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© 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. Printed on chlorine-free recycled paper. 79805L-001 Printhead Conversion Kit Installation 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. Prepare for Installation Parts List Before proceeding, verify that your kit contains the items for your printer listed below. 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. Table 1 • Kit List Item Qty Part Number Description Ref 1 79805 ZM400 600/300 to 203 dpi Ref 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 Bold = Part available for purchase. Italic = Part not available for purchase; listed and shown for reference only.

Zebra Conversion 300 Dpi a 203 Dpi

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Page 1: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion Kit

Installation 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.

Prepare for Installation

Parts List

Before proceeding, verify that your kit contains the items for your printer listed below.

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.

Table 1 • Kit List

Item Qty Part Number Description

Ref 1 79805 ZM400 600/300 to 203 dpiRef 1 79806 ZM400 203/600 to 300 dpiRef 1 79807 ZM400 203/300 to 600 dpiRef 1 79808 ZM600 203 to 300 dpiRef 1 79809 ZM600 300 to 203 dpi

Bold = Part available for purchase.Italic = Part not available for purchase; listed and shown for reference only.

© 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.

Printed on chlorine-free recycled paper. 79805L-001

Page 2: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitPrepare for Installation

2

Figure 1 • Kit Contents

Reference Materials

The following manuals and CDs may be helpful references while performing this procedure.

• ZM400/ZM600 User CD

• ZM400/ZM600 Maintenance Manual

• Z Series® Maintenance Manual (CD)

Tools Required

Table 2 • Parts List

Kit Number 79805 79806 79807 79808 79809

1 Printhead 79800M 79801M 79802M 79804M 79803M2 Drive Belt 79866M 79867M 79867M 79867M 79866M3 Pulley 79524 79525 79525 79525 79524

1 2 3

Tools • You need these tools to complete this procedure:

Phillips Screwdriver SetMetric Hex Key (Allen wrench) SetAntistatic Wriststrap

Metric Nutdriver Set47362* Zebra Preventive Maintenance Kit

* In place of the Preventive Maintenance Kit, you may use clean swabs and a solution containing isopropyl alcohol (≥ 90%) with deionized water (≤10%).

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 3: Zebra Conversion 300 Dpi a 203 Dpi

3Printhead Conversion KitPrepare for Installation

Remove the Electronics Cover

1.

Open the media cover and remove the media and ribbon.

2. See Figure 2. Remove the screw and washer securing the electronics cover.

Figure 2 • Locate the Electronics Cover Mounting Screw

3. Close the media door.

Note • Retain all parts removed during disassembly, unless otherwise directed.

Caution • Turn off (O) the printer and disconnect it from the power source before performing the following procedure.

1 Media door2 Electronics cover3 Washer4 Mounting screw

1

2

34

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 4: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitPrepare for Installation

4

4. See Figure 3. Remove the four mounting screws on the rear of the printer.

Figure 3 • Remove the Electronics Cover Mounting Screws

5. See Figure 4. Remove the electronics cover by pressing in on the electronics cover with the palm of your hand, and then lifting up on the cover.

Figure 4 • Remove the Electronics Cover

1 Electronics cover2 Mounting screws (4)

2

1

2

1

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 5: Zebra Conversion 300 Dpi a 203 Dpi

5Printhead Conversion KitRemove the Old Drive Belt and Platen Pulley

Remove the Old Drive Belt and Platen Pulley1. See Figure 5. Loosen the stepper motor locking and pivot screws.

Figure 5 • Remove the Drive Belt

2. Swing the stepper motor to the right to loosen the drive belt and then tighten the locking screw to snug the motor in place.

3. Remove the drive belt from the stepper motor and then from the platen pulley and discard it.

4. Loosen the two set screws securing the platen pulley.

1 Pivot screw2 Stepper motor3 Drive belt4 Set screws (2)5 Platen pulley6 Locking screw

1 3

6

2

5

4

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 6: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitInstall the New Drive Belt and Platen Pulley

6

5. See Figure 6. Slide the platen pulley from the coupling assembly and discard it.

Figure 6 • Remove the Platen Pulley

Install the New Drive Belt and Platen Pulley1. See Figure 7. 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.

Figure 7 • Align the Screws

2. See Figure 5 on page 5. Install the drive belt onto the platen pulley and the stepper motor pulley.

1 Setscrews (2)2 Flats on shaft

1

22

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 7: Zebra Conversion 300 Dpi a 203 Dpi

7Printhead Conversion KitRemove the Gear Cover

3.

Remove the Gear Cover1. See Figure 8. Lay the printer on its side, media door down on a mat.

Figure 8 • Lay the Printer on its Side

Caution • Do not over tighten the drive belt, or damage to the bearings and platen roller will occur. The belt should deflect under finger pressure but no more than 6 mm (1/4 inch).

Loosen the locking screw and then rotate the motor down until the drive belt is just taut. Tighten the locking screw and then the pivot screw.

1 Gear cover2 Mounting screw

12

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 8: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitRemove the Gear Cover

8

2. Remove the gear cover mounting screw.

Figure 9 • Remove the Gear Cover

3. Slide the cover off the drive assembly.

1 Mounting screw2 Gear cover3 Compound gear

1

2

3

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 9: Zebra Conversion 300 Dpi a 203 Dpi

9Printhead Conversion KitRemove the Gear Cover

4. See Figure 10. Remove the compound gear.

Figure 10 • Remove the Compound Gear

1 Compound gear turned to 300/600 dpi2 Compound gear turned to 200 dpi

1 2

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 10: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitReinstall the Compound Gear and Gear Cover

10

5. See Figure 11. Turn the compound gear around to the proper dpi.

Figure 11 • Compound Gear DPI Location

Reinstall the Compound Gear and Gear Cover1. See Figure 9 on page 8. With the proper side facing out slide the compound gear into the

printer. Ensure that the gears mesh.

2. Ensure all gears mesh together.

3. Align the gear cover and slide it back into place.

4. Install the mounting screw in the proper hole in the gear cover, through the compound gear, and then into the proper mounting hole in the main frame.

5. Tighten the mounting screw.

Note • There is a statement on both sides of the compound pulley.THIS SIDE OUT/200 dpi. and THIS SIDE OUT/300 DPI. THIS SIDE OUT/300 DPI is also used for 600 dpi.

DPI Statement

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 11: Zebra Conversion 300 Dpi a 203 Dpi

11Printhead Conversion KitReinstall the Electronics Cover

Reinstall the Electronics Cover1. 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.

Figure 12 • Locate the Upper and Lower Flanges

2. See Figure 3 on page 4. Install the four mounting screws.

3. See Figure 2 on page 3. Open the media door.

4. Install the electronics cover mounting screw and lock washer.

1 Electronics cover2 Upper flanges (3)3 Lower flanges (2)

21

3

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 12: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitRemove the Old Printhead

12

Remove the Old Printhead

1.

2. See Figure 13. Rotate the printhead pressure dials to the #1 position.

Figure 13 • Locate the Printhead Pressure Dials

3. Do you have a cutter option installed?

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.

Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

1 Postion #12 Pressure dial

If… Then…

No Continue with step 4.Yes You may find it easier to replace the printhead with the cutter assembly

removed. Go to Remove the Cutter Assembly on page 18.

1 21

21 2

12

ZM400 ZM600

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 13: Zebra Conversion 300 Dpi a 203 Dpi

13Printhead Conversion KitRemove the Old Printhead

4. See Figure 14. Locate and remove the thumbscrew from the print mechanism.

Figure 14 • Remove the Thumbscrew

1 Print mechanism2 Thumbscrew

1

2

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 14: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitRemove the Old Printhead

14

5. See Figure 15. Open the print mechanism and latch it in the vertical position.

6.

7. Remove and discard the printhead assembly from the printer.

Figure 15 • Remove the Printhead

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.

Disconnect the printhead data and power cables.

1 Printhead assembly2 Print mechanism3 Printhead data cable connector4 Printhead power cable connector5 Latch assembly

1

3 42

5

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 15: Zebra Conversion 300 Dpi a 203 Dpi

15Printhead Conversion KitInstall the New Printhead

Install the New Printhead1. See Figure 16. Align the two forks with the bearings and set the printhead assembly onto

the platen housing. This is done for ease of connecting the printhead cables.

2.

Figure 16 • Align the Forks and Bearings

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.

Connect the power and data cables to the printhead.

1 Thumbscrew2 Alignment holes (2)3 Cable guide4 Alignment pins (2)5 Platen housing6 Forks (2)7 Bearings (2)

4

6

2

3

5

1

7

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 16: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitInstall the New Printhead

16

3. Connect both printhead power and data cables to the printhead connectors and carefully slide them into position. Ensure the cables are in their proper channels and are not binding the printhead.

4. See Figure 17. Tip the printhead fork assembly slightly and insert the printhead ribbon guide into the print mechanism as shown.

5. Tip the printhead fork assembly up and into the print mechamism ensuing that the two locating protrusions on either side of the print printhead snap into the locating holes of the ribbon guide plate. Move the assembly back and forth to be sure that it is engaged. There should be little movement.

6. While holding the printhead in place, install the thumb screw to secure the fork assembly.

Figure 17 • Install the Printhead Fork Assembly

Note • When mounting the printhead fork assembly onto the print mechanism, visually inspect and ensure the cables are in their channels at the back of their carrier assembly, power cable under data cable, and are not binding on the print mechanism.

1 Thumbscrew2 Print mechanism3 Printhead fork assembly4 Ribbon guide plate5 Printhead ribbon guide

1 1

2 2

33

4 4

5 5

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 17: Zebra Conversion 300 Dpi a 203 Dpi

17Printhead Conversion KitInstall the New Printhead

7. Clean the printhead with the Zebra Preventative Maintenance kit.

8. See Figure 13 on page 12. Rotate the two printhead pressure dials to the desired position for your daily printing.

9. Did you remove a cutter assembly?

10.

11. Reconnect the AC power cord and data cables

12. Turn on (l) the printer.

If… Then…

No Continue with step 10.Yes Got to Reinstall the Cutter Assembly on page 19.

Caution • When you are loading media or ribbon, remove all jewelry that could come into contact with the printhead or other printer parts.

Reinstall the media and ribbon.

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B

Page 18: Zebra Conversion 300 Dpi a 203 Dpi

Printhead Conversion KitRemove the Cutter Assembly

18

Remove the Cutter Assembly1. See Figure 18. Unlatch the printhead and turn the latch assembly clockwise to access the

cutter mounting screw.

2.

Figure 18 • Remove the Cutter Assembly

3. Slide the cutter assembly to the left then lift up and remove the assembly from the platen assembly hooks.

4. Go to step 4 on page 13.

Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers.

Remove the cutter mounting screw.

1 Cutter assembly2 Mounting screw3 Printhead latch4 Platen assembly hooks (2)5 Cutter harness

Note • The cutter guard does not need to be removed from the cutter assembly during this procedure.

235

1

4

79805L-001 B ZM400/ZM600 Installation Instruction 7/27/07

Page 19: Zebra Conversion 300 Dpi a 203 Dpi

19Printhead Conversion KitReinstall the Cutter Assembly

Reinstall the Cutter Assembly1. See Figure 18 on page 18. Reinstall the cutter assembly on the hooks of the platen

housing. a. Hold the cutter assembly as far to the left as possible, and align the larger part of the

step slot with the hooks on the platen housing. b. Slide the cutter assembly onto the hooks and then push down and slide the assembly

to the right.

2. Using the cutter mounting screw removed earlier, secure the cutter assembly onto the platen assembly. The mounting tab on the cutter fits behind and attaches to the platen assembly.

3. Turn the latch assembly counterclockwise until it snaps in place.

4.

5. Reconnect the AC power cord and data cables

6. Turn on (l) the printer.

Caution • When you are loading media or ribbon, remove all jewelry that could come into contact with the printhead or other printer parts.

Reinstall the media and ribbon.

7/27/07 ZM400/ZM600 Installation Instruction 79805L-001 B