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.
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

Printhead Conversion Kit

Prepare for Installation

Table 2 Parts List

Kit Number

79805

79806

79807

79808

79809

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

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
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%).

79805L-001 B

ZM400/ZM600 Installation Instruction

7/27/07

Printhead Conversion Kit

Prepare for Installation

Remove the Electronics Cover

Note Retain all parts removed during disassembly, unless otherwise directed.
1.

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

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

1
2

1
2
3
4

Media door
Electronics cover
Washer
Mounting screw

3. Close the media door.

7/27/07

ZM400/ZM600 Installation Instruction

79805L-001 B

Printhead Conversion Kit

Prepare for Installation

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

Figure 3 Remove the Electronics Cover Mounting Screws

1

1
2

Electronics cover
Mounting screws (4)

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
2

79805L-001 B

ZM400/ZM600 Installation Instruction

7/27/07

Printhead Conversion Kit

Remove the Old Drive Belt and Platen Pulley

Remove the Old Drive Belt and Platen Pulley

1. See Figure 5. Loosen the stepper motor locking and pivot screws.

Figure 5 Remove the Drive Belt

1

3
4

5
6

1
2
3
4
5
6

Pivot screw
Stepper motor
Drive belt
Set screws (2)
Platen pulley
Locking screw

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.

7/27/07

ZM400/ZM600 Installation Instruction

79805L-001 B

Printhead Conversion Kit

Install the New Drive Belt and Platen Pulley

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 Pulley

1. 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
1

1
2

Setscrews (2)
Flats on shaft

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

pulley.

79805L-001 B

ZM400/ZM600 Installation Instruction

7/27/07

Printhead Conversion Kit

Remove the Gear Cover

3.

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.

Remove the Gear Cover

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

Figure 8 Lay the Printer on its Side

1

1
2

7/27/07

Gear cover
Mounting screw

ZM400/ZM600 Installation Instruction

79805L-001 B

Printhead Conversion Kit

Remove the Gear Cover

2. Remove the gear cover mounting screw.

Figure 9 Remove the Gear Cover

1
2

1
2
3

Mounting screw
Gear cover
Compound gear

3. Slide the cover off the drive assembly.

79805L-001 B

ZM400/ZM600 Installation Instruction

7/27/07

Printhead Conversion Kit

Remove the Gear Cover

4. See Figure 10. Remove the compound gear.

Figure 10 Remove the Compound Gear

1

1
2

7/27/07

Compound gear turned to 300/600 dpi

Compound gear turned to 200 dpi

ZM400/ZM600 Installation Instruction

79805L-001 B

10

Printhead Conversion Kit

Reinstall the Compound Gear and Gear Cover

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

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.
Figure 11 Compound Gear DPI Location
DPI Statement

Reinstall the Compound Gear and Gear Cover

1. 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.

79805L-001 B

ZM400/ZM600 Installation Instruction

7/27/07

Printhead Conversion Kit

Reinstall the Electronics Cover

Reinstall the Electronics Cover

1. 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
1

1
2
3

Electronics cover
Upper flanges (3)
Lower flanges (2)

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.

7/27/07

ZM400/ZM600 Installation Instruction

79805L-001 B

11

12

Printhead Conversion Kit

Remove the Old Printhead

Remove the Old Printhead

Caution The printhead may be hot and could cause severe burns. Allow the printhead to
cool.
1.

Caution Observe proper electrostatic safety precautions when handling

static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

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

Figure 13 Locate the Printhead Pressure Dials

1 2

1 2

ZM400
1
2

ZM600

Postion #1
Pressure dial

3. Do you have a cutter option installed?

79805L-001 B

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.

ZM400/ZM600 Installation Instruction

7/27/07

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

14

Printhead Conversion Kit

Remove the Old Printhead

5. See Figure 15. Open the print mechanism and latch it in the vertical position.
6.

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

Disconnect the printhead data and power cables.

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

Figure 15 Remove the Printhead

3

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

Printhead Conversion Kit

Install the New Printhead

Install the New Printhead

1. 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.

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.

Figure 16 Align the Forks and Bearings
1

2
3
4

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

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. Ensure the cables are in their proper channels and are not binding
the printhead.
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.
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

1

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

Printhead Conversion Kit

Install 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.

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.

11. Reconnect the AC power cord and data cables
12. Turn on (l) the printer.

7/27/07

ZM400/ZM600 Installation Instruction

79805L-001 B

17

18

Printhead Conversion Kit

Remove the Cutter Assembly

Remove the Cutter Assembly

1. See Figure 18. Unlatch the printhead and turn the latch assembly clockwise to access the

cutter mounting screw.

2.

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

Remove the cutter mounting screw.

Figure 18 Remove the Cutter Assembly

5
1
2
3
4
5

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.
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.

79805L-001 B

ZM400/ZM600 Installation Instruction

7/27/07

Printhead Conversion Kit

Reinstall the Cutter Assembly

Reinstall the Cutter Assembly

1. 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.

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.

5. Reconnect the AC power cord and data cables
6. Turn on (l) the printer.

7/27/07

ZM400/ZM600 Installation Instruction

79805L-001 B

19