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ZM400 Series
Zebra ZM400 Series User Manual
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Corrective Maintenance
Control Pane
l
388
14207L-001 A
ZM400/ZM600 Maintenance Manual
8/9/07
Control Panel
T
ools Required
T
ools •
Y
ou need these tools to
complete thi
s
procedure:

Phillips Screwdriver Set

Antistatic
Pad and Wrist S
trap

Metric Nut Dr
iver Set
387
389
Table of Contents
About This Document
23
Who Should Use This Document
24
How This Document Is Organized
24
Contacts
25
Web Site
25
The Americas
25
Europe, Africa, Middle East, and India
25
Asia Pacific
25
Document Conventions
26
System Description
29
External View
30
Printer Media Compartment
31
Control Panel
32
Control Panel Buttons
33
Control Panel Lights
34
Printer Language Modes
35
Firmware Downloads
35
Additional Printer Language Information
35
General Specifications
36
Printing Specifications
37
Media Specifications
39
Ribbon Specifications
40
Printer Options
41
Operations
43
Before You Begin
45
Handling the Printer
46
Unpack and Inspect the Printer
46
Store the Printer
46
Ship the Printer
46
Select a Site for the Printer
47
Select a Surface
47
Provide Proper Operating Conditions
47
Allow Proper Space
47
Provide a Data Source
47
Provide a Power Source
47
Select a Data Communication Interface
48
Data Cables and Wireless Cards
49
Connect the Printer to the Computer or Network
49
Connect the Printer to a Power Source
52
Power Cord Specifications
53
Types of Media
54
Print Modes and Printer Options
55
Print Mode Descriptions and Printer Requirements
55
Media Paths
56
Load Media
58
Ribbon Overview
62
When to Use Ribbon
62
Coated Side of Ribbon
62
Load Ribbon
64
Remove Used Ribbon
68
Calibrate the Printer
69
Auto Calibration
69
Manual Calibration
69
Adjust Printhead Pressure
70
Setup Mode
72
Enter Setup Mode
72
Exit Setup Mode
73
Change Password-Protected Parameters
74
Default Password Value
74
Disable the Password Protection Feature
74
Print a Configuration Label
75
Print a Network Configuration Label
76
Control Panel Parameters
77
How to View or Modify Parameters
77
Additional Parameters
77
Standard Printer Parameters
78
Troubleshooting
103
Troubleshooting Checklists
104
LCD Error Messages
105
Print Quality Problems
109
Calibration Problems
112
Communications Problems
113
Ribbon Problems
114
Miscellaneous Printer Problems
115
Printer Diagnostics
117
Power-On Self Test
117
CANCEL Self Test
118
PAUSE Self Test
119
FEED Self Test
120
FEED and PAUSE Self Test
123
Communications Diagnostics Test
124
Sensor Profile
125
Preventive and Corrective Maintenance
127
Preventive Maintenance
129
Cleaning Schedule and Procedures
130
Clean the Exterior
130
Clean the Printhead and Platen Roller
131
Clean the Media Compartment and Sensors
134
Clean the Cutter Module
135
Routine Maintenance for the Rewind Option
137
Remove Printed Labels or Liner from the Rewind Spindle
137
Adjust Media Alignment for Rewind Option
139
Replacing Printer Components
140
Ordering Replacement Parts
140
Recycling Printer Components
140
Lubrication
140
Corrective Maintenance
141
Print System
143
Printhead Assembly
144
Tools Required
144
Remove the Old Printhead
145
Install the New Printhead Assembly
148
Remove the Cutter Assembly
151
Reinstall the Cutter Assembly
152
Print Mechanism
153
Tools Required
153
Remove the Electronics Cover
153
Remove the Wireless Board
156
Gain Access to the Power Supply
158
Disconnect the Print Mechanism
160
Remove the Cutter Assembly
161
Remove the Print Mechanism
162
Install the New Print Mechanism
162
Reinstall the Electronics Cover
163
Adjust the Print Mechanism
164
Reinstall the Cutter Assembly
167
Printhead Cables
168
Tools Required
168
Remove the Electronic Cover
171
Remove the Wireless Board
171
Gain Access to the Power Supply
173
Remove the Printhead
176
Install the New Printhead Cables
181
Remove the Cutter Assembly
186
Reinstall the Cutter Assembly
187
Reinstall the Electronics Cover
187
Ribbon Strip Plate
189
Tools Required
189
Remove the Old Ribbon Strip Plate
189
Install the New Ribbon Strip Plate
191
Adjust the Strip Plate
191
Printhead Latch
192
Tools Required
192
Remove the Old Latch
192
Install the New Latch Kit
195
Adjust the Print Mechanism
196
Printhead Pressure Dials
199
Tools Required
199
Remove the Printhead
199
Remove the Old Pressure Dials
202
Install the New Pressure Dials
203
Magnetic Printhead Latch
206
Tools Required
206
Remove the Electronics Cover
206
Remove the Old Magnetic Latch
209
Install the New Magnetic Latch
211
Reinstall the Electronics Cover
212
Sensors
213
Sensor Assemblies
214
Tools Required
214
Remove the Electronics Cover
214
Remove the Wireless Board
217
Access the Power Supply
219
Remove the Stepper Motor
221
Remove the Media Sensor Connections
222
Remove the Sensor Assemblies
223
Install the New Upper Media Sensor Assembly
226
Install the New Upper Media Sensor Assembly
228
Connect the Media Sensor Cables
230
Reinstall the Stepper Motor
230
Reinstall the Electronics Cover
231
Adjust the Sensor Gap
232
Ribbon/Head Open Sensor Assembly
235
Tools Required
235
Remove the Electronics Cover
235
Remove the Old Sensor
238
Install the New Ribbon/Head Open Sensor Assembly
240
Reinstall the Electronics Cover
242
Drive System
243
Drive System
244
Remove the Electronics Cover
244
Remove the Gear Cover
247
Remove the Old Gears, Drive Belt, and Pulley
249
Install the New Gears, Drive Belt, and Compound Pulley
249
Reinstall the Electronics Cover
251
Drive Belt Maintenance Kit
252
Remove the Electronics Cover
252
Remove the Old Gears, Drive Belt, and Pulley
254
Install the New Drive Bet
254
Reinstall the Electronics Cover
255
Stepper Motor Assembly
256
Tools Required
256
Remove the Electronics Cover
256
Remove the Wireless Board
259
Gain Access to the Power Supply
261
Remove the Old Stepper Motor and Gear
263
Install the New Stepper Motor and Gear
264
Reinstall the Electronics Cover
265
Ribbon Take-up Spindle Clutch
266
Tools Required
266
Remove the Gear Cover
269
Remove the Old Ribbon Take-Up Clutch
271
Install the New RTU Clutch
272
Reinstall the Gear Cover
273
Reinstall the Electronics Cover
273
Ribbon Take-up Spindle
275
Tools Required
275
Remove the Gear Cover
278
Remove the Old RTU Spindle Assembly
280
Install the New Ribbon Take-up Spindle Assembly
281
Reinstall the Gear Cover
282
Reinstall the Electronics Cover
282
Printhead Conversion
283
Tools Required
283
Remove the Electronics Cover
283
Remove the Old Drive Belt and Platen Pulley
286
Install the New Drive Belt and Platen Pulley
287
Reinstall the Compound Gear and Gear Cover
291
Reinstall the Electronics Cover
292
Remove the Old Printhead
293
Install the New Printhead
296
Remove the Cutter Assembly
299
Reinstall the Cutter Assembly
300
Ribbon Supply Spindle
301
Tools Required
301
Remove the Electronics Cover
301
Remove the Old Ribbon Supply Spindle
304
Remove the Gear Cover
304
Remove the Stepper Motor
306
Install the New Ribbon Supply Spindle
311
Reinstall the Gear Cover
314
Reinstall the Electronics Cover
315
Media Hanger
316
Tools Required
316
Replace the Old Hanger Assembly
316
Tear-Off Bar
318
Tools Required
318
Remove the Front Cover
318
Remove the Old Tear-Off Bar
319
Install the New Tear-Off Bar
320
Static Brush
321
Tools Required
323
Remove the Old Static Brush Assembly
323
Install the New Static Brush Assembly
324
Cutter Option
325
Tools Required
325
Remove the Electronics Cover
325
Remove the Front Cover
328
Install the Cutter Option
329
Reinstall the Electronics Cover
333
Peel Maintenance Assembly
334
Tools Required
334
Remove the Old Peel Assembly
334
Install the New Peel Assembly
335
Peel Rewind Option
337
Tools Required
337
Remove the Electronics Cover
337
Remove the Base
340
Install the Rewind Pan
342
Install the Rewind Spindle Assembly
344
Reinstall the Electronics Cover
347
Install the Peel Assembly
348
Remove the Existing Peel Assembly
349
Install the New Peel Assembly
350
Load the Media
351
Align the Rewind/Peel Media
354
Outer Guard Rewind
355
Tools Required
355
Remove the Old Outer Rewind Guide
355
Install the New Outer Rewind Guide
359
Roller System
361
Platen Roller
362
Tools Required
362
Remove the Old Platen Roller
362
Install the New Platen Roller Assembly
365
Platen Coupling
368
Tools Required
368
Remove the Electronics Cover
368
Remove the Platen Roller Assembly
371
Remove the Drive Belt and Platen Pulley
373
Remove the Drive Shaft
375
Install the New Drive Shaft
377
Reinstall the Platen Pulley
377
Reinstall the Electronics Cover
378
Reinstall the Platen Roller
379
Pinch Roller
382
Tools Required
382
Remove the Pinch Roller
382
Printed Circuit Boards
387
Control Panel
388
Tools Required
388
Remove the Electronics Cover
389
Remove the Old Control Panel
391
Install the New Control Panel
392
Reinstall the Electronics Cover
393
Main Logic Board
394
Tools Required
394
Print a Configuration Label
394
Remove the Electronics Cover
395
Remove the Wireless Board
397
Remove the Wired Ethernet Board
400
Remove the Old MLB
401
Install the New MLB Board
402
Reinstall the Electronics Cover
404
Check Hardware ID and Firmware Version
405
Wireless Option
406
Tools Required
406
Remove the Electronics Cover
406
Remove the Wireless Board
408
Install the Wireless Board
410
Reinstall the Electronics Cover
413
Wired Ethernet
414
Tools Required
414
Remove the Electronics cover
415
Remove the Wired Ethernet Board
417
Install the Wired Ethernet Board
418
Reinstall the Electronics Cover
420
Outer Casing Components
421
Electronic Cover
422
Tools Required
422
Remove the Old Electronics Cover
422
Media Cover
426
Tools Required
426
Remove the Old Media Door
426
Install the New Media Door
428
Media Window
429
Tools Required
429
Remove the Defective Window
429
IInstall the New Window
430
Lower Front Panel
432
Tools Required
432
Install the New Lower Front Panel
433
Rear End Cap
435
Tools Required
435
Remove the Old Rear End-Cap
435
Install the New End-Cap
436
Drawings and Parts
437
5
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Zebra ZM400 Series Specifications
General
Brand
Zebra
Model
ZM400 Series
Category
Label Maker
Language
English
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