Specifications

ManualsBrandsZebra ManualsComputer equipmentZ6M

=HEUD,WDOLF!6/

0DLQWHQDQFH0DQXDO

Summary of content (168 pages)

PAGE 1
=HEUD ,WDOLF!6/ 0DLQWHQDQFH 0DQXDO 0DLQWHQDQFH 0DQXDO
PAGE 2
7DEOH RI &RQWHQWV Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation. 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 expressed written permission of Zebra Technologies Corporation.
PAGE 3
Table of Contents Table of Contents Section 1 System Description ........................................................................................1-1 Scope ......................................................................................................................................... 1-1 RELATED MANUALS ......................................................................................................... 1-1 Printer Specifications .........................................................
PAGE 4
Table of Contents Remove Ribbon ........................................................................................................... 2-5 Load Media .................................................................................................................. 2-5 Tear-Off Mode ......................................................................................................... 2-5 Cutter Mode ......................................................................................................
PAGE 5
Table of Contents Equipment Safety Tips ........................................................................................................ 4-2 Equipment Safety Tips (Continued) .................................................................................... 4-3 Personal Safety Tips ........................................................................................................... 4-4 Cleaning ..................................................................................................
PAGE 6
Table of Contents Install Drive Belt ......................................................................................................... 4-38 Front Panel Replacement ................................................................................................. 4-38 Remove Front Panel .................................................................................................. 4-38 Install Front Panel ..............................................................................................
PAGE 7
Table of Contents Rewind Motor and Spindle Assembly ........................................................................ 4-78 Remove Rewind Motor and Spindle Assembly Removal ........................................... 4-78 Rewind Motor and Spindle Installation ....................................................................... 4-80 Rewind PCB Motor Assembly .................................................................................... 4-81 Remove Rewind PCB Motor Assembly ....................
PAGE 8
Table of Contents viii Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 9
/LVW RI 7DEOHV List of Tables Table 1-1. Font Matrix for 8 dot/mm (203 dpi) Printhead ................................................................. 1-3 Table 1-2. Font Matrix for 12 dot/mm (300 dpi) Printhead ............................................................... 1-4 Table 3-1. Technical Support Telephone Numbers ......................................................................... 3-1 Table 4-1. Preventive Maintenance Schedule ..............................................................
PAGE 10
/LVW RI 7DEOHV x Z4M/Z6M Maintenance Manual 12/16/03
PAGE 11
List of Figures List of Figures Figure 1-1. Default Fonts Examples ................................................................................................ 1-4 Figure 1-2. Interface Connections.................................................................................................... 1-8 Figure 1-3. RS-232 Signaling......................................................................................................... 1-10 Figure 1-4. RS-422/RS-485 Signaling ..............................
PAGE 12
List of Figures Figure 4-15. Remove the Electronics Cover.................................................................................. 4-21 Figure 4-16. Changing the Compound Gear and Compound Pulley ............................................. 4-22 Figure 4-17. Latch Kit Parts ........................................................................................................... 4-23 Figure 4-18. Strike Plate Installation ...........................................................................
PAGE 13
List of Figures Figure 4-52. Cutter Shield and Catch Tray .................................................................................... 4-60 Figure 4-53. Cutter Option Connector Location on Main Logic Board ........................................... 4-61 Figure 4-54. Removal of Front and Latch Cover............................................................................ 4-62 Figure 4-55. Tear Bar Removal ............................................................................................
PAGE 14
List of Figures Figure 5-5. Platen Roller Shaft Maintenance Kit.............................................................................. 5-8 Figure 5-6. Printhead Housing Maintenance Kit .............................................................................. 5-9 Figure 5-7. Static Brush Assembly Maintenance Kit...................................................................... 5-10 Figure 5-8. Dancer Assembly Maintenance Kit ....................................................................
PAGE 15
6\VWHP 'HVFULSWLRQ 6HFWLRQ 6HFWLRQ 6\VWHP 'HVFULSWLRQ This manual contains information about the service and maintenance of Zebra’s Z4M™ and Z6M™ printers. The Z4M/Z6M thermal demand printers print high quality labels containing bar codes, alphanumeric characters and graphics. Capable of printing in either thermal direct or thermal transfer mode, configured with a wide range of field installable options, the printers have the flexibility to meet a variety of applications.
PAGE 16
6HFWLRQ 6\VWHP 'HVFULSWLRQ 3ULQWHU 6SHFLILFDWLRQV A general description of the printer and the options available follows.
PAGE 17
6\VWHP 'HVFULSWLRQ 6HFWLRQ 6WDQGDUG 3ULQWHU )RQWV Fonts A, B, C,D,E,F,G,H, and GS are expandable up to 10 times, height and width independently. However, fonts E and H (OCR-A and OCR-B) are not considered “inspec" when expanded. The scalable smooth font 0 (CG Triumvirate™ Bold Condensed) is expandable on a dotby-dot basis, height and width independent, while maintaining smooth edges. Maximum character size depends on available memory.
PAGE 18
6HFWLRQ 6\VWHP 'HVFULSWLRQ Table 1-2. Font Matrix for 12 dot/mm (300 dpi) Printhead Font Matrix Height Width Baseline Dots Type* Inter-Character Cell Gap Width Character Size Inches Font Matrix Height Millimeters Width Char/ Inch Height Width Char/ mm A 9 5 7 1 6 U-L-D 0.030 0.020 50.00 0.76 0.51 1.97 B 11 7 11 2 9 U 0.037 0.030 33.33 0.93 0.76 1.31 C,D 18 10 14 2 12 U-L-D 0.060 0.040 25.00 1.52 1.02 0.98 E 41 20 32 6 26 OCR-B 0.137 0.087 11.
PAGE 19
6\VWHP 'HVFULSWLRQ 6HFWLRQ 0HGLD VSHFLILFDWLRQV Media Specifications Minimum label length Z4M Z6M Tear-off 0.5″ (13 mm) 0.5″ (13 mm) Peel-off 1″ (25.4 mm) 1″ (25.4 mm) Cutter 1″ (25.4 mm) 1″ (25.4 mm) Rewind 0.5″ (13 mm) 0.5″ (13 mm) 39″ (991 mm) Maximum Minimum 1″ (25.4 mm) Total media Tear/Cutter 4.5″ (114 mm) width (Includes Maximum Peel/ liner, if 4.25″ (108 mm) Rewind any) 39"″(991 mm) (203dpi) 2″ (737 mm) (300dpi) 2″ (51 mm) 7″" (178 mm) 6.75″ (171 mm) 0.0023″ (0.058 mm) 0.
PAGE 20
6HFWLRQ 6\VWHP 'HVFULSWLRQ 5LEERQ 6SHFLILFDWLRQV Ribbon Specifications Z4M Z6M Minimum 2″ 51 mm 2″ 51 mm Maximum 4.3″ 109 mm 6.85″ 174 mm 2:1 media to ribbon roll ratio 984′ 300 m 984′ 300 m 3:1 media to ribbon roll ratio 1476′ 450 m 1476′ 450 m Maximum ribbon roll size (outer diameter) 3.2″ (81.3 mm) 3.2″ (81.3 mm) Inner diameter of core 1″ 25.4 mm 1″ 25.
PAGE 21
6\VWHP 'HVFULSWLRQ 6HFWLRQ *HQHUDO 6SHFLILFDWLRQV Physical Characteristics Z4M Z6M Height 13.32" 338 mm 13.32" 338 mm Width 10.93" 278 mm 13.43" 341 mm Depth 18.69" 475 mm 18.69" 475 mm Weight (without options) 32.4 lbs. 15 kg 34.7 lbs. 16 kg (OHFWULFDO 5HTXLUHPHQWV • Autoselect 90-264 VAC; 48-62 Hz • 5 Amps for entire AC voltage range • 2 5 Watts standby power consumption • 200/300/350/450 Watts maximum power consumption for Z4M/Z6M.
PAGE 22
6HFWLRQ 6\VWHP 'HVFULSWLRQ &RPPXQLFDWLRQ 6SHFLILFDWLRQV 6HULDO 'DWD &RPPXQLFDWLRQ ,QWHUIDFH 2YHUYLHZ The Zebra Z4M/Z6M has a single data terminal equipment (DTE) port that supports RS232, RS-422 and RS-485 serial data communications. Baud rate, parity, data length, stop bits, and XON/XOFF or DTR control protocols are front panel selectable. Refer to Figure 1-2.
PAGE 23
6\VWHP 'HVFULSWLRQ 6HFWLRQ &RPPXQLFDWLRQ %XIIHU The Z4M/Z6M printers have a communication buffer that stores the incoming data until that information can be acted upon (imaged). Communication handshaking (DTR/DSR control signals or XON/XOFF control codes) is used to control when the host can send data to the printer. The size of the buffer is 5000 characters. As data is received by the printer, the processor monitors the number of characters in the buffer.
PAGE 24
6HFWLRQ 6\VWHP 'HVFULSWLRQ 6HULDO &RPPXQLFDWLRQ 6LJQDO /HYHOV Refer to Figure 1-3. RS-232 data signals are defined as either Mark or Space, while control signals are ON (Active-Positive Voltage) or OFF (Inactive-Negative Voltage).
PAGE 25
6\VWHP 'HVFULSWLRQ 6HFWLRQ &RPPXQLFDWLRQ &RGH The Z4M/Z6M printer sends and receives ASCII (American Standard Code for Information Interchange) characters in one of two formats, Serial Data or Parallel Data. Note • When using the serial data format, the baud rate, number of data and stop bits per character, and parity are selectable. Parity only applies to data transmitted by the printer. For received data, the parity bit is ignored.
PAGE 26
6HFWLRQ 6\VWHP 'HVFULSWLRQ 36-pin Connector Description 1 nStrobe/HostClk 2-9 Data Bits 1-8 10 nACK/PtrClk 11 Busy/PtrBusy 12 PError/ACKDataReq 13 Select/Xflag 14 nAutoFd/HostBusy 15 Not Used 16 & 17 Ground 18 +5V @ 1A 19-30 Ground 31 ninit 32 nFault/NDataAvail 33 & 34 Not Used 35 +5V through a 4.
PAGE 27
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 6HFWLRQ 2SHUDWLRQV 2YHUYLHZ ,QVWDOODWLRQ Following is a detailed description of the installation procedures for the printer. 8QSDFN 3ULQWHU Save the carton and all packing materials in case shipping is ever required. Inspect the printer for possible damage incurred during shipment. Check all exterior surfaces for damage. Raise the media access door and inspect the media compartment for damage to components.
PAGE 28
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 2SHUDWRU &RQWUROV This section discusses the functions of the various controls and indicators on the printer. The operator should become familiar with each of these functions. )URQW 3DQHO 'LVSOD\ The front panel display communicates operational and programming modes and parameters. PAUSE Figure 2-1. Location of Control Panel Keys Page 2-2 Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 29
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ )URQW 3DQHO .H\V Key Function Forces the printer to feed one blank label each time the key is pressed. • Printer not printing: one blank label immediately feeds. • Printing: one blank label feeds after the current batch of labels is complete. Note • Equivalent to the Slew to Home Position (~PH, ^PH) ZPL II instruction. PAUSE Stops and starts the printing process. Printer not printing: no printing can occur. Printing: printing stops once the current label is complete.
PAGE 30
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Scrolls to the previous selection. Scroll Mode Change Mode Decreases the value. Selects the digit you wish to change. Answers no. )URQW 3DQHO /LJKWV Light Status Indication Off Printer turned off or no power is applied. On Power applied and turned on. Off Normal printer operation. On Printer stopped all printing operations Flashing In peel-off mode, the PAUSE light flashes when the label is available for removal.
PAGE 31
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ To place this spindle in the "normal" position, firmly pull out the spindle end segment (plastic part only) until it clicks into place as shown in Figure 2-2. To place the spindle in the "low tension" position, firmly push in the spindle end segment until it clicks into place. Refer to Figure 2-2. 1. Press the printhead open lever. The printhead assembly springs up. 2. Push the ribbon roll completely onto the ribbon supply spindle. 3.
PAGE 32
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6. Feed the media under the dancer, through the slot in the transmissive sensor, under the ribbon sensor, and out the front of the printer. 7.
PAGE 33
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Cutter Mode (Cutter option required) Refer to Figure 2-4. 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide the media guide out as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6.
PAGE 34
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Value Peel-Off Mode (Value peel option required) Refer to Figure 2-5. Page 2-8 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide. Slide in the media supply guide so that it just touches, but does not restrict, the edge of the roll. 6.
PAGE 35
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Ribbon Sensor Transmissive Sensor Dancer Media Supply Guide Printhead Assembly Lever Label Liner Printhead Open Lever Media Supply Hanger Media Guide Media Peel Bar Figure 2-5. Media Loading Value Peel 77259L Rev.
PAGE 36
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Value Peel-Off Mode with Liner Take-up Note • Liner Take-up only available on Z4M. Refer to Figure 2-5. Page 2-10 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media supply guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide.
PAGE 37
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Ribbon Sensor Transmissive Sensor Dancer Media Supply Guide Printhead Assembly Lever Label Printhead Open Lever Media Guide Liner Take up Media Supply Hanger Figure 2-6. Media Loading Value Peel with Liner Take-up Remove Liner 1. Using the liner slide tab, pull the liner slide towards you (as shown) until it stops (about a third of the way down the liner take-up spindle). 2. Slide the liner from the take-up spindle.
PAGE 38
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Value Peel Rewind (Peel-off Mode) Note • Value peel option is replacing the power peel option. Refer to Figure 2-7 Page 2-12 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media supply guide as far from the printer frame as possible. 4. Place the roll of media on the media supply hanger. 5. Flip up the media supply guide.
PAGE 39
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Ribbon Sensor Media Supply Guide Printhead Assembly Lever Media Supply Hanger Dancer Label Printhead Open Lever Media Alignment Spindle Take-up Spindle Media Guide Transmissive Thumbscrew Sensor Rewind Media Guide Figure 2-7. Value Peel Rewind (Peel-Off Mode) Value Peel Rewind (Rewind Mode) Refer to Figure 2-8. 77259L Rev. 4 12/16/03 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3.
PAGE 40
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 13. Slide the rewind media guide against the media, and tighten the thumbscrew to lock it into position. 14. Close the printhead assembly. Ribbon Sensor Printhead Assembly Media Supply Guide Lever Media Supply Hanger Dancer Take-up Spindle Printhead Open Lever Media Alignment Spindle Media Transmissive Guide Sensor Rewind Media Guide Thumbscrew Figure 2-8. Value Peel Rewind (Rewind Mode) Page 2-14 Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 41
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Value Peel Rewind Media Alignment Note • The media/liner should be installed flush against the back plate of the take-up spindle to prevent the media/liner from winding too loosely. Perform the following adjustment if the media does not track properly onto the take-up spindle. 1. Refer to Figure 2-9. Turn the adjustment dial clockwise to align the media/liner material toward the inboard (i.e., main frame or electronics) side. This is the most likely adjustment. or 2.
PAGE 42
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 8. Ensure that the media is against the back of the transmissive sensor. Then, slide in the media guide so that it just touches, but does not restrict, the edge of the media. 9. Open the front housing assembly by lifting the handles; then, pivot down the front housing assembly. 10. Remove at least 12” (305 mm) of labels from the liner material. 11.
PAGE 43
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 3. Loosen the thumbscrew, slide the rewind media guide to the end of the take-up spindle and flip the media guide horizontal. 4. Slide the core and liner material from the take-up spindle. Power Rewind Mode Note • Power peel-off option required. (Being replaced with value peel/rewind option). Refer to Figure 2-11. 77259L Rev. 4 12/16/03 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3.
PAGE 44
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Printhead Assembly Transmissive Dancer Media Supply Guide Sensor Front Housing Assembly Media Supply Hanger Take-up Spindle Printhead Open Lever Media Ribbon Sensor Alignment Spindle Rewind Media Guide Media Guide Thumbscrew Figure 2-11. Power Rewind Loading Media Removal Page 2-18 1. Cut the media prior to where it ends on the take-up spindle. 2. Rotate the take-up spindle until the rewind media guide is in the “12 o’clock” position. 3.
PAGE 45
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Power Peel Rewind Media Alignment Note • The media liner should be installed flush against the back plate of the take-up spindle to prevent the media/liner from winding too loosely. Perform the following adjustment if the media does not track properly onto the take-up spindle. 1. Refer to Figure 2-12. Turn the adjustment dial clockwise to align the media/liner material toward the inboard (i.e., main frame or electronics) side. This is the most likely adjustment. or 2.
PAGE 46
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Fanfold Media Loading Fanfold media feeds through either the bottom or rear access slot. The lower rear cover guide surface can be used as a reference to align media in printer. Refer to Figure 2-13. Page 2-20 1. Press the printhead open lever. The printhead assembly springs up. 2. Flip down the media supply guide. 3. Slide out the media guide as far from the printer frame as possible. 4. Pass the fanfold media over the media supply hanger. 5.
PAGE 47
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Media Supply Guide Printhead Assembly Printhead Open Lever Media Guide Rear Slot Feed Media Supply Hanger Media Supply Guide Printhead Assembly Printhead Open Lever Media Guide Bottom Feed Media Supply Hanger Figure 2-13. Media Loading Fanfold 77259L Rev.
PAGE 48
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Note • Placing an empty 3” core on the hanger will assist the media movement. $OLJQ 6HQVRUV 7UDQVPLVVLYH 6HQVRU There is no positioning of the transmissive sensor. All media is to be loaded through the transmissive sensor as described in the media and ribbon loading chapters. Note • The transmissive sensor should not be used when the sensor type is set to MARK.
PAGE 49
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ 0HGLD DQG 0HGLD 6HQVRU &RQVLGHUDWLRQV It is important that the appropriate media sensor is selected for the type media being used. If the Transmissive Sensor is set to Auto Select mode and an auto-calibration condition occurs (see media calibration), the appropriate media sensor will be selected. If Sensor Select is set for Reflective Sensor or Transmissive Sensor, the auto-calibration will calibrate the selected Media Sensor and ignore the other.
PAGE 50
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 3ULQWHU 6HOI 7HVWV The Z4M/Z6M printer is designed to work with most Zebra media and ribbon combinations. However, in some applications, changes to the printer’s configuration and mechanical settings may be required. For these situations, printer self test labels can be used to check print quality and ensure proper operation. These self tests produce sample printouts and provide specific information that determines the operating conditions for the printer.
PAGE 51
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Figure 2-14. CANCEL Key Self Test Label (Configuration Label) 3DXVH .H\ 6HOI 7HVW Press and hold PAUSE while turning the printer power On (l). Release the key anytime after the first front panel LED turns off. The Pause Key Self Test prints a series of labels which can be used when making print quality adjustments. 9999 labels at two inches per second pausing every 15 labels. 9999 labels at six inches per second pausing every 15 labels.
PAGE 52
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ Figure 2-15. PAUSE Key Self Test Label )HHG .H\ 6HOI 7HVW Press and hold FEED while turning the printer power on (l). Release the key anytime after the first front panel LED turns off. The quantity of labels printed during this print quality test depends on the dot density of the printhead. 300 dpi printers: 7 labels are printed at the 2 ips and 6 ips print speeds. 200 dpi printers: 7 labels are printed at the 2 ips, 6 ips and 10 ips print speeds.
PAGE 53
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Figure 2-16. FEED Key Self Test Label 3DXVH DQG &DQFHO .H\ 6HOI 7HVW Press and hold both PAUSE and CANCEL while turning the printer power On (l). Release both keys anytime after the first front panel LED turns off. The Pause and Cancel Key Self Test prints a series of 500 labels which can be used when making print quality adjustments. The printed label will look like the PAUSE Key Self Test label and will be sequentially numbered.
PAGE 54
6HFWLRQ 2SHUDWLRQV 2YHUYLHZ 3DXVH DQG )HHG .H\ 6HOI 7HVW 5HVHW 'HIDXOWV Press and hold both PAUSE and FEED while turning the printer On (l). Release both keys anytime after the first front panel LED turns off. PAUSE and FEED together reset the printer to the default settings. These values are not saved in EEPROM, but may be saved by sending the ZPL command ^JUS or saving through the LCD on the front panel.
PAGE 55
2SHUDWLRQV 2YHUYLHZ 6HFWLRQ Figure 2-18. Communications Diagnostics Self Test 77259L Rev.
PAGE 56
6HFWLRQ Page 2-30 2SHUDWLRQV 2YHUYLHZ Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 57
7URXEOHVKRRWLQJ 6HFWLRQ 6HFWLRQ 7URXEOHVKRRWLQJ *HQHUDO Consult the following troubleshooting tables. If you encounter any problems that cannot be corrected with the aid of this manual, contact Zebra’s Technical Support immediately to minimize or avoid printer downtime. Technical Support can also assist in determining if the printer should be returned for repair (See Table 3-1 for Technical Support numbers). Another service of Zebra, Technical Support via the Internet (ZIP Support™ http:// support.
PAGE 58
6HFWLRQ 7URXEOHVKRRWLQJ 7URXEOHVKRRWLQJ &KDUWV Symptom Diagnosis No AC power applied to the printer. No LEDs light. Faulty AC power fuse. No voltage available from the internal power supply. Printer locks up when running the Power On Self Test with some or all LEDs ON. Action Ensure the AC power cable is connected to a working voltage source. Replace fuse. Replace the power supply PC board(s). Refer to the Pause and Cancel Key Self Test on page 2-27. Printer not configured properly.
PAGE 59
7URXEOHVKRRWLQJ 6HFWLRQ Symptom In Peel-off Mode, skewed or stuck labels. Diagnosis Action Glue material from back of labels causing media movement problems. Media and liner not properly aligned in printer. Ribbon fed through printer incorrectly. Perform maintenance and clean the printer (see Table 4 1). Incorrect darkness setting. Wrinkled ribbon. Incorrect printhead pressure. Check media guide position. Re-install ribbon.
PAGE 60
6HFWLRQ Page 3-4 7URXEOHVKRRWLQJ Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 61
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3UHYHQWLYH 0DLQWHQDQFH Preventive maintenance consists of: • Visual Inspection • Regular cleaning of the printhead and platen roller • General cleaning of the printer’s interior and exterior An operator or technician may perform preventive maintenance (see Table 4-1) from the preventive maintenance chart. 7RROV 5HTXLUHG IRU 3UHYHQWLYH 0DLQWHQDQFH 77259L Rev.
PAGE 62
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH (TXLSPHQW 6DIHW\ 7LSV After reviewing each procedure, place a check in the box. The AC power plug and IEC 320 connectors on all Zebra printers must bear the certification mark of at least one international safety organizations listed below. + R Unless indicated otherwise, turn the printer Off (O) before performing any maintenance procedures to the printer.
PAGE 63
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ (TXLSPHQW 6DIHW\ 7LSV &RQWLQXHG Zebra recommends using solvent containing 90% isopropyl alcohol, 10% deionized water for cleaning of; • Printheads • Platen Rollers • Peel-Off Roller • Media Path • Peel/Tear Bar • Spindles • Zebra PN 47362 preventive maintenance kit contains pre-moistened swabs soaked in the recommended solution. Ribbons used in the printers must be as wide as or wider than the media.
PAGE 64
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3HUVRQDO 6DIHW\ 7LSV Do not wear jewelry (rings, watches, etc.) or loose clothing when servicing the printers. Beware of “Pinch Points” on the printers. Be especially careful of: • Opening and closing of covers. • Printhead • Rewind Spindle • Platen Roller Wear protective eye wear when installing or removing E-rings, C-clips, snap rings, and springs. These are under tension and could fly off.
PAGE 65
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ &OHDQLQJ ([WHULRU The exterior surfaces of the printer may be cleaned with a lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents. If necessary, a mild detergent or desktop cleaner may be used sparingly. ,QWHULRU Remove any accumulated dirt and lint from the interior of the printer using a soft bristle brush and/or vacuum cleaner. Refer to Table 4-1 for the correct interval for cleaning the printhead and platen roller.
PAGE 66
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads. 3ULQWKHDG DQG 3ODWHQ 5ROOHU Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty printhead. For best results, perform the following cleaning procedure after every roll of ribbon. Note • The printer can remain on while you are cleaning the printhead.
PAGE 67
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Printhead Ribbon Sensor Take Label Sensor Transmissive Sensor Reflective Sensor Platen Roller Figure 4-1. Printhead, Platen Roller and Sensor Cleaning &OHDQLQJ WKH 6HQVRUV Refer to Figure 4-1. Open the media door. Brush or vacuum any accumulated paper lint and dust away from the printer sensors. The reflective sensor, transmissive sensor, and ribbon sensor should be cleaned on a regular basis to ensure proper operation of the printer.
PAGE 68
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 4. Manually rotate the pinch and deflector rollers, clean thoroughly with solvent and a swab. 5. Close the pivot bracket assembly. 6. Close the printhead assembly. Close media door. Printhead Assembly Tear/Peel Bar Pinch Roller Deflector Rollers Pivot Bracket Assembly Figure 4-2. Cleaning the Value Peel-Off Module &OHDQ WKH &XWWHU 0RGXOH Refer to Figure 4-3.
PAGE 69
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 8. 6HFWLRQ If the cutter continues to perform unsatisfactorily, contact an authorized service technician. Cutter Shield Thumb Screw and Lock Washer Upper Cutter Blade Lower Cutter Blade Cutter Motor Thumbnut Figure 4-3. Cutter Module Cleaning /XEULFDWLRQ No lubricating agents of any kind should be used on the printer! Some commercially available lubricants will damage the finish and the mechanical parts. 77259L Rev.
PAGE 70
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH &RUUHFWLYH 0DLQWHQDQFH Corrective maintenance consists of the following: • Troubleshooting printer faults to a modular level. • Replacing or adjusting faulty or inoperable components. • Returning the printer to proper operating condition.
PAGE 71
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Media Door Electronics Cover Mounting Screws (2) Electronics Cover Early Version Z4M/Z6M Upper Flange Media Door Star Washer Electronics Cover Mounting Screw Lower Flange Electronics Cover Current Version Z4M/Z6M Figure 4-4. Removal and Installation of the Electronics Cover Caution • Turn OFF (O) the printer and disconnect it from the power source before performing the following maintenance. 77259L Rev.
PAGE 72
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 4. Refer to Figure 4-5. Rotate the two printhead pressure dials to the #1 position. Printhead Pressure Knobs Printhead Pressure Knobs Front of Printer Front of Printer Thumbscrew Position #4 Position #1 Thumbscrew Position #1 Position #8 Z4M 5. 6. Z6M Figure 4-5. Print Mechanism Unlatch the print mechanism. Refer to Figure 4-6. Remove and retain the screw securing the printhead grounding strap.
PAGE 73
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 7. 6HFWLRQ Refer to Figure 4-7. If installed, remove the PCMCIA card by removing the back cover from the printer. Screen AC Power Switch PCMCIA Screen Mounting Screws AC Connector 8. Figure 4-7. Back Cover Removal and Installation Refer to Figure 4-8. Remove and retain the mounting screw and washer on the top of the PCMCIA card. Note • Make sure not to lose the three insulating washers. 9. 77259L Rev.
PAGE 74
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Power Supply Main Logic Board Mounting Screw Printhead Power Cable Elastomeric Connector Stud Plate Cable Ties J1 J3 P2 Insulating Washers PCMCIA Board Non-Component Side P3 P4 P8 P5 P6 P7 P1 Printhead Ground Strap Thumb Nut Printhead Data Cable Ground Strap Mounting Screw Cable Clips 13. Figure 4-8. Cable Locations and Routing Refer to Figure 4-9.
PAGE 75
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ ,QVWDOO WKH 3ULQW 0HFKDQLVP 1. Feed the cables of the new print mechanism through the print mechanism mounting hole. 2. Refer to Figure 4-9. Install, but do not tighten, the three mechanism mounting screws and insulating washers. 3. Visually align the top edge of the print mechanism with the top edge of the raised mounting surface. 4. Snug the two hex head screws at this time, leaving the Phillips head loose. 5. Latch the print mechanism.
PAGE 76
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 4. Insert the print mechanism gap pin gauges through the holes in the front of the ribbon guide plate. 5. Refer to Figure 4-9. Slightly loosen the two hex head print mechanism mounting screws. 6. Refer to Figure 4-10. Place a 4-inch crescent wrench on the print mechanism adjustment cam. Turn the wrench counterclockwise, and push in and pull out the inside gap pin gauge. Adjust the cam until a small amount of friction can be felt. 7.
PAGE 77
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 11. Reinstall the electronics cover and tighten the two screws to secure the cover to the printer. 12. Reinstall media and ribbon and reconnect power to the printer. 13. Rotate the two printhead pressure dials to the #3 position (Z4M), or the #6 position (Z6M). 14. Turn the printer power on and print the Pause Key and Cancel Key Self Test Label.
PAGE 78
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Printhead Pressure Knobs Printhead Pressure Knobs Front of Printer Front of Printer Thumbscrew Position #4 Position #1 Thumbscrew Position #1 Position #8 Z4M Z6M Figure 4-12. Top View of Printhead Mechanism Thumbscrew Printhead Pressure Dials Mounting Plate Printhead Mechanism Assembly Printhead Connectors Locating Holes Printhead Fork Assembly Figure 4-13. Printhead Removal/Install Page 4-18 Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 79
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ ,QVWDOOLQJ WKH 3ULQWKHDG Refer to Figure 4-12 and Figure 4-13. 1. Connect the printhead cables to the printhead fork assembly and carefully slide the assembly into the print mechanism. 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.
PAGE 80
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 'ULYH 6\VWHP 3ULQWKHDG &KDQJHRYHU IURP '3, WR '3, Caution • This installation must be performed by a qualified service technician. A field installable option for Z4M permits changing printhead density and drive system from 203 dpi to 300 dpi. 1. Refer to page 4-17. Remove the 203 dpi printhead, and install the 300 dpi printhead supplied in the kit. 2. Refer to Figure 4-15.
PAGE 81
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Media Door Electronics Cover Mounting Screws (2) Electronics Cover Early Version Z4M/Z6M Upper Flange Media Door Star Washer Electronics Cover Mounting Screw Lower Flange Electronics Cover Current Version Z4M/Z6M 77259L Rev. 4 12/16/03 3. Figure 4-15. Remove the Electronics Cover Refer to Figure 4-16. Use a hex key to remove the compound gear mounting screw. Turn the gear around. 4.
PAGE 82
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 7. Using a hex key, remove and retain the two set screws on the platen roller pulley. Remove the pulley and belt. Turn the pulley around so that the large pulley faces away from the printer. 8. Slide the pulley and belt back onto the platen roller shaft. Note • Make sure there is approximately a 0.020 inch (0.5 mm) gap between the pulley and the printer frame. 9. Secure it back onto the platen roller shaft using the set screws previously removed.
PAGE 83
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Adjustment Screw Print Mechanism 6HFWLRQ Strike Plate Cap Front Edge Strike Plate Washer Ribbon Guide Plate Strike Plate Mounting Screws Spring Platen Housing Latch Cover Spring Latch Front Edge Pin Figure 4-17. Latch Kit Parts Note • The spring pin must be tapped out from the rear and removed from the front of the platen housing. Trying to remove the pin in the other direction will damage the platen housing. 7.
PAGE 84
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Adjustment Screw Short Side Short Side In here Long Side Here Washer Print Mechanism Mounting Screws 4. Figure 4-18. Strike Plate Installation Install the adjustment screw into the strike plate by sliding it in the opening as seen in Figure 4-19. Strike Plate Adjustment Screw Shoulder Adjustment Screw 5. Page 4-24 Figure 4-19. Adjustment Screw Location Refer to Figure 4-19.
PAGE 85
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 6. Refer to Figure 4-18. Insert the two mounting screws and washer through the strike plate and into the print mechanism. Do not tighten at this time, leave them approximately ½ turn loose. 7. Latch the print mechanism. $GMXVW 3ULQWKHDG 0HFKDQLVP 1. Refer to Figure 4-19. Insert the print mechanism gap pin gauges through the holes provided in the front of the ribbon guide plate. 2.
PAGE 86
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 9. Tighten the printhead mechanism mounting screws when equal pressure is obtained. 10. Refer to Figure 4-20. Tighten the two print mechanism hex screws and the phillips head screw. 11. Figure 4-21. Print Mechanism Mounting Screws Reinstall the strike plate cap. 12. Reinstall the latch cover. 13. Reinstall the ribbon and media. 14. Reconnect AC power cord and restore power. 15. Remove the screw and the print mechanism adjustment cam.
PAGE 87
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 5HPRYH 3ODWHQ 5ROOHU 1. Turn the printer power OFF at the rear of the printer. Disconnect the AC power cord. 2. Open the media door and remove all media and ribbon from the printer. 3. Refer to Figure 4-15. Remove the electronic side cover by removing the one or two screws that secure the cover to the printer. Note • Make note of the orientation of pulley and around which pulley the belt is installed. 4. Refer to Figure 4-16.
PAGE 88
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 8. Locate the circular cut-out on the top of the outer spring clip, insert a screwdriver, gently pry up and remove the clip. Use the same procedure for the clip on the inboard side of the platen roller to loosen the clip. Circular Cut-Out Barbed Legs 9. Figure 4-23. Platen Roller Disassembly Remove and discard the platen roller and bearings. Install Platen Roller 1.
PAGE 89
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ . Spring Clip Platen Roller Platen Roller Bearing Spring Clip Curved Spring Washer Platen Roller Bearing 4. Figure 4-24. Platen Roller Kit Once the inboard bearing is fully against the clip, angle up the outboard end of the platen just enough to slide on the wave washer and outboard bearing. Seat the platen roller and bearings in the platen housing. 5. Verify that the bearings are seated in the housing with the flat side up.
PAGE 90
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 12. Replace the electronic side cover. Place media and ribbon back into the printer. Close the media door. Reconnect the AC power cord. 13. Turn the printer power ON and print a configuration label. 5HSODFH 0DLQ /RJLF %RDUG 5HPRYH 0DLQ /RJLF %RDUG Caution • This installation must be performed by a qualified service technician. 1. From the rear of the printer, turn the printer power Off (O) and disconnect the AC power cord. 2. Refer to Figure 4-15.
PAGE 91
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 7. 6HFWLRQ Refer to Figure 4-25. Remove and retain the two screws that secure the main logic board to the printer. Remove the main logic board. ws 2) B d Figure 4-25. Removal and Replacement of the Main Logic Board ,QVWDOO 0DLQ /RJLF %RDUG 1. If PCMCIA option is installed, refer to “Installing the Memory Card (PCMCIA) Interface Option Kit” on page 4-53 and remove the PCMCIA card, the elastomic connector and the stud plate. Note • Refer to Figure 4-26.
PAGE 92
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 8. Turn the printer power ON (l) and print a configuration label using the Cancel Key Self Test. Flash Memory Socket (U7) Power In Connector (P2) Parallel Port Power Rewind Cutter Option Connector (P3) Serial Port Ribbon/head Open Sensor Connector (P4) Transmissive Sensor Connector (P5) Reflective Sensor Connector (P6) Print Mechanism Ribbon Cable (P1) Fuses (1/2 A 270 V) Front Panel Connector (P7) Figure 4-26.
PAGE 93
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5. 6HFWLRQ Refer to Removing Main Logic Board on page 4-30 and remove the main logic board. Note • Place a soft cloth on your work surface. 6. Place the printer on its side, media door side down. 7. Refer to Figure 4-28. Disconnect all connectors from the power supply board. Note • Make note of the orientation and location of all the connectors. 8. Refer to Figure 4-27.
PAGE 94
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 12. Refer to Figure 4-27. Remove the three screws that secure the power supply board to the printer. Remove the power supply board along with the insulator pad. ,QVWDOO 3RZHU 6XSSO\ %RDUG 1. Refer to Figure 4-27. Place the insulator pad over the locating pins on the printer. Verify that all holes align with holes in the main frame. Caution • Improper alignment or installation of this insulator pad can cause injury.
PAGE 95
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5. 6HFWLRQ Remove the old clamp pad and clamp insulator from the heatsink. Note • Clamp pad and clamp insulator must be replaced on the heatsink. 6. Assemble the new heatsink, insulator and foam pad. Caution • Improper alignment or installation of this insulator pad can cause injury. 77259L Rev. 4 12/16/03 7. Peel the protective covering off the foam pad then with the adhesive side up, set it on a flat surface. 8.
PAGE 96
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 19. Refer to Figure 4-29. Set your VOM (voltage ohm meter) to the lowest ohm range and connect the meter between the main frame and the main AC input ground. The reading must be less than one ohm. Main Frame Positive Probe Ground Probe To Chassis Ground VOM 20. 21. Figure 4-29. Test the Power Supply Leave the AC power cord disconnected and turn the power switch On (l).
PAGE 97
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 'ULYH %HOW 5HSODFHPHQW 5HPRYH 'ULYH %HOW Caution • This installation must be performed by a qualified service technician. 1. Turn the printer Off (O) and disconnect the AC power cord. 2. Refer to Figure 4-15. Open the media door and remove the two screws that secure the electronics cover to the printer. Remove the cover. Note • Take note around which pulley of the compound pulley the belt is installed. 3. Refer to Figure 4-30.
PAGE 98
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH ,QVWDOO 'ULYH %HOW 1. Install the belt on the correct pulley of the compound pulley. 2. Lift up on the stepper motor, place the belt onto the stepper motor drive gear. Note • Belt deflection should be no more than ¼ inch (6 mm). 3. Adjust the position of the stepper motor to achieve the correct belt deflection and tighten the locking screw to secure the motor. Tighten the pivot screw. 4. Install the electronics side cover. 5.
PAGE 99
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5. 6HFWLRQ Cut the cable tie holding the panel cable to the motor wires. Disconnect the front panel ribbon cable connector from the main logic board. Remove the cable and the front panel. Washer Detail Mounting Screw Front Panel Grounding Cable Front Panel Data Cable Cable Tie Access Hole White Ferrite Block Cable Tie P7 Connector Motor Wires Main Logic Printhead Board Data Cable Figure 4-31.
PAGE 100
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3. Refer to the detail in Figure 4-31 and fold the flat end on the new ground cable shiny side to shiny side. Note • Use caution when securing the front panel that the ground cable does rotate more than 1/8 turn. 4. Install the previously removed screw through the washer and ground strap. Tighten the screw to snug in the new front panel. 5. Check the wiring routing. Use cable ties as necessary to bundle and secure wires.
PAGE 101
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Torsion Spring Dancer Bearing E-Ring Figure 4-32. Dancer Assembly ,QVWDOOLQJ WKH 'DQFHU $VVHPEO\ 1. Install the new torsion spring, the first bearing, the dancer, the second bearing, and then the e-ring. 2. Place the dancer assembly torsion spring back to its operating position against the printer post and dancer tab. Check to make sure there is tension on the dancer assembly. 3. Reload the media and ribbon.
PAGE 102
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3. Refer to Figure 4-15. Remove the electronics side cover by removing the two screws that secure the cover to the printer. Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads. 4. Refer to Figure 4-33. Loosen and remove the screw that secures the ribbon/head open sensor assembly.
PAGE 103
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ ,QVWDOOLQJ WKH 5LEERQ +HDG 2SHQ 6HQVRU $VVHPEO\ 1. Refer to Figure 4-33. Feed the sensor cable through the opening in the main frame. Attach the sensor to the main frame with the screw previously removed. Do not tighten the mounting screw until the sensor gap is established. Main Logic Board Assembly 2. 77259L Rev. 4 12/16/03 Main Logic Board Connector (P4) Ribbon/Head Open Sensor Connector Figure 4-34.
PAGE 104
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH . Print Mechanism 0.060 inch ± 0.015 inch (1.5 mm ± 0.4 mm) Mounting Screw Ribbon/Printhead Open Sensor Figure 4-35. Ribbon/Printhead Sensor Gap 7UDQVPLVVLYH 6HQVRU 5HSODFHPHQW 5HPRYH 7UDQVPLVVLYH 6HQVRU Caution • This installation must be performed by a qualified service technician. 1. Turn the printer Off (O) and disconnect the AC power cord. 2. Open the media door and remove all media and ribbon from the printer. 3. Refer to Figure 4-15.
PAGE 105
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Main Logic Board Connector (P5) Access Hole Transmissive Sensor Cable Main Logic Board Main Logic Board Bracket 7. Figure 4-36. Transmissive Sensor Assembly Connection Refer to Figure 4-37. While using the phillips screwdriver, loosen and remove the transmissive sensor mounting screw and sensor. 8. Remove the transmissive sensor connection on the main logic board.
PAGE 106
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH ,QVWDOO 7UDQVPLVVLYH 6HQVRU 1. Feed the sensor cable through the opening under the printhead assembly as shown in Figure 4-37. 2. Install the sensor to the main frame. Make sure the guide pin of the sensor body seats in the lower hole for proper positioning. Note • Do not overtighten the mounting screw. Damage to the transmissive assembly housing can occur by overtightening the mounting screw. 3. Refer to Figure 4-36.
PAGE 107
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 5HSODFH 5HIOHFWLYH 0HGLD 6HQVRU 5HPRYH 5HIOHFWLYH 0HGLD 6HQVRU $VVHPEO\ Caution • This installation must be performed by a qualified service technician. 1. Turn the printer Off (O) and disconnect the AC power cord. 2. Open the media door and remove media and ribbon from the printer. 3. Refer to Figure 4-15. Remove the electronics cover by removing the two screws that secure the cover to the printer.
PAGE 108
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH . Platen Roller Assembly Latch Cover Media Sensor Holder Mounting Tabs Media Sensor Carrier Media Sensor Assembly Figure 4-39. Media Sensor Removal ,QVWDOO 0HGLD 6HQVRU $VVHPEO\ 1. Refer to Figure 4-39. Install the new media sensor assembly into the carrier by snapping the sensor portion into the carrier. Ensure that the button, spring and insulator have the proper spring action by pressing down on the button and releasing it. 2.
PAGE 109
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 5HSODFH 5LEERQ 7DNH 8S $VVHPEO\ 5HPRYH 5LEERQ 7DNH 8S $VVHPEO\ Caution • This installation must be performed by a qualified service technician. 1. Turn the printer Off (O) and disconnect the AC power cord. 2. Open the media door and remove media and ribbon from the printer. 3. Refer to Figure 4-15. Remove the electronic cover by loosening and removing the two screws that secure the cover to the printer. 4. Refer to Figure 4-40.
PAGE 110
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5HSODFH 5LEERQ 6XSSO\ $VVHPEO\ 5HPRYH 5LEERQ 6XSSO\ $VVHPEO\ Caution • This installation must be performed by a qualified service technician. Refer to Figure 4-41. 1. Turn the printer Off (O) and disconnect the AC power cord. 2. Open the media door and remove media and ribbon from the printer. 3. Refer to Figure 4-15. Remove the electronics cover by removing the two screws that secure the cover to the printer. 4.
PAGE 111
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3. 6HFWLRQ Loosely reinstall the stepper motor using the pivot screw, locking screw and adjustment nut. Note • Belt deflection should be no more than ¼ inch (6 mm). 4. While lifting up on the stepper motor, reinstall the drive belt. Release the stepper motor to provide tension on the belt. 5. Adjust the position of the stepper motor to achieve the correct belt deflection and tighten the locking screw to secure the motor. Tighten the pivot screw. 6.
PAGE 112
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Main Logic Board Flash Socket U7 Pin #1 Position Figure 4-42. Flash Memory Socket Location Caution • Pin #1 on the memory chips may vary from different manufacturers. Please check the manufacturer’s documentation to ensure proper #1 position when installing memory chips. Improper positioning may cause damage to the chip and to the printer. Caution • Exercise caution when handling the memory chip.
PAGE 113
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Note • Locate position #1 on the socket and position #1 on the chip. The #1 pin on the chip is identified by a circle near the corner of the chip. Some chip manufactures have two circles on the chip. The #1 pin in this case is the one on the same side as the notch on the chip. 7. Place the flash memory chip inside the socket as shown. 8. Close socket and slide #1 to the left until it snaps in place. 9. Place the printer in the upright position.
PAGE 114
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Media Door Electronics Cover Mounting Screws (2) Electronics Cover Early Version Z4M/Z6M Upper Flange Media Door Star Washer Electronics Cover Mounting Screw Lower Flange Electronics Cover Current Version Z4M/Z6M 3. Page 4-54 Figure 4-44. Electronics Cover Removal Refer to Figure 4-45. Remove and retain the two screws that secure the back cover on the printer and then remove the cover. Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 115
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ . Screen PCMCIA Screen Mounting Screws AC Power Switch AC Connector 4. Figure 4-45. Back Cover Mounting Screws Refer to Figure 4-46. Remove and retain the nearest to the top left corner of the power supply and replace it with the standoff supplied with the kit.
PAGE 116
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5. Refer to Figure 4-47. From behind the main PC board assembly, place the stud plate through the three holes on the main PC board assembly. Also from behind the main PC board, push the temporary fastener through the aligning hole on the right hand side, as shown. Stud Plate Elastomeric Connector Temporary Fastener Main Logic Board Figure 4-47. Elastomeric Connector and Stud Plate Installation Refer to Figure 4-48.
PAGE 117
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6. 6HFWLRQ Refer to Figure 4-46. Place the elastomeric connector over the stud plate. Place the PCMCIA board against the elastomeric connector. Make sure the connector is fully seated and both conductive elements are in place. Note • Make sure the elastomeric connector is fully seated between the PCMCIA board and the main PC board. If the connector is not fully seated, the PCMCIA option will not function. 7. Refer to Figure 4-46.
PAGE 118
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Media Door Electronics Cover Mounting Screws (2) Electronics Cover Early Version Z4M/Z6M Upper Flange Media Door Star Washer Electronics Cover Mounting Screw Lower Flange Electronics Cover Current Version Z4M/Z6M 5. 6. Page 4-58 Figure 4-49. Front Cover and Electronics Cover Removal Reinstall the latch cover. Refer to Figure 4-50. Locate the cutter assembly in the kit.
PAGE 119
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Detail A M Must be in this Location “M” Mounting Bracket M Detail B Cutter Assembly Z6M Cutter Z4M Cutter Assembly Assembly Mounting Brackets Mounting Brackets Figure 4-50. Mounting Bracket Location and Position 7. Refer to Figure 4-51. While holding the cutter assembly, route the cutter assembly wire harness through the main frame access hole. Cutter Shield Tear Bar Tear Bar Mounting Screws Thumb Screw Cutter Assembly 8. 77259L Rev.
PAGE 120
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 9. Secure the cutter assembly onto the platen assembly. The mounting bracket tab on the cutter fits behind and attaches to the platen assembly leg, using the screw provided to secure it to the platen housing assembly. 10. Refer to Figure 4-52. Place the cutter shield over the cutter assembly and secure in place using the thumb screw provided.
PAGE 121
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Main Logic Board Connector (P3) Cutter Connector Cutter Harness Access Hole Figure 4-53. Cutter Option Connector Location on Main Logic Board 13. Reinstall the electronics side cover and secure with the two screws previously removed. 14. Reinstall media and ribbon and close the media door. 15. Reinstall the AC power cord and restore power. ,QVWDOO 9DOXH 3HHO 2SWLRQ 1. Turn the printer Off (O) and disconnect the AC power cord. 2.
PAGE 122
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5. Refer to Figure 4-55. Remove the tear bar and discard the mounting screws. Media Cover Mounting Screws (2) Front Cover Latch Cover 6. Figure 4-54. Removal of Front and Latch Cover Refer to Figure 4-57. Remove existing value peel assembly. 7. Refer to Figure 4-51. Remove existing cutter assembly. 8. Using the supplied hex key, install the two flanged mounting screws from the kit into the tear bar mounting screw holes.
PAGE 123
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 10. 6HFWLRQ Refer to Figure 4-57. Install the value peel assembly with the pems to the rear and the opening in the mounting slot to the top. Insert the mounting slot opening over the two screws and lift up on the assembly. Now push the assembly back against the vertical surface of the platen assembly then down so that pems are resting on the horizontal surface of the platen housing. Value Peel Assembly Mounting Slots Pems 11. Figure 4-56.
PAGE 124
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 12. Refer to Media Loading, Value Peel, on page 2-29 for instructions on loading ribbon and media. ,QVWDOO /LQHU 7DNH XS 2SWLRQ Caution • This installation must be performed by a qualified service technician. The Liner Take-up Assembly Kit is shown in Figure 4-58. Motor Tape Cable 1. Figure 4-58. Contents of Liner Take-up Assembly Kit Turn the printer Off (O) and disconnect the AC power cord. 2. Refer to Figure 4-49.
PAGE 125
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6. 6HFWLRQ Attach the other end of the liner take-up motor cable to the liner take-up motor assembly. . Main Logic Board Connector (P3) Liner Take-up Motor Connector Access Hole 7. Liner Take-up Motor Cable Figure 4-60. Liner Take-up Motor Harness Installation Refer to Figure 4-61. Align the holes in the motor assembly mounting plate with the holes in the main frame. Secure the motor assembly with two screws.
PAGE 126
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Caution • Wear protective eyewear when removing E-rings, C-clips, snap rings, and springs. These are under tension and could fly off while removing. 8. Refer to Figure 4-59. Slide the spindle on the shaft, and install the E-ring provided. 9. Reinstall the electronics cover. 10. Reinstall the AC power cord and apply power. 11. Turn the printer On (l). For media loading, see value peel-off mode with liner take-up on page 2-10.
PAGE 127
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ 4. Carefully remove the plastic latch cover from the platen housing latch. 5. Slide the front cover to the right, then lift to remove. 6. Reinstall the plastic latch cover. 7. Refer to Figure 4-63. Loosen, but do not remove, the three screws that attach the rear cover to the main frame and base.
PAGE 128
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 4. Reinstall the rear cover by sliding it under the screw loosened previously on the main frame. Leave the screw loose. 5. Using the two screws supplied in the kit, attach the rear cover to the rewind pan. Tighten the two screws and the one screw on the main frame. Note • Make sure the two holes on rewind support bracket face up and are aligned with the mounting holes in the main frame. 6. Refer to Figure 4-64.
PAGE 129
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Main Logic Board Connector (P3) Rewind Motor Cable Connector Access Hole 9. Rewind Motor Cable Figure 4-65. Main Logic Board Connector Refer to Figure 4-66. Align one of the two access holes on the rewind back plate to one of the mounting holes on the rewind support. Note • For ease of alignment do not tighten the first screw until the second screw is installed. 10.
PAGE 130
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 13. Install the electronics cover and secure with the two screws removed previously. ,QVWDOODWLRQ RI 9DOXH 3HHO $VVHPEO\ Note • If there is an existing value peel assembly, it must be removed. If a value peel assembly in not currently installed the tear bar must be removed. 1. To remove an existing tear bar, refer to Figure 4-67 remove the two mounting screws and remove the tear bar. Tear Bar Tear Bar Mounting Screws Page 4-70 2. Figure 4-67.
PAGE 131
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Mounting Slots 6HFWLRQ Mounting Screws Rest Pems on Housing Here 4. Figure 4-68. Value Peel Installation and Removal Using the hex key supplied in the kit, install the two flanged mounting screws from the kit into the tear bar mounting screw holes. Tighten them to within 1/8 inch of the platen housing. 5. Refer to Figure 4-69. Take note of the pems and the mounting slots. Value Peel Assembly Mounting Slots Pems Figure 4-69.
PAGE 132
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6. Refer to Figure 4-68. Install the value peel assembly with the pems to the rear and the opening in the mounting slot to the top. Insert the mounting slot opening over the two screws and lift up on the assembly. Now push the assembly back against the vertical surface of the platen assembly then down so that pems are resting on the horizontal surface of the platen housing. 7.
PAGE 133
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Main Frame Mounting Screws 6HFWLRQ Main Frame Rear Cover Mounting Screws Rear Cover Platen Housing Mounting Screw Base Assembly Main Frame Mounting Screws Figure 4-70. Pan Removal Note • Do not remove the screws attaching the platen housing to the main frame. 8. Remove the screw that attaches the platen housing to the base. If there is a plastic washer present, discard it. 9. Remove the four screws that attach the main frame to the base. 10. 77259L Rev.
PAGE 134
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH ,QVWDOODWLRQ RI 5HZLQG 3DQ Note • Alignment is very important. The platen housing leg must be inside the mounting tab of the rewind pan. 1. Refer to Figure 4-71. 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.
PAGE 135
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 7. 6HFWLRQ Refer to Figure 4-72. Place the rewind motor and spindle assembly inside the rewind pan assembly. Rewind Motor Assembly Rewind Pan Assembly 8. 77259L Rev. 4 12/16/03 Figure 4-72. Rewind Motor Location Feed the wire harness up through the hole in the bottom of the main frame. 9. Refer to Figure 4-73. Connect the rewind motor harness connector to the main logic board assembly connector P3. 10. Refer to Figure 4-74.
PAGE 136
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH Main Logic Board Connector (P3) Rewind Motor Cable Connector Access Hole Rewind Motor Cable Figure 4-73. Main Logic Board Connector Access Hole Access Hole Rewind Back Plate 13. Page 4-76 Rewind Back Plate Figure 4-74. Rewind Motor Assembly Mounting Replace the electronics side cover. Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 137
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ ,QVWDOO 3HHO $VVHPEO\ 1. Refer to Figure 4-75. Hook the peel assembly hooks onto the hooks of the platen housing. Note • Verify that the ribbon cable running between the inside mounting plate and the main frame is located above the inside mounting screw. 2. With the peel assembly in the “open” position, secure the inside mounting plate of the assembly to the platen housing using the mounting screw provided with the kit. 3.
PAGE 138
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 0DLQWHQDQFH .LWV 5HZLQG 0RWRU DQG 6SLQGOH $VVHPEO\ Caution • This installation must be performed by a qualified service technician. KIT NUMBER Printer 77498M 77898M 78007M 78007-6M Z4M with Power Peel/Rewind Z6M with Power Peel/Rewind Z4M with Value Peel/Rewind Z6M with Value Peel/Rewind Note • For 78007M and 78007-6M, the firmware must be version 39.11.0 or higher. To download the correct version of firmware go to: www.zebra.
PAGE 139
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Main Logic Board Connector (P3) Rewind Motor Cable Connector Access Hole 6. 7. Rewind Motor Cable Figure 4-76. Main Logic Board Connection Refer to Figure 4-77. Rotate the spindle until one of the two access holes on the rewind back plate align with one of the mounting screws on the rewind support. Remove the screw. Align the other access hole of the rewind back plate to the other mounting screw and remove the screw.
PAGE 140
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 9. Refer to Figure 4-78. Cut the cable tie securing the media rewind cable to the PCB assembly. Rewind Motor/Spindle Assembly Cable Tie Media Rewind Cable 10. Figure 4-78. Cable Location Disconnect the media rewind cable from the connector on the PCB. 5HZLQG 0RWRU DQG 6SLQGOH ,QVWDOODWLRQ Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads. 1.
PAGE 141
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 9. 6HFWLRQ Reinstall the media and ribbon. Close the media door. 10. Reconnect the AC power cord and restore power. 11. Turn the printer On (l). Place the printer into the rewind or peel mode (see the User Guide for proper set-up and media loading instruction). 5HZLQG 3&% 0RWRU $VVHPEO\ Caution • This installation must be performed by a qualified service technician.
PAGE 142
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 5. Refer to Figure 4-79. Disconnect the media rewind cable connector from P3 on the main logic board. Main Logic Board Connector (P3) Rewind Motor Cable Connector Access Hole 6. 7. Rewind Motor Cable Figure 4-79. Rewind Motor Cable Location Refer to Figure 4-80. Rotate the spindle until one of the two access holes on the rewind back plate align with one of the mounting screws on the rewind support. Remove the screw.
PAGE 143
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 8. 6HFWLRQ Carefully slide the rewind motor and spindle assembly out of the rewind pan while guiding the media rewind cable through the hole in the bottom of the main frame. Caution • Wear protective eyewear when removing E-rings, C-clips, snap rings, and springs. These are under tension and could fly off while removing. 9. Refer to Figure 4-81. Using a standard screwdriver, remove the E-ring from the rewind shaft. wind /Spindle E-Ring 10. Figure 4-81.
PAGE 144
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 12. Refer to Figure 4-82. Remove and retain the two mounting screws that secure the rewind PCB assembly to the rewind support. Rewind Back Plate ewind e 13. Figure 4-82. PC Board Assembly Removal and Installation Cut the cable tie securing the media rewind cable to the PCB assembly. 14. Disconnect the media rewind cable from the connector on the PCB. ,QVWDOO 3&% 0RWRU $VVHPEO\ 1. Refer to Figure 4-83.
PAGE 145
3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 6HFWLRQ Cable Tie Diode D1 Correct 4. Incorrect Figure 4-83. PCB Motor Assembly Orientation Refer to Figure 4-81. Reinstall the rewind spindle using the E-ring previously removed. 5. Carefully guide the media rewind cable through the access hole in the bottom of the main frame while sliding the rewind motor and spindle assembly into the rewind pan. 6. Refer to Figure 4-80.
PAGE 146
6HFWLRQ 3UHYHQWLYH DQG &RUUHFWLYH 0DLQWHQDQFH 3LQFK 5ROOHU .LW ,QVWDOODWLRQ 1. Lower pinch roller holder assembly to open position. Caution • Wear protective eyewear when removing E-rings, C-clips, snap rings, and springs. These are under tension and could fly off while removing. Note • If the E-rings are not accessible, you can remove the value peel assembly. To do so, loosen the two screws mounting the value peel assembly and remove it from the printer. 2. Refer to Figure 4-84.
PAGE 147
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ 6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV *HQHUDO ,QIRUPDWLRQ Use the mechanical assembly drawings when troubleshooting or replacing components and use the associated parts list when ordering replacement parts. Item parts that do not have associated part numbers are not available and need to be ordered using the next highest assembly number.
PAGE 148
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-1.
PAGE 149
Maintenance and Assembly Drawings Section 5 1 4 2 6 5 3 10 7 8 9 14 17 11 16 15 18 12 13 Figure 5-1. Main Printer Assemblies 77259L Rev.
PAGE 150
Section 5 Maintenance and Assembly Drawings Table 5-2.
PAGE 151
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ Table 5-3. (Reflective) Media Sensor Assembly Maintenance Kit ITEM PART NUMBER REF 77807M 1 N/A 2 Q06020 N/A: Not Available Separately DESCRIPTION QTY Kit, Maintenance Media Sensor Assembly (Reflective) . Media Sensor Assembly . Tie Wrap 1 1 3 1 2 Figure 5-3. (Reflective) Media Sensor Assembly Maintenance Kit 77259L Rev.
PAGE 152
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-4. Platen Assembly ITEM PART NUMBER DESCRIPTION QTY 1 †HW44216 Screw, M4.2 x 1.41 2 77752M Kit, Maintenance Optical (Transmissive) Media Sensor 3 77935M Kit, Maintenance Media Edge Guide 4 †HW46128 Washer, Nylon 5 77807M Kit, Assembly (Reflective) Media Sensor (See Figure 5-3. ) 6 77023M Kit, Maintenance Platen Roller Shaft (Z4M) (See Figure 5-5. ) 6 77022M Kit, Maintenance Platen Roller Shaft (Z6M) (See Figure 5-5.
PAGE 153
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ 3 1 2 4 6 5 8 9 7 10 11 12 13 14 15 Figure 5-4. Platen Assembly 77259L Rev.
PAGE 154
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-5. Platen Roller Shaft Maintenance Kit ITEM PART NUMBER DESCRIPTION QTY REF 77023M Kit, Maintenance Platen Roller, Z4M REF 77022M Kit, Maintenance Platen Roller, Z6M 1 N/A …Roller, Platen Shaft 2 N/A …Bearing, Platen 3 N/A …Spring, Clip 4 N/A …Washer, Spring N/A: Not Available Separately 1 1 1 1 2 1 3 1 2 3 4 2 Figure 5-5. Page 5-8 Platen Roller Shaft Maintenance Kit Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 155
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ Table 5-6. Printhead Housing Maintenance Kit ITEM PART NUMBER DESCRIPTION QTY 1 77171M Kit, Maintenance Printhead Housing (203 dpi printhead) Z4M 2 77804M Kit, Maintenance Cable Printhead 4 inch 2 77831M Kit, Maintenance Cable Printhead 6 inch 3 77500M Kit, Maintenance Printhead 300 dpi (Z4M) 3 77000M Kit, Maintenance Printhead 203 dpi (Z4M) 3 77001M Kit, Maintenance Printhead 203 dpi (Z6M) 3 77501M Kit, Maintenance Printhead 300 dpi (Z6M) 4 *HW77047 .
PAGE 156
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-7. Static Brush Assembly Maintenance Kit ITEM PART NUMBER REF 77302M REF 77303M 1 ††HW10401 2 10472 3 77318 3 77319 4 N/A 5 *HW77237 N/A: Not Available Separately DESCRIPTION QTY Kit, Maintenance Static Brush Assembly (Z4M) Kit, Maintenance Static Brush Assembly (Z6M) . Screw, M3 x 0.5 . Washer, Star M3 . Brush, Ribbon Static Brush, Ribbon Static . Bracket, Ribbon Static Brush . Screw, M4 x 0.
PAGE 157
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ Table 5-8. Dancer Assembly Maintenance Kit ITEM PART NUMBER DESCRIPTION QTY Kit, Maintenance Dancer Assembly (Z6M) 1 77331M (Sold as a Complete Assembly only for Z6M) 2 77238M Kit, Maintenance Dancer Assembly (Z4M) 3 N/A . Bearing, 0.38 x 0.63 x 0.50 4 N/A . Spring, Torsion 5 N/A . Dancer 6 ††HW30224 . Ring, External Crescent, 0.375 7 N/A Shaft, Dancer 8 †HW44356 Washer, 0.198 x 0.75 x 0.085 9 †HW10432 Screw, Cap M4 x 0.
PAGE 158
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-9. Ribbon Supply Assembly Maintenance Kit ITEM PART NUMBER REF 77085M REF 77082M 1 †HW10432 2 †HW44356 3 N/A 4 44390 5 ††HW30224 6 N/A 7 N/A 8 N/A 9 †HW44147 10 N/A 11 ††HW10401 12 N/A 13 N/A 14 N/A N/A: Not Available Separately DESCRIPTION QTY Kit, Maintenance Ribbon Supply, Z4M Kit, Maintenance Ribbon Supply, Z6M Screw, Cap, M4 x 0.7 Washer, 0.198 x 0.75 x 0.085 Shaft, Ribbon Supply Washer, 0.500 x 0.377 x 0.020 Ring, Crescent, Ext.
PAGE 159
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ Table 5-10. Print Mechanism Latch Kit ITEM REF 1 PART NUMBER DESCRIPTION QTY 77112M Kit, Latch Print Mechanism 77276 . Cap, Strike Plate 1 . Latch, Strike Plate 1 2 N/A REF 3 10473 . Washer, Flat M4 1 4 Q10011 . Screw, M4 x 10 Cp Hx H Bo 1 5 *HW77237 . Screw, M4 x 0.7 x 10 mm 1 6 77236 . Cover, Latch Plate 1 7 N/A . Latch 1 8 N/A . Spring, Compression 1 9 N/A .
PAGE 160
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-11. Drive System – Belts/Pulleys ITEM PART NUMBER 1 77814M 2 N/A 3 N/A 4 N/A 5 N/A 6 N/A 7 N/A 8 44118 9 †HW4147 10 77803M 11 N/A 12 N/A 13 77396 14 N/A 15 †HW10856 16 N/A 17 *HW77237 18 †HW10432 19 77813M 20 †HW44924 21 N/A N/A: Not Available Separately DESCRIPTION Kit, Maintenance Clutch Ribbon Take-Up . Hub, Clutch . Gear, Clutch . Bearing, Clutch . Spring, Return Washer, Nylon Flat, 0.375 x 0.75 x 0.062 Washer, Flat 0.379 x 0.53 x 0.
PAGE 161
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 3 1 6HFWLRQ 7 2 8 11 12 5 14 4 13 21 6 15 9 16 20 10 19 Note: Gear #11 and Pulley #14 are Pictured for 203 dpi. The Small Part Facing Out. 18 17 For 300 dpi they must be turned around. The Large Part Facing Out. Figure 5-11. Drive System – Belts/Pulleys 77259L Rev.
PAGE 162
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-12. Cutter Kit (Option) ITEM PART NUMBER 1 77971 1 77972 2 77041 2 77997 3 77973M 3 77697 3 77974M 3 77698 4 77990M 4 77401M 5 N/A 6 77630 7 77427 8 77408 8 77409 N/A: Not Available Separately DESCRIPTION QTY Kit, Optional Cutter, (Z4M) Kit, Optional Cutter, (Z6M) . Tray, Catch (Z4M) . Tray, Catch (Z6M) . Cutter Cover and PC Board Assembly (Z4M) . . Cutter Cover (Z4M) . Cutter Cover and PC Board Assembly (Z6M) . Cutter Cover (Z6M) .
PAGE 163
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ Table 5-13. Value Peel Assembly (Optional) ITEM PART NUMBER 1 78002M 1 78002-6M 2 77231 3 77197M 3 77727M 4 10094 5 N/A 6 N/A N/S 77222 N/S 77738 N/S: Not Shown DESCRIPTION QTY Kit, Maintenance Value Peel, Z4M Kit, Maintenance Value Peel, Z6M . Screw, M3 x 8 mm Kit, Maintenance Value Peel Pinch Roller, Z4M Kit, Maintenance Value Peel Pinch Roller, Z6M . E-Ring, 3 mm . Bearing . Roller, Pinch . Brush, Value Peel Static Z4M .
PAGE 164
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-14. Liner Take-up Assembly (Z4M Only) ITEM 1 2 3 4 PART NUMBER 77347M 77648 *HW77237 06313 DESCRIPTION QTY Kit, Z4M Liner Take-up . Cable, Motor . Screw, M4 x 10 mm . E-ring 1 1 2 1 *Minimum Quantity of 5 NOTE: The Liner Take-up is Only Available for the Z4M!!! 1 4 2 3 Figure 5-14. Liner Take-up Assembly (Z4M Only) Page 5-18 Z4M/Z6M Maintenance Manual 77259L Rev.
PAGE 165
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ Table 5-15. Power Rewind/Peel (Option) ITEM PART NUMBER 1 77058 1 77059 2 77498M 3 77898M 3 77740M 4 77648M 5 Q06020 6 77247M 6 77257M 7 *HW77237 8 N/A N/A: Not Available Separately DESCRIPTION QTY Kit, Power Rewind/Peel, Z4M Kit, Power Rewind/Peel, Z6M . Kit, Maintenance Motor/Spindle Z4M . Kit, Maintenance Motor/Spindle Z6M . Kit, Maintenance PCB DC Motor . Cable, Media Rewind . . Cable Tie 0.09 W x 3.63 L . Kit, Maintenance Power Peel, Z4M .
PAGE 166
6HFWLRQ 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Table 5-16. Value Peel Rewind Kit (Released in Fourth Quarter 2001) ITEM PART NUMBER 1 78005 1 Factory Install Only 2 78007M 3 78007-6M 3 78010M 4 77648M 5 Q06020 6 78002 7 78002-6 8 *HWW77237 9 N/A N/A: Not Available Separately DESCRIPTION QTY Kit, Rewind/Peel, Z4M Kit, Power Rewind/Peel, Z6M . Kit, Maintenance Motor/Spindle Z4M . Kit, Maintenance Motor/Spindle Z6M . Kit, Maintenance Value Peel Rewind PCB . Cable, Media Rewind . . Cable Tie 0.09 W x 3.
PAGE 167
0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV 6HFWLRQ Table 5-17. Miscellaneous Options Item Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 N/S N/S N/S N/S N/S: 48924 48752 30757 30753 48925 48761 30757 48753 46692 46689 — 46709 47210 46686 77823 77824 77978 77978 Not Shown Description Qty Kit, Field Upgrade IBM Twinax . Assembly, PCB IBM Twinax . AP Cable, Ribbon 40 Option Signal . Assembly, Cable IBM Twinax Kit, Field Upgrade IBM Coax . Assembly, PCB IBM Coax . AP Cable, Ribbon 40 Option Signal .
PAGE 168
6HFWLRQ Page 5-22 0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV Z4M/Z6M Maintenance Manual 77259L Rev.