Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitInstallation Instructions This kit includes the parts and documentation necessary to install the Printhead Conversion kit in the following printers: • ZM400™ • ZM600™ Read these instructions thoroughly before installing this kit. Caution • A qualified service technician must perform this installation. Note • For optimal printing quality and proper printer performance across our product line, Zebra strongly recommends the use of genuine Zebra™ supplies as part of the total solution. Specifically, the ZM400 and ZM600 are designed to work only with genuine Zebra™ printheads, thus maximizing safety and print quality. Prepare for Installation Parts List Before proceeding, verify that your kit contains the items for your printer listed below. Table 1 • Kit List 3 Item Qty Part Number Description Ref 1 79805 ZM400 600/300 to 203 dpi 1 79806 ZM400 203/600 to 300 dpi Ref 1 79807 ZM400 203/300 to 600 dpi Ref 1 79808 ZM600 203 to 300 dpi Ref 1 79809 ZM600 300 to 203 dpi Ref Bold = Part available for purchase. Italic = Part not available for purchase; listed and shown for reference only. Printed on chlorine-free recycled paper. © 2007 ZIH Corp. All product names and numbers are Zebra trademarks, and Zebra and the Zebra logo are registered trademarks of ZIH Corp. All rights reserved. 79805L-001 79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07 . • ZM400/ZM600 User CD • ZM400/ZM600 Maintenance Manual • Z Series® Maintenance Manual (CD) Tools Required Tools • You need these tools to complete this procedure: ‰ Phillips Screwdriver Set ‰ Metric Nutdriver Set ‰ Metric Hex Key (Allen wrench) Set ‰ 47362* Zebra Preventive Maintenance Kit ‰ Antistatic Wriststrap * In place of the Preventive Maintenance Kit. you may use clean swabs and a solution containing isopropyl alcohol (≥ 90%) with deionized water (≤10%).2 Printhead Conversion Kit Prepare for Installation Table 2 • Parts List Kit Number 79805 79806 79807 79808 79809 1 79800M 79866M 79524 79801M 79867M 79525 79802M 79867M 79525 79804M 79867M 79525 79803M 79866M 79524 2 3 Printhead Drive Belt Pulley Figure 1 • Kit Contents 1 2 3 Reference Materials The following manuals and CDs may be helpful references while performing this procedure. 7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B 3 . See Figure 2. Close the media door. Caution • Turn off (O) the printer and disconnect it from the power source before performing the following procedure. unless otherwise directed. 2. Remove the screw and washer securing the electronics cover. 1.Printhead Conversion Kit Prepare for Installation Remove the Electronics Cover Note • Retain all parts removed during disassembly. Figure 2 • Locate the Electronics Cover Mounting Screw 1 2 3 1 2 3 4 4 Media door Electronics cover Washer Mounting screw 3. Open the media cover and remove the media and ribbon. Remove the electronics cover by pressing in on the electronics cover with the palm of your hand. Figure 3 • Remove the Electronics Cover Mounting Screws 1 2 1 2 Electronics cover Mounting screws (4) 5. and then lifting up on the cover. See Figure 3. See Figure 4.4 Printhead Conversion Kit Prepare for Installation 4. Remove the four mounting screws on the rear of the printer. Figure 4 • Remove the Electronics Cover 2 1 79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07 . 3. 7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B 5 . Loosen the stepper motor locking and pivot screws. See Figure 5. Loosen the two set screws securing the platen pulley. Swing the stepper motor to the right to loosen the drive belt and then tighten the locking screw to snug the motor in place.Printhead Conversion Kit Remove the Old Drive Belt and Platen Pulley Remove the Old Drive Belt and Platen Pulley 1. 4. Remove the drive belt from the stepper motor and then from the platen pulley and discard it. Figure 5 • Remove the Drive Belt 1 2 3 4 5 6 1 2 3 4 5 6 Pivot screw Stepper motor Drive belt Set screws (2) Platen pulley Locking screw 2. Install the drive belt onto the platen pulley and the stepper motor pulley. Slide the platen pulley from the coupling assembly and discard it. See Figure 6. Slide the platen pulley all the way onto the coupling drive shaft in the proper orientation and align the set screws with the flat spots on the drive shaft.6 Printhead Conversion Kit Install the New Drive Belt and Platen Pulley 5. Figure 6 • Remove the Platen Pulley Install the New Drive Belt and Platen Pulley 1. See Figure 7. 79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07 . See Figure 5 on page 5. Figure 7 • Align the Screws 1 2 2 1 2 Setscrews (2) Flats on shaft 2. or damage to the bearings and platen roller will occur. Caution • Do not over tighten the drive belt. Lay the printer on its side. Tighten the locking screw and then the pivot screw.Printhead Conversion Kit Remove the Gear Cover 3. Remove the Gear Cover 1. Loosen the locking screw and then rotate the motor down until the drive belt is just taut. media door down on a mat. The belt should deflect under finger pressure but no more than 6 mm (1/4 inch). See Figure 8. Figure 8 • Lay the Printer on its Side 1 1 2 7/27/07 2 Gear cover Mounting screw ZM400/ZM600 Installation Instruction 79805L-001 B 7 . Figure 9 • Remove the Gear Cover 1 2 3 1 2 3 Mounting screw Gear cover Compound gear 3.8 Printhead Conversion Kit Remove the Gear Cover 2. 79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07 . Slide the cover off the drive assembly. Remove the gear cover mounting screw. Figure 10 • Remove the Compound Gear 1 1 2 7/27/07 2 Compound gear turned to 300/600 dpi Compound gear turned to 200 dpi ZM400/ZM600 Installation Instruction 79805L-001 B 9 .Printhead Conversion Kit Remove the Gear Cover 4. See Figure 10. Remove the compound gear. 4. and THIS SIDE OUT/300 DPI. Install the mounting screw in the proper hole in the gear cover. Align the gear cover and slide it back into place. through the compound gear. See Figure 11. 79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07 . Note • There is a statement on both sides of the compound pulley. 5. Turn the compound gear around to the proper dpi. Ensure all gears mesh together. 3.10 Printhead Conversion Kit Reinstall the Compound Gear and Gear Cover 5. 2. Ensure that the gears mesh. THIS SIDE OUT/200 dpi. THIS SIDE OUT/300 DPI is also used for 600 dpi. See Figure 9 on page 8. Figure 11 • Compound Gear DPI Location DPI Statement Reinstall the Compound Gear and Gear Cover 1. Tighten the mounting screw. With the proper side facing out slide the compound gear into the printer. and then into the proper mounting hole in the main frame. See Figure 12. Install the electronics cover by aligning it and sliding down. ensuring the lower flanges are inside the base and the upper flanges are between the main frame and the media door. 4. See Figure 2 on page 3. Install the four mounting screws.Printhead Conversion Kit Reinstall the Electronics Cover Reinstall the Electronics Cover 1. 7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B 11 . Open the media door. Install the electronics cover mounting screw and lock washer. See Figure 3 on page 4. 3. Figure 12 • Locate the Upper and Lower Flanges 1 2 3 1 2 3 Electronics cover Upper flanges (3) Lower flanges (2) 2. Allow the printhead to cool. Rotate the printhead pressure dials to the #1 position. Connect yourself to an antistatic device. Figure 13 • Locate the Printhead Pressure Dials 1 2 1 2 1 2 ZM400 1 2 1 2 ZM600 Postion #1 Pressure dial 3. See Figure 13. Yes You may find it easier to replace the printhead with the cutter assembly removed. 2. ZM400/ZM600 Installation Instruction 7/27/07 . 1. Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.12 Printhead Conversion Kit Remove the Old Printhead Remove the Old Printhead Caution • The printhead may be hot and could cause severe burns. Go to Remove the Cutter Assembly on page 18. Do you have a cutter option installed? 79805L-001 B If… Then… No Continue with step 4. Printhead Conversion Kit Remove the Old Printhead 4. See Figure 14. Locate and remove the thumbscrew from the print mechanism. Figure 14 • Remove the Thumbscrew 2 1 1 2 7/27/07 Print mechanism Thumbscrew ZM400/ZM600 Installation Instruction 79805L-001 B 13 . Allow the printhead to cool. See Figure 15. Caution • The printhead may be hot and could cause severe burns. 6. 7.14 Printhead Conversion Kit Remove the Old Printhead 5. Open the print mechanism and latch it in the vertical position. Remove and discard the printhead assembly from the printer. Figure 15 • Remove the Printhead 3 2 4 1 5 1 2 3 4 5 79805L-001 B Printhead assembly Print mechanism Printhead data cable connector Printhead power cable connector Latch assembly ZM400/ZM600 Installation Instruction 7/27/07 . Disconnect the printhead data and power cables. Caution • An improperly connected printhead data or power cable may cause the printhead to generate excessive heat and/or display HEAD COLD or other false error messages.Printhead Conversion Kit Install the New Printhead Install the New Printhead 1. Align the two forks with the bearings and set the printhead assembly onto the platen housing. See Figure 16. Connect the power and data cables to the printhead. Figure 16 • Align the Forks and Bearings 1 7 2 3 4 6 5 1 2 3 4 5 6 7 7/27/07 Thumbscrew Alignment holes (2) Cable guide Alignment pins (2) Platen housing Forks (2) Bearings (2) ZM400/ZM600 Installation Instruction 79805L-001 B 15 . This is done for ease of connecting the printhead cables. 2. power cable under data cable. Tip the printhead fork assembly up and into the print mechamism ensuing that the two locating protrusions on either side of the print printhead snap into the locating holes of the ribbon guide plate. 4. Tip the printhead fork assembly slightly and insert the printhead ribbon guide into the print mechanism as shown. and are not binding on the print mechanism. Ensure the cables are in their proper channels and are not binding the printhead.16 Printhead Conversion Kit Install the New Printhead 3. Connect both printhead power and data cables to the printhead connectors and carefully slide them into position. See Figure 17. While holding the printhead in place. Note • When mounting the printhead fork assembly onto the print mechanism. There should be little movement. 6. Move the assembly back and forth to be sure that it is engaged. install the thumb screw to secure the fork assembly. Figure 17 • Install the Printhead Fork Assembly 1 1 2 2 3 3 4 5 1 2 3 4 5 79805L-001 B 4 5 Thumbscrew Print mechanism Printhead fork assembly Ribbon guide plate Printhead ribbon guide ZM400/ZM600 Installation Instruction 7/27/07 . 5. visually inspect and ensure the cables are in their channels at the back of their carrier assembly. Yes Got to Reinstall the Cutter Assembly on page 19.Printhead Conversion Kit Install the New Printhead 7. See Figure 13 on page 12. Caution • When you are loading media or ribbon. If… Then… No Continue with step 10. Reconnect the AC power cord and data cables 12. 11. 7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B 17 . Rotate the two printhead pressure dials to the desired position for your daily printing. 8. Clean the printhead with the Zebra Preventative Maintenance kit. Turn on (l) the printer. Did you remove a cutter assembly? 10. Reinstall the media and ribbon. remove all jewelry that could come into contact with the printhead or other printer parts. 9. Slide the cutter assembly to the left then lift up and remove the assembly from the platen assembly hooks.18 Printhead Conversion Kit Remove the Cutter Assembly Remove the Cutter Assembly 1. Figure 18 • Remove the Cutter Assembly 1 5 1 2 3 4 5 4 3 2 Cutter assembly Mounting screw Printhead latch Platen assembly hooks (2) Cutter harness Note • The cutter guard does not need to be removed from the cutter assembly during this procedure. 79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07 . Do not touch or rub the blade with your fingers. See Figure 18. Caution • The cutter blade is sharp. Go to step 4 on page 13. Unlatch the printhead and turn the latch assembly clockwise to access the cutter mounting screw. 2. Remove the cutter mounting screw. 3. 4. and align the larger part of the step slot with the hooks on the platen housing. The mounting tab on the cutter fits behind and attaches to the platen assembly. b. 7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B 19 . remove all jewelry that could come into contact with the printhead or other printer parts. Using the cutter mounting screw removed earlier. Caution • When you are loading media or ribbon. Reconnect the AC power cord and data cables 6. Reinstall the cutter assembly on the hooks of the platen housing. a.Printhead Conversion Kit Reinstall the Cutter Assembly Reinstall the Cutter Assembly 1. See Figure 18 on page 18. Hold the cutter assembly as far to the left as possible. 2. 5. Turn on (l) the printer. Reinstall the media and ribbon. Slide the cutter assembly onto the hooks and then push down and slide the assembly to the right. 4. 3. Turn the latch assembly counterclockwise until it snaps in place. secure the cutter assembly onto the platen assembly.