ZT600 Series

Industrial Printers

Maintenance Manual

P1090462-002 Rev. A
 ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corporation, registered in
many jurisdictions worldwide. All other trademarks are the property of their respective owners.
© 2019 Zebra Technologies Corporation and/or its affiliates. All rights reserved.
Information in this document is subject to change without notice. The software described in this document
is furnished under a license agreement or nondisclosure agreement. The software may be used or copied
only in accordance with the terms of those agreements.
For further information regarding legal and proprietary statements, please go to:
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Terms of Use
Proprietary Statement
This manual contains proprietary information of Zebra Technologies Corporation and its subsidiaries
(“Zebra Technologies”). It is intended solely for the information and use of parties operating and
maintaining the equipment described herein. Such proprietary information may not be used, reproduced,
or disclosed to any other parties for any other purpose without the express, written permission of Zebra
Technologies.

Product Improvements
Continuous improvement of products is a policy of Zebra Technologies. All specifications and designs are
subject to change without notice.

Liability Disclaimer
Zebra Technologies takes steps to ensure that its published Engineering specifications and manuals are
correct; however, errors do occur. Zebra Technologies reserves the right to correct any such errors and
disclaims liability resulting therefrom.

Limitation of Liability
In no event shall Zebra Technologies or anyone else involved in the creation, production, or delivery of the
accompanying product (including hardware and software) be liable for any damages whatsoever
(including, without limitation, consequential damages including loss of business profits, business
interruption, or loss of business information) arising out of the use of, the results of use of, or inability to
use such product, even if Zebra Technologies has been advised of the possibility of such damages. Some
jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.

Publication Date
July 3, 2019

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Contents
Printer Configuration and Adjustment ................................................................................................ 18
Calibrate the Ribbon and Media Sensors ..................................................................... 19
Adjust the Printhead Pressure and Toggle Position ...................................................... 25
Set the Printhead Balance ........................................................................................... 30
Adjust the Printhead Position ....................................................................................... 31
Adjust the Strip Plate .................................................................................................... 33
Adjust the Sensor Position ............................................................................................ 34
Install the Rewind/Liner Take-Up Plate ......................................................................... 35

Data Ports .......................................................................................................................................... 39

Applicator Interface Option ............................................................................................ 40
Parallel Data Port .......................................................................................................... 48
Serial Data Port ............................................................................................................. 50
USB 2.0 Port ................................................................................................................. 54

Routine Maintenance ......................................................................................................................... 55

Cleaning Schedule and Procedures .............................................................................. 55
Remove Used Ribbon ................................................................................................... 70
Replacing Printer Components ..................................................................................... 72
Storing the Printer ......................................................................................................... 72
Lubrication ..................................................................................................................... 72

Diagnostics and Troubleshooting ...................................................................................................... 73

Judging Barcode Quality ............................................................................................... 74
Configuration Labels ..................................................................................................... 76
PAUSE Self Test ........................................................................................................... 77
Sensor Profile ............................................................................................................... 78
Communication Diagnostics Mode ............................................................................... 79
Load Defaults or Last Saved Values ............................................................................ 80

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Alert and Error States .................................................................................................... 81

Troubleshooting ............................................................................................................ 89
Service the Printer ....................................................................................................... 102

Specifications ................................................................................................................................... 103

General Specifications ................................................................................................ 103
Power Specifications .................................................................................................. 104
Power Cord Specifications ......................................................................................... 105
Communication Interface Specifications ..................................................................... 106
Printing Specifications ................................................................................................ 111
Media Specifications .................................................................................................. 113
Ribbon Specifications .................................................................................................. 114

Print Mechanism
Components .................................................................................................................................... 115

Printhead Assembly Maintenance Kit .............................................................................................. 120

Remove the Old Printhead Assembly ........................................................................ 121
Install the New Printhead Assembly ............................................................................ 123
Resume Printer Operation ......................................................................................... 124

Printhead Conversion Maintenance Kit ........................................................................................... 125

Remove the Old Printhead Assembly ........................................................................ 127
Install the New Printhead Assembly ............................................................................ 129
Remove the Electronics Cover ................................................................................... 130
Replace the Old Pulleys ............................................................................................. 133
Reinstall the Electronics Cover ................................................................................... 137
Resume Printer Operation ......................................................................................... 139
.................................................................................................................................... 139

Printhead Mounting Screw Maintenance Kit .................................................................................... 140

Replace the Old Printhead Mounting Screw ............................................................... 141
Resume Printer Operation ......................................................................................... 142

Toggle Bar and Toggles Maintenance Kit ........................................................................................ 143

Remove the Electronics Cover ................................................................................... 145
Remove the Old Toggle Bar Assembly ...................................................................... 148
Install the New Toggle Bar Assembly ........................................................................ 152

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Reinstall the Electronics Cover ................................................................................... 155

Resume Printer Operation ......................................................................................... 157

Toggle Assembly Maintenance Kit .................................................................................................. 158

Remove the Electronics Cover ................................................................................... 159
Remove the Old Toggle Assembly ............................................................................. 162
Install the Toggle Assembly ........................................................................................ 166
Reinstall the Electronics Cover ................................................................................... 167
Complete the Installation ............................................................................................ 170
Toggle Position Adjustment ........................................................................................ 170
Toggle Pressure Adjustment ...................................................................................... 171
Resume Printer Operation ......................................................................................... 172

Toggle Position Ruler Maintenance Kit ............................................................................................ 173

Remove the Old Toggle Position Ruler ...................................................................... 174
Install the New Toggle Position Ruler ........................................................................ 175
Resume Printer Operation ......................................................................................... 175

Print Mechanism Hardware Maintenance Kit ................................................................................... 176

Remove the Electronics Cover and the Media Door ................................................... 177
Remove the Old Upper Print Mechanism ................................................................... 181
Replace the Old Ground Contact ............................................................................... 195
Install the Upper Print Mechanism ............................................................................. 196
Reinstall the Toggle Bar Assembly ............................................................................. 196
Reinstall the Electronics Cover ................................................................................... 199
Adjust the Toggle Position and Pressure .................................................................... 201
.................................................................................................................................... 202
Set the Printhead Balance ......................................................................................... 203
Adjust the Printhead Position ...................................................................................... 205
Adjust the Strip Plate ................................................................................................... 207
Resume Printer Operation ......................................................................................... 207

Printhead Ground Contact Maintenance Kit .................................................................................... 208

Replace the Printhead Ground Contact Assembly ...................................................... 209
Resume Printer Operation ......................................................................................... 210

Strip Plate and Static Brush Maintenance Kit .................................................................................. 211

Remove the Old Static Brush ..................................................................................... 212

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Install the New Static Brush ........................................................................................ 214

Remove the Old Ribbon Strip Plate ........................................................................... 215
Install the New Ribbon Strip Plate ............................................................................... 215
Adjust the Strip Plate ................................................................................................... 216
Resume Printer Operation ......................................................................................... 216

Media Support Maintenance Kit ....................................................................................................... 217

Remove the Old Media Support ................................................................................. 218
Install the New Media Support ................................................................................... 219
Resume Printer Operation ......................................................................................... 220

Drive System Components .............................................................................................................. 221

Drive System Parts and Drawings .............................................................................. 222

Main Drive System Maintenance Kit ................................................................................................ 224

Remove the Electronics Cover ................................................................................... 226
Remove the Old Main Drive System .......................................................................... 229
Install the New Main Drive System ............................................................................ 233
Reinstall the Electronics Cover ................................................................................... 234
Resume Printer Operation ......................................................................................... 236

Drive Motor and Pulley Maintenance Kit ......................................................................................... 237

Remove the Electronics Cover ................................................................................... 238
Remove the Main Drive Belt ....................................................................................... 240
Remove the Rewind Drive Belt .................................................................................. 242
Remove the Old Drive Motor and Pulley .................................................................... 243
Install the New Drive Motor and Pulley ...................................................................... 246
Reinstall the Rewind Belt ............................................................................................ 246
Reinstall the Main Drive Belt ....................................................................................... 247
Reinstall the Electronics Cover ................................................................................... 248
Resume Printer Operation ......................................................................................... 250

Drive Belt Maintenance Kit .............................................................................................................. 251

Remove the Electronics Cover ................................................................................... 252
Remove the Old Main Drive System ........................................................................... 254
Install the Main Drive Belt ........................................................................................... 255
Remove the Old Rewind Drive Belt ............................................................................ 256
Reinstall the Main Drive Belt ....................................................................................... 257

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Reinstall the Electronics Cover ................................................................................... 258

Resume Printer Operation ......................................................................................... 260

Idler Pulley and Tension Spring Maintenance Kit ............................................................................ 261

Remove the Electronics Cover ................................................................................... 262
Replace the Main Drive Idler Pulley and Spring ......................................................... 265
Replace the Rewind Drive Idler Pulley and Spring ..................................................... 266
Reinstall the Electronics Cover ................................................................................... 269
Resume Printer Operation ......................................................................................... 271

Media Path Components ................................................................................................................. 272

Media Spindle Maintenance Kit ....................................................................................................... 277

Remove the Electronics Cover ................................................................................... 278
Remove the Old Media Supply Spindle ..................................................................... 281
Install the New Media Supply Spindle ......................................................................... 284
Reinstall the Electronics Cover ................................................................................... 285
Resume Printer Operation ......................................................................................... 287

Media Guide and Black Mark Assembly Maintenance Kit ............................................................... 288
Remove the Electronics Cover ................................................................................... 289
Remove the Old Media Guide .................................................................................... 292
Install the New Media Guide Assembly ....................................................................... 294
Reinstall the Electronics Cover ................................................................................... 295
Resume Printer Operation ......................................................................................... 297

Side Plates Maintenance Kit ............................................................................................................ 298

Replace the Upper Side Plate Assembly .................................................................... 299
Adjust the Printhead Assembly .................................................................................. 306
Adjust the Toggle Position and Pressure ................................................................... 307
Adjust the Printhead Position ..................................................................................... 310
Replace the Lower Side Plate .................................................................................... 313
Replace the Rewind Side Plate .................................................................................. 317
Resume Printer Operation ......................................................................................... 317

Media Dancer Assembly Maintenance Kit ....................................................................................... 318

Remove the Old Dancer Assembly ............................................................................ 319

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Install the New Media Dancer Assembly ..................................................................... 321

Resume Printer Operation ......................................................................................... 321

Ribbon Supply Spindle Maintenance Kit .......................................................................................... 322

Remove the Electronics Cover ................................................................................... 323
Remove the Old Ribbon Supply Spindle .................................................................... 326
Install the New Ribbon Supply Spindle ...................................................................... 329
Reinstall the Electronics Cover ................................................................................... 330
Resume Printer Operation ......................................................................................... 332

Ribbon Supply Spindle

Hardware Maintenance Kit .............................................................................................................. 333
Replace the Ribbon Supply Hardware ....................................................................... 335
Adjust the Ribbon Supply Spindle ............................................................................... 336
Resume Printer Operation ......................................................................................... 337

Ribbon Take-Up Spindle Maintenance Kit ....................................................................................... 338

Remove the Electronics Cover ................................................................................... 339
Remove the Old Ribbon Take-Up Spindle ................................................................. 342
Install the New Ribbon Take-Up Spindle .................................................................... 345
Reinstall the Electronics Cover ................................................................................... 346
Resume Printer Operation ......................................................................................... 348

Ribbon Rollers Maintenance Kit ...................................................................................................... 349

Remove the Old Ribbon Rollers .................................................................................. 350
Remove the Electronics Cover ................................................................................... 351
Remove the Old Ribbon Roller .................................................................................. 354
Install the New Ribbon Roller Assembly ..................................................................... 355
Reinstall the Electronics Cover ................................................................................... 356
Remove the Old Lower Ribbon Idler Non-RFID Roller .............................................. 363
Remove the ZT610R Lower Ribbon Idler Roller ........................................................ 364
Resume Printer Operation ......................................................................................... 365

Upper Platen Roller Maintenance Kit ............................................................................................... 366

Remove the Electronics Cover ................................................................................... 367
Remove the Old Upper Platen Roller ......................................................................... 370
Install the New Upper Platen Roller ........................................................................... 374
Align the Fork and Locater Pin ................................................................................... 377

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Reinstall the Electronics Cover ................................................................................... 378

Resume Printer Operation ......................................................................................... 380

Platen Bearing Retainers Maintenance Kit ..................................................................................... 381

Remove the Old Upper Platen Bearing Retainer ........................................................ 382
Install the New Upper Platen Bearing Retainer ........................................................... 383
Align the Fork and Locater Pin ................................................................................... 384
Remove the Old Lower Platen Roller Bearing Retainer .............................................. 385
Install the New Lower Platen Roller Bearing Retainer ............................................... 386
Resume Printer Operation ......................................................................................... 386

Peel/Tear Bar Maintenance Kit ........................................................................................................ 387

Remove the Electronics Cover ................................................................................... 388
Remove the Main Drive Belt and Pulley ..................................................................... 391
Remove the Old Peel/Tear Bar .................................................................................. 393
Install the New Peel/Tear Bar ..................................................................................... 394
Reinstall the Platen Pulley and Main Drive Belt ......................................................... 398
Reinstall the Electronics Cover ................................................................................... 399
Resume Printer Operation ......................................................................................... 401

Cutter Option Kit .............................................................................................................................. 404

Remove the Tear-Off Front Trim Panel ...................................................................... 406
Install the Cutter Option ............................................................................................. 407
Apply the Label .......................................................................................................... 413
Resume Printer Operation ......................................................................................... 413

Cutter Cover and Printed Circuit Board Assembly (PCBA) Maintenance Kit ................................... 414
Remove the Cutter Catch Tray .................................................................................. 416
Remove the Cutter Assembly .................................................................................... 417
Remove the Old Cutter Cover and PCBA .................................................................. 418
Install the New Cutter Cover and PCBA Assembly .................................................... 420
Reinstall the Cutter Assembly ..................................................................................... 420
Resume Printer Operation ......................................................................................... 422

Magnetic Cutter Tray Maintenance/Option Kit ................................................................................. 423

Install the Cutter Catch Tray ...................................................................................... 424
Resume Printer Operation ......................................................................................... 426

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Media Hanger Option/Maintenance Kit ............................................................................................ 427

Remove the Electronics Cover ................................................................................... 428
Remove the Media Supply Spindle ............................................................................ 432
Install the Media Supply Hanger ................................................................................ 434
Replace the Media Hanger ........................................................................................ 435
Install the Media Hanger ............................................................................................. 435
Reinstall the Electronics Cover .................................................................................. 436
Resume Printer Operation ......................................................................................... 439

Media Rewind Option Kit ................................................................................................................. 440

Remove the Tear-Off Front Trim Panel ...................................................................... 442
Install the Media Rewind Assembly ........................................................................... 443
Remove the Electronics Cover ................................................................................... 445
Install the Rewind Pulley, Tensioner, and Belt ........................................................... 448
Install the Take-Label Sensors .................................................................................... 455
Reinstall the Electronics Cover ................................................................................... 458
Install the Rewind Plate .............................................................................................. 461
Apply the Rewind Loading Label ................................................................................ 465
Resume Printer Operation ......................................................................................... 465

Media Rewind Spindle Maintenance Kit .......................................................................................... 466

Remove the Electronics Cover ................................................................................... 467
Remove the Main Drive Belt ...................................................................................... 470
Remove the Rewind Drive Belt .................................................................................. 471
Remove the Rewind Spindle Pulley ........................................................................... 472
Remove the Old Rewind Spindle Assembly ............................................................... 473
Install the New Rewind Spindle Assembly .................................................................. 474
Reinstall the Electronics Cover ................................................................................... 476
Resume Printer Operation ......................................................................................... 478

Media Rewind and Liner Take-Up Plate Maintenance Kit ............................................................... 479
Install the Liner Take-Up Plate ................................................................................... 480
Install the Rewind Plate .............................................................................................. 481
Resume Printer Operation ......................................................................................... 483

Rewind Drive System Maintenance Kit ............................................................................................ 484

Remove the Electronics Cover ................................................................................... 486
Remove the Old Rewind Drive System ...................................................................... 489
Install the New Rewind Drive System ........................................................................ 494

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Reinstall the Electronics Cover ................................................................................... 497

Resume Printer Operation ......................................................................................... 499

Rewind Platen Roller Maintenance Kit ........................................................................................... 500

Remove the Electronics Cover ................................................................................... 501
Remove the Rewind Platen Roller ............................................................................. 504
Install the New Rewind Platen Roller ......................................................................... 509
Reinstall the Electronics Cover ................................................................................... 512
Resume Printer Operation ......................................................................................... 514

40 mm Media Spindle Maintenance Kit ........................................................................................... 515

Remove the Electronics Cover ................................................................................... 516
Remove the Old Option Card ..................................................................................... 519
Remove the Main Logic Board (MLB) ........................................................................ 521
Remove the 3-Inch Media Supply Spindle ................................................................. 523
Reinstall the Main Logic Board (MLB) ........................................................................ 525
Reinstall Option Boards .............................................................................................. 525
Install 40 mm Media Supply Spindle .......................................................................... 526
Adjust the Spindle Tension ........................................................................................ 527
Reinstall the Electronics Cover ................................................................................... 528
Resume Printer Operation ......................................................................................... 530

Offset Printing Kit ............................................................................................................................. 531

Remove the Electronics Cover ................................................................................... 532
Remove the Media Guide .......................................................................................... 535
Replace the Media Guide Rail ................................................................................... 538
Reinstall the Media Guide Assembly ......................................................................... 541
Reinstall the Electronics Cover ................................................................................... 544
Resume Printer Operation ......................................................................................... 546

Electronic Components .................................................................................................................... 547

Standard Control Panel Maintenance Kit ......................................................................................... 560

Remove the Electronics Cover ................................................................................... 562
Remove the Control Panel ......................................................................................... 565
Install the New Control Panel ..................................................................................... 569
Reinstall the Electronics Cover ................................................................................... 573
Resume Printer Operation ......................................................................................... 575

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Touch Control Panel Option/Maintenance Kit .................................................................................. 576

Remove the Electronics Cover ................................................................................... 578
Remove the Control Panel ......................................................................................... 581
Install the New Control Panel ..................................................................................... 584
Reinstall the Electronics Cover ................................................................................... 585
Resume Printer Operation ......................................................................................... 587

Light Assemblies Maintenance Kit ................................................................................................... 588

Remove the Electronics Cover ................................................................................... 590
Remove the Old Ribbon Path Light Assemblies ........................................................ 593
Install the New Ribbon Path Light Assemblies ........................................................... 596
Remove the Old Media Path Light Assemblies .......................................................... 598
Remove the Applicator Interface Board ..................................................................... 600
Remove the Internal Print Server IPv4 ....................................................................... 601
Remove the Wireless Print Server ............................................................................. 602
Remove the USB Host Board .................................................................................... 604
Remove the Parallel Port Board ................................................................................. 605
Remove the Main Logic Board (MLB) ........................................................................ 606
Install the New Media Path Light Assemblies ............................................................. 608
Reinstall the Main Logic Board ................................................................................... 608
Remove the Old Case Light Assembly ....................................................................... 609
Install the New Case Light .......................................................................................... 610
Reinstall the Electronics Cover ................................................................................... 611
Resume Printer Operation ......................................................................................... 613

USB Cover Maintenance Kit ............................................................................................................ 614

Remove the Old USB Cover ....................................................................................... 615
Install the New USB Cover ......................................................................................... 616

USB Board and Cover Maintenance Kit .......................................................................................... 617

Remove the Electronics Cover ................................................................................... 618
Remove the Control Panel ......................................................................................... 621
Remove the USB Interface Board .............................................................................. 625
Install the New USB Interface Board ........................................................................... 625
Remove and Install the USB Cover ........................................................................... 626
Reinstall the Control Panel .......................................................................................... 627
Reinstall the Electronics Cover ................................................................................... 628
Resume Printer Operation ......................................................................................... 630

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Main Logic Board Replacement Kit ................................................................................................. 631

Remove the Electronics Cover ................................................................................... 632
Remove the Applicator Interface Board ..................................................................... 635
Remove the IPv4 Internal Print Server ....................................................................... 636
Remove the Wireless Print Server ............................................................................. 637
Remove the USB Host Board .................................................................................... 639
Remove the Parallel Port Board ................................................................................. 640
Remove the Old Main Logic Board (MLB) ................................................................. 641
Install the New Main Logic Board (MLB) .................................................................... 643
Reinstall the Electronics Cover ................................................................................... 644
Resume Printer Operation ......................................................................................... 646

Power Supply Maintenance Kit ........................................................................................................ 647

Remove the Electronics Cover ................................................................................... 648
Remove the Old Power Supply ................................................................................... 651
Install the New Power Supply ..................................................................................... 653
Reinstall the Electronics Cover ................................................................................... 655
Resume Printer Operation ......................................................................................... 657

Connectivity Board Maintenance Kit ................................................................................................ 658

Remove the Electronics Cover ................................................................................... 660
Remove the Old Connectivity Board .......................................................................... 663
Install the New Connectivity Board ............................................................................ 665
Reinstall the Electronics Cover .................................................................................. 666
Resume Printer Operation ......................................................................................... 668

IPv4 Internal Print Server

Option/Maintenance Kit ................................................................................................................... 669
Getting Started ........................................................................................................... 670
Remove the Old Option Card ..................................................................................... 671
Remove the Cover Plate ............................................................................................ 672
Install the IPv4 Internal Print Server ........................................................................... 673
Resume Printer Operation ......................................................................................... 674

USB Host Option/Maintenance Kit ................................................................................................... 675

Remove the Old Option Card ..................................................................................... 677
Remove the Cover Plate ............................................................................................ 678
Install the New USB Host Card .................................................................................. 679
Resume Printer Operation ......................................................................................... 680

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Applicator Interface Option/Maintenance

Kit for ZT600 Series Printers ........................................................................................................... 681
Applicator Interface Option .......................................................................................... 682
Remove the Old Option Card or Cover Plate ............................................................. 690
Remove the Old Option Card ..................................................................................... 691
Remove the Cover Plate ............................................................................................ 692
Install the New Applicator Interface ............................................................................ 693
Resume Operation with the New Option Board .......................................................... 694
Resume Printer Operation ......................................................................................... 694

Parallel Port Option/Maintenance Kit ............................................................................................... 695

Getting Started ............................................................................................................ 696
Remove the Old Option Card ...................................................................................... 696
Remove the Cover Plate ............................................................................................ 698
Install the New Parallel Port Card .............................................................................. 699
Resume Printer Operation ......................................................................................... 700

ZebraNet 802.11ac Radio Wireless

Print Server Option/Maintenance Kit ............................................................................................... 701
Prepare for Installation ................................................................................................ 702
Remove the Old Option Card ..................................................................................... 703
Remove the Cover Plate ............................................................................................ 705
Install the ZebraNet 802.11ac Radio Print Server ...................................................... 706
Apply the Compliance Label on ZT600 Series and ZT510 Printers ........................... 708
Programming the ZebraNet 802.11ac Radio Wireless Print Server ........................... 709
Resume Printer Operation ......................................................................................... 709

ZT610 RFID Upgrade/Maintenance Kit ........................................................................................... 710

Remove the Media Support, Roller, and Shaft ........................................................... 712
Install the New Ribbon Idler Roller ............................................................................. 715
Remove the Old RFID Module ................................................................................... 716
Install the RFID Module .............................................................................................. 719
Verify the Operation of the RFID Assembly ............................................................... 722
Resume Printer Operation ......................................................................................... 724

RFID Upgrade/Maintenance Kit ...................................................................................................... 725

Before Installation ....................................................................................................... 726
Remove the Media Support ....................................................................................... 727
Remove the Old RFID Module ................................................................................... 729

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Install the RFID Module ............................................................................................... 732

Verify the Operation of the RFID Assembly ............................................................... 735
Complete the Installation ............................................................................................. 736
Resume Printer Operation ......................................................................................... 737

RFID Hardware and Cables Maintenance Kit .................................................................................. 738

Remove the Electronics Cover ................................................................................... 740
Disconnect the RFID Module ..................................................................................... 743
Remove the ZT610 RFID Module .............................................................................. 745
Reinstall the ZT610 RFID Module ............................................................................... 749
Remove the ZT620 RFID Module .............................................................................. 753
Install the ZT620 RFID Module .................................................................................. 757
Reinstall the Electronics Cover ................................................................................... 761
Resume Printer Operation ......................................................................................... 763

Media Sensor Assembly Maintenance Kit ....................................................................................... 764

Remove the Electronics Cover ................................................................................... 765
Remove the Old Media Sensor .................................................................................. 768
Install the New Media Sensor ..................................................................................... 770
Reinstall the Electronics Cover ................................................................................... 771
Resume Printer Operation ......................................................................................... 773

Reflective (Black Mark) Sensor

Assembly Maintenance Kit .............................................................................................................. 774
Installation Instructions ................................................................................................ 774
Remove the Electronics Cover ................................................................................... 775
Remove the Old Reflective Sensor ............................................................................ 778
Install the New Reflective Sensor ............................................................................... 781
Reinstall the Electronics Cover ................................................................................... 782
Resume Printer Operation ......................................................................................... 784

Ribbon Out Sensor Maintenance Kit ............................................................................................... 785

Remove the Electronics Cover ................................................................................... 787
Disconnect Old Ribbon Sensor .................................................................................. 790
Remove the Upper Print Mechanism ......................................................................... 791
Replace the Reflective Bracket ................................................................................... 804
Install the New Ribbon Sensor Assembly .................................................................. 805
Reinstall the Electronics Cover ................................................................................... 807
Resume Printer Operation ......................................................................................... 809

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Take-Label Sensors Maintenance Kit .............................................................................................. 810

Remove the Electronics Cover ................................................................................... 812
Remove the Take-Label Sensors ............................................................................... 815
Remove the ZT600 Take-Label Sensors from Main Frame ....................................... 818
Install the New Take-Label Sensors ........................................................................... 819
Reinstall the Electronics Cover ................................................................................... 820
Resume Printer Operation ......................................................................................... 822

Head Open Sensor Assembly

Maintenance Kit ............................................................................................................................... 823
Remove the Electronics Cover ................................................................................... 824
Remove the Old Head Open Sensor ......................................................................... 827
Install the New Head Open Sensor Assembly ........................................................... 829
Reinstall the Electronics Cover ................................................................................... 831
Resume Printer Operation ......................................................................................... 833

Electronic Cables Maintenance Kit .................................................................................................. 834

Remove the Electronics Cover ................................................................................... 836
Reinstall the Electronics Cover ................................................................................... 839
Resume Printer Operation ......................................................................................... 841

Outer Casing Components .............................................................................................................. 842

.................................................................................................................................... 849

Touch Control Panel Cover Kit ........................................................................................................ 851

Clean the Front Panel ................................................................................................ 852
Remove Control Panel Cover Backing ........................................................................ 852
Install the Control Panel Cover .................................................................................. 853

Electronics Cover Maintenance Kit .................................................................................................. 854

Remove the Electronics Cover ................................................................................... 855
Install the New Electronics Cover ............................................................................... 858
Resume Printer Operation ......................................................................................... 860

Media Door Maintenance Kit ........................................................................................................... 861

Remove the Old Media Door ....................................................................................... 862
Install the New Media Door ........................................................................................ 863
Resume Printer Operation ......................................................................................... 864

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Media Door Window Maintenance Kit .............................................................................................. 865

Remove the Old Media Door Window ......................................................................... 866
Install the New Media Door Window .......................................................................... 868

Option Covers Maintenance Kit ....................................................................................................... 869

Prepare for Installation ................................................................................................ 870
Remove the Electronics Cover ................................................................................... 871
Install Long Option Cover ........................................................................................... 874
Reinstall the Electronics Cover ................................................................................... 875
Install the Option Board Covers ................................................................................. 878
Install the Rewind Cover ............................................................................................ 879
Install the Take-Label Plugs ....................................................................................... 880
Resume Printer Operation ......................................................................................... 881

Printer Feet Maintenance Kit ........................................................................................................... 882

Replace the Feet ........................................................................................................ 883

Front Trim Panels Maintenance Kit ................................................................................................. 884

Remove the Old Tear-Off Front Trim Panel ................................................................ 885
Install the New Tear-Off Front Trim Panel .................................................................. 886
Remove the Lower Front Trim Panel .......................................................................... 886
Install the Lower Front Trim Panel .............................................................................. 887
Resume Printer Operation ......................................................................................... 887

Miscellaneous Hardware Maintenance Kit ....................................................................................... 888

Repackaging Kit ............................................................................................................................... 895

Repacking the ZT600 .................................................................................................. 897
Load the Printer into the Box ...................................................................................... 899

17
Printer Configuration
and Adjustment
This section assists you with configuration of and adjustments to the printer.

18
 Printer Configuration and Adjustment

Calibrate the Ribbon and Media Sensors

Use the procedure in this section to calibrate the printer, which adjusts the sensitivity of the media and
ribbon sensors.
• For issues that may be resolved by sensor calibration, see Printing or Print Quality Issues on page 72.
• For a summary of the options for initiating calibration, refer to the User Guide.

IMPORTANT: Follow the calibration procedure exactly as presented. You may press and hold CANCEL at
any step in the procedure to cancel the calibration process.

Color Touch Display

1. Touch Print > Sensors > Manual Calibration.

2. Touch Start Calibration.

3. Follow the steps in the calibration procedure.

4. When calibration is complete, press PAUSE to exit pause mode and enable printing.

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 Printer Configuration and Adjustment

Standard Display
1. With the printer in the Ready state, initiate media and ribbon calibration in one of these ways:
• Press and hold PAUSE + CANCEL for 2 seconds.
• Send the ezpl.manual_calibration SGD command to the printer. See the Zebra Programming
Guide for more information about this command.
• Navigate to the following menu item on the control panel display. This item is located under the
TOOLS menu and the SENSORS menu. Press RIGHT SELECT to select START.

The printer does the following:

• The STATUS light and SUPPLIES light flash yellow once.
• The PAUSE light blinks yellow.
• The control panel displays:

LOAD BACKING
REMOVE RIBBON

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 Printer Configuration and Adjustment

CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
2. Open the printhead assembly by rotating the printhead-open lever upward.

3. Extend the media approximately 8 in. (203 mm) out of the printer.

4. Remove the exposed labels so that only the liner remains.

21
 Printer Configuration and Adjustment

5. Pull the media into the printer so that only the backing is over the green light on the lower part of the
media sensor.

6. Remove the ribbon (if used).

7. Rotate the printhead-open lever downward until it locks the printhead in place.

22
 Printer Configuration and Adjustment

8. Press PAUSE to begin the media calibration process.

• The PAUSE light turns off.

• The SUPPLIES light flashes.
• The control panel displays:

CALIBRATING
PLEASE WAIT

When the process is complete:

• The SUPPLIES light stops flashing.
• The PAUSE light flashes yellow.
• The control panel displays:

RELOAD ALL
CONTINUE

9. Open the printhead assembly again.

10. Pull the media forward until a label is positioned under the media sensors.

11. Reload the ribbon (if used).

23
 Printer Configuration and Adjustment

12. Close the printhead.

13. Close the media door.

14. Press PAUSE to enable printing.

24
 Printer Configuration and Adjustment

Adjust the Printhead Pressure and Toggle Position

The printhead pressure toggles can be adjusted to create more or less pressure, as needed. They can
also be moved from side to side to adjust the pressure in certain areas.
If the toggles are not positioned correctly or adjusted to apply the correct pressure, the following types of
issues may result:
• media and ribbon may slip
• ribbon may wrinkle
• media may move from side to side during printing
• printing may be too light or too dark on one side of the media
Use the lowest printhead pressure necessary to produce good print quality. Higher pressures may cause
premature wear on the printhead elements.

Figure 1 Printhead Pressure Toggles

1 2

1 Inside toggle
2 Outside toggle

25
 Printer Configuration and Adjustment

Toggle Position Adjustment

1. Open the printhead assembly by rotating the printhead-open lever to lessen the pressure on the
toggles.

2. Loosen the locking nut at the top of the toggle to be moved.

26
 Printer Configuration and Adjustment

3. Reposition the toggle as necessary to provide even pressure on the media. For extremely narrow
media, position the inside toggle over the center of the media, and decrease the pressure on the
outside toggle.

4. Tighten the locking nut.

27
 Printer Configuration and Adjustment

Printhead Pressure Adjustment

If positioning the toggles properly does not solve a print quality or other issue, try adjusting the printhead
pressure. Maximize printhead life by using the lowest pressure that produces the desired print quality.
1. Initiate a PAUSE Self Test on page 60.

2. While printing labels, use the control panel to lower the darkness setting until the labels are printing
gray instead of black.
3. Are you experiencing any of the following issues?

If the media... Then...

Requires higher pressure overall to print well Increase the pressure on both toggles.
Requires lower pressure overall to print well Decrease the pressure on both toggles.
Prints too lightly on the left side of the label. Increase the pressure on the inside toggle.
Prints too lightly on the right side of the label. Increase the pressure on the outside toggle.
Shifts left while printing Increase the pressure on the outside toggle.
OR
Decrease the pressure on the inside toggle.
Shifts right while printing Increase the pressure on the inside toggle.
OR
Decrease the pressure on the outside toggle.

If none of these issues exist, do not continue with this procedure.

4. To make adjustments to the printhead pressure, loosen the upper knurled nut on the toggle to be
adjusted.

28
 Printer Configuration and Adjustment

5. Increase or decrease the pressure by rotating the lower nut.

Increase pressure Decrease pressure

6. Hold the lower nut in place and tighten the upper knurled nut.

7. If necessary, reinitiate a PAUSE Self Test on page 60.

8. While printing labels, use the control panel to raise the darkness setting until the labels are again
printing black instead of gray.
9. Check the print quality, and if necessary, repeat this procedure until the printhead pressure is
adequate.

29
 Printer Configuration and Adjustment

Set the Printhead Balance

If positioning the toggles properly does not solve a print quality or other issue, try adjusting the printhead
pressure. Maximize printhead life by using the lowest pressure that produces the desired print quality.
1. Initiate a PAUSE Self Test on page 60.

2. While printing labels, use the control panel to lower the darkness setting until the labels are printing
gray instead of black.
3. Did the box on the label print with the same level of darkness on the left and right?

If… Then…
Yes Continue with step 4.
No a. Loosen the balance plate lock screw slightly.

Balance plate lock screw

Balance plate eccentric

b. Press PAUSE to restart the printer.

c. Adjust the balance plate clockwise to reduce the pressure on the outboard side of the label
or adjust it counterclockwise to increase the pressure on the outboard side of the label.
d. When even print quality is achieved, hold the eccentric in position and tighten the balance
plate lock screw.
e. Press PAUSE to stop the printer.
f. Continue with step 4.

4. Press PAUSE to print additional test labels.

5. Press the UP ARROW to increase the darkness setting until the labels are at optimum resolution and
contrast.
6. Check the print quality, and if necessary, repeat this procedure until the printhead balance is adequate.

7. Press and hold CANCEL to exit the test sequence.

30
 Printer Configuration and Adjustment

Adjust the Printhead Position

IMPORTANT: Other than printhead pressure, printhead adjustments rarely need to be performed, even
after replacing the printhead. These adjustments should be performed only by a qualified technician who
has been specifically trained. Do not perform these adjustments unless you have been trained to do so.

Adjusting the printhead position moves the printhead with respect to the platen for optimum print quality. If
satisfactory print quality cannot be achieved or can be achieved only with higher than normal darkness
settings or higher than normal printhead pressure, the printhead may not be in the proper position.
1. Locate the three (ZT610) or four (ZT620) printhead position lock screws through the openings in the
upper support extrusion.

Access holes for the printhead position lock screws

2. Loosen the printhead position lock screws 1/4 turn each.

3. Engage each printhead position adjustment screw with a T15 Torx-head wrench.

31
 Printer Configuration and Adjustment

4. Locate the printhead adjustment screws located at the back of the print mechanism.

printhead position adjustment screws

5. Initiate a PAUSE Self Test on page 60.

6. While the labels are printing, make small adjustments to the printhead position by turning equally the
two printhead position adjustment screws, and observe the changes in print quality. (To make more
labels print, press PAUSE.)
• Turn the screws to the left to move the printhead toward the front of the printer.
• Turn the screws to the right to move the printhead toward the back of the printer.

NOTE: When changing directions, due to spring pressure, there may be a dead spot in the actual
printhead movement.

7. Continue to make small adjustments until parallelism and the best print quality is achieved.
8. Decrease the darkness setting until the self test labels are a charcoal-gray color.

9. Inspect the test labels for streaks and other print quality problems.

10. If required, adjust the printhead position until print quality problems are corrected.

11. Increase the darkness until the self test labels are printed at optimum resolution and contrast.

12. When acceptable print quality is achieved, tighten the printhead position lock screws at the top of the
printhead.
13. Press PAUSE to print additional test labels.

14. Check the print quality, and if necessary, repeat this procedure until the printhead position is adequate.
15. Press and hold CANCEL to exit the test sequence.

32
 Printer Configuration and Adjustment

Adjust the Strip Plate

The strip plate can be adjusted to achieve proper ribbon tension and separation of the ribbon from the
media after printing.
1. Initiate a PAUSE Self Test on page 60.

2. While the labels are printing, check the ribbon for problems such as wrinkling. If necessary, continue
with this procedure to make adjustments.
3. Loosen, but do not remove the two screws securing the strip plate to the front of the printhead
assembly.

Ribbon strip plate

mounting screws

4. Set the strip plate so the mounting screws are centered in the slots and tighten. Ensure that the ribbon
tracks flat and smoothly.
5. Press PAUSE to print additional test labels.

6. Check for ribbon wrinkle, tracking, and media and ribbon separation problems. If wrinkle is present, the
strip plate can be adjusted to lower one end or the other slightly, depending on the wrinkle pattern. If
necessary, repeat this procedure until the strip plate position is adequate.
7. Press and hold CANCEL to exit the test sequence.

33
 Printer Configuration and Adjustment

Adjust the Sensor Position

The transmissive media sensor assembly consists of two parts: a light source and a light sensor. The lower
part of the media sensor is the light source, and the upper part of the media sensor is the light sensor. The
media passes between the two parts.
Adjust the position of the sensor only if the printer cannot detect the top of the labels. In this situation, the
display shows a media out error even though there is media loaded in the printer. For non-continuous
media with a notch or hole, the sensor must be positioned directly at the notch or hole.
1. Remove the ribbon so you can clearly see the media path.

2. With media loaded, locate the green light that shines from the lower part of the media sensor.

3. If necessary, turn the gold transmissive sensor adjustment wheel to move the sensor until it is
positioned at a notch or hole in the media.

34
 Printer Configuration and Adjustment

Install the Rewind/Liner Take-Up Plate

The rewind/liner take-up plate is used in different positions for Rewind mode versus Peel mode or
Applicator Mode.

Peel Mode/Applicator Mode

1. Loosen the knurled nut on the outside stud on the printer’s base.

35
 Printer Configuration and Adjustment

2. Align the large hole of the keyhole in the rewind/peel plate over the knurled nut, and then slide the plate
down until it hits the studs.

3. Tighten the knurled nut.

36
 Printer Configuration and Adjustment

Rewind Mode

To install the rewind/liner take-up plate for Rewind mode:

1. Locate the four mounting slots for the rewind/liner take-up plate.

37
 Printer Configuration and Adjustment

2. Locate the four mounting tabs on the rewind/liner take-up plate.

3. Insert the mounting tabs of the rewind plate into the mounting slots of the printer, and then slide the
rewind plate to the left until it will not go any farther.

38
Data Ports
This section describes the standard communication ports available to connect the printer to your computer
or network.

39
 Data Ports

Applicator Interface Option

The optional Applicator Interface provides a robust electrical signal interface between the printer and the
outside world via a standard DB15 connector (see Figure 1 on page 25). The applicator input signals allow
an external device to control when the printer prints. The applicator output signals provide handshaking
and status information to the external host.
The applicator provides 5V or 24V of power to run the I/O interface and to power small external loads. All
output signals are open collector with a light pull-up resistor built in. All signals and power are galvanically
isolated from the host printer. The applicator provides a jumper to connect printer and applicator grounds,
if required, but the default setting is isolation.
The applicator output voltage can be set to three levels: 0Vdc, 5Vdc and 24Vdc. The 0V setting can be
used if the application requires a unique voltage—12V for example, but 12V must be provided externally.
Setting of voltages (0V, 5V, 24V) is done through SGD command. (See Applicator Specifications on
page 24.)
The applicator output power supply can sustain momentary short circuits but may be damaged with
long-term shorts. There are no user-replaceable fuses on the applicator option PCBA.

Energy Star Effect on the Applicator Board

If the Energy Star feature is enabled and the printer goes to sleep, the applicator board shuts down. If the
applicator board needs to remain on at all times, disable the Energy Star feature in one of the following
ways:
• Setting the Energy Star user menu item to OFF:

• Sending the Energy Star disabling SGD command:

! U1 setvar "power.energy_star.enable" "off"
To reenable Energy Star, send the SGD command with the value "on".

40
 Data Ports

Applicator Specifications

Output voltage selections • 0 volts

• 5 Vdc (+/- 10%) <= 1.0 Adc
• 24 volts (+/- 10%) <= 0.4 Adc
Set by the following SGD command:
! U1 setvar "device.applicator.voltage" "X"
where X is 0, 5, or 24 to indicate the desired voltage. The printer
must be power cycled before the setting takes effect.

A high-voltage lockout jumper installed on the applicator

interface PCBA prevents the output from going above 5V,
even if the SGD is sent for 24V output. This precaution
prevents accidental damage to external equipment. The
jumper must be repositioned to allow for 24V operation.
The default setting is for 5V operation.
Pull-up resistor on output 10K +/- 5%
Pull-up resistor on input 4.7K +/- 5%
Output signal current sink <= 7 mAdc
User-supplied voltage range when 0-24 volts
output voltage set to 0V

41
 Data Ports

Applicator Option External Pinouts

Figure 2 DB15 Connector

Figure 3 External Pinouts

DC-DC Power Converter DB-15
(Isolated Input) Connector

Printer V OUT V OUT

Power High- 7 OUTPUT
voltage V OUT POWER
lockout 2
GND ISO
GND GND ISO 1
GND ISO
8

Jumper J3 Jumper J5
High-voltage Isolation
lockout

START PRINT
Typical Input 3
FEED
V OUT 4
PAUSE INPUT
5
4.7K Ohm REPRINT
6

RIBBON LOW
9
SERVICE REQUIRED
10
END PRINT
Typical Output 11
MEDIA OUT OUTPUT
V OUT 12
RIBBON OUT
13
DATA READY
10K Ohm 14
RFID VOID
15

2NF
GND ISO GND Chassis

42
 Data Ports

Jumper Configuration
Figure 4 Location of Jumpers J3 and J5 on the Applicator Board

DB15 connector

Jumper J3 — High-Voltage Lockout

Pins 1 and 2 connected

V out = 5V max (default)
3 2 1

Pins 2 and 3 connected

V out = 0V, 5V, 24V
3 2 1

Jumper J5 — Ground Isolation Jumper

Pins 1 and 2 connected

3

isolated (default)
2
1

Pins 2 and 3 connected

3

not isolated
2
1

43
 Data Ports

Applicator Interface Pin Configuration

Table 1 Applicator Interface Connector Pin Configuration

Pin No. Signal Name Signal Type Description
1 GROUND Ground Using jumper J5, this pin can be configured as isolated or non-isolated
ISOLATED from the printer circuit ground (see Jumper Configuration on page 26).
Default position is set to isolation.
2 VOUT Power Programmable output voltage of 0V, 5Vdc, 24Vdc. Voltage selection
done by SGD command. Depending on configuration, jumper J3 will
lock out 24V operation (see Jumper Configuration on page 26). If set in
5V position, only 0V and 5V will be available. If set to 24V position, 0V,
5V and 24V will be available, depending on the SGD command. Default
is 5V configuration.
3 START PRINT Input See Applicator Signals on page 29 for more information about the start
and end print signals.
• Pulse Mode—The label printing process begins on the HIGH to
LOW transition of this signal if a format is ready. Deassert this signal
HIGH to inhibit printing of a new label.
• Level Mode—Assert LOW to enable the printer to print if a label
format is ready. When deasserted HIGH, the printer completes the
label that is printing then stops and waits for this input to be
reasserted LOW.
4 FEED Input When the printer is idle or has been paused, assert this input LOW to
trigger repeated feeding of blank labels. Deassert HIGH to stop feeding
blank labels and register to the top of the next label.
5 PAUSE Input To toggle the current Pause state, this input must be asserted LOW for
200 milliseconds, or until the SERVICE REQUIRED output (pin 10)
changes state.
6 REPRINT Input • If the Reprint feature is enabled, this input must be asserted LOW to
cause the printer to reprint the last label.
• If the Reprint feature is disabled, this input is ignored.
7 VOUT Power Programmable output voltage of 0V, 5Vdc, 24Vdc. Voltage selection
done by SGD command. Depending on configuration, jumper J3 will
lock out 24V operation (see Jumper Configuration on page 26). If set in
5V position, only 0V and 5V will be available. If set to 24V position, 0V,
5V and 24V will be available, depending on the SGD command. Default
is 5V configuration.
8 GROUND Ground Using jumper J5, this pin can be configured as isolated or non-isolated
ISOLATED from the printer circuit ground (see Jumper Configuration on page 26).
Default position is set to isolation.

9 RIBBON LOW Output Asserted LOW if the Supplies Warning feature is enabled and the
amount of ribbon remaining on the supply spindle is below the
threshold level.

44
 Data Ports

Table 1 Applicator Interface Connector Pin Configuration (Continued)

Pin No. Signal Name Signal Type Description
10 SERVICE Output Asserted LOW in the following circumstances:
REQUIRED
• the printhead is open
• the ribbon or media is out
• the printer is paused
• an operational fault occurs
• a Resynch error occurs while the applicator Resynch mode is set to
Error mode
11 END PRINT Output See Applicator Signals on page 29 for more information about the start
and end print signals.

NOTE: A format (^XA ... ^XZ) that does not print will signal that it
is being processed. However, it will not trigger an End Print
signal because no motion/printing is required.
• MODE 0—The applicator port is OFF.
• MODE 1—Asserted LOW only while the printer is moving the label
forward; otherwise deasserted HIGH.
• MODE 2—Asserted HIGH only while the printer is moving the label
forward; otherwise deasserted LOW.
• MODE 3—(Default) Asserted LOW for 20 milliseconds when a label
is completed and positioned. Not asserted during continuous
printing.
• MODE 4—Asserted HIGH for 20 milliseconds when a label is
completed and positioned. Not asserted during continuous printing.
12 MEDIA OUT Output Asserted LOW when there is no media in the printer.
13 RIBBON OUT Output Asserted LOW when there is no ribbon in the printer.
14 DATA READY Output See Applicator Signals on page 29 for more information about this
signal.
• Asserted LOW when sufficient data has been received to begin
processing the next label format.
• Deasserted HIGH when printing/processing stops after the current
label format, either due to a pause condition or the absence of a
label format.
15 RFID VOID Output • Asserted LOW when the RFID transponder over the antenna is
“voided.”
• Deasserted HIGH when the end print signal is asserted.

45
 Data Ports

Applicator Signals
The following timing diagrams show how applicator signals function in each applicator mode during the
stages of printing a non-RFID label. For more information about applicator signals during RFID operation,
see the RFID Programming Guide 3.

Figure 5 Applicator Signals (Mode 1)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

Figure 6 Applicator Signals (Mode 2)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

Figure 7 Applicator Signals (Mode 3)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

46
 Data Ports

Figure 8 Applicator Signals (Mode 4)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

47
 Data Ports

Parallel Data Port

The parallel data interface supports IEEE 1284 bidirectional parallel communications in nibble mode. The
parallel interface provides a means of communication that typically is faster than the serial interface
methods. In this method, the bits of data that make up a character are sent all at one time over several
wires in the cable, one bit per wire.
When communicating via the parallel port, the values selected on the printer must be the same as those
used by the host equipment connected to the printer. Port selection for status information is determined by
the channel sending the request. The parallel port can be set for bidirectional or unidirectional
communication. The default setting is bidirectional.

Parallel Cabling Requirements

A standard 36-pin parallel connector is available on the back of the printer for connection to the data
source. An IEEE-1284 compatible bidirectional parallel data cable is required when this communication
method is used. The required cable must have a standard 36-pin parallel connector on one end that is
plugged into the mating connector located at the rear of the printer. The other end of the cable connects to
the printer connector at the host computer. Port selection for status information is determined each time
the printer is turned on.

Parallel Port Interconnections

Table 1 shows the pin configuration and function of a standard computer-to-printer parallel cable.

Table 2 Parallel Cable Pin Configuration

36-Pin Connectors Description
1 nStrobe/HostClk
2–9 Data Bits 1–8
10 nACK/PtrClk
11 Busy/PtrBusy
12 PError/ACKDataReq
13 Select/Xflag
14 nAutoFd/HostBusy
15 Not used
16, 17 Ground
18 +5 V at 750 mA
The maximum current draw may be limited by option configuration.
IMPORTANT: To enable this capability, a qualified service technician
must install a jumper on the printer’s main logic board on JP1, pins 2
and 3.
19–30 Ground

48
 Data Ports

Table 2 Parallel Cable Pin Configuration (Continued)

36-Pin Connectors Description
31 nInit
32 nFault/NDataAvail
33, 34 Not used
35 +5 V through a 1.8 K Resistor
36 NSelectin/1284 active

49
 Data Ports

Serial Data Port

To communicate using the serial data port of the printer, you must choose the number of data bits, parity,
and handshaking. Parity applies only to data transmitted by the printer because the parity of received data
is ignored.
The values selected must be the same as those used by the host equipment connected to the printer.
Default printer settings are 9600 baud, 8 data bits, no parity, and XON/XOFF. The printer will accept any
host setting for stop bits.

Hardware Control Signal Descriptions

For all RS-232 input and output signals, the printer follows both the Electronics Industries Association
(EIA) RS-232 and the Consultative Committee for International Telegraph and Telephone (CCITT) V.24
standard signal level specifications.
When DTR/DSR handshaking is selected, the Data Terminal Ready (DTR) control signal output from the
printer controls when the host computer may send data. DTR ACTIVE (positive voltage) permits the host to
send data. When the printer places DTR in the INACTIVE (negative voltage) state, the host must not send
data.

NOTE: When XON/XOFF handshaking is selected, data flow is controlled by the ASCII Control Codes
DC1 (XON) and DC3 (XOFF). The DTR Control lead has no effect.

Request To Send (RTS) is a control signal from the printer that is connected to the Clear To Send (CTS)
input at the host computer.

Pin Configuration
Connect the serial data cable to the female DB-9 connector on the back of the printer. For all RS-232
connections through a DB-25 cable, use a DB-9 to DB-25 interface module (see DB-9 to DB-25
Connections on page 35).
Table 1 shows the pin configuration of the serial data connector.

Table 3 Serial Connector Pin Configuration

Pin No. Name Description
1 – Connected to Pin 9 Unused and unterminated
2 RXD Receive data—data input to printer
3 TXD Transmit data—data output from printer
4 DTR Data terminal ready—output from printer
5 SG Signal ground
6 DSR Data set ready—input to printer

50
 Data Ports

Table 3 Serial Connector Pin Configuration (Continued)

Pin No. Name Description
7 RTS Request to send—output from printer
8 CTS Clear to send—input to printer
9 +5 VDC +5 VDC at 750 mA (connected to Pin 1)
The maximum current draw may be limited by option configuration.

IMPORTANT: To enable this capability, a qualified service technician

must install a jumper on the printer’s main logic board on JP2, pins 2
and 3.

RS-232 Interface Connections

The printer is configured as Data Terminal Equipment (DTE). Figure 1 shows the internal connections of
the printer’s RS-232 connector.

NOTE: Use a null modem (crossover) cable to connect the printer to a computer or any other DTE device.

Figure 9 RS-232 DB9 MLB Connections

1 +5VDC signal source

2 RXD (receive data) input

3 TXD (transmit data) output

4 DTR (data terminal ready) output

5 SG (signal ground)

6 DSR (data set ready) input

7 RTS (request to send) output

8 CTS (clear to send) input

+5VDC
R1
9 +5VDC signal source
1K
When the printer is connected via its RS-232 interface to Data Communication Equipment (DCE) such as
a modem, use a standard RS-232 (straight-through) interface cable. Figure 2 illustrates the connections
required for this cable.

51
 Data Ports

Figure 10 RS-232 to DCE Cable Connectors

RXD (receive data)

2 2
TXD (transmit data)
3 3
DTR (data terminal ready)
4 4
SG (signal ground)
5 5
DSR (data set ready)
6 6
RTS (request to send)
7 7
CTS (clear to send)
8 8
+5 VDC signal source
9 9

DB-9 to DB-25 Connections

To connect the printer’s RS-232 DB-9 interface to a DB-25 connector, an interface adapter is required. A
generic DB-25 adapter can be used, although the +5 VDC signal source would not be passed through the
adapter. Figure 3 shows the connections required for the DB-9 to DB­25 interface.

Figure 11 DB-9 to DB-25 Cable Connections

2 RXD FG 1

3 TXD TXD 2

4 DTR RXD 3
SG RTS 4
5
DSR CTS 5
6
DSR 6
7 RTS
SG 7
8 CTS +5 VDC
9
+5 VDC SIGNAL
9 DTR
SIGNAL 20

52
 Data Ports

Modem Connection
When the printer is connected via its RS-232 interface to Data Communication Equipment (DCE) such as
a modem, use a standard RS-232 (straight-through) interface cable. Figure 4 shows the connections
required for this cable.

Figure 12 RS-232 Cable Connections

RXD (receive data)

2 2
TXD (transmit data)
3 3
DTR (data terminal ready)
4 4
SG (signal ground)
5 5
DSR (data set ready)
6 6
RTS (request to send)
7 7
CTS (clear to send)
8 8
+5 VDC signal source
9 9

53
 Data Ports

USB 2.0 Port

A USB 2.0 port (which is USB 1.1 and 1.0 compatible) is available to connect your printer to the host
equipment. The industry-standard USB cable has an A-male connector on one end and a B-male
connector on the other end as shown in Figure 1.
NOTE: Maximum cable length of 16.4 ft (5 m).

Figure 13 USB Connectors

Printer Computer
=

2
5 4

1 “B” male connector, attaching to printer

2 “B” male connector, detail
3 “A” male connector, attaching to computer
4 “A” male connector, detail
5 Maximum cable length = 16.4 ft. (5 m)

54
Routine Maintenance
This section provides routine cleaning and maintenance procedures.

Cleaning Schedule and Procedures

Routine preventive maintenance is a crucial part of normal printer operation. By taking good care of your
printer, you can minimize the potential problems that you might have with it and help to achieve and to
maintain your standards for print quality.
Over time, the movement of media or ribbon across the printhead wears through the protective ceramic
coating, exposing and eventually damaging the print elements (dots). To avoid abrasion:
• Clean the printhead frequently.
• Minimize printhead pressure and burn temperature (darkness) settings by optimizing the balance
between the two.
• When using Thermal Transfer mode, ensure that the ribbon is as wide or wider than the media to
prevent exposing the printhead elements to the more abrasive label material.

IMPORTANT: Zebra is not responsible for damage caused by the use of cleaning fluids on this printer.

Specific cleaning procedures are provided on the following pages. Table 1 shows the recommended
cleaning schedule. These intervals are intended as guidelines only. You may have to clean more often,
depending upon your application and media.
.

Table 4 Recommended Cleaning Schedule

Area Method Interval
Printhead Solvent* Direct Thermal Mode: After every roll of media
(or 500 feet of fanfold media).
Platen roller Solvent*
Thermal Transfer Mode: After every roll of
Media sensors Air blow
ribbon.
Ribbon sensor Air blow
Media path Solvent*
Ribbon path Solvent*
Pinch roller (part of Peel-Off option) Solvent*
*Zebra recommends using the Preventive Maintenance Kit (p/n 47362 or p/n 105950-035 - multipack). In place of this kit, you may
use a clean swab dipped in 99.7% isopropyl alcohol.
For 600 dpi printers, use Save-a-Printhead cleaning film. This specially coated material removes contamination buildup without
damaging the printhead. Call your authorized reseller or distributor for more information.

55
 Routine Maintenance

Table 4 Recommended Cleaning Schedule

Area Method Interval
Cutter If cutting continuous, Solvent* After every roll of media (or more often,
module pressure-sensitive media depending upon your application and media).
If cutting tag stock or Solvent* and After every two or three rolls of media.
label liner material air blow
Tear-off/peel-off bar Solvent* Once a month.
Take-label sensor Air blow Once every six months.
*Zebra recommends using the Preventive Maintenance Kit (p/n 47362 or p/n 105950-035 - multipack). In place of this kit, you may
use a clean swab dipped in 99.7% isopropyl alcohol.
For 600 dpi printers, use Save-a-Printhead cleaning film. This specially coated material removes contamination buildup without
damaging the printhead. Call your authorized reseller or distributor for more information.

56
 Routine Maintenance

Clean the Exterior, the Media Compartment, and the Sensors

Over time, dust, grime, and other debris may build up on the outside and inside of your printer, particularly
in a harsh operating environment.

Printer Exterior
You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a mild
detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

IMPORTANT: Zebra is not responsible for damage caused by the use of cleaning fluids on this printer.

Media Compartment and Sensors

1. Brush, air blow, or vacuum any accumulated paper lint and dust away from the media and ribbon paths.

2. Brush, air blow, or vacuum any accumulated paper lint and dust away from the sensors.

2 3

1 Take-label sensor
2 Ribbon sensor
3 Media sensor

57
 Routine Maintenance

Clean the Printhead and Platen Roller

Inconsistent print quality, such as voids in the barcode or graphics, may indicate a dirty printhead. For the
recommended cleaning schedule, see Table 1 on page 38.

IMPORTANT: You are not required to turn off the printer power when working near an open printhead, but
Zebra recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as
label formats, and you must reload them before you resume printing.

CAUTION—ESD: Before touching the printhead assembly, discharge any built-up static electricity by
touching the metal printer frame or by using an anti-static wriststrap and mat.

1. Raise the media door.

58
 Routine Maintenance

CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
2. Open the printhead assembly by rotating the printhead-open lever upward.

3. Remove the ribbon (if used) and the media.

4. Using the swab from a Zebra Preventive Maintenance Kit, wipe along the brown strip on the printhead
assembly from end to end. In place of the Preventive Maintenance Kit, you may use a clean swab
dipped in 99.7% isopropyl alcohol. Allow the solvent to evaporate.

59
 Routine Maintenance

5. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the solvent to
evaporate.

6. Reload the ribbon (if used) and the media. Refer to the User Guide for instructions.

7. Rotate the printhead-open lever downward until it locks the printhead in place.

60
 Routine Maintenance

8. Close the media door.

The printer is ready to operate.

9. Press PAUSE to exit pause mode and enable printing.
The printer may perform a label calibration or feed a label, depending on your settings.

NOTE: If performing this procedure does not improve print quality, try cleaning the printhead with
Save-A-Printhead cleaning film. This specially coated material removes contamination buildup without
damaging the printhead. Call your authorized Zebra reseller for more information.

61
 Routine Maintenance

Clean and Lubricate the Cutter Module

If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter blades.

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

1. Turn off (O) the printer and disconnect the AC power cord.

2. Raise the media door.

3. Remove the media from the cutter module.

4. Remove the cutter catch tray (if used).

62
 Routine Maintenance

5. Loosen and remove the thumbscrew and lock washer on the cutter shield.

CAUTION: The cutter blade is sharp. Do not touch or rub the blade with your fingers.
6. Remove the cutter shield.

63
 Routine Maintenance

7. Is the cutter blade fully exposed?

Blade in lowered position Blade fully exposed

If the blade is… Then…

Lowered Continue with step a to remove the cutter module from the printer so
that you can rotate the blade upward.
Fully exposed Skip to step 8 on page 50.

This part of the procedure should be performed only by experienced users and only when the cutter blade
is not fully exposed for cleaning, as shown in the previous step.
a. Remove the cutter mounting screw.

64
 Routine Maintenance

b. Slide the cutter module to the right to align the cutter assembly tabs (1) and cutter cover tabs (2)
with the corresponding slots (3) in the printer, and then lift the cutter module out of the printer. Take
care not to damage the wires that connect the cutter module to the printer. If desired, you may
disconnect these wires.

3
2

CAUTION: The cutter blade is sharp. Do not touch or rub the blade with your fingers.
c. On the back of the cutter module, rotate the cutter motor thumbscrew to fully expose the cutter
blade.

d. If you disconnected the wires that connect the cutter module to the printer, reconnect them.

65
 Routine Maintenance

e. Align the cutter assembly tabs (1) and cutter cover tabs (2) with the corresponding slots (3) in the
printer, and then slide the cutter assembly back into the printer. Take care not to damage the wires
that connect the cutter module to the printer.

3
2

f. Slide the cutter module to the left, and then reinstall the cutter mounting screw.

g. Continue with step 8.

66
 Routine Maintenance

8. Using the swab from the Preventive Maintenance Kit (part number 47362), wipe along the upper cutting
surface and the cutter blade. In place of the Preventive Maintenance Kit, you may use a clean swab
dipped in 99.7% isopropyl alcohol. Allow the solvent to evaporate.

9. When the solvent has evaporated, soak a clean swab in a general-purpose, higher-viscosity silicone or
PTFE oil lubricant.

67
 Routine Maintenance

10. Apply an even layer along all exposed surfaces of both cutter blades. Remove any excess oil so that
none of it comes in contact with the printhead or platen roller.

CAUTION: The cutter blade is sharp. Do not touch or rub the blade with your fingers. For operator safety,
replace the cutter shield.
11. Replace the cutter shield and secure it with the thumbscrew and lock washer that you removed earlier.

12. Reinstall the media.

68
 Routine Maintenance

13. Close the media door.

14. Plug the printer into its power source, and then turn on (I) the printer.
The cutter blade returns to its operating position.
15. Reinstall the cutter catch tray (if used).

16. If the cutter continues to perform unsatisfactorily, contact an authorized service technician.

69
 Routine Maintenance

Remove Used Ribbon

At minimum, remove used ribbon from the ribbon take-up spindle each time you change the roll of ribbon.
With ribbon that is half or less the width of the printhead, remove used ribbon each time you load a new roll
of media. This ensures that uneven pressure on the ribbon take-up spindle does not interfere with the
ribbon release bars on the spindle.
1. If the ribbon has not yet run out, cut or break the ribbon before the ribbon take-up spindle.

IMPORTANT: Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may damage the
spindle.

2. While holding the ribbon take-up spindle, turn the ribbon release knob as shown until it stops.

The ribbon release bars pivot down, easing the spindle’s grip on the used ribbon.

70
 Routine Maintenance

3. Slide the used ribbon off of the ribbon take-up spindle and discard.

71
 Routine Maintenance

Replacing Printer Components

Some printer components, such as the printhead and platen roller, may wear out over time and can be
replaced easily. Regular cleaning may extend the life of some of these components. See Table 1 on
page 38 for the recommended cleaning intervals.

Ordering Replacement Parts

Zebra ™ printers are designed to work only with genuine Zebra printheads, thus maximizing safety and
print quality. Contact your authorized Zebra reseller for part ordering information.

Recycling Printer Components

The majority of this printer’s components are recyclable. The printer’s main logic board may
include a battery that you should dispose of properly.
Do not dispose of any printer components in unsorted municipal waste. Please dispose of the
battery according to your local regulations, and recycle the other printer components according
to your local standards. For more information, see www.zebra.com/environment.

Storing the Printer

If you are not placing the printer into immediate operation, repackage it using the original packing
materials. You may store the printer under the following conditions:
• Temperature: –40°F to 140°F (–40° to 60°C)
• Relative humidity: 5% to 85% non-condensing

Lubrication
No lubrication is needed for this printer.

IMPORTANT: Some commercially available lubricants will damage the finish and the mechanical parts if
used on this printer.

72
Diagnostics and
Troubleshooting
This section provides diagnostic tests and other information that may help you to optimize printing or to
troubleshoot issues with your printer.
Go to www.zebra.com/zt600-info for access to videos and additional online information designed to assist
you.

73
 Diagnostics and Troubleshooting

Judging Barcode Quality

Figure 1 shows how printer settings such as darkness and print speed can affect the quality of barcodes.
Set the print darkness to the lowest setting that provides good print quality. Initiate the PAUSE Self Test on
page 60 to print sample labels.

Figure 14 Barcode Darkness Comparison

Too Dark
Labels that are too dark are fairly obvious. They may be readable but not “in-spec.”
• The normal barcode bars increase in size.
• The openings in small alphanumeric characters may fill in with ink.
• Rotated barcode bars and spaces run together.

Slightly Dark
Slightly dark labels are not as obvious.
• The normal barcode will be “in-spec.”
• Small character alpha numerics will be bold and could be slightly filled in.
• The rotated barcode spaces are small when compared to the “in-spec” code, possibly making the code
unreadable.

74
 Diagnostics and Troubleshooting

“In-Spec”
The “in-spec” barcode can only be confirmed by a verifier, but it should exhibit some visible characteristics.
• The normal barcode will have complete, even bars and clear, distinct spaces.
• The rotated barcode will have complete, even bars and clear, distinct spaces. Although it may not look
as good as a slightly dark barcode, the barcode will be “in-spec.”
• In both normal and rotated styles, small alphanumeric characters look complete.

Slightly Light
Slightly light labels are, in some cases, preferred to slightly dark ones for “in-spec” barcodes.
• Both normal and rotated barcodes will be in spec, but small alphanumeric characters may not be
complete.

Too Light
Labels that are too light are obvious.
• Both normal and rotated barcodes have incomplete bars and spaces.
• Small alphanumeric characters are unreadable.

75
 Diagnostics and Troubleshooting

Configuration Labels
Some of the most commonly used diagnostic items are the printer configuration label and the network
configuration label. Sample labels are shown in Figure 1. Analyzing the information on these labels can
help you to troubleshoot potential issues.
To print a printer configuration label, touch Menu > Settings > Print: System Settings.
To print a network configuration label, touch Menu > Networks > Print: Network Info.

Figure 15 Sample Labels

Printer Configuration Label Network Configuration Label

76
 PAUSE Self Test

PAUSE Self Test

This self test can be used to provide the test labels required when making adjustments to the printer’s
mechanical assemblies or to determine if any printhead elements are not working. Figure 2 shows a
sample printout.
1. Turn off (O) the printer.

2. Press and hold PAUSE while turning on (I) the printer. Hold PAUSE until the first control panel light
turns off.
• The initial self test prints 15 labels at the printer’s slowest speed, and then automatically pauses the
printer. Each time PAUSE is pressed, an additional 15 labels print. Figure 2 shows a sample of the
labels.

Figure 16 PAUSE Test Label

• While the printer is paused, pressing CANCEL alters the self test. Each time PAUSE is pressed, 15
labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a second time. Each time
PAUSE is pressed, 50 labels print at the printer’s slowest speed
• While the printer is paused, pressing CANCEL again alters the self test a third time. Each time
PAUSE is pressed, 50 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a fourth time. Each time
PAUSE is pressed, 15 labels print at the printer’s maximum speed.
3. To exit this self test at any time, press and hold CANCEL.

77
 Sensor Profile

Sensor Profile
Tap Diagnostics > Printer Information > Print Sensor Profile to Label to print a sensor profile image (which
will extend across several actual labels or tags). Use the sensor profile image to troubleshoot the following
situations:
• The printer experiences difficulty in determining gaps (web) between labels.
• The printer incorrectly identifies preprinted areas on a label as gaps (web).
• The printer cannot detect ribbon.
Compare your results to the examples shown in this section. If the sensitivity of the sensors must be
adjusted, calibrate the printer (see Calibrate the Ribbon and Media Sensors on page 20).

Ribbon Sensor Profile (Figure 3) The line labeled RIBBON (1) on the sensor profile indicates the ribbon
sensor readings. The ribbon sensor threshold setting is indicated by OUT (2). If the ribbon readings are
below the threshold value, the printer does not acknowledge that ribbon is loaded.

Figure 17 Sensor Profile (Ribbon Section)

1
2

Media Sensor Profile (Figure 4) The line labeled MEDIA (1) on the sensor profile indicates the media
sensor readings. The media sensor threshold settings is indicated by WEB (2). The media out threshold is
indicated by OUT (3).The downward spikes (4) indicate gaps between labels (the web), and the lines
between the spikes (5) indicate where labels are located.
If you compare the sensor profile printout to a length of your media, the spikes should be the same
distance apart as the gaps on the media. If the distances are not the same, the printer may be having
difficulty determining where the gaps are located.

Figure 18 Sensor Profile (Media Section)

4 4 4 1
2
5 5 5

78
 Communication Diagnostics Mode

Communication Diagnostics Mode

The communication diagnostics test is a troubleshooting tool for checking the interconnection between the
printer and the host computer. When the printer is in diagnostics mode, it prints all data received from the
host computer as straight ASCII characters with the hex values below the ASCII text. The printer prints all
characters received, including control codes such as CR (carriage return). Figure 5 shows a typical test
label from this test.

NOTE: The test label prints upside-down.

Figure 19 Sample Communications Diagnostics Mode Label

1. Set the label width equal to or less than the actual media width being used for the test. Tap Settings >
Media Settings to access the label width setting.
2. Tap the Diagnostics icon, and set the Diagnostic Mode option to ENABLED.
The printer enters diagnostics mode and prints any data received from the host computer on a test label
3. Check the test label for error codes. For any errors, check that your communication parameters are
correct.
Errors show on the test label as follows:
• FE indicates a framing error.
• OE indicates an overrun error.
• PE indicates a parity error.
• NE indicates noise.
4. To exit this self test and return to normal operation, power cycle the printer or set the Diagnostic Mode
option to DISABLED.

79
 Load Defaults or Last Saved Values

Load Defaults or Last Saved Values

Restoring the printer to default values or to the last saved values can help if things are not working as
expected.
• PRINTER—Restores all printer settings other than the network settings back to the factory defaults.
Use care when loading defaults because you will need to reload all settings that you changed manually.
• NETWORK—Reinitializes the printer’s wired or wireless print server. With a wireless print server, the
printer also reassociates with your wireless network.
• LAST SAVED—Loads settings from the last permanent save.

Standard Printer Display

Color Touch Display

Touch Menu > System > Restore Defaults to see the available options.

80
 Diagnostics and Troubleshooting

Alert and Error States

Color Touch Display Background Color
If the background color of the Home screen changes, you may need to take an action to restore the printer
to a Ready status. Red and yellow backgrounds typically halt printing until the issue is resolved.
Informational messages with a green background usually disappear without user intervention, and printing
continues as normal.

Touch the icons in the bar at the top of the Home screen to view the error, alert, or informational message.
See Alerts and Error Messages on page 65 for recommended actions.

81
 Alerts and Error Messages

Alerts and Error Messages

NOTE: The messages for the standard display and the color touch display are similar. When applicable,
both are shown in this table. The steps for resolving issues are the same for both displays.

Display/Indicator Lights Possible Causes Recommended Solutions

The printhead is not fully closed. Close the printhead completely.
HEAD OPEN
CLOSE HEAD The printhead open sensor is not Call a service technician to replace the
working properly. sensor.
Head Open
Printhead is open.
Close the printhead.

The media is not loaded or is loaded Load media correctly. Refer to the
MEDIA OUT
LOAD MEDIA incorrectly. User Guide for instructions.
Misaligned media sensor. Check the position of the media
Media Out sensor.

Media is out.
The printer is set for noncontinuous 1. Install the proper media type, or
Load additional media. media, but continuous media is reset printer for the current media
loaded. type.
2. Calibrate the printer. See Calibrate
the Ribbon and Media Sensors on
page 20.
There is an issue with the media in the 1. Check for media that is loaded
Paper Jam media path. incorrectly or stuck to components
Media jammed. in the media path.
Check the media.
2. Check if media is wrapped around
the platen roller. Carefully remove
any labels. If necessary, clean the
platen roller to remove adhesive
(see Clean the Printhead and
Platen Roller on page 41).

82
 Alerts and Error Messages

Display/Indicator Lights Possible Causes Recommended Solutions

In thermal transfer mode: 1. Load ribbon correctly. Refer to the
ALERT
User Guide for instructions for
RIBBON OUT • ribbon is not loaded
loading ribbon and media.
• ribbon is loaded incorrectly
Ribbon Out 2. Calibrate the printer. See Calibrate
• the ribbon sensor is not detecting the Ribbon and Media Sensors on
Ribbon is out.
Replace the ribbon.
ribbon page 20.
• media is blocking the ribbon sensor
In thermal transfer mode, the printer 1. Print a sensor profile (see the User
did not detect the ribbon even though Guide for instructions). The ribbon
it is loaded correctly. out threshold (1) is likely too high,
above the line that indicates where
the ribbon is detected (2).

1
2

Calibrate the printer or load printer

defaults. See Calibrate the Ribbon
and Media Sensors on page 20 or
refer to the User Guide for information
about loading printer defaults.
If you are using direct thermal media, Set the printer for Direct Thermal
the printer is waiting for ribbon to be mode. Refer to the User Guide for
loaded because it is incorrectly set for more information.
thermal transfer mode.
Ribbon is loaded, but the printer is set Ribbon is not required with direct
WARNING
RIBBON IN for direct thermal mode. thermal media. If you are using direct
thermal media, remove the ribbon.
This error message will not affect
Ribbon In printing.
Ribbon was detected in If the message persists with no ribbon
Direct Thermal mode.
Remove the ribbon.
in the printer, Calibrate the printer.
See Calibrate the Ribbon and Media
Sensors on page 20.
If you are using thermal transfer
media, which requires ribbon, set the
printer for Thermal Transfer mode.
Refer to the User Guide for
information about changing the print
method.

83
 Alerts and Error Messages

Display/Indicator Lights Possible Causes Recommended Solutions

The printhead was replaced with one Install a genuine Zebra ™ printhead.
PH NOT AUTHENTICATED
REPLACE PRINTHEAD that is not a genuine Zebra ™
printhead.

Head Identification Failed

Printhead is not a Zebra
Certified Product
Replace the Printhead

A printhead element is no longer If the location of the failed element

Head Element Out working. affects printing, replace the printhead.
A printhead element failed.
The printhead may need to be replaced.

The printhead is nearing the end of its Replace the printhead.

Replace Printhead life and should be replaced.
Replace the printhead.

The printhead needs to be cleaned. Follow the cleaning instructions in

Head Maintenance Needed Clean the Printhead and Platen Roller
Clean the printhead. on page 41.

The printhead may be hot enough to cause severe burns. Allow the
PRINT HEAD OVERTEMP
PRINTING HALTED printhead to cool.

The printhead is over temperature. Allow the printer to cool. Printing

Head Over Temp automatically resumes when the
Printhead is too hot.
printhead elements cool to an
All printing is halted. acceptable operating temperature.
If this error persists, consider
changing where the printer is located
or using a slower print speed.

84
 Alerts and Error Messages

Display/Indicator Lights Possible Causes Recommended Solutions

An improperly connected printhead data or power cable can cause
HEAD COLD
PRINTING HALTED these error messages. The printhead may be hot enough to cause
severe burns. Allow the printhead to cool.
THERMISTOR
REPLACE PRINTHEAD The printhead data cable is not Hook up the printhead properly. Install
properly connected. the New Printhead Assembly on
Head Under Temp page 124.

Printhead is too cold.

The printhead has a faulty thermistor. Replace the printhead. Install the New
All printing is halted. Printhead Assembly on page 124.

Head Thermistor Fault

Faulty thermistor detected.
Replace the printhead.

The printer shows one of these

messages or cycles between them.
An improperly connected printhead data or power cable can cause this
Head Under Temp error message. The printhead may be hot enough to cause severe
Printhead is too cold. burns. Allow the printhead to cool.
All printing is halted.
The printhead temperature is Continue printing while the printhead
approaching its lower operating limit. reaches the correct operating
HEAD COLD
PRINTING HALTED temperature. If the error remains, the
environment may be too cold for
proper printing. Relocate the printer to
a warmer area.
The printhead data cable is not Hook up the printhead properly. Install
properly connected. the New Printhead Assembly on
page 124.
The printhead has a faulty thermistor. Replace the printhead. Install the New
Printhead Assembly on page 124.
The cutter blade is sharp. Do not touch or rub the blade with your
CUT ERROR
fingers.
The cutter blade is in the media path. Turn off the printer power and unplug
Cutter Error the printer. Inspect the cutter module
for debris and clean as needed
A cutter error occurred.
Restart the printer. following the cleaning instructions in
Clean and Lubricate the Cutter
Module on page 45.

85
 Alerts and Error Messages

Display/Indicator Lights Possible Causes Recommended Solutions

There is not enough memory to Free up some of the printer’s memory
OUT OF MEMORY
STORING GRAPHIC perform the function specified. by adjusting the label format or printer
parameters. One way to free up
OUT OF MEMORY memory is to adjust the print width to
STORING FORMAT the actual width of the label instead of
leaving the print width set to the
OUT OF MEMORY default.
STORING BITMAP
Ensure that the data is not directed to
OUT OF MEMORY a device that is not installed or is
STORING FONT unavailable.
Replace the MLB. Main Logic Board
Out of Memory Storing XXX Replacement Kit on page 629.
XXX not stored.
Out of memory.

86
 Indicator Lights

Indicator Lights
The indicator lights located above the printer’s display also communicate the printer’s status.

Table 5 Status of Printer As Shown by Indicator Lights

• STATUS light steady green (other lights steady yellow for 2 seconds
during printer power-up)
The printer is ready.
• PAUSE light steady yellow.
The printer is paused.

• STATUS light steady red

• SUPPLIES light steady red
The media supply is out. The printer needs attention and cannot continue
without user intervention.
• STATUS light steady red
• SUPPLIES light flashing red
The ribbon supply is out. The printer needs attention and cannot continue
without user intervention.
• STATUS light steady yellow
• SUPPLIES light flashing yellow
The printer is in Direct Thermal mode, which does not require ribbon;
however, ribbon is installed in the printer.
• STATUS light steady red
• PAUSE light steady yellow
The printhead is open. The printer needs attention and cannot continue
without user intervention.
• STATUS light steady yellow
The printhead is over temperature.

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

• STATUS light flashing yellow

This indicator light flashing indicates one of the following:
a. The printhead is under temperature.
b. The power supply is over temperature.
c. The main logic board (MLB) is over temperature.
• STATUS light steady red
• PAUSE light steady red
• DATA light steady red
The printhead was replaced with one that is not a genuine Zebra ™
printhead. Install a genuine Zebra ™ printhead to continue.

87
 Indicator Lights

Table 5 Status of Printer As Shown by Indicator Lights (Continued)

• STATUS light flashing red
The printer is unable to read the dpi setting of the printhead.

Printers with a ZebraNet wired Ethernet option

• NETWORK light off
No Ethernet link is available.

• NETWORK light steady green

A 100 Base link was found.

• NETWORK light steady yellow

A 10 Base link was found.

• NETWORK light steady red

An Ethernet error condition exists. The printer is not connected to your
network.
Printers with a ZebraNet wireless option
• NETWORK light off
A radio was found during power-up. The printer is attempting to associate
with the network. The light flashes red while the printer associates with the
network. The light then flashes yellow while the printer is authenticating
with the network.

• NETWORK light steady green

The radio is associated with your network and authenticated, and the
WLAN signal is strong.
• NETWORK light flashing green
The radio is associated with your network and authenticated, but the
WLAN signal is weak.

• NETWORK light steady red

A WLAN error condition exists. The printer is not connected to your
network.

88
 Diagnostics and Troubleshooting

Troubleshooting
Printing or Print Quality Issues

Barcode Does Not Scan

Issue Possible Cause Recommended Solution
The barcode printed on a The barcode is not within 1. Initiate a PAUSE Self Test on page 60.
label does not scan. specifications because the printer
2. If necessary, manually adjust the darkness or print
is set at an incorrect darkness
speed settings.
level.
• Set the print darkness to the lowest setting that
provides good print quality. If you set the
darkness too high, the label image may print
unclearly, barcodes may not scan correctly, the
ribbon may burn through, or the printhead may
wear prematurely.
• Slower print speeds typically yield better print
quality.
3. If the issue is not resolved, check the printhead
pressure and toggle position. See Adjust the
Printhead Pressure and Toggle Position on page 8
There is not enough blank space Leave at least 1/8 in. (3.2 mm) between the barcode
around the barcode. and other printed areas on the label and between the
barcode and the edge of the label.
Poor Print Quality
Issue Possible Cause Recommended Solution
Smudge marks on labels The media or ribbon is not Replace supplies with those recommended for
designed for high-speed operation. high-speed operation. For more information, see
www.zebra.com/supplies.
Poor results with thick The print line is not at an optimal Refer to the Maintenance Manual for instructions on
labels position for your media. how to adjust the print line for thick media.

89
 Diagnostics and Troubleshooting

Print Consistently Too Light or Too Dark

Issue Possible Cause Recommended Solution
Printing is too light or too The media or ribbon is not Replace supplies with those recommended for
dark over the entire label designed for high-speed operation. high-speed operation. For more information, see
www.zebra.com/supplies.
The printer is set at an incorrect For optimal print quality, set the darkness to the lowest
darkness level. possible setting for your application.
1. Initiate a PAUSE Self Test on page 60.
2. If necessary, manually adjust the darkness or print
speed settings.
• Set the print darkness to the lowest setting that
provides good print quality. If you set the
darkness too high, the label image may print
unclearly, barcodes may not scan correctly, the
ribbon may burn through, or the printhead may
wear prematurely.
• Slower print speeds typically yield better print
quality.
You are using an incorrect 1. Switch to a different type of media or ribbon to try
combination of media and ribbon to find a compatible combination.
for your application.
2. If necessary, consult your authorized Zebra
reseller or distributor for information and advice.
Incorrect printhead pressure. Set the printhead pressure to the minimum needed for
good print quality. See Adjust the Printhead Pressure
and Toggle Position on page 8.
Printing is too light or too Uneven printhead pressure. Adjust the printhead pressure as needed for good
dark on one side of the print quality. See Adjust the Printhead Pressure and
label Toggle Position on page 8.

90
 Diagnostics and Troubleshooting

Issue Possible Cause Recommended Solution

General print quality The printer is set at an incorrect For optimal print quality, set the print speed and the
issues print speed or darkness level. Keep darkness to the lowest possible settings for your
in mind that printer settings may be application.
affected by the driver or software
1. Initiate a PAUSE Self Test on page 60.
being used.
2. If necessary, manually adjust the darkness or print
speed settings.
• Set the print darkness to the lowest setting that
provides good print quality. If you set the
darkness too high, the label image may print
unclearly, barcodes may not scan correctly, the
ribbon may burn through, or the printhead may
wear prematurely.
• Slower print speeds typically yield better print
quality.
You are using an incorrect 1. Switch to a different type of media or ribbon to try
combination of labels and ribbon to find a compatible combination.
for your application.
2. If necessary, consult your authorized Zebra
reseller or distributor for information and advice.
The printhead is dirty. Clean the printhead and platen roller. See Clean the
Printhead and Platen Roller on page 41.
Incorrect or uneven printhead Set the printhead pressure to the minimum needed for
pressure. good print quality. See Adjust the Printhead Pressure
and Toggle Position on page 8.
The label format is scaling a font Check the label format for font issues.
that is not scalable.
Angled Gray Lines on Blank Labels
Issue Possible Cause Recommended Solution
Fine, angular gray lines Wrinkled ribbon. See wrinkled ribbon causes and solutions in Ribbon
on blank labels Issues on page 76.
Missing Print
Issue Possible Cause Recommended Solution
Long tracks of missing Print element damaged. Replace the printhead. Printhead Assembly
print on several labels Maintenance Kit on page 121.
Wrinkled ribbon. See wrinkled ribbon causes and solutions in Ribbon
Issues on page 76.
Loss of Registration
Issue Possible Cause Recommended Solution
Loss of printing The platen roller is dirty. Clean the printhead and platen roller. See Clean the
registration on labels. Printhead and Platen Roller on page 41.
Media guides are positioned Ensure that the media guides are properly positioned.
Excessive vertical drift in improperly. See the User Guide for instructions.
top-of-form registration. The media type is set incorrectly. Set the printer for the correct media type (gap/notch,
continuous, or mark).
The media is loaded incorrectly. Load media correctly. See the User Guide for
instructions.

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 Diagnostics and Troubleshooting

Misregistration/skips The printer is not calibrated. Calibrate the printer. See Calibrate the Ribbon and
labels Media Sensors on page 20.
Improper label format. Check your label format, and correct it as necessary.
Misregistration and The platen roller is dirty. Clean the printhead and platen roller. See Clean the
misprint of one to three Printhead and Platen Roller on page 41.
labels Media does not meet Use media that meets specifications. See Media
specifications. Specifications on page 96.
Vertical drift in top-of-form The printer is out of calibration. Calibrate the printer. See Calibrate the Ribbon and
position Media Sensors on page 20.
The platen roller is dirty. Clean the printhead and platen roller. See Clean the
Printhead and Platen Roller on page 41.
Horizontal movement in The previous labels were torn off Pull down and to the left when tearing off labels so that
placement of the label incorrectly. the tear-off bar assists in tearing through the label
image. backing. Pulling up or down and to the right can shift
the media sideways.
Vertical image or label The printer is using non-continuous Set the printer for the correct media type (gap/notch,
drift labels but is configured in continuous, or mark) and calibrate the printer, if
continuous mode. necessary (see Calibrate the Ribbon and Media
Sensors on page 20).
The media sensor is calibrated Calibrate the printer. See Calibrate the Ribbon and
improperly. Media Sensors on page 20.
The platen roller is dirty. Clean the printhead and platen roller. See Clean the
Printhead and Platen Roller on page 41.
Improper printhead pressure Adjust the printhead pressure to ensure proper
settings (toggles). functionality. See Adjust the Printhead Pressure and
Toggle Position on page 8.
The media or ribbon is loaded Ensure that the media and ribbon are loaded correctly.
incorrectly. See the User Guide for instructions.
Incompatible media. You must use media that meets the printer
specifications. Ensure that the interlabel gaps or
notches are 2 to 4 mm and consistently placed (see
Media Specifications on page 96).

92
 Diagnostics and Troubleshooting

Ribbon Issues
For videos of some common procedures, go to www.zebra.com/zt600-info.

Wrinkled Ribbon
Issue Possible Cause Recommended Solution
Wrinkled ribbon Ribbon was loaded incorrectly. Load the ribbon correctly. See the User Guide for
information.
Incorrect burn temperature. 1. Initiate a PAUSE Self Test on page 60.
2. If necessary, manually adjust the darkness or print
speed settings.
• Set the print darkness to the lowest setting that
provides good print quality. If you set the
darkness too high, the label image may print
unclearly, barcodes may not scan correctly, the
ribbon may burn through, or the printhead may
wear prematurely.
• Slower print speeds typically yield better print
quality.
Incorrect or uneven printhead Set the printhead pressure to the minimum needed for
pressure. good print quality. See Adjust the Printhead Pressure
and Toggle Position on page 8.
Media not feeding properly; 1. Make sure that media is snug by adjusting the
“walking” from side to side. media guide.
2. Check that the printhead and platen roller are
installed correctly. Install the New Printhead
Assembly on page 124 and Upper Platen Roller
Maintenance Kit on page 367.
The printhead or platen roller may Check that the printhead and platen roller are installed
be installed incorrectly. correctly. Install the New Printhead Assembly on
page 124 and Upper Platen Roller Maintenance Kit on
page 367.

93
 Diagnostics and Troubleshooting

Broken Ribbon
Issue Possible Cause Recommended Solution
Broken or melted ribbon Darkness setting too high. 1. Initiate a PAUSE Self Test on page 60.
2. If necessary, manually adjust the darkness or print
speed settings.
• Set the print darkness to the lowest setting that
provides good print quality. If you set the
darkness too high, the label image may print
unclearly, barcodes may not scan correctly, the
ribbon may burn through, or the printhead may
wear prematurely.
• Slower print speeds typically yield better print
quality.
3. Clean the printhead thoroughly. See Clean the
Printhead and Platen Roller on page 41.
The ribbon is coated on the wrong Replace the ribbon with one coated on the correct
side and cannot be used in this side. For more information, see the User Guide.
printer.
Ribbon Detection Issues
Issue Possible Cause Recommended Solution
The printer does not The printer may have been 1. Make sure that ribbon is loaded correctly so that it
detect when the ribbon calibrated without ribbon or without can be detected by the ribbon sensor. Under the
runs out. the ribbon loaded properly. printhead, the ribbon should track all the way back,
In thermal transfer mode, near the printer’s firewall. Refer to the User Guide
the printer did not detect for instructions for loading ribbon.
the ribbon even though it 2. Calibrate the printer. See Calibrate the Ribbon and
is loaded correctly. Media Sensors on page 20.
The printer indicates that The printer was not calibrated for Calibrate the printer. See Calibrate the Ribbon and
ribbon is out, even though the label and ribbon being used. Media Sensors on page 20.
ribbon is loaded correctly.

94
 Diagnostics and Troubleshooting

RFID Issues

Printer Stops at RFID Inlay

Issue Possible Cause Recommended Solution
The printer stops at the The printer calibrated the label 1. Tap the Advanced icon and then select FEED for
RFID inlay. length only to the RFID inlay the Power Up and Head Close actions.
instead of to the interlabel gap.
2. Manually calibrate the printer (see Calibrate the
Ribbon and Media Sensors on page 20).
Voided Labels
Issue Possible Cause Recommended Solution
The printer voids every The printer is not calibrated for the Manually calibrate the printer (see Calibrate the
label. media being used. Ribbon and Media Sensors on page 20).
You are using an RFID label with a These printers support only Gen 2 RFID labels. For
tag type that is not supported by more information, refer to the RFID Programming
your printer. Guide 3, or contact an authorized Zebra RFID reseller.
The printer is unable to 1. Turn off (O) the printer.
communicate with the RFID reader.
2. Wait 10 seconds.
3. Turn on (I) the printer.
4. If the problem persists, you may have a bad RFID
reader or a loose connection between the RFID
reader and the printer. Contact Technical Support
or an authorized Zebra RFID service technician for
assistance.
Radio frequency (RF) interference Do one or more of the following as necessary:
from another RF source.
• Move the printer away from fixed RFID readers or
other RF sources.
• Make sure that the media door is closed at all
times during RFID programming.
The settings are incorrect in your The software settings override the printer settings.
label designer software. Make sure that the software and printer settings
match.
You are using an incorrect Do one or more of the following as necessary:
programming position, particularly
• Check the RFID programming position or the
if the tags being used are within
program position setting in your label designer
printer specifications.
software. If the position is incorrect, change the
setting.
• Restore the RFID programming position back to
the default value.
For more information, refer to the RFID Programming
Guide 3. For transponder placement details, go to
www.zebra.com/transponders.
You are sending RFID ZPL or SGD Check your label formats. For more information, refer
commands that are incorrect. to the RFID Programming Guide 3.

95
 Diagnostics and Troubleshooting

Voided Labels (Continued)

Issue Possible Cause Recommended Solution
Low yields. Too many The RFID labels are not within Make sure that the labels meet transponder
RFID tags per roll are specifications for the printer, which placement specifications for your printer. See
voided. means that the transponder is not www.zebra.com/transponders for transponder
in an area that can be programmed placement information.
consistently. For more information, refer to the RFID Programming
Guide 3, or contact an authorized Zebra RFID reseller.
Incorrect read and write power Change the RFID read and write power levels. For
levels. instructions, refer to the RFID Programming Guide 3.
Radio frequency (RF) interference Do one or more of the following as necessary:
from another RF source.
• Move the printer away from fixed RFID readers.
• Make sure that the media door is closed at all
times during RFID programming.
The printer is using outdated Go to www.zebra.com/firmware for updated firmware.
printer firmware and reader
firmware versions.

96
 Diagnostics and Troubleshooting

Other RFID Issues

Issue Possible Cause Recommended Solution
RFID parameters do not The printer was powered off (O) Wait at least 10 seconds after turning the printer
appear in Setup mode, and then back on (I) too quickly for power off before turning it back on.
and RFID information the RFID reader to initialize
1. Turn off (O) the printer.
does not appear on the properly.
printer configuration label. 2. Wait 10 seconds.
3. Turn on (I) the printer.
The printer does not void 4. Check for the RFID parameters in Setup mode or
RFID labels that are not for RFID information on a new configuration label.
programmed correctly.
An incorrect version of printer or 1. Verify that the correct firmware version is loaded
reader firmware was loaded on the on your printer. For more information, refer to the
printer. RFID Programming Guide 3.
2. Download the correct printer or reader firmware if
necessary.
3. If the problem persists, contact Technical Support.
The printer is unable to 1. Turn off (O) the printer.
communicate with the RFID
2. Wait 10 seconds.
subsystem.
3. Turn on (I) the printer.
4. If the problem persists, you may have a bad RFID
reader or a loose connection between the RFID
reader and the printer. Contact Technical Support
or an authorized service technician for assistance.
The DATA light flashes The download was not successful. 1. Turn off (O) the printer.
indefinitely after you For best results, cycle power on the
2. Wait 10 seconds.
attempt to download printer before downloading any
printer or reader firmware. 3. Turn on (I) the printer.
firmware.
4. Attempt to download the firmware again.
5. If the problem persists, contact Technical Support.

97
 Diagnostics and Troubleshooting

Communications Issues

Label Formats Not Recognized

Issue Possible Cause Recommended Solution
A label format was sent to the The communication Check the printer driver or software communications
printer but was not recognized. parameters are incorrect. settings (if applicable) for your connection. You may
The DATA light does not flash. wish to reinstall the printer driver using the Zebra
Setup Utility. For instructions, see the User Guide.
A label format was sent to the The prefix and delimiter Verify the prefix and delimiter characters.
printer but was not recognized. characters set in the printer do
The DATA light flashes but no not match the ones in the label
printing occurs. format.
Incorrect data is being sent to Check the communication settings on the computer.
the printer. Ensure that they match the printer settings.
If the problem continues, check the label format.
Labels Stop Printing Correctly
Issue Possible Cause Recommended Solution
A label format was sent to the The serial communication Ensure that the flow control settings match.
printer. Several labels print, settings are incorrect. Check the communication cable length. See
then the printer skips, RS-232/C Serial Data Interface on page 91 for
misplaces, misses, or distorts requirements.
the image on the label.
Check the printer driver or software communications
settings (if applicable).

98
 Diagnostics and Troubleshooting

Miscellaneous Issues

Issues with the Display

Issue Possible Cause Recommended Solution
The control panel display The language parameter was 1. On the Home screen, touch Menu, which is the icon
shows a language that I changed through the control panel on the bottom-left.
cannot read or a firmware command.

2. Touch the top selection on the screen.

3. Scroll through the language selections under this
menu option. The selections for this parameter are
displayed in the actual languages to make it easier
for you to find one that you are able to read.
4. Touch the language that you want to display to select
it.
5. Touch the Home icon to return to the Home screen.
The display is missing The display may need replacing. Replace the display.Standard Control Panel
characters or parts of Maintenance Kit on page 558 or Touch Control Panel
characters Option/Maintenance Kit on page 574.
The USB Host Port Is Not Acknowledging a USB Device
Issue Possible Cause Recommended Solution
The printer is not The printer currently supports USB Use a USB drive that is 1 TB or smaller.
acknowledging a USB drives only up to 1 TB in size.
device or is not reading The USB device may require its If your USB device requires external power, make
the files on a USB device own external power. sure that it is plugged into a working power supply.
that is plugged into the
USB host port.
Printer Parameters Are Not Set As Expected
Issue Possible Cause Recommended Solution
Changes in parameter A firmware setting or command Check your label formats or the settings of the
settings did not take prevented the ability to change the software that you use to send formats to the printer.
effect. parameter. If necessary, refer to the Programming Guide for ZPL,
OR A command in a label format ZBI, Set-Get-Do, Mirror, and WML or call a service
Some parameters changed the parameter back to the technician. A copy of the manual is available at
changed unexpectedly. previous setting. www.zebra.com/manuals.
If the problem persists, there may Replace the main logic board. Main Logic Board
be a problem with the main logic Replacement Kit on page 629
board.

99
 Diagnostics and Troubleshooting

IP Address Changing
Issue Possible Cause Recommended Solution
My printer reassigns a The settings for your network are If the printer changing IP addresses causes issues for
new IP address to the causing the network to reassign a you, follow these steps to assign it a static IP address:
print server after the new IP address. 6. Find out what values need to be assigned to the IP
printer has been off for a address, subnet mask, and gateway for your print
while. server (wired, wireless, or both).
7. Change the appropriate IP protocol value to
PERMANENT.
8. Change the values for the IP address, subnet mask,
and gateway for the appropriate print server to what
you want them to remain.
9. Reset the network by touching Menu >
Connections > Networks > Reset Network and
then touching the check mark to save the changes.
Cannot Connect through Wired or Wireless Connections
Issue Possible Cause Recommended Solution
I manually entered a The printer’s network must be reset Reset the network by touching Menu > Connections
wireless IP address, after values are changed. > Networks > Reset Network and then touching the
subnet, and gateway on check mark to save the changes.
my printer, but it won’t An ESSID value has not been 1. For a wireless connection, specify the ESSID value
connect to my wired or specified. that matches the value used by your wireless
wireless network. router using the following Set/Get/Do command:
! U1 setvar "wlan.essid" "value"
where "value" is the ESSID (sometimes called a
network SSID) for your router. You can look on the
back of your router for a sticker with the router’s
default information. If the information has been
changed from the default, check with your network
administrator for the ESSID value to use.
1. If the printer still does not connect, reset the
network by touching Menu > Connections >
Networks > Reset Network and then touching the
check mark to save the changes, and then power
cycle the printer.
The ESSID or other value was not 1. Print a network configuration label and verify that
specified correctly. your values are correct.
2. Make corrections as necessary.
3. Reset the network by touching Menu >
Connections > Networks > Reset Network and
then touching the check mark to save the changes.

100
 Diagnostics and Troubleshooting

Calibration Issues
Issue Possible Cause Recommended Solution
Non-continuous labels The printer was not calibrated for Calibrate the printer. See Calibrate the Ribbon and
are being treated as the media being used. Media Sensors on page 20.
continuous labels. The printer is configured for Set the printer for the correct media type (gap/notch,
continuous media. continuous, or mark). Refer to the User Guide for
information about changing the media type.
Printer Locks Up
Issue Possible Cause Recommended Solution
All indicator lights are on, Internal electronic or firmware Main Logic Board Replacement Kit on page 629.
nothing is on the display, failure.
and the printer locks up.
The printer locks up while Main logic board failure. Replace the main logic board. Main Logic Board
booting up. Replacement Kit on page 629.

101
 Diagnostics and Troubleshooting

Service the Printer

If you have a problem using the printer, contact your facility's technical or systems support. If there is a
problem with the printer, they will contact the Zebra Global Customer Support Center at:
www.zebra.com/support.
When contacting Zebra Global Customer Support, have the following information available:
• Serial number of the unit
• Model number or product name
• Firmware version number
Zebra responds to calls by e-mail, telephone, or fax within the time limits set forth in service agreements. If
your problem cannot be solved by Zebra Global Customer Support, you may need to return your
equipment for servicing and will be given specific directions.
If you purchased your product from a Zebra business partner, please contact that business partner for
support.

Ship the Printer

If you must ship the printer:
• Turn off (O) the printer, and disconnect all cables.
• Remove any media, ribbon, or loose objects from the printer interior.
• Close the printhead.
• Carefully pack the printer into the original container or a suitable alternate container to avoid damage
during transit. A shipping container can be purchased from Zebra if the original packaging has been lost
or destroyed.
Zebra is not responsible for any damages incurred during shipment if an approved shipping container is
not used. Shipping the units improperly can possibly void the warranty.

102
Specifications
This section lists general printer specifications, printing specifications, ribbon specifications, and media
specifications.

General Specifications
ZT610 ZT620
Height 15.58 in. (395.68 mm) 15.58 in. (395.68 mm)
Width 10.56 in. (268.2 mm) 13.44 in. (341.45 mm)
Depth 19.88 in. (505.0 mm) 19.88 in. (505 mm)
Weight 50 lb (22.7 kg) 57.4 lb (26 kg)
Temperature Operating Thermal Transfer: 40° to 105°F (5° to 40°C)
Direct Thermal: 32° to 105°F (0° to 40°C)
Storage –22° to 140°F (–30° to 60°C)
Relative Humidity Operating 20% to 85%, non-condensing
Storage 20% to 85%, non-condensing
Memory 1 Gigabyte DRAM (32 MB user available)
2 Gigabyte Flash (512 MB user available on-board Flash)

103
 Specifications

Power Specifications
ZT610 ZT620
Electrical 100–240 VAC, 50-60 Hz
Power consumption 120 VAC, 60 Hz
Inrush Current (Irms) 37.0 37.0
Idle Power (Watts) 7.8 8.2
Idle Power (VA) 13.9 17.5
Sleep Power (Watts) 3.0 3.1
Sleep Power (VA) 10.6 14.3
Print Power (Watts) 122.0 128.0
Print Power (VA) 130.0 156.0
Power consumption 230 VAC, 50 Hz
Inrush Current (Irms) 49.0 49.0
Idle Power (Watts) 7.5 7.9
Idle Power (VA) 26.9 35.6
Sleep Power (Watts) 3.2 3.2
Sleep Power (VA) 23.2 31.6
Print Power (Watts) 120.0 127.0
Print Power (VA) 134.0 156.0

104
 Specifications

Power Cord Specifications

Depending on how your printer was ordered, a power cord may or may not be included. If one is not
included or if the one included is not suitable for your requirements, see Figure 1 for specifications.
CAUTION—PRODUCT DAMAGE: For personnel and equipment safety, always use an approved
three-conductor power cord specific to the region or country intended for installation. This cord must use
an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug
configuration.

Figure 20 Power Cord Specifications

3
1

1 AC power plug for your country—This should bear the certification mark of at least one of the
known international safety organizations (Figure 2). The chassis ground (earth) must be
connected to ensure safety and reduce electromagnetic interference.
2 3-conductor HAR cable or other cable approved for your country.
3 IEC 320 connector—This should bear the certification mark of at least one of the known
international safety organizations (Figure 2).
4 Length  9.8 ft. (3 m). Rating 10 Amp, 250 VAC.

Figure 21 International Safety Organization Certification Symbols

105
 Specifications

Communication Interface Specifications

Figure 22 Location of Communication Interfaces

Parallel port
Internal wired Ethernet print server

Serial port
USB port

NOTE: You must supply all data cables for your application. The use of cable strain relief clamps is
recommended.
Ethernet cables do not require shielding, but all other data cables must be fully shielded and fitted with
metal or metalized connector shells. Unshielded data cables may increase radiated emissions above the
regulated limits.
To minimize electrical noise pickup in the cable:
• Keep data cables as short as possible.
• Do not bundle the data cables tightly with the power cords.
• Do not tie the data cables to power wire conduits.

106
 Specifications

Standard Connections
Bluetooth® version 4.0
Limitations and Requirements Many mobile devices can communicate with the printer within a 30-foot
radius of the printer.

Connections and Configuration Refer to the Zebra Bluetooth User Guide for specific instructions for
configuring your printer to use a Bluetooth interface. A copy of this manual is available at
www.zebra.com/manuals.

Two USB host ports

Limitations and Requirements You can only plug one device into each of the printer’s two USB host ports.
You cannot use a third device by plugging it into a USB port on one of the devices, nor can you use an
adapter to split a USB host port on the printer to accept more than one device at a time.

Connections and Configuration No additional configuration is necessary.

Zebra PrintTouch/Near Field Communication (NFC)

Limitations and Requirements NFC communication must be initiated by touching your device to the
appropriate location on the printer.

Connections and Configuration Some devices may not support NFC communication with the printer until
you alter their settings.

USB 2.0 Data Interface

Limitations and Requirements Maximum cable length of 16.4 ft (5 m).

Connections and Configuration No additional configuration is necessary.

Wired Gigabit Internal Ethernet Print Server

Limitations and Requirements
• The printer must be configured to use your LAN.
• A second wired print server can be installed in the bottom option slot.

Connections and Configuration Refer to the ZebraNet Wired and Wireless Print Servers User Guide for
configuration instructions. A copy of this manual is available at www.zebra.com/manuals.

107
 Specifications

RS-232/C Serial Data Interface

• 2400 to 115000 baud
• parity, bits/character
• 7 or 8 data bit
• XON-XOFF, RTS/CTS, or DTR/DSR handshake protocol required
• 750mA at 5 V from pins 1 and 9

Limitations and Requirements You must use a null-modem cable to connect to the printer or a
null-modem adapter if using a standard modem cable.
• Maximum cable length of 50 ft (15.24 m).
• You may need to change printer parameters to match the host computer.

Connections and Configuration The baud rate, number of data and stop bits, the parity, and the
XON/XOFF or DTR control must match those of the host computer.

108
 Specifications

Optional Connections
Wireless print server
See Wireless Specifications on page 93 for more details.

Limitations and Requirements

• Can print to the printer from any computer on your Wireless Local Area Network (WLAN).
• Can communicate with the printer through the printer’s web pages.
• The printer must be configured to use your WLAN.
• Can be installed only in the top option slot.

Configuration Refer to the ZebraNet Wired and Wireless Print Servers User Guide for configuration
instructions. A copy of this manual is available at www.zebra.com/manuals.

IEEE 1284 Bidirectional Parallel data interface

Limitations and Requirements
• Maximum cable length of 10 ft (3 m).
• Recommended cable length of 6 ft (1.83 m).
• No printer parameter changes required to match the host computer.
• Can be installed in either the top or bottom option slot.

Connections and Configuration No additional configuration is necessary.

Applicator interface
with DB15F connector

External ZebraNet 10/100 Print Server

Requires the parallel data interface option

109
 Specifications

Wireless Specifications
Antenna Information
• Type = chip antenna gain 1.69dBi
• Type = Omni directional antenna gain 3dBi @ 2.4GHz; 5dBi @ 5GHz
• Type = PCBA antenna gain = –30dBi @ 900MHz

WLAN Specifications

802.11 b Bluetooth 4.1 + Low Energy (LE)

• 2.4 GHz • 2.4 GHz
• DSSS (DBPSK, DQPSK, and CCK) • FHSS (BDR/EDR), GFSK (Bluetooth Low
Energy)
• RF power 17.77 dBm (EIRP)
• RF power 9.22 dBm (EIRP)
802.11 g
Bluetooth Classic + Low Energy (LE)
• 2.4 GHz
• 2.4 GHz
• OFDM
• FHSS (BDR/EDR), DSSS (Bluetooth LE)
(16-QAM and 64-QAM with BPSK, and QPSK)
• RF power 9.22 dBm (EIRP)
• RF power 18.61 dBm (EIRP)
• FHSS (BDR/EDR), DSSS (Bluetooth LE)
802.11 n
• RF power 9.22 dBm (EIRP)
• 2.4 GHz
RFID M6e Radio Module
• OFDM
• 865-928 MHz
(16-QAM and 64-QAM with BPSK, and QPSK)
• FHSS
• RF power 18.62 dBm (EIRP)
• RF power 27.893 dBm
802.11 a/n
• 5.15-5.25 GHz, 5.25-5.35 GHz, 5.47-5.725 GHz
• OFDM (16-QAM and 64-QAM with BPSK and
QPSK)
• RF power 17.89 dBm (EIRP)
802.11 ac
• 5.15-5.25 GHz, 5.25-5.35 GHz, 5.47-5.725 GHz
• OFDM (16-QAM and 64-QAM with BPSK and
QPSK)
• RF power 13.39 dBm (EIRP)

110
 Specifications

Printing Specifications
ZT610 ZT620
Print resolution 203 dpi (dots/in.)/8 dots/mm 203 dpi (dots/in.)/8 dots/mm
300 dpi/12 dots/mm 300 dpi/12 dots/mm
600 dpi/24 dots/mm N/A
Maximum print width 203 dpi 4.09 in. (104 mm) 6.6 in. (168 mm)
300 dpi 4.09 in. (104 mm) 6.6 in. (168 mm)
600 dpi 4.09 in. (104 mm) N/A
Programmable constant print 203 dpi 2 to 14 in. (50.8 to 355.6 mm) 2 to 12 in. (50.8 to 304.8 mm)
speeds (inches per second/ips or per second in 1-in. (25.4 mm) per second in 1-in. (25.4 mm)
millimeters per second) increments increments
300 dpi 2 to 12 in. (50.8 to 304.8 mm) 2 to 8 in. (50.8 to 203.2 mm)
per second in 1-in. (25.4 mm) per second in 1-in. (25.4 mm)
increments increments
600 dpi 1 to 6 in. (25.4 to 152.4 mm) N/A
per second in 1-in. (25.4 mm)
increments
Dot size (nominal) 203 dpi 0.0049 in. x 0.0049 in. 0.0049 in. x 0.0049 in.
(width x length) (0.125 mm x 0.125 mm) (0.125 mm x 0.125 mm)
300 dpi 0.0033 in. x 0.0039 in. 0.0033 in. x 0.0039 in.
(0.084 mm x 0.099 mm) (0.084 mm x 0.099 mm)
600 dpi 0.0016 in. x 0.0016 in. N/A
(0.042 mm x 0.042 mm)
First dot location 203 dpi 0.14 in. ±0.05 in. 0.10 in. ±0.035 in.
(measured from the inside edge (3.5 mm ±1.25 mm) (2.5 mm ±0.9mm)
of the media) 300 dpi 0.08 in. ±0.05 in. 0.10 in. ±0.035 in.
(2.1 mm ±1.25 mm) (2.5 mm ±0.9mm)
600 dpi 0.08 in. ±0.05 in. N/A
(2.1 mm ±1.25 mm)
Barcode modulus (X) dimension
Picket fence (non-rotated) 203 dpi 4.9 mil to 49 mil 3.3 mil to 49 mil
orientation 300 dpi 3.3 mil to 49 mil
600 dpi 1.6 mil to 16 mil N/A
Ladder (rotated) orientation 203 dpi 4.9 mil to 49 mil 3.9 mil to 39 mil
300 dpi 3.9 mil to 39 mil
600 dpi 1.6 mil to 16 mil N/A
Vertical registration < 4 ips ±0.30 mm ±1.5 mm
(203 and 300 dpi) 4 to 6 ips ±0.50 mm
> 6 ips ±1.5 mm
Vertical registration Tear ±0.20 mm N/A
(600 dpi) (1 and 2 ips) Rewind ±0.20 mm
Peel ±0.20 mm
Cutter ±0.40 mm

111
 Specifications

ZT610 ZT620
Vertical registration Tear ±0.43 mm N/A
(600 dpi) (3 to 6 ips) Rewind ±0.37 mm
Peel ±0.37 mm
Cutter ±0.43 mm
Horizontal registration ±1.5 mm ±1.5 mm

112
 Specifications

Media Specifications
ZT610 ZT620
Label length MINIMUM Non-RFID
(203 and 300 dpi) Tear-off 0.7 in. (18 mm) 0.7 in. (18 mm)
Rewind 0.25 in. (6 mm) 0.25 in. (6 mm)
Peel-off 0.5 in (13 mm) 0.5 in (13 mm)
Cutter 1.5 in. (38 mm) 1.5 in. (38 mm)
RFID Varies for each transponder type
Label length MINIMUM Non-RFID
(600 dpi) Tear-off 0.125 in. (3 mm) N/A
Rewind 0.125 in. (3 mm)
Peel-off 0.5 in. (13 mm)
Cutter 1.5 in. (38 mm)
RFID Varies for each transponder type
Label length MAXIMUM 39 in. (991 mm)
(non-continuous media)
Print length MAXIMUM 200 dpi 150 in. (3810 mm) 150 in. (3810 mm)
(continuous media) 300 dpi 100 in. (2540 mm) 80 in. (2032 mm)
600 dpi 30 in. (762 mm) N/A
Label width MINIMUM Non-RFID 0.79 in. (20 mm) 2 in. (51 mm)
RFID Varies for each transponder type
Label width MAXIMUM (label and liner) 4.5 in. (114 mm) 7.1 in. (180 mm)
Total thickness MINIMUM (includes liner, if any) 0.003 in. (0.076 mm)
Total thickness MAXIMUM Cutter 0.009 in. (0.23 mm) 0.007 in. (0.18 mm)
(includes liner, if any) Other 0.012 in. (0.30 mm) 0.012 in. (0.30 mm)
Roll outside diameter MAXIMUM 8 in. (203 mm)
on a 3-in. (76-mm) inside diameter core
Inter-label gap Minimum 0.079 in. (2 mm)
Preferred 0.118 in. (3 mm)
Maximum 0.157 in. (4 mm)
Ticket/tag notch size (width x length) 0.25 in. x 0.12 in. (6 mm x 3 mm)
Sensing hole diameter 0.125 in. (3 mm)
Black mark density, in Optical Density Units (ODU) > 1.0 ODU
Media density MAXIMUM (black mark) 0.5 ODU
Black mark length (parallel to inside media edge) 0.12 to 0.43 in. (3 to 11 mm)
Black mark width (perpendicular to inside media edge) > 0.43 in. (> 11 mm)
Black mark location within 0.040 in. (1 mm)
of inside media edge

113
 Specifications

Ribbon Specifications
Standard printers use ribbon that is coated on the outside. An optional ribbon spindle is available to use
ribbon that is coated on the inside. Contact your authorized Zebra reseller for ordering information.

ZT610 ZT620
Ribbon width MINIMUM* 0.79 in. (20 mm) 2 in.** (51 mm**)
Ribbon width MAXIMUM 4.33 in. (110 mm) 6.7 in. (170 mm)
Ribbon length MAXIUMUM 1476 ft (450 m)
Ribbon core inside diameter 1 in. (25 mm)
Ribbon roll outside diameter MAXIMUM 3.2 in. (81.3 mm)
* Zebra recommends using ribbon that is at least as wide as the media to protect the printhead from wear.
** Depending on your application, you may be able to use ribbon narrower than 2 in. (51 mm), as long as the ribbon is wider than the media being
used. To use a narrower ribbon, test the ribbon’s performance with your media to assure that you get the desired results.

114
Print Mechanism
Components
This section supplies you with the parts information and installation procedures for the print system.

115
Print Mechanism Components Parts and Drawings
Figure 23 Print Mechanism Components Overview

116
 Item Description Qty
1 P1083320-022 ZT610 Print Mechanism Hardware Maintenance Kit 1
P1083320-023 ZT620 Print Mechanism Hardware Maintenance Kit
2 P1083320-024 ZT610/ZT620 Ground Contact Maintenance Kit 1
3 P1083320-010 ZT610 Printhead Assembly Maintenance Kit, 203 dpi 1
P1083320-011 ZT610 Printhead Assembly Maintenance Kit, 300 dpi
P1083320-012 ZT610 Printhead Assembly Maintenance Kit, 600 dpi
P1083320-013 ZT610 Extended Life Printhead Assembly Maintenance Kit, 203 dpi
P1083320-014 ZT610 Extended Life Printhead Assembly Maintenance Kit, 300 dpi
P1083320-015 ZT620 Printhead Assembly Maintenance Kit, 203 dpi
P1083320-016 ZT620 Printhead Assembly Maintenance Kit, 300 dpi
4 P1083320-027 ZT610 Toggle Bar and Toggles Maintenance Kit 1
P1083320-028 ZT620 Toggle Bar and Toggles Maintenance Kit
5 P1083320-076 ZT610 Media Support Maintenance Kit 1
P1083320-077 ZT620 Media Support Maintenance Kit

117
Figure 24 Print Mechanism Components Kits
1
4

3
2

6
7

10

118
 Item Description
1 P1083320-022 ZT610 Print Mechanism Hardware Maintenance Kit
P1083320-023 ZT620 Print Mechanism Hardware Maintenance Kit
2 P1083320-024 ZT610/ZT620 Ground Contact Maintenance Kit
3 P1083320-097 ZT610/ZT620 Printhead Mounting Screw and Spring
4 P1083320-010 ZT610 Printhead Assembly Maintenance Kit, 203 dpi
P1083320-011 ZT610 Printhead Assembly Maintenance Kit, 300 dpi
P1083320-012 ZT610 Printhead Assembly Maintenance Kit, 600 dpi
P1083320-013 ZT610 Extended Life Printhead Assembly Maintenance Kit, 203 dpi
P1083320-014 ZT610 Extended Life Printhead Assembly Maintenance Kit, 300 dpi
P1083320-015 ZT620 Printhead Assembly Maintenance Kit, 203 dpi
P1083320-016 ZT620 Printhead Assembly Maintenance Kit, 300 dpi
5 P1083320-030 ZT600 Ribbon Strip Plate and Static Brush Maintenance Kit
P1083320-031 ZT620 Ribbon Strip Plate and Static Brush Maintenance Kit
6 P1083320-017 ZT610 Printhead Conversion Maintenance Kit 203 dpi
P1083320-018 ZT610 Printhead Conversion Maintenance Kit 300 dpi
P1083320-019 ZT610 Printhead Conversion Maintenance Kit 600 dpi
P1083320-020 ZT620 Printhead Conversion Maintenance Kit 300 dpi
P1083320-021 ZT620 Printhead Conversion Maintenance Kit 203 dpi
7 P1083320-027 ZT610 Toggle Bar and Toggles Maintenance Kit
P1083320-028 ZT620 Toggle Bar and Toggles Maintenance Kit
8 P1083320-029 Toggle Assembly Maintenance Kit
9 P1083320-076 ZT610 Media Support Maintenance Kit
P1083320-077 ZT620 Media Support Maintenance Kit
10 P1083320-025 ZT610 Toggle Position Ruler Maintenance Kit
P1083320-026 ZT620 Toggle Position Ruler Maintenance Kit

119
Printhead Assembly Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the printhead assembly maintenance kit
in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one of the printheads listed below in Table 6.

Figure 25 Kit Contents

1

Table 6 Parts List

 Item Description Qty
1 ZT610 Printhead Assembly Maintenance Kit, 203/300/600 dpi 1
ZT610 Extended Life Printhead Assembly Maintenance Kit, 203/300 dpi 1
2 ZT620 Printhead Assembly Maintenance Kit, 203/300 dpi 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Antistatic Wriststrap and Mat
• Flatblade Screwdriver
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Old Printhead Assembly
CAUTION—ELECTRIC SHOCK: Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon from the printer.

CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
3. See Figure 26. Loosen the printhead mounting screw.

Figure 26 Loosen the Printhead Mounting Screw

1

1 Flatblade screwdriver
2 Printhead mounting screw access hole
3 Printhead mounting screw

121
4. See Figure 27. Open the print mechanism.

Figure 27 Open the Print Mechanism

1 Printhead-open lever
2 Print mechanism assembly
3 Printhead assembly

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.Connect yourself to an antistatic device.

122
 5. See Figure 28. Pull the printhead out of the printhead connector, and then out of the printer.

Figure 28 Disconnect the Printhead

1

4 2

1 Upper print mechanism assembly

2 Printhead connector
3 Printhead guide posts (2)
4 Printhead assembly

Install the New Printhead Assembly

1. See Figure 28 on page 123. Align the new printhead with the printhead connector.

2. Slide the printhead into the printhead connector until it stops.

3. Push the printhead up into the upper print mechanism ensuring that the guide posts enter the guide
holes.
4. See Figure 27 on page 122. Turn the printhead-open to the locked position.

5. See Figure 26 on page 121. Tighten the printhead mounting screw.

6. Open the printhead, and then using a swab from a Zebra Preventive Maintenance Kit, wipe along the
brown strip on the printhead assembly from end to end. In place of the Preventive Maintenance Kit, you
may use a clean swab dipped in 90% or higher isopropyl alcohol. Allow the solvent to evaporate.

123
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

124
Printhead Conversion Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Printhead Conversion Maintenance
Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits listed in Table 7.

1 2

3 4

Table 7 Parts List

 Item Description Qty
Ref ZT610 Convert to 203 dpi
1 203 dpi Printhead Maintenance Kit 1
3 203 dpi Upper Platen Pulley 1
4 203 dpi Lower Platen Pulley 1
Ref ZT610 Convert to 300 dpi
1 300 dpi Printhead Maintenance Kit 1
4 300/600 dpi Upper Platen Pulley 1
5 300/600 dpi Lower Platen Pulley 1
Ref ZT610 Convert to 600 dpi
1 600 dpi Printhead Maintenance Kit 1
4 300/600 dpi Upper Platen Pulley 1
5 300/600 dpi Lower Platen Pulley 1
Ref ZT620 Convert to 203 dpi
2 203 dpi Printhead Maintenance Kit 1
3 203 dpi Upper Platen Pulley 1

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 7 Parts List
 Item Description Qty
4 203 dpi Lower Platen Pulley 1
Ref ZT620 Convert to 300 dpi
2 300 dpi Printhead Maintenance 1
4 300 dpi Upper Platen Pulley 1
5 300 dpi Lower Platen Pulley 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Hexalobular Wrench Set
• Flatblade Screwdriver • Antistatic Wriststrap and Mat
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

126
Remove the Old Printhead Assembly
NOTE: Retain all parts removed during disassembly, unless otherwise directed.

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
2. Loosen the printhead mounting screw.

1 Flatblade screwdriver
2 Printhead mounting screw access hole
3 Printhead mounting screw

127
3. Open the print mechanism.

1 Printhead-open lever
2 Upper print mechanism assembly
3 Printhead assembly

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.See Figure 29. Pull the printhead out of the printhead
connector, and then out of the printer.
4. Connect yourself to an antistatic device.

128
 Figure 29 Disconnect the Printhead
1

2
4

1 Upper print mechanism assembly

2 Printhead connector
3 Printhead guide posts (2)
4 Printhead assembly

Install the New Printhead Assembly

1. See Figure 29 on page 129. Align the new printhead with the printhead connector.

2. Slide the printhead into the printhead connector until it stops.

3. Push the printhead up into the upper print mechanism ensuring that the guide posts enter the guide
holes.
4. See Figure 3 on page 128. Turn the printhead-open lever to the locked position.

5. See step 2 on page 127. Tighten the printhead mounting screw.

6. Using a swab from a Zebra Preventive Maintenance Kit, wipe along the brown strip on the printhead
assembly from end to end. In place of the Preventive Maintenance Kit, you may use a clean swab
dipped in 90% or higher isopropyl alcohol.Allow the solvent to evaporate.

129
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

130
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

131
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

132
Replace the Old Pulleys
NOTE: If you are going from 300 dpi to 600 dpi or from 600 dpi to 300 dpi you will not need to change the
pulleys. Go to Reinstall the Electronics Cover on page 137.
1. See Figure 30. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 30 Remove the Main Drive Belt

1 4
2 3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. See Figure 31. Loosen, but do not remove, the clamp screw in the platen roller pulley assembly.

133
Figure 31 Remove the Upper Platen Roller Pulley

1 Upper platen roller pulley

2 Upper platen roller pulley clamp screw
3 Upper platen roller shaft

5. Remove and discard the platen roller pulley from the upper platen roller shaft.

6. Locate the proper pulley in the kit, and then slide it on to the upper platen roller shaft.

Figure 32 Pulley Descriptions

1 2 3

1 Upper platen roller pulley 203 DPI

2 Upper platen roller pulley 300/600 DPI
or
Lower platen roller pulley 203 DPI
3 Lower platen roller pulley 300/600 DPI

134
7. Tighten the upper platen roller pulley clamp screw.

8. Do you have the rewind option installed?

If… Then…
Yes Go to step 9.
No Go to step 20 on page 136.

9. Move the rewind tensioner to extend the spring, and then tighten the locking screw.

Figure 33 Remove the Rewind Drive Belt

2
1

3 4

7 6 5

1 Rewind drive belt tensioner

2 Stepper motor pulley
3 Rewind drive belt tensioner locking screw
4 Rewind drive belt
5 Rewind drive belt idler pulley
6 Lower platen pulley
7 Media take-up pulley

10. Remove the rewind drive belt from the rewind spindle, lower platen, idler, and drive pulleys.

135
11. Remove and discard the lower platen roller pulley by loosening the pulley clamp screw, and then sliding
the pulley off of the lower platen roller shaft.

Figure 34 Remove the Lower Platen Roller Platen Pulley

1
2

1 Lower platen roller pulley

2 Lower platen roller pulley clamp screw
3 Lower platen roller shaft

12. See Figure 32 on page 134. Choose the proper pulley in the kit.

13. See Figure 34 on page 136. Slide lower platen roller pulley onto the lower platen roller shaft.

14. See Figure 33 on page 135. Install the idler pulley onto the rewind tensioner shaft.

15. Move the rewind tensioner to extend the spring, and then tighten the locking screw.

16. Slide the rewind belt around the inside pulley on the stepper motor, around the lower platen pulley, and
then around the rewind spindle pulley.
17. Ensure that the belt is on the inside part of the idler pulley.

18. Loosen the rewind tensioner locking screw.

19. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the rewind tensioner.
20. See Figure 30 on page 133. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

21. Ensure that the belt is on the inside part of the idler pulley.

22. Loosen the rewind tensioner locking screw.

23. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

136
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

137
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

138
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

139
Printhead Mounting Screw Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Printhead Mounting Screw
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed in Table 8.

Figure 35 Kit Contents

2

Table 8 Parts List

 Item Description Qty
Ref Printhead Mounting Screw and Spring 1
1 Screw 5
2 Compression Spring 5
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Flatblade Screwdriver

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Replace the Old Printhead Mounting Screw
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Loosen the printhead mounting screw.

Figure 36 Remove the Screw and Spring

2. Let the spring keep upward pressure on the screw and continue to unscrew the screw until it is out of
the upper print mechanism.
3. Remove the screw and spring.

4. See Figure 36 on page 141. Insert the new spring into the screw hole, and then start the new screw.

5. Tighten the new screw into the printhead.

141
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

142
Toggle Bar and Toggles Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Toggle Bar and Toggles
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed in Table 9.

1 2 3

4
8
5 7
6

Table 9 Parts List

 Item Description Qty
Ref Toggle Bar and Toggles Maintenance Kit 1
1 Hexalobular Screw, M3 × 8 1
2 Head-Open Flag 1
3 Nylon Bearing 1
4 Toggle Assembly 1
5 Bronze Bearing 1
6 Curved Washer, 6.45 × 12.62 × 0.15 1
7 Printhead-Open Lever 1
8 Hexalobular Screw, M3 × 0.5 × 8 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Needle-Nose Pliers

144
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

145
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

146
6. Lift the electronics cover off of the printer.

1 Electronics cover

147
Remove the Old Toggle Bar Assembly
1. See Figure 37. Open the upper print mechanism.

Figure 37 Open the Upper Print Mechanism

2 3
1

1 Upper print mechanism

2 Toggle bar assembly
3 Print-head open lever

2. Turn to the electronics side.

148
3. See Figure 38. Remove the head-open flag by removing the mounting screw, and then sliding the flag
off of the toggle bar.

Figure 38 Remove the Head-Open Flag

1

1 Head-open flag
2 Mounting screw
3 Toggle bar

149
4. See Figure 39. Remove the toggle assembly handle by removing the mounting screw, and then sliding
the print-head open lever and curved washer off of the toggle bar.

Figure 39 Remove the Toggle Assembly Handle

1

3
2

1 Toggle bar
2 Curved washer
2 Print-head open lever
3 Mounting screw

5. See Figure 40. Hold down on the printhead assembly while sliding the toggle bar assembly to the left as
far as it will go.

Figure 40 Slide the Toggle Bar Assembly

1 Toggle bar assembly

150
6. See Figure 41. Remove the toggle bar assembly from the printer.

Figure 41 Remove the Toggle Bar Assembly

1 Toggle bar assembly

2 Nylon bearing

7. Remove the nylon bearing.

151
Install the New Toggle Bar Assembly
1. See Figure 42. Install the toggle assembly nylon bearing into the mainframe mounting hole.

Figure 42 Install the Toggle Assembly Nylon Bearing

1
2

1 Toggle assembly mainframe mounting hole

2 Nylon bearing

152
2. See Figure 43. Slide the new toggle bar assembly into the nylon bearing until toggle bar clears the side
plate.

Figure 43 Slide the New Toggle Assembly into the Nylon Bearing

1 2
3

1 Nylon bearing
2 Toggle assembly
3 Brass bearing

3. Slide the bronze bearing onto the toggle assembly.

4. See Figure 44. Slide the toggle bar assembly to the right until it stops.

Figure 44 Install the New Toggle Assembly

2
1

1 Toggle bar assembly

2 Side plate mounting hole

153
5. Ensure that the brass bearing is seated in the side plate mounting hole.

6. Figure 39 on page 150. Holding the toggle assembly in place, slide the curved washer and print-head
lever onto the toggle assembly shaft.
7. Install the mounting screw.

8. See Figure 38 on page 149. From the electronics side, slide the new head-open flag onto the toggle
bar.
9. See Figure 45. With the toggle bar in the closed position, ensure that the flag is centered in the sensor.

Figure 45 Position the Head-Open Flag

1
2

1 Toggle bar assembly

2 Mounting screw
3 Head-open flag
4 Head-open sensor assembly

10. Install the new mounting screw.

154
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

155
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

156
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

157
Toggle Assembly Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Toggle Assembly in the ZT600
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 in Table 10.

Figure 46 • Kit Contents

Table 10 Parts List

 Item Description Qty
Ref Toggle Assembly Maintenance Kit
1 Toggle Assembly 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

159
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

160
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

161
Remove the Old Toggle Assembly
CAUTION—ELECTRIC SHOCK: Turn off (O) the printer and disconnect it from the power source before
performing the following procedure.
1. Disconnect the AC power cord and all data cables.

2. Open the media door and remove the ribbon and media.

3. See Figure 47. Open the upper print mechanism.

Figure 47 Open the Upper Print Mechanism

2 3
1

1 Upper print mechanism

2 Toggle bar assembly
3 Toggle bar assembly handle

162
4. See Figure 48. From the electronics side.
i. Remove the head-open flag by removing the mounting screw.
ii. Slide the flag off of the toggle bar.

Figure 48 Remove the Head-Open Flag

1

1 Head-open flag
2 Mounting screw
3 Toggle bar

163
5. See Figure 49. Remove the toggle assembly handle.
i. Remove the mounting screw.
ii. Slide the handle and curved washer off of the toggle bar.

Figure 49 Remove the Toggle Assembly Handle

1

3
2
4

1 Toggle bar
2 Curved washer
2 Toggle assembly handle
3 Mounting screw

6. See Figure 50. Slide the toggle bar assembly to the left as far as it will go.

Figure 50 Slide the Toggle Bar Assembly

1 Toggle bar assembly

164
7. See Figure 51. Remove the toggle bar assembly from the printer.

Figure 51 Remove the Toggle Bar Assembly

1 Toggle bar assembly

2 Bronze bearing

8. Remove the bronze bearing from the toggle bar assembly.

165
 9. See Figure 52. Loosen the thumb nut on the top thumb nut on the toggle to release it from the toggle
bar, and then slide the toggle off the toggle bar.

Figure 52 Slide the Toggle Off the Toggle Bar

1 2

5
4

1 Toggle bar
2 Toggle on the toggle bar
3 Toggle slide off the toggle bar
4 Thumb nut
5 Position indicator

10. If necessary, repeat step 9 to remove the other toggle.

Install the Toggle Assembly

1. See Figure 52 on page 166. Slide the new toggle assembly onto the toggle bar, with the position
indicator facing out.
2. See Figure 50 on page 164. Slide the toggle bar assembly into the nylon bearing until the right side
clears the side plate.

3. Slide the bronze bearing onto the toggle assembly.

4. See Figure 51 on page 165. Slide the toggle bar assembly and bronze bearing to the right until it stops.

5. Ensure that the bronze bearing is seated in the side plate mounting hole.

6. Figure 49 on page 164. Slide the curved washer and handle onto the toggle assembly shaft.

7. Install the mounting screw.

8. See Figure 48 on page 163. With the toggle bar in the closed position, ensure that the flag is centered
in the sensor.
9. Install the new mounting screw.

166
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

167
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

168
4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

169
Complete the Installation
1. Reinstall the media and ribbon.

2. Reconnect the AC power cord and all data cables and turn on (I) the printer.

3. If necessary, continue with Toggle Position Adjustment on page 170.

Toggle Position Adjustment

1. See Figure 53. Loosen the locking nuts at the top of the toggle assemblies.

Figure 53 Loosen the Locking Nuts

1

1 Locking nuts (2)

2. Slide the toggles until they provide even pressure on the media. For extremely narrow media, position
one toggle over the center of the labels, and decrease the pressure on the unused toggle.
3. Tighten the locking nuts.

170
Toggle Pressure Adjustment
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Print some labels at 2.4 in.(61 mm) per second by running the Pause Self Test.

2. While printing labels, use the control panel controls to lower the darkness setting until the labels are
printing gray instead of black.
3. See Figure 54. Loosen the upper knurled nuts on the toggle assemblies.

Figure 54 Loosen the Upper Knurled Nuts

1

1 Upper knurled nuts (2)

171
 4. See Figure 55. Some media types require higher pressure to print well. For these media types,
increase or decrease pressure using the adjustment nuts until the left and right edges of the printed
area are equally dark.

Figure 55 Adjust the Adjustment Nuts

1 Adjustment nuts (2)

5. Using the control panel, increase the darkness to the desired level.

6. Tighten the upper knurled nuts.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

172
Toggle Position Ruler Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Toggle Position Ruler Maintenance
Kit on ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the following items.

 Item Description Qty

Ref Toggle Position Ruler Maintenance Kit 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Adhesive Solvent

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Old Toggle Position Ruler
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the ribbon from the printer.

3. See Figure 56. Remove the old toggle ruler by peeling it off of the upper print mechanism.

4. Clean with adhesive solvent.

Figure 56 Remove the Old Toggle Position Ruler

1

1 Upper print mechanism

2 Toggle position ruler

174
Install the New Toggle Position Ruler
1. Remove the backing on the new toggle ruler.

2. See Figure 57. Align the new toggle position ruler with the upper print mechanism, and then press it into
place.

Figure 57 Install the New Toggle Position Ruler

1

1 Upper print mechanism

2 Toggle position ruler

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

175
Print Mechanism Hardware Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Print Mechanism Hardware
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one of the kits for your printer listed in Table 11.

Figure 58 Kit Contents

3 1

Table 11 Parts List

 Item Description Qty
Ref Print Mechanism Hardware Maintenance Kit
1 Printhead Pivot Assembly 1
2 Hex-Head Screw, M3 × 6 1
3 Ground Contact Kit 1
4 Crescent Washer 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362 Zebra Preventive Maintenance Kit* • Standard Hex Key Set
• Flatblade Screwdriver • Antistatic Wriststrap and Mat
• Adhesive Solvent • Needle Nose Pliers
• Safety Glasses
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover and the Media Door
NOTE: Retain all parts removed during disassembly, unless otherwise directed.

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon from the printer.

3. See Figure 59. Open the media door, and then remove the electronics cover mounting screw.

Figure 59 Remove the Electronics Cover Mounting Screw

1
2

1 Electronics cover
2 Electronics cover mounting screw

177
Figure 60 Remove the Media Door

1 Media door
2 Mounting screws (4)

NOTE: Removing the media door is optional. Removing the media door allows more access to the
electronics side components.

NOTE: Be sure to hold the door firmly when removing the last screws.

178
Figure 61 Remove the Mounting Screws

1 Electronics cover
2 Electronics cover mounting screws (3)

179
1. See Figure 62. Lift the electronics cover off of the printer.

Figure 62 Remove the Electronics Cover

1 Electronics cover

180
Remove the Old Upper Print Mechanism
CAUTION—HOT SURFACE: The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
1. See Figure 63. Loosen the printhead mounting screw.

Figure 63 Loosen the Printhead Mounting Screw

1

1 Flatblade screwdriver
2 Printhead mounting screw access hole
3 Printhead mounting screw

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

181
3. See Figure 64. Open the print mechanism.

Figure 64 Open the Print Mechanism

1 Toggle bar handle

2 Print mechanism assembly
3 Printhead assembly

182
4. See Figure 65. Pull the printhead out of the printhead connector, and then out of the printer.

Figure 65 Disconnect the Printhead

1

2
4

1 Upper print mechanism assembly

2 Printhead connector
3 Printhead guide posts (2)
4 Printhead assembly

183
5. See Figure 66. Disconnect the printhead cable from J34 and the ribbon sensor cable from J45 on the
main logic board (MLB).

Figure 66 Main Logic Board Connections

;

J45

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

6. See Figure 67. Disconnect the printhead power cable from the power supply connector.

Figure 67 Disconnect the Printhead Power Cable

1 Power supply
2 Printhead power connector

184
7. See Figure 68. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 68 Remove the Main Drive Belt and Idler Pulley

3 4

1 Main drive belt

2 Idler pulley
3 Main drive belt tensioner
4 Locking screw

8. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

9. Slide the main drive belt out of the printer.

10. Slide the idler pulley out of the printer.

185
CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
11. See Figure 69. Using a needle-nose pliers remove the spring’s hook from the tensioning post.

Figure 69 Remove the Print Mechanism Spring Tension

2 1

1 Print mechanism spring

2 Spring hook tensioning post

12. See Figure 70. Remove the E-rings and spring.

186
Figure 70 Remove the E-rings and Spring

1
2

1 E-ring (2)
2 Spring

187
13. See Figure 71. Remove the toggle assembly head-open flag by removing the mounting screw, and then
sliding the head-open flag off of the toggle bar shaft.

Figure 71 Remove the Head-Open Flag

1 Mounting screw
2 Head-open flag
3 Toggle bar shaft

188
14. See Figure 72. Remove the nut securing cable clamp 6, and then remove the printhead power cable.

Figure 72 Locate the Cable Clamps

1 2 7

6 5 4

1 Cable Clamp 1 - Ribbon Sensor, Black Mark Sensor, Transmissive Sensor,

Head Open Sensor, and Media Path Light
2 Cable Clamp 2- Printhead Power, Printhead Data, and Ribbon Path Light
3 Cable Clamp 3- Head Open Sensor and Ribbon Path Light, Printhead
Ground
4 Cable Clamp 4- Stepper Motor and Bulkhead Connector
5 Cable Clamp 5 - Stepper Motor and Bulkhead Connector
6 Cable Clamp 6 - Printhead Power
7 Printhead Grounding Strap

15. Open cable clamp 1 by removing the nut, and then remove only the ribbon sensor cable.

16. Open cable clamp 2 by removing the nut, and then remove the printhead power cable and printhead
data ribbon cable.
17. See Figure 72. Remove the nut securing cable clamp 3, and then remove the cable clamp from the
mounting stud.
18. See Figure 72 on page 189. Remove the printhead ground cable from the stud that cable clamp 3 was
mounted on.
19. Clear all printhead cables, ensuring that they are free of all harnesses.

20. See Figure 73. Remove the upper ribbon idler roller by removing the mounting screw.

189
Figure 73 Remove the Upper Idler Roller Mounting Screw
1
2

1 Upper ribbon idler roller

2 Mounting hole
3 Mounting screw

21. See Figure 74. Pull the right side of the upper ribbon idler roller out of the upper print mechanism.

Figure 74 Pull the Right Side of the Upper Ribbon Idler Roller
3
2
1

1 Upper ribbon idler roller

2 Right side of upper ribbon idler roller
3 Upper print mechanism

190
22. See Figure 75. Remove the upper ribbon idler roller, bearings, and shaft from the printer.

Figure 75 Remove the Upper Ribbon Idler Roller

1

1 Upper ribbon idler roller

23. See Figure 76. Remove the toggle handle and curved washer by removing the handle mounting screw.

Figure 76 Remove the Toggle Handle and Curved Washer

1 Toggle bar handle

2 Mounting screw
3 Curved washer
4 Side plate
5 Toggle bar shaft

191
24. See Figure 77. Remove the three screws securing the side plate to the printer.

NOTE: Do not remove or turn the lock screw (item3 in Figure 77).

Figure 77 Remove the Side Plate Mounting Screws

1

1 Side plate
2 Mounting screws (3)
3 Lock screw

192
25. See Figure 78. Remove the upper side plate from the printer.

Figure 78 Remove the Upper Slide Plate

3
2

1 Upper side plate

2 Lower locating pin
3 Upper locating pin

26. See Figure 79. Slide the toggle bar assembly and bearing out of the printer.

Figure 79 Remove the Toggle Bar Assembly

1 Toggle bar assembly

2 Toggle bar bronze bearing

193
27. See Figure 80. Remove the upper print mechanism assembly by turning the assembly up at an angle.

Figure 80 Remove the Upper Print Mechanism

4
3

1 Upper print mechanism

2 Crescent washer (2)
3 Cable access hole
4 Upper print mechanism shaft mounting hole

28. Remove and discard the two old crescent washers from the toggle bar shaft.

29. While guiding the printhead cables through the access hole, slide the upper print mechanism out of the
printer.
30. Discard the old upper print mechanism.

194
Replace the Old Ground Contact
1. See Figure 81. Remove and discard the ground contact mounting screw.

Figure 81 Remove the Ground Contact

1
2

4 3

1 Ground contact
2 Ground contact mounting screw
3 Leftover tape and adhesive
4 Ground contact main frame mounting hole

2. Peel the ground contact off of the printer main frame and discard it.
3. Clean the left-over tape and adhesive off of the main frame by using an adhesive solvent.

4. Remove the new ground contact and mounting screw from the kit.
5. Peel the adhesive cover off the back.

6. Align the mounting hole of the ground contact with the mounting hole in the main frame.

7. Press the ground contact onto the main frame, and then install the new mounting screw.

195
Install the Upper Print Mechanism
1. See Figure 80 on page 194. While guiding the print mechanism cables through the access hole, slide
the toggle bar shaft through the two new crescent washers and into the upper print mechanism shaft
mounting hole.

2. See Figure 78 on page 193. Reinstall the side plate.

3. Reinstall the three mounting screws.

4. See Figure 75 on page 191. Insert the upper ribbon idler roller shaft with the D-shaped end into the
printer main frame mounting hole.

5. See Figure 74 on page 190. Slide the right side of the upper ribbon idler roller into the upper print
mechanism.
6. See Figure 73 on page 190. Install the new mounting screw and tighten.

Reinstall the Toggle Bar Assembly

1. See Figure 82. Slide the toggle bar assembly into the nylon bearing until it stops.

Figure 82 Slide the New Toggle Assembly into the Nylon Bearing

1
2 3

1 Nylon bearing
2 Toggle assembly
3 Bronze bearing

2. Slide the bronze bearing onto the toggle assembly.

196
3. See Figure 83. Slide the toggle bar assembly to the right until it stops.

Figure 83 Install the New Toggle Assembly

2
1

1 Toggle bar assembly

2 Side plate mounting hole

4. Ensure that the bronze bearing is seated in the side plate mounting hole.

5. Figure 76 on page 191. Slide the curved washer and handle onto the toggle assembly shaft.

6. Compress the curved washer, and then install the mounting screw.

7. See Figure 71 on page 188. From the electronics side, slide the head-open flag onto the toggle shaft.

197
8. See Figure 84. With the toggle bar in the closed position, ensure that the flag is centered in the sensor,
and then install the mounting screw.

Figure 84 Position the Head-Open Flag

1
2

1 Toggle bar assembly

2 Mounting screw
3 Head-open flag
4 Head-open sensor assembly

9. See Figure 70 on page 187. Reinstall the print mechanism spring, and E-rings, and then hook the
spring onto the tension post.
10. See Figure 72 on page 189. Route the ribbon sensor cable under the belt tensioner, and along the
stiffener bracket.
11. Route the ribbon sensor through cable clamp 1 and then reinstall the cable clamp nut.

12. See Figure 66 on page 184. Connect the ribbon sensor cable to J45 on the MLB.

13. See Figure 72 on page 189. Route the printhead data cable through cable clamp 2.

14. See Figure 65 on page 183. Connect the printhead data cable to J34 on the MLB.

15. See Figure 72 on page 189. Route the printhead power cable through cable clamp 2.

16. See Figure 72 on page 189. Reinstall the printhead ground cable behind clamp 3.
17. See Figure 72 on page 189. Route the printhead power cable through cable clamp 6.

18. Reinstall the cable clamps onto the threaded studs, and then reinstall the nuts.

19. See Figure 67 on page 184. Reconnect the printhead power cable to the power supply connector.

20. See Figure 65 on page 183. Align the printhead with the printhead connector.

21. Slide the printhead into the printhead connector until it stops.

22. Push the printhead up into the upper print mechanism ensuring that the guide posts enter the guide
holes.
23. Close the printhead upper print mechanism with the toggle shaft assembly.

198
 24. See Figure 63 on page 181. Tighten the printhead mounting screw.

25. Using a swab from a Zebra Preventive Maintenance Kit, wipe along the brown strip on the printhead
assembly from end to end. In place of the Preventive Maintenance Kit, you may use a clean swab
dipped in 90% or higher isopropyl alcohol. Allow the solvent to evaporate.

Reinstall the Electronics Cover

1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

199
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

200
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Adjust the Toggle Position and Pressure

1. Reinstall the media and ribbon.

2. Ensure that the printer is turned off (O).

3. See Figure 85. Set the pressure lock nut against the pressure adjuster. Measure the distance between
the bottom of the “U” bracket and the top of the pressure lock nut.
4. Set the distance as follows for call out number 7 in Figure 85:
For ZT610, set the distance to 9.5mm (0.375 in)
For ZT620, set the distance to 12mm (0.500 in)

201
Figure 85 Set the Toggle Pressure and Position

1 “U” bracket
2 Position lock nut
3 Pressure lock nut
4 Pressure adjuster
5 Toggle foot
6 Spring

5. Tighten the pressure lock nut against the adjuster nut to lock the pressure adjustment.

6. Repeat step 3 and step 4 on the other toggle.

7. Set the toggle positions.

For the ZT600, set to 20 and 80 on the toggle position scale.
For the ZT620, set to 40 and 130 on the toggle position scale.
8. To increase the pressure, loosen the pressure lock nut, and then turn the adjuster nut downward.

9. To decrease the pressure, loosen the pressure lock nut, and then turn the adjuster nut upward.

202
Set the Printhead Balance
1. Reinstall the media and ribbon.

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

3. Turn on (l) the printer.

4. Press and hold PAUSE while turning on the printer. Print Line/Pause self test labels will start printing.

5. Press PAUSE to pause the printer.

6. Press SETUP/EXIT to enter the configuration mode, DARKNESS will be displayed.

7. Press Minus (–) to decrease the darkness setting.

8. Press PAUSE to restart the printer. Continue to press Minus (–) until the black box on the labels is
charcoal gray.
9. Press PAUSE to stop the printer.

10. Is the black box on the label the same darkness on the left and right?

If… Then…
Yes Go to step 12 on page 204.
No a. See Figure 86 on page 204. Loosen the balance plate lock screw slightly.
b. Press PAUSE to restart the printer.
c. Adjust the balance plate lock screw clockwise to reduce the pressure on the outboard
side of the label or adjust it counterclockwise to increase the pressure on the outboard
side of the label.
d. When even print quality is achieved, hold the eccentric in position and tighten the
balance plate lock screw.
e. Press PAUSE to stop the printer.
f. Go to step 12 on page 204.

203
Figure 86 Adjust the Printhead Balance

1 Balance plate lock screw

2 Balance plate eccentric

11. Press PAUSE to restart the printer.

12. Press Plus (+) to increase the darkness setting until the labels are at optimum resolution and contrast.

13. Press PAUSE to stop the printer.

204
Adjust the Printhead Position
NOTE: Other than printhead pressure, printhead adjustments rarely need to be performed, even after
replacing the printhead. These adjustments should be performed only by a qualified technician who has
been specifically trained. Do not perform these adjustments unless you have been trained to do so.
1. Adjusting the printhead position moves the printhead with respect to the platen for optimum print
quality. If satisfactory print quality cannot be achieved or can be achieved only with higher than normal
darkness settings or higher than normal printhead pressure, the printhead may not be in the proper
position.
2. See Figure 87. Locate the three (ZT610) or four (ZT620) printhead position lock screws through the
openings in the upper support extrusion.

Figure 87 Loosen the Printhead Position Lock Screws

1

1 Printhead position lock screws access holes (3)

3. Loosen the printhead position lock screws 1/4 turn each.

205
4. See Figure 88. Engage each printhead position adjustment screw with a 7/64 inch hex key.

Figure 88 Locate the Printhead Adjustment Screws

1 Printhead position adjustment screws (2)

5. Press PAUSE to restart the printer.

NOTE: Make very small adjustments and check the results. Turn the screws counterclockwise to move
the printhead toward the front of the printer. Turn the screws clockwise to move the printhead toward the
back of the printer.
6. Adjust the printhead position by turning equally the two screws located at the back of the print
mechanism. Turn both screws one-eighth of a turn clockwise and observe the changes in print quality.
Turn both screws one-sixteenth of a turn counterclockwise and observe the changes in print quality.
When changing directions, due to spring pressure, there may be a dead spot in the actual printhead
movement.
7. Continue to make small adjustments until parallelism and the best quality is achieved.

8. Decrease the darkness setting until the Print Line/Pause self test labels are a charcoal-gray color.

9. Inspect the test labels for streaks and other print quality problems.

10. If required, adjust the printhead position until print quality problems are corrected.

11. Increase the darkness until the Print Line/Pause self test labels are printed at optimum resolution and
contrast.
12. When acceptable print quality is achieved, tighten the printhead position lock screws at the top of the
printhead.
13. Run additional Print Line/Pause self test labels to verify proper positioning.

206
Adjust the Strip Plate
The strip plate can be adjusted to achieve proper ribbon tension and separation of the ribbon from the
media after printing.
1. Press and hold PAUSE while turning on the printer. Print Line/Pause self test labels will start printing.

2. Press PAUSE, wait until the printer pauses, then check the ribbon for problems such as wrinkling.

3. See Figure 89. Loosen, but do not remove the two screws securing the strip plate to the front of the
printhead assembly.

Figure 89 Adjust the Ribbon Strip Plate

1

1 Ribbon strip plate

2 Mounting screws (2)

4. Set the strip plate so the mounting screws are centered in the slots and tighten. Ensure ribbon tracks
flat and smoothly.
5. Print a minimum of 25 labels and check for ribbon wrinkle, tracking, and media and ribbon separation
problems. If wrinkle is present, the strip plate can be adjusted to slightly lower one end or the other,
depending on the wrinkle pattern.
6. Press SETUP/EXIT, and then press NEXT/SAVE.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

207
Printhead Ground Contact Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Printhead Ground Contact
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 12.

Figure 90 Kit Contents

Table 12 Parts List

 Item Description Qt
y
Ref Ground Contact Maintenance Kit
1 Ground Contact 1
2 Hexalobular Screw, M3 × 6 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Hexalobular Wrench Set
• Adhesive Solvent
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Replace the Printhead Ground Contact Assembly
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon from the printer.

3. See Figure 91. Remove and discard the ground contact and mounting screw.

Figure 91 Remove the Ground Contact

1 2

4 3

1 Ground contact
2 Ground contact mounting screw
3 Leftover tape and adhesive
4 Ground contact main frame mounting hole

4. Peel the ground contact off of the printer main frame and discard it.

5. Clean the leftover tape and adhesive off of the main frame by using a adhesive solvent.
6. Remove the new ground contact and mounting screw from the kit.

7. Peel the adhesive cover off the back.

8. Align the mounting hole of the ground contact with the mounting hole in the main frame.

9. Press the ground contact onto the main frame, and then install the new mounting screw.

10. Using a swab from a Zebra Preventive Maintenance Kit, wipe along the brown strip on the printhead
assembly from end to end. In place of the Preventive Maintenance Kit, you may use a clean swab
dipped in 90% or higher isopropyl alcohol. Allow the solvent to evaporate.

209
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

210
Strip Plate and Static Brush Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Ribbon Strip Plate and Static Brush
Maintenance Kit on the ZT600 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 in Table 13.

Figure 92 Kit Contents

3
1

Table 13 Parts List

 Item Description Qty
Ref Ribbon Strip Plate and Static Brush Maintenance Kit
1 Ribbon Strip Plate 1
2 Screw, M3 × 0.5 × 6 2
3 Static Brush 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Adhesive Solvent

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Old Static Brush
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Open the media door and remove the media and ribbon.

2. See Figure 93. Remove the upper ribbon idler roller mounting screw.

Figure 93 Remove the Upper Ribbon Idler Roller Mounting Screw

1

1 Upper ribbon idler roller

2 Upper ribbon idler roller mounting screw

212
3. See Figure 94. Pull the right side of the upper ribbon idler roller out of the upper print mechanism.

Figure 94 Pull the Right Side of the Upper Ribbon Idler Roller
3
1 2

1 Upper ribbon idler roller

2 Right side of upper ribbon idler roller
3 Upper print mechanism

4. See Figure 95. Remove the upper ribbon idler roller, bearings, and shaft from the printer.

Figure 95 Remove the Upper Ribbon Idler Roller

1

1 Upper ribbon idler roller

213
 5. See Figure 96. Peel the old static brush off of the printer and discard it.

Figure 96 Peel the Static Brush off of the Printer

1 Antistatic brush

6. Clean the area with a adhesive solvent.

Install the New Static Brush

1. Ensure that the area is dry and clear of adhesive; clean with adhesive solvent if not.
2. Remove the new static brush from the kit.

3. See Figure 96. Install the static brush onto the printer with the brush facing to the front.

4. See Figure 94 on page 213. Reinstall the upper ribbon idler roller.
5. See Figure 93 on page 212. Reinstall the upper ribbon idler roller mounting screw.

214
Remove the Old Ribbon Strip Plate
1. See Figure 97. Remove and discard the two ribbon strip plate mounting screws.

Figure 97 Remove the Old Ribbon Strip Plate

1 Ribbon strip plate

2 Mounting screws (2)

2. Remove and discard the old ribbon strip plate.

Install the New Ribbon Strip Plate

1. See Figure 97. Align the new ribbon strip plate with the print mechanism and install the two mounting
screws supplied in the kit.
2. Slightly tighten the mounting screws.

3. Align the strip plate with the screw heads in the center of the slots in the ribbon strip plate.
4. Reinstall the media and ribbon.

5. Reinstall the AC power cord and data cables.

6. Press and hold PAUSE, and then turn on (l) the printer.

7. After the Power On Self Test (POST), the printer will start to print the Pause test labels.

8. Press PAUSE. After the printer pauses, observe the ribbon for possible problems such as wrinkling.

9. Does the ribbon wrinkle or track incorrectly?

If… Then…
No 10. Tighten the mounting screws.

11. Go to Resume Printer Operation.

Yes Go to Adjust the Strip Plate on page 216.

215
Adjust the Strip Plate
1. The strip plate can be adjusted for proper tracking and separation of the ribbon from the media after
printing.
2. Press PAUSE to restart the printing.

3. While the printer is running, adjust the strip plate so that the ribbon is flat and smooth and tracks
properly when fed to the ribbon take-up spindle.
4. Tighten the strip plate mounting screws, and print a minimum of 25 labels while checking for ribbon
wrinkle, tracking issues, and media/ribbon separation problems.
5. If the problem persists, repeat step 2, step 3, and step 4 until the desired results are reached.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

216
Media Support Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Support Maintenance Kit in
the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 14.

Figure 98 Kit Contents

2 2

Table 14 Parts List

 Item Description Qty
Ref Media Support Maintenance Kit
1 Media Support 1
2 Hexalobular Screw, M3 × 8 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Antistatic Wriststrap and Mat
• Hexalobular Wrench Set
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Old Media Support
1. See Figure 99. Remove the two mounting screws.

Figure 99 Remove the Media Support

1 Media support
2 Mounting screws
3 Lower print mechanism

2. Slide the media support out of the lower print mechanism.

218
Install the New Media Support
1. See Figure 100. Align the media support slides with the lower print mechanism guides, and then slide
the media support into the lower print mechanism.

Figure 100 Slide the Media Support into the Printer

1 3

1 Media support
2 Media support slides (2)
3 Media support guides (2)

219
 2. See Figure 101. Install the two new mounting screws.

Figure 101 Install the Mounting Screws

1 Media support mounting screws (2)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

220
Drive System Components
This section supplies you with the parts information and installation procedures for the drive system.

221
Drive System Parts and Drawings
Figure 102 Drive System Overview

Table 15 Kit Parts List

Item Part Number Description
1 P1083320-056 Main Drive System Maintenance Kit (less motor and bracket)

222
Figure 103 Drive System Kits

Table 16 Kit Parts List

Item Part Number Description
1 P1083320-056 Main Drive System Maintenance Kit
2 P1083320-057 Drive Motor and Pulley Maintenance Kit
3 P1083320-054 Drive Belt Maintenance Kit
4 P1083320-055 Idler Pulley and Tension Spring Maintenance Kit

223
Main Drive System Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Main Drive System Maintenance Kit
in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed in Table 17
on page 224.

Figure 104 Kit Contents

5 6
1 2 3 4

12
9
13

11 10

8 7

Table 17 Parts List

 Item Description Qty
Ref Main Drive System Maintenance Kit
1 Wave Washer, 0.74 × 0.52 × 0.08 1
2 Flat Washer, 0.76 × 0.51 × 0.03 1
3 Spacer 0.75 × 0.520 1
4 E-Ring, 0.500 × 0.042 1
5 Ribbon Take-Up Pulley 1
6 Main Drive Belt Kit 1
7 300/600 dpi Platen Pulley 1
8 203 dpi Platen Pulley 1
9 Idler Pulley and Spring Maintenance Kit 1
10 Locking Screw 1
11 Shoulder Screw 1

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 17 Parts List
 Item Description Qty
12 Idler Pulley and Spring Maintenance Kit 1
13 Tensioner Bracket 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Flat-Blade Screwdriver Set
• Needle-Nose Pliers • Anti-Static Wriststrap and Mat
• Safety Glasses

225
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

226
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

227
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

228
Remove the Old Main Drive System
1. See Figure 105. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 105 Remove the Main Drive Belt

1 4
2 3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Turn the main drive belt tensioner to extend the spring, and then tighten the locking screw.
3. Slide the main drive belt out of the printer.

CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
4. See Figure 106. Loosen the locking screw to release the tension on the spring.

229
Figure 106 Remove the Tensioner Spring
1 2

1 Main drive belt tensioner bracket

2 Tensioner spring
3 Locking screw

230
5. See Figure 107. Remove the spring, idler pulley, locking screw, shoulder screw, and tensioner bracket.

Figure 107 Remove the Tensioner Bracket

1 3
2

5 4

1 Tensioner bracket
2 Idler pulley
3 Tensioner spring
4 Locking screw
5 Shoulder screw

6. See Figure 108. Remove the ribbon take-up spindle pulley by removing the E-ring, and then sliding the
pulley, spacer, flat washer, and wave washer off of the ribbon take-up shaft.

231
Figure 108 Remove the Ribbon Take-Up Spindle Pulley
1
5
2 3 4
6

9
7

1 Ribbon take-up spindle shaft

2 Wave washer
3 Flat washer
4 Spacer
5 Ribbon take-up spindle pulley
6 E-ring
7 Platen roller pulley
8 Platen roller pulley set screw
9 Platen roller shaft

232
Install the New Main Drive System
1. See Figure 109. Remove the proper platen pulley from the maintenance kit.

Figure 109 Choose the Proper Main Drive Platen Pulley

1 2

1 203 dpi pulley

2 300 dpi pulley

2. See Figure 108 on page 232. Slide the new platen pulley onto the platen roller shaft until it hits the
spacer, and then tighten the set screw.
3. Slide the wave washer, flat washer, and spacer onto the ribbon take-up spindle shaft.

4. Slide the ribbon take-up pulley onto the spindle shaft, and then install the E-ring.

5. See Figure 107 on page 231. Install the new tensioner bracket by aligning the shoulder screw holes.
6. Install the new shoulder screw.

7. Install, but do not tighten the new locking screw.

8. Install the tensioner spring onto the tensioner bracket and the drive motor bracket.

9. Slide the idler pulley onto the tensioner bracket shaft.

10. Turn the main drive belt tensioner to extend the spring, and then tighten the locking screw.

11. See Figure 105 on page 229. Install the new drive belt.

12. Ensure that the belt is on the inside part of the idler pulley.

13. Loosen the rewind tensioner locking screw.

14. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

233
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

234
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

235
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

236
 Drive Motor and Pulley Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Drive Motor and Pulley Maintenance
Kit into the ZT610/ZT620 printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 18.

Figure 110 Kit Contents

1
2

Table 18 Parts List

 Item Description Qty
1 Drive Motor and Pulley Assembly 1
2 Idler Pulley, included idler puller and tensioner spring kit 1
3 Grommet, 0.25 × 0.18 × 0.25 1
4 Hexalobular Screw, M4 × 8 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Metric Hex Wench Set
• Antistatic Wrist Strap and Mat • Safety Glasses

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

238
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

239
 6. Lift the electronics cover off of the printer.
=

1 Electronics cover

Remove the Main Drive Belt

1. See Figure 111. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

240
Figure 111 Remove the Main Drive Belt
1 4
2 3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. Is there a media rewind installed on your printer?

If… Then…
Yes Go to Remove the Rewind Drive Belt on page 242.
No Go to Remove the Old Drive Motor and Pulley on page 243.

241
Remove the Rewind Drive Belt
1. See Figure 112. Remove the rewind drive belt by loosening the locking screw on the rewind drive belt
tensioner.

Figure 112 Remove the Rewind Drive Belt

2
1

3 4

7 6 5

1 Rewind drive belt tensioner

2 Stepper motor pulley
3 Rewind drive belt tensioner locking screw
4 Rewind drive belt
5 Rewind drive belt idler pulley
6 Lower platen pulley
7 Media take-up pulley

2. Move the rewind drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the rewind drive belt out of the printer.

242
Remove the Old Drive Motor and Pulley
1. Disconnect the drive motor cable from J26 on the main logic board (MLB).

Figure 113 Disconnect the Drive Motor

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J35
J49

J26

J26
J17
J40
J19

J39
J37 J38

243
2. See Figure 114. Remove the drive motor and mounting bracket from the printer by removing the three
mounting screws.

Figure 114 Remove the Drive Motor and Mounting Bracket

(shown with the rewind tensioner)

2
3

1 Drive motor and mounting bracket

2 Mounting screws (3)
3 Rewind Tensioner

3. Is there a rewind tensioner attached?

If… Then…
Yes Go to step on page 245.
No Go to Install the New Drive Motor and Pulley on page 246.

CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
1. Remove the rewind tensioner plate and spring from the drive motor bracket.

244
Figure 115 Remove the Rewind Tensioner Plate and Spring

1
2
1

4
3
2

3 2

6
5

1 Rewind tensioner plate

2 Shoulder screw
3 Locking screw
4 Expansion spring
5 Rewind idler pulley
6 Rewind idler pulley shaft
7 Tensioner spring hook
8 Drive motor bracket spring hook

245
Install the New Drive Motor and Pulley
1. See Figure 115 on page 245. Align the new drive motor and pulley, cable connector facing down, with
the four mounting holes in the printer main frame.
2. Install the four mounting screws.

3. Do you have a rewind option installed?

If… Then…
Yes Go to step 4.
No Go to Reinstall the Main Drive Belt on page 247.

4. See Figure 115 on page 245. Reinstall the rewind tensioner plate, spring, and idler pulley.

5. Go to Reinstall the Rewind Belt on page 246.

Reinstall the Rewind Belt

1. See Figure 116. Install the idler pulley onto the tensioner shaft.

Figure 116 Install the Rewind Drive Belt

3
4

1 Rewind drive belt

2 Stepper motor pulley
3 Rewind tensioner locking screw
4 Rewind tensioner idler pulley
5 Lower platen roller pulley
6 Rewind spindle pulley

246
 2. Move the rewind tensioner to extend the spring, and then tighten the locking screw.

3. Slide the rewind belt around the inside pulley on the stepper motor, around the lower platen pulley, and
then around the rewind spindle pulley.
4. Ensure that the belt is on the inside part of the idler pulley.

5. Loosen the rewind tensioner locking screw.

6. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the rewind tensioner.

Reinstall the Main Drive Belt

1. See Figure 111 on page 241. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

2. Ensure that the belt is on the inside part of the idler pulley.

3. Loosen the rewind tensioner locking screw.

4. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

247
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

248
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

249
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

250
Drive Belt Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Drive Belt Maintenance Kit in the
ZT600 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 in Table 19.

Figure 117 Kit Contents

1

Table 19 Parts List

 Item Description Qty
Ref Drive Belt Maintenance Kit 1
1 Main and Rewind Drive Belt 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

252
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

253
 6. Lift the electronics cover off of the printer.
=

1 Electronics cover

Remove the Old Main Drive System

1. See Figure 118. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

254
 Figure 118 Remove the Main Drive Belt
1 4
2 3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

Install the Main Drive Belt

1. See Figure 118 on page 255. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

2. Ensure that the belt is on the inside part of the idler pulley.

3. Loosen the rewind tensioner locking screw.

4. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

255
Remove the Old Rewind Drive Belt
1. See Figure 119. Move the rewind tensioner to extend the spring, and then tighten the locking screw.

Figure 119 Remove the Rewind Drive Belt

1

3
4

1 Rewind drive belt

2 Stepper motor pulley
3 Rewind tensioner locking screw
4 Rewind tensioner idler pulley
5 Lower platen roller pulley
6 Rewind spindle pulley

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. See Figure 120. Move the rewind tensioner to extend the spring, and then tighten the locking screw.

256
 Figure 120 Remove the Main Drive Belt
1 4
2 3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

1. Slide the rewind belt around the inside pulley on the stepper motor, around the lower platen pulley, and
then around the rewind spindle pulley.
2. Ensure that the belt is on the inside part of the idler pulley.

3. Loosen the rewind tensioner locking screw.

4. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the rewind tensioner.

Reinstall the Main Drive Belt

1. See Figure 118 on page 255. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

2. Ensure that the belt is on the inside part of the idler pulley.

3. See Figure 120 on page 257. Loosen the rewind tensioner locking screw.
4. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

257
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

258
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

259
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

260
Idler Pulley and Tension Spring Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Idler Pulley and Tension Spring
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 20.

Figure 121 Kit Contents

Table 20 Parts List

 Item Description Qty
Ref Idler Pulley and Tension Spring Maintenance Kit
1 Idler Pulley 5
2 Extension Spring 5
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

262
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

263
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

7. Which idler pulley and spring are you replacing?

The… Then…
Main Drive Go to Replace the Main Drive Idler Pulley and Spring on page 265.
Rewind Drive Go to Replace the Rewind Drive Idler Pulley and Spring on page 266.

264
Replace the Main Drive Idler Pulley and Spring
1. See Figure 122. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 122 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Turn the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. Slide the Idler pulley off of the shaft.

CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
5. See Figure 122 on page 265. Relieve the tension on the spring, and then remove the spring.

6. Install the new spring onto the main drive belt tensioner plate spring mounting post.

7. Install the other end of the spring onto the drive motor bracket spring mounting post.
8. Slide the idler pulley onto the shaft on the main drive tensioner.

9. See Figure 122 on page 265. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

265
 10. Loosen the rewind tensioner locking screw.

11. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

Replace the Rewind Drive Idler Pulley and Spring

1. See Figure 122. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 123 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Turn the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. Turn the rewind drive belt tensioner to extend the spring, and then tighten the locking screw.

266
Figure 124 Remove the Rewind Drive Belt
2
1

3 4

7 6 5

1 Rewind drive belt tensioner

2 Stepper motor pulley
3 Rewind drive belt tensioner locking screw
4 Rewind drive belt
5 Rewind drive belt idler pulley
6 Lower platen pulley
7 Media take-up pulley

5. Slide the rewind drive belt out of the printer.

6. Slide the idler pulley off of the shaft.

CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
7. See Figure 122 on page 265. Relieve the tension on the rewind drive belt spring, and then remove the
spring.

267
Figure 125 Install the Rewind Drive Belt
1

3
4

1 Rewind drive belt

2 Stepper motor pulley
3 Rewind tensioner locking screw
4 Rewind tensioner idler pulley
5 Lower platen roller pulley
6 Rewind spindle pulley

8. Turn the rewind tensioner to extend the spring, and then tighten the locking screw.

9. Slide the rewind belt around the inside pulley on the stepper motor, around the lower platen pulley, and
then around the rewind spindle pulley.
Ensure that the belt is on the inside part of the idler pulley.
10. Loosen the rewind tensioner locking screw.

11. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the rewind tensioner.
12. See Figure 122 on page 265. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

13. Loosen the rewind tensioner locking screw.

14. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

268
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

269
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

270
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

271
Media Path Components
This section supplies you with the parts information and installation procedures for the media handling
options.

272
Media Path Components Parts and Drawings
Figure 126 Media Path Components Overview

3
2

11 7 5
6
8

9
10

273
Table 21 Media Path Overview Kit List
Item Part Number Description
1 P1083320-060 ZT610 Media Supply Spindle Maintenance Kit
P1083320-062 ZT620 Media Supply Spindle Maintenance Kit
2 P1083320-080 ZT610 Ribbon Rollers Maintenance Kit
P1083320-081 ZT620 Ribbon Rollers Maintenance Kit
3 P1083320-063 ZT610 Ribbon Supply Spindle Maintenance Kit
P1083320-064 ZT610 Inside Coated Ribbon Supply Spindle Maintenance Kit
P1083320-065 ZT620 Ribbon Supply Spindle Maintenance Kit
P1083320-066 ZT620 Inside Coated Ribbon Supply Spindle Maintenance Kit
5 P1083320-074 ZT610 Media Guide and Black Mark Sensor Assembly Maintenance Kit
P1083320-075 ZT620 Media Guide and Black Mark Sensor Assembly Maintenance Kit
6 P1083320-034 ZT600 Platen Roller Bearing Retainers Maintenance Kit
7 P1083320-032 ZT610 Upper Platen Roller Maintenance Kit
P1083320-033 ZT620 Upper Platen Roller Maintenance Kit
8 P1083320-072 ZT610 Media Dancer Assembly Maintenance Kit
P1083320-073 ZT620 Media Dancer Assembly Maintenance Kit
9 P1083320-078 ZT610 Peel/Tear Bar Maintenance Kit
P1083320-079 ZT620 Peel/Tear Bar Maintenance Kit
10 P1083320-068 ZT610 Ribbon Take-Up Spindle Maintenance Kit
P1083320-069 ZT620 Ribbon Take-Up Spindle Maintenance Kit
11 P1083320-093 ZT600 Side Plates Maintenance Kit

274
Figure 127 Media Handling System Kits

1 2

4 5 6

7
8

10
9

11

275
Table 22 Media Handling System Kits
Item Part Number Description
1 P1083320-060 ZT610 Media Supply Spindle Maintenance Kit
P1083320-062 ZT620 Media Supply Spindle Maintenance Kit
2 P1083320-080 ZT610 Lower Ribbon Rollers Maintenance Kit
P1083320-081 ZT620 Lower Ribbon Rollers Maintenance Kit
3 P1083320-063 ZT610 Ribbon Supply Spindle Maintenance Kit
P1083320-064 ZT610 Inside Coated Ribbon Supply Spindle Maintenance Kit
P1083320-065 ZT620 Ribbon Supply Spindle Maintenance Kit
P1083320-066 ZT620 Inside Coated Ribbon Supply Spindle Maintenance Kit
4 P1083320-074 ZT610 Media Guide and Black Mark Sensor Assembly Maintenance Kit
P1083320-075 ZT620 Media Guide and Black Mark Sensor Assembly Maintenance Kit
5 P1083320-034 ZT600 Platen Roller Bearing Retainers Maintenance Kit
6 P1083320-032 ZT610 Upper Platen Roller Maintenance Kit
P1083320-033 ZT620 Upper Platen Roller Maintenance Kit
7 P1083320-072 ZT610 Media Dancer Assembly Maintenance Kit
P1083320-073 ZT620 Media Dancer Assembly Maintenance Kit
8 P1083320-078 ZT610 Peel/Tear Bar Maintenance Kit
P1083320-079 ZT620 Peel/Tear Bar Maintenance Kit
9 P1083320-068 ZT610 Ribbon Take-Up Spindle Maintenance Kit
P1083320-069 ZT620 Ribbon Take-Up Spindle Maintenance Kit
10 P1083320-093 ZT600 Side Plates Maintenance Kit
11 P1083320-067 Ribbon Supply Spindle Hardware Maintenance Kit

276
Media Spindle Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Supply Spindle Maintenance
Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 23.

Figure 128 Kit Contents

1 2

Table 23 Parts List

 Item Description Qty
Ref Media Supply Spindle Maintenance Kit
1 Media Supply Spindle Assembly 1
2 Hexalobular Screw, M4 × 8 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Phillips Screwdriver Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

278
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

279
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

280
Remove the Old Media Supply Spindle
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 129. Disconnect the media low sensor cables from J41 and J43 on the main logic board
(MLB).

Figure 129 Main Logic Board Connections

J43
J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41 J41
J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

3. See Figure 130. Remove the MLB by removing the six screws securing it to the printer.

281
Figure 130 Remove the MLB
1

1 Main logic board (MLB)

2 Mounting screws (6)

4. See Figure 131. Align the holes in the back plate with the mounting screws.

282
Figure 131 Align the Media Supply Spindle Mounting Screws
1
2 3

1 Media supply spindle assembly back plate

2 Holes in the back plate (3)
3 Mounting screws (3)

5. See Figure 132. Remove the three media supply spindle mounting screws.

283
 Figure 132 Remove the Media Supply Spindle

1 2

1 Media supply spindle assembly

2 Media low sensor access holes (2)
3 Mounting screws (3)

6. Remove the media supply spindle, while guiding the two media low sensor cables through the access
holes.

Install the New Media Supply Spindle

1. See Figure 132 on page 284. While guiding the media low sensor cables through the pass through
holes align the three media spindle mounting holes with the holes in the main frame.
2. Install the three media supply spindle mounting screws to secure the spindle to the printer.

3. Route the media low cable through all cable clamps that were used when they were removed.

4. See Figure 129 on page 281. Reinstall the MLB and then reconnect all cables.

5. Connect the five pin media low sensor cable connector to J43 on the MLB.
6. Connect the six pin media low sensor cable connector to J41 on the MLB.

284
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

285
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

286
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

287
Media Guide and Black Mark Assembly
Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Guide and Black Mark Sensor
Assembly Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 24.

Figure 133 Kit Contents

3
3

Table 24 Parts List

 Item Description Qty
Ref Media Guide and Black Mark Sensor Assembly Maintenance Kit
1 ZT610 Media Guide Assembly 1
2 ZT620 Media Guide Assembly 1
3 Hexalobular Screw, M3 × 6 2 or 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

289
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

290
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

291
Remove the Old Media Guide
1. See Figure 134. Remove the black mark sensor cable from J44 on the main logic board (MLB).

Figure 134 MLB Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J44

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

2. See Figure 135. Remove and discard the two or three media guide and black mark sensor assembly
mounting screws.

292
Figure 135 Remove the Media Guide Mounting Screws
1

1 Media guide and black mark sensor assembly

2 Mounting screws (2)
3 Mounting holes (2)

3. See Figure 136. While guiding the black mark sensor cable through the access hole, slide the media
guide assembly out of the printer.

293
 Figure 136 Remove the Media Guide and Black Mark Sensor Assembly from the Printer
1 2

1 Media guide and black mark sensor assembly

2 Black mark sensor cable access hole

Install the New Media Guide Assembly

1. See Figure 136. Guide the black mark sensor cable through the access hole while sliding the new
media guide assembly into the printer.
2. See Figure 135 on page 293. Install the two mounting screws.

3. See Figure 134 on page 292. Connect the black mark sensor cable to J44 on the MLB.

294
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

295
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

296
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

297
Side Plates Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Side Plates Maintenance Kit in the
ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts for your printer listed below in Table 25.

Figure 137 Kit Contents

1
2

Table 25 Parts List

 Item Description Qty
Ref Side Plates Maintenance Kit
1 Upper Side Plate Assembly 1
2 Lower Side Plate 1
3 Hexalobular Screw, M3 × 8 11
4 Rewind Side Plate 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Flatblade Screwdriver Set • Long Metric Hex Key Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Which Plate are you installing?
If… Then…
Upper side plate Go to Replace the Upper Side Plate Assembly.
Lower side plate Go to Replace the Lower Side Plate on page 313.
Rewind side plate Go to Replace the Rewind Side Plate on page 317.

Replace the Upper Side Plate Assembly

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon from the printer.

NOTE: Retain all parts removed during disassembly, unless otherwise directed.
1. See Figure 138. Remove the upper ribbon idler roller by removing the mounting screw.

Figure 138 Remove the Upper Idler Roller Mounting Screw

1
2

1 Upper ribbon idler roller

2 Mounting hole
3 Mounting screw

2. See Figure 139. Pull the right side of the upper ribbon idler roller out of the upper print mechanism.

299
Figure 139 Pull the Right Side of the Upper ribbon Idler Roller
3
1 2

1 Upper ribbon idler roller

2 Right side of upper ribbon idler roller
3 Upper print mechanism

3. See Figure 140. Remove the upper ribbon idler roller, bearings, and shaft from the printer.

Figure 140 Remove the Upper Ribbon Idler Roller

-

1 Upper ribbon idler roller

300
4. See Figure 141. Remove the mounting screw from the toggle assembly handle, and then slide the
handle and curved washer of the toggle bar shaft.

Figure 141 Remove the Toggle Assembly Handle

1

4
2

1 Toggle bar
2 Curved washer
3 Toggle handle mounting screw
4 Toggle assembly handle

301
5. See Figure 142. Remove the three screws securing the upper side plate to the printer.

Figure 142 Remove the Upper Side Plate Mounting Screws

1 Upper side plate assembly

2 Mounting screws (3)
3 Lower locating pin
4 Upper locating pin

6. Remove the side plate.

302
7. See Figure 143. Align the new upper side plate assembly with the guide pins and shafts, and then slide
the upper side plate onto the printer.

NOTE: Do not remove or turn the lock screw (item 6 in Figure 143).

Figure 143 Align the Upper Side Plate

1 2
3 4

1 Toggle shaft and bearing

2 Upper guide pin
3 Printhead assembly shaft
4 Lower guide pin
5 Upper side plate assembly
6 Lock screw

8. See Figure 144. Install the three new mounting screws.

303
Figure 144 Install the Mounting Screws

1 Mounting Screws (3)

9. See Figure 141 on page 301. Slide the curved washer and handle on to the toggle bar assembly, and
then install the mounting screw into the handle and tighten.
10. See Figure 145. Reassemble the upper ribbon idler roller.

Figure 145 Reassemble the Upper Ribbon Idler Roller

1
2
1

1 Upper ribbon idler roller bearing (2)

2 Upper ribbon idler roller shaft
3 Upper ribbon idler roller
4 D shape on the shaft toward the printer.

304
11. See Figure 146. Insert the upper ribbon idler roller shaft into the (D) shaped end into the printer main
frame mounting hole.

Figure 146 Insert the Shaft into the Main Frame

1
2 3

1 Main frame mounting hole

2 Upper ribbon idler roller shaft
3 Upper ribbon idler roller

12. Slide the right side of the upper ribbon idler roller into the upper print mechanism.

13. See Figure 138 on page 299. Install the mounting screw and tighten.

305
Adjust the Printhead Assembly
Other than printhead pressure, printhead adjustments rarely need to be performed, even after replacing
the printhead. These adjustments should be performed only by a qualified technician who has been
specifically trained. Do not perform these adjustments unless you have been trained to do so.
• NOTE: The following adjustments are interrelated and may have to be performed more than once to
achieve desired results.
• Printhead Pressure
• Printhead Balance
• Printhead Position
NOTE: To achieve optimum results with print quality adjustments, install full width media and ribbon. Verify
that the media and ribbon are properly matched and the printer is set to the thermal transfer mode before
performing any mechanical adjustments.

306
Adjust the Toggle Position and Pressure
1. Ensure that the is turned off (O).

2. See Figure 147. Set the pressure lock nut against the adjuster nut. Measure the distance between the
bottom of the “U” bracket and the top of the pressure lock nut.

Figure 147 Set the Toggle Pressure and Position

1

1 “U” bracket
2 Position lock nut
3 Pressure lock nut
4 Pressure adjuster
5 Toggle foot
6 Spring
7 For ZT610, set the distance to 9.5mm (0.375 in)
For ZT620, set the distance to 12mm (0.500 in)

3. Tighten the pressure lock nut against the adjuster nut to lock the pressure adjustment.

4. Repeat step 2 and step 3 on the other toggle.

307
 5. Set the toggle positions:
• For the ZT600, set to 20 and 80 on the toggle position scale.
• For the ZT620, set to 40 and 130 on the toggle position scale.
6. Set the toggle pressures:
• To increase the pressure, loosen the pressure lock nut, and then turn the adjuster nut downward.
• To decrease the pressure, loosen the pressure lock nut, and then turn the adjuster nut upward.

Set the Printhead Balance

1. Reinstall the media and ribbon.

2. Press and hold PAUSE while turning on the printer. Pause Key Test Labels will start printing.

3. Press PAUSE to pause the printer.

4. Press SETUP/EXIT to enter the configuration mode, DARKNESS will be displayed.
5. Press Minus (–) to decrease the darkness setting.

6. Press PAUSE to restart the printer. Continue press Minus (–) until the black box on the labels is
charcoal gray.
7. Press PAUSE to stop the printer.

8. Is the black box on the label the same darkness on the left and right?

If… Then…
Yes Go to step 10.
No a. See Figure 148. Loosen the balance plate lock screw slightly.
b. Press PAUSE to restart the printer.
c. Adjust the balance plate:
• clockwise to reduce the pressure on the outboard of the label
• counterclockwise to increase the pressure on the outboard side of the label.
d. When even print quality is achieved, hold the eccentric in position and tighten the
balance plate lock screw.
e. Press PAUSE to stop the printer.
f. Go to step 10.

308
Figure 148 Adjust the Printhead Balance

1 Balance plate lock screw

2 Balance plate eccentric

9. Press PAUSE to restart the printer.

10. Press Plus(+) to increase the darkness setting until the labels are at optimum resolution and contrast.

11. Press PAUSE to stop the printer.

309
Adjust the Printhead Position

Other than printhead pressure, printhead adjustments rarely need to be performed, even after replacing
the printhead. These adjustments should be performed only by a qualified technician who has been
specifically trained. Do not perform these adjustments unless you have been trained to do so.

Adjusting the printhead position moves the printhead with respect to the platen for optimum print quality. If
satisfactory print quality cannot be achieved or can be achieved only with higher than normal darkness
settings or higher than normal printhead pressure, the printhead may not be in the proper position.
1. See Figure 149. Locate the printhead position lock screws through the openings in the upper support
extrusion.
• The ZT610 has 3 screws.
• The ZT620 has 4 screws.

Figure 149 Loosen the Printhead Position Lock Screws

1
1

1 Printhead position lock screws access holes (3)

2. Loosen the printhead position lock screws 1/4 turn each.

3. Engage each printhead position adjustment screw with a 2.5mm hex key.

310
Figure 150

1 Printhead position adjustment screws (2)

4. Press PAUSE to restart the printer.

NOTE: Make very small adjustments and check the results. Turn the screws counterclockwise to move the
printhead toward the front of the printer. Turn the screws clockwise to move the printhead toward the back
of the printer.
5. Adjust the printhead position by turning equally the two screws located at the back of the print
mechanism. Turn both screws one-eighth of a turn clockwise and observe the changes in print quality.
Turn both screws one-sixteenth of a turn counterclockwise and observe the changes in print quality.
When changing directions, due to spring pressure, there may be a dead spot in the actual printhead
movement.
6. Continue to make small adjustments until the best quality is achieved.

7. Decrease the darkness setting until the Pause Key Self Test labels are a charcoal-gray color.

8. Inspect the test labels for streaks and other print quality problems.

9. If required, adjust the printhead position until print quality problems are corrected.

10. Increase the darkness until the Pause Key Self Test labels are printed at optimum resolution and
contrast.
11. Verify that the lines are parallel to the to edge of the label.
If not make slight adjustment on one side or the other.
12. When acceptable print quality is achieved, tighten the 3 or 4 printhead position lock screws at the top of
the printhead.
13. Run additional Pause Key Self Test labels to verify proper positioning.

311
Adjust the Strip Plate
The strip plate can be adjusted to achieve proper ribbon tension and separation of the ribbon from the
media after printing.
1. Print Pause Key Self Test labels.

2. Press PAUSE, wait until the printer pauses, then observe the ribbon for problems such as wrinkling.

3. See Figure 151. Loosen but do not remove the two screws securing the strip plate to the front of the
printhead assembly.

Figure 151 Adjust the Ribbon Strip Plate

1

1 Ribbon strip plate

2 Mounting screws (2)

4. Set the strip plate so the mounting screws are centered in the slots and tighten. Ensure that the ribbon
tracks flat and smoothly.
5. Print a minimum of 25 labels and check for ribbon wrinkle, tracking, and media and ribbon separation
problems. If wrinkle is present, the strip plate can be adjusted to slightly lower either end, depending the
wrinkle pattern.
6. Press SETUP/EXIT, and then press NEXT/SAVE.

7. Go to Resume Printer Operation on page 317.

312
Replace the Lower Side Plate
1. See Figure 152. Open the printhead assembly.

2. Remove the screw and washer securing the platen bearing retainer assembly to the printer.

Figure 152 Remove the Printhead Platen Bearing Retainer Assembly

1 2

3 4

1 Platen bearing
2 Platen bearing retainer
3 Flat washer
4 Mounting screw

3. Remove the platen bearing retainer.

4. Remove the platen bearing.

5. Remove the lower side plate by removing the peel/tear bar mounting screw

313
6. See Figure 153. Remove and discard the four screws securing the lower side plate to the printer.

Figure 153 Remove the Lower Side Plate

1
2
3

1 Lower side plate

2 Peel/tear bar mounting screw
3 Mounting screws (4)

7. Remove and discard the lower side plate.

8. See Figure 154. Align the two guide pins with the new lower side plate, and then slide the lower side
plate onto the guide pins.

314
Figure 154 Align the Lower Side Plate with the Guide Pins
1

1 Guide pins (2)

2 Lower side plate

9. See Figure 155. Align the bearing retainer with the bearing flange, and then insert it over the bearing.

Figure 155 Install the Bearing Retainer

1 Platen roller bearing retainer

2 Bearing
3 Mounting Screw

315
10. Install, but do not tighten, the mounting washer and screw.

11. Lower the upper print mechanism while aligning the locater pin in the bearing retainer with fork in the
upper print mechanism.
12. See Figure 156. Repeatedly close and open the upper print mechanism while adjusting the locater pin
left or right until the mechanism moves freely.

Figure 156 Adjust the Fork and Locater Pin

1

1 Upper print mechanism

2 Platen roller bearing retainer
3 Mounting Screw
4 Locating pin
5 Locating fork

13. Tighten the bearing retainer mounting screw.

14. Verify that the upper print mechanism move freely. If not repeat step 12 and step 13 until it does.

15. Go to Resume Printer Operation on page 317.

316
Replace the Rewind Side Plate
1. See Figure 157. Remove and discard the two rewind side plate mounting screws.

Figure 157 Remove the Rewind Side Plate

1 Rewind side plate

2 Mounting screws (2)
3 Mounting holes (2)

2. Remove and discard the rewind side plate.

3. Align the new rewind plate wit the mounting holes. and then install and tighten the two new mounting
screws.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

317
Media Dancer Assembly Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Dancer Assembly
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 26.

Figure 158 Kit Contents

Table 26 Parts List

 Item Description Qty
Ref Media Dancer Assembly Maintenance Kit
1 Media Dancer Assembly 1
2 Screw, M3 × 0.5 × 6 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Needle Nose Pliers
• Metric Hex Key Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Old Dancer Assembly
Turn off (O) the printer and disconnect it from the power source before performing the following procedure.
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon.

3. See Figure 159. Relieve the spring tension on the media dancer assembly by removing the spring hook
from the hole in the main frame.

Figure 159 Remove the Spring Tension

1
2

1 Tensioning spring hook

2 Tensioning hole

319
4. See Figure 160. Remove and discard the three media dancer assembly mounting screws.

Figure 160 Remove the Mounting Screws

2
1

1 Media dancer assembly

2 Mounting screws (3)

5. See Figure 161. Remove and discard the media dancer assembly from the printer.

Figure 161 Remove the Media Dancer Assembly

1 Media dancer assembly

320
Install the New Media Dancer Assembly
1. See Figure 161 on page 320.Holding the spring vertically, slide the new media dancer into the printer.

2. Install the three new media dancer mounting screws.

3. See Figure 160 on page 320. Apply spring tension by hooking the spring into the spring tension hole in
the mainframe.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

321
Ribbon Supply Spindle Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Ribbon Supply Spindle Maintenance
Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 27.

Figure 162 Kit Contents

1
2

Table 27 Parts List

 Item Description Qty
Ref Ribbon Supply Spindle Maintenance Kit
Inside Coated Ribbon Supply Spindle Maintenance Kit
1 Ribbon Supply Spindle 1
2 Hexalobular Screw, M4 × 12 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

323
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

324
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

325
Remove the Old Ribbon Supply Spindle
1. Disconnect the ribbon low sensors from J42 and J46 on the main logic board (MLB).

Figure 163 Main Logic Board Connections

J42

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J46

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

2. See Figure 164. Remove the three mounting screws securing the ribbon supply spindle to the printer
through the access holes in the MLB.

326
Figure 164 Remove the Ribbon Supply Spindle
1

3
2

1 Ribbon supply spindle

2 MLB access holes (3)
3 Mounting holes (3)

3. While guiding the ribbon low sensor cables through the access holes in the printer main frame, remove
the ribbon supply spindle from the printer.
4. See Figure 165. If installed, remove the two screws securing the ribbon low sensors to the ribbon
supply spindle.

327
Figure 165 Remove the Ribbon Low Sensors
1
2

3
4

Ribbon low sensor

1 Ribbon supply spindle

2 Ribbon low sensor
3 Mounting screws (2)
4 Ribbon quad sensor

5. Discard the ribbon low sensors.

328
Install the New Ribbon Supply Spindle
1. Remove the new ribbon supply spindle from the maintenance kit.

Figure 166 Install the Ribbon Supply Spindle

1 Ribbon supply spindle

2 Mounting screws (3)
3 Mounting holes (3)

2. See Figure 164 on page 327. Install the three mounting screws to secure the ribbon supply spindle to
the printer through the three access holes in the MLB.
3. Route the ribbon low sensor cables through the cables clamps they came through at removal.

4. Connect the five pin ribbon low sensor cable connector to J41 on the MLB.

5. Connect the six pin ribbon low sensor cable connector to J48 on the MLB.

329
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

330
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

331
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

332
Ribbon Supply Spindle
Hardware Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Ribbon Supply Spindle Hardware
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 28.

Figure 167 Kit Contents

1
2
3 4

8
6 5

Table 28 Parts List

 Item Description Qty
Ref Ribbon Supply Spindle Hardware Maintenance Kit
1 Ribbon Supply Blade, 2.363 1
2 Ribbon Supply Blade,1.688 3
3 Ribbon Supply Blade, 0.750 1
4 Screw, 4-40 × 0.12 10
5 Nut, 3/8-24 1
6 Spring Housing 1
7 Torsion Spring (for outside coated ribbon) 1
8 Torsion Spring (for inside coated ribbon) 1
9 Compression Spring 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Spring Tension Gauge • Ribbon Roll Core
• Metric Hex Key Set • Adjustment Tape
• Metric Open End Wrench Set

334
Replace the Ribbon Supply Hardware
NOTE: Retain all parts removed during disassembly, unless otherwise directed.

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon.

3. See Figure 168. Remove and discard the nut, spring housing, torsion spring, and compression spring.
Retain the two flat washers and bearing.

Figure 168 Remove the Ribbon Supply Spindle Hardware

1 2 4
3

5 6
7
8 9
10
11

1 Mounting screw (4 for ZT610 and 6 for 7 Torsion spring (for outside coated or
ZT620) inside coated ribbon)
2 Long blade 8 Bearing (retained)
3 Shorter blade 9 Flat washer (retained)
4 Shortest blade 10 Spring housing
5 Compression spring 11 Nut
6 Flat washer (retained)

1. Remove and discard the blades and the mounting screws.

335
 2. Install the new blades and mounting screws.

3. Install the compression spring, flat washer, bearing, flat washer, proper torsion spring, spring housing,
and nut.

Adjust the Ribbon Supply Spindle

1. See Figure 169. Align the sections of the spindle, and then install a 1-inch inside-diameter cardboard
core on the spindle.

Figure 169 Adjust the Ribbon Supply Spindle Tension

2

1 3

4 5

1 Ribbon supply spindle

2 Align the plates
3 Core
4 Mylar strip

1. Push the spring housing in to increase the tension. Let the cap move out to decrease the tension.

2. Use adhesive tape to attach a 2 inch wide strip of polyester strip to the core. Wind the polyester strip
around the core about 5 times in the direction shown.
3. Slowly and evenly, at about 2 inches per second, pull the strip of polyester using a spring scale. The
rotation of the spindle should be smooth and should not cause the reading on the spring scale to move
excessively.
4. Compare the spring scale reading with the load values provided.

Table 29 Ribbon Supply Spindle Tensions

Model ZT610 ZT620
(Grams) (Grams)
Tension (Grams) 450 ±50 500 ±50

5. Turn the adjustment nut clockwise to increase the tension or counter clockwise to decrease.

336
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

337
Ribbon Take-Up Spindle Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Ribbon Take-Up Spindle
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 30.

Figure 170 Kit Contents

1 2
3
4 6 7
5

Table 30 Parts List

 Item Description Qty
Ref ZT610 Ribbon Take-Up Spindle Maintenance Kit
1 E-ring 1
2 Spacer 1
3 Flat Washer, 0.76 × 0.51 × 0.03 1
4 Wave Washer, 0.74 × 052 × 0.08 1
5 Screw, 8-32 × 0.38 3
6 Flat Washer, 0.375 × 0.172 × 0.048 3
7 Bearing Housing 1
8 Ribbon Take-Up Spindle 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Metric Hex Key Set • Safety Glasses

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

339
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

340
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

341
Remove the Old Ribbon Take-Up Spindle
CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
1. See Figure 171. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 171 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. See Figure 172. Remove the ribbon take-up pulley by removing and discarding the E-ring from the
ribbon take-up spindle shaft.

342
Figure 172 Remove the Ribbon Take-Up Pulley

5
2 3 4
6

1 Ribbon take-up spindle shaft

2 Wave washer
3 Flat washer
4 Spacer
5 Ribbon take-up spindle pulley
6 E-ring

5. Slide the pulley off of the ribbon take-up spindle shaft.

6. Remove and discard the spacer, flat washer, and wave washer from the ribbon take-up spindle shaft.

7. See Figure 173. Slide the ribbon take-up spindle out of the bearing housing.

343
Figure 173 Remove the Ribbon Take-Up Spindle
1

1 Ribbon take-up bearing housing

2 Ribbon take-up spindle

8. See Figure 174. From the electronics side, remove and discard the three bearing housing mounting
screws and flat washers.

344
 Figure 174 Remove the Ribbon Spindle Bearing Housing

1 2

1 Mounting screws (3)

2 Mounting flat washers (3)
3 Ribbon take-up bearing housing

Install the New Ribbon Take-Up Spindle

1. See Figure 174. Align the new ribbon take-up spindle bearing housing with the mounting holes in the
printer main frame.
2. From the electronics side, install the three new flat washers and mounting screws.

3. See Figure 173 on page 344. Slide the new ribbon take-up spindle into the bearing housing.

4. See Figure 172 on page 343. Install the wave washer, flat washer onto the ribbon take-up spindle shaft.
5. Install the ribbon take-up spindle pulley, and then install the new e-ring.

6. See Figure 171 on page 342. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

NOTE: Ensure that the belt is on the inside part of the idler pulley.

7. Loosen the main tensioner locking screw.

8. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

345
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

346
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

347
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

348
Ribbon Rollers Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Ribbon Rollers Maintenance Kit in
the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed in Table 31 on page 350.

Figure 175 Kit Contents

2 1

5 2

6
4
7

7
2

8
2
3

1
10

11

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 31 Parts List
 Item Description Qty
Ref Ribbon Rollers Maintenance Kit
1 Upper and Lower Ribbon Idler Roller Shaft 2
2 Upper and Lower Ribbon Idler Roller Bearings 4
3 Hexalobular Screw, M3 × 8 2
4 Upper and Lower Ribbon Idler Roller 2
5 Hexalobular Screw, M4 × 8 3
6 Ribbon Roller Shaft Assembly 1
7 Flat Washer, 18OD × 10.5ID × 1.6 2
8 E-Ring 1
9 Ribbon Roller 1
10 ZT610R Lower Ribbon Idler Roller, only used in ZT610R 1
11 ZT610R Lower Ribbon Idler Roller Shaft, only used in ZT610R 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Antistatic Wriststrap and Mat
• Hexalobular Wrench Set
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

Remove the Old Ribbon Rollers

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon from the printer.

3. Which ribbon rollers are you replacing? Go to all that you are replacing.

If you have a… Then…

Ribbon roller Go to Remove the Old Ribbon Roller.
Upper idler Go to Remove the Old Upper Ribbon Idler Roller on page 358.
Lower idler non-RFID Go to Remove the Old Lower Ribbon Idler Non-RFID Roller on page 363.
Lower ZT610R idler Go to Remove the ZT610R Lower Ribbon Idler Roller on page 364.

350
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

351
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

352
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

353
Remove the Old Ribbon Roller
CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
1. See Figure 176. Remove the ribbon roller by removing the E-ring.

Figure 176 Remove the Ribbon Roller

2
3
2
4

1 Ribbon roller shaft assembly

2 Flat washer (2)
3 Ribbon roller
4 E-ring

2. Slide the flat washer, roller, and flat washer off of the ribbon roller shaft assembly.

3. See Figure 177. From the electronics side, remove and discard the three ribbon roller shaft assembly
mounting screws.

354
 Figure 177 Remove the Ribbon Roller Shaft Assembly

1 Ribbon roller shaft assembly

2 Mounting screws (3)
3 Ribbon roller shaft assembly mounting pems (3)

4. Pull the ribbon roller shaft assembly out of the printer and discard it.

Install the New Ribbon Roller Assembly

1. See Figure 177. Insert the new ribbon roller shaft assembly into the printer and over the mounting
pems.
2. Install the three new mounting screws.

3. See Figure 176 on page 354. Slide the new flat washer, roller, and flat washer onto the ribbon roller
shaft assembly.
4. Install the new E-ring.

355
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

356
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

357
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Remove the Old Upper Ribbon Idler Roller

1. See Figure 178. Remove the upper ribbon idler roller by removing the mounting screw.

358
Figure 178 Remove the Upper Idler Roller Mounting Screw
1
2

1 Upper ribbon idler roller

2 Mounting hole
3 Mounting screw

359
2. See Figure 179. Pull the right side of the upper ribbon idler roller out of the upper print mechanism.

Figure 179 Pull the Right Side of the Upper Ribbon Idler Roller
3
1 2

1 Upper ribbon idler roller

2 Right side of upper ribbon idler roller
3 Upper print mechanism

3. See Figure 180. Remove the upper ribbon idler roller, bearings, and shaft from the printer.

360
 Figure 180 Remove the Upper Ribbon Idler Roller

1 Upper ribbon idler roller

Install the New Upper Ribbon Idler Roller

1. See Figure 181. Assemble the upper ribbon idler roller.

Figure 181 Assemble the Upper Ribbon Idler Roller

1
2
1
3

1 Upper ribbon idler roller bearing (2)

2 Upper ribbon idler roller shaft
3 Upper ribbon idler roller
4 D-shape on the shaft

361
2. See Figure 182. Insert the upper ribbon idler roller shaft into the (D) shaped end into the printer main
frame mounting hole.

Figure 182 Insert the Shaft into the Main Frame

1
2 3

1 Main frame mounting hole

2 Upper ribbon idler roller shaft
3 Upper ribbon idler roller

3. See Figure 179 on page 360. Slide the right side of the upper ribbon idler roller into the upper print
mechanism.
4. See Figure 178 on page 359. Install the new mounting screw and tighten.

362
Remove the Old Lower Ribbon Idler Non-RFID Roller
1. Remove the media and ribbon from the printer.

2. See Figure 183. Remove the lower non-RFID ribbon idler roller and shaft.

Figure 183 Remove the Non-RFID Ribbon Idler

1 Non-RFID lower ribbon idler roller mounting screw

2 Non-RFID lower ribbon idler roller, bearings (2), and
shaft

Install the Lower Ribbon Idler Non-RFID Roller

1. See Figure 181 on page 361. Assemble the lower ribbon idler roller.

2. See Figure 183. Install the new lower ribbon idler roller, and then install the new mounting screw.

363
Remove the ZT610R Lower Ribbon Idler Roller
1. Remove the media and ribbon from the printer.

2. See Figure 184. Remove the lower ZT610R ribbon idler roller and shaft.

Figure 184 Remove the ZT610R Ribbon Idler Roller

1 Lower ZT610R ribbon idler roller mounting screw

2 Lower ZT610R ribbon idler roller

3. See Figure 185. Assemble the lower ZT610R ribbon idler roller.

Figure 185 Assemble the Lower ZT610R Ribbon Idler Roller

1

1 Lower ZT610R ribbon idler roller shaft

2 Lower ZT610R ribbon idler roller

364
 4. See Figure 186. Insert the lower ZT610R ribbon idler roller D-shaped end into the mounting hole in the
printhead pivot bracket.

Figure 186 Insert the Shaft into the Printhead Pivot Bracket

1 Printhead pivot bracket

2 D-shaped mounting hole

5. See Figure 184 on page 364. Install the ZT610R lower ribbon idler roller mounting screw.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

365
Upper Platen Roller Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Upper Platen Roller Maintenance Kit
into the ZT600 Series Printers.
Before proceeding, verify that your kit contains the items for your printer listed below in Table 32.

Parts List
Figure 187 Kit Contents
1

Table 32 Parts List

 Item Description Qty
1 Platen Roller Assembly 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

367
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

368
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

369
Remove the Old Upper Platen Roller
1. See Figure 188. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 188 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

370
4. See Figure 189. Loosen, but do not remove, the screw in the platen pulley assembly.

Figure 189 Remove the Upper Platen Roller Pulley

1 Upper Platen pulley

2 Platen pulley set screw
3 Platen roller shaft

5. Remove the platen pulley from the platen roller shaft.

6. From the media side.

7. Open the upper print mechanism.

371
8. See Figure 190. Loosen the captive mounting screw securing the bearing retainer to the lower print
mechanism.

Figure 190 Remove the Bearing Retainer

1

1 Platen roller assembly

2 Platen bearing retainer
3 Platen bearing retainer captive mounting screw

372
9. See Figure 191. Remove the upper platen roller from the printer by sliding the platen roller assembly
toward the outside of the printer until the bearings clear their mounting holes.

Figure 191 Remove the Platen Roller

2
6 5 3

1 Platen roller assembly

2 Bearings (2)
3 Bearing retainer mounting screw
4 Bearing retainer
5 Side plate platen roller mounting hole
6 Main frame platen roller mounting hole

10. Lift the platen roller out of the printer.

373
Install the New Upper Platen Roller
1. See Figure 192. Start the platen roller shaft into the mounting hole in the main frame.

Figure 192 Insert the Platen Roller Shaft

3 1

1 Platen roller assembly

2 Main frame
3 Main frame mounting hole

2. Slide the platen roller into the platen mounting hole until the bearing is aligned with the mounting hole.

374
3. See Figure 193. Align both bearings with the mounting hole in the main frame and the side plate, and
then insert the two bearings into the mounting holes.

Figure 193 Insert the Bearings into the Mounting Holes

1

2
3
5

1 Platen roller assembly

2 Side plate mounting hole
3 Side plate bearing
4 Main frame bearing
5 Main frame mounting hole

375
4. See Figure 194. Align the bearing retainer with the bearing flange, insert it over the bearing.

Figure 194 Install the Bearing Retainer

1 Platen roller bearing retainer

2 Mounting Screw
3 Bearing

5. Slightly tighten the mounting washer and screw.

6. Lower the upper print mechanism while aligning the locater pin in the bearing retainer with fork in the
upper print mechanism.

376
Align the Fork and Locater Pin
1. Repeatedly close and open the upper print mechanism while adjusting the locater pin from front to rear
until the mechanism moves freely.

Figure 195 Align the Fork

1

3 2

1 Upper print mechanism

2 Platen roller bearing retainer
3 Mounting Screw
4 Locating pin
5 Locating fork

2. Tighten the bearing retainer mounting screw.

3. Verify that the upper print mechanism moves freely. If not repeat step 1 and step 2 until it does.

4. See Figure 189 on page 371. Reinstall the upper platen roller pulley to the upper platen roller shaft.

5. Tighten the pulley mounting screw.

6. See Figure 188 on page 370. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

7. Ensure that the belt is on the inside part of the idler pulley.
8. Loosen the rewind tensioner locking screw.

9. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

377
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

378
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

379
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

380
 Platen Bearing Retainers Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Platen Bearing Retainers
Maintenance Kit into the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit in Table 33.

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

Figure 196 Kit Contents

1 2

Table 33 Parts List

 Item Description Qty
1 ZT610 Upper Platen Roller Bearing Retainer 1
2 ZT620 Upper Platen Roller Bearing Retainer 1
3 Lower Platen Roller Bearing Retainer 1
4 Hexalobular Screw, M3 × 10 1
5 Hexalobular Captive Screw 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set

Which Bearing retainer are you replacing?

If… Then…
Upper Platen Roller Go to Remove the Old Upper Platen Bearing Retainer.
Lower Platen Roller Go to Remove the Old Lower Platen Roller Bearing Retainer on page 385.

Remove the Old Upper Platen Bearing Retainer

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.
2. Remove the media and ribbon.

3. See Figure 197. Loosen the captive mounting screw securing the bearing retainer to the lower print
mechanism.

Figure 197 Remove the Bearing Retainer

1

1 Platen roller assembly

2 Platen bearing retainer
3 Platen bearing retainer captive mounting screw
4 Side plate

4. Pull out slightly and continue to unscrew the captive mounting screw until it unscrews from the side
plate.

382
Install the New Upper Platen Bearing Retainer
1. See Figure 198. Align the bearing retainer with the bearing flange, and then insert retainer over the
bearing flange.

Figure 198 Install the Bearing Retainer

1

3 1

1 Platen roller bearing retainer

2 Captive mounting screw
3 Bearing

2. Install the captive mounting screw through the side plate.

3. Push the screw further into the printer until it stops.

4. Secure the captive screw into the printer until it is snug.

5. See Figure 199 on page 384. Lower the upper print mechanism while aligning the locater pin in the
bearing retainer with fork in the upper print mechanism.

383
Align the Fork and Locater Pin
1. See Figure 199. Repeatedly close and open the upper print mechanism while adjusting the locater pin
left or right until the mechanism moves freely.

IMPORTANT: Even slight contact can influence the printhead position.

Figure 199 Adjust the Locater Pin

1
4

1 Upper print mechanism

2 Platen roller bearing retainer
3 Mounting Screw
4 Locating pin
5 Locating fork

2. Tighten the bearing retainer mounting screw.

3. Verify that the upper print mechanism moves freely. If does not, repeat step 1 and step 2 until it does.
4. Reinstall the media and ribbon.

5. Reconnect the AC power cord and all cables.

6. Turn On (I) the printer.

7. Are you replacing the lower bearing retainer?

If… Then…
No 8. Reinstall the media and ribbon.

9. Go to Resume Printer Operation on page 386

Yes Go to Install the New Lower Platen Roller Bearing Retainer on page 386.

384
Remove the Old Lower Platen Roller Bearing Retainer
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.
2. Remove the media and ribbon.

3. See Figure 200. Remove the lower bearing retainer mounting screw, and then remove the bearing
retainer.

Figure 200 Remove the Lower Platen Roller Bearing Retainer

1 Mounting screw
2 Bearing retainer
3 Bearing

385
Install the New Lower Platen Roller Bearing Retainer
1. See Figure 201. Align the bearing retainer with the bearing flange, and then insert it over the bearing

Figure 201 Install the Lower Platen Roller Bearing Retainer

2
1

1
3

1 Bearing retainer
2 Bearing
3 Mounting screw

2. Install the mounting screw.

Resume Printer Operation

1. Reinstall media and ribbon (if used).
2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

386
Peel/Tear Bar Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Peel/Tear Bar Maintenance Kit in the
ZT600 Series Printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 34.

Figure 202 Kit Contents

1

Table 34 Parts List

 Item Description Qty

Ref Peel/Tear Bar Maintenance Kit
1 Peel/Tear Bar 1
2 Screw, M3 × 8 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Feeler Gauge with 0.003 inch (0.075 mm)

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

388
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

389
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

390
Remove the Main Drive Belt and Pulley
1. See Figure 203. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 203 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Rotate the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. Loosen, but do not remove, the set screw in the platen pulley assembly.

391
Figure 204 Remove the Platen Pulley

1 Platen pulley
2 Platen pulley set screw
3 Platen roller shaft

5. Remove the platen pulley from the platen roller shaft.

392
Remove the Old Peel/Tear Bar
1. From the electronics side, remove the peel/tear bar mounting screw.

Figure 205 Remove the Mounting Screw (electronics side)

1

1 Peel/tear bar mounting screw

2. See Figure 206. From the media side, remove the peel/tear bar mounting screw.

Figure 206 Remove the Peel/Tear Bar Mounting Screw

1
2

1 Peel/tear bar
2 Peel/tear bar mounting screw

393
 3. See Figure 207. Remove the peel/tear bar from the printer.

Figure 207 Slide the Peel/Tear Bar Out of the Printer

Install the New Peel/Tear Bar

1. See Figure 208. Install the peel/tear bar into the printer.

Figure 208 Install the Peel/Tear Bar

394
2. See Figure 209. Ensure that the orientation line is facing up and is nearest the printer main frame.

Figure 209 Orientation of the Peel/Tear Bar

1 Printer main frame

2 Peel/Tear bar
3 Orientation line

3. See Figure 210. Align the peel /tear bar with the mounting holes and install one of the new mounting
screws. Do not tighten at this time.

395
Figure 210 Install the Media Side Mounting Screw

1 Mounting screw

4. Install the other mounting screw. Do not tighten at this time.

Figure 211 Install the Electronics Side Mounting Screw

1 Mounting screw

5. Insert the 0.003 inch (0.075 mm) feeler gauge between the peel/tear bar and the platen roller.
Ensure that the clearance is equal along the length of the platen roller.

396
Figure 212 Set Peel/Tear Bar Gap

1
2

1 Feeler gauge (0.003 inch or 0.075 mm)

2 Peel/tear bar
3 Mounting screw

6. Tighten both mounting screws.

397
Reinstall the Platen Pulley and Main Drive Belt
1. See Figure 213. Slide the platen pulley onto the shaft, and tighten the set screw.

Figure 213 Reinstall Platen Pulley

1 Platen roller shaft

2 Platen roller pulley

2. See Figure 203 on page 391. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

3. Slide the main drive belt out of the printer.

4. Ensure that the belt is on the inside part of the idler pulley.

5. Loosen the rewind tensioner locking screw.

6. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

398
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

399
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

400
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

401
Media Handling Option Parts and Drawings
Figure 214 Media Handling Options Kits
1 2 3

6
7
5
4

11 12
9 10

402
Table 35 Kit Parts List
Item Part Number Description
1 P1083320-118 ZT610 Cutter Option Kit
P1083320-119 ZT620 Cutter Option Kit
2 P1083320-088 ZT610 Cutter Cover with PCBA Maintenance Kit
P1083320-089 ZT620 Cutter Cover with PCBA Maintenance Kit
3 P1083320-086 ZT610 Cutter Catch Tray
P1083320-087 ZT620 Cutter Catch Tray
4 P1083320-059 ZT610 Media Hanger Option/Maintenance Kit
P1083320-061 ZT620 Media Hanger Option/Maintenance Kit
5 P1083320-084 ZT610 Rewind Option Kit, 4 inch
P1083320-085 ZT620 Rewind Option Kit, 6 inch
6 P1083320-070 ZT610 Ribbon Rewind Spindle Maintenance Kit
P1083320-071 ZT620 Ribbon Rewind Spindle Maintenance Kit
7 P1006121 ZT610 J-Hook (2)
P1006122 ZT620 J-Hook (2)
8 P1083320-090 ZT610 Media Rewind Plate Maintenance Kit
P1083320-091 ZT620 Media Rewind Plate Maintenance Kit
9 P1083320-058 Rewind Drive System Maintenance Kit
10 P1083320-103 ZT610 Rewind Roller Maintenance Kit
P1083320-104 ZT620 Rewind Roller Maintenance Kit
11 P1083320-113 ZT610 Media 40 mm Supply Spindle Maintenance Kit
P1083320-114 ZT620 Media 40 mm Supply Spindle Maintenance Kit
12 P1100732 ZT610/ZT620 Offset Printing Kit

403
Cutter Option Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Cutter Option Kit into the ZT600
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 in Table 36 on page 404.

Figure 215 Kit Contents

1
2

7 3 3
4 4

6
5

Table 36 Kit Parts List

 Item Description Qty
Ref Cutter Option Kit
1 Cutter Assembly 1
2 Screw, M3 × 8 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 36 Kit Parts List
 Item Description Qty
3 Mounting Nut, M3 2
4 Flat Washer, M3 2
5 Lower Mounting Bracket 1
6 Media Loading Label 1
7 Cutter Cable 1
8 Cutter Catch Tray Kit 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Phillips Screwdriver Set • Safety Glasses
• Hexalobular Wrench

405
Remove the Tear-Off Front Trim Panel
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon.

3. See Figure 216. Remove the two tear-off front trim panel mounting screws.

Figure 216 Remove the Tear-Off Front Trim Panel

1
2

1 Tear-off front trim panel

2 Tear-off front trim panel mounting screws (2)

4. Tip the top of the tear-off front trim panel forward, and then slide the tear-off front panel out of the
printer.

406
Install the Cutter Option
CAUTION: The cutter blade is sharp. Do not touch or rub the blade with your fingers.
1. Remove the cutter mounting bracket from the kit.

2. See Figure 217. Align the bracket with the printer mounting plate so that it does not interfere with any of
the other mounting hardware.
3. Slide the bracket onto the two mounting studs, and then install the two flat washers and mounting nuts.

Figure 217 Install the Cutter Lower Mounting Bracket

1 Cutter mounting bracket

2 Cutter mounting bracket mounting studs (2)
3 Cutter mounting bracket flat washers (2)
4 Cutter mounting bracket nuts (2)

407
4. See Figure 218. While holding the cutter assembly, connect the cutter cable to the connector on the
printer main frame.

Figure 218 Connect the Cutter Cable

2
1

1 Cutter assembly
2 Cutter cable connector

408
5. See Figure 219. Align the cutter assembly and cutter cover tabs with the slots in the printer, and then
slide the cutter assembly into the printer.

Figure 219 Install the Cutter Assembly

2
1

5 5

1 Cutter assembly
2 Cutter assembly mounting slots
3 Cutter motor hole
4 Cutter motor
5 Cutter cover mounting slots (2)
6 Cutter cover tabs (2)
7 Cutter assembly tabs (2)

409
6. See Figure 220. Slide the cutter assembly to the left, and then install the cutter mounting screw.

Figure 220 Install the Cutter Mounting Screw

1
1 2
2

1 Cutter assembly mounting bracket

2 Cutter mounting screw

410
7. See Figure 221. Place the catch tray in the cutter catch tray mounting slot of the cutter cover assembly.
Let the pivot bracket rest against the cutter cover.

Figure 221 Cutter Catch Tray

3
4

1 Cutter assembly
2 Cutter cover assembly
3 Cutter catch tray mounting slot
4 Cutter catch tray pivot bracket
5 Cutter catch tray

411
8. See Figure 222. Adjust the cutter tray rail and stops for your media width and length.

Figure 222 Adjust the Cutter Tray

1 Movable rail
2 Movable stops (2)

412
Apply the Label
1. Remove the media loading label from the kit.

2. See Figure 223. Install the label on the inside top of the media door. Align and center the media loading
label with the hinges on the media door.

Figure 223 Install the Media Loading Label

1
2

1 Media door
2 Media loading label
3 Hinges

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

413
Cutter Cover and Printed Circuit Board Assembly
(PCBA) Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Cutter Cover and PCBA
Maintenance Kit onto the ZT600 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 in Table 37 on page 415.

Figure 224 Kit Contents

1

3 5
6
4 7 3

9 10

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 37 Kit Parts List
 Item Description Qty
Ref Cutter Cover with PCBA Maintenance Kit
1 Cutter Cover and PCBA 1
2 Cutter Cable 1
3 Screw, M3 × 0.5 × 6 4
Replacement parts for parts damaged during the installation of the cutter cover and PCBA or previously
damaged.
4 Outer Mounting Bracket 1
5 Inner Mounting Bracket 1
6 Flat Washer, M3 2
7 Lock Washer, M3 2
8 Lower Mounting Bracket 1
9 Flat Washer 2
10 Mounting Nut, M3 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Phillips Screwdriver • Safety Glasses

415
Remove the Cutter Catch Tray
1. See Figure 225. Lift up on cutter catch tray and pull away from the cutter.

Figure 225 Cutter Catch Tray

1

3
4

1 Cutter assembly
2 Cutter cover assembly
3 Cutter catch tray mounting slot
4 Cutter catch tray pivot bracket
5 Cutter catch tray

416
Remove the Cutter Assembly
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon.

3. Open the media side of the printer.

4. See Figure 226. Remove the cutter mounting screw.

Figure 226 Remove the Cutter Mounting Screw

1

1 Cutter assembly
2 Cutter assembly mounting screw

5. Slide the cutter assembly to the right, and then remove it from the printer.

417
Remove the Old Cutter Cover and PCBA
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

CAUTION: The cutter blade is sharp. Do not touch or rub the blade with your fingers.
2. Remove the cutter assembly.

3. See Figure 227. Remove the cutter cover and PCBA by removing the two cutter cover assembly
mounting screws.

Figure 227 Remove the Cutter Cover

1
2
3

1 Cutter cover assembly

2 PCBA
3 Cutter assembly
4 Cutter cover assembly mounting screws (2)

418
4. See Figure 228. Disconnect the cutter cable and motor cable from the PCBA.

Figure 228 Disconnect Cables

1 2

1 Cutter motor cable connector

2 Cutter cable connector

419
Install the New Cutter Cover and PCBA Assembly
1. See Figure 227 on page 418. Install the new cutter cover and PCBA onto the cutter assembly by
aligning the mounting studs on the cover with the mounting hole in the cutter assembly.
2. See Figure 228. Connect the cutter cable and the cutter motor cable to the PCBA.

Reinstall the Cutter Assembly

1. See Figure 229. Align the cutter assembly and cutter cover tabs with the slots in the printer, and then
slide the cutter assembly into the printer.

Figure 229 Install the Cutter Assembly

1 2

1 Cutter assembly
2 Cutter assembly mounting slots
3 Cutter motor hole
4 Cutter motor
5 Cutter cover mounting slots (2)
6 Cutter cover tabs (2)
7 Cutter assembly tabs (2)

2. See Figure 226 on page 417. Slide the cutter assembly to the left, and then install the cutter mounting
screw.
3. See Figure 225 on page 416. Place the catch tray in the cutter catch tray mounting slot of the of cutter
cover assembly. Let the pivot bracket rest against the cutter cover.

420
4. See Figure 230. Adjust the cutter tray rail and stops for your media width and length.

Figure 230 Adjust the Cutter Tray

1

1 Movable rail
2 Pivot bracket lock nuts (2)
3 Movable stops (2)

5. Loosen the two pivot bracket lock nuts and adjust the angle of the cutter tray off the cutter module.

421
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

422
Magnetic Cutter Tray Maintenance/Option Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Magnetic Cutter Catch Tray Kit into
the ZT600 Series Printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed below in Table 38.

Figure 231 Kit Contents

Table 38 Parts List

 Item Description Qty
Ref Magnetic Cutter Catch Tray 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Install the Cutter Catch Tray
1. See Figure 232. Place the catch tray in the cutter catch tray mounting slot of the cutter cover assembly.
Let the pivot bracket rest against the cutter cover.

Figure 232 Cutter Catch Tray

1

5
3
4

1 Cutter assembly
2 Cutter cover assembly
3 Cutter catch tray mounting slot
4 Cutter catch tray pivot bracket
5 Cutter catch tray angle knurled nuts (2)
6 Cutter catch tray

424
2. See Figure 233. Adjust the cutter tray rail and stops for your media width and length.

Figure 233 Adjust the Cutter Catch Tray

1

1 Movable rail
2 Pivot bracket lock nuts (2)
3 Pivot bracket
4 Movable stops (2)

3. Loosen the two pivot bracket lock nuts and adjust the angle of the cutter tray.

425
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

426
Media Hanger Option/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Hanger Option/Maintenance
Kit in the ZT600 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 in Table 39.

Figure 234 Kit Contents

Table 39 Parts List

 Item Description Qty
Ref Media Hanger Option/Maintenance Kit
1 Hanger Assembly 1
2 Hexalobular Screw, M4 × 8 4
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

428
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

429
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

430
7. See Figure 235. Disconnect the media low sensor cables from J41 and J43 on the main logic board
(MLB).

Figure 235 Main Logic Board Connections

J43
J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18

J41
J44

J41

J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

Are you replacing a media spindle?

If… Then…
Yes Go to Install the Media Hanger on page 435.
No Go to Replace the Media Hanger on page 435.

431
Remove the Media Supply Spindle
1. See Figure 1. Go to the media side and align the holes in the media supply spindle back plate with the
mounting screws.

Figure 236 Align the Media Supply Spindle Mounting Screws

1
2 3

1 Media supply spindle assembly back plate

2 Holes in the back plate (3)
3 Mounting screws (3)

432
2. See Figure 237. Remove the three media supply spindle mounting screws.

Figure 237 Remove the Media Supply Spindle

1 2

1 Media supply spindle assembly

2 Media low sensor access holes (2)
3 Mounting screws (3)

3. Remove the media supply spindle, while guiding the two media low sensor cables through the access
holes.

433
Install the Media Supply Hanger
1. See Figure 238. Align the media hanger mounting holes with the four mounting holes in the printer main
frame.

Figure 238 Install the Media Hanger

1 Media hanger
2 Mounting screws (4)
3 Media hanger mounting holes (4)
4 Printer main frame mounting holes (4)

2. Install the four mounting screws from the kit through the media hanger and into the four mounting hole
in the printer main frame.
3. Tighten the four mounting screws.

434
Replace the Media Hanger
Remove the Media Hanger
1. See Figure 239. Remove the four media hanger mounting screws.

Figure 239 Remove the Media Hanger

1 Media hanger
2 Mounting screws (4)
3 Media hanger mounting holes (4)
4 Printer main frame mounting holes (4)

2. Remove the media hanger from the printer.

Install the Media Hanger

1. See Figure 239 on page 435. Align the media hanger mounting holes with the four mounting holes in
the printer main frame.
2. Install the four mounting screws from the kit through the media hanger and into the four mounting hole
in the printer main frame.
3. Tighten the four mounting screws.

435
Reinstall the Electronics Cover
1. Slide the electronics cover onto the printer.

1 Electronics cover

436
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

437
4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

438
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

439
Media Rewind Option Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Rewind Option Kit into the
ZT600 series printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 40 on page 441.

Figure 240 Kit Contents

1 3

5 4
13
15

14

12

6
7

8
9
11 10

16

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 40 Kit Parts List
 Item Description Qty
Ref Rewind Option Kit, 4 inch
1 Rewind Assembly 1
2 Knurled Nut 1
3 Rewind Plate Maintenance Kit 1
4 Screw, M4 × 12 4
5 Belt Tensioning Plate 1
6 Rewind Platen Pulley, 203 DPI 1
7 Rewind Platen Pulley, 300/600 DPI 1
8 Screw, M4 × 10 2
9 Take-Label Sensor Kit 2
10 Screw, M4 × 8 1
11 Shoulder Screw 1
12 Idler Pulley 1
13 Spring 1
14 Drive Belt Kit 1
15 Rewind Module Jumper Cable 1
16 Media Loading Label 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Phillips Screwdriver Set • Antistatic Wriststrap and Mat
• Metric Hex Key Set • Safety Glasses
• Hexalobular Wrench Set

441
Remove the Tear-Off Front Trim Panel
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Remove the media and ribbon.

3. See Figure 241. Remove the two tear-off front trim panel mounting screws.

Figure 241 Remove the Tear-Off Front Trim Panel

1 Tear-off front trim panel

2 Tear-off front trim panel mounting nuts (2)

4. Tip the top of the tear-off front trim panel forward, and then slide the tear-off front panel out of the
printer.

442
Install the Media Rewind Assembly
1. See Figure 242. Remove the rewind option cover plate by removing the four screws securing it to the
main frame.

Figure 242 Remove the Rewind Option Cover Plate

1 Main frame
2 Rewind option cover plate
3 Rewind option cover plate mounting screws (4)

2. See Figure 243. Align the rewind assembly with the lower print mechanism slides.

Figure 243 Align the Rewind Assembly with Slides

1
2

1 Lower print mechanism

2 Lower print mechanism slides
3 Rewind assembly

443
3. See Figure 244. Slide the rewind assembly into the lower print mechanism slides until it stops at the
main frame.

Figure 244 Slide the Rewind Assembly into the Printer

1 Rewind assembly
2 Rewind assembly mounting screws (4)

4. Install the four rewind assembly mounting screws.

444
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

445
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

446
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

447
Install the Rewind Pulley, Tensioner, and Belt
1. See Figure 245. Choose the proper DPI rewind platen pulley from the kit. Verify the DPI of the printer by
matching the platen roller pulley to the illustration.

Figure 245 Pulley Locations

For this platen roller pulley configuration... Use this rewind platen
pulley

203 DPI

For this platen roller pulley configuration... Use this rewind platen
pulley

300/600 DPI

448
2. See Figure 246. Install the rewind platen pulley onto the rewind platen roller.

Figure 246 Install the Rewind Platen Pulley

2
1

1 Rewind platen roller shaft

2 Rewind platen pulley
3 Rewind platen pulley mounting screw

3. Tighten the pulley mounting screw.

449
4. See Figure 247. Align the tensioner with the two mounting holes.

Figure 247 Install the Rewind Belt Tensioner

4 5

1
2

1 Tensioner locking screw mounting hole

2 Tensioner shoulder screw mounting hole
3 Tensioner assembly
4 Tensioner shoulder screw
5 Tensioner locking screw

5. Install and tighten the shoulder screw.

6. Install, but do not tighten the locking screw.

450
CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
7. See Figure 248. Install the rewind tensioner expansion spring onto the two mounting hooks.

Figure 248 Install the Rewind Tensioner Expansion Spring

1 Upper mounting hook

2 Lower mounting hook
3 Expansion spring

451
8. See Figure 249. Loosen the locking screw on the main drive belt tensioner.

Figure 249 Remove the Main Drive Belt

1 4
2 3
7

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

9. Move the main drive belt tensioner down to extend the spring.

10. Tighten the locking screw.

11. Slide the main drive belt out of the printer.

452
12. See Figure 250. Install the idler pulley onto the tensioner shaft, as shown.

Figure 250 Install the Rewind Drive Belt

3
4

1 Rewind drive belt

2 Stepper motor pulley
3 Rewind tensioner locking screw
4 Rewind tensioner idler pulley
5 Lower platen roller pulley
6 Rewind spindle pulley

13. Move the rewind tensioner to extend the spring, and then tighten the locking screw.
14. Slide the rewind belt around the inside pulley on the stepper motor, around the lower platen pulley, and
around the rewind spindle pulley.
15. Loosen the rewind tensioner locking screw.

16. Rotate the belt several times to seat the belt on all the pulleys.

17. Tighten the locking screw on the rewind tensioner.

453
18. See Figure 249 on page 452. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.
NOTE: Ensure that the main drive belt is on the inside part of the idler pulley.

1. Loosen the rewind tensioner locking screw.

2. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.
3. See Figure 251. Install the rewind module jumper cable to J22 on the main logic board (MLB). The
jumper cable indicates that the rewind module is present.

Figure 251 Install Rewind Module Jumper Cable

J22

1 Rewind Module Jumper Cable

2 J22: Rewind Module

454
Install the Take-Label Sensors
1. See Figure 252. Remove the two take-label covers from the printer main frame.

Figure 252 Remove the Take-Label Mounting Hole Plugs

1 Take-label mounting hole plugs (2)

2 Take-label mounting holes (2)

2. See Figure 253. Slide the two take-label sensors into the printer mounting holes.

Figure 253 Install the Take-Label Sensors

1 Take-label sensor (2)

2 Mounting holes (2)

455
3. See Figure 254. Install the two mounting screws securing the take-label sensors to the main frame.

Figure 254 Install the Take-Label Sensor Mounting Screws

1
2

1 Take-label sensor (2)

2 Mounting screws (2)

456
4. See Figure 255. Connect the take-label sensors to J7 and J8 on the control panel.

Figure 255 Connect the Take-Label Sensors

1

1 Lower take-label sensor connector

2 Upper take-label sensor connector

457
Reinstall the Electronics Cover
1. Slide the electronics cover onto the printer.

1 Electronics cover

458
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

459
4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

460
Install the Rewind Plate
Install the Rewind Plate for Peel/Tear
1. See Figure 256. Start the outermost knurled nut onto the stud on the printer’s base.

Figure 256 Install the Rewind Plate for Peel/Tear

1 Rewind plate
2 Knurled nuts (2)
3 Printer base

2. Align the large hole of the keyhole in the rewind plate over the knurled nut, and then slide the plate
down until it hits the studs.
3. Tighten the knurled nut.

461
Install the Plate for Rewind
1. See Figure 257. Locate the four rewind plate mounting slots.

Figure 257 Install the Rewind Plate

1

1 Rewind plate mounting slots (4)

462
2. See Figure 258. Locate the four mounting tabs.

Figure 258 Locate the Mounting Tabs

1
2

1 Rewind plate mounting tabs (4)

2 Top of the rewind plate

463
3. See Figure 259. Insert the mounting tabs of the rewind plate into the mounting slots of the printer, and
then slide the rewind plate to the left until it will not go any farther.

Figure 259 Install the Rewind Plate

1 Rewind plate mounting tabs (4)

2 Top for rewind installation

464
Apply the Rewind Loading Label
1. Remove the loading label from the kit.

2. See Figure 260. Install the label on the inside top of the media door. Align and center the media loading
label with the hinges on top of the media door.

Figure 260 Install the Media Loading Label

1
2

1 Media door
2 Media loading label
3 Hinges

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

465
Media Rewind Spindle Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Rewind Spindle Maintenance
Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 41.

Figure 261 Kit Contents

5 6 7 8
1 2 3 4

Table 41 Parts List

 Item Description Qty
Ref Ribbon Rewind Spindle Maintenance Kit
1 E-Ring 1
2 Spacer, 0.75 × 0.52 × 0.36 1
3 Flat Washer, 0.75 × 0.52 × 0.03 1
4 Wave Washer 0.74 × 0.52 × 0.08 1
5 Screw, 8-32 × 0.38 3
6 Flat Washer, 0.375 × 0.172 × 0.048 3
7 Bearing Housing Assembly 1
8 Rewind Spindle 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Phillips Screwdriver Set • Safety Glasses

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

467
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

468
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

469
Remove the Main Drive Belt
1. See Figure 262. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 262 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

470
Remove the Rewind Drive Belt
1. See Figure 263. Remove the rewind drive belt by loosening the locking screw on the rewind drive belt
tensioner.

Figure 263 Remove the Rewind Drive Belt

2
1

3 4

7 6 5

1 Rewind drive belt tensioner

2 Stepper motor pulley
3 Rewind drive belt tensioner locking screw
4 Rewind drive belt
5 Rewind drive belt idler pulley
6 Lower platen pulley
7 Media take-up pulley

2. Move the rewind drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the rewind drive belt out of the printer.

471
Remove the Rewind Spindle Pulley
CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
1. See Figure 264. Remove the rewind spindle pulley by removing the E-ring, and then sliding it off of the
rewind spindle shaft.

Figure 264 Remove the Rewind Spindle Drive Pulley

2 4 5
3

1 E-ring
2 Rewind spindle pulley
3 Spacer
4 Flat washer
5 Wave washer
6 Rewind spindle shaft

2. Remove and discard the spacer, flat washer, and wave washer from the rewind spindle shaft.

472
Remove the Old Rewind Spindle Assembly
1. See Figure 265. Remove and discard the rewind spindle by sliding it out of the bearing housing.

Figure 265 Remove the Rewind Spindle

1 Rewind spindle
2 Bearing housing

473
 2. See Figure 266. Remove and discard the bearing housing three mounting screws and flat washers.

Figure 266 Remove the Bearing Housing

2 3

1 Bearing housing
2 Mounting flat washers (3)
3 Mounting screws (3)

3. Remove and discard the bearing housing.

Install the New Rewind Spindle Assembly

1. See Figure 266 on page 474. Align the mounting holes in the new bearing housing with the holes in the
printer.
2. Install the three new flat washers and mounting screws.

3. See Figure 265 on page 473. Slide the new rewind spindle assembly shaft through the bearing
housing.
4. See Figure 264 on page 472. Install the new wave washer, flat washer, and spacer onto the rewind
spindle shaft.
5. Reinstall the rewind drive pulley onto the rewind spindle shaft, and then install the new E-ring.

474
6. See Figure 267. Install the idler pulley onto the tensioner shaft.

Figure 267 Install the Rewind Drive Belt

3
4

1 Rewind drive belt

2 Stepper motor pulley
3 Rewind tensioner locking screw
4 Rewind tensioner idler pulley
5 Lower platen roller pulley
6 Rewind spindle pulley

7. Move the rewind tensioner to extend the spring, and then tighten the locking screw.
8. Slide the rewind belt around the inside pulley on the stepper motor, around the lower platen pulley, and
then around the rewind spindle pulley.
NOTE: Ensure that the belt is on the inside part of the idler pulley.
1. Loosen the rewind tensioner locking screw.

2. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the rewind tensioner.
3. See Figure 262 on page 470. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.
4. Loosen the rewind tensioner locking screw.

5. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

475
Reinstall the Electronics Cover
1. Slide the electronics cover onto the printer.

1 Electronics cover

476
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

477
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

478
Media Rewind and Liner Take-Up Plate
Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Rewind and Liner Take-Up
Plate Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 42.

Figure 268 Kit Contents

1

Table 42 Parts List

 Item Description Qty
Ref Media Rewind and Liner Take-Up Plate Maintenance Kit
1 Media Rewind and Liner Take-Up Plate 1
2 Liner Take-Up Top
3 Rewind Top
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Install the Liner Take-Up Plate
1. See Figure 269. Start the knurled nut onto the outside stud on the printer’s base.

Figure 269 Install the Liner Take-Up Plate

1 Liner take-up plate

2 Knurled nut
3 Printer base

2. Align the large hole of the keyhole in the rewind/peel plate over the knurled nut, and then slide the plate
down until it hits the studs.
3. Tighten the knurled nut.

480
Install the Rewind Plate
1. See Figure 270. Locate the four rewind plate mounting slots.

Figure 270 Install the Rewind Plate for Rewind

1

1 Rewind plate mounting slots (4)

481
2. See Figure 271. Locate the four mounting tabs.

Figure 271 Locate the Mounting Tabs

1

1 Rewind top
2 Rewind plate mounting tabs (4)

482
 3. See Figure 272. Insert the mounting tabs of the rewind plate into the mounting slots of the printer, and
then slide the rewind plate to the left until it will not go any farther.

Figure 272 Install the Rewind Plate for Rewind

1

1 Rewind top
2 Rewind plate mounting tabs (4)

Resume Printer Operation

1. Reinstall media and ribbon (if used).
2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

483
Rewind Drive System Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Rewind Drive System Maintenance
Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed in Table 43
on page 484.

Figure 273 Kit Contents

8
7
9 10
6
1 4
3
2
5

11

13 12

Table 43 Parts List

 Item Description Qty
Ref Rewind Drive System Maintenance Kit
1 Wave Washer, 0.74 × 0.52 × 0.08 1
2 Flat Washer, 0.76 × 0.51 × 0.03 1
3 Spacer 1
4 Rewind Take-up Pulley 1
5 E-Ring, 0.50 × 0.042 1
6 Drive Belt Maintenance Kit 1
7 Tensioner Bracket 1
8 Extension Spring 1
9 Shoulder Screw 1
10 Hexalobular Screw, M4 × 8 1
11 Idler Pulley 1
12 203 dpi Rewind Pulley 1
13 300 dpi Rewind Pulley 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Needle Nose Pliers
• Antistatic Wriststrap and Mat

485
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

486
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

487
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

488
Remove the Old Rewind Drive System
NOTE: You must remove the main drive belt to remove the rewind drive system.
1. See Figure 274. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 274 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw

3. Slide the main drive belt out of the printer.

489
4. See Figure 275. Remove the rewind drive belt by loosening the locking screw on the rewind drive belt
tensioner.

Figure 275 Remove the Rewind Drive Belt

2
1

3 4

7 6 5

1 Rewind drive belt tensioner

2 Stepper motor pulley
3 Rewind drive belt tensioner locking screw
4 Rewind drive belt
5 Rewind drive belt idler pulley
6 Lower platen pulley
7 Media take-up pulley

5. Move the rewind drive belt tensioner to extend the spring, and then tighten the locking screw.

6. Remove and discard the rewind drive belt from the printer.

CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
7. See Figure 276. Remove and discard the rewind spindle pulley by removing the E-ring, and then sliding
the rewind pulley off of the rewind spindle shaft.

490
Figure 276 Remove the Rewind Spindle Drive Pulley

2 4 5
3

1 E-ring
2 Rewind spindle pulley
3 Spacer
4 Flat washer
5 Wave washer
6 Rewind spindle shaft

8. Remove and discard the spacer, flat washer, and wave washer from the rewind spindle shaft.

491
9. See Figure 277. Remove and discard the mounting screw from the rewind roller pulley, and then
remove and discard the rewind pulley from the printer.

Figure 277 Remove the Rewind Pulley

1 2

1 Rewind pulley mounting screw

2 Rewind pulley
3 Rewind roller shaft

CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
10. Loosen the locking screw to release the tension on the extension spring.

492
Figure 278 Remove the Belt Tensioner Bracket

4
1

2 3

1 Extension spring
2 Shoulder screw
3 Locking screw
4 Tensioning bracket
5 Idler pulley

11. Remove and discard the extension spring.

12. Remove and discard the locking, shoulder screw, bracket, and idler pulley.

493
Install the New Rewind Drive System
1. Choose the proper DPI rewind pulley from the kit.

2. See Figure 278 on page 493. Install the rewind pulley onto the rewind roller.

3. Tighten the pulley mounting screw.

4. See Figure 276 on page 491. Install the new wave washer, flat washer, spacer, and rewind spindle
pulley onto the rewind spindle shaft.
5. Install the E-ring to secure them to the rewind spindle shaft.
6. See Figure 279. Align the tensioner with the two mounting holes.

Figure 279 Install the Rewind Belt Tensioner

4 5

2 1

1 Tensioner locking screw mounting hole

2 Tensioner shoulder screw mounting hole
3 Tensioner assembly
4 Tensioner shoulder screw
5 Tensioner locking screw

7. Install and tighten the shoulder screw, and then install, but do not tighten the locking screw.

494
8. See Figure 280. Install the rewind tension expansion spring onto the two mounting hooks.

Figure 280 Install the Rewind Tensioner Expansion Spring

1 Upper mounting hook

2 Lower mounting hook
3 Expansion spring

495
9. See Figure 281. Install the idler pulley onto the tensioner shaft.

Figure 281 Install the Rewind Drive Belt

3
4

1 Rewind drive belt

2 Stepper motor pulley
3 Rewind tensioner locking screw
4 Rewind tensioner idler pulley
5 Lower platen roller pulley
6 Rewind spindle pulley

10. Rotate the rewind tensioner to extend the spring, and then tighten the locking screw.
11. Install the rewind belt around the inside pulley on the stepper motor, around the lower platen pulley, and
then around the rewind spindle pulley.
12. Ensure that the belt is on the inside part of the idler pulley.

13. Loosen the rewind tensioner locking screw.

14. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the rewind tensioner.
15. See Figure 274 on page 489. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

16. Ensure that the main belt is on the inside part of the idler pulley.

17. Loosen the rewind tensioner locking screw.

18. Rotate the main drive belt several times to seat the belt on all the pulleys, and then tighten the locking
screw on the main drive belt tensioner.

496
Reinstall the Electronics Cover
1. Slide the electronics cover onto the printer.

1 Electronics cover

497
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

498
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

499
 Rewind Platen Roller Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Rewind Platen Roller Maintenance
Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 44.

Figure 282 Kit Contents

1
2

Table 44 Parts List

 Item Description Qty
Ref Rewind Platen Roller Maintenance Kit
1 Rewind Platen Roller Assembly 1
2 Roller Bearing Retainer Maintenance Kit 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

501
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

502
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

503
Remove the Rewind Platen Roller
1. See Figure 283. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 283 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Rotate the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

504
4. See Figure 284. Remove the rewind drive belt by loosening the locking screw on the rewind drive belt
tensioner.

Figure 284 Remove the Rewind Drive Belt

2
1

3 4

7 6 5

1 Rewind drive belt tensioner

2 Stepper motor pulley
3 Rewind drive belt tensioner locking screw
4 Rewind drive belt
5 Rewind drive belt idler pulley
6 Lower platen pulley
7 Media take-up pulley

5. Rotate the rewind drive belt tensioner to extend the spring, and then tighten the locking screw.

6. Slide the rewind drive belt out of the printer.

505
7. See Figure 285. Remove the rewind pulley by loosening the screw, and then sliding the pulley off the
roller shaft.

Figure 285 Remove the Rewind Platen Roller Pulley

2
3

1 Rewind platen roller shaft

2 Rewind platen roller pulley
3 Rewind platen roller pulley screw

506
8. See Figure 286. From the media side, remove the bearing retainer by removing the screw securing it.

Figure 286 Remove the Bearing Retainer

2
3

1 Bearing retainer
2 Rewind platen roller
3 Outer rewind platen roller bearing
4 Bearing retainer mounting screw

507
9. See Figure 287. Remove the rewind platen roller by sliding the roller toward you until the bearing is just
beyond the mounting bracket.

Figure 287 Remove the Rewind Platen Roller

4
3

1
2

1 Rewind platen roller outer bearing

2 Rewind platen roller mounting bracket
3 Rewind platen roller
4 Main frame mounting hole

10. Push the outside of the roller toward the front of the printer, and then slide the roller out of the printer.

508
Install the New Rewind Platen Roller
1. See Figure 287. Slide the rewind platen roller shaft into the main frame mounting hole.

2. Slide the rewind platen roller into the mounting bracket.

3. Slide the bearings into the mounting holes in the main frame and mounting bracket.

4. See Figure 288. Align the bearing retainer with the bearing flange, insert it over the bearing while
aligning the mounting hole in the retainer with the mounting hole in the mounting bracket.

Figure 288 Install Bearing Retainer

2
4 1

2
3 1

1 Bearing retainer
2 Bearing
3 Mounting screw
4 Bearing flange

5. Ensure that the bearing retainer is seated over the bearing flange, and then install the mounting screw.

6. Slide the rewind pulley onto the rewind platen roller.

509
Figure 289 Install the Rewind Pulley

2
1

1 Rewind platen roller shaft

2 Rewind pulley

7. Tighten the pulley mounting screw.

510
8. See Figure 290. Install the idler pulley onto the tensioner shaft.

Figure 290 Install the Rewind Drive Belt

1

3
4

1 Rewind drive belt

2 Stepper motor pulley
3 Rewind tensioner locking screw
4 Rewind tensioner idler pulley
5 Rewind platen roller pulley
6 Rewind spindle pulley

9. Install the rewind belt around the inside pulley on the stepper motor, around the rewind pulley, and then
around the rewind spindle pulley.
10. Ensure that the belt is on the inside part of the idler pulley.

11. Loosen the rewind tensioner locking screw.

12. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the rewind tensioner.
13. See Figure 283 on page 504. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

14. Ensure that the belt is on the inside part of the idler pulley.

15. Loosen the rewind tensioner locking screw.

16. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

511
Reinstall the Electronics Cover
1. Slide the electronics cover onto the printer.

1 Electronics cover

512
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

513
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

514
40 mm Media Spindle Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the 40 mm Media Supply Spindle
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

IMPORTANT: A qualified service technician must perform this installation.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 45.

Figure 291 Kit Contents

Table 45 Parts List

 Item Description Qty
Ref Media 40 mm Supply Spindle Maintenance Kit
1 Media Supply Spindle Assembly 1
2 Hexalobular Screw, M4 × 8 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• SAE Wrench or Socket Set • Polyester Film
• Phillips Screwdriver Set • Spring Gauge

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

516
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

517
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

518
Remove the Old Option Card
1. See Figure 292 to verify the slots that can be used for the various option cards.

Figure 292 Option Card Locations

1 2 3 4 5

3 4 6
1 2

1 Blank cover
2 Parallel port
3 Applicator interface
4 USB Host
5 Wireless (only in this location)
6 Internal print server IPV4 (only in this location)

2. Remove the two option card mounting screws that secure an option card or blank cover to the top slot.

519
Figure 293 Remove the Option Card

1 Option card
2 Mounting screws (2)

3. Slide the option card out of the printer.

4. Repeat steps 2 and 3 for the bottom slot.

5. Go to Remove the Main Logic Board (MLB) on page 521.

520
Remove the Main Logic Board (MLB)
1. Disconnect all cables from the MLB.
NOTE: Removal of the MLB is necessary to pull the sensor cables attached to the 3-inch media spindle
through the inside wall of the printer.

Figure 294 Disconnect all Cables

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

J1 Upper Option Board J34 Printhead

J13 Internal Use Only J35 Cutter/Rewind/Liner Take-Up
J15 Control Panel Serial and Control J37 Power Supply Input
J16 Control Panel LVDS Display J38 Power Supply Input
J17 Front Panel USB J39 Auxiliary Power Output
J18 Future Use J40 RFID
J19 Future Use J41 Media Low Quadrature Sensor
J20 Media Path Lights J42 Ribbon Low Sensor
J21 Transmissive Sensor Detector J43 Media Low Sensor
J22 Rewind Detect Sensor J44 Black Mark Sensor
J25 Future Use J45 Ribbon Sensor
J26 Drive Motor J46 Head Open Sensor
J27 Print Mechanism Lights J47 Transmissive Sensor LED Control
J28 Media Bay Lights J48 Ribbon Low Quadrature Sensor
J29 Ribbon Path Lights J49 Lower Option Board

521
1. See Figure 295. Remove the MLB by removing the six screws securing it.

Figure 295 Removing the MLB

522
Remove the 3-Inch Media Supply Spindle
1. Align the holes in the back plate with the mounting screws.

Figure 296 Media Supply Spindle Mounting Screws

1
2 3

1 Media supply spindle assembly back plate

2 Holes in the back plate (3)
3 Mounting screws (3)

2. Remove the three media supply spindle mounting screws.

523
Figure 297 Removing the 3-Inch Media Supply Spindle

1 2

1 Media supply spindle assembly

2 Media low sensor access holes (2)
3 Mounting screws (3)

3. Remove the media supply spindle, while guiding the two media low sensor cables through the access
holes.

524
Reinstall the Main Logic Board (MLB)
1. See Figure 295 on page 522. Align the new MLB with the mounting studs and then install the six
mounting screws.
2. See Figure 294 on page 521 and Figure 298. Reconnect all cables to the MLB.

Figure 298 Reconnect cables to the MLB

J43

J41

NOTE: There are no cables connected to J41 or J43 when reinstalling the cables with the 40 mm media
supply spindle.

Reinstall Option Boards

1. See Figure 292 on page 519. Insert the option boards that were removed previously. Make sure to
install the boards in the compatible slots.
2. Reinstall the two mounting screws for each option board or blank cover.
\

525
Install 40 mm Media Supply Spindle
1. See Figure 299. Align the 40 mm media supply spindle as shown so that the pass-through hole in the
spindle mount lines up with one of the screw holes on the printer’s mainframe.
2. Insert a mounting screw into the screw hole, and partially tighten it.

3. Rotate the spindle to align the pass-through hole in the spindle mount with a second screw hole.

4. Insert a mounting screw into the second hole, and tighten it.

5. Repeat steps 3 and 4 with the third mounting screw.

6. Rotate the spindle so that the pass-through hole in the spindle mount again lines up with the first screw
hole, and then fully tighten the first screw.

Figure 299 Install 40 mm Media Supply Spindle

1
4

3
2

1 40 mm media supply spindle assembly

2 Mounting screw hole
3 Mounting screws (3)
4 Mounting screw holes

526
Adjust the Spindle Tension
1. See Figure 300. Use adhesive tape to attach a 5 cm (2 in.) wide strip of polyester film to the spindle
shaft (or core where required).
2. Wind the polyester film around the spindle (or core) about five times in the direction shown.

Figure 300 Adjust the Spindle Tension

1 Media supply spindle

2 Direction
3 Polyester film
4 Core
5 Adjustment nut

3. Measure tension by slowly pulling the film with a spring scale. Pull only in the direction shown. The pull
rate should be 5 cm (2 in.) per second.
4. Is the spring tension reading 300 grams ±50?

If… Then…
No a. See Figure 300. Make adjustments using the tension adjustment nut.
• Clockwise increases tension.
• Counterclockwise decreases tension.
b. Recheck the tension after running a full roll of labels.
c. Go to Reinstall the Electronics Cover on page 528.
Yes d. Go to Reinstall the Electronics Cover on page 528.

527
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

528
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

529
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

530
Offset Printing Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Offset Printing Kit in the ZT600
Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 46.

Figure 301 Kit Contents

Table 46 Parts List

 Item Description Qty
Ref Offset Printing Kit
1 Media Guide Rail 1
2 Media Offset Disk 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Screwdriver Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

532
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

533
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

534
Remove the Media Guide
1. See Figure 302. Disconnect the black mark sensor cable from J44 on the main logic board (MLB).

Figure 302 MLB Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J44

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

2. See Figure 303. Find the sensor cable.

Figure 303 Find the Sensor Cable

1 Sensor cable

535
3. See Figure 304. Pull the cable forward to create slack.

Figure 304 Create Slack in Cable

1 Plug for sensor cable

2 Sensor cable with slack

4. Open the media door.

5. See Figure 305. Remove and save the two or three media guide and black mark sensor assembly
mounting screws. The ZT610 uses two screws and the ZT620 uses three screws.

Figure 305 Remove the Media Guide Mounting Screws

3
1

1 Media guide and black mark sensor assembly

2 Mounting screws (2)
3 Mounting holes (2)

536
6. See Figure 306. While guiding the black mark sensor cable through the access hole, slide the media
guide assembly out of the printer until you can freely access the media guide assembly.

Figure 306 Remove the Media Guide and Black Mark Sensor Assembly
1 2

1 Media guide rail

2 Black mark sensor cable access hole

7. Do not completely remove the media guide assembly or cable from the printer.

537
Replace the Media Guide Rail
1. See Figure 307. Remove and save the screw from the media guide rail.

Figure 307 Remove the Media Guide Rail Screw

1

1 Screw
2 Old media guide rail
3 Media guide
assembly

538
2. See Figure 308. Remove and discard the old media guide rail.

Figure 308 Remove the Old Media Guide Rail

1 Old media guide rail

2 Media guide assembly

3. See Figure 309. Install the new media guide rail.

Figure 309 Install the New Media Guide Rail

1 New media guide rail

2 Media guide assembly

539
4. See Figure 310. Reinstall the screw securing the new media guide rail to the media guide assembly.

Figure 310 Reinstall Screw

1

1 Screw
2 New media guide rail
3 Media guide assembly

540
Reinstall the Media Guide Assembly
1. See Figure 311. Guide the black mark sensor cable back through the access hole while sliding the
media guide assembly into the printer.

Figure 311 Reinstall the Media Guide and Black Mark Sensor Assembly

1 2

1 Media guide assembly

2 Black mark sensor cable access hole

541
1. See Figure 312. Reinstall the two or three mounting screws.

Figure 312 Reinstall the Media Guide Mounting Screws

3
1

1 Media guide and black mark sensor assembly

2 Mounting screws (2 or 3)
3 Mounting holes (2 or 3)

1. See Figure 302 on page 535. Pull the slack out of the cable and reconnect the black mark sensor cable
to J44 on the MLB.

542
2. See Figure 313. Slide the media offset disk onto the media spindle.

Figure 313 Install Media Offset Disk

2 1

1 Media offset disk

2 Media spindle

NOTE: The media offset disk will fit loosely and is held in place by the media when it is installed.

543
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

544
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

545
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

546
Electronic Components
This section supplies you with the parts information and installation procedures for the circuit boards.

547
Circuit Boards Parts and Drawings
Figure 314 Circuit Boards Overview

2
1

16

15

3
14
6
11
12

13
9

10 7

11 8
12

13

548
Table 47 List of Kits
Item Part Number Description
1 P1083320-001 ZT610 Standard Control Panel Maintenance Kit
P1083320-108 ZT620 Standard Control Panel Maintenance Kit
2 P1083320-002 ZT610 Touch Control Panel Maintenance Kit
P1083320-109 ZT620 Touch Control Panel Maintenance Kit
3 P1083320-044 Light Assemblies Maintenance Kit
5 P1083320-003 USB Cover Maintenance Kit
6 P1083320-045 USB Board and Cover Maintenance Kit
7 P1083320-035 Main Logic Board (MLB) Maintenance Kit
8 P1083320-043 ZT610/ZT620 Power Supply Maintenance Kit
9 P1083320-036 Connectivity Board Maintenance Kit
10 P1083320-039 IPv4 Internal Print Server Option/Maintenance Kit
11 P1083320-094 USB Host Option/Maintenance Kit
12 P1083320-038 Applicator Interface Option/Maintenance Kit
13 P1083320-040 Parallel Port Option/Maintenance Kit
14 P1083320-037A ZT610/ZT620 Wireless Print Server 802.11ac Radio Option/Maintenance
Kit, Region A (USA and Canada)
P1083320-037B ZT610/ZT620 Wireless Print Server 802.11ac Radio Option/Maintenance
Kit, Region B (Japan)
P1083320-037C ZT610/ZT620 Wireless Print Server 802.11ac Radio Option/Maintenance
Kit, Region C (All other countries other than regions, A and B)
15 P1083320-041A RFID Upgrade Kit USA and Canada, ZT610
P1083320-041B RFID Upgrade Kit Japan, ZT610
P1083320-041C RFID Upgrade Kit All Countries except, USA, Canada, and Japan, ZT610
P1083320-102A RFID Upgrade Kit USA and Canada, ZT620
P1083320-102B RFID Upgrade Kit Japan, ZT620 Series
P1083320-102C RFID Upgrade Kit All Countries except, USA, Canada, and Japan, ZT620

549
Figure 315 Circuit Board Kits (1)

1 2 3

5 6

550
Table 48 Kits List of Parts
Item Part Number Description
1 P1083320-001 ZT610 Standard Control Panel Maintenance Kit
P1083320-108 ZT620 Standard Control Panel Maintenance Kit
2 P1083320-002 ZT610 Touch Control Panel Maintenance Kit
P1083320-109 ZT620 Touch Control Panel Maintenance Kit
3 P1083320-044 ZT610/ZT620 Light Assemblies Maintenance Kit
4 P1083320-003 ZT610/ZT620 USB Cover Maintenance Kit
5 P1083320-045 USB Board and Cover Maintenance Kit
6 P1083320-035 Main Logic Board (MLB) Maintenance Kit

551
Figure 316 Circuit Board Kits (2)
1 2 3

MANUFACTURER LOGO

Zebra part number

DATE CODE (WW/YY)

UL FILE NUMBER UL TYPE V-0

4 5 6

7
UI D##.
UID#.
D #

ZT610
T610
ZT
ZT 6 0
UID#.
#.
UID#
UI

ZT620
ZT620

552
Table 49 Kits List of Parts
Item Part Number Description
1 P1083320-043 ZT600 Power Supply Maintenance Kit
2 P1083320-035 Connectivity Board Maintenance Kit
3 P1083320-039 ZT610/ZT620 IPv4 Internal Print Server Option/Maintenance Kit
4 P1083320-094 ZT610/ZT620 USB Host Option/Maintenance Kit
5 P1083320-038 ZT610/ZT620 Applicator Interface Option/Maintenance Kit
6 P1083320-040 ZT610/ZT620 Parallel Port Option/Maintenance Kit
7 P1083320-037A ZT610/ZT620 Wireless Print Server 802.11ac Radio Option/Maintenance
Kit, Region A (USA and Canada)
P1083320-037B ZT610/ZT620 Wireless Print Server 802.11ac Radio Option/Maintenance
Kit, Region B (Japan)
P1083320-037C ZT610/ZT620 Wireless Print Server 802.11ac Radio Option/Maintenance
Kit, Region C (All other countries other than regions, A and B)

553
Figure 317 Circuit Board Kits (3)
1 2

554
Table 50 Kits List of Parts
Item Part Number Description
1 P1083320-041A RFID Upgrade Kit USA and Canada, ZT610
P1083320-041B RFID Upgrade Kit Japan, ZT610
P1083320-041C RFID Upgrade Kit All Countries except, USA, Canada, and Japan, ZT610
2 P1083320-102A RFID Upgrade Kit USA and Canada, ZT620
P1083320-102B RFID Upgrade Kit Japan, ZT620 Series
P1083320-102C RFID Upgrade Kit All Countries except, USA, Canada, and Japan, ZT620
3 P1083320-042 RFID Hardware and Cables Maintenance Kit

555
Sensors
Figure 318 Sensors Overview

556
Table 51 List of Kits
Item Part Number Description
1 P1083320-047 Media Sensor Maintenance Kit
2 P1083320-048 Reflective (Black Mark) Sensor Maintenance Kit
3 P1083320-051 ZT610/ZT620 Ribbon Out Sensor Maintenance Kit
4 P1083320-052 ZT610/ZT620 Take-Label Sensors Maintenance Kit
5 P1083320-053 Head-Open Sensor Assembly Maintenance Kit

557
 Figure 319

4
1
Kits List of Parts

558
2

MANUFACTURER LOGO

Zebra part number

DATE CODE (WW/YY)

UL FILE NUMBER UL TYPE V-0

3

5
Table 52 Kits List of Parts
Item Part Number Description
1 P1083320-047 Media Sensor Maintenance Kit
2 P1083320-048 Reflective (Black Mark) Sensor Maintenance Kit
3 P1083320-051 ZT610/ZT620 Ribbon Out Sensor Maintenance Kit
4 P1083320-052 ZT610/ZT620 Take-Label Sensors Maintenance Kit
5 P1083320-053 Head-Open Sensor Assembly Maintenance Kit
6 P1083320-046 Electronic Cables Maintenance Kit

559
Standard Control Panel Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Standard Control Panel Maintenance
Kit on ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.
NOTE:
After installation, you must pair your Bluetooth devices with the printer again.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 53.

Figure 320 Kit Contents

Table 53 Parts List

 Item Description Qty
Ref Standard Control Panel Maintenance Kit
1 Control Panel 1
2 LCD Cable 1
3 Control Panel Logic Cable 1
4 Screw, M4 × 8 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Metric Nutdriver Set

561
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

562
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

563
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

564
Remove the Control Panel
1. See Figure 321. Disconnect the control panel cables from J15 and J16 on the main logic board (MLB).

Figure 321 MLB Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J15 J34

J16

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

565
2. See Figure 322. Remove the mounting nuts and cable clamps securing the control panel cables to the
top of the printers main frame.

Figure 322 Remove the Control Panel Cable Clamps

1 Cable clamp mounts (2)

2 Cable clamps (2)
3 Cable clamp nuts (2)

566
3. Is there is a rewind option installed?

If a rewind option installed… Then…

Yes a. See Figure 323. Remove the take-label sensors cables from
J7 and J8 on the control panel printed circuit board assembly
(PCBA).
b. Go to step 1 on page 568.
No a. Go to step 1 on page 568.

Figure 323 Disconnect Take-label Sensor Cables

J7

J8

J7 Take-label sensor 2 pin connector

J8 Take-label sensor 3 pin connector

567
1. See Figure 324. Remove the control panel by removing the two screws securing it to the printer.

Figure 324 Remove the Control Panel

o

1 Control panel
2 Control panel mounting screws (2)
3 Main frame pass-through hole

2. Slide the control panel out of the printer while guiding the cables through the main frame pass-through
hole.

568
Install the New Control Panel
1. See Figure 325. Connect the new cables to J1 and J3 on the control panel board.

Figure 325 Install Control Panel Cables

J3

J1 J1

1 Top mounting bracket

J1 Control panel MLB interface
J3 MLB to LCD interface

2. Guide the cable from J1 under the top mounting bracket.

569
3. See Figure 326. Guide the cables through the main frame pass-through hole.

Figure 326 Install the New Control Panel

o

1 Control panel
2 Control panel mounting screws (2)
3 Main frame pass-through hole

4. Align the two control panel mounting holes, and install the two new mounting screws.

570
5. See Figure 327. Reinstall the control panel cables into the cable clamps on the top of the main frame.

Figure 327 Reinstall Control Panel Cable Clamps

1 Cable clamp mounts (2)

2 Cable clamps (2)
3 Cable clamp nuts (2)

571
6. See Figure 328. Connect the cables to J15 and J16 on the main logic board.

Figure 328 MLB Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J15 J34

J16

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

7. Is there is a rewind option installed?

If a rewind option installed… Then…

Yes a. See Figure 323 on page 567. Install the take-label sensors
cables to J7 and J8 on the control panel printed circuit board
assembly (PCBA).
b. Go to Reinstall the Electronics Cover.
No Go to Reinstall the Electronics Cover.

572
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

573
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

574
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

575
Touch Control Panel Option/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Touch Control Panel
Option/Maintenance Kit on ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.
NOTE: After installation, you must pair your Bluetooth devices with the printer again.

NOTE: If you are replacing a standard control panel with the Touch Control Panel the printer firmware
must be updated to V80.20.17Z or later BEFORE installing the control touch control panel to ensure proper
operation of the new control panel.
IMPORTANT: A qualified service technician must perform this installation.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 54 on page 577.

Figure 329 Kit Contents

2
1

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 54 Parts List
 Item Description Qty
Ref Touch Control Panel Maintenance Kit
1 Color Touch Control Panel 1
2 Color Control Panel Cable 1
3 Touch Panel Cable 1
4 Screw, M4 × 8 (2) 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Metric Hexalobular Key Set • Antistatic Wriststrap and Mat

577
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

578
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

579
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

580
Remove the Control Panel
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 330. Disconnect the control panel cables from on the main logic board, J15 and J16.

Figure 330 MLB Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J15 J34

J16

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

581
3. See Figure 331. Remove two upper cable clamps.

Figure 331 Remove Control Panel Cables

1 Cable clamps (2)

582
4. See Figure 332. Remove the two control panel mounting screws.

Figure 332 Remove the Control Panel

o

1 Touch control panel

2 Control panel mounting screws (2)
3 Upper main frame access hole

5. Remove the control panel until you can reach the take-label sensor cable connectors, if populated.

6. See Figure 333 on page 584. Disconnect the take-label sensor cables from J5 and J6 on the control
panel.
7. See Figure 332. While guiding the color control panel and touch panel cables through the upper access
hole, remove the control panel.

583
Install the New Control Panel
1. See Figure 333. Connect the color control panel cable to J15 on the control panel.

Figure 333 Control Panel Cable Connections

2 3
1

1 J3 —To J15 on the main logic board (MLB)

2 J5 —To take-label sensor
3 J6 —To take-label sensor
4 J8 —To MLB J16

2. Connect the take-label sensor cables to J5 and J6 on the control panel, if populated.

3. See Figure 332 on page 583. Guide the cables through the upper access hole in the main frame.

4. Align the two control panel mounting holes.

5. Install the two new mounting screws.

6. Connect the color control panel cable to J15 on the MLB.

7. Connect the touch panel cable to J16 on the MLB.

8. Reinstall the two upper cable clamps with the data cable secured inside the printer.

584
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

585
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

586
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

587
Light Assemblies Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the light assembly maintenance kit on
ZT600 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 in Table 55 on page 588.

Figure 334 Kit Contents

1 3
1
2

Table 55 Kit Parts List

 Item Description Qty
Ref Light Assemblies Maintenance Kit
1 Ribbon Path Lights 3
2 Case Light 1
3 Media Path lights 2
4 Hexalobular Screw 1
5 Hexalobular Screw, M3 × 4 5
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Phillips Screwdriver Set • Hexalobular Wrench Set
• Antistatic Wriststrap and Mat

589
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

590
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

591
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

7. Which light assembly are you replacing?

The… Then…
Ribbon Path Go to Remove the Old Ribbon Path Light Assemblies on
page 593.
Media path Go to Remove the Old Media Path Light Assemblies on
page 598.
Case Light Go to Remove the Old Case Light Assembly on page 609.

592
Remove the Old Ribbon Path Light Assemblies
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 335. Disconnect the ribbon path light cables from J29 on the main logic board (MLB).

Figure 335 Ribbon Path Lights Main Logic Board Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J29
J41

J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

593
3. See Figure 336. Open cable clamps 2 and 3 by removing their nuts, and then remove the ribbon path
cables.

Figure 336 Locate the Cable Clamps

3
1 2

6 5 4

1 Ribbon Sensor, Black Mark Sensor, Transmissive Sensor, Head

Open Sensor, and Media Path Light
2 Printhead Power, Printhead Data, and Ribbon Path Light
3 Head Open Sensor and Ribbon Path Light
4 Stepper Motor and Bulkhead Connector
5 Stepper Motor and Bulkhead Connector
6 Printhead Power

594
4. See Figure 337. Remove the mounting screw from each ribbon path light assembly, and then remove
the ribbon path light assembly.

Figure 337 Remove the Old Ribbon Path Light Assemblies

3

1 2

1 Ribbon path light assemblies

2 Mounting screws (3)
3 Mounting standoffs (3)

595
Install the New Ribbon Path Light Assemblies
1. See Figure 338 and Figure 339 on page 597. Insert the arrow on the ribbon path light assembly into the
arrow opening in the printer main frame, and then install the mounting screw.

Figure 338 Align the Arrows

1

1 Printer main frame

2 Main frame arrow opening
3 Ribbon path light assembly
4 Ribbon path light assembly arrow

596
Figure 339 Install the Mounting Screw
1

1 Ribbon path light assembly

2 Mounting screw

2. See Figure 336 on page 594. Insert the ribbon path light cables into the cable clamps 1, 2, and 3.

3. Reinstall the three cable clamp mounting nuts.

597
Remove the Old Media Path Light Assemblies
1. See Figure 340. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 340 Remove the Main Drive Belt

1 2 4
3

6 5

1 Main drive belt tensioner

2 Main drive belt tensioner locking screw
3 Stepper motor pulley
4 Upper platen pulley
5 Main drive belt idler pulley
6 Ribbon take-up pulley
7 Main drive belt

2. Turn the main drive belt tensioner to extend the spring, and then tighten the locking screw.

3. Slide the main drive belt out of the printer.

4. Loosen, but do not remove, the screw in the platen pulley assembly.

598
Figure 341 Remove the Upper Platen Roller Pulley

1 Platen pulley
2 Platen pulley clamp screw
3 Platen roller shaft

5. Remove the platen pulley from the platen roller shaft.

6. Which option or options do you have installed?

If you have an… Then…

Applicator interface board Go to Remove the Applicator Interface Board on page 600.
Internal print server IPv4 Go to Remove the Internal Print Server IPv4 on page 601.
Wireless board with external Go to Remove the Wireless Print Server on page 602.
antenna
USB port host board Go to Remove the USB Host Board on page 604.
Parallel port board Go to Remove the Parallel Port Board on page 605.
None Go to Remove the Main Logic Board (MLB) on page 606.

599
Remove the Applicator Interface Board
NOTE: The applicator interface board can be used in the upper and lower option slots.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Remove the applicator interface board by removing the two screws securing it to the printer, and then
pulling it out of the printer.

Figure 342 Remove the Applicator Interface Board

1
2

1
2

1 Applicator interface board

2 Mounting screws (2)

3. Go to Remove the Main Logic Board (MLB) on page 606.

600
Remove the Internal Print Server IPv4
NOTE: The internal print server board can only be used in the lower option slot.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 343. Remove the internal print server board by removing the two screws securing it to the
printer, and then pulling it out of the printer.

Figure 343 Remove the Internal Print Server Board

1
2

1 Internal print server board

2 Mounting screws (2)

3. Go to Remove the Main Logic Board (MLB) on page 606.

601
Remove the Wireless Print Server
NOTE: The wireless print server board can only be used in the upper option slot.

1. See Figure 344. Remove the wireless print server antenna.

Figure 344 Remove the Antenna

2

1 Back plate
2 RF antenna
3 RF connector

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

602
3. See Figure 343. Remove the internal print server board by removing the two screws securing it to the
printer, and then pulling it out of the printer.

Figure 345 Remove the Wireless Print Server Board

1
2

1 Wireless print server board

2 Mounting screws (2)

4. Go to Remove the Main Logic Board (MLB) on page 606.

603
Remove the USB Host Board
NOTE: The USB host board can be used in the upper and lower option slots.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 346. Remove the USB host board by removing the two screws securing it to the printer, and
then pulling it out of the printer.

Figure 346 Remove the USB Host Board

1
2

1
2

1 USB host board

2 Mounting screws (2)

3. Go to Remove the Main Logic Board (MLB) on page 606.

604
Remove the Parallel Port Board
NOTE: The parallel port board can be used in the upper and lower option slots.

1. See Figure 347. Remove the two screws securing the parallel port board to the printer, and then pull it
out of the printer.

Figure 347 Remove the Parallel Port Board

1
2

1
2

1 Parallel port board

2 Mounting screws (2)

2. Go to Remove the Main Logic Board (MLB) on page 606.

605
Remove the Main Logic Board (MLB)
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 348. Disconnect all cables from the main logic board (MLB).

Figure 348 Media Path Lights Main Logic Board Connections

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

J3 Back Panel Connector J37 Power Supply Input

J15 Control Panel Data J38 Power Output
J17 USB Connector J39 Power Output
J20 Media Path Lights J40 RFID Port
J21 Transmissive Sensor J41 Media Low Quadrature Sensor
J22 Rewind Detect J42 Ribbon Low Sensor
J23 SPI J43 Media Low Sensor
J24 SPI J44 Reflective Sensor
J26 Drive Motor J45 Ribbon Sensor Interface
J27 Enclosure Lights J46 Head Open Sensor
J28 Enclosure Lights Main J47 Transmissive Sensor
J29 Ribbon Path Lights J48 Ribbon Low Quadrature Sensor
J34 Printhead J49 Back Panel Connector
J35 Cutter/Rewind/LTU J50 Audio SPI

606
3. See Figure 349. Remove the MLB by removing the six mounting screws.

Figure 349 Remove the MLB

4. See Figure 336 on page 594. Open cable clamp 1 by removing the nut, and then remove the ribbon
path cable.

607
 5. See Figure 350. Remove the mounting screws, and then remove the media path light assemblies.

Figure 350 Remove the Media Path Light Assemblies

th

1 Media path light assemblies

2 Mounting screws (3)
3 Mounting standoffs (3)

Install the New Media Path Light Assemblies

1. See Figure 338 on page 596. Align the arrow in the printer main frame with the arrow on the media path
light assembly.
2. See Figure 339 on page 597. Insert the arrow on the ribbon path light assembly into the arrow in the
printer main frame, and then install the mounting screw.
3. See Figure 341 on page 599. Reinstall the upper platen pulley and tighten the mounting screw.

4. See Figure 340 on page 598. Reinstall the main drive belt around the outside stepper motor pulley, the
upper platen roller pulley, and then around the ribbon take-up spindle pulley.

5. Ensure that the belt is on the inside part of the idler pulley.

6. Loosen the rewind tensioner locking screw.

7. Rotate the belt several times to seat the belt on all the pulleys, and then tighten the locking screw on
the main drive belt tensioner.

Reinstall the Main Logic Board

1. See Figure 349 on page 607. Reinstall the main logic board (MLB).
2. See Figure 348 on page 606. Reconnect all cables to the MLB.

608
Remove the Old Case Light Assembly
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 351. Remove the case light from J27 on the MLB.

Figure 351 Case Light Main Logic Board Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J27

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

3. Turn the printer to the media side.

609
 4. See Figure 352. Remove the mounting screw, and then, while guiding the case light cable through the
mounting hole, lift the case light assembly out of the printer.

Figure 352 Remove the Case Light Assembly

1 Case light mounting hole

2 Case light mounting screw hole
3 Case light assembly
4 Case light mounting screw

Install the New Case Light

1. See Figure 352. Guide the case light cable through the mounting hole and over the top of the MLB.

2. Insert the tab of the new case light into the case light mounting hole and slide it down until the mounting
screw hole aligns with the hole in the case light.
3. Install the mounting screw.

4. Turn to the electronics side and connect the case light cable to J27 on the MLB.

610
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

611
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

612
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

613
USB Cover Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the USB Cover Maintenance Kit in
ZT600 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 in Table 56.

Figure 353 Kit Contents

1

Table 56 Parts List

 Item Description Qty
Ref USB Cover Maintenance Kit
1 USB Cover 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Non-Conductive Spudger Tool • Wire Cutters
(black stick)

Remove the Old USB Cover

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. See Figure 354. If the cover is not already off, you can pull it out or cut it off with a pair of wire cutters.

Figure 354 Remove the USB Port Cover

1

3
2

1 Control panel
2 USB ports
3 USB cover
4 Cut or torn extension tab

615
Install the New USB Cover
1. See Figure 355. Using a plastic spudger tool, press the new USB cover extension tab all the way into
the extension tab mounting hole.

Figure 355 Install the New USB Cover

2
5

1 Control panel
2 Extension tab mounting hole
3 USB cover
4 Spudger tool
5 Extension tab

The Installation is Complete.

616
USB Board and Cover Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the USB Board and Cover Maintenance
Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contain the parts for your printer listed below in Table 57.

Figure 356 Kit Contents

1
4

Table 57 Parts List

 Item Description Qty
Ref USB Board and Cover Maintenance Kit
1 USB Board 1
2 Hexalobular Screw, M3 × 6 4
3 USB Cable 1
4 USB Cover Maintenance Kit 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Wire Cutters • Non-Conductive Spudger Tool
(black stick)
• Safety Glasses

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.
3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

618
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

619
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

620
Remove the Control Panel
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 357. Disconnect the USB cable from J17 on the main logic board.

Figure 357 MLB Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J49
J17 J35

J26

J17
J40
J19

J39
J37 J38

621
3. See Figure 358. Remove the USB cable from the printer by removing it from the two cable clamps.

Figure 358 Cable Clamps

1 Cable clamps (2)

2 USB board
3 USB cable connector

4. Disconnect the USB cable from the USB board.

622
5. See Figure 359. Remove the two control panel mounting screws.

Figure 359 Remove the Control Panel

o

1 Control panel
2 Control panel mounting screws (2)
3 Main frame pass-through hole

6. Slide the control panel out of the printer while guiding the cables through the main frame pass-through
hole.

623
7. See Figure 360. Disconnect all cables from the control panel.

Figure 360 Disconnect Control Panel Cables

J7

J3 J7 J8
J8
J3

J17

J1 J1

J5

J1 Control panel MLB interface

J3 MLB to LCD interface
J5 NFC antenna
J7 Take-label sensor
J8 Take-label sensor
J17 LCD FLEX interface

624
Remove the USB Interface Board
1. See Figure 361. Remove and discard the four mounting screws.

Figure 361 Remove the Four Mounting Screws

2
3

1 USB board
2 Mounting screws (4)
3 Mounting hole

2. Remove and discard the old USB board.

Install the New USB Interface Board

1. If not already connected, connect the USB cable to the USB interface board.

2. See Figure 361. Align the mounting holes in the USB interface board with the mounting holes in the
printer main frame.
3. Install the four mounting screws.

4. Connect the USB cable to J3 0n the USB board.

5. See Figure 357 on page 621. Connect the other end of the USB cable to J17 on the MLB.

6. Insert the USB cable into the cable clamps.

7. Reinstall the cable clamp nuts.

625
Remove and Install the USB Cover
1. See Figure 362. If the cover is not already off you can pull it out or cut it off with a pair of wire cutters.

Figure 362 Remove the USB Port Cover

1

3 2
4

1 Control panel
2 USB ports
3 USB cover
4 Cut or torn extension tab

626
 2. See Figure 363. Using a plastic spudger tool, press the new USB cover extension tab all the way into
the control panel mounting hole.

Figure 363 Install the New USB Cover

2
5

1 Control panel
2 Extension tab mounting hole
3 USB cover
4 Spudger tool (black stick)
5 Extension tab

Reinstall the Control Panel

1. See Figure 359 on page 623. Guide the cables through the pass-through hole in the main frame.

2. Reconnect all cables to the control panel.

3. Align the two control panel mounting holes.

4. Reinstall the two mounting screws.

627
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

628
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

629
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

630
Main Logic Board Replacement Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Main Logic Board (MLB)
Replacement Kit in the ZT600 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 in Table 58 on page 631.

Figure 364 Kit Contents

Table 58 Kit Parts List

 Item Description Qty
Ref Main Logic Board (MLB) Maintenance Kit
1 MLB 1
2 Screws, 3 × 6 6
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Metric Hexalobular Key Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.
3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

632
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

633
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

7. Which option/options do you have installed?

If you have an… Then…

Applicator interface board Go to Remove the Applicator Interface Board on page 635.
IPv4 Internal print server Go to Remove the IPv4 Internal Print Server on page 636.
Wireless board with external Go to Remove the Wireless Print Server on page 637.
antenna
USB Port host board Go to Remove the USB Host Board on page 639.
Parallel port board Go to Remove the Parallel Port Board on page 640.
None Go to Remove the Old Main Logic Board (MLB) on page 641.

634
Remove the Applicator Interface Board
NOTE: The applicator interface board can be used in the upper or lower option slots.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 365. Remove the applicator interface board by removing the two screws securing it to the
printer, and then pulling it out of the printer.

Figure 365 Remove the Applicator Interface Board

1
2

1
2

1 Applicator interface board

2 Mounting screws (2)

3. Go to Remove the Old Main Logic Board (MLB) on page 641.

635
Remove the IPv4 Internal Print Server
NOTE: The internal print server board can only be used in the lower option slot.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 366. Remove the internal print server board by removing the two screws securing it to the
printer, and then pulling it out of the printer.

Figure 366 Remove the Internal Print Server Board

1
2

1 Internal print server board

2 Mounting screws (2)

3. Go to Remove the Old Main Logic Board (MLB) on page 641.

636
Remove the Wireless Print Server
NOTE: The wireless print server board can only be used in the upper option slot.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 367. Remove the wireless print server antenna.

Figure 367 Remove the Antenna

1

1 Back plate
2 RF antenna
3 RF connector

637
3. See Figure 366. Remove the internal print server board by removing the two screws securing it to the
printer, and then pulling it out of the printer.

Figure 368 Remove the Wireless Print Server Board

1
2

1 Wireless print server board

2 Mounting screws (2)

4. Go to Remove the Old Main Logic Board (MLB) on page 641.

638
Remove the USB Host Board
NOTE: The USB host board can be used in the upper or lower option slots.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 369. Remove the USB host board by removing the two screws securing it to the printer, and
then pulling it out of the printer.

Figure 369 Remove the USB Host Board

1
2

1
2

1 USB host board

2 Mounting screws (2)

3. Go to Remove the Old Main Logic Board (MLB) on page 641.

639
Remove the Parallel Port Board
NOTE: The parallel port board can be used in the upper or lower option slots.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 370. Remove the two screws securing the parallel port board to the printer, and then pull it
out of the printer.

Figure 370 Remove the Parallel Port Board

1
2

1
2

1 Parallel port board

2 Mounting screws (2)

3. Go to Remove the Old Main Logic Board (MLB) on page 641.

640
Remove the Old Main Logic Board (MLB)
1. See Figure 371. Disconnect all cables from the MLB.

Figure 371 Disconnect all Cables

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

J1 Upper Option Board J34 Printhead

J13 Internal Use Only J35 Cutter/Rewind/Liner Take-Up
J15 Control Panel Serial and Control J37 Power Supply Input
J16 Control Panel LVDS Display J38 Power Supply Input
J17 Front Panel USB J39 Auxiliary Power Output
J18 Future Use J40 RFID
J19 Future Use J41 Media Low Quadrature Sensor
J20 Media Path Lights J42 Ribbon Low Sensor
J21 Transmissive Sensor Detector J43 Media Low Sensor
J22 Rewind Detect Sensor J44 Black Mark Sensor
J25 Future Use J45 Ribbon Sensor
J26 Drive Motor J46 Head Open Sensor
J27 Print Mechanism Lights J47 Transmissive Sensor LED Control
J28 Media Bay Lights J48 Ribbon Low Quadrature Sensor
J29 Ribbon Path Lights J49 Lower Option Board

641
2. See Figure 372. Remove the MLB by removing the six screws securing it.

Figure 372 Remove the MLB

642
Install the New Main Logic Board (MLB)
1. See Figure 372 on page 642. Align the new MLB with the mounting studs, and then install the six new
mounting screws.
2. See Figure 371 on page 641. Reconnect all cables to the MLB.

3. Which option/options did you remove?

If you have an… Then…

Applicator interface board a. See Figure 365 on page 635. Insert the applicator board into the
slot that you removed it from, and then push it onto the MLB until it
hits the printer.
b. Install the two mounting screw, remove previously.
c. Go to Reinstall the Electronics Cover on page 644.
IPv4 Internal print server a. See Figure 366 on page 636. Insert the internal print server into the
lower option slot, and then push it onto the MLB until it hits the
printer.
b. Install the two mounting screws remove previously.
c. Go to Reinstall the Electronics Cover on page 644.
Wireless board with external a. See Figure 368 on page 638. Insert the wireless print server into
antenna the upper option slot, and then push it onto the MLB until it hits the
printer.
b. Install the two mounting screws remove previously.
c. See Figure 367 on page 637. Reinstall the antenna.
d. Go to Reinstall the Electronics Cover on page 644.
USB host board a. See Figure 369 on page 639. Insert the USB host board into the
slot that you removed it from, and then push it onto the MLB until it
hits the printer.
b. Install the two mounting screws remove previously.
c. Go to Reinstall the Electronics Cover on page 644.
Parallel Port a. See Figure 370 on page 640. Insert the parallel port board into the
slot that you removed it from, and then push it onto the MLB until it
hits the printer.
b. Install the two mounting screws remove previously.
c. Go to Reinstall the Electronics Cover on page 644.
None Go to Reinstall the Electronics Cover on page 644.

643
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

644
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

645
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

646
Power Supply Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Power Supply Assembly
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed below in Table 59.

Figure 373 Kit Contents

Table 59 Parts List

 Item Description Qty
Ref Power Supply Maintenance Kit
1 Power Supply 1
2 Hexalobular Screw, M3 × 6 4
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Antistatic Wriststrap and Pad • Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.
3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

648
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

649
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

650
Remove the Old Power Supply
Figure 374 Power Supply Front and Rear Views

7
6

1 Power output to main logic board (MLB)

2 Data/Power cable to MLB
3 Power output to the printhead
4 On/Off switch
5 AC power cord receptacle
6 Rear view
7 Front view

651
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 375. Remove all cables to and from the power supply.

Figure 375 Disconnect all Cables

1 Power supply mounting screws (4)

3. Remove the four mounting screws.

4. Slide the power supply toward the front of the printer, and then lift it out of the printer.

652
 Figure 376 Remove the Power Supply

1 Power supply

Install the New Power Supply

1. See Figure 377. Set the new power supply into the printer, and then slide it to rear of the printer.

Figure 377 Install the New Power Supply

1 Power supply

653
2. See Figure 378. Insert the power supply switch and AC receptacle into the access holes in the rear
panel.

Figure 378 Secure the New Power Supply

2
3 2

1 Power supply
2 Power supply mounting screws (4)
3 AC power cord receptacle
4 On/Off switch

3. Install the two rear outside power supply mounting screws.

4. Install the two inside power supply mounting screws.

5. Connect all power supply cables.

654
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

655
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

656
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

657
Connectivity Board Maintenance Kit

This kit includes the parts and documentation necessary to install the Connectivity Board Maintenance Kit
in the ZT600 Series Printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 60 on page 658.

Figure 379 Kit Contents

2 3

MANUFACTURER LOGO

Zebra part number

DATE CODE (WW/YY)

UL FILE NUMBER UL TYPE V-0

Table 60 Kit Parts List

 Item Description Qty
Ref Connectivity Board Maintenance Kit
1 Connectivity Board 1
2 Standoff, 4-40 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 60 Kit Parts List
 Item Description Qty
3 #4 Lock Washer 2
4 Hexalobular Screws, M3 × 6 2
5 Flex Cable 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Mat and Wrist Strap

659
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.
3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

660
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

661
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

662
Remove the Old Connectivity Board
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 380. Disconnect the cable from J3 on the main logic board.

Figure 380 Disconnect the Cable from the Main Logic Board
J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

J3 Connector latch

3. Lift this to release the cable.

663
4. See Figure 381. Remove the mounting screws, standoffs, and washers securing the connectivity board
to the printer.

Figure 381 Remove the Mounting Hardware

1
2

1 Connectivity board
2 Mounting screw (2)
3 Standoff (2)
4 Lock washer (2)

1. Remove the old connectivity board from the printer.

664
Install the New Connectivity Board
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 381. Slide the new connectivity board into the printer and align the mounting holes.

3. Install, but do not tighten the two mounting screws.

4. Align and install the two serial port standoffs and washers.
5. Tighten the standoffs and mounting screws.

6. See Figure 380 on page 663 and Figure on page 658. Align the happy face on the flex cable with the
happy face on the connectivity board, and then connect the flex cable to J3 on the connectivity board
and J3 on the MLB.
7. Lock the cable in place by pushing down on the connector latches.

665
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

666
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

667
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

668
IPv4 Internal Print Server
Option/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the IPv4 Internal Print Server
Option/Maintenance Kit in the ZT600 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 in Table 61.

Figure 382 Kit Contents

Table 61 Parts List

 Item Description Qty
Ref IPv4 Internal Print Server Option/Maintenance Kit
1 IPv4 Internal Print Server 1
2 Hexalobular Screws, M3 × 0.5 × 6 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Driver Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Getting Started
1. See Figure 383 to verify the slots that can be used for the various option cards.

Figure 383 Option Card Locations

1 2 3 4 5

3 4 6
1 2

1 Blank cover
2 Parallel port
3 Applicator interface
4 Ethernet
5 Wireless (only in this location)
6 Internal print server IPV4 (only in this location)

Are you replacing an existing option card?

If… Then…
Yes Go to Remove the Old Option Card.
No Go to Remove the Cover Plate on page 672.

670
Remove the Old Option Card
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.
3. See Figure 384. Remove the two option board mounting screws.

Figure 384 Remove the Option Card

1 Option card
2 Mounting screws (2)

4. Slide the option card out of the printer.

5. Go to Install the IPv4 Internal Print Server on page 673.

671
Remove the Cover Plate
1. See Figure 385. Remove the blank cover by removing the two mounting screws.

Figure 385 Remove the Blank Cover

1 Blank cover
2 Mounting screws (2)

2. Go to Install the IPv4 Internal Print Server on page 673.

672
Install the IPv4 Internal Print Server
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 386. Align the IPv4 internal print server card with the option card guide slots.

Figure 386 Install the New IPv4 Internal Print Server Card

1 3

5
2

1 IPv4 internal print server card

2 Option card guide slots (2)
3 IPv4 internal print server connector
4 Locating post
5 Locating notch

3. Slowly slide the IPv4 internal print server into the printer until it stops.

4. Ensure that the option card connector is aligned with the main logic board connector, and then push it
in on the top and bottom until it is against the printer.
5. Install the two mounting screws.

673
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

674
USB Host Option/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the USB Host Option/Maintenance Kit in
the ZT600 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 in Table 62.

Figure 387 Kit Contents

Table 62 Parts List

 Item Description Qty
Ref USB Host Option/Maintenance Kit
1 USB Host Card 1
2 Hexalobular Screws, M3 × 0.5 × 6 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat

The USB Host Option can be installed in either the top or bottom slot.
Are you replacing an existing option card?

If… Then…
Yes Go to Remove the Old Option Card.
No Go to Remove the Cover Plate on page 678.

676
Remove the Old Option Card
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. See Figure 388. Remove the two option card mounting screws.

Figure 388 Remove the Option Card

1 Option card
2 Mounting screws (2)

4. Go to Install the New USB Host Card on page 679.

677
Remove the Cover Plate
1. See Figure 389. Remove the blank cover by removing the two mounting screws.

Figure 389 Remove the Blank Cover

1 Blank cover
2 Mounting screws (2)

2. Go to Install the New USB Host Card.

678
Install the New USB Host Card
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 390. Align the USB Host card with the option card guides.

Figure 390 Install the New USB Host Option Card

2

3
4

1 USB Host option card

2 Option card guide (2)
3 Option card to main logic board connector
4 Mounting screws (2)

3. Slowly slide the USB host option card into the printer until it stops.

4. Ensure that the option card is aligned with the main logic board connector, and then push it in on the
top and bottom until it is against the printer.

679
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

680
Applicator Interface Option/Maintenance
Kit for ZT600 Series Printers
This kit includes the parts and documentation necessary to install the Applicator Interface
Option/Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.
IMPORTANT: A qualified service technician must perform this installation.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 63.

Figure 391 Kit Contents

1

Table 63 Parts List

 Item Description Qty
Ref Printers Applicator Interface Option/Maintenance Kit
1 Applicator Interface 1
2 Hexoglobular Screw, M3 × 6 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Metric Hexoglobular Wrench Set • Antistatic Wriststrap and Mat
• Hexoglobular Screwdriver Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Applicator Interface Option
The optional Applicator Interface provides a robust electrical signal interface between the printer and the
outside world via a standard DB15 connector (see Figure 392 on page 683). The applicator input signals
allow an external device to control when the printer prints. The applicator output signals provide
handshaking and status information to the external host.
The applicator provides 5V or 24V of power to run the I/O interface and to power small external loads. All
output signals are open collector with a light pull-up resistor built in. All signals and power are galvanically
isolated from the host printer. The applicator provides a jumper to connect printer and applicator grounds,
if required, but the default setting is isolation.
The applicator output voltage can be set to three levels: 0Vdc, 5Vdc and 24Vdc. The 0V setting can be
used if the application requires a unique voltage—12V for example, but 12V must be provided externally.
Setting of voltages (0V, 5V, 24V) is done through Set-Get-Do (SGD) command. (See Applicator
Specifications on page 683.)
The applicator output power supply can sustain momentary short circuits but may be damaged with
long-term shorts. There are no user-replaceable fuses on the applicator option PCBA.

Energy Star Effect on the Applicator Board

If the Energy Star feature is enabled and the printer goes to sleep, the applicator board shuts down. If the
applicator board needs to remain on at all times, disable the Energy Star feature in one of the following
ways:
• Setting the Energy Star user menu item to OFF:

• Sending the Energy Star disabling SGD command:

! U1 setvar "power.energy_star.enable"
"off"
To re-enable Energy Star, send the SGD command with the value "on".

682
Applicator Specifications

Table 64 •
Output voltage selections • 0 volts
• 5 Vdc (+/- 10%) <= 1.0 Adc
• 24 volts (+/- 10%) <= 0.4 Adc
Set by the following SGD command:
! U1 setvar "device.applicator.voltage" "X"
where X is 0, 5, or 24 to indicate the desired voltage. The printer
must be power cycled before the setting takes effect.

A high-voltage lockout jumper installed on the applicator

interface PCBA prevents the output from going above 5V,
even if the SGD is sent for 24V output. This precaution
prevents accidental damage to external equipment. The
jumper must be repositioned to allow for 24V operation.
The default setting is for 5V operation.
Pull-up resistor on output 10K +/- 5%
Pull-up resistor on input 4.7K +/- 5%
Output signal current sink <= 7 mAdc
User-supplied voltage range when 0–24 volts
output voltage set to 0V

Applicator Option External Pinouts

Figure 392 DB15 Connector

683
Figure 393 External Pinouts
DC-DC Power Converter DB-15
(Isolated Input) Connector

Printer V OUT V OUT

Power High- 7 OUTPUT
voltage V OUT POWER
lockout 2
GND ISO
GND GND ISO 1
GND ISO
8

Jumper J3 Jumper J5
High-voltage Isolation
lockout

START PRINT
Typical Input 3
FEED
V OUT 4
PAUSE INPUT
5
4.7K Ohm REPRINT
6

RIBBON LOW
9
SERVICE REQUIRED
10
END PRINT
Typical Output 11
MEDIA OUT OUTPUT
V OUT 12
RIBBON OUT
13
DATA READY
10K Ohm 14
RFID VOID
15

2NF
GND ISO GND Chassis

684
Jumper Configuration
Figure 394 Location of Jumpers J3 and J5 on the Applicator Board

DB15 connector

Jumper J3 — High-Voltage Lockout

Pins 1 and 2 connected

V out = 5V max (default)
3 2 1

Pins 2 and 3 connected

V out = 0V, 5V, 24V
3 2 1

Jumper J5 — Ground Isolation Jumper

Pins 1 and 2 connected

3

isolated (default)
2
1

Pins 2 and 3 connected

3

not isolated
2
1

685
Applicator Interface Pin Configuration

Table 65 Applicator Interface Connector Pin Configuration

Pin No. Signal Name Signal Type Description
1 GROUND Ground Using jumper J5, this pin can be configured as isolated
ISOLATED or non-isolated from the printer circuit ground (see
Jumper Configuration on page 685). Default position is
set to isolation.
2 VOUT Power Programmable output voltage of 0V, 5Vdc, 24Vdc.
Voltage selection done by SGD command. Depending
on configuration, jumper J3 will lock out 24V operation
(see Jumper Configuration on page 685). If set in 5V
position, only 0V and 5V will be available. If set to 24V
position, 0V, 5V and 24V will be available, depending
on the SGD command. Default is 5V configuration.
3 START PRINT Input See Applicator Signals on page 688 for more
information about the start and end print signals.
• Pulse Mode—The label printing process begins on
the HIGH to LOW transition of this signal if a format
is ready. Deassert this signal HIGH to inhibit
printing of a new label.
• Level Mode—Assert LOW to enable the printer to
print if a label format is ready. When deasserted
HIGH, the printer completes the label that is printing
then stops and waits for this input to be reasserted
LOW.
4 FEED Input When the printer is idle or has been paused, assert this
input LOW to trigger repeated feeding of blank labels.
Deassert HIGH to stop feeding blank labels and
register to the top of the next label.
5 PAUSE Input To toggle the current Pause state, this input must be
asserted LOW for 200 milliseconds, or until the
SERVICE REQUIRED output (pin 10) changes state.
6 REPRINT Input • If the Reprint feature is enabled, this input must be
asserted LOW to cause the printer to reprint the last
label.
• If the Reprint feature is disabled, this input is
ignored.
7 VOUT Power Programmable output voltage of 0V, 5Vdc, 24Vdc.
Voltage selection done by SGD command. Depending
on configuration, jumper J3 will lock out 24V operation
(see Jumper Configuration on page 685). If set in 5V
position, only 0V and 5V will be available. If set to 24V
position, 0V, 5V and 24V will be available, depending
on the SGD command. Default is 5V configuration.

686
Table 65 Applicator Interface Connector Pin Configuration (Continued)
Pin No. Signal Name Signal Type Description
8 GROUND Ground Using jumper J5, this pin can be configured as isolated
ISOLATED or non-isolated from the printer circuit ground (see
Jumper Configuration on page 685). Default position is
set to isolation.
9 RIBBON LOW Output Asserted LOW if the Supplies Warning feature is
enabled and the amount of ribbon remaining on the
supply spindle is below the threshold level.
10 SERVICE Output Asserted LOW in the following circumstances:
REQUIRED
• the printhead is open
• the ribbon or media is out
• the printer is paused
• an operational fault occurs
• a Resynch error occurs while the applicator
Resynch mode is set to Error mode
11 END PRINT Output See Applicator Signals on page 688 for more
information about the start and end print signals.

A format (^XA ... ^XZ) that does not print will

signal that it is being processed. However, it will
not trigger an End Print signal because no
motion/printing is required.
• MODE 0—The applicator port is OFF.
• MODE 1—Asserted LOW only while the printer is
moving the label forward; otherwise deasserted
HIGH.
• MODE 2—Asserted HIGH only while the printer is
moving the label forward; otherwise deasserted
LOW.
• MODE 3—(Default) Asserted LOW for 20
milliseconds when a label is completed and
positioned. Not asserted during continuous printing.
• MODE 4—Asserted HIGH for 20 milliseconds when
a label is completed and positioned. Not asserted
during continuous printing.
12 MEDIA OUT Output Asserted LOW when there is no media in the printer.

687
 Table 65 Applicator Interface Connector Pin Configuration (Continued)
Pin No. Signal Name Signal Type Description
13 RIBBON OUT Output Asserted LOW when there is no ribbon in the printer.
14 DATA READY Output See Applicator Signals on page 688 for more
information about this signal.
• Asserted LOW when sufficient data has been
received to begin processing the next label format.
• Deasserted HIGH when printing/processing stops
after the current label format, either due to a pause
condition or the absence of a label format.
15 RFID VOID Output • Asserted LOW when the RFID transponder over the
antenna is “voided.”
• Deasserted HIGH when the end print signal is
asserted.

Applicator Signals
The following timing diagrams show how applicator signals function in each applicator mode during the
stages of printing a non-RFID label. For more information about applicator signals during RFID operation,
see the RFID Programming Guide 3.

Figure 395 Applicator Signals (Mode 1)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

Figure 396 Applicator Signals (Mode 2)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

688
Figure 397 Applicator Signals (Mode 3)
label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

Figure 398 Applicator Signals (Mode 4)

label label waiting label ready
format format for start prints for next
sent processed print signal label
not ready
DATA READY
(pin 14)
ready
do not start
START PRINT
(pin 3)
start
do not end
END PRINT
(pin 11)
end

689
Remove the Old Option Card or Cover Plate
1. See Figure 399 to verify the slots that can be used for the various option cards.

Figure 399 Option Card Locations (ZT600 Shown)

4 5
3
1 2

4 6
2 3
1

1 Blank cover
2 Parallel port
3 Applicator interface
4 Ethernet
5 Wireless (only in this location)
6 Internal print server IPV4 (only in this location)

Are you replacing an existing option card?

If… Then…
Yes Go to Remove the Old Option Card on page 691.
No Go to Remove the Cover Plate on page 692.

690
Remove the Old Option Card
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. See Figure 400. Remove the two option card mounting screws from the top or bottom slots.

Figure 400 Remove the Option Card (ZT600 Shown)

1

1 Option card
2 Mounting screws (2)

4. Slide the option card out of the printer.

5. Go to Install the New Applicator Interface on page 693.

691
Remove the Cover Plate
1. See Figure 401. Remove the blank cover covering the top slot by removing the two mounting screws.

Figure 401 Remove the Blank Cover (ZT600 Shown)

1

1 Blank cover
2 Mounting screws (2)

2. Go to Install the New Applicator Interface on page 693.

692
Install the New Applicator Interface

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Make sure the applicator interface option board is configured according to your requirements.
i. Verify that the high-voltage lockout jumper matches your voltage requirements. See Jumper J3
— High-Voltage Lockout on page 685.
ii. Verify that the ground isolation jumper is set to match your requirements. See Jumper J5 —
Ground Isolation Jumper on page 685.
3. See Figure 402. Align the applicator option card with the option card guide slots in the top or bottom slot
of the printer.

Figure 402 Install the Applicator Interface Card (ZT600 shown)

1

5 2

1 Applicator interface option card

2 Option card guide slots (2)
3 Locating post
4 Locating notch
5 Mounting screws (2)

4. Slowly slide the applicator interface card into the printer until it stops.

5. Ensure that the option card connector is aligned with the main logic board connector, and then push it
in on the top and bottom until it is against the printer.
6. Install the two mounting screws.

7. Reconnect the AC power cord and all data cables, and then turn on (l) the printer.

693
Resume Operation with the New Option Board
1. If necessary, change your Energy Star setting, see Energy Star Effect on the Applicator Board on
page 682.
2. If necessary, change the voltage using the SGD command, see Applicator Specifications on page 683.

3. To see your changes, you must turn the printer off and then on.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

694
Parallel Port Option/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Parallel Port Option/Maintenance Kit
in the ZT600 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 in Table 66.

Figure 403 Kit Contents

Table 66 Parts List

 Item Description Qty
Ref Parallel Port Option/Maintenance Kit
1 Parallel Port 1
2 Hexalobular Screws, M3 × 0.5 × 6 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Tors-Head Wrench Set • Antistatic Wriststrap and Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Getting Started
1. See Figure 404 to verify the slots that can be used for the various option cards.

Figure 404 Option Card Locations

1 2 3 4 5

3 4 6
1 2

1 Blank cover
2 Parallel port
3 Applicator interface
4 Ethernet
5 Wireless (only in this location)
6 Internal print server IPV4 (only in this location)

Are you replacing an existing option card?

If… Then…
Yes Go to Remove the Option Card.
No Go to Remove the Cover Plate on page 698.

Remove the Old Option Card

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

696
3. See Figure 405. Remove the two option card mounting screws.

Figure 405 Remove the Option Card

1 Option card
2 Mounting screws (2)

4. Go to Install the New Parallel Port Option Card on page 699.

697
Remove the Cover Plate
1. See Figure 406. Remove the blank cover by removing the two mounting screws.

Figure 406 Remove the Blank Cover

1

1 Blank cover
2 Mounting screws (2)

2. Go to Install the New Parallel Port Option Card.

698
Install the New Parallel Port Card
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 407. Align the parallel port option card with the main logic card guides.

Figure 407 Install the New Parallel Port Option Card

-

3
4

1 Parallel port option card

2 Option card guide slots (2)
3 Parallel option card to main logic board connector
4 Mounting screws (2)

3. Slowly slide the parallel port option card into the printer until it stops.

4. Ensure that the option card is aligned with the main logic board connector, and then push it in on the
top and bottom until it is against the printer.
5. Install the two mounting screws.

699
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

700
ZebraNet 802.11ac Radio Wireless
Print Server Option/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the ZebraNet 802.11ac Radio Wireless
Print Server Option/Maintenance Kit in the ZT620, ZT510, ZT410, ZT411, ZT420, and ZT421 Printers.
Read these instructions thoroughly before installing this kit.
IMPORTANT: If the print server is being used in countries outside of the USA, Canada, or Japan, a
qualified service technician must perform this installation.

NOTE: Check the part number in the media side of your ZT410/ZT420 Printer. This kit is used on
ZT410/ZT420 Printers with the letter A in the 6th position of the part number. Example: ZT4x0A-xxxxxxxx.
If the part number does not have the letter A in the 6th position of the part number the printer firmware
must be updated to version V75.20.14Z, or later, before installation.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 67 on page 702.

Figure 408 Kit Contents

UID#.
IID#.
UI
U D#.
ID

3
T400
ZT400
T400
T4
ZT
Z 0
UID#.
D#.
ID
UI
U

4
ZT510
ZT
ZT510
T5

6
UID#.
D#.
D#
IID
UI
U

5
ZT600
600
ZT600

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 67 Parts List
 Item Description Qty
Ref Wireless Print Server 802.11ac Radio Option/Maintenance Kit, Region A (USA
and Canada)
Wireless Print Server 802.11ac Radio Option/Maintenance Kit, Region B
(Japan)
Wireless Print Server 802.11ac Radio Option/Maintenance Kit, Region C (All
other countries other than regions, A and B)
1 Wireless Print Server 802.11ac Radio Option
2 ZebraNet Print Server 802.11ac Antenna 1
3 ZT410, ZT411, ZT420, ZT421 Printer Compliance Label 1
5 ZT600 series Compliance Label 1
6 Screws, M3 × 0.5 × 6 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Phillips Screwdriver Set
• Programming Guide for ZPL II, ZBI 2, Set-Get-Do, Mirror, and WML (P1012728-005 or later) or
Internet access to download the guide from zebra.com.

NOTE: Installing this print server disables the ZT410/ZT420 Printer’s PrintTouch capability. After
installation, Bluetooth devices must be paired with the printer manually.

Prepare for Installation

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.Are you replacing an existing option card?

If… Then…
Yes Go to Remove the Old Option Card.
No Go to Remove the Cover Plate on page 705.

702
Remove the Old Option Card
1. See Figure 409 to verify the slots that can be used for the various option cards.

Figure 409 Option Card Locations

1 2 3 4 5

3 4 6
1 2

1 Blank cover
2 Parallel port
3 Applicator interface
4 USB Host
5 Wireless (only in this location)
6 Internal print server IPV4 (only in this location)

703
2. See Figure 410. Remove the two option card mounting screws that secure it to the top slot.

Figure 410 Remove the Option Card

1 Option card
2 Mounting screws (2)

3. Slide the option card out of the printer.

4. Go to Install the ZebraNet 802.11ac Radio Print Server on page 706.

704
Remove the Cover Plate
1. See Figure 411. Remove the blank cover covering the top slot by removing the two mounting screws.

Figure 411 Remove the Blank Cover

1 Blank cover
2 Mounting screws (2)

705
Install the ZebraNet 802.11ac Radio Print Server
1. See Figure 412. Align the print server card with the option card guide slots in the top slot of the printer.

Figure 412 Install the New ZebraNet Print Server Card

2
1

4
3

1 Wireless print server card

2 Option card guide slots (2)
3 Wireless print server card connector
4 Locating post
5 Locating notch

2. Slowly slide the wireless option card into the printer until it stops.

3. Ensure that the option card connector is aligned with the main logic board connector, and then push in
the card on the top and bottom until the card is flush with the back of the printer.
4. Install the two mounting screws.

706
5. See Figure 413. To install the external antenna, screw the antenna onto the RF connector extending
out of the option card.

Figure 413 Close-up of Antenna Installation

1

1 Option card mounting plate

2 RF antenna
3 RF connector

707
Apply the Compliance Label on ZT600 Series and ZT510 Printers
1. Open the media door and remove the media.

2. See Figure 414. Locate the Product Label, already in place.

Figure 414 Locate the Product Label (ZT600 series shown)

UID#.
UID
D#.
D UID#.
UID
D#
D#.
D

ZT610
Z
ZT6
T610
T6
610
0 ZT610
ZT6
ZT
ZT6
610
61 0

1 2

1 Product label, ZT600 series and

ZT510
2 Compliance label

3. Select the proper compliance label for your printer.

4. Peel the backing off of the label, (ZT600 series or ZT510 printer), and then install the label beside the
product label as shown in Figure 414.
5. Reinstall the media.

708
Programming the ZebraNet 802.11ac Radio Wireless Print Server
You may need to set your country code to enable the 5 Ghz band for the print server.
1. Is the printer to be used in the United States, Canada, or Japan?

If… Then…
Yes 2. The country codes have been preset at the factory and cannot be changed.
No 3. Send the following Set/Get/Do to set the country code for which the radio is to be
configured.
! U1 setvar "wlan.country_code" "value"

Once this code has been set, it can not be changed.

The list of country codes is specific to each printer and depends on the printer model
and its wireless radio configuration. The list is subject to change, addition, or deletion
with any firmware update, at any time, without notice.
To determine the country codes available on your printer, you can issue the following
command to return all commands related to WLAN settings. Locate the
wlan.country.code command in the results and view the country codes available for
your printer.
! U1 getvar "wlan"

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

709
ZT610 RFID Upgrade/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the RFID Upgrade/Maintenance Kit in
the ZT610 printer.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 68 on page 710.

Figure 415 Kit Contents

2 2

7 6
4
5

Table 68 Parts List

 Item Description Qty
Ref RFID Upgrade Kit USA and Canada
RFID Upgrade Kit Japan
RFID Upgrade Kit All Countries except, USA, Canada, and Japan,
1 RFID Module 1
2 Hexalobular Screw, M3 × 8 2
3 RFID Roller 1
4 RFID Shaft 1
5 RFID Name Plate 1
6 RFID Test Labels 1
7 RFID Label (for option kit use only) 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Antistatic Wriststrap and Mat
• Hexalobular Wrench Set
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

1. CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the
following procedure.Disconnect the AC power cord and all data cables.
2. Remove the media and ribbon.

3. Are you installing this kit as a new option?

If… Then…
Yes Go to Remove the Media Support, Roller, and Shaft on page 712.
No Go to Remove the Old RFID Module on page 716.

711
Remove the Media Support, Roller, and Shaft
1. See Figure 416. Open the print mechanism.

Figure 416 Open the Print Mechanism

3
2

1 Toggle bar handle

2 Print mechanism assembly
3 Toggle assembly

712
2. See Figure 417. Remove the media support.

Figure 417 Remove the Media Support

1 Media support
2 Mounting screws (2)
3 Mounting holes (2)

713
3. See Figure 418. Remove the ribbon idler roller and shaft.

Figure 418 Remove the Ribbon Idler

1 Ribbon idler mounting screw

2 Ribbon idler roller, bearings (2), and shaft

714
Install the New Ribbon Idler Roller
1. See Figure 419. Install the RFID ribbon idler roller and shaft into the upper print mechanism.

Figure 419 Install the RFID Ribbon Idler Roller and Shaft

1 Ribbon idler roller and shaft mounting screw

2 Ribbon idler roller and shaft

2. Install the ribbon idler roller and shaft mounting screw.

3. Go to Install the RFID Module on page 719.

715
Remove the Old RFID Module
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 420. Open the print mechanism.

Figure 420 Open the Print Mechanism

3
2

1 Toggle bar handle

2 Upper print mechanism assembly
3 Toggle assembly

716
3. See Figure 421. Remove the RFID module from the printer by removing the two mounting screws.

Figure 421 Remove the RFID Module

1 2

1 RFID module
2 RFID module mounting screws (2)
3 Lower print mechanism assembly

717
4. See Figure 422. Pull the RFID module out of the printer.

Figure 422 Remove the RFID Module

1 RFID module

5. Disconnect the RFID cable from the RFID module.

6. Go to Install the RFID Module on page 719.

718
Install the RFID Module
1. See Figure 423. Connect the RFID cable to the RFID module.

Figure 423 Connect the RFID Cable

1

1 RFID module
2 RFID cable support
3 RFID cable connector

719
2. See Figure 424. Align the RFID module mounting slides with the guides on the lower print mechanism.

Figure 424 Install the RFID Module in the Mounting Slides

3
3 1

1 RFID module
2 RFID module mounting slides (2)
3 RFID mounting lower print mechanism guides (2)

720
3. See Figure 425. Slide the RFID module slides into the guides until the RFID module stops at the side
plate of the lower print mechanism.

Figure 425 Install the RFID Mounting Screws

2
1

1 RFID module
2 RFID module mounting holes (2)
3 RFID module mounting screws (2)

4. Install the two mounting screws.

721
Verify the Operation of the RFID Assembly
1. Reconnect the AC power cord.

2. Turn on (l) the printer.

3. See Figure 426. Lay the test labels supplied in the kit over the RFID assembly with the RFID loop at the
inside edge of the platen roller.

Figure 426 Lay the Test Label onto the RFID Assembly
3

2 4
1

1 Test label
2 Inside edge of platen roller
3 RFID loop
4 Platen roller
5 RFID assembly

4. From the control panel, select the HOME menu.

5. Choose the RFID icon, and then select Read Label.

6. Does the screen fill with numbers (no certain sequence is needed)?

If… Then…
Yes The RFID assembly is working. Go to step 7.
No a. Check all RFID assembly cable connections.
b. Repeat step 5.

7. Unplug the AC power cord.

722
Complete the Installation
1. Are you installing this kit as a new option?

If… Then…
Yes a. See Figure 427. Install the name plate to the upper right corner of the upper trim plate
on the media door.
b. See Figure 428 on page 724. Install the label from the kit.
c. Go to Resume Printer Operation on page 724.
No Go to Resume Printer Operation on page 724.

Figure 427 Install the RFID Name Plate

1
2

1 Upper trim plate

2 RFID name plate

2. See Figure 428. Install the labels as shown.

723
 Figure 428 Install Labels
Reinstall the media and ribbon.

UID#.
UID
D#.
D UID#.
UID
D#
D#.
D

ZT610
Z
ZT6
T610
T6
610
0 ZT610
ZT6
ZT
ZT6
610
61 0

Agency Label RFID Radio Label

Location

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

724
 RFID Upgrade/Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the RFID Upgrade Kit into the ZT620
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 in Table 69 on
page 726.

Figure 429 Kit Contents

1
1

2
2
3

6 5
4

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 69 Parts List
 Item Description Qty
Ref RFID Upgrade Kit USA and Canada
RFID Upgrade Kit Japan
RFID Upgrade Kit All Countries except, USA, Canada, and Japan
1 RFID Module 1
2 Hexalobular Screw, M3 × 8 2
3 RFID Media Support 1
4 RFID Name Plate 1
5 RFID Test Labels 1
6 RFID Label (for option kit use only) 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Antistatic Wriststrap and Mat
• Hexalobular Wrench Set
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

Before Installation
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.
2. Remove the media and ribbon from the printer.

3. Are you installing this kit as an option?

If… Then…
Yes Go to Remove the Media Support on page 727.
No Go to Remove the Old RFID Module on page 729.

726
Remove the Media Support
1. See Figure 430. Remove the media support mounting screws.

Figure 430 Remove the Media Support Mounting Screws

3 2

1 Media support
2 Mounting screws (2)
3 Mounting holes (2)
4 Lower print mechanism

727
2. See Figure 431. Slide the media support out of the lower print mechanism.

Figure 431 Remove the Media Support

1 Media support

3. Go to Install the RFID Module on page 732.

728
Remove the Old RFID Module
1. See Figure 432. Open the print mechanism.

Figure 432 Open the Print Mechanism

3
2

1 Toggle bar handle

2 Upper print mechanism assembly
3 Toggle assembly

729
2. See Figure 433. Remove the RFID module from the printer by removing the two mounting screws.

Figure 433 Remove the RFID Module

1

1 RFID module
2 RFID media support
3 RFID module mounting screws (2)
4 Lower print mechanism assembly

730
3. See Figure 434. Pull the RFID module out of the printer.

Figure 434 Remove the RFID Module

1 RFID module
2 RFID media support

731
 4. See Figure 435. Disconnect the RFID cable from the RFID module.

Figure 435 Disconnect the RFID Cable

5. Go to Install the RFID Module on page 732.

Install the RFID Module

1. See Figure 436 and Figure 435 on page 732. Connect the RFID cable to the RFID module.

Figure 436 Connect the RFID Cable

1

1 RFID module
2 RFID cable connector
3 RFID cable support

2. Align the RFID module mounting slides with the guides on the lower print mechanism.

732
Figure 437 Install the RFID Module in the Mounting Slides
3

2 2

1 RFID module
2 RFID module mounting slides (2)
3 RFID mounting lower print mechanism guides (2)

3. Push the RFID module slides into the guides until the RFID module stops at the printer main frame.
4. See Figure 438. Slide the media support into the lower print mechanism.

Figure 438 Install the Media Support

1

3
3

1 RFID media support

2 RFID module mounting slides (2)
3 RFID mounting lower print mechanism guides (2)

733
5. See Figure 439. Install the two mounting screws.

Figure 439 Install the RFID Mounting Screws

1 Mounting screws (2)

734
Verify the Operation of the RFID Assembly
1. Reconnect the AC power cord.

2. Turn on (l) the printer.

3. See Figure 440. Lay the test labels supplied in the kit over the RFID assembly with the RFID loop at the
inside edge of the platen roller.

Figure 440 Lay the Test Label onto the RFID Assembly
3

4
2

1
5

1 Test label
2 Inside edge of the platen roller
3 RFID loop
4 Platen roller
RFID assembly

4. From the control panel, select the HOME menu.

5. Choose the RFID icon, and then select Read Label.

Does the screen fill with numbers (no certain sequence is needed)?

If… Then…
Yes The RFID assembly is working. Go to step 6.
No a. Check all RFID assembly cable connections.
b. Reposition the RFID test labels.
c. Repeat step 5.

6. Unplug the AC power cord.

735
Complete the Installation
1. Are you installing this kit as an option?

If… Then…
Yes a. See Figure 441. Install the name plate to the upper right corner of the upper trim plate
on the media door.
b. See Figure 442 on page 737. Install the label from the kit.
c. Go to Resume Printer Operation on page 737.
No a. Go to Resume Printer Operation on page 737.

Figure 441 Install the RFID Name Plate

1
2

1 Upper trim plate

2 RFID name plate

736
 2. See Figure 442. Install the labels as shown.

Figure 442 Install Labels

UID#.
UID
D#. UID#.
UID
D#
D#.
D

ZT610
Z
ZT6
T
T6
610
610
0 ZT610
ZT6
ZT
ZT6
610
61 0

Agency Label RFID Radio Label

Location

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

737
RFID Hardware and Cables Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the RFID Hardware and Cables
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed below in Table 70.

Figure 443 Kit Contents

1

2
8

7
3

4
6
5
9

Table 70 Parts List

 Item Description Qty
Ref RFID Hardware and Cables Maintenance Kit
1 ZT610 Radome 1
2 ZT620 Radome 1
3 ZT620 Media Support 1
4 Hexalobular Screw, M3 × 6 1
5 Cable Clamp 1
6 Zip-Twist Nut, 188 4
7 RFID PCBA Mounting Bracket 1
8 Spacer 4
9 RFID Cable 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Antistatic Wriststrap and Mat
• Hexalobular Wrench Set
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

739
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

740
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

741
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

742
Disconnect the RFID Module
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 444. Disconnect the RFID cable from J40 on the main logic board (MLB).

Figure 444 Disconnect the RFID Cable

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J35

J40
J49

J26

J17
J40
J19

J39
J37 J38

743
3. See Figure 445. Remove the nut securing cable clamp, and then remove the RFID Cable.

Figure 445 Cable Routing and Clamps

1

1 Cable clamp

4. Which model are you working on?

If… Then…
ZT610 Go to Remove the ZT610 RFID Module on page 745.
ZT620 Go to Remove the ZT620 RFID Module on page 753.

744
Remove the ZT610 RFID Module
1. See Figure 446. Open the print mechanism.

Figure 446 Open the Print Mechanism

3
2

1 Toggle bar handle

2 Upper print mechanism assembly
3 Toggle bar assembly

2. See Figure 447. Remove the RFID module from the printer by removing the two mounting screws.

745
Figure 447 Remove the RFID Module Mounting Screws
1 2

1 RFID module
2 RFID module mounting screws (2)

3. See Figure 448. Slide the RFID module out of the printer, and then disconnect the RFID cable from the
RFID module.

Figure 448 Remove the RFID Module

1 RFID module

746
4. See Figure 449. Replace all parts needed for the RFID Module.

Figure 449 Replace RFID Module Parts ZT610

1 RFID Radome
2 Spacers (4)
3 RFID PCBA bracket
4 Zip-twist nuts (4)

747
5. See Figure 450. Remove the RFID cable clamp.

Figure 450 Remove the RFID Cable Clamp

1 RFID cable clamp mounting screw

2 RFID cable clamp

6. Remove the RFID cable from the printer.

748
Reinstall the ZT610 RFID Module
1. See Figure 451. Guide the RFID cable through the access hole.

Figure 451 Guide the RFID Cable through the Printer Access Hole
1

1 RFID cable access hole

2. See Figure 444 on page 743. Connect the cable to J40 on the MLB.

3. See Figure 445 on page 744. Route the cable through the electronics side cable clamp.

4. Close the clamp by reinstalling the mounting nut.

5. See Figure 452. Align the RFID cable clamp with the black band in the middle of the RFID cable.

Figure 452 Locate the Black Band

1
2

1 RFID cable clamp

2 Black band

6. See Figure 450 on page 748. Install the RFID cable clamp.

749
7. See Figure 453. Connect the cable to the RFID module.

Figure 453 Connect the RFID Cable

1

1 RFID module
2 RFID cable support
3 RFID cable connector

750
8. See Figure 454. Align the RFID module mounting slides with the guides on the lower print mechanism.

Figure 454 Install the RFID Module in the Mounting Slides

3 3
1

1 RFID module
2 RFID module mounting slides (2)
3 RFID mounting lower print mechanism guides (2)

751
9. See Figure 455. While guiding the RFID cable into the electronics side, slide the RFID module slides
into the guides until the RFID module stops at the side plate of the lower print mechanism.

Figure 455 Install the RFID Mounting Screws

1
2

1 RFID module
2 RFID module mounting holes (2)
3 RFID module mounting screws (2)

10. Install the two mounting screws.

11. Open the printhead, and then using a swab from a Zebra Preventive Maintenance Kit, wipe along the
brown strip on the printhead assembly from end to end. In place of the Preventive Maintenance Kit, you
may use a clean swab dipped in 90% or higher isopropyl alcohol. Allow the solvent to evaporate..
12. Go to Reinstall the Electronics Cover on page 761.

752
Remove the ZT620 RFID Module
1. See Figure 456. Open the print mechanism.

Figure 456 Open the Print Mechanism

3
2

1 Toggle bar handle

2 Upper print mechanism assembly
3 Toggle assembly

753
2. See Figure 457. Remove the RFID module from the printer by removing the two mounting screws.

Figure 457 Remove the RFID Module

1

1 RFID module
2 RFID media support
3 RFID module mounting screws (2)

754
3. See Figure 458. Slide the RFID module and media support out of the printer, and then disconnect the
RFID cable from the RFID module.

Figure 458 Remove the RFID Module and Media Support

1 RFID module
2 RFID media support

755
4. See Figure 459. Remove the RFID cable clamp.

Figure 459 Remove the RFID Cable Clamp

1 RFID cable clamp mounting screw

2 RFID cable clamp

5. Remove the RFID cable from the printer.

756
Install the ZT620 RFID Module
1. See Figure 460. Guide the RFID cable through the access hole.

Figure 460 Guide the RFID Cable through the Printer Access Hole
1

1 RFID cable access hole

2. See Figure 444 on page 743. Connect the cable to J40 on the MLB.
3. See Figure 445 on page 744. Route the cable through the electronics side cable clamp.

4. Close the clamp by reinstalling the mounting nut.

5. See Figure 452 on page 749. Align the RFID cable clamp with the black band in the middle of the RFID
cable.
6. See Figure 459 on page 756. Connect the cable to the RFID module.

757
Figure 461 Connect the RFID Cable
1

1 RFID module
2 RFID cable support
3 RFID cable connector

7. See Figure 462. Align the RFID module mounting slides with the guides on the lower print mechanism.

758
Figure 462 Install the RFID Module in the Mounting Slides

3
1

2
2

1 RFID module
2 RFID module mounting slides (2)
3 RFID mounting lower print mechanism guides (2)

8. Slide the RFID module slides into the guides until the RFID module stops.

759
9. See Figure 463. Slide the media support into the lower print mechanism.

Figure 463 Install the Media Support

1

3
3

1 RFID module
2 RFID module mounting slides (2)
3 RFID mounting lower print mechanism guides (2)

10. See Figure 464. Install the two mounting screws.

Figure 464 Install the RFID Mounting Screws

1 Mounting screws (2)

11. See your User Guide and clean the printhead.

760
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

761
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

762
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

763
Media Sensor Assembly Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Sensor Assembly
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed below in Table 71.

Figure 465 Kit Contents

Table 71 Parts List

 Item Description Qty
Ref Media Sensor Maintenance Kit
1 Media Sensor 1
2 Hexalobular Screws, M4 × 8 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Antistatic Wriststrap and Mat • Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

765
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

766
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

767
Remove the Old Media Sensor
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 466. Disconnect the media sensor cables from J21 and J47 on the main logic board (MLB).

Figure 466 Disconnect the Media Sensor from the MLB

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J47
J21

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

3. Remove the media sensor cable from all cable clamps and cable ties.

768
4. See Figure 467. From the media side, remove the two screws securing the media sensor to the printer.

Figure 467 Remove the Mounting Screws

1

1 Media sensor
2 Mounting screws (2)

769
 5. See Figure 468. While guiding the media sensor cables through the access holes, remove the media
sensor assembly from the printer

Figure 468 Remove the Media Sensor Assembly

1

1 Media sensor
2 Access holes (2)

Install the New Media Sensor

1. See Figure 468. Guide the new media sensor cables through the access holes.

2. See Figure 467 on page 769. Align the media sensor with the mounting holes in the printer main frame.

3. Install the two mounting screws.

4. Connect the new media sensor to J21 and J47 on the MLB.

770
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

771
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

772
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

773
Reflective (Black Mark) Sensor
Assembly Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Reflective (Black Mark) Sensor
Assembly Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed below in Table 72.

Figure 469 Kit Contents

1

Table 72 Parts List

 Item Description Qty
Ref Reflective (Black Mark) Sensor Maintenance Kit
1 Reflective (Black Mark) Sensor 1
2 Hexalobular Screw, M3 × 6 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Antistatic Wriststrap and Pad • Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

775
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

776
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

777
Remove the Old Reflective Sensor
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. See Figure 470. Disconnect the reflective sensor from J44 on the main logic board (MLB).

Figure 470 MLB Connection

J44

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

778
3. See Figure 471. Remove the media guide assembly mounting screws.

Figure 471 Remove the Media Guide Mounting Screws

1

1 Media guide assembly

2 Mounting screws (2)
3 Mounting holes (2)

779
4. See Figure 472. Slide the media guide assembly out of the printer while guiding the reflective (black
mark) sensor cable through the pass-through hole.

Figure 472 Slide the Media Guide Assembly Out of the Printer
1 2

1 Media guide assembly

2 Reflective sensor pass-through hole

780
 5. See Figure 473. Remove the reflective sensor from the media guide assembly by removing the
mounting screw.

Figure 473 Remove the Reflective Sensor

1
2

1 Media guide assembly

2 Reflective sensor
3 Reflective sensor mounting screw
4 Reflective sensor mounting hole
5 Reflective sensor locating pin

Install the New Reflective Sensor

1. See Figure 473 on page 781. Align the new reflective sensor with the mounting hole and locating pin on
the media guide assembly.
2. Install the mounting screw.
3. See Figure 472 on page 780. While guiding the reflective cable, slide the media guide into the printer,
and then align the mounting hole in the media guide with the mounting holes in the printer.
4. See Figure 471 on page 779. Reinstall the two media guide mounting screws.

5. See Figure 470 on page 778. Connect the reflective sensor cable to J44 on the MLB.

6. Install the reflective cable into the proper cable clamps.

781
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

782
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

783
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

784
Ribbon Out Sensor Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Ribbon Out Sensor Maintenance Kit
in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 73.

Figure 474 Kit Contents

3
4 1

Table 73 Parts List

 Item Description Qty
Ref Ribbon Out Sensor Maintenance Kit
1 Ribbon Out Sensor Assembly 1
2 Hexalobular Screw, M3 × 6 1
3 Hexalobular Screw, M3 × 4 1
4 Ribbon Out Reflective Bracket 1
5 Cable Tie, 0.09 × 3.62 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Wire Cutters

786
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

787
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

788
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

789
Disconnect Old Ribbon Sensor
1. See Figure 475. Disconnect the old ribbon out sensor from J45 on the main logic board (MLB)

Figure 475 MLB Connection

J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J45

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

2. Remove the ribbon out sensor cable from all cable clamps.

790
Remove the Upper Print Mechanism
CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
1. See Figure 476. Using a needle nose pliers, remove the hook of the spring from the tensioning post.

Figure 476 Remove the Print Mechanism Spring Tension

2 1

1 Print mechanism spring

2 Spring hook tensioning post

791
2. See Figure 477. Remove the E-Ring, spring and then the E-Ring.

Figure 477 Remove the E-Ring, Spring and C-Ring

1
2

1 E-Ring
2 Spring

792
3. See Figure 478. Remove the main drive belt by loosening the locking screw on the main drive belt
tensioner.

Figure 478 Remove the Main Drive Belt and Idler Pulley

3 4

1 Main drive belt

2 Idler pulley
3 Main drive belt tensioner
4 Locking screw

4. Move the main drive belt tensioner to extend the spring, and then tighten the locking screw.

5. Slide the main drive belt out of the printer.

6. Slide the idler pulley out of the printer.

793
7. See Figure 479. Remove the toggle assembly head-open flag by removing the mounting screw, and
then sliding the head-open flag off of the toggle shaft.

Figure 479 Remove the Head-Open Flag n

1 Mounting screw
2 Head-open flag
3 Toggle bar shaft

794
8. See Figure 480. On the media side, remove the toggle handle and curved washer by removing the
handle mounting screw.

Figure 480 Remove the Toggle Handle and Curved Washer

2 1

5 4

1 Toggle bar handle

2 Mounting screw
3 Curved washer
4 Side plate
5 Toggle bar shaft

9. Slide the handle and curved washer off of the toggle bar shaft.

795
10. See Figure 481. Remove the nut securing cable clamp 7 and then remove the printhead power cable.

Figure 481 Cable Routing and Clamps

4
1 2 3

8
7 6 5

1 Ribbon Sensor, Black Mark Sensor, Transmissive Sensor, Head Open

Sensor, and Media Path Light
2 Printhead Power, Printhead Data, and Ribbon Path Light
3 Belt Tensioner
4 Head Open Sensor and Ribbon Path Light
5 Stepper Motor and Bulkhead Connector
6 Stepper Motor and Bulkhead Connector
7 Printhead Power
8 Stiffener bracket

11. Remove the nut securing cable clamp 1 and then remove only the ribbon sensor cable.

12. Remove the nut securing cable clamp 2 and then remove the printhead power cable and printhead data
cable.
13. Remove the nut securing cable clamp 4 and then slide the cable clamp off of the mounting stud.

14. Remove the printhead ground cable from the stud.

796
15. See Figure 482. On the media side, remove the upper ribbon idler roller by removing the mounting
screw.

Figure 482 Remove the Upper Idler Roller Mounting Screw

1
2

1 Upper ribbon idler roller

2 Mounting hole
3 Mounting screw

797
16. See Figure 483. Pull the right side of the upper ribbon idler roller out of the upper print mechanism.

Figure 483 Pull the Right Side of the Upper ribbon Idler Roller
3
1 2

1 Upper ribbon idler roller

2 Right side of upper ribbon idler roller
3 Upper print mechanism

798
17. See Figure 484. Remove the four screws securing the side plate to the printer.

NOTE: Do not remove or turn screw 3; it is adjusted at the factory.

Figure 484 Remove the Side Plate Mounting Screws

1

1 Side plate
2 Mounting screws (3)
3 Factory clamp screw

799
18. See Figure 485. Slide the side plate and upper ribbon idler roller out of the printer.

Figure 485 Remove the Side Plate and Upper Ribbon Idler Roller

3
2

1 Side plate and upper ribbon idler roller assembly

2 Lower guide pin
3 Upper guide pin

800
19. See Figure 486. Slide the toggle assembly and bearing out of the printer.

Figure 486 Slide the Toggle Assembly Out of the Printer

1
2

1 Toggle assembly
2 Bearing

801
20. See Figure 487. Remove the upper print mechanism assembly by turning the assembly up at an angle.

Figure 487 Remove the Upper Print Mechanism

3
1

1 Upper print mechanism

2 Cable access hole
3 Upper print mechanism shaft mounting hole

21. While guiding the printhead cable through the access hole slide the upper print mechanism out of the
printer.

802
22. See Figure 488. Cut the cable tie securing the ribbon sensor cable to the cable bundle.

Figure 488 Cut the Cable Tie

1 Upper print mechanism

2 Cable tie
3 Ribbon sensor cable

23. See Figure 489. Remove the ribbon sensor mounting screw, and then remove the ribbon sensor.

Figure 489 Remove the Ribbon Sensor

1 Upper print mechanism

2 Ribbon sensor assembly
3 Mounting screw

803
Replace the Reflective Bracket
1. See Figure 490. Remove the old mounting screw and bracket.

Figure 490 Remove and Install the Reflective Bracket

3
1
2

1 Reflective bracket
2 Mounting screw
3 Locating hole
4 Mounting hole

2. Align the new reflective bracket with the guide hole, and then install the new mounting screw.

804
Install the New Ribbon Sensor Assembly
1. See Figure 489 on page 803. Align the new ribbon sensor with the mounting hole in the upper print
mechanism, and then install the new mounting screw.
2. See Figure 488 on page 803. Install the new cable tie.

3. See Figure 487 on page 802. While guiding the upper print mechanism cable through the mounting
hole, push the upper print mechanism into the printer.
4. See Figure 491. Reinstall the side plate.

Figure 491 Install the Side Plate

2
3

1 Side plate
2 Lower locating pin
3 Upper locating pin
4 Toggle assembly shaft

5. See Figure 484 on page 799. Reinstall the three mounting screws.

6. See Figure 480 on page 795. Reinstall the curved washer, toggle handle, and mounting screw.

805
7. See Figure 492. Insert the upper ribbon idler roller shaft into the (D) shaped end into the printer main
frame mounting hole.

Figure 492 Insert the Shaft into the Main Frame

1
2 3

1 Main frame mounting hole

2 Upper ribbon idler roller shaft
3 Upper ribbon idler roller

8. See Figure 483 on page 798. Slide the right side of the upper ribbon idler roller into the upper print
mechanism.
9. See Figure 482 on page 797. Reinstall the mounting screw and tighten.
10. See Figure 479 on page 794. From the electronics side, slide the new head-open flag onto the toggle
shaft, and then install the mounting screw.
11. See Figure 475 on page 790. Reinstall the ribbon out sensor cable to J45 on the MLB.

12. Reinstall the sensor cable into all cable clamps.

CAUTION—EYE INJURY: Wear protective eyewear when installing or removing E-rings, C-clips, snap
rings, springs, and mounting buttons. These are under tension and could fly off.
13. Reinstall the E-Ring, spring, and E-Ring to secure the upper print mechanism.

14. See Figure 476 on page 791. Using a needle nose pliers, reset the hook of the spring onto the
tensioning post.

806
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

807
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

808
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

809
Take-Label Sensors Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Take-Label Sensors Maintenance Kit
in the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 74.

Figure 493 Kit Contents

1

Table 74 Parts List

 Item Description Qty
Ref Take-Label Sensors Maintenance Kit
1 Upper Take-Label Sensor (short cable assembly) 1
2 Screw, M4 × 10 2
3 Lower Take-Label Sensor (long cable assembly) 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Antistatic Wriststrap and Mat
• Phillips Screwdriver Set

811
Remove the Electronics Cover
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

812
4. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

813
5. Lift the electronics cover off of the printer.
=

1 Electronics cover

814
Remove the Take-Label Sensors
1. See Figure 494. Remove the control panel by removing the two screws securing it to the printer.

Figure 494 Remove the Control Panel

o

1
3

1 Control panel
2 Control panel mounting screws (2)
3 Main frame access-hole

2. Pull the control panel out of the printer while guiding the cables through the main frame access hole.

3. See Figure 495. Slide the control panel out of the printer, enough to access J7 and J8.

4. Disconnect the take-label sensor from J7 and J8 on the control panel.

815
Figure 495 Disconnect the Take-Label Sensors
1

1 J7, Lower take-label sensor connector

2 J8, Upper take-label sensor connector

5. Go to Remove the ZT600 Take-Label Sensors from Main Frame on page 818.

816
6. See Figure 496. Slide the control panel out of the printer, enough to access J7 and J8.

7. Disconnect the take-label sensors from J7 and J8 on the control board.

Figure 496 Control Panel Connectors

J8
J7 J8
J3

J7

J2
J1

J1

J1 To J15 on the main logic board

J2 To J14 on the main logic board
J7 To take-label sensor 3 pin connector
J8 To take-label sensor 5 pin connector

8. Go to Remove the ZT600 Take-Label Sensors from Main Frame on page 818.

817
Remove the ZT600 Take-Label Sensors from Main Frame
1. See Figure 497. Remove the two screws securing the take-label sensors to the main frame.

Figure 497 Remove the Take-Label Sensor Mounting Screws

1 Main frame
2 Mounting screws (2)

818
 2. See Figure 498. Remove the two take-label sensors from the printer.

Figure 498 Remove the Take-Label Sensors

1 Take-label sensor (2)

2 Mounting holes (2)

Install the New Take-Label Sensors

1. See Figure 498. Slide the new upper take-label sensor, 3-pin connector, into the mounting hole as
shown.
2. See Figure 497 on page 818. Install a new mounting screw.

3. See Figure 498. Slide the lower new take-label sensor, 4-pin connector into the mounting hole as
shown.
4. See Figure 497 on page 818. Install a new mounting screw.

5. See Figure 495 on page 816 for ZT600 or Figure 496 on page 817 for ZT510. Connect the take-label
sensors to J7 and J8 on the control panel.
6. Install the control panel.

7. See Figure 494 on page 815. Align the control panel with the two mounting holes.

8. Reinstall the two control panel mounting screws.

819
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

820
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

821
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

822
Head Open Sensor Assembly
Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Head Open Sensor Assembly
Maintenance Kit in the ZT600 Series Printers.
Read these instructions thoroughly before attempting to install this kit.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed below in Table 75.

Figure 499 Kit Contents

1
3
4

Table 75 Parts List

 Item Description Qty
Ref Head-Open Sensor Assembly Maintenance Kit
1 Head-Open Sensor Assembly 1
2 Nut, 6-32 1
3 Head-Open Flag 1
4 Hexalobular Screw, M3 × 8 1
5 Trimount Clip 1
6 Curved Washer, 0.344 × 0.172 × 0.006 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Antistatic Wriststrap and Pad • Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

824
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

825
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

826
Remove the Old Head Open Sensor
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.

2. Open the upper print mechanism.

3. See Figure 500. Disconnect the head open sensor from J46 on the main logic board (MLB).

Figure 500 Disconnect the Head Open Sensor from the MLB
J42
J15 J45

J29 J22
J20 J25
J43
J47

J27

J13 J48

J1 J16 J28 J46

J21
J18
J44

J41

J34

J46

J3

J35
J49

J26

J17
J40
J19

J39
J37 J38

4. Remove the head open sensor cable from all cable clamps.

827
5. See Figure 501. Remove the screw securing the head open flag to the printer.

Figure 501 Remove the Mounting Screws

1 2

4 3

1 Head open flag

2 Flag mounting screw
3 Head open sensor assembly nut
4 Head open sensor assembly
5 Head open sensor assembly mounting stud
6 Head open flag mounting shaft

6. Remove the mounting nut securing the head open sensor, and then remove it.

828
Install the New Head Open Sensor Assembly
1. See Figure 502. Align the flat in the flag with the flat on the shaft, and then slide the flag onto the shaft.

Figure 502 Align the Flats

2. See Figure 503. Install the mounting screw.

Figure 503 Install the Mounting Screw

1

1 Head open flag

2 Flag mounting screw

829
3. See Figure 504. Slide the head open sensor assembly onto the mounting stud and into the mounting
slot.
4. Install the mounting nut.

Figure 504 Install the Head Open Sensor Assembly

1
2

1 Head open sensor assembly mounting stud

2 Head open sensor assembly positioning slot
3 Head open sensor assembly
4 Head open sensor assembly mounting nut

5. Run the head open sensor cable through the same cable clamps as the old cable.

6. See Figure 500 on page 827. Connect the head open sensor cable to J46 on the MLB.

830
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

831
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

832
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

833
Electronic Cables Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Electronic Cables Maintenance Kit in
the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 76 on page 835.

Figure 505 Kit Contents

1 2 3 4 5 6 7 8 9

UL FILE NUMBER UL TYPE V-0

MANUFACTURER LOGO

DATE CODE (WW/YY)

Zebra part number
10

11

12

16 19
17 20
13 21
15 18
14

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 76 Parts List
 Item Description Qty
Ref Electronic Cables Maintenance Kit
1 Main Logic Board to Cutter Interface 1
2 ZT610 RFID Coupler Cable 1
3 ZT620 RFID Coupler Cable 1
4 Cutter Cable 1
5 USB Host Cable 1
6 Control Panel LCD Cable 1
7 Ribbon Cable 1
8 Rewind Available Cable 1
9 Flex Cable 1
10 Drive Motor Cable 1
11 Grommet, 0.437 × 0.172 × 0.250 1
12 Cable Tie 2
13 Cable Clamp 2
14 Nut, M4 9
15 RFID Cable Clamp 1
16 Hexalobular Screws, M3 × 6 2
17 Flat Cable Clamp, 1 in. × 1 in. 1
18 Flat Washer, 0.50 × 0.19 × 0.09 1
19 Cable Clamp, 0.50 2
20 Cable Clamp, 0.312 6
21 Cable Clamp 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• 47362* Zebra Preventive Maintenance Kit • Antistatic Wriststrap and Mat
• Hexalobular Wrench Set
* In place of the Preventive Maintenance Kit, you may use a clean swab dipped in 90% or higher isopropyl alcohol.

835
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

836
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

837
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

Remove and Install the Electronics Cables

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
1. Connect yourself to an antistatic device.
2. Remove the defective cable from the printer.

3. Choose the proper replacement cable from the kit.

4. Install the new cable.

5. Install any cable ties previously removed.

838
Reinstall the Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

839
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

840
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

841
Outer Casing Components
This section supplies you with the parts information and installation procedures for the exterior parts.

842
Exterior Parts and Drawings
Figure 506 Exterior Overview

3
2

6 7

843
Table 77 Kit Parts List
Item Part Number Description
1 P1083320-004 ZT610/ZT620 Electronics Cover Maintenance Kit
2 P1083320-005 ZT610 Media Door Maintenance Kit
P1083320-006 ZT620 Media Door Maintenance Kit
3 P1083320-007 ZT600 Media Door Window Maintenance Kit
4 P1083320-092 ZT610/ZT620 Option Covers Maintenance Kit
5 P1083320-095 Feet for ZT600 Printers
6 P1083320-008 ZT610 Lower Front Trim Panels Maintenance Kit
P1083320-009 ZT620 Lower Front Trim Panels Maintenance Kit
7 P1083320-125 ZT610/ZT620 Touch Control Panel Cover Kit

844
Figure 507 Exterior Kits (1)
1 2 3

4
5

845
Table 78 Kit Parts List
Item Part Number Description
1 P1083320-004 ZT610/ZT620 Electronics Cover Maintenance Kit
2 P1083320-005 ZT610 Media Door Maintenance Kit
P1083320-006 ZT620 Media Door Maintenance Kit
3 P1083320-007 ZT600 Media Door Window Maintenance Kit
4 P1083320-092 ZT610/ZT620 Option Covers Maintenance Kit
5 P1083320-095 Feet for ZT600 Printers
6 P1083320-008 ZT610 Lower Front Trim Panel Maintenance Kit
P1083320-009 ZT620 Lower Front Trim Panel Maintenance Kit

846
Miscellaneous Hardware
Figure 508 Miscellaneous Hardware Kit
1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40

41 42 43 45 46
44

847
Table 79 Kit Parts List
Item Qty Part Number Description
Ref 1 P1083320-096 ZT610 and ZT620 Miscellaneous Hardware
1 4 HW06250 E-Ring,EXT,0.312 YEL
2 5 HW10460 NUT M3 HX ZN
3 5 HW23827 SC M4 X 0.7 × 8 CP SO SS
4 2 HW30115 WASHER,WAVE, 0.740 × 0.520 × 0.080
5 3 HW30392-008 SC 6-32 × 0.50 CP SO H SS
6 5 HW30393-006 SC 8-32 × 0.38 CP SO H ZN
7 2 HW32373 RING CRES EXT 0.312 ZN
8 3 HW32406 STANDOFF, 4-40, HEX, M-F
9 3 HW33804 WASHER,FLAT, 0.76 × 0.51 0.03
10 2 HW33809 NUT 6-32 HEX FLNG SS
11 5 HW33811 RING E EXTRNL 0.500 0.042
12 10 HW33812-004 SC 8-32 × 0.225 FL PH SS
13 5 HW40193 WASHER,FLAT, 0.375 0.172 0.048
14 2 HW45937 SC M4 × 10 OV PH ZN TFMNG
15 3 HW45945 WASHER,LOCK, #4
16 2 46909 SPCR 0.750 × 0.520 × 0.360 THK
17 5 HW78805 SC M3 × 0.5 6 × 6 CP SO ZN
18 2 79606 SCR SHLDR 5.5MM DIA 2MM LG M4
19 2 806111-308 WSHR HD SCREW, M3 × 8L × 6.5OD, PLASTITE,
HEXALOBULAR
20 5 806170-410 LRG WSHR HD SCREW, PLASTITE, HEXALOBULAR, M4 ×10
BLACK
21 2 P1040560 WASHER, FLAT, M3
22 5 P1042500 WASHER, CRESCENT, 0.465 0.323 0.062 0.005
23 2 P1051017-08 SC M3 × 8 HX TX NI
24 5 P1059768 SC M3X.5 6 PN PH NI
25 10 P1079327 NUT, M4, HEX, FLNG
26 2 P1079553 WASH, FLAT, 18OD × 10.5ID × 1.6
27 2 P1079555 RING, RET, E, EXTRNL
28 10 P1080494-3004 Hexalobular Pan Washer Mach Screw M3 × 4
29 20 P1080494-3006 Hexalobular Pan Washer Mach Screw M3 × 6
30 2 P1080494-3008 Hexalobular Pan Washer Mach Screw M3 × 8
31 2 P1080494-3010 Hexalobular Pan Washer Mach Screw M3 × 10
32 20 P1080494-4008 Hexalobular Pan Washer Mach Screw M4 × 8
33 10 P1080494-4010 Hexalobular Pan Washer Mach Screw M4 × 10
34 5 P1080494-4012 Hexalobular Pan Washer Mach Screw M4 × 12

848
Table 79 Kit Parts List
Item Qty Part Number Description
35 5 P1082375 NUT M3 KNURLED
36 2 P1082935-001 SC,M3X0.5,8,SML,HD,CP,TX
37 5 P1084618-3006 Hexalobular Pan Head Cap Screw 3 × 6
38 2 P1085222-2504 Hexalobular Pan Hd Washer Mach Screw M2.5 × 4
39 10 P1085222-3006 Hexalobular Pan Hd Washer Mach Screw M3 × 6
40 10 P1085222-3008 Hexalobular Pan Hd Washer Mach Screw M3 × 8
41 2 P1085222-3012 Hexalobular Pan Hd Washer Mach Screw M3 × 12
42 10 P1085222-4008 Hexalobular Pan Hd Washer Mach Screw M4 × 8
43 5 P1085222-4010 Hexalobular Pan Hd Washer Mach Screw M4 × 10
44 10 P1086437 NUT, HEX, M3, CUSTOM (catch tray magnet nuts)
45 2 P1089248 WASHER,CURVED, 0.0377, 0.465, 0.006
46 2 P1090516 Screw,Platen,Retainer,Captive,ZT600
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

849
Repackaging
Figure 509 Repackaging for the ZT600 Series Printers

TOP

Table 80 Kit Parts List

Item Part Number Description
Ref P1083320-098 ZT610 Single-Box Packaging Kit
Ref P1083320-100 ZT620 Single-Box Packaging Kit
Ref P1083320-116 ZT610 Multi-Box Packaging Kit (8)
1 N/A Bag
2 N/A Lift-Out Straps
3 N/A Top Left Insert
4 N/A Top Right Insert
5 N/A Bottom Left Insert
6 N/A Bottom Right Insert
7 N/A Door Shim
8 N/A Window Insert
9 N/A Box

850
Touch Control Panel Cover Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Touch Control Panel Cover Kit on
ZT600 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 in Table 81.

Figure 510 Kit Contents

Table 81 Parts List

 Item Description Qty
Ref ZT600 Touch Control Panel Cover Kit 3
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Microfiber Cloth • Mild degreaser/detergent

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Clean the Front Panel
1. Wipe any dust and debris from the printer front panel with a microfiber cloth. If there is extensive debris
stuck on the front panel, moisten the microfiber cloth with a mild degreaser/detergent and remove the
debris.
2. Allow time for the front panel to be completely dry.

Remove Control Panel Cover Backing

1. Pull up on the tab attached to the backing on the Touch Control Panel Cover.

Figure 511 Remove Backing

1 2

1 Touch screen overlay

2 Tab
3 Backing
4 Button covers

2. Stop when the backing is roughly 0.25 inch above the bottom of the touch screen overlay opening.

852
Install the Control Panel Cover
1. Align the control button covers over the buttons and the bottom of the screen cover overlay nests
squarely into the bottom of the touch screen window frame.

Control Panel Cover Control Panel

1
2

1 Control panel overlay

2 Touch screen window frame
3 Control buttons
4 Control button covers

2. Press the bottom portion of the protective cover until it adheres to the printer front panel.

3. Gently remove the remainder of the backing.

4. Press and smooth the protective cover from the bottom of the control panel towards the top until it is
adhered with the complete front panel of the printer.

The Installation is Complete.

853
Electronics Cover Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Electronics Cover Maintenance Kit
on the ZT600 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 in Table 82.

Figure 512 Kit Contents

1

Table 82 Parts List

 Item Description Qty
Ref Electronics Cover Maintenance Kit
1 Electronics Cover 1
2 Hexalobular Screw, M3 × 6 4
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

855
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

856
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

857
Install the New Electronics Cover
1. See Figure 1. Slide the electronics cover onto the printer.

1 Electronics cover

858
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

859
 4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

860
Media Door Maintenance Kit

Installation Instructions
These instructions are for the installation of the Media Door on the ZT600 series printers.
Read these instructions thoroughly before attempting to install this assembly.

Parts List
Before proceeding, verify that your kit contains the items for your printer listed in Table 83 on page 861.

Figure 513 Kit Contents

Table 83 Kit Parts List

 Item Description Qty
Ref Media Door Maintenance Kit
1 Door Assembly 1
2 Screw, M4 4
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Old Media Door
1. See Figure 514. Open the existing media door.

Figure 514 Remove the Media Door

1 Media door
2 Mounting screws (4)

2. Remove and discard the four mounting screws.

NOTE: Be sure to hold the door firmly when removing the last screw.
1. Remove and discard the old door.

862
Install the New Media Door
1. See Figure 515. Align the media door with the mounting holes in the main frame.

Figure 515 Install the Media Door

1 Media door
2 Mounting screws (4)

2. Hold the door assembly securely, and then install the screw closest to the control panel first.

3. Install the other three screws, and then tighten all screws.

863
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

864
Media Door Window Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Media Door Window Maintenance Kit
in the ZT600 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 in Table 84.

Figure 516 Kit Contents

Table 84 Parts List

 Item Description Qty
1 Media Door Window Maintenance Kit
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Flat-blade Screwdriver Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Remove the Old Media Door Window
1. See Figure 517. Remove the window by pressing on the seven snap tabs until it is free on three sides.

Figure 517 Remove the Old Window

1 2
2

1 Window
2 Snap Tabs (7)
3 Stationary Tabs (3)

866
2. See Figure 518. Lift the window out of the door.

Figure 518 Lift the Window Out

1 Media door window

2 Media door guide holes (2)
3 Media door guide posts (2)
4 Media window stationary tabs (3)

867
Install the New Media Door Window
1. See Figure 519. Set the three stationary tabs onto the door.

Figure 519 Install the New Window

1

1 Media door window

2 Media door posts (2)
3 Media door stationary tabs (3)

2. See Figure 517 on page 866. Push the new window into the door opening, ensuring that all seven snap
tabs snap into place.
3. Close the media door.

The installation is complete.

868
Option Covers Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Option Covers Maintenance Kit in
the ZT600 Series Printers.
Read these instructions thoroughly before installing this kit.

Parts List
Before proceeding, verify that your kit contains the parts listed in Table 85 on page 869.

Figure 520 Kit Contents

1 2
5
3

7
8

Table 85 Parts List

 Item Description Qty
Ref Option Covers Maintenance Kit
1 Option Board Blank Cover 2
2 ZT610/ZT620 Long Option Blank Cover 1
3 Take-Label Sensor Plug 2
4 Hexalobular Screw, M3 × 6 6
5 ZT610/ZT620 Rewind cover plate 1
6 ZT610/ZT620 Hexalobular Screw 4
7 ZT510 Large Rewind Access Hole Plug 1
8 ZT510 Small Rewind Access Hole Plug 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set

Prepare for Installation

Which cover are you installing?

If… Then…
Long option cover Go to Install Long Option Cover on page 874.
Option board cover Go to Install the Option Board Covers on page 878.
ZT610/ZT620 Go to Install the Rewind Cover on page 879.
rewind cover
Take-Label sensor plugs Go to Install the Take-Label Plugs on page 880.

870
Remove the Electronics Cover
CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.
2. Connect yourself to an antistatic device.

3. Open the media door, and then remove the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

4. Close the media door.

871
5. Remove the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

872
6. Lift the electronics cover off of the printer.
=

1 Electronics cover

873
Install Long Option Cover
1. See Figure 521. Slide the long option cover into the printer as shown.

Figure 521 Install the Long Option Cover

1 Long option cover

2 Mounting screws (2)

2. Align the mounting holes in the cover with the holes in the printer, and then install the two mounting
screws.

874
Reinstall the Electronics Cover
1. Slide the electronics cover onto the printer.

1 Electronics cover

875
2. Open the media door, and then install the electronics cover mounting screw.

1
2

1 Electronics cover
2 Electronics cover mounting screw

3. Close the media door.

876
4. Install the three electronics cover mounting screws.

1 Electronics cover
2 Electronics cover mounting screws (3)

5. Are you installing other covers?

If… Then…
Yes Go to Prepare for Installation on page 870 to locate additional installation instructions.
No Go to Resume Printer Operation on page 881.

877
Install the Option Board Covers
1. See Figure 522. Align the mounting holes in the covers with the mounting holes in the printer.

2. Install the mounting screws.

Figure 522 Install the Option Board Covers

2 1

1 Option board covers (2)

2 Mounting screws (4)

3. Are you installing other covers?

If… Then…
Yes Go to Prepare for Installation on page 870 to locate additional installation instructions.
No Go to Resume Printer Operation on page 881.

878
Install the Rewind Cover
1. Align the rewind cover plate with the four mounting holes in the main frame.

Figure 523

1 Mounting screws (4)

2 Rewind cover plate
3 Mounting holes (4)

2. Install the four mounting screws.

3. Are you installing other covers?

If… Then…
Yes Go to Prepare for Installation on page 870 to locate additional installation instructions.
No Go to Resume Printer Operation on page 881.

879
Install the Take-Label Plugs
1. Align the take-label plugs as shown.

Figure 524 Install the Take-Label Plugs

1 Take-label sensor mounting holes (2)

2 Take-label sensor mounting hole plugs (2)

2. Press the plugs into the two take-label sensor mounting holes.
3. Are you installing other covers?

If… Then…
Yes Go to Prepare for Installation on page 870 to locate installation instructions.
No Go to Resume Printer Operation on page 881.

880
Resume Printer Operation
1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

881
Printer Feet Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Printer Feet Maintenance Kit into the
ZT600 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 in Table 86.

Figure 525 Kit Contents

1

Table 86 Parts List

 Item Description Qty
1 Foot 12
2 Hexalobular Screw, M4 × 10 12
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set • Mat

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Replace the Feet
1. See Figure 526. Lay the printer on a mat on the electronics side.

Figure 526 Replace the Feet

1 2

1 Foot (4)
2 Foot mounting screw (4)

2. Remove and discard the mounting screw and foot.

3. Install the new mounting screw and foot.

4. Repeat step 2 and step 3 for the other feet.

5. Set the printer back up on its feet.

The installation is complete.

883
Front Trim Panels Maintenance Kit

Installation Instructions
This kit includes the parts and documentation necessary to install the Front Trim Panels Maintenance Kit in
the ZT610/ZT620 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 in Table 87.

Figure 527 Kit Contents

ZT610 ZT620

1 1

2 2

3 3

4 4

Table 87 Parts List

 Item Description Qty
Ref ZT610 Front Trim Panels Maintenance Kit
ZT620 Front Trim Panels Maintenance Kit
1 Tear-Off Front Trim Panel 1
2 Knurled Nut, M3 2
3 Screw, M4 × 10, ZT610 (2) and ZT620 (3) 2 or 3
4 Lower Front Trim Panel 1
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Hexalobular Wrench Set

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Which trim panel are you replacing?

If you have a… Then…

Tear-Off Front Trim Go to Remove the Old Tear-Off Front Trim Panel.
Panel
Lower Front Trim Panel Go to Remove the Lower Front Trim Panel on page 886.

Remove the Old Tear-Off Front Trim Panel

CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the following
procedure.
1. Disconnect the AC power cord and all data cables.

2. Open the media cover.

3. See Figure 528. Remove the tear-off front trim panel by removing the two or three mounting screws.

Figure 528 Remove the Tear-Off Front Trim Panel Mounting Nuts
1

1 Tear-off front trim panel

2 Mounting knurled nuts (2)

4. Tip the top of the front tear-off trim panel away from the printer, and then slide the panel out of the
printer.

885
Install the New Tear-Off Front Trim Panel
1. See Figure 528. Tip the new tear-off front trim panel as shown.

2. Slide the panel onto the two mounting studs.

3. Install and tighten the two mounting nuts.

4. Reconnect the AC power cord and all data cables, and turn on (I) the printer.

5. Go to Resume Printer Operation on page 887.

Remove the Lower Front Trim Panel

1. CAUTION: Turn off (O) the printer and disconnect it from the power source before performing the
following procedure.Disconnect the AC power cord and all data cables.
2. Open the media cover.
3. See Figure 529. Remove the lower front trim panel by removing the two or three mounting screws.

Figure 529 Remove the Lower Front Trim Panel Screws

1 Lower trim panel

2 Mounting screws (2 or 3)

886
 4. See Figure 530. Tip the top of the lower front trim panel away from the printer, and then lift the panel out
of the printer.

Figure 530 Remove the Lower Front Trim Panel

Install the Lower Front Trim Panel

1. See Figure 530. Tip the new lower front trim panel as shown, and slide the panel into the base slots,
and then push the top toward the printer.
2. See Figure 529 on page 886. Install and tighten the two or three mounting screws.

Resume Printer Operation

1. Reinstall media and ribbon (if used).

2. Close the media door.

3. If you disconnected the AC power cord and interface cables, reconnect them, and then turn on the
printer power.
4. If necessary, press Pause to resume printer operation.

The installation is complete.

887
Miscellaneous Hardware Maintenance Kit

Installation Instructions
This kit includes the parts necessary for the Miscellaneous Hardware Maintenance Kit in the ZT600 Series
Printers.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 88 on page 889.

Figure 531 Kit Contents

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40

42 43 45
41 44 46 47

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
Table 88 Parts List
Item Description Qty
Ref ZT610/ZT620 Miscellaneous Hardware 1
1 E-Ring,EXT,0.312 YEL 4
2 NUT M3 HX ZN 5
3 SC M4 X 0.7 × 8 CP SO SS 5
4 WASHER,WAVE, 0.740 × 0.520 × 0.080 2
5 SC 6-32 × 0.50 CP SO H SS 3
6 SC 8-32 × 0.38 CP SO H ZN 5
7 RING CRES EXT 0.312 ZN 2
8 STANDOFF, 4-40, HEX, M-F 3
9 WASHER,FLAT, 0.76 × 0.51 0.03 3
10 NUT 6-32 HEX FLNG SS 2
11 RING E EXTRNL 0.500 0.042 5
12 SC 8-32 × 0.225 FL PH SS 10
13 Nylon Washer, 0,252 × 0.472 × 0.059 2
14 WASHER,FLAT, 0.375 0.172 0.048 5
15 SC M4 × 10 OV PH ZN TFMNG 2
16 WASHER,LOCK, #4 3
17 SPCR 0.750 × 0.520 × 0.360 THK 2
18 SC M3 × 0.5 6 × 6 CP SO ZN 5
19 SCR SHLDR 5.5MM DIA 2MM LG M4 2
20 WSHR HD SCREW, M3 × 8L × 6.5OD, PLASTITE, HEXALOBULAR 2
21 LRG WSHR HD SCREW, PLASTITE, HEXALOBULAR, M4 ×10 BLACK 5
22 WASHER, FLAT, M3 3
23 WASHER, CRESCENT, 0.465 0.323 0.062 0.005 5
24 SC M3 × 8 HX TX NI 2
25 SC M3X.5 6 PN PH NI 5
26 NUT, M4, HEX, FLNG 10
27 WASH, FLAT, 18OD × 10.5ID × 1.6 2
28 RING, RET, E, EXTRNL 2
29 Hexalobular Pan Washer Mach Screw M3 × 4 10
30 Hexalobular Pan Washer Mach Screw M3 × 6 20
31 Hexalobular Pan Washer Mach Screw M3 × 8 2
32 Hexalobular Pan Washer Mach Screw M3 × 810 2
33 Hexalobular Pan Washer Mach Screw M4 × 8 20
34 Hexalobular Pan Washer Mach Screw M4 × 10 10
35 Hexalobular Pan Washer Mach Screw M4 × 12 5

889
Table 88 Parts List
Item Description Qty
36 NUT M3 KNURLED 5
37 SC,M3X0.5,8,SML,HD,CP,TX 2
38 Hexalobular Pan Head Cap Screw 3 × 6 5
39 Hexalobular Pan Hd Washer Mach Screw M2.5 × 4 2
40 Hexalobular Pan Hd Washer Mach Screw M3 × 6 10
41 Hexalobular Pan Hd Washer Mach Screw M3 × 8 10
42 Hexalobular Pan Hd Washer Mach Screw M3 × 12 2
43 Hexalobular Pan Hd Washer Mach Screw M4 × 8 10
44 Hexalobular Pan Hd Washer Mach Screw M4 × 10 5
45 NUT, HEX, M3, CUSTOM (catch tray magnet nuts) 10
46 WASHER,CURVED, 0.0377, 0.465, 0.006 2
47 Screw,Platen,Retainer,Captive,ZT600 2
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

890
Figure 532 Media Side View
43 43
30
30
41

38 43

24

47

40 33
41
21

43
43
43

891
Figure 533 Electronics Side View
33
35 29 44

26 31

30
29

33
29

34
26
34

33

30

892
Figure 534 Rear View

30

16

17

16

30

21

33

893
Figure 535 Front View

18

894
Repackaging Kit

NOTE: Before repacking, call 1.877.ASK.ZEBRA (1.877.275.9327) for a Repair Order number (RO) or
refer to www.zebra.com/repair.
This repackaging kit includes all of the material needed to repack the printer to transport it safely. Before
packaging the printer, remove media and ribbon, and make sure that the printhead is closed.

Parts List
Before proceeding, verify that your kit contains one or the other of the kits for your printer listed below in
Table 89 on page 895.

Figure 536 Kit Contents

3
1

TOP 5

Table 89 Parts List

 Item Description Qty
Ref Single-Box Packaging Kit
1 Bag 1
2 Lift-Out Straps 2
3 Top Left Insert 1
4 Shared End Inserts 3
5 Door Shim 1
6 Window Insert 1
7 Box 1
Ref ZT610 Multi-Box Packaging Kit
1 Bag 8
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corp., registered in many jurisdictions
worldwide. All other trademarks are the property of their respective owners. © 2019 Zebra Technologies Corp. and/or
its affiliates. All rights reserved. | www.zebra.com
P1090462-002
 Table 89 Parts List
 Item Description Qty
2 Lift-Out Straps 16
3 Top Left Insert 8
4 Shared End Inserts 24
5 Door Shim 8
6 Window Insert 8
7 Box 8
To reorder specific parts, navigate to http://www.zebra.com/parts, and select your printer model.

Tools Required

TOOLS: You need these tools to complete this procedure:

• Packing Tape Dispenser

896
Repacking the ZT600
.

1. Lift the media door slightly.

2. Insert the door shim into the space between the hinges until the
fold is at the edge of the door.
3. Close the media door, and then fold the shim until it is flat
against the printer.
4. Slide the bag over the printer.

1. Slide the bag under the printer.

2. Gather the bag and tape it shut.

3. Open the media door slightly, and then insert the excess plastic
from the bag into the printer.
4. Close the media door.

1. Lift the front of the printer and slide the first lift-out strap toward
the center of the printer until they are just past the printer’s feet.
2. Lift the back of the printer and repeat step 9 with the second
lift-out strap.

897
1. See Figure 537. Turn the printer on its side as shown.

Figure 537 Repacking the Printer

1 Top Left Insert

2 Shared End Insert
3 Window Insert
The insert placement is based on the physical location on an
upright front-facing printer.

2. Lift the side of printer, and then fit the top left insert under the top left of the printer.

3. Lift the other side of the printer, and then fit one shared end insert under the bottom right of the printer.

4. Lay the window insert on the printer.

5. Install the two remaining shared end inserts on the top of the printer.

898
Load the Printer into the Box
1. Cut open both ends of the box.

2. See Figure 538. Lower the box over the printer with the packing inserts attached.

Figure 538 Lower the Box Over the Printer

3. See Figure 539. Close the box flaps, and seal the shipping carton with postal quality shipping tape.

Figure 539 Seal Top with Postal Quality Shipping Tape

4. Turn and shift the box until a short flap is off the edge of the table. Lift the edge of the printer slightly
and fold the short flap under the printer.
5. Turn and shift the box 180 degrees and repeat step 4 with the second short flap.

899
 6. See Figure 540. Rotate the box until a large flap is hanging off the table. Lift the edge of the printer
slightly and fold the large flap under the printer.

Figure 540 Fold Under Large Flaps

7. Turn and shift the box 180 degrees and repeat step 6 with the second large flap.

8. See step 541. Turn the printer over while supporting the closed flaps. Seal the shipping carton with
postal quality shipping tape.

Figure 541 Seal the Shipping Carton

9. Apply the return shipping label to the box and write the RO number on the outside of the box.

The installation is complete.

900
www.zebra.com