Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Industrial/Commercial Printer
Maintenance Manual
14207L-004 Rev. A
2 Copyright and Liability Disclaimer
2011 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described
therein are owned by ZIH Corp. and Zebras licensors. Unauthorized reproduction of this manual or the software
and/or firmware in the printer may result in imprisonment of up to one year and fines of up to $10,000
(17 U.S.C.506). Copyright violators may be subject to civil liability.
This product may contain ZPL, ZPL II, and ZebraLink programs; Element Energy Equalizer Circuit; E3;
and Monotype Imaging fonts. Software ZIH Corp. All rights reserved worldwide.
ZebraLink, Element Energy Equalizer, E3 and all product names and numbers are trademarks, and Zebra, the Zebra
head graphic, ZPL and ZPL II are registered trademarks of ZIH Corp. All rights reserved worldwide.
All other brand names, product names, or trademarks belong to their respective holders. For additional trademark
information, please see Trademarks on the product CD.
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation and its
subsidiaries (Zebra Technologies). It is intended solely for the information and use of parties operating and
maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed
to any other parties for any other purpose without the express, written permission of Zebra Technologies Corporation.
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.
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Print Modes and Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Standard Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Additional Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
System Description
Table 1 Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Table 2 Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Operations
Table 3 Storage Temperature and Humidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Table 4 Operating Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Table 5 Data Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Table 6 Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Table 7 Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Table 8 Media Paths for Print Modes with Various Printer Options . . . . . . . . . . . . . . . . . . . .52
Table 9 ZM400 and RZ400 Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Table 10 ZM600 and RZ600 Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Table 11 Printer Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Table 12 Print Width Ranges and Maximum Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Table 13 RFID Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Troubleshooting
Table 14 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Table 15 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Table 16 Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Table 17 Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Table 18 Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Table 19 Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Table 20 Judging Bar Code Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
This section provides you with contact information, document structure and organization, and additional
reference documents.
Contents
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section Description
System Description on page 25 This section provides an overview of the printer. Included are
specifications of the printer and a brief explanation of each
component and its function.
Operations on page 39 This section assists the technician with out of the box installation,
initial setup, and printer operation.
Troubleshooting on page 101 This section provides information about LCD, print quality,
communications, and other errors that you might need to
troubleshoot. The tables provide symptoms, diagnoses of probable
causes, and recommended actions that should result in proper
printer operation. Working with these tables, the technician can
diagnose printer faults and determine the needed repair.
Preventive and Corrective This section provides various levels of printer maintenance required
Maintenance on page 123 for optimum performance. This section also provides information
on cleaning and general maintenance, replacement of major
assemblies, and mechanical adjustments.
Drawings and Parts on page 545 This section provides the technician with assembly drawings and
part number to maintain the printer.
Contacts
Technical Support via the Internet is available 24 hours per day, 365 days per year.
Regional Headquarters Zebra Technologies Corporation Zebra Technologies Europe Zebra Technologies Asia Pacific
475 Half Day Road, Suite 500 Limited Pte. Ltd.
Lincolnshire, IL 60069 USA Dukes Meadow 120 Robinson Road
T: +1 847 634 6700 Millboard Road #06-01 Parakou Building
Toll-free +1 866 230 9494 Bourne End Singapore 068913
F: +1 847 913 8766 Buckinghamshire, SL8 5XF T: + 65 6858 0722
United Kingdom F: +65 6885 0838
T: +44 (0) 1628 556000
F: +44 (0) 1628 556001
Technical Support T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1628 556039 T: +65 6858 0722
For questions on the F: +1 847 913 2578 F: +44 (0) 1628 556003 F: +65 6885 0838
operation of Zebra Hardware: ts1@zebra.com E: Tseurope@zebra.com E: China: tschina@zebra.com
equipment and software, Software: ts3@zebra.com All other areas:
please call your distributor. Kiosk printers: tsasiapacific@zebra.com
For additional assistance, T: +1 866 322 5202
contact us. E: kiosksupport@zebra.com
Please have your model and
serial numbers available.
Repair Service T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1772 693069 T: +65 6858 0722
Department F: +1 847 821 1797 F: +44 (0) 1772 693046 F: +65 6885 0838
For back-to-base service E: repair@zebra.com New requests: ukrma@zebra.com E: China: tschina@zebra.com
and repair. To request a repair in the U.S., Status updates: All other areas:
go to www.zebra.com/repair. repairupdate@zebra.com tsasiapacific@zebra.com
Technical Training T: +1 847 793 6868 T: +44 (0) 1628 556000 T: + 65 6858 0722
Department T: +1 847 793 6864 F: +44 (0) 1628 556001 F: +65 6885 0838
For Zebra product training F: +1 847 913 2578 E: Eurtraining@zebra.com E: China: tschina@zebra.com
courses. E: ttamerica@zebra.com All other areas:
tsasiapacific@zebra.com
Inquiry Department T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1628 556037 E: China:
For product literature and E: inquiry4@zebra.com F: +44 (0) 1628 556005 GCmarketing@zebra.com
distributor and dealer E: mseurope@zebra.com All other areas:
information. APACChannelmarketing@zebra.co
m
Customer Service T: +1 877 ASK ZEBRA (275 9327) T: +44 (0) 1628 556032 T: +65 6858 0722
Department (US) E: clientcare@zebra.com F: +44 (0) 1628 556001 F: +65 6885 0836
Internal Sales E: cseurope@zebra.com E: China: order-csr@zebra.com
Department (UK) All other areas:
csasiapacific@zebra.com
For printers, parts, media,
and ribbon, please call your
distributor or contact us.
Key: T: Telephone
F: Facsimile
E: E-mail
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 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.
Illustration Callouts Callouts are used when an illustration contains information that needs
to be labeled and described. A table that contains the labels and descriptions follows the
graphic.
Tools Figure
Tells 1 provides
you anyou
what tools example.
need to complete a given task.
1 2
1 FEED button
2 CANCEL button
Notes ___________________________________________________________________
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This section provides an overview of the printer. Included are specifications of the printer and
a brief explanation of each component and its function.
Contents
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Printer Language Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
External View
Figure 2 and Figure 3 show the components and connections on the outside of the printer.
2
1
1 Control panel
2 Media door
6
1 7
2 8
6
1 7
2 8
Note For optimal printing quality and proper printer performance across our product line,
Zebra strongly recommends the use of genuine Zebra supplies as part of the total solution.
Specifically, the ZM400, ZM600, RZ400, and RZ600 are designed to work only with
genuine Zebra printheads, thus maximizing safety and print quality.
4
5
8
9
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.
1 2 3 4
12
11 6
10
9 7
1 Power LED
2 Pause LED
3 Error LED
4 Data LED
5 LCD
6 CANCEL button
7 PLUS (+) button
8 SETUP/EXIT button
9 MINUS () button
10 SELECT button
11 FEED button
12 PAUSE button
Button Function
FEED Forces the printer to feed one blank label each time the button is pressed.
Printer not printing: one blank label immediately feeds.
Printing: one blank label feeds after the current batch of labels is complete.
PAUSE Starts and stops the printing process.
Printer not printing: no printing occurs. (Press PAUSE again to resume printing.)
Printing: printing stops after the current label is complete.
CANCEL Cancels print jobs when the printer is paused.
Printer not printing: the next stored label format does not print.
Printing: current label completes printing, and the next label format is cancelled.
Press and hold for several seconds to cancel all print jobs in memory.
SETUP/EXIT Enters and exits the configuration mode.
SELECT Toggles the function of PLUS (+) and MINUS () between the Scroll and Change
Modes.
Press once to use PLUS (+) and MINUS () to change the values of the selection.
Press again to use PLUS (+) and MINUS () to scroll through the menu items.
PLUS (+) Scrolls to the next selection.
(scroll mode)
PLUS (+) Increases the value.
(change mode) Performs the action on the bottom right of the LCD.
MINUS () Scrolls to the previous selection.
(scroll mode)
MINUS () Decreases the value.
(change mode) Moves to the next available digit in a number.
Performs the action on the bottom left of the LCD.
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.
General Specifications
Printing Specifications
Media Specifications
Ribbon Specifications
Ribbon can be wound with the coated side on the inside or outside. The ribbon used must
match the Thermal Transfer option installed. The standard Thermal Transfer option (black
ribbon spindle) uses ribbon coated on the outside, and the alternate Thermal Transfer option
(gray ribbon spindle) uses ribbon coated on the inside. For more information, see Ribbon
Overview on page 58.
Printer Options
This section assists the technician with out of the box installation, initial setup, and printer
operation.
Contents
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Select a Data Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Data Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Print Modes and Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contents (Continued)
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Enter and Use Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Print a Configuration Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Standard Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Additional Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
RFID Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Unpack and Inspect the Printer Have you unpacked the printer and inspected it for
damage? If you have not, see Unpack and Inspect the Printer on page 42.
Select a Site Have you selected an appropriate location for the printer? If you have not,
see Select a Site for the Printer on page 43.
Connect to a Data Source Have you determined how the printer will connect to a
data source (usually a computer)? For more information, see Select a Data
Communication Interface on page 44.
Attach a Power Cord Do you have the correct power cord for your printer? If you are
unsure, see Power Cord Specifications on page 49. To attach the power cord and connect
the printer to a power source, see Connect the Printer to a Power Source on page 48.
Select Media Do you have the correct media for your application? If you are unsure,
see Types of Media on page 50.
Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if
needed? If you are unsure, see Ribbon Overview on page 58.
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.
Select a Surface
Select a solid, level surface of sufficient size and strength to accommodate the printer and
other equipment (such as a computer), if necessary. The choices include a table, countertop,
desk, or cart. For the printers weight and dimensions, see General Specifications on page 33.
Table 4 shows the temperature and relative humidity requirements for the printer when it is
operating.
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.
Table 5 also shows how to connect the different types of data cables to your printer and
computer. The connectors on the back of your computer may be in different locations than on
the sample computer shown in this section.
Caution Ensure that the printer power is off (O) before connecting data communications
cables. Connecting a data communications cable while the power is on (I) may damage the
printer.
Standard or
Interface Description
Optional
RS-232 Serial Standard Limitations and Requirements
Maximum cable length of 50 ft (15.24 m).
You may need to change printer parameters to match the host
computer.
You need to use a null-modem adaptor to connect to the printer
if using a standard modem cable.
Connections and Configuration The baud rate, number of
data and stop bits, the parity, and the XON/XOFF or DTR control
must match those of the host computer. See Standard Control
Panel Parameters on page 72 to view or change these parameters.
Standard or
Interface Description
Optional
IEEE 1284 Standard Limitations and Requirements
Bidirectional Parallel Maximum cable length of 10 ft (3 m).
Recommended cable length of 6 ft (1.83 m).
No printer parameter changes required to match the host
computer.
Connections and Configuration No additional
configuration is necessary.
Standard or
Interface Description
Optional
Internal wired Limitations and Requirements
Ethernet print server Can print to the printer from any computer on your LAN.
Can communicate with the printer through the printers web
pages when in ZPL mode.
The printer must be configured to use your LAN.
Connections and Configuration Refer to the ZebraNet
10/100 Print Server User and Reference Guide for configuration
instructions. A copy of this manual is available at
http://www.zebra.com/manuals or on the user CD that came with
your printer.
Note To use this connection, you may need to remove a
factory-installed plug that is designed to keep someone
from accidentally plugging a USB connector into this port.
Data Cables
You must supply all data cables for your application.
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.
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.
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.
The control panel LCD and lights activate, indicating that the printer is booting up.
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.
2 3
1
Types of Media
The printer can use various types of media (Table 6).
Media Paths
Table 8 shows the media paths for print mode and printer option combinations using roll
media. Fanfold media uses the same print modes and printer options as roll media. RFID
printers can use all of these printer options and have the same media paths.
Table 8 Media Paths for Print Modes with Various Printer Options
Rewind
Table 8 Media Paths for Print Modes with Various Printer Options (Continued)
Rewind Rewind
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.
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.
1. Press the printhead release latch to open the printhead assembly. Lift the printhead until it
latches open.
3. Insert media into the printer. Follow the instructions for roll or fanfold media, as
appropriate.
a. Remove and discard any tags or a. Flip down the media supply guide.
labels that are dirty or that are held
by adhesives or tape.
b. Flip down the media supply guide. b. Feed the media through the rear or
bottom access slot.
Rear Feed
Bottom Feed
d. Flip up the media supply guide. c. Drape the media over the media
supply hanger.
e. Slide in the media supply guide until d. Flip up the media supply guide.
it touches the edge of the roll.
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
5. Slide in the media guide until it touches the outer edge of the media.
7. If the printer is paused (the Pause light is on), press PAUSE to enable printing.
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.
1. Scratch the print surface of the media rapidly with your fingernail.
2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.
4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?
Load Ribbon
Always use ribbon that is wider than the media to protect the printhead from wear. For direct
thermal printing, do not load ribbon in the printer.
The standard Thermal Transfer option (black ribbon spindle) uses ribbon coated on the
outside, and the alternate Thermal Transfer option (gray ribbon spindle) uses ribbon coated on
the inside. To avoid damaging your printer, follow the directions for the Thermal Transfer
option installed in your printer.
Figure 9 shows the ribbon paths for ribbon coated on the outside and ribbon coated on the
inside. The coated surfaces of the ribbon are shown in gray when they are visible. To
determine which side of a ribbon is printed, see Coated Side of Ribbon on page 58.
1 1
2 2
3 3
4 4
5 5
1 Tension blade
2 Ribbon take-up spindle
3 Ribbon supply spindle
4 Printhead assembly
5 Printhead release latch
1. Press the printhead release latch to open the printhead assembly. Lift the printhead until it
latches open.
2. Insert the ribbon into the printer. In this step, follow the instructions for the Thermal
Transfer option installed in your printer.
Ribbon Coated Outside Ribbon Coated Inside
(black ribbon spindle) (gray ribbon spindle)
a. Hold the ribbon with the loose end unrolling a. Hold the ribbon with the loose end unrolling
clockwise. counterclockwise.
b. Place the roll of ribbon on the ribbon supply b. Place the roll of ribbon on the ribbon supply
spindle (1) and push it all the way back. spindle (1) and push it all the way back.
1 1
c. Pull the end of the ribbon under the printhead c. Pull the end of the ribbon under the printhead
assembly (1) and out the front of the printer. assembly (1) and out the front of the printer.
Extend the ribbon approximately 24 in. Extend the ribbon approximately 24 in.
(610 mm) out of the printer. (610 mm) out of the printer.
1 1
4. Wind the ribbon clockwise onto the ribbon take-up spindle (1).
1 1
1.
Caution Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may
damage the spindle.
If the ribbon has not run out, cut or break it before the ribbon take-up spindle (1).
2. To loosen the ribbon, squeeze it against the ribbon take-up spindle tension blades (1). At
the same time, turn the ribbon take-up spindle release knob counterclockwise (2).
The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.
3. Slide the used ribbon off of the ribbon take-up spindle and discard.
Auto Calibration
When the control panel setting for MEDIA POWER UP or HEAD CLOSE is set to
CALIBRATION, the printer automatically calibrates on power up or when the printhead is
closed. During auto calibration, the printer determines the label length and sensor settings. The
results of the auto calibration are stored in the printers memory and are retained even if printer
power is removed. These parameters remain in effect until the next calibration is performed.
Note If the control panel settings for MEDIA POWER UP or HEAD CLOSE are set to
LENGTH, NO MOTION, or FEED, the printer starts printing without auto calibrating. See
Select Media Power-Up Option on page 92 or Select Head Close Option on page 92.
Manual Calibration
Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the
media and ribbon are detected more accurately. If you change the type of ribbon or media,
your printer may operate better if you perform this calibration.
For instructions, refer to Calibrate Media and Ribbon Sensor Sensitivity on page 86.
See Figure 10. The ZM400 and RZ400 pressure adjustment dials have four possible settings
designated by blocks of increasing size embossed on the print mechanism. The smallest block
(fully counterclockwise) is considered position 1, and the largest block (fully clockwise) is
considered position 4. The ZM600 and RZ600 dials have seven settings instead of four.
1 2
1 Outside dial
2 Inside dial
1. Use Table 9 or Table 10 to select the initial dial settings for your media, depending on
which printer you have.
Table 9 ZM400 and RZ400 Printhead Pressure
Setup Mode
After you have installed the media and the Power-On Self Test (POST) is complete, the control
panel displays PRINTER READY. You may now set printer parameters for your application
using the control panel display and the buttons directly below it. If it becomes necessary to
restore the initial printer defaults, see FEED and PAUSE Self Test on page 120.
Important Certain printing conditions may require that you adjust printing parameters,
such as print speed, darkness, or print mode. These conditions include (but are not
limited to):
printing at high speeds
peeling the media
the use of extremely thin, small, synthetic, or coated labels
Because these and other factors affect print quality, run tests to determine the best
combination of printer settings and media for your application. A poor match may limit print
quality or print rate, or the printer may not function properly in the desired print mode.
Note If the printer is operating on an IP network and you have a ZebraNet wired or
wireless print server, you can change the printers parameters in these additional ways:
with ZebraLink WebView. For information, see the appropriate print server user guide.
with ZebraNet Bridge. For information, see the ZebraNet Bridge Enterprise Printer
Management User Guide.
LCD Description
PERMANENT Stores values in the printer even when power is turned off.
TEMPORARY Saves the changes until power is turned off.
CANCEL Cancels all changes made since you entered Setup mode,
except for changes made to the darkness and tear-off settings,
which go into effect as soon as they are made.
LOAD DEFAULTS Restores all parameters other than the network settings back to
the factory defaults. Use care when loading defaults because
you will need to reload all settings that you changed manually.
Note On non-RFID printers, loading factory defaults
causes the printer to auto-calibrate.
LOAD LAST SAVE Loads values from the last permanent save.
DEFAULT NET Restores the wired and wireless network settings back to
factory defaults.
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.
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.
2. Press PLUS (+) or MINUS (-) to scroll through the parameters until you reach
LIST SETUP.
3. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the parameters until you reach
LIST NETWORK.
3. Press SELECT to select the parameter.
asterisk
indicating the
active print
server
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.
Language/Parameter Action/Explanation
Adjust Print Darkness
Darkness (burn duration) settings depend on a variety of factors, including
ribbon type, media type, and the condition of the printhead. You may adjust
the darkness for consistent high-quality printing.
Important Set the darkness to the lowest setting that provides
good print quality. If the darkness is set too high, the ink may
smear, the ribbon may burn through, or the printhead may wear
prematurely.
If printing is too light or if there are voids in printed areas, increase the
darkness. If printing is too dark or if there is spreading or bleeding of
printed areas, decrease the darkness.
The FEED Self Test on page 118 can be used to determine the best darkness
setting. You may want to adjust darkness while performing the PAUSE Self
Test on page 117. Because the darkness setting takes effect immediately,
you can see the results on labels that are currently printing. Darkness
settings also may be changed by the driver or software settings.
Language/Parameter Action/Explanation
Adjust Print Speed
Adjusts the speed for printing a label (given in inches per second). Slower
print speeds typically yield better print quality. Print speed changes take
effect upon exiting Setup mode.
Language/Parameter Action/Explanation
Adjust the Tear-Off Position
This parameter establishes the position of the media over the
tear-off/peel-off bar after printing.
See Figure 13. Higher numbers move the media out (the tear line moves
closer to the leading edge of the next label), and lower numbers move the
media in (the tear line moves closer to the edge of the label just printed).
1
2
1 Media direction
2 Factory-set tear line location at position 00
Language/Parameter Action/Explanation
Select Print Mode
This parameter tells the printer how printed labels will be removed. Make
sure that you select a print mode that is compatible with your printer and
printer options. For information about how the print modes work with
different printer options, see Print Modes and Printer Options on page 51.
Language/Parameter Action/Explanation
APL-D only Set Module A Storage Device for APL-D
Language/Parameter Action/Explanation
Select Print Method
The print method parameter tells the printer the method of printing that you
want to use: direct thermal (no ribbon) or thermal transfer (using thermal
transfer media and ribbon).
Printhead
Printer
Resolution ZM400/RZ400 ZM600/RZ600
200 dpi Default Value: 832 Default Value: 1344
Range: 2 to 832 dots Range: 2 to 1344 dots
300 dpi Default Value: 1248 Default Value: 1984
Range: 2 to 1248 dots Range: 2 to 1984 dots
600 dpi Note 600 dpi is N/A
not available on the
RZ400.
Note Setting the width too narrow can result in portions of a label
format not being printed on the media. Setting the width too wide
wastes formatting memory and can cause printing off of the label
and on the platen roller. This setting can affect the horizontal
position of the label format if the image was inverted using the
^POI ZPL II command.
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to change the value shown.
3. Press SELECT to accept any changes and deselect the parameter.
Language/Parameter Action/Explanation
ZPL, EPL, APL-I Set Maximum Label Length
This parameter is used during the media portion of the calibration process.
Always set maximum label length to a value that is at least 1.0 in.
(25.4 mm) greater than the actual label length (Figure 14). If the value is set
to a smaller value than the label length, the printer assumes that continuous
media is loaded, and the printer cannot calibrate.
For example, if the label length is 5.0 inches (126 mm) including the
interlabel gap, set the parameter for 6.0 inches (152 mm). If the label length
APL-D only is 7.5 inches (190 mm), set the parameter for 9.0 inches (229 mm).
}2
3
1
Language/Parameter Action/Explanation
Set Early Warning for Maintenance
When this feature is enabled, the printer provides warnings when the
printhead needs to be cleaned.
Language/Parameter Action/Explanation
Set Printhead Life for Early Warning
This parameter appears only when Early Warning for Maintenance is
enabled. Set this value to the number of inches of media that the printhead
is expected to print.
Language/Parameter Action/Explanation
Print Counter Readings
Prints a label that lists the odometer readings for the following:
the non-resettable counter
the two user-controlled counters
the Early Warning for Maintenance counters, which indicate when the
printhead was last cleaned and the printhead life
If the Early Warning for Maintenance feature is disabled, the counters
related to it do not print.
To print a list of the odometer readings:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to print the odometer readings.
3. Press SELECT to deselect the parameter.
ZPL, EPL, APL-D List Fonts
This option prints a label that lists the available fonts in the printer,
including standard printer fonts plus any optional fonts. Fonts may be
stored in RAM or Flash memory.
To print a list of the available fonts:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
ZPL only List Bar Codes
This option prints a label that lists the available bar codes in the printer. Bar
codes may be stored in RAM or Flash memory.
To print a list of the available bar codes:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
ZPL, EPL, APL-D List Images
This option prints a label that lists the available images stored in the
printers RAM, Flash memory, or optional memory card.
To print a list of the available images:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
Language/Parameter Action/Explanation
ZPL, EPL, APL-D List Formats
This option prints a label that lists the available formats stored in the
printers RAM, Flash memory, or optional memory card.
To print a list of the available formats:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
ZPL, EPL, APL-D List Setup
This option prints a configuration label (see Figure 11 on page 70), which
lists the current printer configuration.
To print a configuration label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
APL-I only
Language/Parameter Action/Explanation
APL-I only Print Quality Test Label
A print quality test label contains test bar codes and relevant printer
settings.
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
APL-I only Print Pitch Test Label
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
Default Value: 0
To modify this parameter:
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
Language/Parameter Action/Explanation
APL-I only Print Stored APL-I Format
Up to 100 formats can be stored and printed.
Selections: 0 through 99
Default Value: 0
To modify this parameter:
To print this label:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select PRINT.
3. Press SELECT to deselect the parameter.
Format Memory Card
Note This parameter appears only when a Wireless Plus option
board with the flash chip populated is installed.
This option erases all previously stored information from the 64 MB flash
chip.
Caution This option completely erases the flash chip.
To format a memory card:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to select A: or OPT:MEM (APL-D only).
If your printer is set to require a password, you are prompted to enter
the password.
3. Enter the password. For instructions, see Change Password-Protected
Parameters on page 69.
4. Press the appropriate button again to select the desired card.
The display shows ARE YOU SURE?.
5. Do you want to continue?
Press MINUS (-) to select NO to cancel the request and return to
FORMAT CARD prompt.
Press PLUS (+) to select YES and begin initialization.
When initialization is complete, the control panel displays
FORMATTING CARD COMPLETED.
Note Depending on the amount of memory in the memory card,
initialization may take up to 5 minutes to complete.
Language/Parameter Action/Explanation
Initialize Flash Memory
This option erases all previously stored information from Flash memory.
Caution This option completely erases the Flash memory.
To initialize Flash memory:
1. Press SELECT to select the parameter.
2. If prompted for a password, enter the printer password. For
instructions, see Change Password-Protected Parameters on page 69.
The display shows INITIALIZE FLASH?
3. Press PLUS (+) to select YES.
The display shows ARE YOU SURE?.
4. Do you want to continue?
Press MINUS (-) to select NO to cancel the request and return to the
INITIALIZE FLASH prompt.
Press PLUS (+) to select YES and begin initialization.
When initialization is complete, the control panel displays
INITIALIZING MEMORY COMPLETED.
Note Depending on the amount of free FLASH memory,
initialization may take up to 1 minute to complete.
Language/Parameter Action/Explanation
Calibrate Media and Ribbon Sensor Sensitivity
Use this procedure to adjust sensitivity of media and ribbon sensors.
Important Follow this procedure exactly as presented. All of the
steps must be performed even if only one of the sensors requires
adjustment. You may press MINUS (-) at any step in this procedure
to cancel the process.
To perform a media and ribbon sensor calibration:
1. Press SELECT to select the parameter.
2. Press PLUS (+) to start the calibration procedure.
The LOAD BACKING prompt displays.
3. Open the printhead.
4. Remove approximately 8 in. (203 mm) of labels from the backing, and
pull the media into the printer so that only the backing is between the
media sensors.
5. Leave the printhead open.
6. Press PLUS (+) to continue.
The REMOVE RIBBON prompt displays.
7. Remove the ribbon (if used).
8. Close the printhead.
9. Press PLUS (+) to continue.
The message CALIBRATING PLEASE WAIT displays.
The printer adjusts the scale (gain) of the signals that it receives from
the media and ribbon sensors based on the specific media and ribbon
combination being used. On the sensor profile, this essentially
corresponds to moving the peak of the graph up or down to optimize
the readings for your application.
When calibration is complete, RELOAD ALL displays.
10. Open the printhead and pull the media forward until a label is
positioned under the media sensor.
11. Reload the ribbon (if used).
12. Close the printhead.
13. Press PLUS (+) to continue.
The printer performs an auto-calibration. During this process, the
printer checks the readings for the media and ribbon based on the new
scale established, determines the label length, and determines the print
mode. To see the new readings on the new scale, print a sensor profile.
14. Press SELECT to accept any changes and deselect the parameter.
Language/Parameter Action/Explanation
Set Parallel Communications
Select the communications port that matches the one being used by the host
computer.
Language/Parameter Action/Explanation
Set Data Bits
This setting applies only when the serial port is used. The data bits of the
printer must match the data bits of the host computer for accurate
communications to take place. Set the data bits to match the setting being
used by the host computer.
Language/Parameter Action/Explanation
APL-I only Send APL-I Status Response
Determines if a response is sent after inquiry commands.
Default Value: ON
Selections: ON, OFF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to toggle between the options.
3. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Protocol
Protocol is a type of error checking system. Depending on the selection, an
indicator may be sent from the printer to the host computer signifying that
data has been received. Select the protocol that is requested by the host
computer. Further details on protocol can be found in the ZPL
Programming Guide.
Language/Parameter Action/Explanation
Set Communications Mode
The communication diagnostics mode is a troubleshooting tool for
checking the interconnection between the printer and the host computer.
For more information, see Communications Diagnostics Test on page 121.
Default Value: 7E ~
Range: 00 to FF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to increase the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.
ZPL only Set Format Prefix Character
The format prefix is a two-digit hex value used as a parameter place marker
in ZPL/ZPL II format instructions. The printer looks for this hex character
to indicate the start of a ZPL/ZPL II format instruction. See the ZPL
Programming Guide for more information.
Note Do not use the same hex value for the control, format, and
delimiter character. The printer must see different characters to
work properly.
Default Value: 5E ^
Range: 00 to FF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to increase the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.
Language/Parameter Action/Explanation
ZPL only Set Delimiter Character
The delimiter character is a two-digit hex value used as a parameter place
marker in ZPL/ZPL II format instructions. See the ZPL Programming
Guide for more information.
Note Do not use the same hex value for the control, format, and
delimiter character. The printer must see different characters to
work properly.
Default Value: 2C ,
Range: 00 to FF
To change the value shown:
1. Press SELECT to select the parameter.
2. Press MINUS (-) to move to the next digit position.
3. Press PLUS (+) to increase the value of the digit.
4. Press SELECT to accept any changes and deselect the parameter.
ZPL only Select ZPL Mode
The printer remains in the selected mode until it is changed by this
parameter or by using a ZPL/ZPL II command. The printer accepts label
formats written in either ZPL or ZPL II, eliminating the need to rewrite any
ZPL formats that already exist. See the ZPL Programming Guide for more
information on the differences between ZPL and ZPL II.
Language/Parameter Action/Explanation
Select Media Power-Up Option
This parameter sets the action of the media when you turn on the printer.
Language/Parameter Action/Explanation
Select Backfeed Sequence
This parameter sets when label backfeed occurs after a label is removed in
some print modes. It has no effect in Rewind mode. This setting is
superseded by ~JS when received as part of a label format (see the ZPL
Programming Guide for more information).
Language/Parameter Action/Explanation
Adjust Left Position
This parameter adjusts the print position horizontally on the label. Positive
numbers adjust printing to the left by the specified number of dots.
Negative numbers shift printing to the right.
Language/Parameter Action/Explanation
See next column View Sensor Settings
These parameters are automatically set during the calibration procedure
and should be changed only by a qualified service technician. Refer to the
ZPL II Programming Guide for information on these parameters.
To skip these parameters:
1. Press PLUS (+) to skip each of the following parameters:
Language/Parameter Action/Explanation
Select Idle Display
This parameter selects the LCD options for the real-time clock.
Note If the default value is not selected, pressing PLUS (+) or
MINUS (-) briefly displays the firmware version of the printer.
Language/Parameter Action/Explanation
Select the Display Language
This parameter changes the language displayed on the LCD. Each language
selection is displayed in the language itself.
Copies of the print server manuals and the RFID Programming Guide are available at
http://www.zebra.com/manuals or on the user CD that came with your printer.
Parameter Action/Explanation
Calibrate RFID Tag
RUN If the media being used does not conform to transponder placement
RFID TAG CALIB requirements for your printer, use the RUN option to have the printer
RESTORE RUN determine the optimum programming position for the non-standard labels.
Important Do not perform transponder calibration for RFID
media that meets the transponder placement specifications for your
printer. RFID tag calibration is necessary only if the transponder is
not in the ideal location for programming at the printers default
position.
The printer feeds an RFID label one millimeter at a time while taking
readings (via the READ TAG command and the WRITE TAG commands)
to profile the RFID transponder. Based on the results, the printer
determines the optimum programming position for the media and saves the
position to nonvolatile memory (the value is saved even if the power is
turned off). The calibrated value is used as the programming position for
the ^RS command unless the command specifies a different value.
Tag calibration takes into account the print mode, backfeed mode, and tear
off position. The ^HR ZPL command performs the same calibration and
returns a results table to the host. An auto-calibration occurs after the tag
calibration. This realigns the media to its proper rest position and updates
the media tracking values in the printer.
To restore the programming position to the default:
1. Press to select RESTORE.
To calibrate an RFID tag:
1. Load the printer with RFID media.
2. Close the printhead.
3. Press to select RUN.
4.
View or Change RFID Read Power
This parameter displays the current value for RFID read power.
Default: 16
RFID READ PWR Selections: 0 to 30
16
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
Parameter Action/Explanation
View or Change RFID Write Power
This parameter displays the current value for RFID write power.
Default: 16
RFID WRITE PWR Selections: 0 to 30
16
To change the value shown:
1. Press SELECT to select the parameter.
2. Press PLUS (+) or MINUS (-) to scroll through the options.
3. Press SELECT to accept any changes and deselect the parameter.
RFID Error Status
During an error condition, an error message shows on the second line of the
display. This field cannot be modified. For more information on an error
RFID ERR STATUS message, refer to the RFID Programming Guide.
This section provides information about LCD, print quality, communications, and other errors
that you might need to troubleshoot. The tables provide symptoms, diagnoses of probable
causes, and recommended actions that should result in proper printer operation. Working with
these tables, the technician can diagnose printer faults and determine the needed repair.
Contents
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Troubleshooting Checklists
If an error condition exists with the printer, review this checklist:
Is there an error message on the LCD? If yes, see LCD Error Messages on page 103.
Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media
and Ribbon Sensor Sensitivity on page 86.
Is the printer reporting a ribbon error when ribbon is loaded properly? If yes, see Calibrate
Media and Ribbon Sensor Sensitivity on page 86.
Are you experiencing problems with print quality? If yes, see Print Quality Problems
on page 107.
Are you experiencing communications problems? If yes, see Communications Problems
on page 111.
If the labels are not printing or advancing correctly, review this checklist:
Are you using the correct type of labels? Review the types of label in Types of Media
on page 50.
Are you using a label that is narrower than the maximum print width? See Set Print Width
on page 77.
Review the label- and ribbon-loading illustrations in Load Media on page 43 and Load
Ribbon on page 59.
Does the printhead need to be adjusted? See Adjust Printhead Pressure on page 65 for
more information.
Do the sensors need to be calibrated? See Calibrate Media and Ribbon Sensor Sensitivity
on page 86 for more information.
If none of the above suggestions correct the problem, review this checklist:
Perform one or more of the self-tests given in Printer Diagnostics on page 115. Use the
results to help identify the problem.
If you are still having problems, see Contacts on page 21 for customer support
information.
LCD Display/
Possible Cause Recommended Solution
Printer Condition
The printhead was replaced with Install a genuine Zebra printhead.
ERROR CONDITION one that is not a genuine Zebra
INVALID HEAD printhead.
1
2
LCD Display/
Possible Cause Recommended Solution
Printer Condition
Ribbon is loaded, but the printer is Ribbon is not required with direct
WARNING set for direct thermal mode. thermal media. If you are using direct
RIBBON IN thermal media, remove the ribbon. This
error message will not affect printing.
The RIBBON light is on; the If you are using thermal transfer media,
ERROR light flashes. The which requires ribbon, set the printer
ERROR light flashes. for Thermal Transfer mode. See Select
Print Method on page 77.
The media is not loaded or is Load media correctly. See Load Media
ERROR CONDITION loaded incorrectly. on page 54.
PAPER OUT
Misaligned media sensor. Check position of the media sensor.
The printer stops; the The printer is set for Install proper media type, or reset
ERROR light flashes. noncontinuous media, but printer for current media type and
continuous media is loaded. perform calibration.
The printhead is not fully closed. Close printhead completely.
ERROR CONDITION
HEAD OPEN The head open sensor is not Replace the sensor.
working properly.
The printer stops; the
ERROR light flashes.
The printhead has a faulty Replace the printhead.
THERMISTOR thermistor.
FAULT
LCD Display/
Possible Cause Recommended Solution
Printer Condition
The printer prints while the The printhead temperature is Continue printing while the printhead
ERROR light flashes. approaching its lower operating reaches the correct operating
limit. temperature. If the error remains, the
environment may be too cold for
proper printing. Relocate the printer to
a warmer area.
The printhead data cable is not
Caution Turn off (O) the printer
properly connected. before performing this procedure.
Failure to do so can damage the
printhead.
1. Turn off (O) the printer.
2. Disconnect and reconnect the data
cable to the printhead.
3. Ensure that the cable connector is
fully inserted into the printhead
connector.
4. Turn on (I) the printer.
The printer stops; the The printhead is over temperature. Allow the printer to cool. Printing
ERROR light flashes. automatically resumes when the
printhead elements cool to an
acceptable operating temperature.
LCD Display/
Possible Cause Recommended Solution
Printer Condition
The printer is defragmenting
DEFRAGMENTING Caution Do NOT turn off the printer
memory. power during defragmenting. Doing so
can damage the printer.
ERROR CONDITION Caution The cutter blade is sharp. Do not touch or rub the blade
CUTTER JAM with your fingers.
The cutter blade is in the media Turn off the printer power and unplug
The printer stops; the path. the printer. Inspect the cutter module
ERROR light flashes. for debris and clean as needed
following the cleaning instructions in
Clean the Cutter Module on page 130.
Calibration Problems
Table 16 identifies problems with calibration, the possible causes, and the recommended
solutions.
Communications Problems
Table 17 identifies problems with communications, the possible causes, and the recommended
solutions.
Ribbon Problems
Table 18 identifies problems that may occur with ribbon, the possible causes, and the
recommended solutions.
The ribbon light is on The printer was not calibrated Perform the calibration procedure in Calibrate
even though ribbon is for the label and ribbon being Media and Ribbon Sensor Sensitivity on page 86.
loaded correctly. used.
The LCD is missing The LCD may need replacing. Run the Power-On Self Test on page 115 and
characters or parts of check that the LCD display shows all characters.
characters If not, replace the LCD.
A firmware command changed Refer to the Programming Guide for the printer
the parameter back to the language being used.
previous setting.
A ZPL command changed the
parameter back to the previous
setting.
All lights are on, but Internal electronic or firmware Turn the printer power off (O) and then on (I). If
nothing displays on failure. the printer locks up again, replace the main logic
the LCD, and the board.
printer locks up.
The printer locks up Main logic board failure. Replace the main logic board.
while running the
Power-On Self Test.
Printer Diagnostics
Self tests and other diagnostics provide specific information about the condition of the printer.
The self tests produce sample printouts and provide specific information that helps determine
the operating conditions for the printer. The most commonly used are the Power-On and the
CANCEL self tests.
Important Use full-width media when performing self tests. If your media is not wide
enough, the test labels may print on the platen roller. To prevent this from happening, check
the print width using Set Print Width on page 77, and ensure that the width is correct for the
media that you are using.
Each self test is enabled by pressing a specific control panel key or combination of keys while
turning on (I) the printer power. Keep the key(s) pressed until the first indicator light turns off.
The selected self test automatically starts at the end of the Power-On Self Test.
Note
When performing these self tests, do not send data to the printer from the host.
If your media is shorter than the label to be printed, the test label continues on the next
label.
When canceling a self test prior to its actual completion, always reset the printer by
turning it off (O) and then on (l).
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).
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.
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.
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
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.
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.
5. Note the relative darkness value and the print speed printed on the best test label.
6. Add or subtract the relative darkness value from the darkness value specified on the
configuration label. The resulting numeric value is the best darkness value for that specific
label/ribbon combination and print speed.
7. If necessary, change the darkness value to the darkness value on the best test label. See
Adjust Print Darkness on page 72.
8. If necessary, change the print speed to the same speed as on the best test label. See Adjust
Print Speed on page 73.
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.
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.
1. Set the print width equal to or less than the label width being used for the test. See Set
Print Width on page 77 for more information.
2. Set the printer to DIAGNOSTICS. For instructions, see Set Communications Mode
on page 90.
The printer enters diagnostics mode and prints any data received from the host computer
on a test label
3. Check the test label for error codes. For any errors, check that your communication
parameters are correct.
Errors show on the test label as follows:
FE indicates a framing error.
OE indicates an overrun error.
PE indicates a parity error.
NE indicates noise.
4. Turn the printer off (O) and then back on (I) to exit this self test and return to normal
operation.
Sensor Profile
Use the sensor profile label to troubleshoot the following types of problems:
If the media sensor experiences difficulty in determining gaps (web) between labels.
If the media sensor incorrectly identifies preprinted areas on a label as gaps (web).
If the ribbon sensor cannot detect ribbon.
For instructions on printing a sensor profile, see Print Sensor Profile on page 85. If the
sensitivity of the sensors must be adjusted, perform Calibrate Media and Ribbon Sensor
Sensitivity on page 86.
Ribbon Sensor Profile (Figure 21) The bars (1) on the sensor profile indicate the ribbon
sensor readings. The ribbon sensor threshold setting is indicated by the word RIBBON (2). If
the ribbon readings are below the threshold value, the printer does not acknowledge that
ribbon is loaded.
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.
1 2
3 4
This section provides various levels of printer maintenance required for optimum
performance. This section also provides information on cleaning and general maintenance,
replacement of major assemblies, and mechanical adjustments.
Contents
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
This scection shows various levels of prventative maintenance including cleaning procedures
and schedules.
Contents
Cleaning Schedule and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Clean the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . 132
Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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.
.
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.
1 Printhead assembly
2 Platen roller
Caution The printhead may be hot and could cause severe burns. Allow the printhead
to cool.
Caution Before touching the printhead assembly, discharge any built-up static electricity
by touching the metal printer frame or by using an antistatic wriststrap and mat.
3. Using the swab from the Preventive Maintenance Kit (part number 47362), wipe along the
brown strip on the printhead assembly from end to end. In place of the Preventive
Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol
(minimum 90%) and deionized water (maximum 10%). Allow the solvent to evaporate.
4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the
solvent to evaporate.
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.
Caution For personnel safety, always power off and unplug the printer before performing
this procedure.
1. Turn the printer off (O), and unplug the printer from its power source.
2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.
Remove the cutter shield (1) by removing the cutter shield thumbscrew and lock
washer (2).
1 2
3. To expose the V-shaped cutter blade, turn the cutter motor thumbscrew (1)
counterclockwise to lower the blade.
4. See Figure 24. Using the swab from the Preventive Maintenance Kit (part number 47362),
wipe along the upper cutting surface (1) and the cutter blade (2). In place of the
Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl
alcohol (minimum 90%) and deionized water (maximum 10%). Allow the solvent to
evaporate.
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.
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.
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.
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).
Contact your authorized Zebra reseller for part ordering information, or see Contacts
on page 21 for contact addresses and telephone numbers.
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.
Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Contents
Print System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Roller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Outer Casing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
RFID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
Notes ___________________________________________________________________
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This section provides replacement, conversion and installation procedures for the
ZM400/ZM600 print system.
Contents
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Printhead Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Magnetic Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Printhead Assembly
This procedure is for installing the Printhead Assembly. Read these ionstructions throughy
before performing this procedure.
Note For optimal printing quality and proper printer performance across our product line,
Zebra strongly recommends the use of genuine Zebra supplies as part of the total solution.
Specifically, the ZM400 and ZM600 are designed to work only with genuine Zebra
printheads, thus maximizing safety and print quality.
Tools Required
Open the media door and remove the media and ribbon.
2.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
3. See Figure 25. Take note of the position of the pressure dials and then rotate the printhead
pressure dials to the #1 position.
ZM400 ZM600
1 Position #1
2 Pressure dial
If Then
No Continue with step 5.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Go to Remove the Cutter Assembly on page 146.
5. See Figure 26. Locate and remove the thumbscrew from the print mechanism.
1 Print mechanism
2 Thumbscrew
6.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
See Figure 27. Open the print mechanism and latch it in the vertical position.
7.
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
1 Printhead assembly
2 Print mechanism
3 Printhead data cable connector
4 Printhead power cable connector
5 Latch assembly
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.
8
3
5
6
1 Thumbscrew
2 Ribbon guide plate
3 Alignment holes (2)
4 Alignment pins (2)
5 Printhead ribbon guide
6 Platen housing
7 Forks (2)
8 Bearings (2)
3. See Figure 27 on page 143. Connect both printhead power and data cables to the printhead
connectors and carefully slide them into position. Ensure the cables are in their proper
channels and are not binding the printhead.
Note When mounting the printhead fork assembly onto the print mechanism, visually
inspect and ensure the cables are in their channels at the back of their carrier assembly,
power cable under data cable, and are not binding on the print mechanism.
4. See Figure 28 and Figure 29. Tip the printhead fork assembly slightly and insert the
printhead ribbon guide into the print mechanism as shown.
5. See Figure 28 and Figure 29. Tip the printhead fork assembly up and into the print
mechanism ensuing that the two locating protrusions on either side of the print printhead
snap into the locating holes of the ribbon guide plate. Move the assembly back and forth to
be sure that it is engaged. There should be little movement.
1 1
2 2
3
3
4 4
5 5
1 Thumbscrew
2 Print mechanism
3 Printhead fork assembly
4 Ribbon guide plate
5 Printhead ribbon guide
6. While holding the printhead in place, install the thumb screw to secure the fork assembly.
8. See Figure 25 on page 141. Rotate the two printhead pressure dials to the desired position
for your daily printing.
If Then
No Continue with step 10.
Yes Got to Reinstall the Cutter Assembly on page 147.
10.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.
5 4 3 2
1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness
Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.
3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.
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.
4.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Print Mechanism
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
3. See Figure 31. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 32. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 33. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
If Then
No Go to Gain Access to the Power Supply on page 157.
Yes Continue with Remove the Zebra Wireless Board.
2. See Figure 34. Press in on the eject button to remove the radio card.
1 Eject button
2 Radio card
3. See Figure 35. Remove the screw from the upper left corner of the wireless board.
4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).
1 Wireless board
2 Mounting screws (4)
2 3
4
1 Rear cover
2 Antenna connector
3 Lock washer
4 Mounting nut
5 Antenna
2. See Figure 37. Remove the top left mounting screw securing the SEH IPv6 print server
board.
5
4
3. Remove the three SEH IPv6 print server board mounting screws securing it to the MLB.
4. Remove the SEH IPv6 print server board from the printer.
5. See Figure 38. Remove the three wireless mounting standoffs from the MLB.
1 MLB
2 Mounting standoffs (3)
2. See Figure 39. Remove the standoff from the upper left of the power supply shield.
3. Remove the mounting screw from the upper right of the power supply shield.
1 Mounting screw
2 Mounting standoff
3 Power supply shield
4. See Figure 40. Pull the top of the shield away from the main frame and fold it down to
access the printhead power connector.
1 Shield
If Then
No Go to step 1 on page 160.
Yes Continue with step 1.
1.
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
See Figure 41. Remove the printhead ribbon cable clip by lifting up on the tabs and then
pulling it away from the main logic board.
Note Some models have a ribbon cable retaining clip on the printhead data cable for
shipping purposes. It may be left off if you ensure that the printhead data cable is properly
seated into the main logic board MLB connector P19 upon reinstallation of the cable.
2. Drop it slightly out of the printhead connect and then remove it from the printer.
3 3
1 2 4
5
6
9 8 7
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.
If Then
No Go to Remove the Print Mechanism on page 162.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Continue with Remove the Cutter Assembly.
2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.
5 4 3 2
1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness
Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.
3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.
1 Print mechanism
2 Washers (2)
3 Screws (3)
2. Remove the printhead housing assembly from the printer. Guide the print mechanism
cable out through the access hole after removing the print mechanism.
2. Install the three print mechanism mounting screws and two washers.
4. See Figure 42 on page 160. Route the printhead power cable under the stepper motor and
up to the power supply.
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. See Figure 45. Insert the bottom locating tab into the bottom hole in the main logic board
(MLB) connector and then lift up and around with the upper locating tab in the top hole of
the MLB connector.
9. Install the printhead data cable into the flat cable clip on the base of the printer.
10. Connect the ground strap from the print mechanism to the printer.
11. See Figure 40 on page 158. Close the shield on the power supply and then reinstall the
standoff and mounting screw.
If Then
No Go to Reinstall the Electronics Cover on page 165.
Yes Continue with the next step.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 48. Using the screw provided in the kit, install the print mechanism adjustment
cam on the printer main frame.
Note The cam should be in contact with print mechanism. Just snug the cam in place.
3. See Figure 47. Insert the print mechanism gap pin gauges through the holes that are
provided in the front of the ribbon guide plate.
4. See Figure 44 on page 162. Slightly loosen the three print mechanism mounting screws.
5. See Figure 47. Place a 10 cm adjustable wrench on the print mechanism adjustment cam.
While turning the wrench counterclockwise, push in and pull out the inside gap pin gauge
until a small amount of friction can be felt.
6. After aligning the inside pin gauge, use a screwdriver and turn the adjustment screw on
top of the latch plate strike.
7. Push in and pull out the outside gap pin gauge until a small amount of friction can be felt.
Double check both pin gauges for equal amount of friction.
9. Tighten the print mechanism mounting screws when equal pressure is obtained.
2. See Figure 49. Push down on the print mechanism with a flat blade screw driver while
pushing in and pulling out the inside gap pin gauge until a small amount of friction can be
felt. Snug the two hex head screws.
Note On most printers, the print mechanism housing aligns with the mounting boss on
the main frame.
4
1
2
3
1 Screwdriver
2 Main frame
3 Print mechanism
4 Main frame mounting boss
3. See Figure 47 on page 166. After adjusting the inside pin gauge, use a screwdriver and
turn the adjustment screw on top of the latch plate strike.
4. Push in and pull out the outside gap pin gauge until a small amount of friction can be felt.
5
4
1 Printhead housing
2 Gap, 1.25 mm (0.050 in.)
3 Ribbon/Printhead open sensor
4 Mounting screw
5 Ribbon guide plate
2. Use a 1.25 mm (0.050 in.) feeler gauge and check the distance between the ribbon/head
open sensor assembly and the ribbon guide plate.
If the distance is incorrect, loosen the mounting screw for the ribbon/head open sensor and
adjust for the proper distance. Once this distance is achieved, tighten the mounting screw.
If Then
No Continue with step 4.
Yes Go to Reinstall the Cutter Assembly on page 170.
4.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
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.
4.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Printhead Cables
Tools Required
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove the media and ribbon.
3. See Figure 51. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 52. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 53. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
If Then
No Go to Gain Access to the Power Supply on page 178.
Yes Continue with Remove the Wireless Board.
2. See Figure 54. Press in on the eject button to remove the radio card.
1 Eject button
2 Radio card
3. See Figure 55. Remove the screw from the upper left corner of the wireless board.
4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).
1 Wireless board
2 Mounting screws (4)
2 3
4
1 Rear cover
2 Antenna connector
3 Lock washer
4 Mounting nut
5 Antenna
2. See Figure 57. Remove the top left mounting screw securing the SEH IPv6 print server
board.
5
4
3. Remove the three SEH IPv6 print server board mounting screws securing it to the MLB.
4. Remove the SEH IPv6 print server board from the printer.
2. See Figure 58. Remove the standoff from the upper left of the power supply shield.
3. Remove the mounting screw from the upper right of the power supply shield.
1 Mounting screw
2 Mounting standoff
3 Power supply shield
4. See Figure 59. Pull the top of the shield away from the main frame and fold it down to
access the printhead connector.
1 Shield
5. See Figure 61 on page 181. Unplug the printhead power cable from J3 on the power
supply.
If Then
No Go to step 8 on page 180.
Yes Continue with step 6.
6.
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
See Figure 60. Remove the printhead ribbon cable clip by lifting up on the tabs and then
pulling it away from the main logic board.
Note Some models have a ribbon cable retaining clip on the printhead data cable for
shipping purposes. It may be left off if you ensure that the printhead data cable is properly
seated into the main logic board MLB connector P19 upon reinstallation of the cable.
7. Drop the clip slightly out of the printhead connect and then remove it from the printer.
8. Unplug the printhead data cable from P19 on the main logic board (MLB).
2
3
10. Turn the printer around and open the media door.
Front Front
3 3 3 3
ZM400 ZM600
2.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
If Then
No Continue with step 4.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Go to Remove the Cutter Assembly on page 192.
4. See Figure 63. Remove the thumbscrew to loosen the printhead fork assembly.
1 Thumb screw
2 Printhead fork assembly
5. See Figure 64. Unlatch the print mechanism, and then lift and latch it in the open position.
1 Print mechanism
2 Printhead data cable
3 Printhead power cable
4 Printhead assembly
5 Platen housing
8. See Figure 65. Disconnect the ground cable from the print mechanism by removing the
screw securing it.
1 Ground cable
2 Mounting screw
9. See Figure 66. Guide the printhead cable connectors through the gap in the print
mechanism and discard them.
1 Cable connector
2 Gap
1 2
1 Cable connector
2 Print mechanism
3 Ground cable
2. Tightly secure the ground cable to the printer with the screw previously removed.
3. See Figure 66 on page 185. Tightly secure the ground cable to the print mechanism.
4. See Figure 68. Align the two forks with the bearings and set the printhead assembly onto
the platen housing.This is done for ease of connecting the printhead cables.
5.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or display HEAD COLD or other false error
messages.
7
2
3
1 Thumbscrew
2 Alignment holes (2)
3 Cable guide
4 Alignment pins (2)
5 Platen housing
6 Forks (2)
7 Bearings (2)
6. See Figure 64 on page 183. Connect both printhead power and data cables to the printhead
connectors.
7. See Figure 69. Tip the printhead fork assembly slightly and insert the printhead ribbon
guide into the print mechanism as shown.
Note When mounting the printhead fork assembly onto the print mechanism, visually
inspect and ensure the cables are in their channels at the back of their carrier assembly,
power cable under data cable, and are not binding on the print mechanism.
8. Tip the printhead fork assembly up and into the print mechanism ensuing that the two
locating protrusions on either side of the print printhead snap into the locating holes of the
ribbon guide plate. Move the assembly back and forth to be sure that it is engaged. There
should be little movement.
9. While holding the printhead in place, install the thumb screw to secure the fork assembly.
1 1
2 2
3
3
4 4
5 5
1 Thumbscrew
2 Print mechanism
3 Printhead fork assembly
4 Ribbon guide plate
5 Printhead ribbon guide
10. Clean the printhead with the Zebra preventative maintenance kit.
11. See Figure 62 on page 181. Rotate the two printhead pressure dials to the desired position
for your daily printing.
12. See Figure 70. Route the printhead power cable as shown and then connect it to J3 on the
power supply board.
13. Insert the printhead power cable into the two cable clips shown.
14. Ensure that the printhead power cable is routed around the standoff as shown.
8
9
11 10
15. Install the cable tie around all three printhead cables at the location shown in Figure 70.
Be sure to clip off the excess cable tie.
16.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or a false HEAD COLD message to display
while the printhead is hot enough to cause severe burns. Allow the printhead to cool.
See Figure 70 on page 189. Route the printhead data cable connector under the main
logic board (MLB) mounting bracket and then connect it to P19 on MLB.
17. See Figure 71. Insert the bottom locating tab into the bottom hole in the main logic board
(MLB) connector and then lift up and around with the upper locating tab in the top hole of
the MLB connector.
18. Ensure that all connectors are properly seated into their connectors.
19. See Figure 59 on page 179. Lift the power supply shield back into place.
If Then
No Go to Reinstall the Electronics Cover on page 193.
Yes Go to Reinstall the Electronics Cover on page 193.
2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.
5 4 3 2
1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness
Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.
3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.
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.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove the media and ribbon.
3. See Figure 74. Remove the two mounting screws securing the ribbon strip plate to the
print mechanism.
1 Print mechanism
2 Ribbon strip plate
3 Mounting screws (2)
3. Align the strip plate with the screw heads in the center of the slots in the ribbon strip plate.
4.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
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.
If Then
No a. Tighten the mounting screws.
b. Installation is complete.
Yes Continue with Adjust the Strip Plate.
2. Loosen the two mounting screws securing the strip plate to the front of the print
mechanism assembly.
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.
Printhead Latch
Tools Required
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
See Figure 75. Open the media door and remove the media and ribbon.
1 Media door
2 Strike plate cap
3 Latch assembly
3. See Figure 76. Remove the strike plate cap by placing a small screwdriver under the front
edge and lifting upward.
4
5
6
14
7 8
9 11
10
13 12
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.
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.
7. Remove the shoulder screw and wave washer securing the latch assembly to the platen
housing and remove the latch assembly.
3. See Figure 77. Install the adjustment screw into the strike plate by sliding it in the opening
with the shoulder below the top piece of sheet metal and above the bottom piece of sheet
metal.
1 Strike plate
2 Adjustment screw
3 Adjustment screw shoulder
5. See Figure 76 on page 200. Tighten the adjustment screw until the top of the strike plate is
just below the top of the print mechanism.
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.
2. Turn the adjustment screw until a small amount of friction is felt on the gap pin gauge.
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.
If Then
No Continue with step 6.
Yes Go to step 13.
7. See Figure 79. Install the print mechanism adjustment cam on the printer frame with the
screw provided in the kit.
1 Print mechanism
2 Adjusting cam
3 Hex head mounting screws (2)
4 Large washer
5 Hex head mounting screw no washer
8. Slightly loosen the three screws that secure the print mechanism assembly to the
mainframe.
9. Use an adjustable wrench on the print mechanism adjustment cam. While turning the
wrench counterclockwise, push in and pull out the inside gap pin gauge until a small
amount of friction can be felt. Snug the two hex head screws.
10. After aligning the inside gap pin gauge, verify that the outside adjustment is correct.
Double-check both gap pin gauges for equal amount of friction. Tighten the latch strike
plate screws.
11. See Figure 79. Tighten the three printhead mechanism mounting screws when equal
pressure is obtained.
12. Remove the print mechanism adjustment cam by removing the mounting screw.
13. See Figure 76 on page 200. Install the strike plate cap.
14.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door, open the printhead, and remove media and ribbon.
3.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
4. See Figure 80. Close the printhead and rotate the printhead pressure dials to the #1
position.
ZM400 ZM600
1 Postion #1
2 Pressure dial
3 Position #4
4 Position #8
5.
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
2
1
4
5
7
6
6.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the print mechanism, and lift and latch it in the vertical position.
9. Remove the printhead assembly and set it aside on the antistatic mat.
To remove the pressure dials you must partially disassemble the print mechanism.
10. See . Place a soft pad down on your workbench and lay the printer on it with the
electronics cover side down.
12. See Figure 82. Put a piece of masking tape over the pressure roller to secure it to the
pressure bracket.
This is being done for ease of reinstallation of the roller and bracket.
1
7
8
3
1 Print mechanism
2 Pressure bracket
3 Masking tape (2)
4 Pressure bracket mounting screw
5 Lifting spring
6 Lower print mechanism latch screw
7 Upper print mechanism latch screw
13. Remove the lower print mechanism latch screw and then remove the stabilizer.
14. Remove the pressure bracket mounting screw, and swing the bracket out of the way.
15. See Figure 83. Remove and discard the dials and springs from the print mechanism.
1
2
1 Pressure dial
2 Spring
2. See Figure 83 on page 209. Insert the new dials and springs into the print mechanism.
3. See Figure 82 on page 208. Reinstall the pressure bracket and roller, and then remove the
masking tape.
4. Reinstall the stabilizer by inserting it into the print mechanism until it stops.
6. See Figure 81 on page 207. Connect the printhead cables to the printhead fork assembly.
Lift the assembly and carefully slide the assembly into the print mechanism, ensuring the
data cable and power cable are kept away from the printhead lifting spring (see Figure 82
on page 208).
7. Route the printhead cables over the top of the wire guide.
8. See Figure 85. Align the two alignment pins on the printhead with the two alignment holes
in the print mechanism.
7
2
1 Thumbscrew
2 Alignment holes
3 Wire guide
4 Alignment pins
5 Platen housing
6 Forks (2)
7 Bearings (2)
9. Lift and hold the printhead in position while securing it with the previously removed
thumbscrew and then close the print mechanism.
11. Open the print mechanism and latch it in the open position.
12.
Caution Do not use sharp objects to clean the printhead or platen roller.
Using the Zebra Preventive Maintenance Kit, clean the printhead and platen roller.
13.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
14. See Figure 80 on page 206. Rotate the two printhead pressure dials to the desired position
for your daily printing.
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 86. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 87. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 88. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
7.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
Anytime you expose electronic printed circuit boards, connect yourself to an antistatic
device.
2. See Figure 90. Remove and discard the old magnetic strike plate mounting screw.
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.
1
2
1 Mounting hole
2 Tabs (4)
3 Magnetic latch
2. Push the magnetic latch into the mounting hole until all four tabs snap into the housing
and the magnetic latch is secure.
3. See Figure 92. Slide the tab of the magnetic latch clamp into the magnetic latch slot on the
right side of the latch and then press on the left side of the clamp to snap it into the slot on
the left side.
1 Magnetic latch
2 Magnetic latch clamp
3 Tabs (2)
4 Slot (2)
4. See Figure 90 on page 216. Install the new magnetic latch strike plate.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
This section provides replacement and installation procedures for the ZM400/ZM600 sensors.
Contents
Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Sensor Assemblies
Tools Required
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove the media and ribbon.
3. See Figure 94. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 95. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 96. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
If Then
No Go to Access the Power Supply on page 227.
Yes Continue with Remove the Wireless Board.
2. See Figure 97. Press in on the eject button to remove the radio card.
1 Eject button
2 Radio card
3. See Figure 98. Remove the screw from the upper left corner of the wireless board.
4. Remove the two lower mounting screws and then remove the wireless board from the
main logic board (MLB).
2
3
1 Wireless board
2 Mounting screws (3)
3 Main logic board (MLB)
2. See Figure 99. Remove the mounting stud from the upper left of the power supply shield.
3. Remove the mounting screw from the upper right of the power supply shield.
1 Mounting screw
2 Mounting stud
3 Power supply shield
4. See Figure 100. Pull the top of the power supply shield away from the main frame and
fold it down to access the stepper motor connector.
7
4
6 5
1 Power supply, J2
2 Stepper motor cable routing
3 Stepper motor
4 Platen pulley
5 Drive belt
6 Locking screw
7 Pivot screw
5 Drive belt
6 Locking screw
7 Pivot screw
4. Remove the pivot screw and then remove the stepper motor.
2. See Figure 102. Disconnect the upper media sensor cables from J3 and P7 of the main
logic board (MLB).
3 2
3. Disconnect the lower media sensor cable from P9 of the main logic board (MLB).
1 2
5 4
2. Remove the mounting screw and split washer from the lower media sensor assembly.
3.
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
See Figure 104. Release the dancer spring from the dancer spring stop
4. See Figure 105. Slowly slide the lower media sensor assembly out of the printer, while
guiding the sensor cable through the hole in the main frame.
The cable connector will need to be turned sideways.
5. Slowly slide the upper media sensor assembly out of the printer, while guiding the sensor
cables through the holes in the main frame.
2.
Caution The end of the shaft has barbs that are used for alignment. Use caution not to
damage the barbs.
2 1
3
1 Shaft
2 Protective cap
3 Barbs
3. See Figure 107. Guide the cable of the lower media sensor through the access hole in the
main frame.
1 2
4. Slide the lower media sensor assembly into the mounting hole while aligning the two
locating pins with the opening in the main frame until it stops.
5. Turn the shaft in the hole to ensure that the barbs are in the slots on the inside of the main
frame mounting hole.
6. See Figure 103 on page 231. While holding the lower media sensor in the slots, install the
mounting screw and washer.
2.
Caution The end of the shaft has barbs that are used for alignment. Use caution not to
damage the barbs.
2 1
3
1 Shaft
2 Protective cap
3 Barbs
3. See Figure 109. Guide the cables of the upper media sensor through their proper access
holes in the main frame.
4. Slide the upper media sensor assembly into the mounting hole until it stops.
5. See Figure 104 on page 232. Relocate the arm of the dancer spring onto the dancer spring
stop.
6. Turn the shaft in the hole to ensure that the barbs are in the slots on the inside of the main
frame mounting hole.
7. See Figure 103 on page 231. While holding the upper media sensor in the slots, install the
mounting screw, lock washer, and flat washer.
2. Reinstall the locking screw and nut, but do not tighten at this time.
Note The drive belt should deflect under finger pressure but no more than 6 mm
(1/4 in.).
3. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.
4. Route the stepper motor cable as shown and connect it to J2 on the power supply.
5. See Figure 99 on page 227 and lift the power supply shield back into place.
If Then
No Continue with Reinstall the Electronics Cover.
Yes a. See Figure 98 on page 226 and replace the wireless board.
b. See Figure 97 on page 225 and replace the radio card.
c. Continue with Reinstall the Electronics Cover.
4. See Figure 94 on page 223. Reinstall the electronics cover mounting screw and lock
washer.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Squeeze
Here
1
2 3
2
Squeeze
Here
1 Mounting screw
2 Gapping shim
3 Notch
2
2
Squeeze
Here
Tools Required
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove the media and ribbon.
3. See Figure 112. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 113. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 114. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
2. See Figure 115. Unplug the ribbon/printhead open sensor cable from P4 on the main logic
board (MLB).
1 2 3 4
4. See Figure 116. Remove the screw securing the ribbon/head open sensor assembly.
Note You may find it easier to lay the printer on its side for easy access to the mounting
screw.
5. Pull the ribbon sensor cable and connector through the main frame.
Access Hole
Mounting Hole
2. Place the sensor cable wires back into the protective wrap.
4. Install the ribbon/head open sensor to the mainframe with the new screw. Do not tighten it
at this time.
5. See Figure 118. Check the gap on the ribbon/printhead open sensor and adjust as
necessary.
5
4
1 Printhead housing
2 Gap, 1.25 mm (0.050 in.)
3 Ribbon/Printhead open sensor
4 Mounting screw
5 Ribbon guide plate
6. Using a 1.25 mm (0.050 in.) feeler gauge, check the distance between the ribbon/head
open sensor assembly and the ribbon guide plate.
If the distance is incorrect, loosen the mounting screw for the ribbon/head open sensor and
adjust for the proper distance. Once this distance is achieved, tighten the mounting screw.
1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)
3. See Figure 113 on page 244. Install the four mounting screws.
6.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
7. If the ribbon/head open sensor is not recognized by the main logic board see your User
Guide for calibration and setup procedures.
Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
This section provides replacement and installation procedures for the ZM400/ZM600 drive
system.
Contents
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Drive Belt Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Stepper Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Ribbon Take-up Spindle Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Printhead Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Peel Maintenance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Media Hanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Sheet Metal Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Outer Guard Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Media Edge Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Drive System
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 120. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 121. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 122. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
8.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
9. See Figure 123. Lay the printer on its side, media door down on a mat.
1 Gear cover
2 Mounting screw
10. See Figure 124. Mark the proper mounting hole in the gear cover.
You will use this mark as areference when you reinstall the gear cover.
1 Mounting screw
2 Gear cover
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.
12. Slide the cover off the drive assembly and discard.
13. Mark the outside facing side of the compound gear and remove it.
You will use this mark as areference when you reinstall the compound gear.
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.
2
7
203 dpi
3
6
4 5
2 300 dpi
7
300/600 dpi 600 dpi
3
8
4
5
1 Gear cover
2 Compound gear mounting screw
3 Stepper motor pivot screw
4 Stepper motor locking screw
5 Platen pulley set screws (2)
6 Platen pulley (203 dpi)
7 Compound Gear
8 Platen pulley (300/600 dpi)
2. See Figure 125. Slide the new platen pulley onto the platen roller shaft in the proper
orientation to approximately 1/32 in. (0.80 mm) from the main frame and then tighten the
platen pulley set screws.
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.
Note The belt should deflect under finger pressure but no more than inch (6 mm).
7. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.
8. See Figure 124 on page 256. With the marked side facing out slide the compound gear
into the printer. Ensure that the gears mesh.
Note Look at the old compound gear to see what side you marked for facing out.
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.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 121 on page 254. Install the four mounting screws.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
2. See Figure 127. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
4. See Figure 128. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
5. See Figure 129. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 2
3
5 4
1 Stepper motor
2 Pivot screw
3 Drive belt
4 Platen pulley
5 Locking screw
4. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.
Note The belt should deflect under finger pressure but no more than 6 mm (1/4 inch).
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 128 on page 261. Install the four mounting screws.
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove the media and ribbon.
3. See Figure 4. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 133. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 134. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 Eject button
2 Radio card
2. See Figure 136. Remove the screw from the upper left corner of the wireless board.
1 Wireless board
2 Mounting screws (4)
3. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).
2. Remove the mounting screw from the upper right of the power supply shield.
1 Mounting screw
2 Standoff
3 Power supply shield
3. See Figure 138. Pull the top of the shield away from the main frame and fold it down to
access the stepper motor connector.
1 Shield
2 Stepper motor cable
3 Stepper motor connector, J2
2. See Figure 139. Locate the stepper motor and drive belt.
7
4
6 5
1 Power supply, J2
2 Stepper motor cable routing
3 Stepper motor
4 Platen pulley
5 Drive belt
6 Locking screw
7 Pivot screw
4. Remove the pivot screw and then remove the stepper motor.
2. Reinstall the locking screw and nut, but do not tighten at this time.
Note Belt should deflect under finger pressure but no more than inch (6 mm).
3. Rotate the motor down until the drive belt is just taut. Tighten the locking screw and then
the pivot screw.
4. Route the stepper motor cable as shown and connect it to J2 on the power supply.
5. See Figure 137 on page 269 and lift the power supply shield back into place.
8. See Figure 136 on page 268 and replace the wireless board.
9. See Figure 135 on page 267 and replace the radio card.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 133 on page 266. Install the four mounting screws.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
1. See Figure 141. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
3. See Figure 142. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
4. See Figure 143. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 Gear cover
2 Mounting screw
2. See Figure 145. Mark the proper mounting hole in the gear cover.
This ensures correct installation when the ribbon take-up spindle installation is complete.
1 2
1 Gear cover
2 Mounting screw
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.
5. Mark the outside facing side of the compound gear and remove it.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.
2.
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
Loosen the two set screws on the ribbon take-up collar and slide the collar off of the shaft
and discard it.
3. See Figure 147. Remove and discard the plastic thrust washer, clutch bearing, hub, spring,
gear and washer or washers from the ribbon take-up (RTU) spindle shaft.
4 5 7
1
3
2 9
8
1 Collar
2 Set screws (2)
3 Thrust washer
4 Bearing and hub
5 Spring
6 Clutch gear
7 Flat washers (2)
8 RTU spindle shaft
9 0.50 mm gap between the collar and thrust washer
3. Slide the spring, thrust washer and collar onto the RTU spindle shaft.
4. Place a 0.50 mm feeler gauge between the thrust washer and the collar.
5. From the media side, push in on the RTU spindle and then tighten the two set screws in the
collar and ensure that the RTU spindle turns freely.
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 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)
2. See Figure 142 on page 276. Install the four mounting screws.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove the media and ribbon.
3. See Figure 149. Remove the screw and washer securing the electronics cover.
1 2
3
5 4
1 Electronics cover
2 Media cover
3 Upper flange
4 Mounting screw
5 Lock washer
6 Lower flange
4. See Figure 150. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 Gear cover
2 Mounting screw
2. See Figure 152. Mark the proper mounting hole in the gear cover.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.
1 Gear cover
2 Mounting screw
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.
5. Mark the outside facing side of the compound gear and remove it.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.
2. Loosen the two set screws on the ribbon take-up collar and slide the collar off of the shaft.
3. See Figure 154. Remove the plastic thrust washer, clutch gear assembly, and washer(s)
from the shaft of the ribbon take-up spindle assembly.
7 3
6 5
4
2
1
4. From the media side, remove the ribbon take-up assembly and washer.
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.
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 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)
4. Reconnect the AC power cord and data cables and then turn on (l) the printer.
Printhead Conversion
Note For optimal printing quality and proper printer performance across our product line,
Zebra strongly recommends the use of genuine Zebra supplies as part of the total solution.
Specifically, the ZM400 and ZM600 are designed to work only with genuine Zebra
printheads, thus maximizing safety and print quality.
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
1.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
2. See Figure 156. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
4. See Figure 157. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
5. See Figure 158. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 2 3
1 Pivot screw
2 Stepper motor
3 Drive belt
4 Set screws (2)
5 Platen pulley
6 Locking screw
2. Swing the stepper motor to the right to loosen the drive belt and then tighten the locking
screw to snug the motor in place.
3. Remove the drive belt from the stepper motor and then from the platen pulley and discard
it.
5. See Figure 160. Slide the platen pulley from the coupling assembly and discard it.
2
2
1 Setscrews (2)
2 Flats on shaft
2. See Figure 159 on page 293. Install the drive belt onto the platen pulley and the stepper
motor pulley.
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 Gear cover
2 Mounting screw
1 Mounting screw
2 Gear cover
3 Compound gear
1 2
5. See Figure 165. Turn the compound gear around to the proper dpi.
4. Install the mounting screw in the proper hole in the gear cover, through the compound
gear, and then into the proper mounting hole in the main frame.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 157 on page 292. Install the four mounting screws.
Caution The printhead may be hot and could cause severe burns. Allow the printhead to
cool.
1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
2. See Figure 167. Rotate the printhead pressure dials to the #1 position.
ZM400 ZM600
1 Postion #1
2 Pressure dial
If Then
No Continue with step 4.
Yes You may find it easier to replace the printhead with the cutter assembly
removed. Go to Remove the Cutter Assembly on page 306.
4. See Figure 168. Locate and remove the thumbscrew from the print mechanism.
1 Print mechanism
2 Thumbscrew
5. See Figure 169. Open the print mechanism and latch it in the vertical position.
6.
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
1 Printhead assembly
2 Print mechanism
3 Printhead data cable connector
4 Printhead power cable connector
5 Latch assembly
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.
7
2
3
1 Thumbscrew
2 Alignment holes (2)
3 Cable guide
4 Alignment pins (2)
5 Platen housing
6 Forks (2)
7 Bearings (2)
3. Connect both printhead power and data cables to the printhead connectors and carefully
slide them into position. Ensure the cables are in their proper channels and are not binding
the printhead.
Note When mounting the printhead fork assembly onto the print mechanism, visually
inspect and ensure the cables are in their channels at the back of their carrier assembly,
power cable under data cable, and are not binding on the print mechanism.
4. See Figure 171. Tip the printhead fork assembly slightly and insert the printhead ribbon
guide into the print mechanism as shown.
5. Tip the printhead fork assembly up and into the print mechamism ensuing that the two
locating protrusions on either side of the print printhead snap into the locating holes of the
ribbon guide plate. Move the assembly back and forth to be sure that it is engaged. There
should be little movement.
6. While holding the printhead in place, install the thumb screw to secure the fork assembly.
1 1
2 2
3
3
4 4
5 5
1 Thumbscrew
2 Print mechanism
3 Printhead fork assembly
4 Ribbon guide plate
5 Printhead ribbon guide
8. See Figure 167 on page 300. Rotate the two printhead pressure dials to the desired
position for your daily printing.
If Then
No Continue with step 10.
Yes Got to Remove the Cutter Assembly on page 306.
10.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
2.
Caution The cutter blade is sharp. Do not touch or rub the blade with your fingers.
5 4 3 2
1 Cutter assembly
2 Mounting screw
3 Printhead latch
4 Platen assembly hooks (2)
5 Cutter harness
Note The cutter guard does not need to be removed from the cutter assembly during this
procedure.
3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen
assembly hooks.
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.
4.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
3. See Figure 173. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 174. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 175. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 Gear cover
2 Mounting screw
2. See Figure 177. Mark the proper mounting hole in the gear cover.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.
1 Gear cover
2 Mounting screw
3 Mark the proper mounting hole.
4 Compound gear. Mark the side of the compound
gear that faces out.
5. Mark the outside facing side of the compound gear and remove it.
This is done to be sure it is mounted correctly when the ribbon take-up spindle installation
is complete.
If Then
No Go to step 6 on page 315.
Yes Continue to the next step.
1.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
2. See Figure 178. Press in on the eject button to remove the radio card.
1 Eject button
2 Radio card
3. See Figure 179. Remove the screw from the upper left corner of the wireless board.
4. Remove the two lower mounting screws and then remove the wireless board from the
main logic board (MLB).
1 Wireless board
2 Mounting screws (3)
5.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
6. See Figure 180. Disconnect the stepper motor cable from the power supply.
9. Swing the stepper motor to the right to loosen the drive belt.
10. Remove the drive belt from the stepper motor pulley.
12. See Figure 181. Remove the pivot screw and then slide the stepper motor out of the
printer.
3
1 2
4
5
1 Pivot screw
2 Stepper motor
3 Intermediate gear
4 Locking screw nut
5 Locking screw
14. See Figure 182. Remove the ribbon supply spindle (RSS) mounting screw and washer.
2
1
1 Mounting screw
2 Mounting washer
3 Washer
4 RSS
16. See Figure 183. Slide the spindle remove tool over the ribbon supply spindle on the
printer.
17. Install the screw into the end of the spindle assembly until it bottoms out.
18. Slide the washer over the end of the screw until it is against the remove tool.
1 Spindle assembly
2 Spindle remove tool
3 Washer
4 Screw
5 Nut
20. While holding the remove tool and using the nut driver, turn the nut clockwise to remove
the ribbon supply spindle from the printer.
21. Remove the nut, washer, and screw from the spindle.
1 2
1 Thin washer
2 Ribbon supply spindle shaft
3. See Figure 185. Place a small amount of grease on the tolerance rings of the ribbon supply
spindle shaft.
4. See Figure 183 on page 318. Slide the remove tool onto the new spindle assembly, then
gently push the ribbon supply spindle assembly into the printer main frame.
Important In step 4, do not use force or pound on the ribbon supply spindle or the
remove tool.
5. See Figure 186. Install the tool screw into the spindle shaft until it bottoms out.
6. Slide the washer over the end of the screw until it is against the main frame.
1 Nut
2 Screw
8. While holding the remove tool, turn the nut clockwise to draw the ribbon supply spindle
into the printer. Once the spindle is in the printer, turn the spindle nut turn
counterclockwise and remove the screw, nut, and washer.
9. See Figure 182 on page 317. Install the spindle mounting screw and washer.
10. See Figure 181 on page 316. Reinstall the intermediate gear, ensuring the gears mesh
properly.
11. Loosely reinstall the stepper motor using the pivot screw, locking screw, and adjustment
nut.
Note The belt should have some deflection, but no more than inch.
12. While lifting up on the stepper motor, reinstall the drive belt. Release the stepper motor to
provide tension on the belt.
13. Ensure the belt tension is correct and then tighten the locking screw to secure the motor.
15. Route the stepper motor cable up to the power supply connector stepper motor connector.
16. See Figure 180 on page 315. Reconnect the stepper motor to the power supply.
17. Fold the power supply shield back into place and reinstall the mounting screw and
mounting standoff.
Note Look at the old compound gear to see what side you marked for facing out.
4. Install the mounting screw in the proper hole in the gear cover, through the compound
gear, and then into the proper mounting hole in the main frame.
If Then
No Go to Reinstall the Electronics Cover on page 322.
Yes a. See Figure 179 on page 314. Reinstall the wireless board.
b. See Figure 178 on page 313. Reinstall the radio card.
c. Go to Reinstall the Electronics Cover on page 322.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 174 on page 310. Install the four mounting screws.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Note If your ribbon is wide, use the high tension setting. If you experience ribbon
slippage, use the low tension setting.
Media Hanger
Tools Required
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
6. Align the media hanger assembly with the mounting holes and then install the three
mounting screws supplied in the kit.
Caution Use the screws supplied in the kit to avoid damaging the peinter.
7.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
8. Reconnect the AC power cord and data cables and then turn on (l) the printer.
Tools Required
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
7. Align the media hanger assembly with the mounting holes and then install the two
mounting screws supplied in the kit.
Caution Use the screws supplied in the kit to avoid damaging the printer.
8.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
9. Reconnect the AC power cord and data cables and then turn on (l) the printer.
Tear-Off Bar
Tools Required
2. See Figure 190. Remove the front cover by pulling out on the upper corners of the cover
and then lifting it out of the printer.
1 Front cover
2 Mounting hooks
2
2
1 Tear-off bar
2 Tear-off bar mounting screws (2)
1
3
1 Tear-off bar
2 Platen housing
3 Horizontal mounting bar
4 Rest the pems on top of the horizontal mounting bar.
5 Mounting screws (2)
2. Lift the tear-off bar up slightly. See Figure 193. Push the tear-off bar back against the
horizontal mounting bar of the platen housing and then back down until the pems are
resting on the mounting bar.
Pems
3. Tighten the mounting screws while keeping pressure down on the tear-off bar.
Static Brush
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Open the media cover and remove all media and ribbon.
2. See Figure 194. Remove the two mounting screws securing the static brush assembly.
2. Reinstall the ribbon and media and close the media cover.
Cutter Option
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 195. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 196. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 197. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 Front cover
2 Mounting hooks
M
M
Detail B
Cutter
Assembly
2. See Figure 200. While holding the cutter assembly, route the cutter assembly wire harness
through the mainframe access hole.
2
4
6 4
7 5
1 Tear bar
2 Latch assembly
3 Mounting screw
4 Platen assembly hook
5 Main frame access hole
6 Cutter cable
7 Cutter assembly
4. See Figure 200. Secure the cutter assembly onto the platen assembly. The mounting
bracket tab on the cutter fits behind and attaches to the platen assembly using the screw
provided.
5. See Figure 201. Place the catch tray in the slot or slots of the front cover of cutter
assembly. Place the cutter shield over the cutter assembly and secure in place using the
thumb screw provided.
1
1
2
2
3 4
4 3
A ZM400
B ZM600
1 Cutter shield
2 Thumbscrew
3 Cutter assembly
4 Cutter catch tray
6. See Figure 202. Locate the connector P26 on the main logic board (MLB) and plug in the
cutter assembly connector. Route the cable as shown and ensure that it is away from the
drive belt and gears.
1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)
2. See Figure 196 on page 334. Install the four mounting screws.
9. Place the printer into the Cutter Mode (see your User Guide for proper setup and media
loading instructions).
Tools Required
Metric Hex Key (Allen wrench) Set Antistatic Wrist Strap and Mat
Metric Nutdriver Set
1 Peel Assembly
2 Mounting Screw (2)
1 Peel assembly
2 Mounting slots (2)
3 Mounting screws (2)
4 Platen housing
5 Rest pems on housing here.
6 Peel lever
2. See Figure 206. Notice the pems and the mounting slots.
3. See Figure 205 on page 342. Install the peel assembly with the pems to the rear and the
opening in the mounting slot to the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Now push the assembly back against the vertical surface of the platen housing then
down, so that the pems are resting on the horizontal surface of the platen housing.
4. Maintain a slight pressure downward on the peel assembly, to keep the pems on the
horizontal surface, and tighten the mounting screws.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
8. Refer to your User Guide for information on selecting the Peel Option Mode.
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove the media and ribbon.
3. See Figure 207. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 208. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 209. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 Front cover
2. See Figure 211. Remove the two screws that attach the rear cover to the base.
Note Do not remove the screws attaching the platen housing to the main frame.
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.
1. See Figure 212. Place the main frame onto the rewind pan assembly. Ensure the rear ledge
of the main frame rests completely on the rear support in the pan.
7 6 5
1 Main frame
2 Main frame mounting screws (4)
3 Rear end cap mounting screws (2)
4 Rear end cap
5 Platen housing mounting screw
6 Flat washer
7 Rewind Pan
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.
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.
Note Make sure the two holes on rewind support bracket face up and are in line with the
printer main frame.
1. See Figure 213. Place the rewind motor and spindle assembly in the rewind pan assembly.
2. Feed the media rewind cable through the hole in the bottom of the main frame.
3.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
4. See Figure 214. Connect the rewind cable connector to P26 on the main logic board
(MLB).
Figure 214 Connect the Rewind Cable to the Main Logic Board
1
2
4
5
5. See Figure 215. Align one of the two access holes in the rewind back plate to one of the
mounting holes on the rewind support plate.
6. Using a nut driver, mount the rewind motor and spindle assembly to the printer main
frame using one of the two screws provided.
Note For ease of alignment, do not tighten the first screw until the second screw is
installed.
1 1
2
2
1 Access hole
2 Rewind back plate
7. Align the other access hole of the rewind back plate to the other mounting hole on the
rewind support plate.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 208 on page 346. Install the four mounting screws.
If Then
No Continue with Remove the Tear Bar.
Yes Go to Remove the Existing Peel Assembly on page 356.
Note If there is an existing peel assembly, it must be removed. If a peel assembly in not
currently installed, the tear bar must be removed.
Retain all parts removed during disassembly, unless otherwise directed.
1. See Figure 217. Remove the two mounting screws and remove the tear bar.
2 2
1 Tear bar
2 Mounting screws (2)
1 Peel assembly
2 Platen housing
3 Peel assembly mounting screws
2. See Figure 219. Take note of the pems and the mounting slots.
1 Peel assembly
2 Mounting slots (2)
3 Pems (2)
3. See Figure 220. Install the peel assembly with the pems to the rear and the opening in the
mounting slot to the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Push the assembly back against the vertical surface of the platen assembly then down
so that the pems are resting on the horizontal surface of the platen housing.
4. Maintain a slight pressure downward on the peel assembly to keep the pems on the
horizontal surface, and tighten the mounting screws.
1 Peel assembly
2 Platen housing
3 Mounting screws (2)
4 Rest pems here.
1.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
2. Load media and pull about two feet of media through the front of the printer.
a. Slide the media supply guide to the outer edge of the media hanger.
b. Fold the media supply guide down.
c. Place the roll of media on the media supply hanger and push it on all the way.
d. Fold the media supply guide up.
e. Slide the media supply guide toward the outer edge of the media roll until it makes
light contact.
f. Press the printhead open lever and raise the printhead assembly.
g. Feed the media under the dancer, between the transmissive sensor, under the ribbon
sensor, and out the front of the printer.
h. Slide the media guide in until it is against the outer edge of the media.
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.
8. Slide it in against the media and tighten the thumbscrew to lock it in position.
11. Turn the power on (l). Place the printer into Rewind or Peel Mode.
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.
Dial
Tools Required
Note Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
4.
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
See Figure 224. Remove the e-ring securing the rewind spindle.
5. Remove the flat and wave washers from the rewind spindle shaft.
3 4
1 Rewind spindle
2 E-ring
3 Wave washer
4 Flat washer
6. See Figure 223. Remove the spindle by sliding it off the rewind spindle shaft.
1 2
7. See Figure 7 and Figure 227. Remove the rewind back plate from the spindle by pressing
in on the two tabs shown on the left and right sides of the spindle.
1 1
3
3
4
2
9. See Figure 228. Remove the outer rewind guide by sliding it off the rear of the spindle.
Rear
1 Thumb screw
2 Outer rewind guide
3 Spindle
Rear
2. See Figure 228 on page 366. Slide the outer rewind guide onto the spindle and install the
thumb screw.
3. See Figure 227 on page 365 and Figure 7 on page 365. Align the rewind back plate with
the spindle and press it into the spindle until the tabs snap into the mounting holes.
4. See Figure 223 on page 355. Slide the rewind spindle assembly onto the rewind spindle
shaft.
5. See Figure 224 on page 363. Slide the wave washer onto the rewind spindle shaft.
6. Slide the flat washer onto the rewind spindle shaft and then install the e-ring.
7.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
This section provides replacement and installation procedures for the ZM400/ZM600 roller
system.
Contents
Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Linerless Media Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Platen Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Platen Roller
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
3. See Figure 230. Open and latch the print mechanism in the vertical position.
1 Print mechanism
2 Platen roller assembly
3 Latch assembly
4. If you have a peel unit installed, you will have to open it.
5. Turn the latch assembly clockwise to gain access to the platen roller.
a c
b
d
Important The grooves in the inner and outer bearings must be facing up.
1. See Figure 232. Verify that the bearings are oriented properly.
1
2
3
4
1 Inner bearing
2 Inner bearing grooves
3 Outer bearing grooves
4 Outer bearing
2. See Figure 233 and Figure 234. Slide the platen roller assembly into the platen housing,
while aligning the platen roller bearings with the platen housing and the drive pin with the
slot in the drive shaft.
a c
b d
3. Turn the latch assembly to the vertical position to secure the platen roller assembly.
4. Clean the platen roller using the Zebra preventative maintenance kit or equivalent.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 235. Being careful not to damage the sensor cable, loosen the three thumb
screws securing the linerless media guide assembly and then pull it out slightly and set it
down.
4
3
1 Print mechanism
2 Thumbscrews (3)
3 Latch assembly
4 Linerless media guide assembly
5. See Figure 236. Turn the latch assembly clockwise 90 degrees to gain access to the platen
roller.
a c
b d
Important The grooves in the inner and outer bearings must be facing up.
1. See Figure 237. Verify that the bearings are oriented properly.
1
2
3
4
1 Inner bearing
2 Inner bearing grooves
3 Outer bearing grooves
4 Outer bearing
a c
b d
3. Turn the latch assembly to the vertical position to secure the linerless media platen roller
assembly.
4. Clean the linerless media platen roller using the 47362 Zebra preventive maintenance kit.
5. See Figure 240. Verify that the take-label sensor cable is securely pushed into the cable
retention device.
1 2 3 4
6. See Figure 235 on page 377. Reinstall the linerless media guide and tighten the three
thumbscrews.
7.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Platen Coupling
Tools Required
2. See Figure 241. Open the media door and remove the screw and washer securing the
electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
4. See Figure 242. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
5. See Figure 243. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
1 Print mechanism
2 Platen roller assembly
3 Latch assembly
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
4. Turn the latch assembly clockwise to gain access to the platen roller.
a c
b
d
1 2 3
1 Pivot screw
2 Stepper motor
3 Drive belt
4 Set screws (2)
5 Platen pulley
6 Locking screw
2. Swing the stepper motor to the right to loosen the drive belt and then tighten the locking
screw to snug it in place.
3. Remove the drive belt from the stepper motor and then from the platen pulley. Set the
drive belt aside for reuse.
4. Loosen the two set screws securing the platen pulley to the coupling assembly.
5. See Figure 247. Slide the platen pulley from the coupling assembly and set it aside for
reuse.
See Figure 248. Using a flat-blade screwdriver or needle nose pliers, remove and discard
the e-ring and washer from the drive shaft.
1 Drive shaft
2 Washer
3 E-ring
2. See Figure 249. Push the drive shaft through to the media side of the printer and then
remove and discard it.
Drive Shaft
3. See Figure 250. Using a bent tip scribe or small hooked tool, remove the roller bearing
from the media side of the platen housing.
4. Using a bent tip scribe or small hooked tool, remove the roller bearing from the
electronics side of the platen housing.
2. See Figure 248 on page 390. Install the new washer and e-ring onto the new drive shaft.
3. Ensure that the e-ring is in the slot on the drive shaft and that the drive shaft moves freely.
2. See Figure 246 on page 388. Reinstall the drive belt between the stepper motor and the
platen pulley.
3. Reinstall the drive belt onto the platen pulley and the stepper motor pulley.
4.
Caution Do not over tighten the drive belt, or damage to the bearings and platen
roller will occur. The belt should deflect under finger pressure but no more than 6 mm
( inch).
Loosen the locking screw and then rotate the motor down until the drive belt is just taut.
Tighten the locking screw and then the pivot screw.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
3. See Figure 242 on page 385. Install the four mounting screws.
Important The grooves in the inner and outer bearings must be facing up.
1. See Figure 253. Verify that the bearings are oriented properly.
1
2
3
4
1 Inner bearing
2 Inner bearing grooves
3 Outer bearing grooves
4 Outer bearing
2. See Figure 254 and Figure 255. Slide the platen roller assembly into the platen housing,
while aligning the platen roller bearings with the platen housing and the drive pin with the
slot in the drive shaft.
a c
b d
3. Turn the latch assembly to the vertical position to secure the platen roller assembly.
4. Clean the platen roller using the Zebra preventative maintenance kit or equivalent.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Pinch Roller
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media door and remove media and ribbon from the printer.
3. See Figure 258 on page 400. Lower the pinch roller holder assembly to the open position.
4.
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
See Figure 256. Using a small flat blade screwdriver or an awl, remove and discard the
two E-rings.
Note If you have trouble reaching the E-rings and have a peel assembly installed, you
may have to remove it to access the E-rings. See Figure 258 on page 400. Loosen the two
mounting screws, and then remove the peel assembly from the printer.
2
1
2. Install the two new bearings on the shaft of the pinch roller, flange facing out, as shown.
4. See Figure 257. Notice the pems and the mounting slots.
5. See Figure 258. Remove the old tear bar by removing the two mounting screw. Reinstall
the them into the mounting holes, to within 3.175 mm of the platen housing.
2
3
4
6
5
1 Peel assembly
2 Tear bar
3 Mounting screw
4 Mounting holes
5 Pinch roller
6 Rest the pems on the housing here.
6. Install the peel assembly with the pems to the rear and the opening in the mounting slot to
the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Push the assembly back against the vertical surface of the platen housing then down,
so that the pems are resting on the horizontal surface of the platen housing.
7. Maintain a slight downward pressure on the peel assembly to keep the pems on the
horizontal surface, and tighten the mounting screws.
8. Raise the pinch roller assembly to the closed position. Ensure the pinch holder assembly
snaps into position and exerts force on the platen roller.
9.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
10. Reconnect the AC power cord and turn on (l) the printer.
Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
This section provides replacement and installation procedures for the various printed circuit
boards in the ZM400/ZM600.
Contents
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Wireless Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Control Panel
Tools Required
2. See Figure 259. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
4. See Figure 260. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
5. See Figure 261. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
2. See Figure 263 on page 407. Is there already a ferrite block installed?
If Then
No Continue to step 3.
Yes a. See Figure 262. Using a screwdriver carefully pry open the ferrite block and
remove the control panel cable from the ferrite block.
b. Continue to step 3.
2
1
1 Ferrite block
2 Flat blade screwdriver
3 Plastic locking tabs (3)
3. See Figure 263. Remove the control panel cable from the cable clip and the ferrite block.
3
2
1 Cable clip
2 Ferrite block
3 Control panel cable
4. See Figure 264. Disconnect the control panel cable from P29 on the main logic board
(MLB).
7 6 5 4 3 2
1 Control panel
2 Access hole
3 Star lock washer
4 Split lock washer
5 Mounting screw
6 Control panel cable
7 Main logic board (MLB)
5. Remove the mounting screw, split lock washer, and star lock washer securing the control
panel.
6. Remove the control panel while carefully guiding the control panel cable out of the
printer.
7. See Figure 263 on page 407. Is there already a ferrite block installed?
If Then
No a. See Figure 265. Peel the backing off the tape on the ferrite block.
b. Position the ferrite block as shown and then press it to the main frame.
c. Continue to step 1.
Yes Continue to step 1.
1 2
1 Main frame
2 Ferrite block
2. See Figure 264 on page 408. Guide the control panel cable into the printer.
3. Align the new control panel and then install the star lock washer, split lock washer, and
mounting screw and tighten.
6. See Figure 263 on page 407. Ensure that the control panel cable is laying in the ferrite
block and then close and snap the ferrite block around it.
7. Fold the control panel cable over itself to take up the slack and then slide it under the cable
clip.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 260 on page 405. Install the four mounting screws.
Tools Required
If Then
No Go to Remove the Electronics Cover.
Yes Continue with step 2.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 267. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 268. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 269. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
2. See Figure 270. Press in on the eject button to remove the radio card.
1 Eject button
2 Radio card
3. See Figure 271. Remove the screw from the upper left corner of the wireless board.
4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).
1 Wireless board
2 Mounting screws (4)
5. See Figure 272. Remove the three wireless mounting standoffs from the MLB.
1 MLB
2 Mounting standoffs (3)
2 3
4
1 Rear cover
2 Antenna connector
3 Lock washer
4 Mounting nut
5 Antenna
2. See Figure 274. Remove the top left mounting screw securing the SEH IPv6 print server
board.
5
4
3. Remove the three SEH IPv6 print server board mountung screws securing it to the MLB.
4. Remove the SEH IPv6 print server board from the printer.
5. See Figure 275. Remove the three SEH IPv6 print server board mounting standoffs from
the MLB.
1 MLB
2 Mounting standoffs (3)
2. Slide the wired ethernet board off the three mounting standoffs and set aside for
reinstallation.
3. See Figure 277. Remove the three standoffs from the MLB.
Standoffs
If Then
No Go to step 3 on page 424.
Yes Continue with step 1.
1. page 423
Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
See Figure 278. Remove the printhead ribbon cable clip by lifting up on the tabs and then
pulling it away from the main logic board.
Note Some models have a ribbon cable retaining clip on the printhead data cable for
shipping purposes. It may be left off if you ensure that the printhead data cable is properly
seated into the main logic board MLB connector P19 upon reinstallation of the cable.
2. Drop the cable clip slightly out of the printhead connect and then remove it from the
printer.
3. See Figure 279. Unplug all ribbon cables and small wire connections.
J4
P26
J4
P4
P36
P9
J2 P7
P29 P19
4. See Figure 280. Remove and discard the two mounting studs and washers securing the
9-pin serial port connector.
5. Remove and discard the two screws securing the 36-pin parallel port connector.
2 1
6. Remove and discard the two mounting screws securing the MLB to the printer.
7. Pull out the front end of the board. As you do, guide its two connectors out of the rear
panel openings.
2. See Figure 280 on page 425. Align the new MLB with the rear panel and insert the two
connectors into the mounting holes.
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.
Caution An improperly connected printhead data or power cable may cause the
printhead to generate excessive heat and/or a false HEAD COLD message to display
while the printhead is hot enough to cause severe burns. Allow the printhead to cool.
See Figure 279 on page 424. Reconnect the ribbon cables and small wire connections to
the MLB.
7. See Figure 281. Insert the bottom locating tab into the bottom hole in the main logic board
(MLB) connector and then lift up and around with the upper locating tab in the top hole of
the MLB connector.
8. Ensure that all connectors are properly seated into their connectors.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 268 on page 414. Install the four mounting screws.
5.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
7. Turn on (l) the printer. The printer performs the POST, and then displays
PRINTER READY.
Important If the front panel is unable to communicate with the MLB, it will display
Internal Printer Error, Please contact your Zebra Service Representative. The
troubleshooting section of the maintenance manual should detail what conditions would
cause the front panel to display this message. Possibilities include but are not limited to
the cable between the MLB and the front panel not being connected properly or the MLB
not having a valid bootblock or firmware
2. If you printed a configuration label at the beginning of these kit instructions, compare the
configuration label you just printed to that one.
Wireless Option
Tools Required
See Figure 284. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
3. See Figure 285. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
4. See Figure 286. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
If Then
No Go to Install the Wireless Board on page 434.
Yes Continue with Remove the Wireless Board.
2. See Figure 287. Press in on the eject button to remove the radio card.
1 Eject button
2 Radio card
3. See Figure 288. Remove the screw from the upper left corner of the wireless board.
4. Remove the three lower mounting screws and then remove the wireless board from the
main logic board (MLB).
1 Wireless board
2 Mounting screws (4)
2. See Figure 289. Remove the blank cover from the rear panel of the printer.
3. See Figure 290. Install the three standoffs from the kit into the main logic board (MLB).
4. See Figure 291. Align the mounting holes in the wireless board with the mounting
standoffs and then install the four mounting screws.
1 Existing standoff
2 Wireless board
3 Mounting screws (4)
4 Installed standoffs (3)
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 285 on page 431. Install the four mounting screws.
Important After you have completed this installation, you must download the latest
version of firmware for your printer from: www.zebra.com.
7. Look at the front panel. If the wireless PCMCIA board was installed correctly, the
wireless link status indicator displays an underscore _ on the LCD, providing a real-time
display of the printers network status.
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 293. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 294. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 295. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
7. Is there a ZebraNet Internal Wireless Plus Print Server or Wireless Plus Print Server
already installed on the printer?
If Then
No Go to Install the New Internal Wireless Plus Print Server Board
on page 442.
Yes Continue with Remove the Old Print Server Board on page 441.
2. See Figure 296. Depending on your wireless plus print server, your printer may have
either three or four mounting screws. Remove the mounting screws from the either Print
Server board.
4. Go to Install the New Internal Wireless Plus Print Server Board on page 442.
2. Are you installing the Internal Wireless Plus Print Server for the first time?
If Then
No a. See Figure 297. If needed, install one standoff in between the two beige
connectors (P23 and P24) on the main logic board as shown.
b. Go to step 3.
Yes a. See Figure 297. Install the three studded standoffs on the main logic board
as shown.
b. Continue with step 3.
1 Cast boss
2 Studded standoffs (3)
3 Main logic board
3. Insert the upper edge of the Internal Wireless Plus board into the electronics area and in
front of the main logic board.
4. Place the RF connector through the option board slot in the back of the printer.
5. Align the connectors along the bottom edge of the Internal Wireless Plus board with the
connectors on the main logic board.
6. While supporting the back of the MLB with your fingers, press the wireless plus print
server board into place.
7. Install the Internal Wireless Plus board by inserting the four mounting screws into the
standoffs.
2. See Figure 298. Fasten the top of the cover into place using one of the screws provided in
the kit.
3. From the back of the printer, place the lock washer and nut on the RF connector and hand
tighten.
4. Using an open-end wrench, tighten the brass nut by turning it clockwise one quarter of a
turn.
5. To install the external antenna, screw the antenna onto the RF connector extending out
from the back plate of the printer.
3. See Figure 293 on page 439. Open the media door and install the mounting screw and
washer to secure the electronics cover.
Resume Operations
1.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Firmware
After you have completed this installation, you must download firmware version V53.16.x (or
later) a second time from: www.zebra.com/firmware.
Attach Labels
1. See Figure 299. Examine the labels included with the kit.
There may be several labels included with your kit.
39545-xxx ZM400
2 1
1 Printer model
2 Zebra part number
2. Locate your printer model in the lower right-hand corner of the label.
3. See Figure 300. If present, remove the old plastic label with part number 39545-xxx
affixed inside the media compartment of your printer.
Note Do not remove the electrical ratings label, also known as the model plate. The
model plate contains essential user information.
4. See Figure 299. Remove the backing from the new label (part number 39545-xxx included
in this kit) for your specific printer.
5. See Figure 300. Affix the new printer label in the area to the left of the model plate.
Compliance Information
2. This device must accept any interference received, including interference that may cause
undesired operation.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies Corporation could void the users authority to operate the equipment. To ensure
compliance, this printer must be used with Shielded Communication Cables.
This transmitter must not be co-located or operating in conjunction with any other antenna or
transmitter.
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 301. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 302. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 303. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
7. Is there a ZebraNet Wireless Plus Print Server, ZebraNet Internal Wireless Plus Print
Server, or ZebraNet b/g Print Server already installed?
If Then
No Go to Install the ZebraNet b/g Print Server Board on page 452.
Yes Continue with Remove the Old Print Server Board on page 5.
2. See Figure 304. Depending on your wireless print server, you may have either three or
four mounting screws. Remove all mounting screws from the print server board.
If Then
Yes a. See Figure 305. If there is an empty mounting hole between the two
connectors (P23 and P24) on the main logic board, install one of the studded
standoffs.
b. Go to step 3.
No a. See Figure 305. Install the three studded standoffs on the main logic board
as shown.
b. Continue with step 3.
1 Cast boss
2 Studded standoffs (3)
3 Main logic board
3. Insert the upper edge of the ZebraNet b/g Print Server board into the electronics area and
in front of the main logic board.
4. Place the RF connector through the option board slot in the back of the printer.
5. Align the connectors along the bottom edge of the ZebraNet b/g Print Server board with
the connectors on the main logic board.
6. While supporting the back of the MLB with your fingers, press the wireless print server
board into place.
7. Install the ZebraNet b/g Print Server board by inserting the four mounting screws into the
standoffs.
2. See Figure 306. Fasten the top of the cover into place using one of the screws provided in
the kit.
1
2 3
1 Cover
2 RF connector
3 Antenna nut
4 RF antenna
3. From the back of the printer, place the lock washer and nut on the RF connector and hand
tighten.
4. Using an open-end wrench, tighten the brass nut by turning it clockwise one quarter of a
turn.
5. To install the external antenna, screw the antenna onto the RF connector extending out
from the back plate of the printer.
2. See Figure 302 on page 450. Install the four mounting screws on the back of the printer.
3. See Figure 301 on page 449. Open the media door and install the mounting screw and
washer to secure the electronics cover.
Resume Operations
1.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Firmware
After you have completed this installation, you must download firmware version V53.17.11Z
(or later) from: www.zebra.com.
Attach Labels
1. See Figure 307. Examine the labels included with the kit.
There may be several labels included with your kit.
2 1
1 Printer model
2 Zebra part number
2. Locate your printer model in the lower right-hand corner of the label.
3. See Figure 308. If present, remove the old plastic label affixed to the inside of the media
compartment of your printer.
Note Do not remove the electrical ratings label, also known as the model plate. The
model plate contains essential user information.
1 2
4. See Figure 307. Remove the backing from the new approvals label for your specific
printer.
5. See Figure 308. Affix the new approvals label in the area to the left of the model plate.
Compliance Information
2. This device must accept any interference received, including interference that may cause
undesired operation.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies Corporation could void the users authority to operate the equipment. To ensure
compliance, this printer must be used with Shielded Communication Cables.
This transmitter must not be co-located or operating in conjunction with any other antenna or
transmitter.
Tools Required
Do you need to install the ZebraNet b/g Print Server PC Board Cover?
If Then
Yes Continue with Install the Board Cover.
No Go to Install the Antenna on page 459.
2. Secure the cover using the screw provided in this kit for your specific printer.
2. See Figure 309. From the back of the printer, place the lock washer and nut on the RF
connector and hand tighten.
1
3 4
2 5
1 Cover
2 RF connector
3 Lock washer
4 Nut
5 Antenna nut
6 RF antenna
3. Using an open-end wrench, tighten the brass nut by turning it clockwise one quarter of a
turn.
4. To install the external antenna, screw the antenna onto the RF connector extending out
from the back plate of the printer.
Wired Ethernet
Tools Required
Important Do not use needle nose pliers in place of the nutdriver, as you can damage the
Ethernet board. Always use recommended tools.
Note Retain all parts removed during disassembly, unless otherwise directed.
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
See Figure 310. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
3. See Figure 311. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
4. See Figure 312. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
If Then
No Go to Install the Wired Ethernet Board on page 464.
Yes Continue with Remove the Wired Ethernet Board.
2. See Figure 313. Remove and discard the three nuts securing the wired Ethernet board.
2 3
2. See Figure 315. Clean the J4 pads using the Zebra Preventive Maintenance Kit part
number 47362.
1 2
J4
1 J4
2 Pads
3. See Figure 316. Install the three mounting standoffs supplied in the kit into the three
threaded mounting holes on the main logic board (MLB).
4. See Figure 313 on page 463. Install the wired Ethernet board.
a. Insert the Ethernet connector into the back panel.
b. Rotate the board down onto the three mounting studs.
c. Secure the board with the three nuts supplied in the kit.
1 Electronics Cover
2 Upper Flanges (3)
3 Lower Flanges (2)
2. See Figure 311 on page 462. Install the four mounting screws.
7. See your ZebraNet 10/100 Internal PrintServer User Guide to set up your Ethernet
board.
This section provides replacement and installation procedures for the various outer casing
components on the ZM400/ZM600.
Contents
Electronic Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Media Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Lower Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
Electronic Cover
Tools Required
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 318. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 319. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 320. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
8. See Figure 321. Install the electronics cover by aligning it and sliding down, ensuring the
lower flange is inside the base and the upper flange is between the main frame and the
media door.
10. See Figure 318 on page 469. Install the electronics cover mounting screw and lock
washer.
Media Door
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
3. See Figure 322. Remove the four screws and lock washers securing the old door and lift
the door off of the printer.
1 Media door
2 External lock washers (4)
3 Mounting screws (4)
Note The front hole is a locating hole; install this screw and lock washer first.
1. See Figure 322 on page 473. Install the new door by aligning the front hinge with the front
hole and installing the mounting screw and lock washer.
2. Install the other three screws and lock washers supplied in the kit. Ensure the door is
aligned properly and reinstall media and ribbon.
3.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Media Window
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
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.
A A
\
1
2
2
3
3
4
4
3. Lift the old window out of the door and discard it.
1 New window
2 Door edge
3 Non-flexible tabs (3)
1
2
1 Non-flexible tab
2 Inside door edge
2. Lift and press the window into place until all flexible tabs have snapped in place and the
window is secure.
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
See Figure 326. Pull out on both sides of the lower front panel until it comes loose of the
mounting hooks and then lift it out of the printer. Use a small flat blade screwdriver if
you are having trouble.
Hooks
Lower
Front
Panel
1 2
3 4
2
5
1 Notches (2)
2 Base
3 Upper tabs (2)
4 Guide posts (2)
5 Lower tabs (2)
2. Align the two notches in the new lower front panel with the two guideposts on the base.
3. See Figure 328. Tip the new lower front panel up and snap the upper tabs onto the two
mounting hooks.
Tools Required
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
Open the media cover and remove the media and ribbon.
3. See Figure 329. Remove the three screws securing the rear end-cap and then remove the
end-cap.
3 1
1 Rear end-cap
2 Mounting screws (3)
3 Mounting holes (3)
2. Slide the new end-cap under the mounting screws and then tighten the mounting screws.
3.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
This section provides replacement and installation procedures for the ZM400/ZM600 roller
system.
Contents
RFID Upgrade Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
RFID Coupler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
RFID Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
RZ400/RZ600 Media Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
RZ400 and RZ600 RFID Hardware Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
Important You must have the proper firmware loaded in your printer for the main logic
board (MLB) to recognize the RFID upgrade. Go to http://www.zebra.com and download the
latest firmware for the RZ400/RZ600 printer.
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 330. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 331. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 332. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
5
3
1 Media door
2 Lock washers (2)
3 Media door front mounting screws (2)
4 Antistatic brush assembly mounting screws (2)
5 Antistatic brush assembly
3. See Figure 334. Install the new media door mounting screws and lock washers into the
two front mounting holes.
4. Align the antistatic brush assembly with the mounting holes and then install the two new
mounting screws.
5. See Figure 335. Turn the printer around and then slide the four spacers onto the four
screws just installed.
1
3
1 Spacers (4)
2 RFID mounting bracket
3 Mounting nuts (4)
6.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
7. Align the RFID reader mounting bracket with the four mounting screws and the slide it
onto the four screws.
1 3 4
1 Standoffs (3)
2 RFID reader board assembly
3 Split washers (3)
4 Mounting screws (3)
10. Install one of the split lock washers onto one of the mounting screws.
11. Repeat step 10 for the remaining two mounting screws and split lock washers.
12. Align the RFID reader assembly mounting holes with the standoffs and then install, but do
not tighten, the mounting screw and split lock washer through one of the RFID assembly
mounting holes and into the corresponding standoff.
13. After all three mounting screws and split lock washers are started, tighten all three.
8 9 10 1
7
5
4
3
2
2. Connect one end of the data cable to P13 on the main logic board and the other end to
P1 HOST on the RFID reader assembly.
3. Connect one end of the power cable to P28 on the main logic board and the other end to
J1 PWR on the RFID reader assembly.
4. Wrap a cable tie around the data and power cables at mid-point between the main logic
board and the RFID reader assembly and pull it tight.
See Figure 338. Turn the latch assembly 90 degrees to the left to gain access to the
mounting screw and then remove the mounting screw.
4
3
1 Cutter assembly
2 Latch assembly
3 Mounting screw
4 Platen assembly hooks
Note You may have to lift slightly higher on the left to clear the base.
1 Peel assembly
2 Mounting screws (2)
1 Front cover
2 Mounting hooks
1 Tear bar
2 Tear bar mounting screws (2)
2. Lift the tear bar out of the platen housing and discard it.
1 Media shelf
2 Mounting screws (2)
3. See Figure 343. Turn the coupler assembly on its side as shown.
2 3
4 2
1 Coupler assembly
2 Media guide
3 Access hole
4 Coupler cable
6. See Figure 344. Align the mounting holes and then install the two mounting screws.
2
1
7. See Figure 345. Connect the coupler cable to J1 on the RFID reader board.
3
4
7
6
8. Slide the cable clamp over the coupler cable and install it on the coupler cable guide
bracket as shown with the flat washer and screw.
9. Continue with Install the New Media Door Front End Cap.
2
1
2. Remove the new end cap and mounting screws from the kit.
3. See Figure 346. Align the new end cap with the media door and install the three mounting
screws.
2. Hold the cutter assembly as far to the left as possible, and align the larger part of the step
slot with the hooks on the platen housing.
3. Slide the cutter assembly onto the hooks and then push down and slide the assembly to the
right.
4. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the
platen assembly.
The mounting tab on the cutter fits behind and attaches to the platen assembly.
1 Tear bar
2 Platen housing
3 Mounting screws (2)
2. Align the two notches in the lower front panel with the two guideposts on the base.
4 2
1 Notches (2)
2 Base
3 Upper tabs (2)
4 Guide posts (2)
5 Lower tabs (2)
3. See Figure 349. Tip the lower front panel up and snap the upper tabs onto the two
mounting hooks.
1 Peel assembly
2 Mounting screws (2)
3 Rest pems on housing here.
2. See Figure 351. Notice the pems and the mounting slots.
3. See Figure 350 on page 504. Install the peel assembly with the pems to the rear and the
opening in the mounting slot to the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Push the assembly back against the vertical surface of the platen housing then down,
so that the pems are resting on the horizontal surface of the platen housing.
4. Maintain a slight pressure downward on the peel assembly to keep the pems on the
horizontal surface, and tighten the mounting screws.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 332 on page 486. Install the four mounting screws.
Attach Labels
1. See Figure 353. Examine the labels included with the kit and choose the proper one for
your printer model.
There may be several labels included with your kit.
1 2
If Then
Yes Note Do not remove the plastic label with part number 39545-xxx affixed
inside the media compartment with the serial number of your printer.
Continue with step 3.
No Continue with step 3.
Note Do not remove the printer model or the configuration labels. The model plate and
configuration labels contain essential user information.
3. Remove the backing from the new agency label for your specific printer.
4. See Figure 354. Affix the agency label in the area to the left of the model plate and
ensuring that it does not cover any other label that may be installed.
1 2
Configuration:
RZ4752511010R0
6 4
5 3
1 License label
2 Agency label (RZ400 shown)
3 Printer model plate (Do not remove)
4 Printer configuration label (Do not remove)
5 Locate the agency label here (RZ400 shown)
6 Locate the license label here
5. Remove the backing from the license label and affix it above the printhead as shown.
7.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
2. RFID TAG DATA will be displayed on the first line of the LCD display if the upgrade was
installed properly. If it is not displayed check your installation.
Compliance Information
2. This device must accept any interference received, including interference that may cause
undesired operation.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies Corporation could void the users authority to operate the equipment. To ensure
compliance, this printer must be used with Shielded Communication Cables.
This transmitter must not be co-located or operating in conjunction with any other antenna or
transmitter.
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2. See Figure 355. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
4. See Figure 356. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
5. See Figure 357. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
2.
Caution Grasp the cable connector and pull straight down when removing the
coupler cable.
See Figure 358. Disconnect the coupler cable from J1 the old RFID reader assembly.
J1 1
P1
J3
J2
J2 J1
1 Reader Adaptor
J1 Power
J2 Open
J3 Open
P1 Host
2 Reader
J1 Coupler Cable
J2 Open
3. Disconnect the J1 PWR and P1 HOST cables from the RFID reader.
4. See Figure 359. Remove the three mounting screws and washers securing the RFID reader
assembly and then remove it.
2
3
2. Align the RFID reader assembly mounting holes with the standoffs and then install, but do
not tighten, the mounting screw and split lock washer through one of the RFID assembly
mounting holes and into the corresponding standoff.
3. Repeat step 2 for the remaining two mounting screws and split lock washers.
5. Connect the PWR cable to J1 and the HOST cable to P1 on the radio adaptor board.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 356 on page 511. Install the four mounting screws.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
Tools Required
1.
Caution Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2.
Caution While performing any tasks near an open printhead, remove all rings,
watches, hanging necklaces, identification badges, or other metallic objects that could
touch the printhead.
3. See Figure 361. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
5. See Figure 362. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
6. See Figure 363. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
4
3
1 Cutter assembly
2 Latch assembly
3 Mounting screw
4 Platen assembly hooks
Note You may have to lift slightly higher on the left to clear the base.
1 Peel assembly
2 Mounting screws (2)
1 Front cover
2 Mounting hooks
RZ400
1. See Figure 367. Remove and retain the two tear bar mounting screws.
1 Tear bar
2 Tear bar mounting screws (2)
RZ600
1. Remove and retain the two tear bar mounting screws.
1 Tear bar
2 Tear bar mounting screws (2)
4.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
3
4
7
6
2. Remove the cable clamp mounting screw and washer and then remove the cable clamp
from the coupler cable.
3. See Figure 370. Remove the two coupler assembly mounting screws.
2
1
1 Platen housing
2 Coupler assembly
3 Mounting screws (2)
4. See Figure 371. Slide the media guide out as far as possible.
5. While guiding the coupler cable, rotate the coupler away from the platen housing and then
remove and discard the coupler assembly.
1
2
2. See Figure 372. Turn the coupler assembly on its side as shown.
2 3
4 2
1 Coupler assembly
2 Media guide
3 Access hole
4 Coupler cable
5. See Figure 370 on page 524. Align the mounting holes and then install the two mounting
screws.
6.
Caution Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.
7. See Figure 369 on page 523. Connect the coupler cable to J1 on the RFID reader board.
8. Slide the cable clamp over the coupler cable and install it on the coupler cable guide as
shown with the washer and screw.
2. Align the two notches in the lower front panel with the two guideposts on the base.
1 2
3 4
3
5
1 Notches (2)
2 Base
3 Upper tabs (2)
4 Guide posts (2)
5 Lower tabs (2)
3. See Figure 374. Tip the lower front panel up and snap the upper tabs onto the two
mounting hooks.
2. Hold the cutter assembly as far to the left as possible, and align the larger part of the step
slot with the hooks on the platen housing.
3. Slide the cutter assembly onto the hooks and then push down and slide the assembly to the
right.
The mounting tab on the cutter fits behind and attaches to the platen assembly.
4. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the
platen assembly.
1 Peel assembly
2 Mounting screws (2)
3 Rest pems on housing here.
2. See Figure 376. Notice the pems and the mounting slots.
3. See Figure 375 on page 529. Install the peel assembly with the pems to the rear and the
opening in the mounting slot to the top.
a. Insert the mounting slot opening over the two screws and lift up on the assembly.
b. Now push the assembly back against the vertical surface of the platen housing then
down, so that the pems are resting on the horizontal surface of the platen housing.
4. Maintain a slight pressure downward on the peel assembly, to keep the pems on the
horizontal surface, and tighten the mounting screws.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 362 on page 517. Install the four mounting screws.
5.
Caution When you are loading media or ribbon, remove all jewelry that could come
into contact with the printhead or other printer parts.
8. After the Power On Self Test (POST) is completed, press SETUP/EXIT and then press
PREVIOUS () twice.
9. RFID TAG DATA will be displayed on the first line of the LCD display, if the reader
assembly was installed properly.
Tools Required
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2. See Figure 378. Remove the screw and washer securing the electronics cover.
3
4
1 Media door
2 Electronics cover
3 Washer
4 Mounting screw
4. See Figure 379. Remove the four mounting screws on the rear of the printer.
1 Electronics cover
2 Mounting screws (4)
5. See Figure 380. Remove the electronics cover by pressing in on the electronics cover with
the palm of your hand, and then lifting up on the cover.
See Figure 381. Disconnect the coupler cable from J1 of the old RFID reader assembly.
J1 1
P1
J3
J2
2
J2 J1
1 Reader Adaptor
J1 Power
J2 Open
J3 Open
P1 Host
2 Reader
J1 Coupler Cable
J2 Open
2. Disconnect the J1 PWR and P1 HOST cables from the RFID reader assembly.
3. See Figure 382. Remove the three mounting screws and split washers securing the RFID
reader assembly and then remove it.
2
3
2
3
1 Media door
2 External lock washers (4)
3 Mounting screws, short (2)
4 Mounting screws, long (2)
Note The front hole is a locating hole; install this screw and lock washer first.
1. See Figure 384 on page 538. Install the new door by aligning the front hinge with the front
hole and installing a long mounting screw and lock washer.
2. Install the other long mounting screw and lock washer in the next hole.
3. Install the other two screws and lock washers supplied in the kit.
4. Ensure the door is aligned properly and then tighten the four mounting screws.
2. Align the RFID reader mounting bracket with the four mounting screws and the slide it
onto them.
2. Repeat step 1 for the remaining two mounting screws and split lock washers.
3. Align the RFID reader assembly mounting holes with the standoffs and then install, but do
not tighten, the mounting screw and split lock washer through one of the RFID assembly
mounting holes and into the corresponding standoff.
4. After all three mounting screws and split lock washers are started tighten all three.
5. See Figure 381 on page 535. Reconnect the data cable to P1 HOST on the RFID reader
adaptor board.
6. Reconnect the power cable to J1 PWR on the RFID reader adaptor board.
1 Electronics cover
2 Upper flanges (3)
3 Lower flanges (2)
2. See Figure 379 on page 534. Install the four mounting screws.
Tear-Off Bar
Tools Required
1 Front cover
2 Mounting hooks
Turn off (O) the printer and disconnect the AC power cord and all data cables.
2. See Figure 387. Remove and discard the two tear-off bar mounting screws.
1 Tear-off bar
2 Tear-off bar mounting screws (2)
3. Lift the tear-off bar out of the platen housing and discard it.
2. Align the two notches in the lower front panel with the two guideposts on the base.
4 2
1 Notches (2)
2 Base
3 Upper tabs (2)
4 Guide posts (2)
5 Lower tabs (2)
3. See Figure 386 on page 541. Lift up on the lower front panel and snap in place.
Parts List
Before proceeding, verify that your kit contains the items for your printer listed below.
1 2 3 4 5 6 7 8 9 10 11 12
This section provides the technician with assembly drawings and part number to maintain the
printer.
Contents
Outer Casings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
Media and Ribbon Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
Media Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
Ribbon Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
Print Mechanism View 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
Print Mechanism View 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
Platen Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
Static Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Drive System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
Wireless Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
Wired Ethernet Board/Internal PrintServer . . . . . . . . . . . . . . . . . . . 567
Available Media Handling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
Peel and Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
Liner Take-up Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
Inside Coated Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . 573
RFID Upgrade Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
Reader and Coupler Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . 576
RZ400/RZ600 Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
4 4
3 3
2 3
3 3
1 2
4 5
3 3
6
6
Important Only use the screws supplied in the maintenance kit. Damage may occur if
longer screws are used.
1 2
6 7 6 7
3 4 3 4
5 5
3 4 3 4
8 8
2 10 2
3 3
8
6
Gr
ea
7
se
Table G Ribbon Supply Spindle
4
3
2
1
5
3
6
4
7
7
2 3 4
12
11
15
18 17 14
16 13 9 8
10 7
20
19
1 2
1 2
Table O Electronics
4 J4
2
3
1 2 3
1 2 1 2
5 5
3
3
4 4
3 7
9
11
8
8
10
2 3
1
23
4 6 7 8
3 5
2
21
22
18
9
19 15 13 10
14
20 12
17
16 11
5 3 5 3
4 4
Notes ___________________________________________________________________
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http://www.zebra.com
Printed on
chlorine-free
recycled paper. 14207L-004 Rev. A