Zebra 77997 User Manuals

Table of Contents

• Scope

  1
• Related Manuals

  1
• Printer Specifications

  2
• Options

  2
• Zebra Programming Language II (ZPL II)

  2
• Bar Codes

  3
• Standard Printer Fonts

  3
• Figure 1-1. Default Fonts Examples

  5
• Media Specifications

  6
• Ribbon Specifications

  7
• Printer Specifications

  7
• General Specifications

  8
• Electrical Requirements

  8
• Environmental Operating Ranges

  8
• Communication Specifications

  9
• Serial Data Communication Interface Overview

  9
• Figure 1-2. Interface Connections Z4Mplus and Z6Mplus

  9
• Communication Buffer

  10
• Standard Serial Communication Connector

  10
• RS-232 Interface Connections

  11
• Figure 1-3. RS-232 Connections

  11
• Figure 1-4. DTE to DTE Interconnection

  11
• Figure 1-5. RS-232 Cable Connections

  12
• RS-232 Interconnections Using a DB-25 Cable

  13
• Figure 1-6. DB-9 to DB-25 Connections

  13
• RS-422/RS-485 Interconnections

  14
• Figure 1-7. RS-422/RS-485 Interconnecting Cable

  14
• Serial Communication Signal Levels

  15
• Figure 1-8. RS-232 Signaling

  15
• Communication Code

  16
• Parallel Data Communications Interface Overview

  16
• Figure 1-9. RS-422/RS-485 Signaling

  16
• Parallel Port Connector

  17
• Data Status Indicator

  17
• Installation

  19
• Unpack Printer

  19
• Storage and Reship

  19
• Operator Controls

  20
• Front Panel Display

  20
• Figure 2-1. Location of Control Panel Keys

  20
• Front Panel Keys

  21
• Front Panel Lights

  22
• Load Media and Ribbon

  23
• Load Ribbon

  23
• Figure 2-2. Ribbon Loading

  23
• Remove Ribbon

  24
• Load Media

  24
• Tear-Off Mode

  24
• Figure 2-3. Media Loading Tear-Off Mode

  24
• Cutter Mode

  25
• Figure 2-4. Media Loading Cutter Mode

  25
• Peel-Off Mode

  26
• Figure 2-5. Media Loading Peel

  27
• Peel-Off Mode with Liner Take-up

  28
• Figure 2-6. Locate Slot

  28
• Remove Liner

  29
• Figure 2-7. Media Loading Peel with Liner Take-up

  29
• Figure 2-8. Remove Liner

  29
• Peel Rewind (Peel-Off Mode)

  30
• Figure 2-9. Peel Rewind (Peel-Off Mode)

  31
• Peel Rewind (Rewind Mode)

  32
• Figure 2-10. Peel Rewind (Rewind Mode)

  33
• Peel Rewind Media Alignment

  34
• Figure 2-11. Peel Rewind Media Adjustment

  34
• Fanfold Media Loading

  35
• Figure 2-12. Media Loading Fanfold

  36
• Sensors

  37
• Align Transmissive Sensor

  37
• Optional Transmissive Sensor

  37
• Adjusting the Optional Transmissive Sensor

  37
• Select Media Sensor

  38
• Figure 2-13. Adjusting the Optional Transmissive Sensor

  38
• Media and Media Sensor Considerations

  39
• Auto-Calibrate

  39
• Calibrate Control

  39
• Printer Self Tests

  40
• Cancel Key Self Test

  40
• Figure 2-14. Cancel Key Self Test Label (Configuration Label)

  41
• Pause Key Self Test

  42
• Figure 2-15. PAUSE Key Self Test Label

  42
• Feed Key Self Test

  43
• Figure 2-16. Feed Key Self Test Label

  43
• Pause and Cancel Key Self Test

  44
• Pause and Feed Key Self Test - Reset Defaults

  44
• Communications Diagnostic Self-Test

  44
• Figure 2-17. Pause and Cancel Key Self Test Label

  44
• Figure 2-18. Communications Diagnostics Self Test

  45
• General

  47
• Troubleshooting Charts

  48
• Preventive Maintenance

  55
• Tools Required for Preventive Maintenance

  55
• Preventive Maintenance

  55
• Tools Required for Preventive Maintenance

  55
• Equipment Safety Tips

  56
• Equipment Safety Tips

  56
• Equipment Safety Tips (Continued)

  57
• Equipment Safety Tips (Continued)

  57
• Personal Safety Tips

  58
• Personal Safety Tips

  58
• Cleaning

  59
• Exterior

  59
• Interior

  59
• Recommended Preventive Maintenance Schedule

  59
• Cleaning

  59
• Exterior

  59
• Interior

  59
• Recommended Preventive Maintenance Schedule

  59
• Printhead and Platen Roller

  60
• Printhead and Platen Roller

  60
• Sensors

  61
• Peel Module

  61
• Figure 4-1. Printhead, Platen Roller and Sensor Cleaning

  61
• Sensors

  61
• Peel Module

  61
• Figure 4-2. Cleaning the Peel-Off Module

  62
• Cutter Module

  63
• Lubrication

  63
• Figure 4-3. Cutter Module Cleaning

  63
• Cutter Module

  63
• Lubrication

  63
• Corrective Maintenance

  64
• Tools Required

  64
• Corrective Maintenance

  64
• Tools Required

  64
• Replace Printhead

  65
• Remove Printhead

  65
• Figure 4-4. Top View of Print Mechanism

  65
• Replace Printhead

  65
• Remove Printhead

  65
• Figure 4-5. Printhead Removal/Install

  66
• Install Printhead

  67
• Install Printhead

  67
• Figure 4-6. Configuration Label

  68
• Figure 4-7. Pause Test Label

  68
• Changeover Printhead

  69
• Figure 4-8. Locate Electronics Cover Mounting Screw

  69
• Changeover Printhead

  69
• Figure 4-9. Remove the Electronics Cover

  70
• Figure 4-10. Change the Compound Gear and Platen Roller Pulley

  71
• Replace Latch Kit

  72
• Remove Latch

  72
• Figure 4-11. Latch Kit Parts

  72
• Replace Latch Kit

  72
• Remove Latch

  72
• Install Latch

  73
• Figure 4-12. Strike Plate Installation

  73
• Install Latch

  73
• Figure 4-13. Adjustment Screw Location

  74
• Adjust Print Mechanism

  75
• Figure 4-14. Print Mechanism Adjustments

  75
• Adjust Print Mechanism

  75
• Figure 4-15. Print Mechanism Mounting Screws

  76
• Replace Platen Roller

  77
• Remove Platen Roller

  77
• Figure 4-16. Locate Electronics Cover Mounting Screw

  77
• Replace Platen Roller

  77
• Remove Platen Roller

  77
• Figure 4-17. Remove the Electronics Cover

  78
• Figure 4-18. Platen Roller Assembly (Z4Mplus Shown)

  79
• Figure 4-19. Platen Roller Disassembly

  80
• Install Platen Roller

  81
• Figure 4-20. Platen Roller Kit

  81
• Install Platen Roller

  81
• Replace Main Logic Board

  83
• Remove Main Logic Board

  83
• Figure 4-21. Locate Electronics Cover Mounting Screw

  83
• Replace Main Logic Board

  83
• Remove Main Logic Board

  83
• Figure 4-22. Remove the Electronics Cover

  84
• Figure 4-23. Set the PSII on the Printer Top

  85
• Figure 4-24. Remove and Install PCMCIA and PSII Boards

  86
• Figure 4-25. Removal and Replacement of the Main Logic Board

  86
• Install Main Logic Board

  87
• Figure 4-26. Main Logic Board Assembly Connection Locations

  87
• Install Main Logic Board

  87
• Replace Power Supply Board

  89
• Remove the Power Supply Board

  89
• Figure 4-27. Locate Electronics Cover Mounting Screw

  89
• Replace Power Supply Board

  89
• Remove the Power Supply Board

  89
• Figure 4-28. Remove the Electronics Cover

  90
• Figure 4-29. Power Supply Board Assembly Connection Locations

  91
• Figure 4-30. Remove the Power Supply Board

  92
• Install the Power Supply Board

  93
• Figure 4-31. Install the Insulator and Insulating Pad

  93
• Install the Power Supply Board

  93
• Figure 4-32. Heatsink Assembly

  95
• Figure 4-33. Install Heatsink

  96
• Figure 4-34. Test the Power Supply

  97
• Replace Drive Belt

  98
• Remove Drive Belt

  98
• Figure 4-35. Locate Electronics Cover Mounting Screw

  98
• Replace Drive Belt

  98
• Remove Drive Belt

  98
• Figure 4-36. Remove the Electronics Cover

  99
• Install Drive Belt

  100
• Figure 4-37. Removal of the Drive Belt

  100
• Install Drive Belt

  100
• Replace Front Panel

  101
• Remove Front Panel

  101
• Figure 4-38. Locate Electronics Cover Mounting Screw

  101
• Replace Front Panel

  101
• Remove Front Panel

  101
• Figure 4-39. Remove the Electronics Cover

  102
• Install Front Panel

  103
• Figure 4-40. Front Panel Installation and Connector Location

  103
• Install Front Panel

  103
• Replace the Dancer Assembly

  105
• Remove the Dancer Assembly

  105
• Figure 4-41. Locate Electronics Cover Mounting Screw

  105
• Replace the Dancer Assembly

  105
• Remove the Dancer Assembly

  105
• Figure 4-42. Remove the Electronics Cover

  106
• Install Dancer Assembly

  107
• Figure 4-43. Dancer Assembly

  107
• Install Dancer Assembly

  107
• Replace Ribbon/Head Open Sensor

  108
• Remove Ribbon /Head Open Sensor Assembly

  108
• Figure 4-44. Locate Electronics Cover Mounting Screw

  108
• Replace Ribbon/Head Open Sensor

  108
• Remove Ribbon /Head Open Sensor Assembly

  108
• Figure 4-45. Remove the Electronics Cover

  109
• Figure 4-46. Ribbon/Head Open Sensor Assemble and Disassemble

  110
• Install Ribbon/Head Open Sensor Assembly

  111
• Figure 4-47. Ribbon/Head Open Connection to Main Logic Board

  111
• Install Ribbon/Head Open Sensor Assembly

  111
• Figure 4-48. Ribbon/Printhead Sensor Gap

  112
• Replace Transmissive Sensor

  113
• Remove Transmissive Sensor

  113
• Figure 4-49. Locate Electronics Cover Mounting Screw

  113
• Replace Transmissive Sensor

  113
• Remove Transmissive Sensor

  113
• Figure 4-50. Remove the Electronics Cover

  114
• Figure 4-51. Transmissive Sensor Assembly Connection

  115
• Figure 4-52. Installing the Transmissive Sensor Assembly

  115
• Install Transmissive Sensor

  116
• Install Transmissive Sensor

  116
• Replace Reflective Media Sensor

  117
• Remove Reflective Media Sensor Assembly

  117
• Figure 4-53. Locate Electronics Cover Mounting Screw

  117
• Replace Reflective Media Sensor

  117
• Remove Reflective Media Sensor Assembly

  117
• Figure 4-54. Remove the Electronics Cover

  118
• Figure 4-55. (Reflective) Media Sensor Connection to Main Logic Board

  119
• Install the Reflective Media Sensor Assembly

  120
• Figure 4-56. Media Sensor Removal

  120
• Install the Reflective Media Sensor Assembly

  120
• Replace Ribbon Take-Up Assembly

  122
• Remove Ribbon Take-Up Assembly

  122
• Figure 4-57. Locate Electronics Cover Mounting Screw

  122
• Replace Ribbon Take-Up Assembly

  122
• Remove Ribbon Take-Up Assembly

  122
• Figure 4-58. Remove the Electronics Cover

  123
• Install Ribbon Take-Up Assembly

  124
• Figure 4-59. Ribbon Take-Up Assembly/Disassembly

  124
• Install Ribbon Take-Up Assembly

  124
• Replace Ribbon Supply Assembly

  125
• Remove Ribbon Supply Assembly

  125
• Figure 4-60. Locate Electronics Cover Mounting Screw

  125
• Replace Ribbon Supply Assembly

  125
• Remove Ribbon Supply Assembly

  125
• Figure 4-61. Remove the Electronics Cover

  126
• Figure 4-62. Ribbon Supply Assembly/Disassembly

  127
• Figure 4-63. Use Remove Tool

  127
• Install Ribbon Supply Assembly

  128
• Figure 4-64. Lubrication

  128
• Figure 4-65. Install Washer

  128
• Install Ribbon Supply Assembly

  128
• Figure 4-66. Spindle installation

  129
• Replace Media Hanger

  131
• Remove Media Hanger

  131
• Install Media Hanger

  131
• Figure 4-67. Remove and Install Hanger

  131
• Replace Media Hanger

  131
• Remove Media Hanger

  131
• Install Media Hanger

  131
• Options

  132
• Install PCMCIA Socket Board

  132
• Figure 4-68. Locate Electronics Cover Mounting Screw

  132
• Options

  132
• Install PCMCIA Socket Board

  132
• Figure 4-69. Remove the Electronics Cover

  133
• Figure 4-70. Standoff Mounting Location

  134
• Figure 4-71. Back Cover Installation

  135
• External PSII

  136
• Install the external PS II

  136
• Figure 4-72. External PrintServer II

  136
• Figure 4-73. Locate Parallel Port

  136
• External PSII

  136
• Install the external PS II

  136
• Figure 4-74. Sample Label

  137
• Internal PSII

  138
• Power Down and Disconnect Cables

  138
• Figure 4-75. PSII Parts

  138
• Internal PSII

  138
• Power Down and Disconnect Cables

  138
• Figure 4-76. Locate Electronics Cover Mounting Screw

  139
• Figure 4-77. Remove the Electronics Cover

  139
• Installing the PSII Board

  140
• Figure 4-78. Locate I/O Board Cable Connector

  140
• Installing the PSII Board

  140
• Figure 4-79. Install PSII Board

  141
• Figure 4-80. Cable Routing with PSII Installed

  142
• Figure 4-81. Install I/O Board

  142
• Figure 4-82. Back Cover Installation

  143
• Restore Printer Operations

  144
• Figure 4-83. Back Cover Options

  144
• Restore Printer Operations

  144
• Status Indicators

  145
• Status Indicators

  145
• Install Cutter Option

  147
• Figure 4-84. Locate Electronics Cover Mounting Screw

  147
• Install Cutter Option

  147
• Figure 4-85. Remove the Electronics Cover

  148
• Figure 4-86. Mounting Bracket Location and Position

  149
• Figure 4-87. Install the Cutter Assembly (Z4Mplus Shown)

  150
• Figure 4-88. Cutter Shield and Catch Tray

  151
• Figure 4-89. Cutter Option Connector Location on Main Logic Board

  152
• Install Peel Option

  153
• Figure 4-90. Remove Front Cover

  153
• Install Peel Option

  153
• Figure 4-91. Tear Bar Removal

  154
• Figure 4-92. Rear of Peel Assembly

  155
• Figure 4-93. Installing and Removing Peel Assembly

  156
• Install Liner Take-up Option

  157
• Figure 4-94. Locate Electronics Cover Mounting Screw

  157
• Install Liner Take-up Option

  157
• Figure 4-95. Remove the Electronics Cover

  158
• Figure 4-96. Install Spindle

  159
• Figure 4-97. Liner Take-up Motor Harness Installation

  159
• Figure 4-98. Liner Take-up Motor Assembly Installation

  160
• Install Rewind Option

  161
• Figure 4-99. Peel Rewind Kit Contents

  161
• Install Rewind Option

  161
• Remove Base

  162
• Figure 4-100. Locate Electronics Cover Mounting Screw

  162
• Remove Base

  162
• Figure 4-101. Remove the Electronics Cover

  163
• Figure 4-102. Base Removal

  164
• Install Rewind Pan

  165
• Figure 4-103. Rewind Pan Installation

  165
• Install Rewind Pan

  165
• Figure 4-104. Rewind Motor Location

  166
• Figure 4-105. Main Logic Board Connector

  167
• Figure 4-106. Rewind Motor Assembly Mounting

  168
• Maintenance Kits

  169
• Install Rewind PCB Motor Assembly

  169
• Remove Rewind PCB Motor Assembly

  169
• Figure 4-107. Locate Electronics Cover Mounting Screw

  169
• Maintenance Kits

  169
• Install Rewind PCB Motor Assembly

  169
• Remove Rewind PCB Motor Assembly

  169
• Figure 4-108. Remove the Electronics Cover

  170
• Figure 4-109. Rewind Motor Cable Location

  171
• Figure 4-110. Motor & Spindle Removal and Installation

  171
• Figure 4-111. E-Ring Removal and Installation

  172
• Figure 4-112. PC Board Assembly Removal and Installation

  173
• Install PCB Motor Assembly

  174
• Figure 4-113. PCB Motor Assembly Orientation

  174
• Install PCB Motor Assembly

  174
• Steering Roller

  176
• Remove Steering Roller

  176
• Figure 4-114. Steering Roller Removal and Installation.

  176
• Steering Roller

  176
• Remove Steering Roller

  176
• Figure 4-115. Steering Roller Removal

  177
• Install Steer Knob and Steering Roller

  178
• Figure 4-116. Steer Knob Removal and Installation

  178
• Install Steer Knob and Steering Roller

  178
• Pinch Roller Kit

  179
• Remove Pinch Roller

  179
• Figure 4-117. Removing and Installing E-Rings and Bearings

  179
• Pinch Roller Kit

  179
• Remove Pinch Roller

  179
• Install Pinch Roller

  180
• Install Pinch Roller

  180
• Replace the Fuse

  181
• Figure 4-118. Removing the Fuse

  181
• Replace the Fuse

  181
• General Information

  183
• Table 5-1. Main Printer Assemblies

  186
• Figure 5-1. Main Printer Assemblies

  187
• Figure 5-1. Main Printer Assemblies

  187
• Figure 5-2. Electronics Maintenance Kits

  188
• Table 5-2. Electronics Maintenance Kits

  188
• Figure 5-2. Electronics Maintenance Kits

  188
• Figure 5-3. (Reflective) Media Sensor Assembly Maintenance Kit

  189
• Table 5-3. (Reflective) Media Sensor Assembly Maintenance Kit

  189
• Figure 5-3. (Reflective) Media Sensor Assembly Maintenance Kit

  189
• Table 5-4. Platen Assembly

  190
• Figure 5-4. Platen Assembly

  191
• Figure 5-4. Platen Assembly

  191
• Table 5-5. Platen Roller Shaft Maintenance Kit

  192
• Figure 5-5. Platen Roller Shaft Maintenance Kit

  193
• Figure 5-5. Platen Roller Shaft Maintenance Kit

  193
• Table 5-6. Printhead Housing Maintenance Kit

  194
• Figure 5-6. Printhead Housing Maintenance Kit

  195
• Figure 5-6. Printhead Housing Maintenance Kit

  195
• Figure 5-7. Static Brush Assembly Maintenance Kit

  196
• Table 5-7. Static Brush Assembly Maintenance Kit

  196
• Figure 5-7. Static Brush Assembly Maintenance Kit

  196
• Figure 5-8. Dancer Assembly Maintenance Kit

  197
• Table 5-8. Dancer Assembly Maintenance Kit

  197
• Figure 5-8. Dancer Assembly Maintenance Kit

  197
• Table 5-9. Ribbon Supply Assembly Maintenance Kit

  198
• Figure 5-9. Ribbon Supply AssemblyMaintenance Kit

  199
• Figure 5-9. Ribbon Supply AssemblyMaintenance Kit

  199
• Table 5-10. Print Mechanism Latch Kit

  200
• Figure 5-10. Print Mechanism Latch Kit

  201
• Figure 5-10. Print Mechanism Latch Kit

  201
• Table 5-11. Drive System – Belts/Pulleys

  202
• Figure 5-11. Drive System – Belts/Pulleys

  203
• Figure 5-11. Drive System – Belts/Pulleys

  203
• Table 5-12. Cutter Option Kit

  204
• Figure 5-12. Cutter Option Kit

  205
• Figure 5-12. Cutter Option Kit

  205
• Table 5-13. Peel Option Assembly

  206
• Figure 5-13. Peel Option Assembly

  207
• Figure 5-13. Peel Option Assembly

  207
• Table 5-14. Liner Take-up Assembly (Z4Mplus Only)

  208
• Figure 5-14. Liner Take-up Assembly (Z4Mplus Only)

  209
• Figure 5-14. Liner Take-up Assembly (Z4Mplus Only)

  209
• Table 5-15. Rewind Option Kit

  210
• Figure 5-15. Peel/Rewind Option Kit

  211
• Figure 5-15. Rewind Option Kit

  211
• Table 5-16. Communication and Miscellaneous Options

  212
• Figure 5-16. Communication and Miscellaneous Options

  213
• Figure 5-16. Communication and Miscellaneous Options

  213
• Table 5-17. Steering Roller Assembly

  214
• Figure 5-17. Steering Roller Assembly

  215
• Figure 5-17. Steering Roller Assembly

  215