Guía de Partes para impresora de etiquetas Zebra ZM600

ZM400/ZM600 and RZ400/RZ600

Industrial/Commercial Printer

Maintenance Manual

14207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

2008 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described therein are owned by ZIH Corp. 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 and all product names and numbers are trademarks, and Zebra, the Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit are registered trademarks of ZIH Corp. All rights reserved worldwide.

All other brand names, product names, or trademarks belong to their respective holders. For additional trademark information, please see Trademarks on the product CD.

Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation and its subsidiaries (Zebra Technologies). It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the express, written permission of Zebra Technologies Corporation.

Product Improvements Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and designs are subject to change without notice.

Liability Disclaimer Zebra Technologies Corporation takes steps to ensure that its published Engineering specifications and manuals are correct; however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liability resulting therefrom.

Limitation of Liability In no event shall Zebra Technologies Corporation or anyone else involved in the creation, production, or delivery of the accompanying product (including hardware and software) be liable for any damages whatsoever (including, without limitation, consequential damages including loss of business profits, business interruption, or loss of business information) arising out of the use of, the results of use of, or inability to use such product, even if Zebra Technologies Corporation has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

14207L-002

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Contents

Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29The Americas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Europe, Africa, Middle East, and India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Table of Contents4Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Ship the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Data Cables and Wireless Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Connect the Printer to the Computer or Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Print Modes and Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 59Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Remove Used Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Enter and Use Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Exit Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Change Password-Protected Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Default Password Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Print a Network Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Standard Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Additional Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

RFID Control Panel Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11214207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

5Table of ContentsPrint Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129FEED and PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Sensor Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4 Preventive and Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 135Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Cleaning Schedule and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Clean the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Routine Maintenance for the Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Remove Printed Labels or Liner from the Rewind Spindle . . . . . . . . . . . . . . . . . . . . 144Adjust Media Alignment for Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Remove the Old Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Install the New Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1607/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Table of Contents6Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Gain Access to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Disconnect the Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Remove the Print Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Install the New Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Adjust the Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Remove the Electronic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Gain Access to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Remove the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184Install the New Printhead Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Remove the Old Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Install the New Ribbon Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Adjust the Strip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Printhead Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Remove the Old Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Install the New Latch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Adjust the Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Replace the Printhead Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Remove the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Remove the Old Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Install the New Pressure Dials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21114207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

7Table of ContentsMagnetic Printhead Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Remove the Old Magnetic Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Install the New Magnetic Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Access the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227Remove the Stepper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229Remove the Media Sensor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230Remove the Sensor Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231Install the New Upper Media Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Install the New Upper Media Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Connect the Media Sensor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Reinstall the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239Adjust the Sensor Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Remove the Old Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246Install the New Ribbon/Head Open Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . 248Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252Remove the Old Gears, Drive Belt, and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257Install the New Gears, Drive Belt, and Compound Pulley . . . . . . . . . . . . . . . . . . . . 258Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Drive Belt Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260Remove the Old Gears, Drive Belt, and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Install the New Drive Bet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2637/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Table of Contents8Stepper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267Gain Access to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269Remove the Old Stepper Motor and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271Install the New Stepper Motor and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Ribbon Take-up Spindle Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274Remove the Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277Remove the Old Ribbon Take-Up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279Install the New RTU Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Reinstall the Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Ribbon Take-up Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Remove the Electronic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Remove the Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285Remove the Old RTU Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287Install the New Ribbon Take-up Spindle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 288Reinstall the Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290Remove the Old Drive Belt and Platen Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293Install the New Drive Belt and Platen Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294Remove the Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Reinstall the Compound Gear and Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299Remove the Old Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300Install the New Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303Remove the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306Reinstall the Cutter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308Remove the Old Ribbon Supply Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311Install the New Ribbon Supply Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Reinstall the Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32214207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

9Table of ContentsMedia Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323Replace the Old Hanger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325Remove the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325Remove the Old Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Install the New Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Static Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Remove the Old Static Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Install the New Static Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Cutter Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Remove the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Install the Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Peel Maintenance Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Remove the Old Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Install the New Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Peel Rewind Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342Remove the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345Install the Rewind Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Install the Rewind Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Install the Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353Remove the Existing Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354Install the New Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Load the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356Align the Rewind/Peel Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

Outer Guard Rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Remove the Old Outer Rewind Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Install the New Outer Rewind Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3647/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Table of Contents10Roller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368Remove the Old Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368Install the New Platen Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

Linerless Media Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374Remove the Old Linerless Media Platen Roller Assembly . . . . . . . . . . . . . . . . . . . . 374Install the New Linerless Media Platen Roller Assembly . . . . . . . . . . . . . . . . . . . . . 377

Platen Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Remove the Platen Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384Remove the Drive Belt and Platen Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386Remove the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388Install the New Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Reinstall the Platen Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391Reinstall the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Pinch Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Remove the Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402Remove the Old Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404Install the New Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Print a Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412Remove the Wired Ethernet Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415Remove the Old MLB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416Install the New MLB Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419Check Hardware ID and Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42014207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

11Table of ContentsWireless Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421Remove the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423Install the Wireless Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

Wired Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429Remove the Electronics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430Remove the Wired Ethernet Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432Install the Wired Ethernet Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

Outer Casing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437Electronic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438Remove the Old Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438Install the New Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442Remove the Old Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442Install the New Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

Media Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Remove the Defective Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445IInstall the New Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Lower Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448Install the New Lower Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

Rear End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Remove the Old Rear End-Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Install the New End-Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4527/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Table of Contents12RFID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453RFID Upgrade Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454Install the RFID Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457Install the Coupler Cable Guide and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461Remove the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462Remove the Peel Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463Remove the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464Remove the Old Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465Remove the Media Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466Install the Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467Install the New Media Door Front End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470Reinstall the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471Reinstall the Tear Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472Reinstall the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473Reinstall the Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476Attach Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477Confirm RFID Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479

RFID Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480Remove the Cutter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483Remove the Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484Remove the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485Remove the Tear Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486Remove the Old Tear-Off Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486Remove the Old Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487Install the New RFID Coupler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489Reinstall the Tear Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490Reinstall the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492Reinstall the Cutter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493Reinstall the Peel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49614207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

13Table of ContentsRFID Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497Remove the Old RFID Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500Install the New RFID Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502Attach Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502Confirm RFID Reader Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

RZ400/RZ600 Media Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506Remove the Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506Remove the RFID Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509Remove the RFID Reader Mounting Bracket and Spacers . . . . . . . . . . . . . . . . . . . 510Remove the Old Media Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512Install the New Media Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513Reinstall the RFID Reader Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513Reinstall the RFID Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513Reinstall the Electronics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

RZ400 and RZ600 RFID Hardware Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

5 Drawings and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517

A Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555Serial Data Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556

Hardware Control Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557RS-232 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558

Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560Parallel Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560Parallel Port Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5617/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Table of Contents14

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Table 12 Printer Parameters............................................................................................ 81Table 13 Print Width Ranges and Maximum Values ....................................................... 86Table 14 RFID Parameters ........................................................................................... 108Troubleshooting ................................................................................................... 111Table 15 LCD Error Messages ...................................................................................... 113Table 16 Print Quality Problems.................................................................................... 118Table 17 Calibration Problems ...................................................................................... 121Table 18 Communications Problems............................................................................. 122Table 19 Ribbon Problems ............................................................................................ 123Table 20 Miscellaneous Printer Problems ..................................................................... 124Table 21 Judging Bar Code Quality............................................................................... 131

Preventive and Corrective Maintenance ............................................................ 135Table 22 Recommended Cleaning Schedule ................................................................ 138Table 23 Parts List......................................................................................................... 515List of Tables

System Description ............................................................................................... 33Table 1 Control Panel Buttons......................................................................................... 38Table 2 Control Panel Lights ........................................................................................... 39

Operations .............................................................................................................. 47Table 3 Storage Temperature and Humidity.................................................................... 50Table 4 Operating Temperature and Humidity ................................................................ 51Table 5 Characteristics of the Data Communication Interfaces....................................... 52Table 6 Connecting the Printer to a Computer or Network.............................................. 54Table 7 Types of Media .................................................................................................. 58Table 8 Print Modes and Printer Options......................................................................... 59Table 9 Media Paths for Print Modes with Various Printer Options................................. 60Table 10 ZM400 and RZ400 Printhead Pressure ............................................................ 74Table 11 ZM600 and RZ600 Printhead Pressure ............................................................ 757/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

List of Tables16Drawings and Parts ............................................................................................. 517Table A Outer Casing Components............................................................................... 521Table B Media Door....................................................................................................... 522Table C Rear End Cap .................................................................................................. 523Table D Media and Ribbon Path.................................................................................... 525Table E Media Hanger................................................................................................... 526Table F Media Sensors.................................................................................................. 527Table G Ribbon Supply Spindle..................................................................................... 528Table H Print Mechanism View 1................................................................................... 529Table I Print Mechanism View 2 .................................................................................... 530Table J Printhead Conversion Kits ................................................................................ 531Table K Platen Housing................................................................................................. 533Table L Static Brush ...................................................................................................... 534Table M Ribbon Take-up Spindle .................................................................................. 535Table N Drive System.................................................................................................... 536Table O Electronics ....................................................................................................... 537Table P Main Logic Board ............................................................................................. 538Table Q Wireless Board................................................................................................. 539Table R Wired Ethernet Board....................................................................................... 540Table S Media Handling Options ................................................................................... 543Table T Cutter Option .................................................................................................... 544Table U Peel and Rewind Option .................................................................................. 545Table V Liner Take-up Option........................................................................................ 546Table W Inside Coated Ribbon Supply Spindle............................................................. 547Table X RFID Upgrade .................................................................................................. 549Table Y Reader and Coupler Maintenance Kit .............................................................. 550Table Z RZ400/RZ600 Media Door ............................................................................... 551

Pinouts .................................................................................................................. 555Table 24 Serial Connector Pin Configuration ................................................................ 557Table 25 Parallel Cable Pin Configuration..................................................................... 56114207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

Figure 11 Sample Configuration Label ...................................................................................... 79Figure 12 Network Configuration Label (With a Wireless Print Server Installed) ..................................... 80Figure 13 Tear-Off Position Adjustment ..................................................................................... 83

Figure 14 Label Length ........................................................................................................ 87

Troubleshooting ................................................................................................... 111Figure 15 Ribbon-Out Threshold Too High ............................................................................... 123Figure 16 Sample Configuration Label .................................................................................... 127Figure 17 PAUSE Test Label ............................................................................................... 128Figure 18 FEED Test Label ................................................................................................. 129Figure 19 Bar Code Darkness Comparison .............................................................................. 130Figure 20 Communications Diagnostics Test Label ..................................................................... 133Figure 21 Sensor Profile (Ribbon Section) ............................................................................... 134Figure 22 Sensor Profile (Media Section) ................................................................................ 134

Preventive and Corrective Maintenance ............................................................ 135Preventive Maintenance ............................................................................................... 137

Figure 23 Location of the Printhead and Platen Roller ................................................................. 139List of Figures

Figure 1 Sample Figure with Callouts ....................................................................................... 31

System Description ............................................................................................... 33Figure 2 Front of Printer ....................................................................................................... 34Figure 3 Rear of Printer ........................................................................................................ 35Figure 4 Printer Components ................................................................................................. 36Figure 5 Control Panel ......................................................................................................... 37

Operations .............................................................................................................. 47Figure 6 Power Cord Specifications .......................................................................................... 57Figure 7 International Safety Organization Certifications ................................................................. 57Figure 8 Tear-Off Mode Media Path ......................................................................................... 62Figure 9 Ribbon Path .......................................................................................................... 68Figure 10 Printhead Pressure Adjustment Dials ........................................................................... 747/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

List of Figures18Figure 24 Cleaning the Cutter Module .................................................................................... 143

Corrective Maintenance ............................................................................................... 149

Print System .................................................................................................................. 151Figure 25 Locate the Printhead Pressure Dials .......................................................................... 153Figure 26 Remove the Thumbscrew ...................................................................................... 154Figure 27 Remove the Printhead Assembly .............................................................................. 155Figure 28 Align the Forks and Bearings .................................................................................. 156Figure 29 Install the Printhead Fork Assembly .......................................................................... 157Figure 30 Remove the Cutter Assembly .................................................................................. 159Figure 31 Locate the Electronics Cover Mounting Screw .............................................................. 162Figure 32 Remove the Electronics Cover Mounting Screws ........................................................... 163Figure 33 Remove the Electronics Cover ................................................................................. 163Figure 34 Remove the Radio Card ........................................................................................ 164Figure 35 Remove the Wireless Board ................................................................................... 165Figure 36 Remove the Standoff and Screw .............................................................................. 166Figure 37 Gain Access the Power Supply ................................................................................ 167Figure 38 Printhead Grounding Strap ..................................................................................... 168Figure 39 Remove the Cutter Assembly .................................................................................. 169Figure 40 Printhead Housing Mounting Screws ......................................................................... 170Figure 41 Locate the Upper and Lower Flanges ........................................................................ 171Figure 42 Adjust the Print Mechanism .................................................................................... 172Figure 43 Install the Adjustment Cam ..................................................................................... 173Figure 44 Ribbon/Printhead Open Sensor ............................................................................... 174Figure 45 Locate the Electronics Cover Mounting Screw .............................................................. 177Figure 46 Remove the Electronics Cover Mounting Screws ........................................................... 178Figure 47 Remove the Electronics Cover ................................................................................. 178Figure 48 Remove the Radio Card ........................................................................................ 179Figure 49 Remove the Wireless Board ................................................................................... 180Figure 50 Remove the Standoff and Screw .............................................................................. 181Figure 51 Gain Access the Power Supply ................................................................................ 182Figure 52 Disconnect Printhead Cables .................................................................................. 183Figure 53 Top View of Printhead Housing ................................................................................ 184Figure 54 Remove the Thumbscrew ...................................................................................... 185Figure 55 Printhead Removal and Installation ........................................................................... 186Figure 56 Remove the Ground Cable Mounting Screw ................................................................. 187Figure 57 Remove the Cables from the Print Mechanism ............................................................. 188Figure 58 Install the New Cables .......................................................................................... 189Figure 59 Align the Forks and Bearings .................................................................................. 190Figure 60 Install the Printhead Fork Assembly .......................................................................... 191Figure 61 Connect the Printhead Cables ................................................................................. 192Figure 62 Remove the Cutter Assembly .................................................................................. 194Figure 63 Locate the Upper and Lower Flanges ........................................................................ 195Figure 64 Remove and Install the Ribbon Strip Plate ................................................................... 198Figure 65 Open the Media Door ........................................................................................... 201Figure 66 Remove the Latch Assembly ................................................................................... 202Figure 67 Adjustment Screw Location .................................................................................... 203Figure 68 Adjust the Print Mechanism .................................................................................... 204Figure 69 Print Mechanism Mounting Screws ........................................................................... 205Figure 70 Locate the Printhead Pressure Dials .......................................................................... 208Figure 71 Remove the Printhead and Cable Connections ............................................................. 20914207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

Figure 72 Remove the Pressure Bracket and Roller .................................................................... 210

19List of FiguresFigure 73 Remove the Pressure Dials .................................................................................... 211Figure 74 Install the Springs ................................................................................................ 211Figure 75 Align the Forks and Bearings .................................................................................. 212Figure 76 Locate the Electronics Cover Mounting Screw .............................................................. 215Figure 77 Remove the Electronics Cover Mounting Screws ........................................................... 216Figure 78 Remove the Electronics Cover ................................................................................. 216Figure 79 Locate the Magnetic Latch ..................................................................................... 217Figure 80 Remove the Old Magnetic Latch .............................................................................. 218Figure 81 Install the New Magnetic Latch ................................................................................ 219Figure 82 Locate the Upper and Lower Flanges ........................................................................ 220

Sensors ........................................................................................................................... 221Figure 83 Locate the Electronics Cover Mounting Screw .............................................................. 223Figure 84 Remove the Electronics Cover Mounting Screws ........................................................... 224Figure 85 Remove the Electronics Cover ................................................................................. 224Figure 86 Remove the Radio Card ........................................................................................ 225Figure 87 Remove the Wireless Board ................................................................................... 226Figure 88 Remove the Standoff and Screw .............................................................................. 227Figure 89 Gain Access the Power Supply ................................................................................ 228Figure 90 Locate Drive System Components ............................................................................ 229Figure 91 Disconnect the Media Sensor Cables ........................................................................ 230Figure 92 Remove the Upper Media Sensor Mounting Screw ........................................................ 231Figure 93 Release the Dancer Spring ..................................................................................... 232Figure 94 Remove the Media Sensor Assemblies ...................................................................... 233Figure 95 Remove the Protective Cap .................................................................................... 234Figure 96 Locate the Access Hole ......................................................................................... 235Figure 97 Remove the Protective Cap .................................................................................... 236Figure 98 Install the Upper Media Sensor Assembly ................................................................... 237Figure 99 Adjust the ZM400 Upper Media Sensor ...................................................................... 241Figure 100 Adjust the ZM600 Upper Media Sensor .................................................................... 242Figure 101 Locate the Electronics Cover Mounting Screw ............................................................ 244Figure 102 Remove the Electronics Cover Mounting Screws ......................................................... 245Figure 103 Remove the Electronics Cover ............................................................................... 245Figure 104 Disconnect the Ribbon/Head Open Sensor ................................................................ 246Figure 105 Ribbon Sensor Removal and Installation ................................................................... 247Figure 106 Locate the Access Hole ....................................................................................... 248Figure 107 Gap Measurement Between Print Mechanism and Sensor ............................................. 249Figure 108 Locate the Upper and Lower Flanges ...................................................................... 250

Drive System.................................................................................................................. 251Figure 109 Locate the Electronics Cover Mounting Screw ............................................................ 253Figure 110 Remove the Electronics Cover Mounting Screws ......................................................... 254Figure 111 Remove the Electronics Cover ............................................................................... 254Figure 112 Lay the Printer on its Side .................................................................................... 255Figure 113 Remove the Gear Cover ...................................................................................... 256Figure 114 Remove and Install Gears, Pulley, and Belt ................................................................ 257Figure 115 Locate the Upper and Lower Flanges ...................................................................... 259Figure 116 Locate the Electronics Cover Mounting Screw ............................................................ 260Figure 117 Remove the Electronics Cover Mounting Screws ......................................................... 261Figure 118 Remove the Electronics Cover ............................................................................... 261Figure 119 Remove the Old Belt .......................................................................................... 2627/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Figure 120 Locate the Upper and Lower Flanges ...................................................................... 263

List of Figures20Figure 121 Locate the Electronics Cover Mounting Screw ............................................................ 265Figure 122 Remove the Electronics Cover Mounting Screws ......................................................... 266Figure 123 Remove the Electronics Cover ............................................................................... 266Figure 124 Remove the Radio Card ...................................................................................... 267Figure 125 Remove the Wireless Board ................................................................................. 268Figure 126 Remove the Standoff and Screw ............................................................................ 269Figure 127 Gain Access the Power Supply .............................................................................. 270Figure 128 Locate Drive System Components .......................................................................... 271Figure 129 Locate the Upper and Lower Flanges ...................................................................... 273Figure 130 Locate the Electronics Cover Mounting Screw ............................................................ 275Figure 131 Remove the Electronics Cover Mounting Screws ......................................................... 276Figure 132 Remove the Electronics Cover ............................................................................... 276Figure 133 Lay the Printer on its Side .................................................................................... 277Figure 134 Remove the Gear Cover ...................................................................................... 278Figure 135 Loosen the Set Screws ....................................................................................... 279Figure 136 Remove the Clutch ............................................................................................ 280Figure 137 Locate the Upper and Lower Flanges ...................................................................... 281Figure 138 Locate the Electronics Cover Mounting Screw ............................................................ 284Figure 139 Remove the Electronics Cover ............................................................................... 284Figure 140 Lay the Printer on its Side .................................................................................... 285Figure 141 Remove the Gear Cover ...................................................................................... 286Figure 142 Loosen the Set Screws ....................................................................................... 287Figure 143 Remove the RTU Spindle ..................................................................................... 288Figure 144 Locate the Upper and Lower Flanges ...................................................................... 289Figure 145 Locate the Electronics Cover Mounting Screw ............................................................ 291Figure 146 Remove the Electronics Cover Mounting Screws ......................................................... 292Figure 147 Remove the Electronics Cover ............................................................................... 292Figure 148 Remove the Drive Belt ........................................................................................ 293Figure 149 Remove the Platen Pulley .................................................................................... 294Figure 150 Align the Screws ............................................................................................... 294Figure 151 Lay the Printer on its Side .................................................................................... 295Figure 152 Remove the Gear Cover ...................................................................................... 296Figure 153 Remove the Compound Gear ................................................................................ 297Figure 154 Compound Gear DPI Location ............................................................................... 298Figure 155 Locate the Upper and Lower Flanges ...................................................................... 299Figure 156 Locate the Printhead Pressure Dials ........................................................................ 300Figure 157 Remove the Thumbscrew .................................................................................... 301Figure 158 Remove the Printhead ........................................................................................ 302Figure 159 Align the Forks and Bearings ................................................................................ 303Figure 160 Install the Printhead Fork Assembly ........................................................................ 304Figure 161 Remove the Cutter Assembly ................................................................................ 306Figure 162 Locate the Electronics Cover Mounting Screw ............................................................ 309Figure 163 Remove the Electronics Cover Mounting Screws ......................................................... 310Figure 164 Remove the Electronics Cover ............................................................................... 310Figure 165 Lay the Printer on its Side .................................................................................... 311Figure 166 Remove the Gear Cover ...................................................................................... 312Figure 167 Remove the Radio Card ...................................................................................... 313Figure 168 Remove the Wireless Board ................................................................................. 314Figure 169 Locate the Drive Components ............................................................................... 315Figure 170 Remove the Stepper Motor and Intermediate Gear ....................................................... 316Figure 171 Remove the Ribbon Supply Spindle ........................................................................ 31714207L-002 A ZM400/ZM600 Maintenance Manual 7/18/08

Figure 172 Using the Remove Tool ....................................................................................... 318

21List of FiguresFigure 173 Install the Thin Washer ........................................................................................ 318Figure 174 Lubrication ...................................................................................................... 319Figure 175 Spindle Installation ............................................................................................. 320Figure 176 Locate the Upper and Lower Flanges ...................................................................... 322Figure 177 Remove and Install the Hanger Assembly ................................................................. 324Figure 178 Remove the Front Cover ...................................................................................... 325Figure 179 Remove and Install the Tear-Off Bar ........................................................................ 326Figure 180 Install the New Tear-Off Bar .................................................................................. 327Figure 181 Locate the Pems ............................................................................................... 327Figure 182 Remove and Install the Static Brush Assembly) ........................................................... 329Figure 183 Locate the Electronics Cover Mounting Screw ............................................................ 331Figure 184 Remove the Electronics Cover Mounting Screws ......................................................... 332Figure 185 Remove the Electronics Cover ............................................................................... 332Figure 186 Remove the Front Cover ...................................................................................... 333Figure 187 Locate and Position the Mounting Brackets ............................................................... 334Figure 188 Install the Cutter Assembly ................................................................................... 335Figure 189 Cutter Shield and Catch Tray ................................................................................ 336Figure 190 Locate Cutter Connector on the Main Logic Board ....................................................... 337Figure 191 Locate the Upper and Lower Flanges ...................................................................... 338Figure 192 Remove Old Peel Assembly ................................................................................. 339Figure 193 Install Peel Assembly .......................................................................................... 340Figure 194 Rear View of Peel Assembly ................................................................................. 341Figure 195 Locate the Electronics Cover Mounting Screw ............................................................ 343Figure 196 Remove the Electronics Cover Mounting Screws ......................................................... 344Figure 197 Remove the Electronics Cover ............................................................................... 344Figure 198 Remove the Front Cover ...................................................................................... 345Figure 199 Remove the Old Base ......................................................................................... 346Figure 200 Install the Rewind Pan ........................................................................................ 347Figure 201 Install the Rewind Spindle Assembly ........................................................................ 349Figure 202 Connect the Rewind Cable to the Main Logic Board ..................................................... 350Figure 203 Install the Motor and Spindle Assembly .................................................................... 351Figure 204 Locate the Upper and Lower Flanges ...................................................................... 352Figure 205 Remove the Tear Bar .......................................................................................... 353Figure 206 Remove the Peel Assembly .................................................................................. 354Figure 207 Locate the Pems ............................................................................................... 355Figure 208 Install the New Peel Assembly ............................................................................... 356Figure 209 Load the Rewind Media ....................................................................................... 358Figure 210 Load the Rewind Peel Media ................................................................................ 358Figure 211 Align the Rewind Media ....................................................................................... 359Figure 212 Remove the E-ring and Washers ............................................................................ 361Figure 213 Remove the Rewind Spindle ................................................................................. 362Figure 214 Remove the Rewind Back Plate ............................................................................. 362Figure 215 Remove the Spindle ........................................................................................... 363Figure 216 Remove the Outer Rewind Guide ........................................................................... 363Figure 217 Align the Outer Rewind Guide ............................................................................... 364

Roller System................................................................................................................. 367Figure 218 Slide the Platen Roller Assembly ............................................................................ 369Figure 219 Remove the Platen Roller Assembly ........................................................................ 370Figure 220 Bearing Keys ................................................................................................... 371Figure 221 Align the Drive Pin and Drive Shaft ......................................................................... 3727/18/08 ZM400/ZM600 Maintenance Manual 14207L-002 A

Figure 222 Install the Platen Roller Assembly ........................................................................... 373

List of Figures22Figure 223 Remove the Linerless Media Guide Assembly ............................................................ 375Figure 224 Remove the Linerless Media Platen Roller Assembly .................................................... 376Figure 225 Bearing Grooves ............................................................................................... 377Figure 226 Install the Linerless Media Platen Roller Assembly ....................................................... 378Figure 227 Align the Drive Pin and Drive Shaft ......................................................................... 379Figure 228 Verify the Take-Label Sensor Cable Routing .............................................................. 380Figure 229 Locate the Electronics Cover Mounting Screw ............................................................ 382Figure 230 Remove the Electronics Cover Mounting Screws ......................................................... 383Figure 231 Remove the Electronics Cover ............................................................................... 383Figure 232 Slide the Platen Roller Assembly ............................................................................ 384Figure 233 Remove the Platen Roller Assembly ........................................................................ 385Figure 234 Remove the Drive Belt ........................................................................................ 386Figure 235 Remove the Platen Pulley .................................................................................... 387Figure 236 Remove the E-ring and Washer ............................................................................. 388Figure 237 Push the Drive Shaft Through ............................................................................... 389Figure 238 Remove the Roller Bearings ................................................................................. 389Figure 239 Align Flat Spots on the Shaft ................................................................................. 390Figure 240 Locate the Upper and Lower Flanges ...................................................................... 391Figure 241 Bearing Keys ................................................................................................... 392Figure 242 Align the Drive Pin and Dri

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