media sensor maintenance kit installation instructions · media sensor assemblies remove the...

Media Sensor Assemblies Maintenance Kit

Installation Instructions

This kit includes the parts and documentation necessary to install the Media Sensor Assembly into the ZT400™ series printers.

Read these instructions thoroughly before installing this kit.

Parts List

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

Figure 1 • Kit Contents

1 2

4

8

5

76

9

3

© 2014 ZIH Corp. All product names and numbers are Zebra trademarks, and Zebra and the Zebra logo are registered trademarks of ZIH Corp. All rights reserved.

P1060947-002 Rev. A4/18/14

Media Sensor AssembliesRemove the Electronics Cover

2

Tools Required

Remove the Electronics Cover

1.

2.

Table 1 • Parts List

Item Qty Part Number Description

1 1 P1058930-035 ZT410™ Media Sensor Maintenance Kit

P1058930-036 ZT420™ Media Sensor Maintenance Kit

2 1 N/A Dancer Assembly

3 2 HWQ06020 Cable Tie, 0.09 × 3.62 (sold in quantities of 20)

4 1 HW78806 Flat Washer, M4 (sold in quantities of 25)

5 2 HW45931 Split Lock Washer (sold in quantities of 25)

6 1 N/A Tension Spring

7 2 HW10432 Screw, M4 × 0.7 × 12 (sold in quantities of 25)

8 1 N/A Transmissive Sensor Emitter

9 1 N/A Media Sensor Gap ShimN/A = Not available as a separate part for purchase (listed for identification purposes only).

Tools • You need these tools to complete this procedure:

Phillips Screwdriver Set

Wire Cutters

Metric Hex Key (Allen wrench) Set

Antistatic Wriststrap and Mat

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

Turn off (O) the printer and disconnect the AC power cord and all data cables.

Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead.

Open the media door and remove the media and ribbon.

P1060947-002 4/18/14

3Media Sensor AssembliesRemove the Electronics Cover

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

Figure 2 • Locate the Electronics Cover Mounting Screw

4. Close the media door.

1 Media door

2 Electronics cover flange

3 Mounting screw

1

2

43

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Media Sensor AssembliesRemove the Electronics Cover

4

5. See Figure 3. Remove the three mounting screws securing the electronics cover to the printer.

Figure 3 • Remove the Electronics Cover Mounting Screws

6. Remove the electronics cover by lifting up on the electronics cover.

1 Electronics cover

2 Mounting screws (3)

2

1

P1060947-002 4/18/14

5Media Sensor AssembliesRemove the Old Media Sensor Assembly

Remove the Old Media Sensor Assembly

1.

2. See Figure 4. Disconnect the media sensor cables from J10, J20, and J28 on the main logic board.

Figure 4 • Disconnect the Media Sensor Cables

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

Connect yourself to an antistatic device.

J10 Reflective sensor

J20 Transmissive sensor, lower

J28 Transmissive sensor, upper

J20J28

J10

4/18/14 P1060947-002

Media Sensor AssembliesRemove the Old Media Sensor Assembly

6

3. See Figure 5. Cut the cable ties securing the media sensor cables to the bundle of cables.

Figure 5 • Cable Routing

1 J20, Transmissive sensor, lower

2 J28, Transmissive sensor, upper

3 Cable ties (2)

4 J10, Reflective sensor

31

4

2

P1060947-002 4/18/14


4. See Figure 6. Remove the dancer assembly mounting screw and washers.

Figure 6 • Remove the Dancer Assembly

5. Remove the dancer assembly while guiding the media sensor cables through the access hole.

1 Dancer assembly

2 Flat washer

3 Lock washer

4 Mounting screw

14

23

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8

6. See Figure 7. Loosen the two screws securing the drive motor.

Figure 7 • Loosen Drive Motor

1 Top mounting screw (pivot screw)

2 Bottom mounting screw (locking screw)

1

2

P1060947-002 4/18/14


7. See Figure 8. Push the bottom of the drive motor toward the front of the printer to loosen the drive belt.

Figure 8 • Remove the Drive Belt

8. Tighten the bottom mounting screw, and then remove the drive belt.

1 Drive belt

1

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10

9. See Figure 9. Remove the drive motor top mounting screw.

Figure 9 • Remove the Drive Motor

10. Hold the adjust nut with your finger while you remove the bottom drive motor mounting screw.

11. Remove the drive motor.

The drive motor cable does not need to be disconnected.

1 Drive motor

2 Top mounting screw

3 Bottom mounting screw

4 Belt tension spring

5 Adjust nut

1 2

345

P1060947-002 4/18/14


12. See Figure 10. Set the drive motor to the side on the base.

Figure 10 • Set the Drive Motor to the Side

1 Drive motor

1

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12

13. See Figure 11. Remove the transmissive sensor emitter mounting screw and lock washer.

Figure 11 • Remove the Transmissive Emitter Mounting Screw

1 Transmissive sensor emitter assembly mounting hole

2 Lock washer

3 Mounting screw

1

2

3

P1060947-002 4/18/14


14. See Figure 12. Slide the transmissive sensor emitter assembly out of the printer while guiding the cable through the access hole.

Figure 12 • Remove the Transmissive Sensor Emitter Assembly

1 Transmissive sensor emitter assembly

1

4/18/14 P1060947-002

Media Sensor AssembliesInstall the New Media Sensor Assembly

14

Install the New Media Sensor Assembly

1. See Figure 13. Guide the new transmissive sensor emitter cable through the cable pass-through hole.

Figure 13 • Install the Transmissive Sensor Emitter Assembly

2. Insert the transmissive sensor emitter assembly shaft into the mounting hole.

3. Slide the shaft into the mounting hole while guiding the guide tabs into the guide on the printer.

1 Transmissive sensor emitter assembly cable

2 Cable pass-through hole

3 Guides (2)

4 Transmissive sensor emitter assembly shaft mounting hole

5 Guide tabs (2)

21

4

5

3

P1060947-002 4/18/14

15Media Sensor AssembliesInstall the New Media Sensor Assembly

4. See Figure 14. Center the shaft in the notch in the mounting hole.

Figure 14 • Locate the Notch

5. See Figure 11 on page 12. From the electronics side install the new mounting screw and lock washer.

1 Mounting hole

2 Notch

3 Centering ridge

4 Shaft

12

3 4

2

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16

6. See Figure 15. Guide the new dancer cables into the cable pass-through holes.

Figure 15 • Install the Dancer Assembly

7. Ensure that the dancer spring is on top of the media sensor assembly.

1 Dancer shaft hole

2 Spring stop

3 Dancer stop

4 Cable pass-through hole

5 Dancer spring

6 Dancer

7 Dancer assembly

8 Dancer assembly shaft

1 2

3

6

4

7

8

5

P1060947-002 4/18/14


Figure 16 • Spring Location

8. See Figure 6 on page 7. Start the mounting screw, lock washer, and flat washer.

Finger tighten only.

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18

9. See Figure 17. Slide the media gap shim between the media sensor assembly and the transmissive sensor emitter assembly outer edge and squeeze them together to set the gap. Leave gap shim in place.and

Figure 17 • Adjust the Gap.

1 Media sensor assembly

2 Gap shim

3 Transmissive emitter assembly

1

2

3

P1060947-002 4/18/14


10. See Figure 18. Tighten the dancer assembly mounting screw while holding the media sensor and transmissive sensor assemblies together.

Figure 18 • Mounting Screw and Washers

11. Ensure the gap shim moves freely, with no binding or excessive up and down movement.

12. Remove the gap shim.

13. See Figure 4 on page 5. Connect the media sensor cables to J10, J20 and J28 on the main logic board.

14. Bundle the cables and then install the cable tie around the bundle.

15. Reinsert all cables removed from the beaded cable tie and then loosely close the beaded cable tie.

1 Dancer assembly

2 Flat washer

3 Lock washer

4 Mounting screw

14

23

4/18/14 P1060947-002

Media Sensor AssembliesReinstall the Electronics Cover

20

Reinstall the Electronics Cover

1. See Figure 3 on page 4. Slide the electronics cover onto the printer.

2. Install the three electronics side mounting screws.

3. See Figure 2 on page 3. Open the media cover and reinstall the media side mounting screw.

4.

5. Reconnect the AC power cord and all data cables.

6. Turn on (l) the printer.

The installation is complete.

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

Reinstall the media and ribbon.

Printed in on chlorine-free recycled paper. P1060947-002

media sensor maintenance kit installation instructions · media sensor assemblies remove the...

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