhead latch Platen assembly hooks (2) 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 146.
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Reinstall the Cutter Assembly

1. See Figure 31 on page 151. Reinstall the cutter assembly on the hooks of the platen
housing.
a. b.
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. 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.

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153
Print Mechanism
Tools Required
Phillips Screwdriver Set Flat-blade Screwdriver Set Metric Hex key (Allen wrench) Set 10 cm Adjustable Wrench
Antistatic Wriststrap and Mat Metric Nutdriver Set *47362 Zebra Preventative 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 Electronics Cover

Caution A qualified service technician must perform this installation.
1.
2.
Open the media cover and remove the media and ribbon.
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3. See Figure 32. Remove the screw and washer securing the electronics cover.
Figure 32 Locate the Electronics Cover Mounting Screw
1 2
1 2 3 4
4. Close the media door.
Media door Electronics cover Washer Mounting screw
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5. See Figure 33. Remove the four mounting screws on the rear of the printer.
Figure 33 Remove the Electronics Cover Mounting Screws

1
1 2
Electronics cover Mounting screws (4)
6. See Figure 34. 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 34 Remove the Electronics Cover
2
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7. Is there a wireless board installed?
If
Then
No Yes
Go to Gain Access to the Power Supply on page 158. Continue with Remove the Wireless Board.
Remove the Wireless Board

1.

2. See Figure 5. Press in on the eject button to remove the radio card.
Figure 35 Remove the Radio Card

1
2 1 2
Eject button Radio card
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3. See Figure 36. 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 36 Remove the Wireless Board

1
1 2
Wireless board Mounting screws (3)
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Gain Access to the Power Supply

1.

2. See Figure 37. 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 37 Remove the Standoff and Screw

1
3 1 2 3
Mounting screw Mounting standoff Power supply shield
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4. See Figure 38. Pull the top of the shield away from the main frame and fold it down to
access the printhead power connector. Figure 38 Gain Access the Power Supply
1
Shield
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Disconnect the Print Mechanism

1. See Figure 39. Remove the printhead housing grounding strap mounting screw.
Figure 39 Printhead Grounding Strap

1 2 3 3 4
5 6
8 7
1 2 3 4 5
Power supply Printhead power cable connector J3 Flat cable clips (5) Stepper motor Printhead housing ground strap
6 7 8 9
Printhead housing ground strap mounting screw Main logic board (MLB) mounting bracket MLB MLB printhead data cable connector P19
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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If
Then
No Yes
Go to Remove the Print Mechanism on page 162. You may find it easier to replace the printhead with the cutter assembly removed. Continue with Remove the Cutter Assembly.

1. See Figure 40. Unlatch the printhead and turn the latch assembly clockwise to remove the

2.
5 1 2 3 4 5
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procedure.
assembly hooks.
Remove the Print Mechanism

1. See Figure 41.Remove the three mounting screws and two washers.
Figure 41 Printhead Housing Mounting Screws
2 1 2 3
Print mechanism Washers (2) 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 41. 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 39 on page 160. Route the printhead power cable under the stepper motor and
up to the power supply.
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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.

8. Install the printhead data cable into the flat cable clip on the base of the printer. 9. Connect the ground strap from the print mechanism to the printer.
Reinstall the Electronics Cover

1. See Figure 42. 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 42 Locate the Upper and Lower Flanges
1 2
1 2 3
Electronics cover Upper flanges (3) Lower flanges (2)
2. See Figure 33 on page 155. Install the four mounting screws. 3. See Figure 32 on page 154. Open the media door. 4. Install the electronics cover mounting screw and lock washer.
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Adjust the Print Mechanism

1. See Figure 43. 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 43 Adjust the Print Mechanism
1 2
3 4
1 2 3 4 5
Strike plate cap Adjustment screw Strike plate Strike plate mounting screws (2) Print mechanism gap pin gauges (2)
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2. See Figure 44. 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 44 Install the Adjustment Cam

3 2
1 2 3
Cam mounting hole Cam Mounting screw
3. See Figure 43. Insert the print mechanism gap pin gauges through the holes that are
provided in the front of the ribbon guide plate.

4. See Figure 41 on page 162. Slightly loosen the three print mechanism mounting screws. 5. See Figure 43. 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.
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10. Replace the strike plate cap. 11. See Figure 45. Check the gap on the ribbon/printhead open sensor and adjust as necessary.
Figure 45 Ribbon/Printhead Open Sensor
3 2
1 2 3 4 5
Printhead housing Gap, 1.25 mm (0.050 in.) Ribbon/Printhead open sensor Mounting screw Ribbon guide plate
12. 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.
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If
Then
No Yes
14.
Continue with step 14. Go to Reinstall the Cutter Assembly.

15. Reconnect the AC power cord and data cables. 16. Turn on (l) the printer.

housing.
a. b.

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Corrective Maintenance Printhead Cables
Printhead Cables
Tools Required
Phillips Screwdriver Set Metric Nutdriver Set Metric Hex Key (Allen wrench) Set
Antistatic Wrist Strap and Pad 47362* Zebra Preventive Maintenance Kit
1.
2.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Electronic Cover

1. What type of communications do you have?
If you have
Then
Wireless Wired or None
Continue with Remove the Wireless Board. Go to Gain Access to the Power Supply on page 173

1.


1
2 1 2
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1
1 2
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1.


1
3 1 2 3
Mounting screw Mounting standoff Power supply shield
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access the printhead connector. Figure 52 Gain Access the Power Supply
1
Shield
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5. See Figure 53. Unplug the printhead power cable from J3 on the power supply. 6. Unplug the printhead data cable from P19 on the main logic board (MLB).
Figure 53 Disconnect Printhead Cables
1 2 3
Printhead power cable connected to J3 of the power supply Printhead braided ground cable mounting screw Printhead data cable connected to P19 on the MLB
7. Remove the printhead braided ground cable mounting screw. 8. Turn the printer around and open the media door.
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Remove the Printhead

1. See Figure 54. Note the positions and then rotate the two printhead pressure knobs to the
#1 position. Figure 54 Top View of Printhead Housing

1 2 1 2
3 1 2 3
2.
Front ZM400
Front ZM600
Position number one Thumbscrew Printhead Pressure Dials (2)

If
Then
No Yes
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4. See Figure 55. Remove the thumbscrew to loosen the printhead fork assembly.
2 1 2
Thumb screw Printhead fork assembly
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5. See Figure 56. Unlatch the print mechanism, and then lift and latch it in the open position.
Figure 56 Printhead Removal and Installation

1
2 3
1 2 3 4 5
Print mechanism Printhead data cable Printhead power cable Printhead assembly 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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8. See Figure 57. Disconnect the ground cable from the print mechanism by removing the
screw securing it. Figure 57 Remove the Ground Cable Mounting Screw
1 2
Ground cable Mounting screw
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9. See Figure 58. Guide the printhead cable connectors through the gap in the print
mechanism and discard them. Figure 58 Remove the Cables from the Print Mechanism
1
1 2
Cable connector Gap
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Install the New Printhead Cables

1. See Figure 59. From the electronics side, guide the new cables up through the gap in the
print mechanism. Figure 59 Install the New Cables

1 2
1 2 3
Cable connector Print mechanism Ground cable

2. Tightly secure the ground cable to the printer with the screw previously removed. 3. See Figure 58 on page 180. Tightly secure the ground cable to the print mechanism.
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the platen housing.This is done for ease of connecting the printhead cables.
5.
1
7 3
1 2 3 4 5 6 7
Thumbscrew Alignment holes (2) Cable guide Alignment pins (2) Platen housing Forks (2) Bearings (2)
6. See Figure 56 on page 178. Connect both printhead power and data cables to the printhead
connectors.
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7. See Figure 61. Tip the printhead fork assembly slightly and insert the printhead ribbon
guide into the print mechanism as shown.

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 61 Install the Printhead Fork Assembly

1 2 1 2
1 2 3 4 5
10. Clean the printhead with the Zebra preventative maintenance kit.
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11. See Figure 54 on page 176. Rotate the two printhead pressure dials to the desired position

12. See Figure 62. 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 62 Connect the Printhead Cables

1 2 3 4 5 6
8 9
11 1 2 3 4 5 6
10 7 8 9 10 11
Power supply board J3 Standoff Printhead power cable Main logic board (MLB) MLB mounting bracket
Cable clips (2) Cable tie Ground cable Printhead data cable P19
15. Route the printhead data cable connector under the main logic board (MLB) mounting
bracket and then connect it to P19 on MLB.
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16. Install the cable around all three printhead cables at the location shown in Figure 62. Be
sure to clip off the excess cable tie.

17. See Figure 52 on page 174 lift the power supply shield back into place. 18. Replace the mounting screw and standoff. 19. See Figure 50 on page 172 and replace the wireless board. 20. See Figure 49 on page 171 and replace the radio card. 21. Did you remove a cutter assembly?
If
Then
No Yes
Go to Reinstall the Electronics Cover on page 187. Go to Reinstall the Cutter Assembly on page 187.
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1. See Figure 63. Unlatch the printhead and turn the latch assembly clockwise to remove the

2.
5 1 2 3 4 5
procedure.
assembly hooks.
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housing.
a. b.
3. Turn the latch assembly counterclockwise until it snaps in place.

lower flange is inside the base and the upper flange is between the main frame and the media door. Figure 64 Locate the Upper and Lower Flanges
1 2
1 2 3
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2. See Figure 47 on page 170. Install the four mounting screws. 3. See Figure 46 on page 169. Open the media door. 4. Install the electronics cover mounting screw and lock washer. 5.

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189
Ribbon Strip Plate

Tools Required
Metric Hex Key (Allen Wrench) Set
Remove the Old Ribbon Strip Plate

1.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
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3. See Figure 65. Remove the two mounting screws securing the ribbon strip plate to the
print mechanism. Figure 65 Remove and Install the Ribbon Strip Plate
2 1 2 3
Print mechanism Ribbon strip plate Mounting screws (2)
4. Remove the ribbon strip plate.
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Install the New Ribbon Strip Plate

1. See Figure 65 on page 190. 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. 4.

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
a. Tighten the mounting screws. b. Installation is complete.
No 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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Corrective Maintenance Printhead Latch
Printhead Latch
Tools Required
Phillips Screwdriver Set Flat-blade Screwdriver Set Safety Glasses
Adjustable Wrench Metric Nutdriver Set Metric Hex Key (Allen Wrench) Set
Remove the Old Latch

1.
2.
See Figure 66. Open the media door and remove the media and ribbon.
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Figure 66 Open the Media Door

1
1 2 3
Media door Strike plate cap Latch assembly
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3. See Figure 67. Remove the strike plate cap by placing a small screwdriver under the front
edge and lifting upward. Figure 67 Remove the Latch Assembly

1 2 3
4 5 13 6
8 9 10 11
12 1 2 3 4 5 6 7
Print mechanism Adjustment screw Strike plate cap Strike plate Washer Strike plate mounting screw (short) Stabilizer
8 9 10 11 12 13
Latch assembly Wave washer Shoulder screw Plug Platen housing 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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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.
Install the New Latch Kit

1. See Figure 67 on page 194. 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 68. 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 68 Adjustment Screw Location

1 3
1 2 3
Strike plate Adjustment screw Adjustment screw shoulder
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5. See Figure 67 on page 194. Tighten the adjustment screw until the top of the strike plate is
just below the top of the print mechanism.

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 69. Insert the print mechanism gap pin gauges through the holes that are
provided in the front of the ribbon guide plate. Figure 69 Adjust the Print Mechanism
1 2 3
4 5
6 1 2 3 4 5 6
Print mechanism adjustment cam location Strike plate cap Adjustment screw Strike plate Strike plate mounting screws (2) Print mechanism gap pin gauges (2)
2. Turn the adjustment screw until a small amount of friction is felt on the gap pin gauge.
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3. Snug the two strike plate mounting screws. 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 Yes
Continue with step 6. Go to step 13.
6. Loosen the two strike plate screws. 7. See Figure 70. Install the print mechanism adjustment cam on the printer frame with the
screw provided in the kit. Figure 70 Print Mechanism Mounting Screws

1 2 3
1 2 3 4 5
Print mechanism Adjusting cam Hex head mounting screws (2) Large washer Hex head mounting screw no washer
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8. Slightly loosen the three screws that secure the print mechanism assembly to the
mainframe.
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 70. 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 67 on page 194. Install the strike plate cap. 14.

15. Close the media door. 16. Reconnect the AC power cord and data cables. 17. Turn on (l) the printer.
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199
Printhead Pressure Dials

Tools Required
Phillips Screwdriver Set Flat-blade Screwdriver Set Metric Nutdriver Set
Antistatic Wriststrap and Mat Masking Tape 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.
Open the media door, open the printhead, and remove media and ribbon.
2.
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3. See Figure 71. Close the printhead and rotate the printhead pressure dials to the #1
position. Figure 71 Locate the Printhead Pressure Dials

1 2 3 1 2 3 1 2 4 1 2 4
ZM400 1 2 3 4
ZM600
Postion #1 Pressure dial Position #4 Position #8
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4.
See Figure 72. Remove the printhead thumbscrew. Figure 72 Remove the Printhead and Cable Connections
Z4M/Z6M, Z4Mplus/Z6Mplus, S4M 2 2 1 2 3 ZM400/ZM600 1 2 3
4 5 7 6 1 2 3 4 5 6 7 8
5.
4 5 8 6
Thumbscrew Printhead pressure dial Print mechanism assembly Printhead data cable Printhead power cable Printhead fork assembly Locating holes Locating pins
Open the print mechanism, and lift and latch it in the vertical position.
6. Slide the printhead fork assembly out of the print mechanism. 7. Disconnect the two printhead cables from the printhead assembly. 8. Remove the printhead assembly and set it aside on the antistatic mat.
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Remove the Old Pressure Dials

To remove the pressure dials you must partially disassemble the print mechanism.
1. See . Place a soft pad down on your workbench and lay the printer on it with the
electronics cover side down.

2. Open the media door. 3. See Figure 73. 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. Figure 73 Remove the Pressure Bracket and Roller
6 7 1
2 8 3
4 5
1 2 3 4 5 6 7 8
Print mechanism Pressure bracket Masking tape (2) Pressure bracket mounting screw Lifting spring Lower print mechanism latch screw Upper print mechanism latch screw Stabilizer, ZM400/ZM600
4. Remove the lower print mechanism latch screw and then remove the stabilizer.
5. Remove the pressure bracket mounting screw, and swing the bracket out of the way.
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6. See Figure 74. Remove and discard the dials and springs from the print mechanism.
Figure 74 Remove the Pressure Dials
1 2
Pressure dial and spring Pressure bracket
Install the New Pressure Dials

1. See Figure 75. Install the new springs in to the new dials.
Figure 75 Install the Springs

1
1 2
Pressure dial Spring
2. See Figure 74 on page 203. Insert the new dials and springs into the print mechanism. 3. See Figure 73 on page 202. 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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5. Reinstall the lower latch screw. 6. See Figure 72 on page 201. 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 73 on page 202).
7. Route the printhead cables over the top of the wire guide. 8. See Figure 76. Align the two alignment pins on the printhead with the two alignment holes
in the print mechanism. Figure 76 Align the Forks and Bearings

1
7 3
1 2 3 4 5 6 7
Thumbscrew Alignment holes Wire guide Alignment pins Platen housing Forks (2) Bearings (2)
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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. Reinstall media. 14. See Figure 71 on page 200. Rotate the two printhead pressure dials to the desired position

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 Magnetic Printhead Latch
Magnetic Printhead Latch

Tools Required
Phillips Screwdriver Set Flat Blade Screwdriver Set
Needle Nose Pliers

1.
2.
Remove the media and ribbon.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Old Magnetic Latch

1. See Figure 80. Reopen the media door and locate the magnetic latch and strike plate.
Figure 80 Locate the Magnetic Latch

1 2
1 2 3
Magnetic latch strike plate Screw Magnetic latch
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2. See Figure 81. Remove and discard the old magnetic strike plate mounting screw. 3. Remove the strike plate.
Figure 81 Remove the Old Magnetic Latch

1
2 3
1 2 3 4
Strike plate mounting screw Strike plate Magnetic latch Tabs
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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 82. From the electronics side, align the new magnetic latch with the mounting
hole, with the tabs facing the printer. Figure 82 Install the New Magnetic Latch
1 2
3 1 2 3
Mounting hole Tabs (4) 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.

3. See Figure 81 on page 210. Install the new magnetic latch strike plate.
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1 2
1 2 3

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Sensors
This section provides replacement and installation procedures for the ZM400/ZM600 sensors.
Contents
Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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Sensor Assemblies
S
Tools Required
Phillips Screwdriver Set Flat-blade Screwdriver Set Safety Glasses
Metric Hex Key (Allen Wrench) Set Antistatic Wriststrap and Pad Metric Nutdriver Set

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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7. Do you have a wireless board installed?
If
Then
No Yes
Go to Access the Power Supply on page 219. Continue with Remove the Wireless Board.

1.


1
2 1 2
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1
1 2 3
Wireless board Mounting screws (3) Main logic board (MLB)
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Access the Power Supply

1.

2. See Figure 89. 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.

1
3 1 2 3
Mounting screw Mounting stud Power supply shield
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4. See Figure 90. Pull the top of the power supply shield away from the main frame and fold
it down to access the stepper motor connector. Figure 90 Gain Access the Power Supply
1
Power supply shield
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Remove the Stepper Motor

1. See Figure 91. Locate the stepper motor and drive belt.
Figure 91 Locate Drive System Components

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

1.

2. See Figure 92. Disconnect the upper media sensor cables from J3 and P7 of the main logic
board (MLB). Figure 92 Disconnect the Media Sensor Cables
5 4 2
3 1 2 3 4 5
Main logic board (MLB) Wire wrap Reflective media sensor connector (P7) Lower media sensor connector (P9) 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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Remove the Sensor Assemblies

1. See Figure 93. Remove the mounting screw, split lock washer, and flat washer from the
upper media sensor assembly. Figure 93 Remove the Upper Media Sensor Mounting Screw
3 1 2
1 2 3 4 5
Upper media sensor mounting screw Upper media sensor mounting split lock washer Upper media sensor mounting flat washer Lower media sensor mounting split lock washer Lower media sensor mounting screw
2. Remove the mounting screw and split washer from the lower media sensor assembly.
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3.
See Figure 94. Release the dancer spring from the dancer spring stop Figure 94 Release the Dancer Spring
1 2
1 2
Dancer spring stop Dancer spring
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4. See Figure 95. 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 95 Remove the Media Sensor Assemblies
1 2
Upper media sensor assembly 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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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 96. Remove the protective cap. Figure 96 Remove the Protective Cap
1
1 2 3
Shaft Protective cap Barbs
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3. See Figure 97. Guide the cable of the lower media sensor through the access hole in the
main frame. Figure 97 Locate the Access Hole

1
3 1 2 3
Cable connector access and locating hole Locating pins 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 93 on page 223. While holding the lower media sensor in the slots, install the
mounting screw and washer.
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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 98. Remove the protective cap. Figure 98 Remove the Protective Cap
1
1 2 3
Shaft Protective cap Barbs
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3. See Figure 99. Guide the cables of the upper media sensor through their proper access
holes in the main frame. Figure 99 Install the Upper Media Sensor Assembly
1 2
1 2 3
Three wire connector access hole Mounting hole Four wire connector access hole
4. Slide the upper media sensor assembly into the mounting hole until it stops. 5. See Figure 94 on page 224. 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 93 on page 223. While holding the upper media sensor in the slots, install the
mounting screw, lock washer, and flat washer.
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Connect the Media Sensor Cables

1. See Figure 92 on page 222. 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. 3. Place the cables in the wire wrap.
Reinstall the Stepper Motor

1. See Figure 91 on page 221. 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 89 on page 219 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 Yes
Continue with Reinstall the Electronics Cover.

a. See Figure 88 on page 218 and replace the wireless board. b. See Figure 87 on page 217 and replace the radio card. c. Continue with Reinstall the Electronics Cover.
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1. See Figure 86 on page 216. 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 85 on page 216. Reinstall the four mounting screws. 3. Open the media door. 4. See Figure 84 on page 215. Reinstall the electronics cover mounting screw and lock
washer.
5.
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Adjust the Sensor Gap

1. Which model printer are you working on?
If you have a
Then
a. See Figure 100. Using a hex key, loosen the mounting screw
ZM400
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 101. 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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Figure 100 Adjust the ZM400 Upper Media Sensor
Squeeze Here
3 2
Squeeze Here
1 2 3
Mounting screw Gapping shim Notch
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Figure 101 Adjust the ZM600 Upper Media Sensor

3 Squeeze Here
Squeeze Here 1 2 3
Mounting screws (2) Gapping shim Notches (2)
2. Turn on (l) the printer.
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Corrective Maintenance Ribbon/Head Open Sensor Assembly
235
Ribbon/Head Open Sensor Assembly

Tools Required
Phillips Screwdriver Set Metric Nutdriver Set
Antistatic Wriststrap and Mat Metric and inch Feeler Gauges; must include: 1.5 mm (0.060 in.)

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Old Sensor

1.

2. See Figure 105. Unplug the ribbon/printhead open sensor cable from P4 on the main logic
board (MLB). Figure 105 Disconnect the Ribbon/Head Open Sensor
1 1 2 3 4
Main logic board (MLB) MLB connector (P4) Ribbon/Head open sensor cable Protective wrap
3. Remove the ribbon/head open cable from the protective wrap.
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4. See Figure 106. 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 106 Ribbon Sensor Removal and Installation

1
2 1 2
Ribbon/Head open sensor assembly Mounting screw
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Install the New Ribbon/Head Open Sensor Assembly

1. See Figure 107. Route the sensor wires, with connector, through the access hole in the
printer mainframe. Figure 107 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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5. See Figure 108. Check the gap on the ribbon/printhead open sensor and adjust as
necessary. Figure 108 Gap Measurement Between Print Mechanism and Sensor
3 2
1 2 3 4 5
Printhead housing Gap, 1.25 mm (0.050 in.) Ribbon/Printhead open sensor Mounting screw 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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1 2
1 2 3
Electronics Cover Upper Flanges (3) Lower Flanges (2)
2. See Figure 104 on page 237. Reinstall the electronics cover. 3. See Figure 103 on page 237. Install the four mounting screws. 4. See Figure 102 on page 236. Open the media door. 5. Install the electronics cover mounting screw and lock washer. 6.

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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Drive System
This section provides replacement and installation procedures for the ZM400/ZM600 drive system.
Contents
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Hanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peel Maintenance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peel Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer Guard Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 252 256 266 275 283 301 316 318 321 325 334 337 355
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Corrective Maintenance Drive System
Drive System
Phillips Screwdriver Set Flat-blade Screwdriver Set
Antistatic Wriststrap and Mat Metric Hex Key (Allen Wrench) Set

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Gear Cover

1.

2. See Figure 113. Lay the printer on its side, media door down on a mat.
Figure 113 Lay the Printer on its Side

1 2
1 2
Gear cover Mounting screw
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3. See Figure 114. Mark the proper mounting hole in the gear cover.
You will use this mark as areference when you reinstall the gear cover.
4. Remove and discard the gear cover mounting screw.
Figure 114 Remove the Gear Cover

1 2
3 4
1 2 3 4
Mounting screw Gear cover Mark the proper mounting hole. Compound gear. Mark the side of the compound gear that faces out.
5. Slide the cover off the drive assembly and discard. 6. 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.
7. Turn the printer back up on its base.
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Remove the Old Gears, Drive Belt, and Pulley

1. See Figure 115. 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 115 Remove and Install Gears, Pulley, and Belt
1
203 dpi
3 4 5 1 2 300/600 dpi 3 4 1 2 3 4 5 6 7 8 5
300 dpi 600 dpi
Gear cover Compound gear mounting screw Stepper motor pivot screw Stepper motor locking screw Platen pulley set screws (2) Platen pulley (203 dpi) Compound Gear Platen pulley (300/600 dpi)
Install the New Gears, Drive Belt, and Compound Pulley

1. Match the size of the platen pulley with the one from the kit.
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2. See Figure 115. 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).
the pivot screw.

8. See Figure 114 on page 248. 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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1 2
1 2 3

6. Reconnect the AC power cord and data cables.
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Drive Belt Drive Belt Maintenance Kit
Drive Belt Maintenance Kit

Tools Required
Phillips Screwdriver Set Flat-blade Screwdriver Set
Antistatic Wriststrap and Mat Metric Hex Key (Allen Wrench) Set

1.
1 2
1 2 3 4
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3. Close the media door. 4. See Figure 118. Remove the four mounting screws on the rear of the printer.

1
1 2
2
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Remove the Old Gears, Drive Belt, and Pulley

1. See Figure 120. 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 120 Remove the Old Belt

1 2 3
5 1 2 3 4 5
Stepper motor Pivot screw Drive belt Platen pulley Locking screw
3. Remove and discard the belt from the platen pulley.
Install the New Drive Bet

1. See Figure 120. 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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the pivot screw.

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

1 2
1 2 3
2. See Figure 118 on page 253. Install the four mounting screws. 3. See Figure 117 on page 252. 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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Corrective Maintenance Stepper Motor Assembly
Stepper Motor Assembly

Tools Required
Phillips Screwdriver Set Metric Hex Key (Allen Wrench) Set
Antistatic Wriststrap and Mat Metric Nutdriver Set

1.
2.
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1 2
1 2 3 4
4. Close the media door and turn the printer around.
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1
1 2
2
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7. Which model of printer are you working on?
If you have a
Then
ZM400/ZM600 Go to Gain Access to the Power Supply on page 261. without wireless board ZM400/ZM600 with wireless board Continue with Remove the Wireless Board.

1.


1
2 1 2
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3. See Figure 126. Remove the two lower mounting screws and then remove the wireless
board from the main logic board (MLB). Figure 126 Remove the Wireless Board
1
1 2
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1
3 1 2 3
Mounting screw Standoff Power supply shield
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access the stepper motor connector.

4. Disconnect the stepper motor cable from the power supply, J2.
Figure 128 Gain Access the Power Supply

1 2
3 1 2 3
Shield Stepper motor cable Stepper motor connector, J2
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Remove the Old Stepper Motor and Gear

1.

2. See Figure 129. Locate the stepper motor and drive belt.
Figure 129 Locate Drive System Components

1 2 3 7
6 1 2 3 4 5 6 7
Power supply, J2 Stepper motor cable routing Stepper motor Platen pulley Drive belt Locking screw Pivot screw
3. Remove the locking screw and nut. 4. Remove the pivot screw and then remove the stepper motor.
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Install the New Stepper Motor and Gear

1. See Figure 129 on page 263. 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).
the pivot screw.

4. Route the stepper motor cable as shown and connect it to J2 on the power supply. 5. See Figure 127 and lift the power supply shield back into place. 6. Replace the mounting screw and standoff. 7. Verify all cable routing. 8. See Figure 126 on page 260 and replace the wireless board. 9. See Figure 125 on page 259 and replace the radio card.
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1 2
1 2 3

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Ribbon Take-Up Spindle Clutch Ribbon Take-up Spindle Clutch
Ribbon Take-up Spindle Clutch

Tools Required
Phillips Screwdriver Set Metric Hex Key (Allen Wrench) Set Metric Nutdriver Set
Antistatic Wriststrap and Mat Metric Feeler Gauges; must include: 0.50 mm

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

1 2
3 4
1 2 3 4
Gear cover Mounting screw Mark the proper mounting hole. 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.
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Remove the Old Ribbon Take-Up Clutch

1. See Figure 136. 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 136 Loosen the Set Screws

1 2
4 1 2 3 4
Ribbon take-up gear and clutch assembly Set screws (2) Collar Main frame. Mark the proper mounting hole.
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3. See Figure 137. Remove and discard the clutch bearing, hub, spring and gear from the
ribbon take-up (RTU) spindle shaft. Figure 137 Remove the Clutch
6 1 3 4 5 3
1 2 3 4 5 6 7 8
Collar Set screws (2) Thrust washer Bearing and hub Spring Clutch gear RTU spindle shaft 0.50 mm gap between the collar and thrust washer
Install the New RTU Clutch

1. See Figure 137. Holding the ribbon take-up (RTU) spindle slide the washer and new
clutch gear onto the RTU spindle shaft.

2. Slide the spring, thrust washer and collar onto the RTU spindle shaft. 3. Place a 0.50 mm feeler gauge between the thrust washer and the collar. 4. 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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Reinstall the Gear Cover

1. See Figure 135 on page 270. With the marked side facing out, slide the compound gear

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.

1 2
1 2 3
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5.

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Corrective Maintenance Ribbon Take-up Spindle
275
Ribbon Take-up Spindle

Tools Required
Phillips Screwdriver Set Metric Hex Key (Allen Wrench) Set Metric Nutdriver Set
Antistatic Wriststrap and Mat Metric Feeler Gauges; must include: 0.5 mm
Remove the Electronic Cover

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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1 2
1 2
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1 2
3 4
1 2 3 4
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Remove the Old RTU Spindle Assembly

1. See Figure 144. 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 144 Loosen the Set Screws

1 2
4 1 2 3 4
Ribbon take-up gear and clutch assembly Set screws (2) Collar Main frame. Mark the proper mounting hole.
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3. See Figure 145. Remove the plastic thrust washer, clutch gear assembly, and washer(s)
from the shaft of the ribbon take-up spindle assembly. Figure 145 Remove the RTU Spindle
7 3
5 4 2 1
1 2 3 4 5 6 7
Ribbon take-up spindle assembly Washer Washer(s) Clutch gear assembly Thrust washer Place a 0.500 mm feeler gauge between the thrust washer and the collar. 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 145. 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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1. See Figure 143 on page 279. With the marked side facing out, slide the compound gear

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.

1 2
1 2 3
2. See Figure 140 on page 277. Install the four mounting screws. 3. See Figure 139 on page 276. Open the media door. 4. Install the electronics cover mounting screw and lock washer. 5. Reconnect the AC power cord and data cables and then torn on (l) the printer.
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283
Printhead Conversion
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
Phillips Screwdriver Set Metric Hex Key (Allen wrench) Set Antistatic Wriststrap
Metric Nutdriver Set 47362* Zebra Preventive Maintenance Kit

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Old Drive Belt and Platen Pulley

1. See Figure 150. Loosen the stepper motor locking and pivot screws.
Figure 150 Remove the Drive Belt

1 2 3 4
5 6
1 2 3 4 5 6
Pivot screw Stepper motor Drive belt Set screws (2) Platen pulley 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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5. See Figure 151. Slide the platen pulley from the coupling assembly and discard it.
Figure 151 Remove the Platen Pulley
Install the New Drive Belt and Platen Pulley

1. See Figure 152. 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 152 Align the Screws
1
1 2
Setscrews (2) Flats on shaft
2. See Figure 150 on page 286. Install the drive belt onto the platen pulley and the stepper
motor pulley.
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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.

1 2
1 2
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1 2
1 2 3
Mounting screw Gear cover Compound gear
6. Slide the cover off the drive assembly.
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7. See Figure 155. Remove the compound gear.
Figure 155 Remove the Compound Gear

1 2
1 2
Compound gear turned to 300/600 dpi Compound gear turned to 200 dpi
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8. See Figure 156. 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 156 Compound Gear DPI Location
DPI Statement
Reinstall the Compound Gear and Gear Cover

1. See Figure 154 on page 289. With the proper side facing out slide the compound gear into
the printer. Ensure that the gears mesh.

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1 2
1 2 3
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Remove the Old Printhead

1.

2. See Figure 158. Rotate the printhead pressure dials to the #1 position.
Figure 158 Locate the Printhead Pressure Dials

1 2 1 2 1 2 1 2
ZM400 1 2
ZM600
Postion #1 Pressure dial
If
Then
No Yes
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4. See Figure 159. Locate and remove the thumbscrew from the print mechanism.

2 1
1 2
Print mechanism Thumbscrew
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5. See Figure 160. Open the print mechanism and latch it in the vertical position. 6.
Disconnect the printhead data and power cables.

7. Remove and discard the printhead assembly from the printer.
Figure 160 Remove the Printhead

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

the platen housing. This is done for ease of connecting the printhead cables.
2.
1
7 3
1 2 3 4 5 6 7
Thumbscrew Alignment holes (2) Cable guide Alignment pins (2) Platen housing Forks (2) Bearings (2)
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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.
4. See Figure 162. 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 162 Install the Printhead Fork Assembly

1 2 1 2
4 5
4 5
1 2 3 4 5
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7. Clean the printhead with the Zebra Preventative Maintenance kit. 8. See Figure 158 on page 293. Rotate the two printhead pressure dials to the desired
position for your daily printing.

If
Then
No Yes
10.
Continue with step 10. Got to Reinstall the Cutter Assembly on page 300.

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1. See Figure 163. Unlatch the printhead and turn the latch assembly clockwise to access the

2.
5 1 2 3 4 5
procedure.
assembly hooks.
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housing.
a. b.

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Corrective Maintenance Ribbon Supply Spindle
301
Ribbon Supply Spindle

Tools Required
Phillips Screwdriver Set Antistatic Wrist Strap and Pad
Metric Hex Key (Allen Wrench) Set

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Old Ribbon Supply Spindle

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


1 2
1 2
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1 2
3 4
1 2 3 4
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Remove the Stepper Motor

Do you have a wireless board installed?
If Then
No Yes
1.
Go to step 6 on page 308. Continue to the next step.


1
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1
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5.

6. See Figure 171. Disconnect the stepper motor cable from the power supply. 7. Locate the stepper motor and drive belt.
Figure 171 Locate the Drive Components

1 2 3 4
5 7
6 1 2 3 4 5 6 7
Stepper motor power connector Stepper motor Stepper motor cable Drive belt Locking screw Pivot screw 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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12. See Figure 172. Remove the pivot screw and then slide the stepper motor out of the
printer. Figure 172 Remove the Stepper Motor and Intermediate Gear
3 1 2
5 1 2 3 4 5
Pivot screw Stepper motor Intermediate gear Locking screw nut Locking screw
13. Remove the intermediate gear.
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14. See Figure 173. Remove the ribbon supply spindle (RSS) mounting screw and washer.
Figure 173 Remove the Ribbon Supply Spindle

3 4
1 2 3 4
Mounting screw Mounting washer Washer RSS
15. Which model printer do you have?
If you have
Then
ZM400 ZM600
Push the spindle out of the main frame. b. Go to Install the New Ribbon Supply Spindle on page 311.
a.
Continue with the next step.
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16. See Figure 174. 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 174 Using the Remove Tool

1 2 3 4 5
1 2 3 4 5
Spindle assembly Spindle remove tool Washer Screw 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 175. Install the thin washer onto the spindle shaft.
Figure 175 Install the Thin Washer
1 2
Thin washer Ribbon supply spindle shaft
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2. Which model of printer do you have?
If you have a
Then
a. Push the RSS into the main frame. b. Go to step 9 on page 313.
ZM400 ZM600
Continue to the next step.
3. See Figure 176. Place a small amount of grease on the tolerance rings of the ribbon supply
spindle shaft. Figure 176 Lubrication
Put grease here.
4. See Figure 174 on page 311. 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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5. See Figure 177. 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 177 Spindle Installation
1 2
Nut 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 173 on page 310. Install the spindle mounting screw and washer. 10. See Figure 172 on page 309. 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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16. See Figure 171 on page 308. 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.

1. See Figure 168 on page 305. With the marked side facing out slide the compound gear

Note Look at the old compound gear to see what side you marked for facing out.
5. Tighten the mounting screw. 6. Did you remove the wireless board?
If
Then
No Yes
Go to Reinstall the Electronics Cover on page 315.

a. See Figure 170 on page 307. Reinstall the wireless board. b. See Figure 169 on page 306. Reinstall the radio card. c. Go to Reinstall the Electronics Cover on page 315.
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1 2
1 2 3

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.

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Corrective Maintenance Media Hanger
Media Hanger
Tools Required
Metric Nutdriver Set
Replace the Old Hanger Assembly

1.
2.
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317
3. See Figure 179. Locate the media hanger assembly. 4. Remove and discard the three mounting screws securing it.
Figure 179 Remove and Install the Hanger Assembly
1 2
Media hanger assembly 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.

8. Reconnect the AC power cord and data cables and then turn on (l) the printer.
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Corrective Maintenance Tear-Off Bar
Tear-Off Bar
This procedure is for installing the peel-off/tear-off bar in the printer. Read these instructions thoroughly before performing this procedure.
Tools Required
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 180. Remove the front cover by pulling out on the upper corners of the cover
and then lifting it out of the printer. Figure 180 Remove the Front Cover
1 2
Front cover Mounting hooks
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Remove the Old Tear-Off Bar

1. See Figure 181. Remove the two tear-off bar mounting screws.
Figure 181 Remove and Install the Tear-Off Bar
1 1
1 2
Tear-off bar Tear-off bar mounting screws (2)
2. Lift the tear-off bar out of the platen housing.
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Install the New Tear-Off Bar

1. See Figure 182. Install the new tear-off bar into the platen housing. Do not tighten the
mounting screws at this time. Figure 182 Install the New Tear-Off Bar
2 1 3 4
5 1 2 3 4 5
Tear-off bar Platen housing Horizontal mounting bar Rest the pems on top of the horizontal mounting bar. Mounting screws (2)
2. Lift the tear-off bar up slightly. See Figure 183. 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 183 Locate the Pems
Pems
3. Tighten the mounting screws while keeping pressure down on the tear-off bar. 4. See Figure 180 on page 318. Reinstall the front cover. 5. Reconnect the AC power cord and data cables 6. Turn on (l) the printer.
14207L-001 A ZM400/ZM600 Maintenance Manual 8/9/07
Corrective Maintenance Static Brush
321
Static Brush
This procedure is for installing the static brush assembly in the printer. Read these instructions thoroughly before performing this procedure. This kit includes the parts and documentation necessary to install the static brush assembly in the following printers: ZM400 ZM600 Read these instructions thoroughly before attempting to install this kit.
Prepare for Installation

Parts List
Table 22 Kit Parts List
Item Qty Part Number 1 2 Description
1 1
79854M 79855M
ZM400 Static Brush Maintenance Kit ZM600 Static Brush Maintenance Kit
Bold = Part available for purchase. Italic = Part not available for purchase, listed and shown for reference only.
Figure 184 Kit Contents

1
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Reference Materials
ZM400/ZM600 User CD ZM400/ZM600 Maintenance Manual Z Series Maintenance Manual (CD)
Tools Required
This kit includes the parts and documentation necessary to install the static brush assembly in the following printers: ZM400 ZM600 Read these instructions thoroughly before attempting to install this kit.
Prepare for Installation

Parts List
Table 23 Kit Parts List
Item Qty Part Number 1 2 Description
1 1
79854M 79855M
ZM400 Static Brush Maintenance Kit ZM600 Static Brush Maintenance Kit
Bold = Part available for purchase. Italic = Part not available for purchase, listed and shown for reference only.
Figure 185 Kit Contents

1
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Reference Materials
ZM400/ZM600 User CD ZM400/ZM600 Maintenance Manual Z Series Maintenance Manual (CD)
Tools Required
Remove the Old Static Brush Assembly

1.
Open the media cover and remove all media and ribbon.
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2. See Figure 186. Remove the two mounting screws securing the static brush assembly. 3. Remove the brush assembly from the printer.
Figure 186 Remove and Install the Static Brush Assembly)
1 2
Mounting screws (2) Static brush assembly
Install the New Static Brush Assembly

1. See Figure 186. 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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Corrective Maintenance Cutter Option
325
Cutter Option
Tools Required
Phillips Screwdriver Set Flat-blade Screwdriver Set Metric Hex Key (Allen Wrench) Set
Antistatic Wriststrap and Mat Safety Goggles

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Front Cover

1. See Figure 190. Remove the front cover by pulling out on the upper left and right corners.
Figure 190 Remove the Front Cover
2 1 2
Front cover Mounting hooks
2. Lift the front cover to remove it. 3. Close the media door.
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Install the Cutter Option

1. See Figure 191, 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 191 Locate and Position the Mounting Brackets
Detail A
M
M
M
M must be in this location.
Detail B
Cutter Assembly
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2. See Figure 192. While holding the cutter assembly, route the cutter assembly wire harness
through the mainframe access hole.

3. Install the cutter assembly on the hooks of the platen housing. a. b. c.
See Figure 191. The ZM400 and ZM600 mounting brackets have step slots. 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. Set the cutter assembly onto the hooks, then push down and slide the assembly to the right. Figure 192 Install the Cutter Assembly
1
2 4
7 1 2 3 4 5 6 7
4 5
Tear bar Latch assembly Mounting screw Platen assembly hook Main frame access hole Cutter cable Cutter assembly
4. See Figure 192. 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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5. See Figure 193. 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 193 Cutter Shield and Catch Tray
A 1 2 1 B
A B 1 2 3 4
ZM400 ZM600 Cutter shield Thumbscrew Cutter assembly Cutter catch tray
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6. See Figure 194. 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 194 Locate Cutter Connector on the Main Logic Board
1 2
3 1 2 3
Main logic board (MLB) connector, P26 Cutter cable connector Access hole
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1 2
1 2 3
2. See Figure 188 on page 327. Install the four mounting screws. 3. See Figure 187 on page 326. 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 Peel Maintenance Assembly
Peel Maintenance Assembly

Tools Required
Metric Hex Key (Allen wrench) Set Metric Nutdriver Set
Antistatic Wrist Strap and Mat
Remove the Old Peel Assembly

1. See Figure 196. Remove the two mounting screws and remove the peel assembly.
Figure 196 Remove Old Peel Assembly
2 1 2
Peel Assembly Mounting Screw (2)
2. Go to Install the New Peel Assembly on page 335.
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Install the New Peel Assembly

1. See Figure 197. 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 197 Install Peel Assembly
1 2
3 1 2 3 4 5 6
Peel assembly Mounting slots (2) Mounting screws (2) Platen housing Rest pems on housing here. Peel lever
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2. See Figure 198. Notice the pems and the mounting slots.
Figure 198 Rear View of Peel Assembly

1
2 1 2
Mounting slots (2) Pems (2)
3. See Figure 197 on page 335. Install the peel assembly with the pems to the rear and the
opening in the mounting slot to the top.

a. b.
Insert the mounting slot opening over the two screws and lift up on the assembly. 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.

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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337
Peel Rewind Option

Tools Required
Phillips Screwdriver Set Antistatic Mat and Wrist Strap

1.
2.
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1 2
1 2 3 4
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1
1 2
2
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Remove the Base

1. See Figure 202. Remove the front cover by sliding it to the right and then lifting it up.
Figure 202 Remove the Front Cover
1 1
Front cover
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2. See Figure 203. 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 203 Remove the Old Base

1 5 2
1 2 3 4
Main frame Rear end cap mounting screws (2) Rear end cap Mounting flat washers (3)
5 6 7
Main frame mounting screws (5) Base Platen housing
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 and end cap. 5. Lift the main frame off the base assembly.
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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 204. 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 204 Install the Rewind Pan
1 2 3
2 7 1 2 3 4 5 6 7 6 5
Main frame Main frame mounting screws (4) Rear end cap mounting screws (2) Rear end cap Platen housing mounting screw Flat washer Rewind Pan
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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 and the one screw on the main frame.
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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 205. Place the rewind motor and spindle assembly in the rewind pan assembly.
Figure 205 Install the Rewind Spindle Assembly

1 2
3 4
5 1 2 3 4 5
Rewind spindle and motor assembly Rewind support bracket (holes must be on top) Rewind spindle back plate Rewind pan 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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3. See Figure 206. Connect the rewind cable connector to P26 on the main logic board
(MLB). Figure 206 Connect the Rewind Cable to the Main Logic Board
1 2
4 5
1 2 3 4 5
Main logic board Connector P26 Rewind cable Access hole Cut away
4. See Figure 207. Align one of the two access holes in the rewind back plate to one of the
mounting holes on the rewind support plate.

5. 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.
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Figure 207 Install the Motor and Spindle Assembly
1 2
1 2
Access hole Rewind back plate
6. Align the other access hole of the rewind back plate to the other mounting hole on the
rewind support plate.

7. Install the mounting screw and tighten. 8. Tighten the screw installed in step 5.
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1 2
1 2 3
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Install the Peel Assembly

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 209. Remove the two mounting screws and remove the tear bar.
Figure 209 Remove the Tear Bar
2 1 2
Tear bar Mounting screws (2)
2. Do you have an existing peel assembly?
If
Then
No Yes
Go to Install the New Peel Assembly on page 350. Continue with Remove the Existing Peel Assembly.
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Remove the Existing Peel Assembly

1. See Figure 210. Remove the two existing mounting screws.
Figure 210 Remove the Peel Assembly

1 2
3 1 2 3
Peel assembly Platen housing Peel assembly mounting screws
2. Remove the peel assembly.
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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 211. Take note of the pems and the mounting slots.
Figure 211 Locate the Pems

1 2
3 1 2 3
Peel assembly Mounting slots (2) Pems (2)
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351
3. See Figure 212. Install the peel assembly with the pems to the rear and the opening in the
mounting slot to the top.

a. b.
Insert the mounting slot opening over the two screws and lift up on the assembly. 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 212 Install the New Peel Assembly
1 4 2
3 1 2 3 4
Peel assembly Platen housing Mounting screws (2) Rest pems here.
Load the Media

Refer to Figure 213 (Rewind) or Figure 214 (Peel) while loading media.
1.
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2. Load media and pull about two feet of media through the front of the printer. a. b. c. d. e. f. g. h.
Slide the media supply guide to the outer edge of the media hanger. Fold the media supply guide down. Place the roll of media on the media supply hanger and push it on all the way. Fold the media supply guide up. Slide the media supply guide toward the outer edge of the media roll until it makes light contact. Press the printhead open lever and raise the printhead assembly. Feed the media under the dancer, between the transmissive sensor, under the ribbon sensor, and out the front of the printer. 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 213. Pass the media down over the front of the peel assembly, through the printer housing, and under the media alignment spindle.
a. See Figure 214. Open the peel assembly by rotating the
Peel/Rewind
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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Figure 213 Load the Rewind Media
Figure 214 Load the Rewind Peel Media
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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 215.
If want to move the media Then
Toward the main frame Away from the main frame
Turn the dial clockwise Turn the dial counterclockwise
Figure 215 Align the Rewind Media
Dial
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Corrective Maintenance Outer Guard Rewind
355
Outer Guard Rewind

Tools Required
Flat-blade Screwdriver Set
Remove the Old Outer Rewind Guide

1.
2.
3. Open the rewind pan door.
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4.
See Figure 216. Remove the e-ring securing the rewind spindle.
5. Remove the flat and wave washers from the rewind spindle shaft.
Figure 216 Remove the E-ring and Washers

1
2 3 4
1 2 3 4
Rewind spindle E-ring Wave washer Flat washer
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6. See Figure 217. Remove the spindle by sliding it off the rewind spindle shaft.
Figure 217 Remove the Rewind Spindle

1
1 2
Rewind spindle shaft Rewind spindle
7. See Figure 218 and Figure 219. 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 218 Remove the Rewind Back Plate
1 1
2 1 2 3
Rewind back plate Spindle Tabs (2)
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Figure 219 Remove the Spindle
3 4 2 3 4
1 2
Rewind back plate Spindle
Mounting Holes (2) Tabs (2)
8. Remove the thumb screw from the outer rewind guide. 9. See Figure 220. Remove the outer rewind guide by sliding it off the rear of the spindle.
Figure 220 Remove the Outer Rewind Guide

1
2 3
Rear
1 2 3
Thumb screw Outer rewind guide Spindle
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Install the New Outer Rewind Guide

1. See Figure 221. Align the new outer rewind guide with the rewind spindle.
Figure 221 Align the Outer Rewind Guide

1
Rear
1 2
Outer rewind guide Rewind spindle
2. See Figure 220 on page 358. Slide the outer rewind guide onto the spindle and install the
thumb screw.
3. See Figure 219 on page 358 and Figure 218 on page 357. 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 217 on page 357. Slide the rewind spindle assembly onto the rewind spindle
shaft.
5. See Figure 216 on page 356. 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.

8. Close the rewind pan door. 9. Close the media door.
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Roller System
This section provides replacement and installation procedures for the ZM400/ZM600 roller system.
Contents
Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362 Platen Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
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Corrective Maintenance Platen Roller
Platen Roller
Tools Required
47362* Zebra Preventive Maintenance Kit

Remove the Old Platen Roller

1.
2.
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3. See Figure 222. Open and latch the print mechanism in the vertical position.
Figure 222 Slide the Platen Roller Assembly

1 2
1 2 3
Print mechanism Platen roller assembly 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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6. See Figure 223. Remove the platen roller assembly. a. b. c. d.
Platen roller in the printer. Slide the platen roller assembly away from the printer until it disengages the platen housing. Lift the platen assembly out of the printer. Platen is out of the printer. Figure 223 Remove the Platen Roller Assembly
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Install the New Platen Roller Assembly

Important The grooves in the inner and outer bearings must be facing up.
1. See Figure 224. Verify that the bearings are oriented properly.
Figure 224 Bearing Keys

1 2
1 2 3 4
Inner bearing Inner bearing grooves Outer bearing grooves Outer bearing
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2. See Figure 225 and Figure 226. 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 225 Align the Drive Pin and Drive Shaft
1
1 2
Platen roller drive pin Drive shaft slot
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Figure 226 Install the Platen Roller Assembly
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.

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Corrective Maintenance Platen Coupling
Platen Coupling
Tools Required
Phillips Screwdriver Set Metric Nutdriver Set Flat-blade Screwdriver Set Bent Tip Scribe or a tool with a small hook
Metric Hex Key (Allen wrench) Set Safety Glasses Needle Nose Pliers

1.
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2. See Figure 227. Open the media door and remove the screw and washer securing the
electronics cover. Figure 227 Locate the Electronics Cover Mounting Screw
1 2
1 2 3 4
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1
1 2
2
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Remove the Platen Roller Assembly

1. See Figure 230.Open and latch the print mechanism in the vertical position.
Figure 230 Slide the Platen Roller Assembly

1 2
1 2 3
2.
Print mechanism Platen roller assembly Latch assembly

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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5. See Figure 231. Remove the platen roller assembly. a. b. c. d.
Platen roller in the printer. Slide the platen roller assembly away from the printer until it disengages the platen housing. Lift the platen assembly out of the printer. Platen is out of the printer. Figure 231 Remove the Platen Roller Assembly
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Remove the Drive Belt and Platen Pulley

1. See Figure 232. Loosen the stepper motor locking and pivot screws.
Figure 232 Remove the Drive Belt

1 2 3 4
5 6
1 2 3 4 5 6
Pivot screw Stepper motor Drive belt Set screws (2) Platen pulley 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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5. See Figure 233. Slide the platen pulley from the coupling assembly and set it aside for
reuse. Figure 233 Remove the Platen Pulley
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Remove the Drive Shaft

1.
See Figure 234. Using a flat-blade screwdriver or needle nose pliers, remove and discard the e-ring and washer from the drive shaft. Figure 234 Remove the E-ring and Washer
1 2
1 2 3
Drive shaft Washer E-ring
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2. See Figure 235. Push the drive shaft through to the media side of the printer and then
remove and discard it. Figure 235 Push the Drive Shaft Through
Drive Shaft
3. See Figure 236. 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 236 Remove the Roller Bearings
Roller Bearings (2)
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5. See Figure 236. Install the new bearings.
Install the New Drive Shaft

1. See Figure 235. 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 234 on page 375. 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 237. 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 237 Align Flat Spots on the Shaft
1 2
1 2
Set screws (2) Platen roller shaft flat spots
2. See Figure 232 on page 373. 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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1 2
1 2 3
2. See Figure 229 on page 370. Reinstall the electronics cover. 3. See Figure 228 on page 370. Install the four mounting screws. 4. See Figure 227 on page 369. Open the media door. 5. Install the electronics cover mounting screw and lock washer.
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Reinstall the Platen Roller

Important The grooves in the inner and outer bearings must be facing up.
1. See Figure 239. Verify that the bearings are oriented properly.
Figure 239 Bearing Keys

1 2
1 2 3 4
Inner bearing Inner bearing grooves Outer bearing grooves Outer bearing
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2. See Figure 240 and Figure 241. 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 240 Align the Drive Pin and Drive Shaft
1
1 2
Platen roller drive pin Drive shaft slot
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Figure 241 Install the Platen Roller Assembly
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.

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Corrective Maintenance Pinch Roller
Pinch Roller
Tools Required
Flat-blade Screwdriver Set Metric Hex Key (Allen Wrench) Set
Safety Goggles
Remove the Pinch Roller

1.
2.
Open the media door and remove media and ribbon from the printer.
3. See Figure 244. Lower the pinch roller holder assembly to the open position.
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4.
See Figure 242. 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 244. 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 242 Removing and Installing E-rings and Bearings

1 2 3
6 1 2 3
E-rings (2 used, 2 spares) Roller bearings (2) Pinch roller
4 5 6
Groove for E-ring Pinch roller mounting hole Pinch roller holder assembly
Install the Pinch Roller

1. See Figure 242 on page 383. 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.
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4. Did you have to remove the old peel assembly?
If
Then
No Yes
Go to step 9 on page 385. Continue with step 5.
5. See Figure 243. Notice the pems and the mounting slots.
Figure 243 Rear View of Peel Assembly

1
2 1 2
Mounting slots (2) Pems (2)
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6. See Figure 244. 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 244 Installing Peel Roller Assembly
2 3 1
4 5 4
1 2 3 4 5 6
Peel assembly Tear bar Mounting screw Mounting holes Pinch roller Rest the pems on the housing here.
7. Install the peel assembly with the pems to the rear and the opening in the mounting slot to
the top.
a. b.
Insert the mounting slot opening over the two screws and lift up on the assembly. 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.
8. Maintain a slight downward pressure on the peel assembly to keep the pems on the
horizontal surface, and tighten the mounting screws.

9. Raise the pinch roller assembly to the closed position. Ensure the pinch holder assembly
snaps into position and exerts force on the platen roller.

10.
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11. Reconnect the AC power cord and turn on (l) the printer. 12. Verify proper printer operation.
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Printed Circuit Boards
This section provides replacement and installation procedures for the various printed circuit boards in the ZM400/ZM600.
Contents
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 394 406 414
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Corrective Maintenance Control Panel
Control Panel
Tools Required
Phillips Screwdriver Set Antistatic Pad and Wrist Strap
Metric Nut Driver Set
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1.
1 2
1 2 3 4
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1
1 2
2
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Remove the Old Control Panel

1.

2. See Figure 248. Remove the control panel cable from the cable clip.
Figure 248 Locate the Cable Clip
1 2
Cable clip Control panel cable
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3. See Figure 249. Disconnect the control panel cable from P29 on the main logic board
(MLB). Figure 249 Remove the Control Panel

1
7 1 2 3 4 5 6 7
Control panel Access hole Star lock washer Split lock washer Mounting screw Control panel cable Main logic board (MLB)
4. Remove the mounting screw, split lock washer, and star lock washer securing the control
panel.
5. Remove the control panel while carefully guiding the control panel cable out of the
printer.
Install the New Control Panel

1. See Figure 249. Remove the new control panel from the antistatic bag. 2. 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 248 on page 391. Fold the control panel cable over itself to take up the slack
and then slide it under the cable clip.
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1 2
1 2 3
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Corrective Maintenance Main Logic Board
Main Logic Board

Tools Required
Phillips Screwdriver Set Antistatic Wrist Strap and Mat
Print a Configuration Label

1. Can the printer print a configuration label?
If
Then
No Yes
Go to Remove the Electronics Cover on page 395. Continue with step 2.
2. Print a configuration label for reference. Set the label aside.
a. c.
Press and hold CANCEL while turning on (l) the printer, Continue with Remove the Electronics Cover.
b. After the DATA light turns off (approximately five seconds), release CANCEL.
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1.
2.

1 2
1 2 3 4
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1
1 2
2
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7. Do you have an existing wireless or wired communication board?
If
Then
No Wired
Go to Figure 259 on page 401 Go toFigure 1 on page 400
Wireless Continue with .

1.


1
2 1 2
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1
1 2
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5. See Figure 256. Remove the two wireless mounting standoffs from the MLB.
Figure 256 Remove the Wireless Board Mounting Standoffs

1
1 2
MLB Mounting standoffs (2)
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Remove the Wired Ethernet Board

1. See Figure 257. Remove the three mounting nuts.
Figure 257 Remove the Wired Ethernet Board
2 1 2
Wired ethernet board Mounting nuts (3)
2. Slide the wired ethernet board off the three mount standoffs and set aside for
reinstallation.
3. See Figure 258. Remove the three standoffs from the MLB.
Figure 258 Remove the Wired Ethernet Board Standoffs
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Remove the Old MLB

1. See Figure 259. Unplug ribbon cables and small wire connections.
Figure 259 Main Logic Board Assembly Connection Locations

P24 J1
J4
P23
J3
P25
P26
J4 P36
P4 P9
J2
P7
P29 J1 J2 J4 P4 P7 P9 P19 P23 P24 P25 P26 P29 P36
P19
Serial port Parallel port Wired ethernet Ribbon/Head open sensor Reflective sensor Transmissive sensor Printhead data
PCMCIA PCMCIA Power Liner Take-up/Cutter/Rewind Control panel USB
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2. See Figure 260. Remove and discard the two mounting studs and washers securing the
9-pin serial port connector.

3. Remove and discard the two screws securing the 36-pin parallel port connector.
Figure 260 Remove the Old MLB
5 4
1 2 3 4 5
MLB mounting screws (2) Parallel port mounting screws (2) Serial port mounting studs (2) Serial port mounting lock washers (2) Rear panel
4. Remove and discard the two mounting screws securing the MLB to the printer. 5. 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 260 on page 402. 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. 6. See Figure 259 on page 401. Reconnect the ribbon cables and small wire connections to
the MLB.
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7. Which communication board do you have?
If you have
Then
a. See Figure 258 on page 400 and reinstall the three mounting
Wired Ethernet
standoffs onto the MLB. b. See Figure 257 on page 400. 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. Wireless Ethernet a. See Figure 256 on page 399 and reinstall the two standoffs onto the MLB. b. See Figure 255 on page 398. 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 three mounting screws. e. See Figure 254 on page 397. Reinstall the radio board.
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1 2
1 2 3

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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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 When 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 262. 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 262 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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Corrective Maintenance Wireless Option
Wireless Option
Tools Required
Antistatic Wriststrap and Mat

1.
See Figure 263. Remove the screw and washer securing the electronics cover. Figure 263 Locate the Electronics Cover Mounting Screw
1 2
1 2 3 4
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1
1 2
2
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5. Are you replacing an existing wireless board?
If
Then
No Yes
Go to Install the Wireless Board on page 410. Continue with Remove the Wireless Board.

1.


1
2 1 2
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1
1 2
5. Continue to step 4 on page 412.
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Install the Wireless Board

1.

2. See Figure 268. Remove the blank cover from the rear panel of the printer.
Figure 268 Remove the Blank Cover
1 2
Blank cover plate Mounting screw
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3. See Figure 269. Install the two standoffs from the kit into the main logic board (MLB).
Figure 269 Install the Standoffs

1
3 1 2 3
Main logic board (MLB) Wireless board mounting standoffs (2) Standoff mounting holes (2)
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4. See Figure 270. Align the mounting holes in the wireless board with the mounting
standoffs and install the three mounting screws. Figure 270 Install the Wireless Board
1
3 4 1 2 3 4
Existing standoff Wireless board Mounting screws (3) Installed standoffs
5. See Figure 266 on page 408. Install your radio card.
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1 2
1 2 3
Electronics Cover Upper flanges (3) Lower flanges (2)
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Corrective Maintenance Wired Ethernet
Wired Ethernet
Tools Required
Antistatic Wriststrap and Mat 47362* Zebra Preventive Maintenance Kit
*In place of the Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%).
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Remove the Electronics cover

1.
See Figure 272. Remove the screw and washer securing the electronics cover. Figure 272 Locate the Electronics Cover Mounting Screw
1 2
1 2 3 4
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1
1 2
2
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5. Are you replacing an existing wired ethernet board?
If
Then
No Yes
Go to Install the Wired Ethernet Board on page 418. Continue with Remove the Wired Ethernet Board.
Remove the Wired Ethernet Board

1.

2. See Figure 275. Remove and discard the three nuts securing the wired ethernet board.
Figure 275 Remove the Ethernet Board
3 4 1 2 3 4
Main logic board (MLB) Wired ethernet board Mounting nuts (3) Mounting studs (3)
3. Remove the wired ethernet board. 4. Continue to step 4 on page 419.
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Install the Wired Ethernet Board

1. See Figure 276. Remove and discard the rear panel ethernet access cover and screw.
Figure 276 Remove the Blank Cover and Screw

2 1 3
1 2 3 4
Wired Ethernet access cover Mounting hole Wired Ethernet access hole Mounting screw
2. See Figure 277. Clean the J4 pads using the Zebra preventive maintenance kit part number
47362. Figure 277 Clean the J4 Pads

1
J4
1 2
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419
3. See Figure 278. Install the three mounting standoffs supplied in the kit into the three
threaded mounting holes on the main logic board (MLB). Figure 278 Install the Mounting Standoffs
2 3 1 2 3
Main logic board (MLB) Mounting studs (3) Mounting holes (3)
4. See Figure 275 on page 417. Install the wired ethernet. a. b. c.
Insert the ethernet connector into the back panel. Rotate the board down onto the three mounting studs. Secure the board with the three nuts supplied in the kit.
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420

1 2
1 2 3
2. See Figure 273 on page 416. Install the four mounting screws. 3. See Figure 272 on page 415. 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 User Guide to set up your Ethernet board.
14207L-001 A
8/9/07
Outer Casing Components
This section provides replacement and installation procedures for the various outer casing components on the ZM400/ZM600.
Contents
Electronic Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 426 429 432 435
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422
Corrective Maintenance Electronic Cover
Electronic Cover
Tools Required
Phillips Screwdriver 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.
2.
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423
1 2
1 2 3 4
8/9/07
14207L-001 A
424

1
1 2
2
7. Install the New Electronics Cover
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425
1 2
9. See Figure 281 on page 424. Open the media door. 10. See Figure 280 on page 423. Install the electronics cover mounting screw and lock
washer.
11. Reconnect the AC power cord and data cables.
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426
Corrective Maintenance Media Cover
Media Cover
Tools Required
Remove the Old Media Door

1.
2.
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427
3. See Figure 284. Remove the four screws and lock washers securing the old door and lift
the door off of the printer. Figure 284 Media Door

1
1 2 3
Media door External lock washers (4) Mounting screws (4)
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428
Install the New Media Door

Note The front hole is a locating hole; install this screw and lock washer first.
1. See Figure 284 on page 427. 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.

4. Reinstall the AC power cord and all data cables. 5. Turn on (l) the printer.
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Corrective Maintenance Media Window
429
Media Window
Tools Required
Glass Cleaner
Remove the Defective Window

1.
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 285 Remove the Old Window
A A
\
3 4
B A B 1 2 3 4
8/9/07
Flexible tabs (7) Non-flexible tabs (3) First tab to press Second set of tabs to press Third set of tabs to press Fourth set of tabs to press
ZM400/ZM600 Maintenance Manual 14207L-001 A
430
3. Lift the old window out of the door and discard it.
IInstall the New Window

1. See Figure 286 and Figure 287. Hold the new window with top away from the windowless
door and set the non-flexible tabs over the door edge. Figure 286 Align the New Window
1 2
3 1 2 3
New window Door edge Non-flexible tabs (3)
14207L-001 A
8/9/07
431
Figure 287 Position Tab

1 2
1 2
Non-flexible tab 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
8/9/07
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432
Corrective Maintenance Lower Front Panel
Lower Front Panel

Tools Required

1.
See Figure 288. 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 288 Remove the Old Lower Front Panel
Hooks
Lower Front Panel
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433
Install the New Lower Front Panel

1. See Figure 289. Hook the lower tabs of the new lower front panel over the front of the
base. Figure 289 Hook the Lower Tabs

1 2
1 2 3 4 5
Notches (2) Base Upper tabs (2) Guide posts (2) 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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434
3. See Figure 290. Tip the new lower front panel up and snap the upper tabs onto the two
mounting hooks. Figure 290 Snap to the Mounting Hooks

2 1
1 2
Lower front panel Mounting hooks
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Corrective Maintenance Rear End Cap
435
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
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.
3. See Figure 291. Remove the three screws securing the rear end-cap and then remove the
end-cap. Figure 291 Remove and Install the Rear End-Cap

3 1
2 1 2 3
Rear end-cap Mounting screws (3) Mounting holes (3)
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436
Corrective Maintenance Rear End Cap
Install the New End-Cap

1. See Figure 291. 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.

4. Reinstall the AC power cord. 5. Turn on (l) the printer.
14207L-001 A
8/9/07
5
Drawings and Parts
List of Figures
Outer Casings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media and Ribbon Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platen Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Static Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wired Ethernet Board/Internal PrintServer . . . . . . . . . . . . . . . . . . . Available Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peel and Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner Take-up Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Coated Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . 440 442 443 444 446 447 448 449 450 451 452 454 455 456 457 458 459 460 462 464 465 466 467
8/9/07
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438
Drawings and Parts List of Tables
List of Tables
Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media and Ribbon Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mechanism View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Conversion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platen Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Static Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wired Ethernet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peel and Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner Take-up Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Coated Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . 441 442 443 445 446 447 448 449 450 451 453 454 455 456 457 458 459 460 463 464 465 466 467
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Drawings and Parts List of Tables
439
Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
8/9/07
14207L-001 A
440
Drawings and Parts Outer Casings
Figure A Outer Casings

2
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Drawings and Parts Outer Casings
441
Table A Outer Casing Components

Item 1 2 Part Number 79825M 79833M 79834M 3 4 5 79826M 79856M 79857M 79858M 79859M Description Qty
ZM400/ZM600 Control Panel Maintenance Kit, contents as shown ZM400 Media Door Maintenance Kit, see page 442 for kit content information ZM600 Media Door Maintenance Kit, see page 442 for kit content information ZM400/ZM600 Electronics Cover Maintenance Kit, see page 443 for kit content information ZM400 Lower Front Cover Maintenance Kit, contents as shown ZM600 Lower Front Cover Maintenance Kit, contents as shown ZM400 Rear End Cap Maintenance Kit, see page 443 for kit content information ZM600 Rear End Cap Maintenance Kit, see page 443 for kit content information
1 1 1 1 1 1 1 1
Bold = Part available for purchase Light italic = Part not available for individual purchase, listed and shown for reference only Boxes = Parts contained in kits listed above
8/9/07
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442
Drawings and Parts Media Door
Figure B Media Door

1 2
4 3
4 3
Table B Media Door

Item 1 2 3 4 5 Part Number 79833M Description Qty
ZM400 Media Door Maintenance Kit ZM600 Media Door Maintenance Kit 79834M HW78814 Screw, M4 0.7 10 (sold in quantities of 5) HW43482 Lock Washer, (sold in quantities of 25) ZM400/ZM600 Media Window Kit 79863M
1 1 4 4 1
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Drawings and Parts Rear End Cap
443
Figure C Rear End Cap

1 5 6
2 3
Table C Rear End Cap

Item 1 2 3 4 5 6 Part Number 79826M Description Qty
ZM400/ZM600 Electronics Cover Maintenance Kit HW43482 Lock Washer, M4 (sold in quantities of 25) HW78814 Screw, M4 0.7 10 (sold in quantities of 5) HW43495 Screw w/lock washer, M3 0.5 6 (sold in quantities of 25) ZM400 Rear End Cap Maintenance Kit 79858M ZM600 Rear End Cap Maintenance Kit 79859M
1 1 1 or 3 4 1 1
8/9/07
14207L-001 A
444
Drawings and Parts Media and Ribbon Path
Figure D Media and Ribbon Path

1
3 2 4 5 6
8 7
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8/9/07
Drawings and Parts Media and Ribbon Path
445
Table D Media and Ribbon Path

1 79839M 79840M 2 79854M 79855M 3 G77100M G77117M 4 79848M 79849M 5 6 7 8 79821M 79828M 79829M Ref Ref
ZM400 Media Hanger Maintenance Kit, see page 446 for kit content information ZM600 Media Hanger Maintenance Kit, see page 446 for kit content information ZM400 Static Brush Maintenance Kit, see page 454 for kit content information ZM600 Static Brush Maintenance Kit, see page 454 for kit content information ZM400 Ribbon Take-up Spindle Maintenance Kit, see page 455 for kit content information ZM600 Ribbon Take-up Spindle Maintenance Kit, see page 455 for kit content information ZM400 Media Sensor Maintenance Kit, see page 447 for kit content information ZM600 Media Sensor Maintenance Kit, see page 447 for kit content information ZM400/ZM600 Head Open/Ribbon Sensor Maintenance Kit ZM400 Ribbon Supply Spindle, see page 448 for kit content information ZM600 Ribbon Supply Spindle, see page 448 for kit content information ZM400/ZM600 Platen Housing Maintenance Kit, see page 453 for further information ZM400/ZM600 Print Mechanism Maintenance Kit, see page 449 for kit content information
1 1 1 1 1 1 1 1 1 1 1 1 1
8/9/07
14207L-001 A
446
Drawings and Parts Media Hanger
Figure E Media Hanger

1 2
Important Only use the three screws supplied in the maintenance kit. Damage may occur if
longer screws are used. Table E Media Hanger

Item 1 2 3 Part Number 79839M Description Qty
ZM400 Media Hanger Maintenance Kit ZM600 Media Hanger Maintenance Kit 79840M HW78828 Screw, M4 0.7 20 (sold in quantities of 25)
1 1 3
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Drawings and Parts Upper Media Sensor
447
Figure F Media Sensors

1 3 4 6 7 3 4 6 2 7
3 4
Table F Media Sensors

Item 1 2 3 4 5 6 7 8 Part Number 79848M 79849M HW45931 HW10432 HW78806 77256 79287 79369 79565 79566 Description Qty
ZM400 Media Sensor Maintenance Kit ZM600 Media Sensor Maintenance Kit Split Lock Washer, M3 (sold in quantities of 25) Screw, M3 0.5 6 (sold in quantities of 25) Flat Washer, M4 (sold in quantities of 25) Torsion Spring ZM400 Upper Media Sensor Assembly ZM600 Upper Media Sensor Assembly ZM400 Lower Media Sensor Assembly ZM600 Lower Media Sensor Assembly
1 1 2 2 1 1 1 1 1 1
8/9/07
14207L-001 A
448
Drawings and Parts Ribbon Supply Spindle
Figure G Ribbon Supply Spindle

1 4
10
5 8 7 6
Gr ea se
Table G Ribbon Supply Spindle

Item 1 2 3 4 5 6 7 8 9 10 N/A 77620 77621 77593 Part Number 79828M HW10432 HW33807 79829M 77594 77598 Description Qty
ZM400 Ribbon Supply Spindle, inside coated Screw, M4 0.7 12 Flat Washer, 0.198 0.75 0.085 ZM600 Ribbon Supply Spindle Screw, M4 0.7 60 Nut, M4 Grease Flat Washer 7 mm Nutdriver Spindle Remove Tool
1 1 1 1 1 1 1 2 1 1
14207L-001 A
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Drawings and Parts Print Mechanism View 1
449
Figure H Print Mechanism View 1

1
5 6
4 3
Table H Print Mechanism View 1

Item 1 Part Number 79810M 79811M 79812M 79813M 79814M 2 3 4 5 6 79822M HWQ06020 49185 77921 77919 Description Qty
ZM400 203 dpi Print Mechanism Maintenance Kit ZM400 300 dpi Print Mechanism Maintenance Kit ZM400 600 dpi Print Mechanism Maintenance Kit ZM600 200 dpi Print Mechanism Maintenance Kit ZM600 300 dpi Print Mechanism Maintenance Kit Cable Tie, 0.09 3.62 (sold in quantities of 20) Screw Cam Gauge Pins ZM400/ZM600 Cable Maintenance Kit
1 1 1 1 1 1 1 1 2 1
8/9/07
14207L-001 A
450
Drawings and Parts Print Mechanism
Figure I Print Mechanism View 2

1 6 2
5 3
Table I Print Mechanism View 2

Item 1 2 3 Part Number G77172M Description Qty
4 5 7 6
ZM400 Pressure Dial Maintenance Kit ZM600 Pressure Dial Maintenance Kit 77172-6M ZM400/ZM600 Latch Maintenance Kit, for further detail see page 453 79819M ZM400 203 dpi Printhead Maintenance Kit 79800M ZM400 300 dpi Printhead Maintenance Kit 79801M ZM400 600dpi Printhead Maintenance Kit 79802M ZM600 203 dpi Printhead Maintenance Kit 79803M ZM600 300 dpi Printhead Maintenance Kit 79804M ZM400 Ribbon Strip Plate Maintenance Kit 79860M ZM600 Ribbon Strip Plate Maintenance Kit 79861M HW78809 Screw, M3 (sold in quantities of 25) HW79041 Flat Washer, 0.250 0.125 0,023 (sold in quantities of 25) ZM400/ZM600 Magnetic Latch Maintenance Kit 79845M
1 1 1 1 1 1 1 1 1 1 2 2 1
14207L-001 A
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Drawings and Parts Printhead Conversion
451
Figure J Printhead Conversion

1 2
3 4 7
5 6
Table J Printhead Conversion Kits

Item 1 2 Part Number 79805 79809 79806 79807 79808 3 4 5 6 7 79866M 79524 79867M 79525 79800M 79803M 79801M 79802M 79804M Description Qty
ZM400 600 or 300 dpi to 203dpi ZM600 600 or 300 dpi to 203dpi ZM400 203 or 600 dpi to300 dpi ZM400 300 or 203 dpi to 600dpi ZM600 203 dpi to 300 dpi Drive Belt 203 dpi Pulley 203 dpi Drive Belt 300/600 dpi Pulley 300/600 dpi ZM400 Printhead Assembly 203 dpi ZM600 Printhead Assembly 203dpi ZM400 Printhead Assembly 300 dpi ZM400 Printhead Assembly 600 dpi ZM600 Printhead Assembly 300 dpi
1 1 1 1 1 1 1 1 1 1 1 1 1 1
8/9/07
14207L-001 A
452
Drawings and Parts Printhead Conversion
Figure K Platen Housing

1 5
4 6 12 15 18 17 14 11
16
13
10
20
19
14207L-001 A
8/9/07
Drawings and Parts Platen Housing
453
Table K Platen Housing

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 79837M 79838M HW77231 79815M 79816M 79819M 79659 79606 79541 79741 HWQ10011 HW78806 79700 78810 77276 HW49185 77921 77919 Part Number 79862M HW06250 HW79554 79252 Description Qty
ZM400/ZM600 Platen Coupling Maintenance Kit E-ring, 0.312 external (sold in quantities of 100) Flat Washer, 0.33 0.69 0.03 (sold in quantities of 100) Roller Bearing ZM400 Platen Roller Maintenance Kit ZM600 Platen Roller Maintenance Kit Printhead Latch Maintenance Kit Plug, 0.486 diameter hole Shoulder Screw, 4M 5.5 2 Curved Washer, 0.216 0.423 0.010 Screw, M4 0.7 12* Screw, M4 0.700 10 (sold in quantities of 100)* Flat Washer, M4 (sold in quantities of 25)* Stabilizer* Adjustment Screw, M4 0.7* Latch Plate Cap* Screw, M3 0.5 6 (sold in quantities of 10) Cam Gauge Pins ZM400 Tear Bar Maintenance Kit ZM600 Tear Bar Maintenance Kit Screw, M3 8 (sold in quantities of 10)
1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2
*.Part of print mechanism
8/9/07
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454
Drawings and Parts Static Brush
Figure L Static Brush
Table L Static Brush

ZM400 Ribbon Static Brush Maintenance Kit ZM600 Ribbon Static Brush Maintenance Kit 79855M HW78814 Screw, M4 0.7 10 (sold inquantities of 5)
1 1 2
14207L-001 A
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Drawings and Parts Ribbon Take-up Spindle
455
Figure M Ribbon Take-up Spindle
Table M Ribbon Take-up Spindle

Item 1 2 Part Number G77100M G77117M Description Qty
ZM400 Ribbon Take-up Maintenance Kit ZM600 Ribbon Take-up Maintenance Kit
1 1
8/9/07
14207L-001 A
456
Drawings and Parts Drive System
Figure N Drive System Components

1 2
Table N Drive System

Item 1 2 3 Part Number 77814M 79818M G77813M Description Qty
ZM400/ZM600 Ribbon Take-up Clutch Maintenance Kit ZM400/ZM600 Drive System Maintenance Kit, see ZM400/ZM600 Stepper Motor Maintenance Kit
1 1 1
14207L-001 A
8/9/07
Drawings and Parts Electronics
457
Figure O Electronic Components

2 1
Table O Electronics
Item 1 2 3 Part Number 79400-001M 79400-002M 29651-006M 79823 Description Qty
ZM400/ZM600 8MB Main Logic Board Maintenance Kit, see page 458 ZM400/ZM600 64MB Main Logic Board Maintenance Kit, see page 458 ZM400/ZM600 Standard Wireless Board Maintenance Kit, see page 459 ZM400/ZM600 Maintenance Kit Internal Wired Ethernet Board, see page 460
1 1 1 1
8/9/07
14207L-001 A
458
Drawings and Parts Main Logic Board
Figure P Main Logic Board

5 1
J4
2 3
Table P Main Logic Board

Item 1 2 3 4 5 Part Number 79400-001M 79400-002M HW78804 HW78802 HW32406 HW45945 Description Qty
ZM400/ZM600 8MB Main Logic Board Maintenance Kit ZM400/ZM600 64MB Main Logic Board Maintenance Kit Screw, M3 0.5 6 (sold in quantities of 50) Screw, 4-4- 0.31 (sold in quantities of 25) Standoff, 4-40 (sold in quantities of 25) Lock Washer #4 (sold in quantities of 100)
1 1 2 2 2 2
14207L-001 A
8/9/07
Drawings and Parts Wireless Board
459
Figure Q Wireless Board

1 2 3 4
Table Q Wireless Board

Item 1 2 3 4 5 Part Number 29651-006M HW78804 34589 45638-xxx HW79293 Description Qty
ZM400/ZM600 Standard Wireless Board Maintenance Kit Screw, M3 0.5 6 (sold in quantities of 5) C F Adaptor Conectivity Solutions CD Standoff, M3 0.5 14 (sold in quantities of 12)
1 3 2 1 1
8/9/07
14207L-001 A
460
Drawings and Parts Wired Ethernet Board
Figure R Wired Ethernet Board/Internal PrintServer

1 2 3
Table R Wired Ethernet Board

Item 1 2 3 4 Part Number 79823 Description Qty
ZM400/ZM600 Wired Ethernet Board Kit HW10460 Nut, M3 2.4 5.5 (sold in quantities of 5) 45638-xxx Connectivity Solutions CD HW79656 Standoff, M3 0.5 10
1 3 1 3
14207L-001 A
8/9/07
461
Notes ___________________________________________________________________
__________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
8/9/07
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462
Figure S Available Media Handling Options

ZM400 ZM600
14207L-001 A
8/9/07
Drawings and Parts Mechanical Options
463
Table S Media Handling Options

Item 1 2 3 4 5 Part Number 79841 79842 79835 79836 79831M 79832M 79868M 79830M Description Qty
ZM400 Cutter Option Kit, see page 464 ZM600 Cutter Option Kit, see page 464 ZM400 Peel/Rewind Option Kit, see page 465 ZM600 Peel/Rewind Option Kit, see page 465 ZM400 Peel Assembly Option/Maintenance Kit, see page 465 ZM600 Peel Assembly Option/Maintenance Kit, see page 465 ZM400 Liner Take-up Option/Maintenance Kit, see page 466 ZM400 Inside Coated Ribbon Supply Spindle Option/Maintenance Kit, see page 467
1 1 1 1 1 1 1 1
8/9/07
14207L-001 A
464
Drawings and Parts Cutter Option
Figure T Cutter Option

1 2 1 2
3 4 4
Table T Cutter Option

Item 1 2 3 4 5 Part Number 79841 79842 79864M 79865M HW43894 77041 77997 79843M 79844M Description Qty
ZM400 Cutter Option Kit ZM600 Cutter Option Kit ZM400 Cutter Static Brush and Thumbscrew Maintenance Kit ZM600 Cutter Static Brush and Thumbscrew Maintenance Kit Screw, M4 0.5 10 ZM400 Cutter Catch Tray ZM600 Cutter Catch Tray ZM400 Cutter Cover w/PCB and Cutter Cable Maintenance Kit ZM600 Cutter Cover w/PCB and Cutter Cable Maintenance Kit
1 1 1 1 1 1 1 1 1
14207L-001 A
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Drawings and Parts Peel and Rewind Option
465
Figure U Peel and Rewind Option

1 2 3 4 5 7 9
8 6
10
11
Table U Peel and Rewind Option

Item 1 2 3 4 5 6 7 8 8 10 11 Part Number 79835 79836 79831M 79832M 77197M 77727M G79026M G70926-6M 79827M HW78804 77459M HW78814 78817 78811 G77167M G77168M Description Qty
ZM400 Peel/Rewind Option Kit ZM600 Peel/Rewind Option Kit ZM400 Peel Assembly Option/Maintenance Kit ZM600 Peel Assembly Option/Maintenance Kit ZM400 Pinch Roller Mainrtenance Kit ZM600 Pinch Roller Mainrtenance Kit ZM400 Rewind Motor and PCB Maintenance Kit ZM600 Rewind Motor and PCB Maintenance Kit ZM400/ZM600 Media Rewind Cable Maintenance Kit Screw, M3 0.5 6 (sold in quantities of 5) ZM400/ZM600 Outside Rewind Media Guide Maintenance Kit Screw, M4 0.7 10 (sold in quantities of 5) Screw, M4 0.7 12 Flat Washer, 0.500 0.195 0.090) ZM400 Steering Roller Maintenance Kit ZM600 Steering Roller Maintenance Ki
1 1 1 1 1 1 1 1 1 2 1 6 5 1 1 1
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466
Drawings and Parts Liner Take-up Option
Figure V Liner Take-up Option

1
3 4
Table V Liner Take-up Option

Item 1 2 3 4 5 Part Number 79868M G34112M 77637 HW06313 HW43968 Description Qty
ZM400 Liner Take-up Option/Maintenance Kit Liner Take-up Printed Circuit Board (PCB) and Motor Screw, M4 0.7 10 E-ring, 0.375 (sold in quantities of 25) Screw, M3 0.5 6 (sold in quantities of 25)
1 1 2 1 2
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Drawings and Parts Inside Coated Ribbon Supply Spindle
467
Figure W Inside Coated Ribbon Supply Spindle

1
Table W Inside Coated Ribbon Supply Spindle

ZM400 Ribbon Supply Spindle Maintenance Kit HW10432 Screw, M4 0.7 12 (sold in quantities of 25) HW33807 Flat Washer, 0.198 0.750 0.085 (sold in quantities of 25)
1 1 1
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14207L-001 A
468
Drawings and Parts Repacking Instructions
Repacking Instructions
Important Before repacking, call 1.847.913.2259 for a Return Material Authorization (RMA) number
The following instructions are for the Z Series printers. Repack the complete unit as shown.This repackaging kit includes all of the material needed to repack the printer to transport it safely.
Before packaging the printer, remove media and ribbon, and make sure that the printhead is closed
Cutter Insert Media Door Insert Media Door
Detail A
Prepare Printer For Shipping

For all Units
For Cutter Units Only (see Detail B) Peel Insert For Peel Units Only (See Detail A) TR (Top Right)
1. Fold the media door insert at the score. 2. Open the media door. 3. Insert one end between the door and the
Detail B
F
main frame and then close the door. For Cutter Units Only
TR
4. Slightly open the media door. Place the cutter
insert on top of the cutter module (see Detail B).

TL (Top Left) Printer in plastic bag
For Peel Units only

1. Slightly open the media door. Insert the peel
insert behind the peel open lever (see Detail A).

BR (Bottom Right)
F
BR
BL (Bottom Left)
HA
UP
ND
LE
WIT
Ze
bra
HC
ARE
UP
AL SE EA IN PL CK L PA
E S CL AL CY RI RE TE MA G
Packaging Instructions
RM A #
Bobs 555 Zanes 43701 Wilso ville, n Avenu -5633 Ohio e
RMA
# XXXX XX
Zebra 333 Verno Techn 60061 Corpo n Hills, ologie -3109 rate Wood Illinois s s Parkw ay
XX XX
1. Close the media door. 2. Slide the printer into the plastic bag. 3. Gather the bag, and tape it shut.
XX
HA
UP
ND
LE
WIT
Ze
bra
HC
ARE
AL
L PA
SE EA PL CKIN
RE AT M G
E CL LS CY ERIA
UP
4. Separate the bottom and top parts of the left and right end caps. The pieces are marked
with their intended location in the shipping box.
14207L-001 A
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Drawings and Parts Repacking Instructions
469
5. Place the bottom left (BL) and bottom right (BR) inserts into the carton, as shown. 6. Place the printer into the carton, aligning the printer front with the front of the inserts. The
front of each insert is marked with a stamped F.

7. Place the top left (TL) and top right (TR) inserts into the carton on top of the printer as
shown.
8. Close the flaps, and seal the box with postal quality shipping tape.
Note BR=Bottom Right, BL=Bottom Left, TR=Top Right, TL=Top Left.

9. Label and send insured to:
Zebra Technologies 333 Corporate Woods Parkway Vernon Hills, Illinois 60060-3109 RMA #XXXXXX
Note Write the RMA number on the mailing label and in large letters and numbers on top
of the box.
8/9/07
14207L-001 A
Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A. Telephone: +1 847 793 2600
Facsimile: +1 847 913 8766

Zebra Technologies Europe Limited Zebra House The Valley Centre, Gordon Road High Wycombe Buckinghamshire HP13 6EQ, UK Telephone: +44 (0) 1494 472872 Facsimile: +44 (0) 1494 450103 Zebra Technologies Asia Pacific, LLC 16 New Industrial Road #05-03 Hudson TechnoCentre Singapore 536204 Telephone: +65 6858 0722 Facsimile: +65 6885 0838
Part Number: 14207L-001 2007 ZIH Corp.

Zebra ZM400-ZM600 Maint Man

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Zebra ZM400-ZM600 Maint Man

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ZM400/ZM600

Product Improvements Continuous improvement of products is a policy of Zebra Technologies Corporation.

Part Number: 14207L-001 A

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

4 Preventive and Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

5 Drawings and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

ZM400/ZM600 Maintenance Manual

4 Preventive and Corrective Maintenance

ZM400/ZM600 Maintenance Manual

5 Drawings and Parts

ZM400/ZM600 Maintenance Manual

Figure 1 Sample Figure with Callouts ..............................................................................................27

ZM400/ZM600 Maintenance Manual

4 Preventive and Corrective Maintenance

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

5 Drawings and Parts

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

About This Document

ZM400/ZM600 Maintenance Manual

About This Document Who Should Use This Document

Who Should Use This Document

How This Document Is Organized

System Description on page 29

Operations on page 43 Troubleshooting on page 103

Preventive and Corrective Maintenance on page 127

Drawings and Parts on page 437

ZM400/ZM600 Maintenance Manual

About This Document Contacts

Europe, Africa, Middle East, and India

ZM400/ZM600 Maintenance Manual

About This Document Document Conventions

Bubbledot ICG font.

Caution Warns you of a potential electric shock situation.

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

ZM400/ZM600 Maintenance Manual

About This Document Document Conventions

FEED button CANCEL button

ZM400/ZM600 Maintenance Manual

About This Document Document Conventions

ZM400/ZM600 Maintenance Manual

ZM400/ZM600 Maintenance Manual

System Description External View

Control panel Media door Figure 3 Rear of Printer

ZM400/ZM600 Maintenance Manual

System Description Printer Media Compartment

Printer Media Compartment

ZM400/ZM600 Maintenance Manual

System Description Control Panel

ZM400/ZM600 Maintenance Manual