1333415-zxp 7 Series

ZXP Series 7™
Card Printer
Service Manual
P1036102-007
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Contents
Introduction......................................................................................................................1
Description..............................................................................................................................................1
Theory of Operation........................................................................................................3
Introduction............................................................................................................................................. 3
Card Movement During Printing.............................................................................................................. 4
Printing Technologies and Ribbons......................................................................................................... 6
Dye Sublimation Printing.................................................................................................................. 8
Thermal Transfer Printing................................................................................................................. 8
System-Level Electronics........................................................................................................................ 9
Main PCBA (CPU).......................................................................................................................... 10
High-Capacity Output Hopper............................................................................................................... 13
Hopper Cassette............................................................................................................................. 13
Stacker...........................................................................................................................................13
Troubleshooting............................................................................................................15
Introduction........................................................................................................................................... 15
OCP Error Messages............................................................................................................................ 16
OCP Test Cards.................................................................................................................................... 25
Ethernet................................................................................................................................................26
Replacement Procedures for the Printer ...................................................................27
Introduction........................................................................................................................................... 27
Required Tools...................................................................................................................................... 28
Removal Sequence............................................................................................................................... 29
Printer.............................................................................................................................................30
Feeder Module............................................................................................................................... 30
Flipper Module................................................................................................................................ 31
Options Module.............................................................................................................................. 31
Procedures............................................................................................................................................32
Reject Bin....................................................................................................................................... 32
Feeder Cartridge............................................................................................................................ 34
Ribbon Drawer................................................................................................................................ 40
Card Guides................................................................................................................................... 42
Shroud for Options......................................................................................................................... 44
Back Cover..................................................................................................................................... 45
Rear Feeder Cover......................................................................................................................... 46
Options Cover................................................................................................................................. 47
P1036102-007 ZXP Series 7 Card Printer Service Manual i

OCP PCBA..................................................................................................................................... 49
Right Cover..................................................................................................................................... 51
Print Cover...................................................................................................................................... 58
Door Button and Latch.................................................................................................................... 60
Left Side Cover............................................................................................................................... 63
Belt and Gear Panel....................................................................................................................... 64
Bottom Cover.................................................................................................................................. 66
Feet................................................................................................................................................67
Reject Bin Bracket.......................................................................................................................... 68
Printer.............................................................................................................................................69
Main PCBA..................................................................................................................................... 73
Ethernet PCBA............................................................................................................................... 76
Print Engine.................................................................................................................................... 77
Feeder/Flipper/Options Assembly................................................................................................ 137
Feeder/Flipper Assembly.............................................................................................................. 142
Ground Plate................................................................................................................................ 145
Power Switch................................................................................................................................ 147
Feeder Module............................................................................................................................. 149
Flipper Module.............................................................................................................................. 157
Options Module............................................................................................................................ 180
Torque Tools Calibration Instructions............................................................................................ 187
Replacement Procedures for Factory Installed Options ........................................191
Introduction.........................................................................................................................................191
Required Tools.................................................................................................................................... 192
Procedures..........................................................................................................................................193
Barcode Scanner Assembly......................................................................................................... 193
SmartCard Control PCBA............................................................................................................. 199
MIFARE/Contact Encoder Module................................................................................................ 200
MIFARE Contact Encoder PCBA.................................................................................................. 203
Contact Station Module................................................................................................................ 205
Contact Station Module PCBA...................................................................................................... 208
Pressure Roller Assembly............................................................................................................ 209
Replacement Procedures for the Laminator ............................................................217
Introduction.........................................................................................................................................217
Required Tools.................................................................................................................................... 218
Removal Sequence............................................................................................................................. 219
Procedures..........................................................................................................................................221
Back Cover................................................................................................................................... 221
Side Cover.................................................................................................................................... 222
Lock Replacement for Left Cover................................................................................................. 223
Lower Door................................................................................................................................... 225
Door Assembly (Door and Hinges)............................................................................................... 227
Latch Assembly............................................................................................................................ 230
Laminator / Printer Separation...................................................................................................... 232
Bottom Panel................................................................................................................................ 236
Feet..............................................................................................................................................237
Mounting Plate.............................................................................................................................. 238
Molded Ribbon Spindle................................................................................................................ 240
Square Corner Spindle................................................................................................................. 241
Laminator Heater Assembly......................................................................................................... 242
Halogen Bulbs.............................................................................................................................. 243
24V Heater Fans.......................................................................................................................... 246
Motor and Plate Assembly............................................................................................................ 248
Laminator Controller PCBA.......................................................................................................... 251
Media Authentication PCBA.......................................................................................................... 253
ii ZXP Series 7 Card Printer Service Manual P1036102-007

Top Laminator Control Motor........................................................................................................ 254

Bottom Laminator Control Motor.................................................................................................. 255
Staging Motor............................................................................................................................... 256
Media Authentication Antenna PCBA........................................................................................... 257
Front Frame.................................................................................................................................. 259
Static Brush.................................................................................................................................. 261
Cassette Latch Assembly (Top & Bottom).................................................................................... 262
Thermopiles (Top & Bottom)......................................................................................................... 270
Top Thermopile Cable.................................................................................................................. 274
Bottom Thermopile Cable............................................................................................................. 275
Flexible Ribbed Rollers (Left & Right).......................................................................................... 276
Card Staging Nip Rollers (Left & Right)........................................................................................ 277
Platen Overrun Roller (Top & Bottom).......................................................................................... 278
Exit Rollers................................................................................................................................... 279
Cutters (Upper & Lower)............................................................................................................... 280
Laminate Ribbon Rollers (Top & Bottom)..................................................................................... 284
Card Entry Sensor Cable Assembly............................................................................................. 285
Card Laminator Sensor Cable Assembly...................................................................................... 286
Card Exit Sensor Cable Assembly................................................................................................ 287
Door Sensor Cable Assembly ...................................................................................................... 288
Replacement Procedures for the High-Capacity Output Hopper ...........................289
Introduction.........................................................................................................................................289
Required Tools.................................................................................................................................... 290
Procedures..........................................................................................................................................291
Output Hopper Cassette............................................................................................................... 291
High-Capacity Output Hopper...................................................................................................... 292
Left Side Panel............................................................................................................................. 304
Platen Roller................................................................................................................................. 311
Pressure Roller............................................................................................................................. 313
Sensors........................................................................................................................................ 316
Drive Assembly............................................................................................................................. 329
Elevator........................................................................................................................................ 339
Elevator Bushing.......................................................................................................................... 346
Base Housing............................................................................................................................... 347
Base Cover and Latch Assembly.................................................................................................. 354
PCBA............................................................................................................................................355
Cleaning.......................................................................................................................361
Introduction.........................................................................................................................................361
Cleaning the Printer............................................................................................................................ 362
When to Clean.............................................................................................................................. 362
Initiate the Cleaning Process........................................................................................................ 362
Clean the Card Path..................................................................................................................... 363
Clean the Feeder Path................................................................................................................. 364
Polish the Printhead..................................................................................................................... 365
Cleaning the Laminator....................................................................................................................... 366
When to Clean.............................................................................................................................. 366
Initiate the cleaning process......................................................................................................... 366
Clean the Laminator Card Path.................................................................................................... 367
Clean the Laminator Media Rollers.............................................................................................. 368
Clean the Laminator Oven (Heater Rollers)................................................................................. 370
Cleaning the High-Capacity Output Hopper........................................................................................ 373
Dual Cleaning Cartridge...................................................................................................................... 374
Manual Feed Cleaning Cassette......................................................................................................... 374
Cleaning Supplies............................................................................................................................... 374
P1036102-007 ZXP Series 7 Card Printer Service Manual iii

Field Upgrades............................................................................................................375
Introduction.........................................................................................................................................375
Placing Labels..................................................................................................................................... 376
Field Upgrade Labels.......................................................................................................................... 377
iv ZXP Series 7 Card Printer Service Manual P1036102-007

1
Introduction
Description
This manual provides detailed information on the service of, and replacement
procedures for the Zebra ZXP Series 7 Card Printer, the optional laminator, and the
optional high-capacity output hopper.
References to “the printer” in this document apply to either the single- or the double-
sided printer. Similarly, references to “the laminator” apply to either the single- or the
double-sided Laminator.
P1036102-007 ZXP Series 7 Card Printer Service Manual 1

2 ZXP Series 7 Card Printer Service Manual P1036102-007
2
Theory of Operation
Introduction
This section includes five major topics:
• Card Movement During Printing
• Printing Technologies and Ribbons
• System-Level Electronics
• Main PCBA (CPU)
• High-Capacity Output Hopper
3
Theory of Operation
Card Movement During Printing

Step 1. The card is fed from the Feeder Cartridge into the Printer.
Step 2. As the card is moved into the Printer, it is cleaned via the Cleaning Cartridge;
this cleans dust and dirt particles from both sides of the card.
Step 3. If the Printer includes an optional Smart Card Encoder (either contact-style
or contactless), the card is moved to the Encoder; and the smart card is
encoded. As the card is encoded, it is checked to verify that it was encoded
properly. If encoding fails, the card is moved to the Reject Bin. This is done
to avoid wasting time and ribbon panels on a defective card. If the encoding
is successful, the card is moved into the pre-print position, just before the
Printhead.
Step 4. If the Printer includes an optional Magnetic Stripe Encoder, the card is
moved to the Encoder; and the magnetic stripe is encoded. The card is then
backed up and run through the Magnetic Stripe Encoder again; on this pass
the card is read to verify that the magnetic stripe was properly encoded.
If encoding fails, the card is moved to the Reject Bin. As with failed smart
card encoding, this is done to avoid wasting time and ribbon panels on a
defective card. If the encoding is successful, the card is moved into the pre-
print position, just before the Printhead.
Step 5. The card is printed.
Dye-Sublimation Printing
When the Print Cover is opened and closed, the ribbon is synchronized,
thereby bringing the leading edge of the Yellow ribbon panel (e.g., a YMCKO
ribbon) under the Printhead.
The leading edge of the card is moved under the Printhead (over the Platen
Roller), and the Printhead is lowered. Lowering the Printhead reduces the
space between the Printhead, the ribbon, and the card, which produces
sharper images.
As the card and ribbon move along, each element of the Printhead receives
a pulse of variable width; a wider pulse results in a hotter element which
melts a larger amount of yellow dye onto that particular spot on the card.
After this Yellow (Y) pass is completed, the Printhead is raised, the card is
moved back, and printing continues with the Magenta (M) ribbon panel,
then the Cyan (C) panel, then the Black (K) panel, and finally the Overlay (O)
panel.
Thermal-Transfer Printing
If using a monochrome ribbon, the card makes a single pass under the
Printhead. The Printhead elements are energized to either on or off. The
on level actually transfers the spot of resin under the Printhead element to
the card. This results in the sharpest possible images; for bar codes you
want the sharpest edges and highest contrast between dark and un-printed
areas.

Theory of Operation
Step 6. For double-sided printing, the card is now moved back to the Card Flipper
where the card is turned over (rotated 180 degrees). The card is moved into
the Print Engine; and the card is printed (same as Step 5).
Step 7. If the Printer has a Laminator:
a. The card is moved through the Printer into the Laminator.
b. As the card passes through the Laminator, laminating film is applied to

the card, the top side or both sides depending on the Laminator.
c. The card (with the laminating film) then passes between a pair of heated
rollers, which seal the laminating film to the card.
d. The card is moved from the Laminator to the Card Exit, where it falls into
the Output Hopper attached to the left side of the Laminator.
Step 8. If the Printer does not have a Laminator; the card moves through the Printer,
where it falls into the Output Hopper attached to the left side of the Printer.

Theory of Operation
Printing Technologies and Ribbons

There are two types of printing technology used in the printer: Dye Sublimation and
Thermal Transfer. The technology to use is determined by the type of dye or ink on
the ribbon.
Monochrome Ribbons have a single color ink on the length of the ribbon. The printer
is programmed to use Thermal Transfer printing for monochrome ribbons.
Multi-Panel Ribbons have a repeating sequence of panels of different dye. RFID

Multi-Panel Ribbons have an RFID tag on the supply spool; the RFID code identifies
the ribbon type and panel count. (Note that the lack of an RFID tag will be interpreted
by the printer as being a Monochrome Ribbon.) Printing with a Multi-Panel Ribbon
requires multiple passes of the card under the Printhead, once per panel.
For double-sided printing, a typical situation would be to print a full-color graphic (such
as a person’s picture) along with black text and/or bar-coding on the front, and black
text and/or bar-coding on the rear. In this case, a YMCKOK Multi-Panel Ribbon would
be used.
A YMCKO ribbon has successive panels as follows:
Color Technology Function / Usage

Full-Color Printing and Dye
Yellow (“Y”) Dye Sublimation
Sublimation Black Printing
Magenta (“M”) Dye Sublimation
Cyan (“C”) Dye Sublimation
K Resin Black Printing (for the
Black Resin (“K”) Thermal Transfer
front of the card)
Overlay (O) - -
Thermal Transfer Dye Sublimation

Printing Process Printing Process
(YMCKO) Overlay Black Cyan Magenta Yellow

Pattern (O) (K) (C) (M) (Y)
Repeats) Resin Dye Dye Dye
Ribbon movement from supply spool
Other ribbons are available for the printer; see the Supplies List on the Driver and
Documentation CD that came with the printer, or visit the Zebra Card Printer Solutions
website at zebra.com/supplies.

Theory of Operation
The ribbon synchronizes to it’s “starting” position whenever the Print Cover is opened
and then closed. For a YMCKO ribbon, the starting position is with the leading edge of
a Yellow Panel at the printhead location.
The figure below shows how the YMCKO ribbon and card move relative to each other
during printing.
1. Ribbon move yellowpanel into Printhead in fixed position

position at printhead.
2. Card is fed to printing position

under the printhead.
3. Card and ribbon move together as

yellow panel is printed.
4. Card and ribbon stop at the end

of the yellow panel.
5. Ribbon remains stationary as card

is moved back to printing position.
6. Card and ribbon move together as

magenta panel is printed.
In addition, the driver software allows the user to specify which ribbon panels are
printed on either side of the card.

Theory of Operation
Dye Sublimation Printing

In Dye Sublimation Printing, each printhead heating element is applied voltage at one
of a number of pulse widths.
A wider pulse results in the element getting hotter, which converts more of the dye (at
that pixel location) to a gas and diffuses it into the surface of the card (a wider pulse
gives more intense color at that pixel).
This is repeated for each of the dye panels (i.e., Yellow, Magenta, and Cyan), to result
in full-color images.
Printhead
Ribbon Carrier
Layer
Ribbon Ink
Layer
Gaseous dye is
Card
absorbed by the card
Thermal Transfer Printing

In Thermal Transfer Printing, voltage is either applied or not applied to each printhead
printing element. If voltage is applied, the ink at that location is transferred to the
surface of the card.
Each pixel is either printed (i.e., the ink is transferred to the card) or not; there are no
intermediate levels.
Thermal Transfer printing with a black (K) resin panel is used for printing bar codes,
since contrast between the light and dark areas is the highest and the edges are the
sharpest.
Printhead
Ribbon Carrier
Layer
Ribbon Ink
Layer
Ink is transferred to the
Card
surface of the card

P1036102-007
UHF Mod
OPTIONS MODULE or
AC Switch & DB9 for
CA_ACPWR (P1013793) Felica Mod
EMI Filter 200W Power Supply External
(PWR_SW, (PWR_SUP, Contact USB Barcode
CA_SUP_GND Media Auth Coupler SmartCard Mag Module PCBA
P1035695) P1008702) Station Host Reader
(P1014040) (PCBA_CPLR_MA, Authentication (PCBA_MAG_MOD_IF
Ports (BARCD)
P1008230-02) (Contact SmartCard P1038451-01) Mag Head
or
for User Auth) ( MAG_ISO)
CA_MTRS_ENG_GND
(P1031857)
(P1029730) P1029189
Ground Plate CA_CPLR_MA
CA_MAG_MOD_IF
(P1027378-01)
(P1027378-02)
CA_MTR_RIBT_GND (300844-001) LED
PCBA_UHF_CAR
(GND_MCB,
(P1029884)
PCBA_FELICA_CAR
P1010902) CA_BRUSH_EXIT SEN_OPMG
(P1022300) MTR_OPMG
PE Media Auth PCBA Options Module Detector (P1039207)
CA_SW_GND (PCBA_MAB, Mag PCBA (PCBA_MAG_
(P1013891) 404870-003P) SmartCard Module (PCBA_OPMAG,
CA_ENGINE_GND MOD_DET,
(Osprey P/N: P1004275)

(SC_MOD, P1038415-01) P1038478-01)
CA_LAM_AC (P1029986)
CA_LAM_GND 806882-001) or SmartCard Coupler
(P1041281) CA_OPTIONS_GND Ext Contact Stn i/f (PCBA_CPLR_SC)
PCBA (if required) CA_MTR_OPMG-MOD_GND (P1033288)
(P1042978)
CA_EXT_DB9
(PCBA_EXTCNT_IF,
WiFi Antenna (ANT, P1005199)

CA_LAM_DC (P1030139) CA_EXT P1006651-01) CA_MTR_OPCM_GND
MAG
CA_MAB
(Osprey P/N: P1004276) (P1043050) (P1033220)
CA_UCONN
(P1025470)
CA_BARCD
CA_DCPWR (P1030122: DC output CN2 is conn)

(Osprey P/N: 300827-001: DC output CN2 is term block)
CA_USRAUTH
CA_SC_MOD
CA_OPMAG (P1026484)
Laminator Ethernet (P1029151) or
CA_LAM_CTL (P1030001) MTR_OPCM
(LAM) Periph Board CA_SC_MOD
(Osprey P/N: P1004277) (P1029200)
USB
OPMAG_PD_N
(PCBA_ENET, _EXT
These connections Port
System-Level Electronics
P1006890-02 (P1042729) CA_MTR_OPCM-MOD_GND (P1033283)

SEN_RIBA Tri-Color are combined into or
(404790-003P) Emitter CA_PH P1006890-03) SmartCard
(P1037316) FSI Conn Module PCBA Gap
FAN_PH (blower) (PCBA_SC_MOD, Sensor Gap SEN_OPCD
(P1044307) P1028126-01) SEN_OPCM Sensor (300238G-002)
CA_OPSC_RF
CA_ENGINE_GND (P1032223) Connectors (P1029126)
Print Head Main Controller Board PCBA
(PCBA_MCB, Options Module
(PH, CA_MTR_OPCD_GND
P1047494-01) SmartCard PCBA
P1040725) CA_OPSC
(PCBA_OPSC,
PH_GND (P1027859)
P1028104-01) MTR_OPCD
Ground Plate (P1044093)
SMARTCARD
CA_OCP_PLUG CA_OCP_RECEPT
(GND_ENG, OCP Assy
(P1032161) (P1032163)
P1030086) (OCP,
P1027292) CA_EP_DEBUG These connections
IP/EP Diagnostic Board are combined into
CA_IP_DEBUG CA_FLIP_PWR (P1026479)
(PCBA_DIAG_IF, CA_FLOPSC
JTAG P1043417-01) CA_FLIP_CTL (P1026480)
(P1026476)
These connections
CA_SEN_RIBB CA_MTRS_ENG_GND are combined into
(P1037399) CA_FLOPMAG
OPSC_PD_N
(P1026478)
MTR_OPCM_CTL
MTR_CAM (P1009302)
CA_BRUSH_CLSOUTS (P1029745-001)
CA_THERM
(P1051848)
CA_BRUSH_FEED_RGHT (P1029727)
CA_BRUSH_FEED_LEFT (P1029728) MTR_OPMG_CTL
Thermistor
ZXP Series 7 Card Printer Service Manual

CA_MTR_FEED_GND (P1029744-001) SEN_RIBB Tri-Color
CA_OPTIONS_GND CA_MTR_RIBS_GND (P1029883-001) MTR_MAIN (P1009157-001)
(405030-003B) Detector
(P1032220) Flipper Board PCBA
CA_MTR_RIBS_GND (PCBA_FLIP,
SEN_TENC Gap P1021234-01)
CA_MTR_MCB (P1014939)
(300364-003) Sensor MTR_RIBS (P1020449) CA_MTR_FLCD_GND
SEN_EXIT Gap
Ground Plate (300364-010) Sensor MTR_FLCD
CA_SEN_MCB (P1014941)
(GND_FLOP, (P1042321)
SEN_SENC Gap
P1029901) (300364-002) Sensor CA_MTR_FLRO_GND
CA_MTR_RIBT_GND
SEN_CAM Gap
MTR_FLRO
(300364-008) Sensor MTR_RIBT (P1020406)
(P1026465-002)
MTR_SP
SEN_CSYN Gap
CA_FLIP_SHFT_GND (P1029747-001) (300364-009) Sensor
Gap SEN_FLCD
CA_MTR_FLCD_GND (P1032300) Sensor (P1030185)
SEN_DOOP Gap FAN_PWR
CA_MTR_OPCD_GND (P1032300) FEEDER
CA_MTR_FLRO_GND (P1032281) (300238G-004) Sensor
CA_BRUSH_ATM (P1029833) CA_MTR_FEED_GND Gap SEN_FLRO
CA_BRUSH_FLIP (P1032340) Sensor (300364-007)
FAN_SP1
CA_MTR_OPMG-MOD_GND (P1033288)
CA_MTR_OPCM-MOD_GND (P1033283) MTR_FEED Gap SEN_FDOP
(Individual motor cables)
(P1041216) Sensor (300364-006)

FAN_SP2 FLIPPER
Theory of Operation
9
Theory of Operation
Main PCBA (CPU)
PCBA Layout
* J50, J51, and J52 are on the bottom side of the Main PCBA

Theory of Operation
PCBA Connections
Connector PCBA ID Functional Description

J1 ETHERNET INTERFACE Ethernet Daughterboard
J2 USB_PERIPH_PC USB peripheral interface from host PC
J3 SEN_RIBA Ribbon tri-color sensor (detector)
J4 SEN_RIBB Ribbon tri-color sensor (emitter)
J5 PH_PWR Power to printhead
J6 JTAG RESERVED
J7 DCPWR DC power input to board
J8 MTR_RIBT Ribbon take-up motor
J9 SEN_TENC Ribbon take-up encoder wheel sensor
J10 LAM_CTL Control signals to Laminator or Hopper
J11 SEN_EXIT Exit sensor
J12 -- RESERVED
J13 -- RESERVED
J14 -- RESERVED
J15 -- RESERVED
J16 MTR_MCB Stepper motors driven by MCB
J17 -- RESERVED
J18 USB_HOST_SP RESERVED
J19 USRAUTH User Authentication
J20 BARCD Barcode Reader
J21 OCP Operator Control Panel
J22 MAB Media Authentication Board
J23 SEN_CAM RESERVED
J24 SEN_MCB Various sensors
J25 N/A N/A
J26 UHF/FELICA RESERVED
J27 FDFLIP_CTL Control signals to Flipper Board
J28 FDFLIP_PWR Power to Flipper Board
J29 PH_DATA Printhead Data
J30 USB_HOST_PANEL USB Dual Host cable
J31 -- RESERVED
J32 IP_DEBUG RESERVED
J33 EP_DEBUG RESERVED
J34 SEN_RIBA_NEW Ribbon tri-color sensor (emitter)
J35 SEN_RIBB_NEW Ribbon tri-color sensor (detector)
J36 THERM RESERVED
J50* OPSC SmartCard option board
J51* OPMAG Mag option board
J52* DIAG I/F Diagnostic test
* J50, J51, and 52 are on the bottom side of the Main PCBA

12
Main PCBA
200W Power Supply
(PWR_SUP)
2 Tri-Color
IP/EP Diagnostic Board SEN_RIBA
Emitter
(PCBA_DIAG_IF,
5
Thermistor
P1043417-01) Tri-Color
SEN_RIBB
CA_DCPWR
Ethernet Detector
CA_UCONN
J2
CA_THERM
Daughter
Theory of Operation
Board
Flipper CA_FDFLIP_PWR (PCBA_ENET)

J28
Module
J1
J7
PCBA CA_FDFLIP_CTL
J52
J35
J34
J36
J30
(PCBA_FLIP) J27
J24 Gap
DC-DC SEN_SENC
Sensor
Mag PCBA CA_OPMAG Power
J51
USB_PERIPH_PC
(PCBA_OPMAG) Conversion Gap
SEN_CAM
USB_HOST_PANEL
Sensor Interface Sensor
PCBA Block Diagram
(tri-color sensor circuit,

USB Logic Gap
74HC14's for digital sensor inputs, SEN_CSYN
CA_SEN_MCB
A2D for analog inputs) Sensor
Debug Interfaces
USB Interfaces Gap
SmartCard PCBA CA_OPSC SEN_DOOP
J50 Sensor
(PCBA_OPSC)
Remote Board Interfaces
MCB Sensor Interfaces
CPU Subsystem
(FPGA, DDR, Flash,
Media Auth clock buffering, I2C mux, etc.) Gap
Coupler PCBA J9 SEN_TENC
External Module Interfaces Sensor
(PCBA_CPLR_MAB) Print Head Interface
Gap
CA_CPLR_MAB J11 SEN_EXIT
Sensor
Media Auth PCBA CA_MAB (PH_PWR)

J22 J5
(PCBA_MAB) CA_PH Print Head
(PH)
J29
(PH_DATA)
MCB Motor Driver Interfaces
CA_LAM_CTL 2
Laminator (LAM) J10 FAN_PH
2
OCP Support PCBA CA_OCP A3979 A4983 A3966 BEMF Circuit J8 MTR_RIBT
J21
ZXP Series 7 Card Printer Service Manual

(PCBA_OCP)
Barcode CA_BARCD
Reader J20 J16
serviceable unit, there is no component level circuit analysis.
(BARCD)
J26
J19
4 4 2
These motors each plug into
a C/A (CA_MTR_MCB) that
CA_USRAUTH
connects to J16 here.
CA_UHF-FELICA
SmartCard
Authentication
(Contact SmartCard
for User Auth) UHF/Felica
(PCBA_USRAUTH)
MTR_RIBS
MTR_CAM
MTR_MAIN
Most of the circuitry in the printer is on the Main PCBA. Since the Main PCBA is not a
P1036102-007
Theory of Operation
High-Capacity Output Hopper
Hopper Cassette
Stacker
Hopper Cassette
• Easily removable from, and replaceable back onto, stacker base (full, partial, or
empty of cards).
• Equipped with a locking mechanism for capturing and holding stacked cards.
• Open front slot to allow for manual removal of cards (from 1 to 250 cards) without
removing stacker from base.
• With the hopper cassette removed, cards can be removed from top, not from
bottom as locking mechanism is not reversible.
Stacker
The high-capacity output hopper receives and automatically stacks cards in the order
they were printed—top face up—with the first card printed at the top of the stack, and
the last card printed at the bottom of the stack.
The high capacity output hopper runs independently of the printer and responds only
to the card present sensor at the entrance to the hopper. With the cassette in place,
the hopper will stack cards continuously based on print job (including overfilling over
the top of the cassette). With the cassette removed, the elevator will not actuate,
but the printer will continue to print and printed cards will accumulate on the stacker
base—up to 9 cards (30 mil) will accumulate before being pushed off the stacker base.

14 Hopper Cassette
3
Troubleshooting
Introduction
The table on the next page offers causes and solutions to symptoms related to
improper operation. Check the table on the following pages when experiencing any
loss of operation or print quality.
For additional information on troubleshooting and advanced operations, you can

access an extensive Knowledge Base at km.zebra.com.

Troubleshooting
OCP Error Messages
OCP Error Messages

Important • If the Possible Solution does not solve your problem, contact Zebra
Technical Support.
CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

FIRMWARE UPGRADE Firmware upgrade Verify the version, and retry installing
5
ERROR incompatibility. the firmware.
Error encountered in
6 DIAGNOSTIC ERROR Power cycle the printer, and retry.
Diagnostic Mode.
FIRMWARE UPGRADE Verify the version, and retry installing
7 Firmware upgrade failed.
ERROR the firmware.
CRITICAL ERROR
8 Major malfunction encountered. Contact Zebra Technical Support.
SHUTTING DOWN
Status toggled (offline/online)
Change status to ONLINE via the
3001 PRINTER OFFLINE via the OCP Advanced Settings
OCP Advanced Settings Menu.
Menu.
4003 CARD JAM Card is jammed in the Printer. Clear the card path.
1. Clear card jam in Feeder
Cartridge, and re-seat Feeder
Card is jammed in Feeder Cartridge.
Cartridge. 2. Ensure that cards are not stuck
together and that they are the
4014 CARD FEED ERROR
correct thickness (10 to 50 mil).
1. Load cards in the Feeder

Printer is out of cards. Cartridge.
2. Re-seat the Feeder Cartridge.
Card was not fed into the

Retry and feed a card into the Manual
4015 CARD NOT INSERTED Manual Feed Slot within
Feed Slot, or cancel the operation.
30-second period.
5001 OUT OF RIBBON Print ribbon has run out. Load a new roll of print ribbon.
Print ribbon does not match the Verify the part number of the print
5002 INVALID RIBBON
printer. ribbon is correct on OCP.
1. Check the print ribbon.
2. Reinstall the print ribbon.
5003 RIBBON JAM Print ribbon is jammed.
3. Repair the break in the print ribbon
and reinstall.
Print ribbon is stretched. Recalibrate ribbon torque.
5004 RIBBON MOTION ERROR Tape the broken ends of the ribbon
together, roll the ribbon around the
Print ribbon is broken. take-up spool, place the ribbon back
in the printer, and power cycle the
printer.
Problem with the Back EMF
5006 RIBBON BEMF ERROR Contact Zebra Technical Support.
(BEMF) of the ribbon motors.
Reinstall the print ribbon. If reinstalling
RIBBON COLOR DETECT Print ribbon is not installed
5007 the ribbon does not solve the problem,
ERROR correctly.
contact Zebra Technical Support.

Troubleshooting
OCP Error Messages

1. Verify the part number of the print
Print ribbon does not match the ribbon is correct on OCP.
5008 INVALID RIBBON
printer.
2. Power cycle the printer, and retry.
6001 - GENERAL MEMORY There is a problem when
Power cycle the printer, and retry.
6008 ERROR accessing general memory.
There is a problem when
6009 FLASH ERASE ERROR Power cycle the printer, and retry.
accessing flash memory.
FLASH ERASE VERIFY There is a problem when
6010 Power cycle the printer, and retry.
ERROR accessing flash memory.
FLASH PROGRAM There is a problem when
ERROR accessing flash memory.
FLASH PROGRAM There is a problem when
VERIFY ERROR accessing flash memory.
There is a problem when
6013 INVALID FW S-RECORD Power cycle the printer, and retry.
accessing flash memory.
6015 - GENERAL MEMORY There is a problem when
Power cycle the printer, and retry.
6025 ERROR accessing general memory.
1. Clear card jam in Feeder
Cartridge, and re-seat Feeder
Card is jammed in Feeder Cartridge.
Cartridge. 2. Ensure that cards are not stuck
7001 CARD FEED ERROR together and that they are the
correct thickness (10 to 50 mil).
1. Load cards in the Feeder
The printer is out of cards. Cartridge.
2. Re-seat the Feeder Cartridge.
7002 CARD CLEAN ERROR
PRINTHEAD CABLE Printhead cable loose or Check printhead cable connection,
7003
ERROR disconnected. reconnect if loose or disconnected.
Card from previous job is stuck
7004 CARD EJECT ERROR Remove the card from the exit area.
in the exit area.
Move the printer to a cooler
Environmental issue -- the
7005 PRINTHEAD TOO HOT environment, or cool the area of
ambient temperature is too hot.
operation.
Environmental issue -- the Move the printer to a warmer
7006 PRINTHEAD TOO COLD ambient temperature is too environment, or warm the area of
cold. operation.
This warning will be displayed if
This warning will be cleared when the
7008 PRINT COVER OPEN the cover protecting the Printer
printer cover is closed.
Module is opened.
Printhead did not move
PRINTHEAD MOTION
7010 to proper position during Power cycle the printer, and retry.
ERROR
initialization.
Incorrect voltage detected at
MOTOR VOLTAGE
7013 one or several motors in the Power cycle the printer, and retry.
ERROR
unit.
SCRIPT PROCESSING
7014 Internal logic error. Power cycle the printer, and retry.
ERROR
This is a magnetic encoding
7015 MAG MOTION ERROR Power cycle the printer, and retry.
retrace error.

Troubleshooting
OCP Error Messages

1. Ensure that you are using the
correct card type.
2. Check that the cards are loaded in
• Encoding error.
7018 SMARTCARD ERROR the correct orientation.
• Faulty card.
3. Ensure that the data conforms to
ISO Specifications.
4. Retry writing and reading.
SCRIPT CONTENT
7019 Internal logic error. Power cycle the printer, and retry.
ERROR
7020 SCRIPT SEND ERROR Internal logic error. Power cycle the printer, and retry.
SMART CARD CAM INIT
7023 Mechanical positioning issue. Power cycle the printer, and retry.
ERROR
Card is jammed in the Options
7024 OPTIONS CARD JAM Clear the card path.
Module, Feeder Cartridge.
7026 FLIPPER CARD JAM Card is jammed in the Flipper. Clear the card path.
This warning will be displayed
This warning will be cleared when the
7028 OPTIONS COVER OPEN if the cover protecting the
options cover is closed.
Options Module is opened.
FLIPPER ROTATION
7029 The Flipper has failed. Contact Zebra Technical Support.
ERROR
7032 SINGLE CARD FEED JAM Clear the card path.
Module, Single Card Feed Slot.
7033 FLIPPER BOARD ERROR The Flipper has failed. Contact Zebra Technical Support.
Remove the cards from the bin, and
REJECT BIN FULL reset the reject bin card count to 0
7034 The Reject Bin is full.
REMOVE CARDS via the OCP (Main Menu > Advanced
Settings > Clear Reject Bin).
7035 OPTIONS CARD JAM Clear the card path.
Module, Magnetic Encoder.
7036 - Card is jammed in Printer
PRINT CARD JAM Clear the card path.
7039 Module.
correct card type.
2. Check that the cards are loaded
with the magnetic stripe in the
correct orientation.
• Encoding error.
9001 MAG READ ERROR 3. Ensure that the cards are set-
• Defective magnetic stripe. up correctly in the printer driver
(coercivity setting).
ISO Specifications.
5. Retry reading.

Troubleshooting
OCP Error Messages

correct card type.
2. Check that the cards are loaded
• Encoding error.
9002 MAG WRITE ERROR 3. Ensure that the cards are set-
• Defective magnetic stripe. up correctly in the printer driver
(coercivity setting).
ISO Specifications.
5. Retry writing.
correct card type.
9004 NO MAG STRIPE Magnetic stripe not detected. 2. Check that the cards are loaded
• Wrong card type is in use. correct card type.
• Card orientation in the 2. Check that the cards are loaded
10001 CONTACT READ ERROR Feeder Cartridge is wrong. with the chip in the correct
orientation.
• Smart Card Options Module
is incorrectly installed. 3. Re-seat the Smart Card Options
Module.
correct card type.
• Wrong card type is in use. 2. Check that the cards are loaded
CONTACT WRITE
10002 • Card orientation in the with the chip in the correct
ERROR
Feeder Cartridge is wrong. orientation.
3. Re-seat the Smart Card Options
Module.
• Wrong card type is in use.
CONTACTLESS READ correct card type.
11001 • Smart Card Options Module
ERROR 2. Re-seat the Smart Card Options
is incorrectly installed.
Module.
• Wrong card type is in use.
CONTACTLESS WRITE correct card type.
11002 • Smart Card Options Module
ERROR 2. Re-seat the Smart Card Options
is incorrectly installed.
Module.
1. Check print ribbon orientation.
An error occurred when
reading the RFID Tag by the 2. Verify part number of the print
15001 MISSING MAB
MAB (Media Authentication ribbon.
Board). 3. Power cycle the printer, and retry.
MAB FIRMWARE MAB (Media Authentication
15002 Install the firmware.
MISSING Board) Firmware is missing.
17001 LAMINATOR MISSING
Laminator was detected by
LAMINATOR FAILED
17002 the printer, but was unable to Contact Zebra Technical Support.
INITIALIZATION
communicate to it.

Troubleshooting
OCP Error Messages

An unknown error has occurred 1. Press RETRY on the OCP.
LAMINATOR UNKNOWN
17003 – this is an indication of a FW
ERROR 2. Contact Zebra Technical Support.
problem and should not occur.
An error occurred when
MISSING LAMINATOR trying to communicate to 1. Power cycle the printer, and retry.
17004
MAB the Laminator MAB (Media 2. Contact Zebra Technical Support.
Authentication Board).
• Top laminate cartridge is not
installed properly. 1. Remove, reposition, and re-install
the top laminate cartridge.
• Cartridge is not removed
TOP LAMINATE FEED when that side of the card is 2. Remove the top laminate
17005
FAIL not being laminated. cartridge.
• A mis-cut piece of laminate 3. Remove the mis-cut piece of
(rare) is obscuring the media laminate.
sensor.
• Bottom laminate cartridge is
1. Remove, reposition, and re-install
not installed properly.
BOTTOM LAMINATE the bottom laminate cartridge.
17006 • Cartridge is not removed
FEED FAIL 2. Remove the bottom laminate
when that side of the card is
cartridge.
not being laminated.
• Improperly prepared
registered laminate.
• Media misfeed. Remove and re-cut laminate in the
TOP LAMINATE
17007 center of the index notch, re-install,
REGISTRATION ERROR • Patch length improperly set. and retry.
• Unexpected end of laminate
roll detected.
Printer has not fed the card
LAMINATOR CARD FEED far enough into laminator Open the Laminator and printer doors
17008
FAIL mechanism for infeed rollers to to check for jammed/stuck cards.
grab it.
Remove the card and/or laminate
LAMINATOR EARLY Card did not make it to the
17009 that is stuck in the laminator staging/
CARD JAM staging rollers.
cutting area.
Card and laminate have
jammed inside heater
LAMINATOR MIDDLE Remove the oven, and inspect for
17010 assembly, often due to mis-
CARD JAM stuck cards.
positioned laminate patch
sticking to heated rollers.
1. Check for card jam in the exit area.
LAMINATOR LATE CARD Card did not unblock the exit
17011 2. Assure that the sliding exit door is
JAM sensor in the specified time.
not partially blocking the exit path.
The laminator expects the
printer to periodically send
commands to it within a
specified time period. If it
fails to do so, it assumes that
LAMINATOR POLL
17012 something is wrong with the Power cycle the printer, and retry.
TIMEOUT
communication link or that the
printer is down. This error may
occur if the printer-to-laminator
communications is having
intermittent problems.

Troubleshooting
OCP Error Messages

Top heater did not turn on
after being instructed to
do so. When the heater
is enabled, the controller
LAMINATOR TOP will wait a certain specified
17013 Replace the top halogen bulb.
HEATER FAIL amount of time for it to attain
the set target temperature. If
the heater fails to reach the
target in the specified time, the
TopHeaterFail fault will be set.
Bottom heater did not turn
on after being instructed
to do so. When the heater
is enabled, the controller
LAMINATOR BOTTOM will wait a certain specified
17014 Replace the bottom halogen bulb.
HEATER FAIL amount of time for it to attain
the set target temperature. If
the heater fails to reach the
target in the specified time, the
BotHeaterFail fault will be set.
If the top roller temperature 1. Power cycle the printer, and retry.
LAMINATOR TOP ever exceeds a fixed
17015 2. If this error persists, contact Tech
TEMPERATURE HIGH temperature threshold, the over
temp error occurs. Support.
If the bottom roller temperature 1. Power cycle the printer, and retry.
LAMINATOR BOTTOM ever exceeds a fixed
17016 2. If this error persists, contact Tech
TEMPERATURE HIGH temperature threshold, the over
temp error occurs. Support.
Top cutter blade is obstructed,

LAMINATOR TOP If this error persists, contact Tech
17017 or top cutter mechanism is
CUTTER STALL Support.
damaged.
Bottom cutter blade is
LAMINATOR BOTTOM If this error persists, contact Tech
17118 obstructed, or bottom cutter
CUTTER STALL Support.
mechanism is damaged.
LAMINATOR TOP If this error persists, contact Tech
17019 Top cutter has failed.
CUTTER FAIL Support.
LAMINATOR BOTTOM If this error persists, contact Tech
17020 Bottom cutter has failed.
CUTTER FAIL Support.
LAMINATOR TOP TEMP The top temperature If this error persists, contact Tech
17021
SENSOR FAIL (thermopile) sensor has failed. Support.
LAMINATOR BOTTOM The bottom temperature If this error persists, contact Tech
17022
TEMP SENSOR FAIL (thermopile) sensor has failed. Support.
This should only happen if one
or both cooling fans fail or the
17023 LAMINATOR FAN FAIL cooling vents near the heated Check for blocked vents.
roller assembly are blocked or
the fan(s) have failed.

Troubleshooting
OCP Error Messages

The parameters stored in
EEPROM have been reset
to their default values. This
will not normally happen, but 1. Press RETRY on the OCP when
LAMINATOR EEPROM could be seen with certain this error occurs.
17024
DEFAULT FW upgrades when new
parameters have been added 2. Power cycle the printer, and retry.
by Engineering. It could also
indicate a problem with the
Laminator’s EEPROM.
TOP AND BOTTOM The top and bottom laminates
17026 Load new rolls of laminate.
LAMINATES OUT have run out.
17027 TOP LAMINATE OUT The top laminate has run out. Load new roll of laminate.
The bottom laminate has run
17028 BOTTOM LAMINATE OUT Load new roll of laminate.
out.
1. Verify the part number of the
Laminate does not match the laminate is correct on OCP.
17029 INVALID TOP LAMINATE
printer.
1. Verify that the top and bottom
laminate cassettes are installed in
Laminate does not match the
the correct locations.
INVALID BOTTOM type allowed in the laminator
17030
LAMINATE or top and/or bottom has been 2. Verify the part number of the
swapped. laminate is correct on OCP.
• Improperly prepared
registered laminate.
• Media misfeed. Remove and recut laminate in the
BOTTOM LAMINATE
17031 center of the index notch, re-install,
REGISTRATION ERROR • Patch length improperly set. and retry.
• Unexpected end of laminate
roll detected.
Top laminate is installed when
17032 REMOVE TOP LAMINATE the driver lamination mode Remove the top laminate cassette.
“Bottom” is selected.
Bottom laminate is installed
REMOVE BOTTOM Remove the bottom laminate
17033 when the driver lamination
LAMINATE cassette.
mode “Top” is selected.
Top and bottom laminates
REMOVE TOP AND are installed when the driver
17034 Remove both laminate cassettes.
BOTTOM LAMINATES lamination mode “Pass
through” is selected.
LAMINATOR COVER This warning will be cleared when the
17038 if the cover protecting the
OPEN laminator cover is closed.
laminator is opened.
LAMINATOR after the laminator door is
17040 No action needed
INITIALIZING closed and laminate spools are
re-read/detected.
LAMINATOR FIRMWARE Laminator Controller Board
17041 Install the firmware.
MISSING (LCB) Firmware is missing.

Troubleshooting
OCP Error Messages

Laminator MAB (Media
LAMINATOR MAB
17042 Authentication Board) Install the firmware.
FIRMWARE MISSING
Firmware is missing.
ETHERNET COMM
18001 Ethernet connection failed. Check network connectivity.
ERROR
19001 WIFI COMM ERROR Hardware failure. Replace the Wireless PCBA.
WIFI ACCESS POINT Attempt to reconnect to the Access
19002 Network failure.
MISSING Point (AP).
Attempt to reconnect to the Access
19003 WIFI LINK LOST Network failure.
Point (AP).
WIFI INCOMPATIBLE Attempt to reconnect to the Access
NETWORK Point (AP).
WIFI ASSOCIATION Attempt to reconnect to the Access
FAILED Point (AP).
WIFI CONNECTION Attempt to reconnect to the Access
FAILED Point (AP).
The Barcode Scanner
Check the Barcode Scanner
20001 BARCODE ERROR INIT Assembly may be incorrectly
Assembly.
installed or defective.
Communications problem
Check the Barcode Scanner
20002 BARCODE ERROR READ with the Barcode Scanner
Assembly.
Assembly.
1. Check for defective barcode on the
card being read.
BARCODE ERROR NO 2. Check the orientation of the cards
20003 Cannot read the barcode.
DATA in the Feeder cartridge.
3. The barcode is printed in the
wrong location.

Troubleshooting
OCP Error Messages
Stacker is missing but is

configured to have it. Stacker
may have been removed or Replace the stacker. The printer
21001 STACKER MISSING communication has been lost configuration will recognize the
between stacker and main logic stacker and operate normally.
board. Printer will still print,
however no cards will stack.
Remove the stacker. The printer
Stacker has been found but
must be configured at the factory
STACKER has not been enabled. Printer
21002 to recognize the stacker. Once the
UNAUTHORIZED will not print until stacker is
stacker is removed, the printer will
enabled.
operate normally.
Something mechanically has Check the card path. Remove the
21003 STACKER INIT ERROR prevented the stacker from fully high-capacity output hopper from the
initializing. Printer will not print. stacker and clear any obstruction.
Card has jammed at the
21004 STACKER CARD JAM stacker entry sensor. Printer Clear the card jam.
will not print.
Elevator jam in which the
1. Replace cam sensor.
elevator has not detected
the home position. Could be 2. Check the stacker card path for
STACKER ELEVATOR
21005 the possibility of a faulty cam jammed or stuck cards.
JAM
sensor for elevator, a card jam, 3. Remove finished cards from the
or too many card in the hopper. hopper.
Printer will not print.
Cannot communicate between Cycle printer power. Check
21006 STACKER COMM ERROR printer and hopper. Printer will connections between printer and
not print until error is fixed. stacker.
Firmware corrupt or missing.
Printer will not print until
21010 STACKER FW MISSING Update printer and stacker firmware.
stacker firmware is installed
and power is cycled.

Troubleshooting
OCP Test Cards
OCP Test Cards

Image Title Description Use
3 sets of light-to-dark
GRADIENT BOXES For factory use only.
grayscale ramps
Used to measure mid

Mid-gray and maximum and max densities. Also
DENSITY SETUP density fields on a flat gray used to check the left/right
surface offsets or the centering of
the image on the card.
Used to verify
MONOCHROME ONLY Barcode and text monochrome print
capability.
Also used to check the left/right offsets or the centering of the image on the card.

Troubleshooting
Ethernet
Ethernet
• Indicators -- Detail
• Link Speed Indicator (Orange)
Off No link (disconnected)

1 Blink The LED blinks once (one blink, pause, one blink,
etc.) when a 10Base link has been established.
2 Blinks The LED blinks twice (two blinks, pause, two blinks,
etc.) when a 100Base link has been established.
• Link Activity Indicator (Green)
Off No link (disconnected)

On Network link has been established
Blinking Network activity has been detected
• Issues
If both LEDs are off, the printer has not detected the presence of a network cable.
To solve the problem:
• Verify that the network cable is appropriate and has an RJ-45 connector.
• Remove the network cable from the printer. Plug the network cable back in
until you hear a positive click. Check the other end of the cable in the same
manner. If the printer still does not detect a cable, then continue.
• Connect the printer to a known good network. If the printer is still unable to
detect the network cable, contact Technical Support for assistance.

4
Replacement Procedures
for the Printer
Introduction
The following sections describe removing both major assemblies and—where
applicable—sub-assemblies and/or components that are considered replaceable.
In general, only removal directions are presented. Unless otherwise noted,

replacement would be performed by reversing the removal steps. Replacement
instructions for some common or simple procedures are not presented.
For a complete listing of Spare Part Kits and Upgrade Kits available for the Zebra ZXP
Series 7 Card Printer, see the ZXP Series 7 Spare Parts Catalog at www.zebra.com/
parts.
Electric Shock • Before performing any of the procedures in this section, set the
printer power to OFF (O) and disconnect the power cord.
Electrostatic Discharge • All replacement procedures must be performed at a static-

free work station, an anti-static wrist strap must be worn and properly terminated, or
other appropriate protection must be used.
Caution • Before beginning any of the procedures that follow, read completely
through the procedure. If you do not have the specified tools or if any step(s) seem
beyond your skill or experience level, do not attempt the procedure. You may cause
additional damage to the printer.
Note • Some of the photographs in this section may show additional parts removed in
addition to removals for the process being described.

Replacement Procedures for the Printer
Required Tools
Required Tools
The following list specifies the tools required to perform the replacement procedures
described in this section. Naturally, not all tools are required for a particular procedure;
specific tools are called out in each step as appropriate.
• Flat-blade Screwdrivers: from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm)
• Phillips Screwdrivers: #0, #1, and #2
• TORX T8, T9, and T10 (standard, 12-inch shaft, and/or ball-end; magnetic tip
recommended)
• Fine-Point, Offset Fine-Point, and Needle-Nose Pliers
• Small Diagonal Cutters or other cutter for cutting cable ties
• 5.5 mm nut driver (this can also be used for securing push nuts)
• 3–10 mm E-Ring Clip Tool
• Small and Medium Spring Hooks
• Adjustable Wrench
• Multimeter
• Loctite® 242
The following list specifies the Zebra Special-Purpose Tools required to calibrate
specific parts/assemblies reinstalled in selected procedures. Note that the Zebra Part
Number is in parentheses following the description.
• Torque Tools for RTU Motor Calibration ZXP7 (P1037750-400)
This kit is comprised of a High Torque Tool and a Low Torque Tool. The recom-
mended calibration cycle for these tools is 50 uses or every 6 months. Please
return your torque tools to the nearest Zebra Repair Center for calibration; or see
page 187 for torque tool calibration instructions.
• Print Head Cam Sync Fixture ZXP7 (P1037750-401).
• Flipper Deck Level (P1037750-402).
• Contact Station Upgrade Tool (P1037750-403).
• AC Power Filter Release Tool (P1037750-404).
• Mag Tensioning Spring Tool (included with all magnetic encoder upgrade kits).
• Gates Sonic Tension Meter 507C. Note that this item is not being sold by Zebra.
• Kit Service CD / ZXP7 (P1037750-090).
• ZMotif Service Partner Tool (SW0000194)

Removal Sequence
Removal Sequence
The following figures show the recommended removal sequence. For each item,
follow the diagram upward to see what must be removed for access. For example: to
remove the control panel door open sensor, remove the back cover, the options cover,
and the right cover.
“Ribbon “Options
“Reject Bin” “Back Cover” “Card Guides”
Drawer” on Cover” on
on page 32 on page 45 on page 42
page 40 page 47
“Left Side “Rear Feeder

“Right Cover” “OCP PCBA”
Cover” on Cover” on
on page 51 on page 49
page 63 page 46
“Belt and “Lock Replacement

“Print Cover”
Gear Panel” for Right Cover” on
on page 58
on page 64 page 53
“Door Button “Control Panel Door

and Latch” on Open Sensor” on
page 60 page 57
“Bottom
Cover” on
page 66
“Ethernet “Main PCBA”

PCBA” on on page 73
page 76
“Ground
Plate” on
page 145
“Printer” on page 69

Removal Sequence
Printer
“Printer” on page 30
“Feeder/Flipper/
“Print Engine”
Options Assembly”
on page 77
on page 137
“Feeder/Flipper
Assembly” on page
142
“Feeder “Flipper “Options

Module” on Module” on Module” on
page 149 page 157 page 180
Feeder Module
“Torque Tools Calibration

Instructions” on page
187
“Feeder “Drive Assembly

Module” on Feeder” on page
page 149 149
“Feeder
Motor” on
page 155

Removal Sequence
Flipper Module
“Flipper “Flipper
Module” on Assembly” on
page 157 page 157
“Flipper “Flipper “Flipper “Flipper Drive

“ESD Brush”
PCBA” on Position Rotation Motor” on
on page 159
page 161 Sensor” on Gear” on page 168
page 163 page 164
“85/35T Gear”
on page 166
“Flipper
Rotation
Motor” on
page 167
“Flexible
Roller” on
page 169
“Flipper Deck “Card Present

Platen Roller” On Flipper
on page 176 Sensor” on
page 178
Options Module
“Options
Module” on
page 180
“Drive Platen “Options

“Card Sensor”
Roller” on Motor” on
on page 180
page 183 page 182

Procedures: Reject Bin
Procedures
Reject Bin
Step 1. Locate the Reject Bin (circled below).
Step 2. Slide the Reject Bin out of the Printer until it stops.

Procedures: Reject Bin
Step 3. Using two fingers, simultaneously, depress the two locking tabs (arrows
below) that prevent the Reject Bin from being removed.
Step 4. Slide the Reject Bin out of the Printer, and set it aside.

Procedures: Feeder Cartridge
Feeder Cartridge
This is the replacement kit for the Standard Feeder Cartridge (i.e., the entire
assembly).
Feeder Cartridge Cover
Step 1. With a Flat-blade screwdriver, carefully press the pivot arm in (arrow below)
to free the tab and thereby releasing the Feeder Cartridge Cover.

Step 2. Set the Feeder Cartridge Cover aside.
Retainer for Feeder Cartridge
Step 1. Lift the Retainer slightly; then slide it forward, up, and out of the Feeder
Cartridge—see arrows below.

Step 2. Remove the Spring (under the Retainer).
Step 3. Set the Retainer and Spring aside.
Lock Replacement for Security Feeder Cartridge
Step 1. With a TORX T10 driver, remove the five screws on the bottom of the Feeder
Cartridge; arrows below.

Step 2. With a TORX T10 driver, remove the two screws holding the Side Cover in
place; arrows below.
Step 3. Separate the Feeder Cartridge into its three components: Top Cover, Bottom
Cover, and Side Cover.
Step 4. With an adjustable wrench, remove the small nut from the Lock Assembly in
the Side Cover.

Step 5. Remove the Lock Pawl; arrow below. Note the orientation of the Lock Pawl.
Step 6. With an adjustable wrench, remove the large nut (arrow below).
Step 7. Remove the Lock Assembly, and set it aside.

Reassembly
Step 1. For proper lock orientation, install the replacement lock with key inserted
slightly, teeth up.
Step 2. Continue installing the replacement Lock Assembly by reversing the

removal steps.
Step 3. Reassemble the Feeder Cartridge as follows:
a. Fit the Side Cover into the slots in the Bottom Cover; ensure that the rod
fits into the alignment hole in the Side Cover.
b. With a TORX T10 driver, install the two screws holding the Side Cover in
place.
c. Fit the Top Cover onto the Bottom Cover; the pieces will “snap” together.
d. With a TORX T10 driver, install the five screws on the bottom of the
Feeder Cartridge.

Procedures: Ribbon Drawer
Ribbon Drawer
Step 1. Open the Print Cover.
Step 2. If a ribbon is installed, remove the ribbon.
Step 3. Slide the Ribbon Drawer out of the Printer until it stops.

Procedures: Ribbon Drawer
Step 4. Depress the two locking tabs (one on each side) to free the Ribbon Drawer.
Step 5. Slide the Ribbon Drawer out of the Printer, and set it aside.

Procedures: Card Guides
Card Guides
Step 1. Remove the Ribbon Drawer (page 40).
Step 2. Locate the Card Guides.
Note • To facilitate reassembly, mark the Card Guides appropriately upon removal;
e.g., left, top; and right, top.
Step 3. With a Flat-blade screwdriver, free the Left Card Guide; it snaps into place.

Procedures: Card Guides
Step 4. With a Flat-blade screwdriver, free the Right Card Guide; it snaps into place.
Step 5. Set the Card Guides aside.

Procedures: Shroud for Options
Shroud for Options

Step 1. Open the Options Cover.
Step 2. Depress the two tabs (one on each side) to unlock the Shroud.
Step 3. Lift the Shroud up and out of the Printer, and set it aside.

Procedures: Back Cover
Back Cover
Step 1. With a TORX T10 driver, remove the three screws holding the Back Cover in
place. Use an 8-inch tapered bit TORX T10 driver for the screw on the left.
Step 2. Remove the Back Cover, and set it aside.

Procedures: Rear Feeder Cover
Rear Feeder Cover

Step 1. With a TORX T10 driver, remove the left screw holding the Rear Feeder
Cover in place.
Step 2. With a TORX T10 driver, remove the right screw and washer holding the Rear
Feeder Cover in place.
Step 3. Remove the Rear Feeder Cover, and set it aside.

Procedures: Options Cover
Options Cover
Step 1. If not already done, remove the Cleaning Cartridge and Cleaning Cassette.
Step 2. With a TORX T10 driver, remove the two screws holding the Options Cover
in place.

Procedures: Options Cover
Step 3. Disconnect the OCP cable connection.
Step 4. Remove the Options Cover, and set it aside.

Procedures: OCP PCBA
OCP PCBA
Step 1. With a TORX T10 driver, remove the five screws holding the Faceplate to the
Options Cover;.
Step 2. Set the Faceplate aside.
Step 3. With a TORX T10 driver, remove the two screws holding the OCP PCBA to
the Options Cover.

Procedures: OCP PCBA
Step 4. Remove the OCP PCBA.
Step 5. Disconnect the Plug at J2 (circled above).
Step 6. Set the OCP PCBA aside.

Procedures: Right Cover
Right Cover
Step 1. From the front of the Printer: With a TORX T10 driver, remove the two screws
holding the Right Cover in place.
Step 2. From the back of the Printer: With a TORX T10 driver, remove the two screws
holding the Right Cover in place.

Step 3. Disconnect the Control Panel Door Open Sensor at connector J12 on the
FLIPPER MODULE PCBA.
Step 4. Carefully cut the cable tie to free the sensor cable.
Step 5. Remove the Right Cover.
Step 6. Set the Right Cover aside.

Lock Replacement for Right Cover
Step 1. With a TORX T10 driver, remove the five screws holding the Inner Cover to
the Right Cover; arrows below.
Step 2. Separate the Inner Cover from the Right Cover, and set the Inner Cover
aside.
Step 3. Remove the Reject Bin Lock Lever and Spring; dashed arrows below. Note
the position of the spring legs.

Step 4. With an adjustable wrench, remove the small nut from the Lock Assembly;
arrow below.
Step 5. Remove the Right Lock Pawl; arrow #1 below. Note the orientation of the
Lock Pawl.
#1
#2
Step 6. With an adjustable wrench, remove the large nut; arrow #2 above.

Reassembly
Step 1. Install the replacement lock with key inserted slightly, teeth up.
Step 2. With an adjustable wrench, install and tighten the large nut holding the Lock
Assembly in place.
Step 3. Install the Right Lock Pawl, and install and loosely tighten the small nut
holding the Right Lock Pawl in place.
Step 4. Install the Spring.

Step 5. Set the Reject Bin Lock Lever in place.
Step 6. Set a 10-mil card between the Reject Bin Lock Lever and the Cover Guide,
arrows below; then tighten the small nut (loosely tightened in Step 3).
10-MIL Gap
Step 7. Remove the 10-mil card.
Step 8. Reassemble the Inner Cover and the Right Cover

Control Panel Door Open Sensor
Step 1. With a TORX T10 driver, remove the five screws holding the Inner Cover to
the Right Cover.
Step 2. Remove the Inner Cover.
Step 3. With a TORX T8 driver, remove the two screws holding the Sensor in place;
and set the Sensor (and cable) aside.

Procedures: Print Cover
Print Cover
Step 1. If not already done, open the Print Cover.
Step 2. With a small Flat-blade screwdriver, carefully remove the left-side E-ring
holding the shaft in place.
Step 3. Slide the shaft out of the print cover brackets.

Procedures: Print Cover
Step 4. Free the two springs (right side and left side of the Print Cover). Note that
you may need to use needle-nose pliers.
Step 5. Slide the cover to the rear thereby freeing the left and right guide pins from
their respective guides.
Step 6. Set the Print Cover (and two springs) aside.
Replacement
Note • the springs go in the slots on the Print Cover when reassembling.

Procedures: Door Button and Latch
Door Button and Latch

Step 1. With a TORX T10 driver, remove the six screws holding the Door Enclosure
and Door Frame together.
Step 2. Separate the Door Enclosure from the Door Frame.
Step 3. Remove the Door Button (arrow above).

Step 4. With a TORX T10 driver, remove the two screws holding the Upper Bearings
in place.
Step 5. Remove the Upper Bearings.

Step 6. With a small Flat-blade screwdriver, release and remove the two latch
springs (solid arrows below). There is a LEFT and RIGHT latch spring; note
the orientation of each spring.
Step 7. Remove the Latch (dashed arrow above), and set it aside.

Procedures: Left Side Cover
Left Side Cover

holding the Left Cover in place.
holding the Left Cover in place.
Step 3. Remove the Left Cover, and set it aside.

Procedures: Belt and Gear Panel
Belt and Gear Panel

Step 1. With a TORX T10 driver, remove the four front screws holding the Belt and
Gear Panel in place.
Step 2. Remove the Belt and Gear Panel, and set it aside.

Procedures: Belt and Gear Panel
Plunger and Spring Assemblies
Step 1. Press each Plunger in, and rotate it counterclockwise. This will free the
assembly.
Step 2. Set the Plungers and associated Springs aside.

Procedures: Bottom Cover
Bottom Cover
Step 1. With a TORX T10 driver, remove the eight screws holding the Bottom Cover
in place.
Step 2. Carefully move the Bottom Cover away from the Printer. Note the green
ground wire attached.
Step 3. With a 5.5-mm nut driver, remove the nut holding the ground wires to the
ground lug; then remove the ground wire.
Step 4. Remove the Bottom Cover.

Procedures: Feet
Feet
Step 1. With a Flat-blade screwdriver, carefully loosen each Foot. Note that the feet
are attached with adhesive.
Step 2. Set the Feet aside.

Procedures: Reject Bin Bracket
Reject Bin Bracket

Step 1. Locate the Reject Bin Bracket (arrow below).
Step 2. With a TORX T10 driver, remove the four screws holding the Reject Bin
Bracket in place.
Step 3. Remove the Reject Bin Bracket, and set it aside.

Procedures: Printer
Printer
The Printer is comprised of three assemblies: the Print Engine, the Feeder/Flipper
Module, and the Options Module. This section details the steps required to separate
the Print Engine from the Feeder/Flipper/Options Assembly.
FLIPPER /
PRINT ENGINE OPTIONS
FEEDER
Step 1. With a 5.5-mm nut driver, remove the two nuts (circled below) holding the
print engine ground wires in place.
Step 2. Remove the ground wires connecting the Print Engine with the Options
Module.

Procedures: Printer
Step 3. For printers with a Mag Encoder and/or Smart Card Encoder: Disconnect
connectors J112 and/or J4 (arrows below). Note that these connectors have
locking tabs; use a small Flat-blade screwdriver to unlock the tabs.
J4 J112
Step 4. Disconnect connectors J5 and J7 from the FLIPPER MODULE PCBA (arrows
below).
J5
J7
Step 5. With a 5.5-mm nut driver, remove ground wires from the L-shaped ground
plate (circled above).

Procedures: Printer
Step 6. Turn the printer on its side so that you can access the Main PCBA.
Step 7. Disconnect connector J21 from the Main PCBA (arrow above).
Step 8. From the top of the Printer: With a long TORX T10 driver, remove the two
screws holding the modules together. Use an 8-inch tapered bit or ball-end
TORX T10 driver for the lower screw.

Procedures: Printer
holding the modules together.
Step 10. Lift the Feeder/Flipper/Options Assembly, and slide it to the right.
Step 11. Disconnect the two ground wires and cut the cable tie.
Step 12. Separate the Print Engine from the Feeder/Flipper/Options Assembly.
FLIPPER /
PRINT ENGINE OPTIONS
FEEDER

Procedures: Main PCBA
Main PCBA
Important • A configuration file, NVM_bkup_< printer serial number >.xml, is saved

when the driver and printer are first installed. If the Main PCBA is not functional, you
can use that file to restore the printer settings.
Preparation
Before you replace the Main PCBA, save the printer configuration settings.
• NVMEM (Non-Volatile Memory): This control is used to back up NVMEM to XML for
importing back into the printer. This does a full restore of all printer settings and
calibration data; e.g., ribbon torque, program values, MAC address, etc.
Use this control when replacing the Main PCBA (MCB):
Step 1. Use the ZXP Toolbox (accessible from Printer Preferences) to save the
printer settings.
Step 2. Select Save/Restore from the menu list.
Step 3. Click Save.
Step 4. In the file save dialog, enter a name for your settings file and click Save.

Removal
Step 1. Disconnect all the connectors to the Main PCBA. Cut cable ties as required.
Step 2. With a Phillips #2 screwdriver, remove the three screws holding the Main
PCBA in place.
Step 3. With a Phillips #1 screwdriver, remove the five screws holding the Shield and
Main PCBA in place; and set the Main PCBA and Shield aside.
Step 4. Carefully pull the PCBA off the mounting posts.

Firmware Update
Step 1. Download the latest firmware from the Zebra web site (www.zebra.com)
under Support & Downloads.
Step 2. Use the ZXP Toolbox (accessible from Printer Preferences) to update the
printer firmware.
Step 3. Select Firmware and Lookup Tables from the menu list.
Step 4. Click Browse.
Step 5. In the file open dialog, locate the firmware (BIN file type) that was
downloaded in Step 1.
Step 6. The update process will begin automatically—do not close the Toolbox
window or turn off the printer until the update is complete.

Procedures: Ethernet PCBA
Ethernet PCBA
Step 1. With a Phillips #0 screwdriver, remove the four screws holding the Ethernet
PCBA to the Main PCBA.
Step 2. Remove the Ethernet PCBA, and set it aside.

Procedures: Print Engine
Print Engine
Cooling Fan
Step 1. With a TORX T10 driver, remove the four screws holding the Cooling Fan in
place.
Step 2. Remove the Cooling Fan, and set it aside.

Power Supply
Step 1. Disconnect the input power and ground connections at the Power Switch;
circled below.
Step 2. Disconnect J7 (DCPWR) from the Main PCBA; arrow below.

Step 3. With a TORX T10 driver, remove the four screws holding the Power Supply in
place.
Step 4. Remove the Power Supply, and set it aside.

Print Engine Ground Plate
Step 1. With a TORX T10 driver, remove the three screws holding the Print Engine
Ground Plate in place—see arrows below.
Step 2. With a 5.5-mm nut driver, remove all nuts and associated ground wires.
Step 3. Remove the Print Engine Ground Plate, and set it aside.

Printhead Assembly
Step 1. Pull the Printhead Assembly and Printhead Housing out of the Print Engine.
Step 2. Push the Printhead Assembly into the Printhead Housing, then pull it up and
out of the Printhead Housing.
Caution • Pulling the Printhead Assembly too far out of the Printhead Housing may
break the wire connected to the ground lug (circled below).

Step 3. With a small Flat-blade screwdriver, carefully disconnect the Printhead

Power and Data Cable, and then remove the Ground (circled below).
Step 4. Set the Printhead Assembly aside.Set the Printhead Assembly aside.
Replacement
Replacement is performed by reversing the removal steps.

Test and Adjustment
Printhead Serial Number and Resistance Change
Note • Access to Print Head options (Serial Number and Resistance) is

controlled via Advanced Security > Security Roles.
After replacing the Printhead, you will need to change the printhead serial number and
resistance value stored in the printer. The new value is located on the label applied to
the Printhead; e.g., R=3662.
Step 1. Select Start > Devices and Printers, right-click on the Zebra ZXP Series 7
Card Printer listing, and select Printer Properties > Device Information. Click
on the ZXP Toolbox button.
Step 2. From the ZXP Toolbox, select Configuration > Printer Settings.
Step 3. In the Printhead > Serial Number and Resistance fields (circled above),
enter the serial number and resistance of the replacement Printhead. The
new resistance value is located on the label applied to the Printhead; e.g.,
R=3380.
Step 4. Click on the Save Settings button.

Power Adjustment
Step 1. Print a card.
Step 2. If card is too dark or too light in comparison with the previously used
printhead, access the ZXP Toolbox.
Select Start > Devices and Printers, right-click on the Zebra ZXP Series 7
Card Printer listing, and select Printer Properties > Device Information. Click
on the ZXP Toolbox button.
Step 3. From the ZXP Toolbox, go to Printer Settings, select Advanced Settings, then
select the Mechanical and Power Adjustment tab.
Step 4. In the Power Adjustment section (circled below), adjust the settings as
follows:
• If the card is too dark, decrease the appropriate power settings (1%
increments recommended).
• If the card is too light, increase the appropriate power settings (1%
increments recommended).
Typically, the following adjustments should be set to the same value; individual
adjustments can be made as required:
• Yellow, Magenta, and Cyan
• K-resin front and K-resin back
• K-dye and Overlay (the overlay option should be disabled with a laminator)
• UV front and UV back

Printhead Housing Assembly
Printhead Housing
Step 1. Remove the Printhead Assembly from the Printhead Housing Assembly
(page 81).
Step 2. Pull the Printhead Power and Data Cable out of the Printhead Housing.
Step 3. Unplug the ribbon sensor cable-to-cable connection.
Step 4. Set the Printhead Housing Assembly aside.
Printhead Latch Assembly
Step 1. When the slot is in the vertical position, the Printhead Latch is locked.

Step 2. With a Flat-blade screwdriver, rotate the slot 90o counter-clockwise to

unlock the Printhead Latch.
Step 3. Slide the Latch out of the housing, and remove the Spring.
Printhead Lift Spring Assembly
Step 1. Remove the eight screws holding the Printhead Front Cover in place. Note
the in-lb torque difference for Steps a and b.
a. With a TORX T10 driver, remove the “outside” four screws.

b. With a TORX T10 driver, remove the “inside” four screws.
Step 2. Locate the Printhead Lift Spring Assembly.

Step 3. Remove the spring, lift, pulley, and dowel.
Ribbon Sensor
Step 1. With a TORX T10 driver, remove the two screws holding the Ribbon Sensor
Assembly (sensor housing and sensor) in the Printhead Housing Assembly.

Step 2. Unplug the ribbon sensor cable-to-cable connection, and set the Ribbon
Sensor Assembly aside.
Covers for Printhead
Printhead Front Cover
Step 1. Remove the eight screws holding the Printhead Front Cover in place. Note
the in-lb torque difference for Steps a and b.
a. With a TORX T10 driver, remove the “outside” four screws.

b. With a TORX T10 driver, remove the “inside” four screws.
Step 2. Remove the Printhead Front Cover.
Step 3. Unplug the door open sensor cable-to-cable connection.
Step 4. With a TORX T8 driver, remove the screw holding the Door Open Sensor in
place.

Step 5. Remove the Door Open Sensor, and set it aside.
Printhead Back Cover
Step 1. Remove the screw holding the cable harness anchor in place.
Step 2. Cut the cable ties as required to free the cable harness.
Step 3. Disconnect J5 (printhead power) and J29 (printhead data) from the Main
PCBA.
Step 4. Disconnect the Cooling Fan.
Step 5. With a TORX T10 driver, remove the four screws holding the Printhead Back
Cover in place.
Step 6. Remove the Printhead Back Cover.

Step 7. Set the Front and Back Covers aside.
Ribbon Spindles
Step 2. Remove the Ribbon Drawer.
Step 3. With a TORX T10 driver, remove the screws holding the Spindles in place.
When replacing the screws, use Loctite 242. In the figure below, parts have
been removed for clarity.

Step 4. Remove the Spindles, and set them aside.
Replacement
The spindles need to be rotated to engage the flat on the shaft.
Ribbon Supply Spindle Assembly
Media Authentication PCBA (MAB)
Step 1. Locate the Media Authentication PCBA.

Step 2. Disconnect J4 and J5 (arrows below).
J4
J5
Step 3. With a TORX T10 driver, remove the two screws holding the Media
Authentication PCBA in place; circled above.
Step 4. Remove the Media Authentication PCBA, and set it aside.
Spindle Clutch Assembly
Step 1. Remove the retaining ring/clip (circled below).
Step 2. With a TORX T10 driver, remove the four screws holding the Bearing Plate in
place—see arrows above.
Step 3. Remove the Bearing Plate, and set it aside.

Step 4. Remove the retaining clip; and then remove the washer, spring, pressure
plate, felt washer, gear, and felt washer.
WASHER
SPRING
PRESSURE PLATE
FELT WASHER
GEAR
FELT WASHER
Ribbon Sync Sensor
Step 1. Unplug the ribbon sync sensor cable-to-cable connection.
Step 2. With a TORX T8 driver, remove the two screws holding the Ribbon Sync
Sensor in place.

Step 3. Remove the Ribbon Sync Sensor, and set it aside.
Spindle Clutch Assembly (continued)
Step 1. With a rubber-faced hammer, carefully tap the shaft out of the Frame.

Step 2. Set the encoder wheel and shaft aside.
Step 3.
Antenna (Media Authentication PCBA)
Step 1. With a TORX T10 driver, remove the two screws holding the Antenna in
Step 2. Disconnect the cable plug (circled above).

Step 3. Remove the Antenna, and set it aside.
Supply Spindle Motor
Step 1. With a TORX T10 driver, remove the two screws holding the Supply Spindle
Motor in place. When replacing the screws, loosely tighten; then fully tighten
when replacing the Bearing Plate (page 94).
Step 2. Cut the cable ties as required to free the motor cable.
Step 3. Unplug the supply spindle motor cable-to-cable connection.

Step 4. Remove the Supply Spindle Motor, and set it aside.
Replacement
Test and Adjustment
Step 1. Launch the ZMotif Service Partner Tool.
Step 2. Run Ribbon Torque Calibration.
Step 3. Run Ribbon Damping Calibration.

Ribbon Take-Up Spindle Assembly
Take-Up Spindle Assembly
Step 1. Remove the retaining ring/clip (circled below).
Step 2. With a TORX T10 driver, remove the three screws holding the Bearing Plate
in place—see arrows above.
Step 3. Remove the Bearing Plate, and set it aside.

Take-Up Spindle Motor
Step 1. Remove the gear (see below).
Step 2. With a TORX T10 driver, remove the three screws holding the Take-Up
Spindle Motor in place—see arrows above. When replacing the screws,
loosely tighten; then fully tighten after replacing the Bearing Plate.
Step 3. Cut the cable ties as required to free the motor cable.
Step 4. If not already done, unplug J8 from the Main PCBA; and disconnect the
ground wire.
Step 5. Remove the Take-Up Spindle Motor, and set it aside.

Encoder Sensor
Step 1. With a TORX T8 driver, remove the two screws holding the Encoder Sensor
in place—see arrows below.
Step 2. Cut the cable ties as required to free the sensor cable.
Step 3. If not already done, unplug J9 from the Main PCBA.
Step 4. Remove the Encoder Sensor, and set it aside.

Take-Up Spindle Assembly (continued)
Step 1. Remove the retaining ring/clip holding the encoder wheel in place.
Step 2. With a rubber-faced hammer, carefully tap the shaft out of the Frame.
Step 3. Set the encoder wheel and shaft aside.

Flexible Rollers
Step 1. Locate the Flexible Rollers.
Step 2. Press the left Flexible Roller down and to the rear of the Print Engine to
release the roller shaft.

Step 3. Pull Flexible Roller up and out of the Print Engine.
Step 4. Repeat Step 2 and Step 3 for the right Flexible Roller.
Step 5. Set the Flexible Rollers aside.

Ribbon Close Outs
Step 1. Locate the two Closeouts (arrows below).
Step 2. From the front of the Print Engine: With a TORX T10 driver, remove the two
screws holding the Ribbon Close Outs in place.

Step 3. From the back of the Print Engine: With a TORX T10 driver, remove the two
screws holding the Ribbon Close Outs in place. Note the ground wires
connections for reassembly.
Step 4. Carefully lift the Ribbon Close Outs and associated springs out of the Print
Engine; The Tricolor Ribbon Sensor is attached to the right Ribbon Close
Out.
Step 5. Set the Ribbon Close Outs aside.

Tricolor Ribbon Sensor
Step 1. With a TORX T8 driver, remove the screw holding the Tricolor Ribbon Sensor
in place.
Step 2. Disconnect the plug at the Tricolor Ribbon Sensor.
Step 3. Remove the Tricolor Ribbon Sensor and set it aside.
Replacement

Test and Adjustment
Step 2. Run Tricolor Sensor Calibration.

Platen Drive Motor Belt
Step 1. With a TORX T10 driver, remove the two screws holding the platen drive
motor in place.
Step 2. From the bottom of the printer, pull the motor out from the belt.
Step 3. Remove the belt from the drive pulley.
Important • Make sure to identify which motor—16-tooth or 20-tooth—is in place so

the correct replacement belt is used. To identify the motor, count the teeth on the
drive gear.
The replacement belt can be identified by the printing on the outside of the belt.
The belt for the 16-tooth motor has the part number—P1028548-001—printed on it as
shown below:
Belt for 16-Tooth Motor Belt for 20-Tooth Motor

Step 4. Position the new belt around the drive pulley.
Step 5. Insert the motor through the access hole at the underside of the printer and
through the belt.

Step 6. Secure the motor with the first screw as shown.
Step 7. Install the tensioning screw making sure to attach the ground wire.
Step 8. Apply tension to the belt by rotating the motor clockwise on the first screw
and tightening the tensioning screw.

Test and Adjustment
Platen Drive Motor Belt Tension Adjustment
For this test, you will need the Gate 507C Sonic Tension Meter.
Step 1. Turn the Sonic Tension Meter power on (press the red Power button).
Step 2. Select measurement setting No02 (press the 2 button).
Step 3. Ensure the meter parameters (preset by Zebra Engineering) are set to:
M 001.1 g/m
W 006.0 mm/R
S 0029 mm
Step 4. Set the range to High (press and hold the Range button until the range
selections display, then use the UP and DOWN buttons to select the desired
range).
Step 5. Press the green Measure button. The green light below the number pad will
flash indicating that measurement is in progress.

Step 6. Align the first hole with the screw.
Step 7. Position/point the meter sensor approximately 5 mm from the belt.
Step 8. Tap the belt until you see the belt tension measurement display, and record
the first belt tension measurement.
Step 9. Rotate the pulley 120°, and align the second hole with the screw.
the second belt tension measurement.
Step 11. Rotate the pulley 120°, and align the third hole with the screw.
the third belt tension measurement.
Step 13. All three belt tension measurements should be between 5.5 to 7.0 for a
20-tooth motor, and between 3.75 and 4.25 for a 16-tooth motor. If not,
readjust the motor (loosen the mounting screws, reposition the motor, and
tighten the mounting screws); and repeat Step 5 through Step 13.
Step 14. This completes the calibration procedure.

Platen Drive Motor
Important • When replacing the motor, the belt (included in the same spare parts kit)
must also be replaced.
Step 1. Disconnect the plug at the motor.
Step 2. With a TORX T10 driver, remove the two screws holding the platen drive
motor in place.
Step 3. Remove the platen drive motor.
Step 4. Remove the two screws holding the dampener in place.
Step 5. Remove the drive belt from the drive pulley.

Platen Drive Motor - Installation
Loctite #242 Thread Lock is required for this procedure.
Step 1. Apply a bead of thread lock to the two screws and secure the dampener to
the motor; tighten screws to 4 in-lbs.
Important • Make sure to identify which motor—16-tooth or 20-tooth—is in place so

the correct replacement belt is used. To identify the motor, count the teeth on the
drive gear.
Step 2. Position the new belt around the drive pulley.

Step 3. Insert the motor through the access hole and through the belt
Step 4. Secure the motor with the first screw as shown.

Step 5. Install the tensioning screw making sure to attach the ground wire.
Step 6. Apply tension to the belt by rotating the motor clockwise on the first screw
and tightening the tensioning screw.
Step 7. Reconnect the wire connector to the motor.
Test and Adjustment
See “Platen Drive Motor Belt Tension Adjustment” on page 113.

NVMEM
To ensure the specified bit in the NVMEM is properly set, launch the ZMotif Service
Partner Tool and run the Set Pinion Ratio test.
Step 1. Select Set Pinion Ratio from the menu list.
Step 2. Select either 16-Tooth or 20-Tooth—depending on which motor was

installed—and click Set.

Drive System Platen Rollers
Step 1. Remove the retaining clip (arrow below), and then remove the large pulley
and belt.
Step 2. Note the belt routing—see outlines below.
Step 3. Remove the retaining clips holding the five pulleys in place.
Step 4. Remove the five pulleys.

Step 5. With a TORX T10 driver, remove the screw, locknut, and washer holding the
Tensioner in place; circled above.
Step 6. Remove the Tensioner and belt.
Step 7. Remove the retaining clips holding the four gears in place.
Step 8. Remove the four gears and associated belts.

Test and Adjustment
Tensioner Belt
Step 1. Turn power on (press the red Power button).
M 000.8 g/m
W 004.7 mm/R
S 0055 mm
Step 4. Set the range to Standard (press and hold the Range button until the range
range).
Step 6. Position/point the meter sensor approximately 5 mm from the belt (arrow
below).
Step 7. Tap the belt until you see the belt tension measurement display.
Step 8. The belt tension should measure between 0.5 to 1.5. If not, readjust the
Tensioner; and repeat Step 5 through Step 8.
Platen Drive Motor Belt
See “Platen Drive Motor Belt Tension Adjustment” on page 113.

Printhead Lift Motor
Step 1. Remove the Gear; circled below.
Step 2. With a TORX T10 driver, remove the four screws and associated washers
holding the Printhead Lift Motor in place; arrows below. Note the orientation
of the motor.

Step 3. Disconnect the cable plug at the motor.
Step 4. Remove the Printhead Lift Motor, and set it aside.

Cam Sensor
Step 1. With a TORX T8 driver, remove the two screws holding the Cam Sensor in
place.
Step 2. Unplug the cam sensor cable-to-cable connection.
Step 3. Remove the Cam Sensor, and set it aside.

Print Engine Platen Rollers
Printhead Lift Gears
Important • Before removal, note the orientation of each gear. If the orientation is not
correct when reinstalling the gears, the printer will not print or even synchronize.
Step 1. Locate the Gears.
3
1 6
2
4 5
Step 2. With a TORX T8 driver, remove the screws holding
Step 3. Gears 1 and 6 in place.
Step 4. Remove the retaining clips holding Gears 2 and 5 in place.
Step 5. With a TORX T10 driver, remove the screw holding Gear 3 in place.
Step 6. With a TORX T10 driver, remove the screw holding Gear 4 in place.
Step 7. Remove the Gears and Belts, and set them aside.

Front Frame
Step 1. With a TORX T10 driver, remove the four screws holding the Front Frame in
place.
Step 2. With a TORX T10 driver, remove the two screws holding the Front Frame in
place.
Step 3. Carefully remove the Front Frame, and set it aside.

Exit Sensor
Step 1. With a TORX T8 driver, remove the two screws holding the Exit Sensor in
place—see arrows below.
Step 2. If not already done, unplug J11 from the Main PCBA.
Step 3. Remove the Exit Sensor, and set it aside.

Sync Sensor
Step 1. With a TORX T8 driver, remove the two screws holding the Sync Sensor in
place—see arrows below.
Step 2. Free the cable from the aluminum cable tie.
Step 3. Unplug the sync sensor cable-to-cable connection.
Step 4. Remove the Sync Sensor, and set it aside.

Pinch Rollers
Step 1. Lift the two Pinch Rollers (arrows below) up and out of the Frame.
Step 2. Set the Pinch Rollers aside.

Middle and Back Frame Separation
Step 1. With a TORX T8 driver, remove the three screws holding the Middle and
Back Frames together—see arrows below.
Step 2. Separate the Frames.

Step 3. Set the Middle Frame aside.
Platen Rollers
Step 1. Remove the five Platen Rollers.
Step 2. Set the Platen Rollers aside.

Printhead Cam Alignment
The following steps show how to align the Printhead Cam. For this procedure, you will
need the Print Head Cam Sync Fixture ZXP7 (P1037750-401).
Step 1. From the back of the printer, align the timing mark on the Printhead Lift Cam
to the vertical (12 o’clock) position—see arrow below.
Step 2. From the front of the printer, align the timing mark on the Printhead Lift Cam
(lower arrow) with the mark on the Frame (upper arrow).

Step 3. Install the Printhead Lift Cam Fixture. The orientation is critical as shown
below.
Step 4. Install the Printhead Cam Sync Holding Fixture (set the lip of the fixture into
the access hole, pivot the fixture down, and then pull the fixture to anchor it).

Step 5. Lock both fixtures in place with the two clips (arrows below).
Step 6. Rotate the gear until the D-notch is aligned with the flat on the shaft. Partially
slide the gear into place.

Step 7. Press the cam shaft from the rear of the printer and the gear from the front
of the printer until the gear slides into place.
Step 8. With a TORX T10 driver, install the screw holding the gear in place—see
arrow below
Step 9. Remove the Print Head Cam Sync Fixture.
Step 10. Continue reassembly.

Procedures: Feeder/Flipper/Options Assembly
Feeder/Flipper/Options Assembly
Step 1. The Feeder/Flipper/Options Assembly is comprised of two modules: the
Feeder/Flipper Module and the Options Module.
FEEDER/FLIPPER OPTIONS
Step 2. From the bottom of the Options Module: With a 5.5-mm nut driver, remove
the two nuts (arrows below) holding the grounds in place; and remove the
grounds.

Step 3. From the back of the Options Module: With a 5.5-mm nut driver, remove the
three nuts (circled below) holding the grounds to the Grounding Plate; and
remove the grounds.
Step 4. From the bottom of the Options Module: With a TORX T10 driver, remove the
four screws holding the Print Engine Ground Plate in place.

Step 5. Remove the Print Engine Ground Plate, and set it aside. Note that the back
edge of the Print Engine Ground Plate is tightly held under plastic clips; use
moderate pressure to free it.
Step 6. Disconnect connectors J1 and J2 from OPSC MODULE PCBA (arrows

below).
J1
J2

Step 7. Disconnect connectors J1 and J2 from OPMAG MODULE PCBA (arrows

below).
J1
J2
Step 8. Disconnect connectors J1 and J10 from FLIPPER MODULE PCBA (arrows
below).
J1
J10
Step 9. Free all the cables.

holding the Feeder/Flipper Module and the Options Module together. Use
an 8-inch tapered bit TORX T10 driver for the lower screw.
holding the Feeder/Flipper Module and the Options Module together.
Step 12. Lift and separate the Feeder/Flipper Module from the Options Module.

Procedures: Feeder/Flipper Assembly
Feeder/Flipper Assembly
The Feeder/Flipper Assembly is comprised of two Modules: Feeder and Flipper.
FEEDER
FLIPPER
Step 1. Disconnect connector J8from the Flipper Module PCBA.

Step 2. From the front of the Assembly: With a TORX T10 driver, remove the four
screws holding the Feeder and the Flipper together.
Step 3. Disconnect the two ground wires that go through the hole close to the top
left side screw.
Step 4. Separate the Feeder Module and the Flipper Module.
FEEDER FLIPPER
Replacement

Test and Adjustment
Step 2. Run Flipper Calibration.
Step 3. Run Feeder Test (10 mil).
Step 4. Run Feeder Test.

Procedures: Ground Plate
Ground Plate
Step 1. With a 5.5-mm nut driver, remove the three nuts (arrows below) holding the
grounds to the Ground Plate; and remove the grounds.
Step 2. With a Phillips #1 screwdriver, remove the screw holding the Ground Plate to
the Power Supply.

Procedures: Ground Plate
Step 3. Remove the two power connections. Note that the blue wire is on the
bottom connector.
Step 4. With a TORX T10 driver, remove the six screws holding the Ground Plate to
the Frame.
Step 5. Set the Ground Plate aside.

Procedures: Power Switch
Power Switch
See next page for alternate Power Switch removal method using the AC Power Filter
Release Tool (P1037750-404).
Step 1. Locate the Power Switch (circled below).
Step 2. With a Flat-blade screwdriver, release the locking tabs (dashed arrows
below) on both sides of the Power Switch.
Step 3. Slide the Power Switch forward, out of the mounting bracket; and set it
aside.

Procedures: Power Switch
Alternate Method
Power Switch removal method using the AC Power Filter Release Tool (P1037750-
404).
Step 1. Locate the Power Switch (circled below).
Step 2. Slide the tool into place (arrow above) thereby releasing the locking tabs on
both sides of the Power Switch.
Step 3. Slide the Power Switch forward, out of the mounting bracket; and set it
aside.

Procedures: Feeder Module
Feeder Module
Drive Assembly Feeder
This is the replacement kit for the Feeder Module; i.e., the entire assembly.
Preparation
Step 1. Remove the Options Cover (page 47).
Step 2. Remove the Back Cover (page 45).

Removal
Step 1. From the rear of the printer, use a 5.5 mm nut driver to remove the ground
wires circled below; remove the two feeder module grounds connected to
lug #2, and remove the feeder motor ground connected to lug #3.
Step 2. Disengage the ground wires from the cable clip (arrow below).
Step 3. Disconnect the feeder motor plug at J8 on the flipper module PCBA (arrow
below).

Step 4. With a TORX T10 driver, remove the four screws holding the feeder module
in place.
Step 5. Remove the feeder module.

Installation
Step 1. Position the replacement feeder module and insert the feeder motor cable
and associated ground wire through the upper access hole in the frame
directly behind the feeder module (upper arrow).
Step 2. Insert the two other ground wires through the lower access hole in the
frame (lower arrow).
Step 3. Set the feeder module in place.
Step 4. From the rear of the printer, use a spring hook tool to reach the feeder motor
and ground cables from behind the PCBA (shown dimmed for clarity).

Step 5. Connect the feeder motor plug to J8 on the flipper module PCBA (arrow
below).
Step 6. From the rear of the printer, reconnect the ground wires circled below;
connect the two feeder module grounds connected to lug #2, and connect
the feeder motor ground connected to lug #3. Secure the ground wires with
a 5.5 mm nut.
Step 7. Secure the ground wires in the cable clip (arrow below).

Step 8. Route the grounds through the cable clip (arrow below).
Step 9. From the front of the printer: With a TORX T10 driver, tighten the four screws
holding the Feeder Module in place in the sequence indicated below.
#2 #3
#4 #1
Reassembly
Step 1. Replace the Back Cover.
Step 2. Replace the Options Cover.

Feeder Motor
Step 1. Locate the Feeder Motor (arrow below).
Step 2. With a TORX T10 driver, remove the four screws and washers holding the
Feeder Motor and Motor Plate in place.
Step 3. Remove the Feeder Motor and Motor Plate.

Step 4. With a TORX T10 driver, remove the two screws, washers, and nuts holding
the Feeder Motor to the Motor Plate.
Step 5. Remove the Feeder Motor and associated green ground wire from the
Motor Plate, and set them aside.

Procedures: Flipper Module
Flipper Module
Flipper Assembly
This is the replacement kit for the Flipper Module; i.e., the entire assembly.

Flipper Calibration
Run the Flipper Calibration any time you work on the Flipper or suspect you have a
misaligned flipper deck.
Step 2. Run Flipper Calibration.

ESD Brush
Step 1. Locate the ESD Brush (arrow below).
Step 2. Free the green ground wire from the cable tie (arrow below).

Step 3. With a small Flat-blade screwdriver, carefully free the ESD Brush (circled
below) from the Frame. Note that the ESD Brush is held in place with
adhesive.
Step 4. Set the ESD Brush aside.

Flipper PCBA
Step 1. Locate the Flipper PCBA (outlined below).
Step 2. Disconnect the plugs (J2, J3, J4, J9, J11, and J13) from the Flipper PCBA.
J2 J3 J4
J13
J11
J2

Step 3. With a TORX T10 driver, remove the three screws holding the Flipper PCBA
in place.
Step 4. Set the Flipper PCBA aside.

Flipper Position Sensor
Step 1. With a TORX T9 driver, remove the two screws holding the Flipper Position
Sensor in place.
Step 2. Remove the Flipper Position Sensor, and set it aside.

Flipper Rotation Gear
Step 1. Remove the retaining clip (arrow below) holding the Flipper Rotation Gear in
place.
Step 2. Remove the four wires from the Sensor connector P11.

Step 3. Slide the Flipper Rotation Gear off the Shaft, the Ground Wire, and Sensor
Wires.
Step 4. Remove the Flipper Rotation Gear, and set it aside.

85/35T Gear
Step 1. With the Flipper Rotation Gear removed, the 85/35T Gear can be removed.
Step 2. Remove the retaining clip (arrow below) holding the 85/35T Gear in place.
Step 3. Remove the 85/35T Gear, and set it aside.

Flipper Rotation Motor
Step 1. Locate the Flipper Rotation Motor (circled below).
Step 2. With a TORX T10 driver, remove the two screws holding the Flipper Rotation
Motor in place.
Step 3. Remove the Flipper Rotation Motor and the associated green ground wire,
and set them aside.

Flipper Drive Motor
Step 1. Locate the Flipper Drive Motor (circled below).
Step 2. With a TORX T10 driver, remove the two screws holding the Flipper Drive
Motor in place. Note that the cable harness has been removed for clarity.
Step 3. Remove the Flipper Drive Motor and the associated green ground wire, and
set them aside.

Flexible Roller
Step 1. Locate the Flexible Roller (circled below).
Step 2. Remove the Flexible Roller.
a. Press the Flexible Roller down and to the right of the Flipper Assembly
to release the roller shaft. Note that the Flexible Roller is shown from the
side for clarity.
b. Pull Flexible Roller up and out of the Flipper Assembly.

Replacement
Step 1. Push one o-ring onto the shaft of the roller, and then slide it toward the
middle as shown (arrow below). The o-ring may be installed at either end.
Step 2. Install the roller into the Flipper Assembly, making sure that the o-ring side
of the roller is toward the back of the printer (arrow below).
a. Insert the near end of the roller into the front opening of the flipper
deck.
b. Then insert the far end (with the o-ring) into the back opening of the
flipper deck.

Step 3. Push the o-ring toward the rear of the printer until it stops against the flange
at the end of the roller (arrow below). The o-ring “locks” the roller in place.
Step 4. Move the roller forward and backward to make sure it is fully seated at both
ends.You should not be able to remove the roller.

Flipper Deck
Step 1. Remove the four Flipper Deck gears.
a. Remove the retaining clips holding Gears #1 and #2 in place; and

remove the gears.
b. Remove the retaining clip holding Gear #3 in place; and remove the
gear.

c. Remove the retaining clip holding Gears #4 in place; and remove the
gear.
d. Set the four Flipper Deck gears aside.

Step 2. With a TORX T10 driver, remove the three screws holding the Flipper Deck
Bearing Plate in place. Note the orientation of the Flipper Deck Bearing
Plate.
Step 3. Remove the Flipper Deck Bearing Plate, and set it aside.

Step 4. With a TORX T10 driver, remove the two screws holding the Bearing Block in
place.
Step 5. Remove the Bearing Block, and set it aside.
Step 6. Lift the Flipper Deck up and out of the Frame.

Step 7. Set the Flipper Deck aside.
Note • To remove the Pressure Roller, push the back end down and to the right to free
it from its holder.
Flipper Deck Platen Roller
Step 1. With a TORX T10 driver, remove the three screws holding the Roller Shaft in

Step 2. With a Phillips #2 screwdriver, remove the screw (arrow below) holding the
ground wire in place.
Step 3. Remove the Roller Shaft Bracket.

Step 4. Slide the Platen Roller forward, far enough to free the shaft; then pull the
Platen Roller up and out of the Flipper Deck.
Step 5. Set the Platen Roller aside.
Card Present On Flipper Sensor
Step 1. With a TORX T8 driver, remove the three screws holding the Sensor in place
(arrows below).

Step 2. Remove the Sensor, and set it aside.

Procedures: Options Module
Options Module
Card Sensor
Step 1. From the bottom of the Options Module: With an 8-inch tapered bit TORX
T10 driver, remove the screw holding the Card Sensor in place.
Step 2. Free the cable from the cable hooks, and then carefully pull the cable and
connector out of the Frame.
Step 3. Set the Card Sensor aside.

Replacement
Test and Adjustment
Step 2. Run the ATM Feed Test.

Options Motor
Step 1. With a TORX T10 driver, remove the two screws washers, and nuts holding
the Options Motor in place. Note the green ground wire attached.
Step 2. Remove the Motor and associated green ground wire from the Motor Plate,
and set them aside.

Drive Platen Roller
Step 1. Locate the Drive Platen Roller.
Step 2. From the front of the Options Module, remove the retaining clip (arrow
below) holding the Roller Shaft in place.
Step 3. With a TORX T10 driver, remove the two screws holding the Bearing Bracket
in place; circled above. Set the Bearing Bracket aside.

Step 4. From the back of the Options Module, remove the retaining clip holding the
Roller Shaft in place.
Step 5. Remove the Belt (circled below) and Gear (arrow below).

Step 6. Slide the Drive Platen Roller forward to clear the Frame, and remove the
Drive Platen Roller.
Step 7. Set the Drive Platen Roller aside.

Test and Adjustment
Belt Tension Adjustment
M 001.2 g/m
W 004.7 mm/R
S 0039 mm
Step 4. Set the range to High (press and hold the Range button until the range
range).
motor (loosen the mounting screws, reposition the motor, and tighten the
mounting screws); and repeat Step 5 through Step 8.

Procedures: Torque Tools Calibration Instructions
Torque Tools Calibration Instructions

This kit will allow users to calibrate the Torque Tools (Low Torque and High Torque) in
Kit, Torque Adjustment for RTU Motor Calibration.
Note that the Torque Watch and the Turntable are not included and need to be
supplied by the user.
Parts List
P1037750-405: Kit Knob and Spindle for Torque Calibration ZXP7
QTY DESCRIPTION
1 KNOB, TORQUE TOOL TURNTABLE
1 SPINDLE, RIBBON
1 SHAFT, SPINDLE, RIBBON
1 SCR, PAN HD, TORX+, M3X6
1 WASHER, LOCK, INT TOOTH, M3
Special Tools
• Torque Tools: Zebra Kit
• Torque Watch: Waters® 651X-3, Tohnichi ATG18Z, or other
• Turntable (motor must be rated at 30 RPM)

Procedure
Step 1. Securely fasten the Knob onto a turntable with a motor rated at 30rpm.
Torque Watch
Spindle Assembly
(Spindle and Shaft)
Torque Tool
(High Torque or Low Torque)
Knob
Turntable
Step 2. Align the Torque Tool’s ball set screws with the Knob’s divets, and insert
the Torque Tool being tested onto the Knob. Ensure the ball set screws are
securely seated in divets of the Knob.
Step 3. Prepare the Spindle Assembly by attaching the Spindle to the Shaft with the
screw and washer included in the kit.
Step 4. Insert the Shaft into the Torque Watch. Tighten the Torque Watch to the shaft
following the manufacturers instructions for the Torque Watch in use.
Step 5. Hold the Torque Watch in the vertical position, and insert Spindle into the
Torque Tool being tested.
Step 6. Ensuring that the Torque Watch needle is on the zero of the dial, turn on the
turntable, following the manufacturers instructions for he turntable in use.

Step 7. While observing the dial on the Torque Watch, record the AVERAGE high
vs. low value that the needle indicates. The average must be between 13
~ 15 in-oz. for the ZXP7 High Torque Tool and 4 ~ 6 in-oz for the ZXP7 Low
Torque Tool.
Step 8. If the AVERAGE value is outside of the specified range for the Torque Tool
being tested, the tool will need to be sent in for repair/calibration.

5
Replacement Procedures
for Factory Installed Options
Introduction
In general, only removal directions are presented. Unless otherwise noted,
instructions for some common or simple procedures are not presented.
parts.


Replacement Procedures for Factory Installed Options
Required Tools
Required Tools
The following list specifies the tools required to perform the replacement procedures
described in this section. Naturally, not all tools are required for a particular procedure;
specific tools are called out in each step as appropriate.
• Flat-blade Screwdrivers: from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm)
• Phillips Screwdrivers: #0, #1, and #2
• TORX T8, T9, and T10 (standard, 12-inch shaft, and/or ball-end; magnetic tip
recommended)
• 5.5 mm nut driver (this can also be used for securing push nuts)
• Small and Medium Spring Hooks
• Multimeter
• Loctite® 242
The following list specifies the Zebra Special-Purpose Tools required to calibrate
specific parts/assemblies reinstalled in selected procedures. Note that the Zebra Part
Number is in parentheses following the description.
• Torque Tools for RTU Motor Calibration ZXP7 (P1037750-400)
This kit is comprised of a High Torque Tool and a Low Torque Tool. The recom-
mended calibration cycle for these tools is 50 uses or every 6 months. Please
return your torque tools to the nearest Zebra Repair Center for calibration; or see
page 187 for torque tool calibration instructions.
• Print Head Cam Sync Fixture ZXP7 (P1037750-401).
• Flipper Deck Level (P1037750-402).
• Contact Station Upgrade Tool (P1037750-403).
• AC Power Filter Release Tool (P1037750-404).
• Mag Tensioning Spring Tool (included with all magnetic encoder upgrade kits).
• Gates Sonic Tension Meter 507C. Note that this item is not being sold by Zebra.
• Kit Service CD / ZXP7 (P1037750-090).
• ZMotif Service Partner Tool (SW0000194)

Procedures: Barcode Scanner Assembly
Procedures
Barcode Scanner Assembly
Barcode Scanner
Step 1. Remove the feeder cartridge (see “Feeder Cartridge” on page 34).
Step 2. Remove the Shroud (see “Shroud for Options” on page 44).
Step 3. Remove the back cover (see “Back Cover” on page 45).
Step 4. Remove the options cover (see “Options Cover” on page 47).
Step 5. Remove the reject bin (see “Reject Bin” on page 32).
Step 6. Remove the bottom cover (see “Bottom Cover” on page 66).
Step 7. From the front of the printer: With a TORX T10 driver, remove the four screws
holding the feeder in place (arrows below).
Caution • Cables are attached to the feeder.
Step 8. Carefully tilt the feeder upward, out of the way.
Step 9. Remove the pressure roller assembly (see “Flipper Module” on page 31).

Step 10. From the bottom of the printer, disconnect J20 (BARCD) on the Main PCBA
(see arrow below).
Step 11. Free the barcode scanner cable (cut associated cable ties as required). Note
the routing of the barcode scanner cable.
Step 12. If installed, remove the UHF-RFID PCBA.
a. From the rear of the Printer: With a TORX T10 driver, remove the three
screws (SCR EJOT 30x8, 5.5 in-lb) and washers holding the PCBA in
place (see arrows below).
b. Move the PCBA to the left, out of the way.

Step 13. If installed, remove the mag encoder PCBA.
a. From the rear of the Printer, with a TORX T10 driver, remove the five
screws and washers holding the PCBA in place (see arrows below).
b. Move the PCBA out of the way.
Step 14. With the PCBAs out of the way, cut the cable tie to free the barcode scanner
cable (see arrow below).

Step 15. Pull the barcode scanner cable through (out of) the access hole.
Step 16. With a TORX T10 driver, remove the two screws holding the barcode
scanner assembly in place (see arrows below).
Step 17. Set the barcode scanner assembly aside.

Barcode Scanner PCBA
Step 1. With a Phillips #1 screwdriver, remove the screw and nylon washer holding
the PCBA in place (see arrow below).
Step 2. Set the PCBA and cable aside.
Replacement

Procedures:
Test and Adjustment
Step 2. Run Barcode Reader Test.

Procedures: SmartCard Control PCBA
SmartCard Control PCBA

Step 1. If not already done, disconnect connectors J1 and J2 from OPSC MODULE
PCBA.
Step 2. Remove the options module (see “Options Module” on page 31).
Step 3. With a TORX T10 driver, remove the four screws (SCR EJOT 30x8, 5.5 in-lb)
and washers holding the Smart Card Control PCBA in place.
Step 4. Remove the Smart Card Control PCBA, and set it aside.

Procedures: MIFARE/Contact Encoder Module
MIFARE/Contact Encoder Module
Removal
Step 1. Locate the MIFARE/Contact Encoder Module (circled below).
Step 2. Rotate the key counterclockwise to unlock the Encoder Module.

Step 3. Push the Encoder Module forward to disconnect the plug (on the back of the
Encoder Module) from the connector (on the Encoder PCBA); then pull the
Encoder Module up and out of the Frame.
Step 4. Set the Encoder Module aside.
Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment
Step 2. Run Smart Card Calibration, Smart Card Contact Read/Write Test, and Smart
Card Contactless Read/Write Test.

Procedures: MIFARE Contact Encoder PCBA
MIFARE Contact Encoder PCBA

Step 1. With a small flat-blade screwdriver, release the three locking tabs (arrows
below) to free the encoder module PCBA.
Step 2. Carefully unplug the connectors (circled below).
Step 3. Remove the encoder module PCBA, and set it aside.

Procedures: MIFARE Contact Encoder PCBA
Step 4. With a TORX T10 driver, remove the screw holding the encoder module
PCBA in place (arrow below).
Step 5. Carefully unplug the three connectors (circled below).
Step 6. Remove the encoder module PCBA, and set it aside.

Procedures: Contact Station Module
Contact Station Module
Removal
Step 1. Locate the contact station module (circled below).
Step 2. Rotate the key counterclockwise to unlock the contact station module.

Step 3. Push the contact station module forward to disconnect the plug (on the back
of the encoder module) from the connector (on the encoder PCBA); then pull
the contact station module up and out of the frame.
Step 4. Set the contact station module aside.
Replacement
Replacement is performed by reversing the removal steps

Test and Adjustment
For these tests, you will need contact station upgrade tool (P1037750-403).
Step 2. Run Smart Card Enable, Smart Card Calibration, and Smart Card Contact
Read/Write Test.

Procedures: Contact Station Module PCBA
Contact Station Module PCBA

Step 1. With a small flat-blade screwdriver, release the three locking tabs (arrows
below) to free the contact station module PCBA.
Step 2. Carefully unplug the two connectors (circled below).
Step 3. Remove the contact station module PCBA, and set it aside.

Procedures: Pressure Roller Assembly
Pressure Roller Assembly
Removal
This procedure applies to both MAG and non-MAG pressure roller assemblies.
Step 1. Locate the pressure roller assembly (circle below).
Step 2. With a TORX T10 driver, remove the screw holding the pressure roller
assembly in place (arrow below).
Step 3. Remove the belt (circled below).

Step 4. Pull the pressure roller assembly forward, up, and out of the frame.
Step 5. Set the pressure roller assembly aside.

Reassembly
Belt Tension Adjustment
M 000.8 g/m
W 004.7 mm/R
S 0055 mm
Step 4. Set the range to Standard (press and hold the Range button until the range
range).
motor (loosen the mounting screws, reposition the motor, and tighten the
mounting screws); and repeat Steps 5 through 8.

Alternate Belt Tension Adjustment
For this adjustment, you will need the Mag Tensioning Spring Tool. Note that his tool is
included with all magnetic encoder upgrade kits..
Step 1. Loosen the two motor mounting screws (arrows below).
Step 2. Hook the belt tensioning tool spring around the motor shaft (right arrow
below).
Step 3. Hook the belt tensioning tool ring in the notch (left arrow above).
Step 4. Tighten the two motor mounting screws; see Step 1.
Step 5. Remove the belt tensioning tool.

MAG Head
Step 1. Locate the MAG Head (circle below).
Step 2. With a TORX T10 driver, remove the two screws holding the MAG head in
place (arrows below).

Step 3. Lift the MAG head out of the frame just far enough to access the cable
connector, and disconnect the MAG head plug (circle below).
Step 4. Set the MAG head aside.

MAG Control PCBA
Removal
Step 1. From the back of the options module: With a TORX T10 driver, remove the
five screws and washers holding the MAG control PCBA in place.
Step 2. Remove the MAG control PCBA. Note the MAG head cable attached to the
MAG control PCBA.
Step 3. Set the MAG control PCBA aside.
Reassembly
Secure the MAG control PCBA to the options module using the five screws and
washers. Make sure not to over tighten the screws and that the PCBA is allowed some
movement.

6
Replacement Procedures for the
Laminator
Introduction
The following sections describe removing both major assemblies and, where
applicable, sub-assemblies and/or components that are considered replaceable on
the Laminator.
In general, only removal directions are presented; unless otherwise noted,

instructions for some items are not presented; removal and replacement of these
items are considered too obvious to warrant a detailed description.
parts.


Replacement Procedures for the Laminator
Required Tools
Required Tools
This section lists the tools required for the replacement procedures described in this
section. Naturally, not all tools are required for a particular procedure; specific tools
are called out in each step as appropriate.
• Flat-blade Screwdrivers, from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm)
• Phillips #0, #1 Screwdriver
• TORX T10, T15 Driver (standard, 8-inch shaft, and/or ball-end; magnetic tip
recommended)
• 5.5 mm Hex Driver (this can also be used for securing push nuts)
• Small and Medium Spring Hook Tools
• Cotton Gloves

Removal Sequence
Removal Sequence
The following figures show the recommended removal sequence. For each item,
follow the diagram to see what must be removed for access.
To remove the Exit Rollers (page 279), first remove the 24V Heater Fans (page
246), then open the Laminator Door, and remove the Laminator Heater Assembly
(page 242) and the Front Frame (page 259) -- follow the red paths.
24V Heater Laminator Open

Fans Controller Laminator
(Page 246) PCBA Door
(Page 251)
Motor Bottom Media Molded

and Plate Laminator Authentication Ribbon
Assembly Control Motor Antenna PCBA Spindle
(Page 248) (Page 255) (Page 257) (Page 240)
Top Laminator Square

Staging Motor
Control Motor Corner
(Page 256)
(Page 254) Spindle
(Page 241)
Card Entry Media

Halogen
Sensor Cable Authentication
Bulbs
Assembly Antenna PCBA
(Page 243)
(Page 285) (Page 257)
Door Sensor 24V Heater

Cable Fans
Assembly (Page 246)
(Page 288)
Laminator
Heater
Assembly
(Page 242)
24V Heater
Exit Rollers Front Frame
Fans
(Page 279) (Page 259)
(Page 246)
Next Page
Frame
Remove the Separate the

baseplate from
Frame from
the Frame and
Base Assembly
the Base
Frame

Removal Sequence
Previous
Page
Laminator
Controller PCBA
(Page 251)
Cassette Latch
Assembly (Top &
Bottom)
(Page 262)
Thermopiles (Top
& Bottom)
(Page 270)
Card Laminator Top Bottom

Sensor Cable Thermopile Thermopile
Assembly Cable Cable
(Page 286) (Page 274) (Page 275)
Card Exit Sensor

Cable Assembly
(Page 287)
Cutters (Upper & Laminate Ribbon

Lower) Rollers (Top &
(Page 280) Bottom)
(Page 284)
Flexible Ribbed
Rollers (Left &
Right)
(Page 276)
Platen Overrun
Roller (Top &
Bottom)
(Page 278)
Card Staging Nip

Rollers (Left &
Right)
(Page 277)
Static Brush
(Page 261)

Procedures: Back Cover
Procedures
Back Cover
Step 1. Open the Laminator Doors (Upper and Lower).
Step 2. With a TORX T10 driver, remove the two screws holding the Back cover in
place.
Step 3. Set the back cover aside.

Procedures: Side Cover
Side Cover
Step 1. From the front of the Laminator: With a TORX T10 driver, remove the two
screws holding the Side Cover in place.
Step 2. From the back of the Laminator: With a TORX T10 driver, remove the two
screws holding the Side Cover in place.
Step 3. Remove the Side Cover, and set it aside.

Procedures: Lock Replacement for Left Cover
Lock Replacement for Left Cover

Step 1. With a TORX T10 driver, remove the six screws holding the Inner Cover to
the Left Cover; arrows below.
Step 2. Separate the Inner Cover from the Left Cover, and set the Inner Cover aside.
Step 3. With an adjustable wrench, remove the small nut from the Lock Assembly.

Procedures: Lock Replacement for Left Cover
Step 4. Remove the Laminator Lock Pawl; arrow #1 below. Note the orientation of
the Lock Pawl.
#1
#2
Step 5. With an adjustable wrench, remove the large nut (arrow #2 above).
Reassembly
Install the replacement lock with key inserted slightly, teeth up, as shown below.
Continue reassembly by reversing the removal steps.

Procedures: Lower Door
Lower Door
Step 1. With a TORX T10 driver, remove the seven screws holding the Inner Panel to
the Lower Door.
Step 2. Set the Inner Panel aside.

Procedures: Lower Door
Step 3. With a small Flat-blade screwdriver, carefully remove the clip holding the
lower hinge pin in place.
Step 4. Slide the Hinge Pin out of the Laminator.
Step 5. Set the Lower Door aside.

Procedures: Door Assembly (Door and Hinges)
Door Assembly (Door and Hinges)

Step 1. From the back of the Laminator: Disconnect the Door Sensor at J9 on the
Main PCBA; circled below. Cut cable ties as required to free the door sensor
cable.
Step 2. With a TORX T10 driver, remove the screw holding the Door Assembly in
place; arrow below.

Step 3. From the front of the Laminator: With a TORX T10 driver, remove the two
screws holding the Door Assembly in place.
Step 4. Slide the Door Assembly to the rear, up, and away from the Laminator.
Step 5. Remove the Door Assembly.
Step 6. Ensure the Door is in the closed position.

Step 7. With a small Flat-blade screwdriver, carefully remove the clip holding the
upper hinge pin in place.
Step 8. Slide the upper hinge pin out of the Door Assembly. This should release the
hinge springs.
Step 9. Separate the Door from the Hinges.

Procedures: Latch Assembly
Latch Assembly
Step 1. With a TORX T10 driver, remove the six screws holding the Inner Cover to
the Door.
Step 2. Separate the Inner Cover and the Door (they snap together).
Step 3. Remove the Button (circled above), and set it aside.

Procedures: Latch Assembly
Step 4. With a TORX T10 driver, remove the two screws holding the bearing caps in
place.
Step 5. Remove the Latch, two springs, and two bearing caps; and set them aside.

Procedures: Laminator / Printer Separation
Laminator / Printer Separation

This section describes how to separate the Laminator from the Printer.
Preparation
Step 2. Open the Laminator Door.
Step 3. Remove the Feeder Cartridge.
Step 4. Open the Options Cover.
Step 5. Remove the Printer Back Cover (page 45).
Step 6. Remove the Laminator Back Cover (page 221).
Step 7. Remove the Ribbon Drawer (page 40).
Step 8. Remove the Belt and Gear Panel (page 64).
Removal
Step 1. Disconnect the three Printer/Laminator Cables.
a. Disconnect the AC Power cable at J8.
J8 J15
J14
b. Disconnect the DC Power cable at J15.
c. Disconnect the Laminator Control cable at J14.

Step 2. With a TORX T10 driver, disconnect the ground cables from the Laminator to
the Printer Power Supply (arrow below).
Step 3. Separate the Laminator from the Printer.
a. With a TORX T10 driver, remove the screw from the rear mounting hole.

b. With a TORX T10 driver, remove the three screws from the front
mounting holes.
c. Lift the Printer up and away from the Laminator.
Reassembly
Reassembly is performed by reversing the removal steps.

Laminator Test
Note • 30 mil PVC cards are required for these tests.
Step 2. Run Laminate Sensor Calibration.
Step 3. Run Laminate Offset Adjustment.
Step 4. Run Lamination Print Test.

Procedures: Bottom Panel
Bottom Panel
Step 1. From the front of the Laminator: With a TORX T10 driver, remove the screw
as shown.
Step 2. From the bottom of the Laminator: With a TORX T10 driver, remove the four
screws as shown.
Step 3. Set the Bottom Panel aside.

Procedures: Feet
Feet
Step 1. With a Flat-blade screwdriver, carefully loosen each Foot. Note that the feet
are attached with adhesive.
Step 2. Set the Feet aside.

Procedures: Mounting Plate
Mounting Plate
Step 1. From the bottom of the Laminator: With a TORX T10 driver, remove the two
screws as shown.
Step 2. From the rear of the Laminator: With a TORX T10 driver, remove the two
screws as shown.

Procedures: Mounting Plate
as shown.
Step 4. Set the Mounting Plate aside.

Procedures: Molded Ribbon Spindle
Molded Ribbon Spindle

Step 1. With a TORX T10 driver, remove the screw (arrow below) holding the Molded
Ribbon Spindle in place.
Step 2. Slide the Molded Ribbon Spindle off the spindle shaft.
Step 3. Set the Molded Ribbon Spindle aside.

Procedures: Square Corner Spindle
Square Corner Spindle

Step 1. With a TORX T10 driver, remove the screw (arrow below) holding the Square
Corner Spindle in place.
Step 2. Slide the Square Corner Spindle off the spindle shaft.
Step 3. Set the Square Corner Spindle aside.

Procedures: Laminator Heater Assembly
Laminator Heater Assembly

Hot Surface • Halogen Bulbs produce intense heat. Use caution when handling the
Laminator Heater Assembly.
Step 1. Remove the four thumbscrews (indicated below) holding the Laminator
Heater Assembly in place.
Step 2. Slide the Laminator Heater Assembly out of the Laminator.

Procedures: Halogen Bulbs
Halogen Bulbs
Removal
Step 1. With a TORX T10 driver, remove the screw (indicated below) holding the
Laminator Heater Cover in place.
Step 2. Remove the Laminator Heater Cover.
Step 3. Locate the Halogen Bulb to be replaced; then with a TORX T10 driver,
loosen the two screws holding the socket (and Halogen Bulb) in place.

Step 4. Rotate the socket maximum counterclockwise, slide the socket out of the
heater, and move the socket and its associated wires out of the way.
Note • The ceramic end of the Halogen Bulb is visible and accessible.
Caution • Do not touch the glass surface of the replacement bulb. Oil from the fingers
will shorten the bulb’s lifetime.
Step 5. Grasp the ceramic end, slide the bulb out of the heater, and set it aside.

Replacement
After installing the replacement Halogen Bulb(s), use a Multimeter to verify that both
bulbs are making proper connection.
Top bulb Bottom bulb

connector pins connector pins
Step 1. With a Multimeter, measure the resistance across the Top Bulb connector
pins.
Step 2. Resistance should range between 8 ohms and 15 ohms.
Step 3. With a Multimeter, measure the resistance across the Bottom Bulb connector
pins.
Step 4. Resistance should range between 8 ohms and 15 ohms.
Step 5. If the resistance is our of range, re-seat the Halogen Bulb(s), and repeat the
resistance measurement.

Procedures: 24V Heater Fans
24V Heater Fans
Exhaust Fan (Upper)
Step 1. With a TORX T10 driver, remove the two screws holding the Exhaust Fan
(circled below) in place. Note the orientation of the fan.
Step 2. Cut the associated cable ties, disconnect the fan plug from the Laminator
Controller PCBA (J12), and remove the Exhaust Fan.

Procedures: 24V Heater Fans
Intake Fan (Lower)
Step 1. With a TORX T10 driver, remove the two screws holding the Intake Fan
(circled below) in place. Note the orientation of the fan.
Step 2. Cut the associated cable ties, disconnect the fan plug from the Laminator
Controller PCBA (J3), and remove the Intake Fan.

Procedures: Motor and Plate Assembly
Motor and Plate Assembly

Step 1. With a TORX T10 driver, remove the three screws (circled below) holding the
Bracket to the Frame.
Step 2. Move the Bracket out of the way.

Step 3. With a TORX T10 driver, remove the four screws (circled below) holding the
Motor and Plate Assembly in place.
Step 4. Carefully free the Motor and Plate Assembly from the Frame. Ensure that all
gears and shafts remain in place.

Step 5. With a TORX T10 driver, disconnect the Ground Wire.
Step 6. Cut the associated cable ties, disconnect the motor plug from J20, and
remove the Motor and Plate Assembly.

Procedures: Laminator Controller PCBA
Laminator Controller PCBA

Step 1. Unplug all the Laminator Controller PCBA cable connectors and ground
connections. To avoid confusion when reinstalling, mark all disconnected
plugs and associated connectors.
Step 2. With a TORX T10 driver, remove the four mounting screws (circled above)
holding the Laminator Controller PCBA in place.
Step 3. Set the Laminator Controller PCBA aside.

Procedures: Laminator Controller PCBA
Main PCBA Connections
J2
J8 J15
J22
J21
J20
J4
J18
J19
J6
J17
J7
J12
J3
J13
J5
J14
J1
J10
J23
J24
J11
J25
J26
J27
J9
Connector Description Connector Description

J1 Host Serial TTL J15 DC to DC Power Conversion
J2 Top and Bottom Halogen Lamps J16 N/A
J3 Fan J17 Top Laminator Control Motor
J4 JTAG Interface J18 Staging Motor
J5 Fan J19 Bottom Laminator Control Motor
J6 Top Thermopile J20 Roller Drive Motor
J7 Bottom Thermopile J21 Bottom Cutter
J8 External AC Power J22 Top Cutter
J9 Laminator Door Sensor J23 Top Laminator Sensor
J10 Debug Serial TTL J24 Bottom Laminator Sensor
J11 Background Debug J25 Card Exit Sensor
J12 Fan J26 Card Laminator Sensor
J13 RFID Control PCBA I/F J27 Card Entry Sensor
J14 HOST I2C -

Procedures: Media Authentication PCBA
Media Authentication PCBA

Step 1. Unplug the three Media Authentication PCBA cable connectors and ground
connection. To avoid confusion when reinstalling, mark all disconnected
plugs and associated connectors.
Step 2. With a TORX T10 driver, remove the two mounting screws (arrows above)
holding the Media Authentication PCBA in place.
Step 3. Set the Media Authentication PCBA aside.

Procedures: Top Laminator Control Motor
Top Laminator Control Motor

Step 1. With a TORX T10 driver, remove the two screws holding the Top Laminator
Control Motor in place.
Note • The left-hand screw connects a ground wire.
Step 2. If not already disconnected, disconnect the motor plug from J17.
Step 3. Cut the associated cable ties, and remove the Top Laminator Control Motor.

Procedures: Bottom Laminator Control Motor
Bottom Laminator Control Motor

Step 1. With a TORX T10 driver, remove the two screws holding the Bottom
Laminator Control Motor in place. Note that the left-hand screw connects a
ground wire.
Step 3. Cut the associated cable ties, and remove the Bottom Laminator Control
Motor.

Procedures: Staging Motor
Staging Motor
Step 1. With a TORX T10 driver, remove the two screws holding the Staging Motor in
place. Note that the left-hand screw connects a ground wire.
Step 3. Cut the associated cable ties, and remove the Staging Motor.

Procedures: Media Authentication Antenna PCBA
Media Authentication Antenna PCBA
Upper PCBA
Step 1. Locate the upper Media Authentication Antenna PCBA.
Step 2. With a Phillips #1 Screwdriver, remove the two screws holding the Media
Authentication Antenna PCBA in place. Note that the left-hand screw
connects a ground wire.
Step 3. Remove the Media Authentication Antenna PCBA.

Procedures: Media Authentication Antenna PCBA
Lower PCBA
Step 1. Locate the lower Media Authentication Antenna PCBA.
Step 2. With a Phillips #1 Screwdriver, remove the two screws holding the Media
Authentication Antenna PCBA in place. Note that the left-hand screw
connects a ground wire.
Step 3. Remove the Media Authentication Antenna PCBA.

Procedures: Front Frame
Front Frame
Removal
Step 1. With a TORX T10 driver, remove the seven mounting screws (indicated
below) holding the Front Frame in place.
Note • A total of five Torsion Springs (arrows below) are released when the Front
Frame is removed.

Procedures: Front Frame
Step 2. Remove the Front Frame.
Replacement
See Replacement on page 265 for details.

Procedures: Static Brush
Static Brush
Step 1. Slide the Static Brush out of its mounting slot.
Step 2. Set the Static Brush aside.

Procedures: Cassette Latch Assembly (Top & Bottom)
Cassette Latch Assembly (Top & Bottom)
Removal
Step 1. Locate the Cassette Latch Assemblies.
Step 2. With a Spring Hook Tool, carefully release the upper Cassette Torsion Spring
(circled below), and slide the Cassette Latch and spring out of the Frame.
Step 3. With a Spring Hook Tool, carefully release the lower Cassette Torsion Spring,
and slide the Cassette Latch and spring out of the Frame.

Step 4. With a TORX T10 driver, remove the two screws (indicated below) holding
the Latch Plate in place.
Step 5. With a small Flat-blade screwdriver, carefully lift and free the Latch Plate.
Note that some force may be required.

Step 6. Rotate the Laminator Levers in the direction indicated, lifting the levers up
and over the stops. Continue until rotation stops; then remove the levers.
Step 7. Set the Laminator Levers, Latch Plate, Cassette Latches, and Cassette
Torsion Springs aside.

Replacement
Step 1. Install a screw in the hole in the Front Frame.
Step 2. Position the Torsion Spring against the screw Note that this Torsion Spring
was released when the Front Frame was removed—see “Front Frame” on
page 259.

Step 3. With a TORX T10 driver, install the seven mounting screws (indicated below)
that hold the Front Frame in place.
Step 4. Remove the screw installed in Step 1. Ensure that the Torsion Spring is
properly aligned on the Exit Roller Bushing.

Step 5. Install the Laminator Latches.
Step 6. Release the top and bottom Cassette Torsion Springs.

Step 7. Set the Laminator Levers in place, rotate the levers in the direction indicated,
lifting the levers up and over the stops. Continue until rotation stops.
Step 8. Reinstall the Latch Plate.

Step 9. With a TORX T10 driver, re-install the two screws holding the Latch Plate in
place.
Step 10. Release the top and bottom Cassette Torsion Springs.

Procedures: Thermopiles (Top & Bottom)
Thermopiles (Top & Bottom)
Top Thermopile
Step 1. Slide out the metal plate.
Step 2. Slide out the Thermopile.

Step 3. Carefully disconnect the Thermopile from the plug.
Set the Thermopile aside.

Bottom Thermopile
Step 1. Slide out the metal plate.
Step 2. Slide out the Thermopile.

Step 3. Carefully disconnect the Thermopile from the plug.
Step 4. Set the Thermopile aside.

Procedures: Top Thermopile Cable
Top Thermopile Cable

Step 1. Remove the Top Thermopile—see “Thermopiles (Top & Bottom)” on page
270.
Step 2. Locate the Top Thermopile Cable (arrow below).
Step 3. Carefully slide the Top Thermopile Cable out of the Laminator.

Procedures: Bottom Thermopile Cable
Bottom Thermopile Cable

Step 1. Remove the Bottom Thermopile—see “Thermopiles (Top & Bottom)” on page
270.
Step 2. Locate the Bottom Thermopile Cable (arrow below).
Step 3. Carefully slide the Bottom Thermopile Cable out of the Laminator.

Procedures: Flexible Ribbed Rollers (Left & Right)
Flexible Ribbed Rollers (Left & Right)

For this procedure you will need to free (i.e., remove the four mounting screws), but
not disconnect, the Laminator Controller PCBA.
Step 1. Carefully remove the Flexible Rib Roller(s)—see arrows below.
Step 2. Set the Flexible Rib Roller(s) aside.

Procedures: Card Staging Nip Rollers (Left & Right)
Card Staging Nip Rollers (Left & Right)

not disconnect, the Laminator Controller PCBA
Step 1. Carefully remove the Card Staging Nip Roller(s)—see arrows below.
Step 2. Set the Card Staging Nip Roller(s) aside.

Procedures: Platen Overrun Roller (Top & Bottom)
Platen Overrun Roller (Top & Bottom)

For this procedure you will need to remove (both free and disconnect) the Laminator
Controller PCBA.
Step 1. Remove the clip(s) holding the Platen Overrun Roller(s) in place; indicated
below.
Step 2. Remove the Platen Overrun Roller(s). Do not remove the gear.

Procedures: Exit Rollers
Exit Rollers
Step 1. Remove the clip from the bottom Exit Roller, and slide the gear off the shaft;
circled below.
Step 2. Remove the top Exit Roller.
Note • Removing the top Exit Roller releases a Torsion Spring; also note that this roller
has bushings.
Step 3. Remove the bottom Exit Roller.

Procedures: Cutters (Upper & Lower)
Cutters (Upper & Lower)
Upper Cutter
Step 1. Locate the Upper Cutter (front view, Front Frame removed).
Step 2. Remove the Ferrite around the Cutter wires (circled below).
Step 3. Disconnect the cutter plug at J22 and the sensor plug at J23 (arrows above).

Step 4. Carefully slide the Upper Cutter out of its pressure-fit mount.
Step 5. Set the Upper Cutter aside.

Lower Cutter
Step 1. Locate the Lower Cutter (front view, Front Frame removed).
Step 2. Remove the Ferrite around the Cutter wires (circled below).
Step 3. Disconnect the cutter plug at J21 and the sensor plug at J24 (arrows above).

Step 4. Carefully slide the Lower Cutter out of its pressure-fit mount.
Step 5. Set the Lower Cutter aside.

Procedures: Laminate Ribbon Rollers (Top & Bottom)
Laminate Ribbon Rollers (Top & Bottom)

Step 1. Locate the Laminate Rib Roller (top and/or bottom); circled below.
Step 2. Remove the corresponding Cutter(s)—see “Cutters (Upper & Lower)” on

page 280.
Step 3. Remove the Laminate Rib Roller(s).

Procedures: Card Entry Sensor Cable Assembly
Card Entry Sensor Cable Assembly

Step 1. Locate the Card Entry Sensor Cable Assembly.
Step 2. With a TORX T10 driver, remove the screw holding the Sensor in place;
indicated above.
Step 3. Carefully slide the Sensor and Cable straight out of the Laminator.

Procedures: Card Laminator Sensor Cable Assembly
Card Laminator Sensor Cable Assembly

Step 1. Locate the Card Laminator Sensor Cable Assembly.
indicated above.
Step 3. Carefully slide the Sensor and Cable straight out of the Laminator.

Procedures: Card Exit Sensor Cable Assembly
Card Exit Sensor Cable Assembly

Step 1. Locate the Card Exit Sensor Cable Assembly.
indicated above.
Step 3. Carefully slide the Sensor and Cable down and out of the Laminator.

Procedures: Door Sensor Cable Assembly
Door Sensor Cable Assembly

Step 1. With a small Flat-blade screwdriver, release the locking tab (indicated below)
to free the Door Sensor.
Step 2. Cut the associated cable ties, disconnect J9 from the Laminator Controller
PCBA, and remove the Door Sensor Cable Assembly.
Step 3. Set the Door Sensor Cable Assembly aside.

7
Replacement Procedures for the
Introduction
The following section describes removing the high-capacity output hopper option for
a ZXP Series 7 Pro printer ONLY with and without a laminator; and, where applicable,
sub-assemblies and/or components that are considered replaceable on the high-
capacity output hopper.
For a complete listing of Spare Part Kits and Upgrade Kits available for the
Zebra ZXP Series 7 Card Printer, see the ZXP Series 7 Spare Parts Catalog at
www.zebra.com/parts.


Replacement Procedures for the High-Capacity Output Hopper
Required Tools
Required Tools
This section lists the tools required for the replacement procedures described in this
section. Naturally, not all tools are required for a particular procedure; specific tools
are called out in each step as appropriate.
• TORX T10 driver (short and long shafts)
• Small diagonal cutters or other cutter for cutting cable ties
• 5.5 mm nut driver

Procedures: Output Hopper Cassette
Procedures
Output Hopper Cassette
Step 1. Press and hold the yellow release button and lift the output hopper cassette
off from the stacker assembly.

Procedures: High-Capacity Output Hopper
Removal
Step 1. Remove the reject bin—see “Reject Bin” on page 32.
Step 2. Remove the ribbon drawer—see ”Ribbon Drawer” on page 40
Step 3. Remove the back cover—see ”Back Cover” on page 45.
Step 4. If the printer is equipped with a laminator, remove the laminator rear cover—
see “Back Cover” on page 221.
Step 5. Remove the bottom cover—see ”Bottom Cover” on page 66.
Step 6. Disconnect the power cable from CN3 on the power supply module.
Step 7. Disconnect the hopper control cable from J10 on the main PCB.

Step 8. Remove the four (4) screws attaching the high-capacity output hopper
assembly to the printer.
Front Back
Step 9. Separate the high-capacity output hopper assembly from the printer—note
the black ground cable attached.
Step 10. Disconnect the ground cable.

Removal - Laminator
Step 11. Disconnect the power cable from CN3 on the printer power supply module...
...and from J15 on the laminator PCBA.

Step 12. Disconnect the high-capacity output hopper control cable from J10 on the
printer PCBA...
...and from J14 on the laminator PCBA.

Step 13. Disconnect the ground cable from the laminator ground plate.
Step 14. Remove the four (4) screws attaching the high-capacity output hopper
assembly to the printer.
Front Rear
Step 15. Separate the high-capacity output hopper assembly from the printer.

Installation
Step 1. Connect the ground cable to the power supply ground plate.
Step 2. Route the high-capacity output hopper control cable through the access
hole.

Step 3. Attach the high-capacity output hopper assembly to the printer with four (4)
screws.
Front Rear
Step 4. Connect the high-capacity output hopper power cable to CN3 on the power
supply module and attach the ferrite to the power cable.

Step 5. Connect the high-capacity output hopper control cable to J10 on the PCBA.
Step 6. Reconnect the reject bin ground wire to the ground post.
Step 7. Install the bottom cover using the eight (8) screws.
Step 8. Install the rear cover using the three (3) screws.
Step 9. Replace the ribbon drawer.
Step 10. Replace the reject bin.

Installation - Laminator
Step 1. Attach the high-capacity output hopper to the laminator with four (4) screws.
Front Rear
Step 1. Connect the ground cable to the laminator ground plate.

Step 2. Connect the high-capacity output hopper power supply cable to J15 on the
laminator PCBA...
...and CN3 pn the printer power supply module. Attach the ferrite to the power cable.

Step 3. Connect the high-capacity output hopper control cable to J14 on the
laminator PCBA.
Step 4. Route the high-capacity output hopper control cable through the access
hole in the printer frame and connect it to J10 on the printer PCBA.

Step 5. Reconnect the reject bin ground wire to the ground post and install the
bottom cover using the eight (8) screws.
Step 6. Install the printer rear cover with three (3) screws.
Step 7. Install the laminator rear cover with two (2) screws.
Step 8. Replace the ribbon drawer.
Step 9. Replace the reject bin.

Procedures: Left Side Panel
Left Side Panel
Removal
Step 1. Un-clip the ferrite and remove it from the power cable.
Step 2. Remove the five (5) screws securing the inside panel, and separate it from
the outside panel.

Step 3. Clip the cable ties securing the cable bundle to the inside panel.
Step 4. Clip the cable tie securing the cable bundle to the outside panel.

Step 5. Remove the five (5) screws securing the stacker assembly to the outside
panel—note the different screw types.
Step 6. Separate the outside panel from the stacker assembly.

Installation
Step 1. Remove the five (5) screws securing the inside panel to the outside panel of
the replacement panel assembly.
Step 2. Run the wire bundle through the access hole in the outside panel.

Step 3. Secure the stacker assembly to the outside panel with the five (screws).
Step 4. Secure the cable bundle to the outside panel with a cable tie and trim the
excess.

Step 5. Secure the cable bundle to the inside panel with two cable ties and trim the
excess.
Step 6. Secure the inside panel to the outside panel with five (5) screws.

Step 7. Clip the ferrite to the power cable.
Installation - Laminator
Using a Torx T10 driver, remove the mounting bracket from the upper position and
re‑attach it to the panel in the lower position.
Follow the procedure for “Installation” on page 307.

Procedures: Platen Roller
Platen Roller
Removal
Step 1. Remove the four (4) screws securing the base cover and latch assembly to
the stacker assembly.
Step 2. From the roller side, carefully lift the roller assembly out from the latching
mechanism—the belt will become slack and drop off.
Step 3. Remove the belt from the drive motor gear.

Procedures: Platen Roller
Installation
Step 1. Place the roller bearing onto the platen.
Step 2. From the inside of the stacker assembly, place the belt onto the drive motor
gear.
Step 3. While still holding the belt, insert the roller gear into the belt and place it into
the latching mechanism—make sure the nylon spacer is in place opposite
the roller.
Step 4. Secure the base cover and latch assembly to the stacker assembly using the
four (4) screws.
Step 5. Reinstall the left side panel; see “Installation” on page 307.

Procedures: Pressure Roller
Pressure Roller
Removal
Step 2. On the base cover and latch assembly, remove the pressure roller assembly
by pushing it up and unseating it from the base cover and latch assembly—
mind the spring.

Step 3. Remove the pressure roller by pushing it up and unseating it from the
pressure roller bracket.
Installation
Step 1. Insert the metal dowel through the pressure roller.

Step 2. Press the roller and dowel into the pressure roller bracket until it clicks into
place.
Step 3. Press the pressure roller assembly into the base cover and latch assembly
until it clicks into place.
Step 4. Insert the pressure spring onto the spring post and into the recessed hole
on the pressure roller bracket.
four (4) screws.
Step 6. Reinstall the left side panel; see “Installation” on page 307.

Procedures: Sensors
Sensors
Prior to starting this procedure, the left side panel must be removed. See
“Left Side Panel” on page 304 for details.
While these procedures can be done without removing the drive assembly and
PCBA, it is recommended that the aforementioned components be removed to avoid
damaging the PCBA with any tools while trying to disconnect or connect the sensors.
Hopper Present Sensor
Removal
Step 2. Remove the platen roller and drive belt.

Procedures: Sensors
Step 3. Remove the screw securing the PCBA assembly to the base housing, and
the three (3) screws securing the drive assembly to the base housing.
Step 4. Carefully pull the PCBA assembly and the drive assembly out from the base
housing.

Procedures: Sensors
Step 5. Disconnect the hopper present sensor cable from J6 on the PCBA.
J6
Step 6. Clip the cable tie securing the hopper present sensor to the base housing
and remove the hopper present sensor.

Procedures: Sensors
Installation
Step 1. Using fingers only, carefully bend the hopper present sensor leads to a 45°
angle with the tapered side of the sensor to the outside of the angle.
Step 2. Insert the hopper present sensor into the base housing and secure with a
cable tie.
Step 3. Connect the hopper present sensor cable to J6 on the PCBA.

Procedures: Sensors
Step 4. Insert the drive motor assembly and the PCBA into the base housing—make
sure the PCBA is inserted into the slots in the base housing.
Step 5. Secure the PCBA to the base housing with a screw, and secure the ground
cables and drive motor assembly to the base housing with three (3) screws.
gear.

Procedures: Sensors
the roller.
four (4) screws.
Step 9. Reinstall the left side panel; see “Left Side Panel” on page 304.

Procedures: Sensors
Lift Cam Sensor
Removal

Procedures: Sensors
housing.

Procedures: Sensors
Step 5. Disconnect the lift cam sensor cable from J4 on the PCBA.
J4
Step 6. Clip the cable ties bundling the lift cam sensor cable and the platen motor
power cable.

Procedures: Sensors
Step 7. Remove the two screws securing the lift cam sensor to the drive assembly
base plate—note the washers between the sensor housing and the
mounting posts.
Installation
Step 1. Secure the lift cam sensor to the drive assembly—be sure to place the
washer between the sensor housing and the mounting posts on the drive
assembly plate.
SCREW
SENSOR
WASHER

Procedures: Sensors
Step 2. Bundle the lift cam sensor cable and the platen motor power cable using
two cable ties.
Step 3. Connect the lift cam sensor to J4 on the PCBA.

Procedures: Sensors
gear.
the roller.

Procedures: Sensors
four (4) screws.
Stacker Entry Sensor
The stacker entry sensor is part of the base housing. For replacement procedure, see
“Base Housing” on page 347.

Procedures: Drive Assembly
Drive Assembly
Removal

housing.

Step 5. Disconnect the elevator motor control/power cable from J1 on the PCBA.
J1
Step 6. Disconnect the platen motor control/power cable from J2 on the PCBA.
J2

Step 7. Disconnect the lift cam sensor cable from J4 on the PCBA.
J4
Step 8. Clip the cable ties bundling the lift cam sensor cable and the platen motor
power cable.

Step 9. Remove the two screws securing the lift cam sensor to the drive assembly
base plate—note the washers between the sensor housing and the
mounting posts.
Step 10. Remove the three screws securing the elevator to the drive assembly base
plate.

Step 11. Slide the elevator connecting rod and the flanged bearing off from the lift
cam post.
Step 12. Remove the elevator assembly.
Installation
Step 13. Insert the elevator connecting rod and shaft through their respective holes
in the drive assembly base plate.

Step 14. Insert the flanged bearing and elevator connecting rod onto the lift cam
post.
Step 15. Secure the elevator assembly to the drive assembly base plate with three (3)
screws.

Step 16. Secure the lift cam sensor to the drive assembly—be sure to place the
washer between the sensor housing and the mounting posts on the drive
assembly plate.
SCREW
SENSOR
WASHER
Step 17. Bundle the lift cam sensor cable and the platen motor power cable using
two cable ties.
Step 18. Connect the platen motor control/power cable to J2, and elevator motor
control/power cable to J1 on the PCBA.
Step 19. Connect the lift cam sensor control to J4 on the PCBA.


gear.
the roller.
four (4) screws.

Procedures: Elevator
Elevator
Removal

housing.

Step 5. Remove the three screws securing the elevator to the drive assembly base
plate.
Step 6. Slide the elevator connecting rod and the flanged bearing off from the lift
cam post.
Step 7. Remove the elevator assembly.

Step 8. Remove the elevator bushing from the elevator shaft.
Installation
Step 1. Insert the elevator bushing onto the elevator shaft with the flat side toward
the lift cam connecting rod.

Step 2. Insert the elevator connecting rod and shaft through their respective holes
in the drive assembly base plate.
Step 3. Insert the flanged bearing and elevator connecting rod onto the lift cam
post.

Step 4. Secure the elevator assembly to the drive assembly base plate with three (3)
screws.

gear.
the roller.

four (4) screws.
Elevator Bushing
To replace the elevator bushing, follow the procedure for replacing the elevator; see
“Elevator” on page 339.

Procedures: Base Housing
Base Housing
This procedure covers procedures for replacement of the base housing, as well as the
stacker entry sensor which is UV glued to the base housing at the factory.
Removal

Step 3. Clip the cable tie securing the hopper present sensor to the base housing
and remove the hopper present sensor.

housing.
Step 6. Disconnect the stacker entry sensor cable from J3 on the PCBA.
J3

Step 7. Pull the hopper control cable through the access hole in the base housing.
Installation
Step 1. Route the high-capacity output hopper control cable and ground cable
through the access hole in the base housing.
Step 2. Connect the stacker entry sensor cable to J3 on the PCBA.


Step 5. Insert the hopper present sensor into the base housing and secure it to the
base housing with a cable tie.
gear.
the roller.

four (4) screws.

Procedures: Base Cover and Latch Assembly
Base Cover and Latch Assembly
Removal
Installation
four (4) screws.

Procedures: PCBA
PCBA
Removal

Procedures: PCBA
housing.
Step 5. Disconnect all cables from the PCBA.

Procedures: PCBA
Installation
Step 1. Connect the platen motor control/power cable to J2, and elevator motor
control/power to J1 on the PCBA.
Step 2. Connect the lift cam sensor control to J4 on the PCBA.
Step 3. Connect the hopper present sensor to J6 on the PCBA.
Step 4. Connect the stacker entry sensor to J3 on the PCBA.
Step 5. Connect the high-capacity output hopper control cable to J7 on the PCBA.
J1 J2
J3
J4
J6
J7
J1 Elevator Motor Control/Power
J2 Platen Motor Control/Power
J3 Stacker Entry Sensor
J4 Lift Cam Sensor
J6 Hopper Present Sensor
J7 Hopper Control/Power

Procedures: PCBA
gear.

Procedures: PCBA
the roller.
four (4) screws.

:

8
Cleaning
Caution • PROTECT YOUR FACTORY WARRANTY!
The recommended maintenance procedures must be performed to maintain the

factory warranty. Other than the recommended cleaning procedures described in this
manual, allow only Zebra authorized technicians to service the Printer.
NEVER loosen, tighten, adjust, or bend, etc., a part or cable inside the printer.
NEVER use a high-pressure air compressor to remove particles from the printer.
Introduction
The regular use of cleaning cards will clean and maintain important parts of your
printer that cannot be reached: including the Printhead, the Transport Rollers, and the
Magnetic Encoder Station (optional feature).
To order ZXP Series 7 cleaning supplies, visit www.zebra.com/supplies.
Printer usage (total number of cards printed and total number of cards laminated) can
be found on the printer’s Properties, Device Information tab.

Cleaning
Cleaning the Printer

When to Clean
Cleaning requirements vary according to the environment. For a typical office
environment, the recommended cleaning cycle is:
• Card Path cleaning should occur every 5,000 cards.
• Feeder Path cleaning should occur every 5,000 cards.
Initiate the Cleaning Process

Step 1. Press the MENU button on the Operator Control Panel (OCP). The OCP will
display the Main Menu.
Step 2. Scroll through the Main Menu, and select Advanced Settings. The OCP will
display the Advanced Settings Menu.
Step 3. Scroll through the Advanced Settings Menu, and select Clean Printer. The
OCP will display the Clean Printer Menu.

Cleaning
Clean the Card Path
Note • Do not use previously used cleaning cards.
Step 1. From the Clean Printer Menu, select CLEAN CARD PATH.
Step 2. Use the Printer Cleaning Card, and follow the OCP instructions.
Step 3. Open print cover, open ribbon drawer, remove ribbon, and then press Next.
Step 4. Close ribbon drawer, close print cover, and then press Next.
Step 5. Insert long cleaning card in Manual Feed Slot, and then press Clean.
Step 6. Wait while cleaning process completes. The card will eject through same
slot.
Step 7. Flip the cleaning card, reinsert it in the Manual Feed Slot, and then press
Clean.
slot.
Step 9. Replace the ribbon, and press Next.
Step 10. The OCP will return to the Clean Printer Menu.

Cleaning
Clean the Feeder Path
Note • Do not use previously used cleaning cards.
Step 1. From the Clean Printer Menu, select CLEAN FEEDER.
Step 2. Use the Feeder Cleaning Card, and follow the OCP instructions.
Step 3. Remove all cards from feeder cartridge, and then press Next.
Step 4. Insert short cleaning card in top slot, then press Clean.
Step 5. Press yellow button in feeder cartridge to release pusher plate, and then
press Next.
slot.
Step 7. Flip the cleaning card, reinsert it in top slot, and then press Clean.
slot.
Step 10. Load the cards back into the feeder cartridge.

Cleaning
Polish the Printhead
Note • Use is password protected and limited to Zebra-authorized service personnel.
The Advanced Cleaning button in the Clean Printer section of the ZXP Toolbox
provides access to printhead polishing. When printhead polishing is enabled in the
ZXP Toolbox, printhead polishing can be done via the OCP.
Step 1. Enable printhead polishing in the ZXP Toolbox
Step 5. Open the printer cover and ribbon drawer, remove the ribbon, and press
Next.
Step 6. Close the ribbon drawer and printer cover, and press Next.
Step 7. Insert a Polishing Card (grit up) in the Manual Feed Slot, and press Clean.
Step 8. Wait until the cleaning process completes. The card will be ejected through
the same slot.
Step 9. Replace the ribbon, and press Next to return to the Advanced Settings
Menu.
Note • Clean the Card Path (page 363) is recommended after printhead polishing to
remove any loose debris from the printer.

Cleaning
Cleaning the Laminator
Note • To order a Laminator Cleaning Kit, visit www.zebra.com/supplies.
When to Clean
Cleaning requirements vary according to the environment. For a typical office
environment, the recommended cleaning cycle is:
Step 1. Laminator Card Path cleaning should occur every 5,000 cards.
Step 2. Laminator Roller cleaning should occur every 5,000 cards.
Step 3. Laminator Oven (Heater Rollers) cleaning should occur every 20,000 cards.
Initiate the cleaning process
Note • To avoid a long wait while the heated rollers cool to 60oC, perform cleaning
before the rollers heat; i.e., when first turned on and the rollers are still cold.

Cleaning
Clean the Laminator Card Path
Note • Recommend doing this at power up when the Laminator is already cold rather
than waiting for it to cool down to 140°F (60°C).
Step 1. From the Clean Printer Menu, select CLEAN LAM CARD PATH to run the
Laminator Cleaning Routine; and follow the OCP instructions.
Step 2. Wait until the oven temperature falls below 140°F (60°C).
Step 3. If you have laminate installed, open the laminator covers, remove the
laminate (top and bottom cassettes), and close the covers.
Step 4. Open the print cover (to raise the printhead), then press Next.
Step 5. Insert the Laminator Cleaning Card into the Manual Feed Slot, then press
Clean.
Step 6. Wait while the cleaning process completes.
Step 7. The card will be ejected into the output hopper.
Step 9. If you want to clean the Laminator Media Rollers at this time, see “Clean the
Laminator Media Rollers” on page 368; otherwise, do Step 10.
Step 10. Open the laminator covers, install the laminate (top and bottom spools), and
close the covers.
Step 11. Close the print cover.

Cleaning
Clean the Laminator Media Rollers
Step 1. From the Clean Printer Menu, select CLEAN LAM ROLLERS to run the
Laminator Media Roller Cleaning Routine; and follow the OCP instructions.
Step 3. Open the laminator covers, remove the laminate (top and bottom cassettes),
and leave both covers open.
Step 4. Prepare a Cleaning Swab for use.
Step 5. Locate the top roller (circled below) for the upper cassette.
Step 6. When ready, press Next; and then press Top.
Step 7. Clean the top media roller by moving the swab tip side-to-side until roller
stops turning. Only use moderate pressure.

Cleaning
Step 8. For double-sided laminators only: Locate the bottom roller (circled below) for
the lower cassette.
Step 9. Prepare a second Cleaning Swab.
Step 10. Locate the bottom roller (circled below) for the lower cassette.
Step 11. When ready, press Bottom.
Step 12. Clean the bottom media roller by moving the swab tip side-to-side until the
roller stops turning. Only use moderate pressure.
Step 13. Press Exit to conclude the laminator rollers cleaning process.
Step 15. Install the laminate (top and bottom spools), and close the covers.

Cleaning
Clean the Laminator Oven (Heater Rollers)
Step 1. From the Clean Printer Menu, select CLEAN LAM OVEN; and follow the OCP
instructions.
Step 3. Open the laminator covers.
Step 4. Remove the four thumb screws (circled below) holding the Heater Assembly
in place.
Step 5. Slide the Heater Assembly out of the Laminator (arrow below).
Caution • For the next step, you may have to wait until the Heater Assembly can be
handled comfortably.
Step 6. When ready, press Next.
Step 7. Prepare the Laminator Hot Roller Cleaning Card for use.

Cleaning
Step 8. Insert the cleaning card between the heater rollers (arrow below).
Step 9. Pull the card all the way through the Heater Assembly.
Step 10. Remove the card from the Heater Assembly.
Step 11. Turn the card over, and repeat Step 8, Step 9, and Step 10.
Step 12. Press Next to conclude the laminator oven cleaning process.

Cleaning
Step 14. Reinstall the Heater Assembly.
a. Remove the Thumb Drive Tool (circled below).
b. While carefully sliding the Heater Assembly into place, use the Thumb
Drive Tool to slowly rotate the gears counterclockwise (dashed arrow)
until the gears mesh and the Heater Assembly seats properly.
c. Install and tighten the four thumb screws removed in Step 4.
Step 15. Close the laminator covers.

Cleaning
Cleaning the High-Capacity Output Hopper
Cleaning the High-Capacity Output Hopper
Note • To order Cleaning Swabs, visit www.zebra.com/supplies.
Step 1. Turn the Printer power off.
Step 2. Remove the hopper cassette.
Step 3. Use a cleaning swab to clean the platen roller, and the pressure roller.

Cleaning
Dual Cleaning Cartridge
Dual Cleaning Cartridge

Important • It is recommended that you replace the Dual Cleaning Cartridge rollers
every time you install a new ribbon.
Two new card cleaning rollers are included with each ribbon or may be purchased
separately. To order additional rollers, visit www.zebra.com/supplies.
Installation of the Dual Cleaning Cartridge is described in the ZXP Series 7 User’s
Guide (P1036101-003) and is not repeated in detail here.
Manual Feed Cleaning Cassette

Important • It is recommended that you replace the Manual Feed Cleaning Cassette
roller every 5,000 cards.
Manual feed card cleaning rollers must be purchased separately. To order additional
rollers, visit www.zebra.com/supplies.
Installation of the Cleaning Cassette is described in detail in the ZXP Series 7 User’s
Guide (P1036101-003) and is not repeated here.
Cleaning Supplies
Part Number Description
105909G-057 Zebra cleaning swab kit (box of 24)
105950-035 Zebra cleaning pens (box of 12)
Zebra Print Station Cleaning Kit: 12 feeder and print path
105999-701
cleaning cards (enough for 60,000 prints)
Zebra Print Station and Laminator Cleaning Kit: 12 feeder, print
105999-704 path and laminator cleaning cards, 12 cleaning swabs, and 3
adhesive cleaning cards (enough for 60,000 prints)
105912-003 Zebra adhesive cleaning rollers (set of 5)
105999-705 Zebra abrasive printhead polishing card

9
Field Upgrades
Introduction
Your printer may have been upgraded with additional features after it left the Zebra
Technologies factory. Field upgrades can be easily identified with upgrade-specific
labels attached to the printer.

Field Upgrades
Placing Labels
Placing Labels
Step 1. An upgrade label (e.g., UHF RFID) is placed on the Printer in the area
outlined by the dotted orange box.
UHF RFID
Step 2. Shipping Box: Two upgrade labels are placed on the Shipping Box as
indicated below.
UHF RFID

Field Upgrades
Field Upgrade Labels
Field Upgrade Labels

Field upgrades can be easily identified with the following labels attached to the
printer.
Contact / Contactless MIFARE Encoder upgrade
Contact Station upgrade
Zebra Duo-Print double-sided Printing upgrade
Magnetic Encoder upgrade
®
UHF RFID upgrade
UHF RFID
Wireless upgrade


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ZXP Series 7™

P1036102-007 ZXP Series 7 Card Printer Service Manual i

ii ZXP Series 7 Card Printer Service Manual P1036102-007

Top Laminator Control Motor........................................................................................................ 254

P1036102-007 ZXP Series 7 Card Printer Service Manual iii

iv ZXP Series 7 Card Printer Service Manual P1036102-007

P1036102-007 ZXP Series 7 Card Printer Service Manual 1

• Card Movement During Printing

• Printing Technologies and Ribbons

• Main PCBA (CPU)

• High-Capacity Output Hopper

Card Movement During Printing

Step 5. The card is printed.

4 ZXP Series 7 Card Printer Service Manual P1036102-007

Step 7. If the Printer has a Laminator:

a. The card is moved through the Printer into the Laminator.

b. As the card passes through the Laminator, laminating film is applied to

P1036102-007 ZXP Series 7 Card Printer Service Manual 5

Printing Technologies and Ribbons

Multi-Panel Ribbons have a repeating sequence of panels of different dye. RFID

A YMCKO ribbon has successive panels as follows:

Color Technology Function / Usage

Thermal Transfer Dye Sublimation

(YMCKO) Overlay Black Cyan Magenta Yellow

Ribbon movement from supply spool

6 ZXP Series 7 Card Printer Service Manual P1036102-007

1. Ribbon move yellowpanel into Printhead in fixed position

2. Card is fed to printing position

3. Card and ribbon move together as

4. Card and ribbon stop at the end

5. Ribbon remains stationary as card

6. Card and ribbon move together as

P1036102-007 ZXP Series 7 Card Printer Service Manual 7

Dye Sublimation Printing

Thermal Transfer Printing

8 ZXP Series 7 Card Printer Service Manual P1036102-007

(Osprey P/N: P1004275)

WiFi Antenna (ANT, P1005199)

CA_DCPWR (P1030122: DC output CN2 is conn)

P1006890-02 (P1042729) CA_MTR_OPCM-MOD_GND (P1033283)

ZXP Series 7 Card Printer Service Manual

(P1041216) Sensor (300364-006)

Main PCBA (CPU)

10 ZXP Series 7 Card Printer Service Manual P1036102-007

Connector PCBA ID Functional Description

P1036102-007 ZXP Series 7 Card Printer Service Manual 11

Flipper CA_FDFLIP_PWR (PCBA_ENET)

(tri-color sensor circuit,

A2D for analog inputs) Sensor

MCB Sensor Interfaces

Media Auth PCBA CA_MAB (PH_PWR)

ZXP Series 7 Card Printer Service Manual

High-Capacity Output Hopper

P1036102-007 ZXP Series 7 Card Printer Service Manual 13

For additional information on troubleshooting and advanced operations, you can

P1036102-007 ZXP Series 7 Card Printer Service Manual 15

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

1. Load cards in the Feeder

Card was not fed into the

Print ribbon is stretched. Recalibrate ribbon torque.

16 ZXP Series 7 Card Printer Service Manual P1036102-007

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION