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57601M
Installation Instructions Manual
12 pgs1.6 Mb0
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Zebra 57600M, 57602M, 57601M Installation Instructions Manual

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Caution • This installation must be performed by a qualified service technician This installation must be performed by a qualified service technician.
This kit includes the par ts and documentation nec essary to ins tall the Printh ead Conversion 300 to 200 dpi Maintenance Kit into the 110PAX4 print engine.
Read these instructions thoroughly before installing this kit.

Kit Part Numbers

3
Caution:
PART
NUMBER
57600M Printhead Conversion Maintenance Kit 300 to 203 dpi, RH/LH 57601M Printhead Conversion Maintenance Kit 203 to 300 dpi, RH 57602M Printhead Conversion Maintenance Kit 203 to 300 dpi, LH
DESCRIPTION
57600L-001 Rev. 1 9/17/04 Page 1 of 12
©2004 ZIH Corp. All product names and numbers are Zebra trademarks, and Zebra and
the Zebra logo are registered trademarks of ZIH Corp. All rights reserved.
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Parts List

Table 1 list the parts found in each kit. Do an inventory of the parts before installing the kit.
Table 1. Kit Parts List
Qty Part Number Description
3
Ref 57600M Printhead Conversion Maintenance Kit 300 to 203 dpi, RH/LH 1 57482 ...Belt, 162G 1 45189-18 ...Belt, 122T 1 57202 ...Printhead Assembly 1 43266 ...Pulley Assembly, 26G Ref 57601M Printhead Conversion Maintenance Kit 203 to 300 dpi, RH 1 57464 ...Belt, 166G 1 43297 ...Belt, 127T 1 57212 ...Printhead Assembly 1 43132 ...Pulley Assembly, 35G Ref 57602M Printhead Conversion Maintenance Kit 203 to 300 dpi, LH 1 57464 ...Belt, 166G 1 43297 ...Belt, 127T 1 43132 ...Pulley Assembly, .080P 1 57242 ...Printhead Assembly
N/A = Not available as a separate part (listed for identification purposes only).
Part available for purchase.
Bold =
Italic =
Part not available for purchase, listed and shown for reference only.

Reference Materials

57512L-001 110PAX4 User Guide 57511L-001 110PAX4 User Guide (CD) 57515L-001 110PAX4 Print Engine Maintenance Manual

Tools Required

Standard Hex Key (Allen Wrench) Set
Metric Open-End Wrench Set Phillips Screwdriver Set
Anti-Static Wriststrap and Mat Small Flat-blade Screwdriver
Note • Retain all parts removed during disassembly, unless otherwise directed.
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Installa tion Instructions

Remove the 110PAX4 Print Engine from the Applicator

Note • Retain all parts removed during disassembly, unless otherwise directed.
Electrostatic Discharge Caution • Observe proper electrostatic saf e ty
precautions when handling any static-sensitive components such as circuit boards and printheads.
1. See Figure . Turn Off (O) the print engine and disconnect the AC power cord and
interface cables.
2. Open the front cover, unlatch the printhead lever, and remove media and ribbon from the print engine.
3. Close and latch the printhead lever, and then close the front cover.
4. See Figure . Remove the four corner mounting screws securing the print engine to the applicator
5. Leave the center mounting bolt until last.
Note • The keyh ole and the center mounting bolt are designed to support the print engine and assist in installing and removing the four mounting screws.
6. To remove the print engine from the applicator, lift the print engine off the center mounting bolt and place on a workbench.
Figure 1. Front View of 110PAX4 Print Engine in Applicator
Power On/Off
Applicator Mounting Screw
Applicator Mounting Screw
Front Panel
Media Door
Switch
Center
Mounting Bolt
Applicator Mounting Screw (2)
57600L-001 Rev. 1 9/17/04 Page 3 of 12
Applicator
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Printhead Conversion Procedure

Printhead Replacement

Caution • The printhead is hot and can cause severe burns. Allow the
printhead to cool.
1. See Figure 2. Hold the printhead from underneath and loosen the printhead mounting screw.
2. See Figure 3. While holding the printhead, remove the power connector first, and then the printhead data connector.
3. Remove the old printhead.
Figure 2. Printhead Mounting Screw, RH
Printhead Mounting Screw
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Figure 3. Printhead Removal and Installation
Printhead Assembly
Mounting Bracket
Data Connector

Install the New Printhead Assembly

Note • Prior to installing the new pri nthead, make a not e of the resist ance val ue
located on the right side of the manufacturer’s label. The “R” valu e is given in Ohms.
Caution • An improperly seated printhead data or power cable may cause the printhead to generate excessive heat and/or a false HEAD COLD message to display while the printhead is hot enough to cause severe burns.
1. Se e Figure 3. Reconnect the printhead power cables to their appropr iate co nnector s. Seat both connectors firmly into place.
2. Align the new printhead into the mounting bracket.
Printhead Power Connecto
Printhead
Printhead
3. Se e Figure 4. Align the printhead alignment posts int o the pri nthead alignmen t slot s.
57600L-001 Rev. 1 9/17/04 Page 5 of 12
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Figure 4. Printhead Alignment, RH
Alignment Posts
Printhead
Data Connector
Printhead Power Connector
Alignment
Slots
4. Verify the printhead is seated properly, then carefully guide the printhead mounting screw into the printhead’s aluminum body. When the screw is aligned properly, tighten it until snug. Do not over-tighten this screw.
5. Clean the new printhead.
Note • Use Preventative Maintenance Kit, part number 47362, or a solution of 90% isopropyl alcohol and 10% deionized water.

Open the 110PAX4 Rear Enclosure

1. See Figure 5. Remove the seven electronics enclosure cover (base back cover) mounting screws. Lift up on the electronics enclosure cover to remove it.
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Figure 5. Rear View of the Removal and Installation of the
Electronics Enclosure Cover
Electronics Enclosure Screws
Electronics Enclosure Cover
Electronics Enclosure Screws
2. Se e Figure 6. From the back of the print engine, remove the two screws securing the rear enclosure.
57600L-001 Rev. 1 9/17/04 Page 7 of 12
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Figure 6. Rear View of Rear Mounting Screw Locations
(Right-Hand Print Engine Shown)
Rear Enclosure
Mounting Screws
3. Se e Figure 7. From inside the front of the print engine, remov e the two rec essed rea r enclosure mounting scre ws with star washers.
Figure 7. Rear Enclosure Front Mounting Screw Location, RH
Recess Rear
Mounting Screws
4. Carefully swing the electronics enclosure open.
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Pulley and Belt Replacement

1. See Figure 8. Loosen, but do not remove, the compound pulley mounting screws.
Compound Pulley
Assembly Mounting
Screws (2)
Figure 8. Print Engine Rear View
Stepper Motor
Belt
Stepper Motor
Mounting Screws (4)
Compound Pulley
Assembly
Stepper Motor Belt Tensioner
Pulle
2. Remove the stepp er motor belt tensioner pulley.
3. Walk the stepper motor belt off of the compound pulley.
4. Turn the print engine until it rests with the media door face down.
5. Loosen and remove the stepper motor mounting screws. Remove the stepper motor.
6. Loosen the two stepper motor pulley set screws. Slide the stepper motor pulley off of the shaft.
Note • Save the old printhead, stepper motor pulley, and stepper motor belt for reverse conversion.
7. See Figure 9. Place the new stepper motor pulley on the shaft. Make sure there is a 3/16 inch (4.76 mm) gap between the pulley and the stepper motor. Tighten the set screws on the two flats on the stepper motor shaft.
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Figure 9. Stepper Motor Pulley Adjustment
tepper Motor
3/16 Inch
Stepper Motor
Pulley
8. See Figure 10. Place the new belt around the stepper motor pulley. Make sure the stepper motor standoff is positioned properly over the st andoff pins and place the stepper motor on top of the stepper mo tor sta ndof f. Rein sta ll and ti ghten the stepper motor mounting screw.
Stepper Motor
Figure 10. Stepper Motor and Belt Removal/Install
Stepper Motor Mounting Screws (4)
Stepper Motor Assembly
Stepper Motor Standoff
Drive Belt
9. See Figure 8. Walk the other end of the belt onto the compound pulley. Replace the stepper motor idler pulley.
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10. Place 6 pounds of st at ic t ensi on on the stepper motor belt by putting pr ess ur e on the compound pulley, and then tighten the compound pulley mounting screws.
11. Turn the print engine back to the upright position.

Close the Print Engine

1. Carefully swing the electronics enclosure closed. Ensure that wires are dr essed and not causing any obstructions.
2. See Figure 7. From inside t he fr ont of the pr int e ngi ne, re place the two re cesse d rear
enclosure mounting scre ws with star washers.
3. See Figure 6. From the back of the prin t engine, r eplac e the t wo screws s ecu ring t he
rear enclosure.
4. See Figure 5. Replace the electronics cover and the se ven mounting screws. Ensure that the wires are dressed and not causing any obstructions.

Reinstall the 110 PAX4 Print Engine in the Applicator

1. To reinstall the print engine into the applicator, carefully place the keyhole on the
center mounting bolt.
Note • The keyh ole and the center mounting bolt are designed to support the print engine and assist in installing and removing the four mounting screws.
2. See Figure 1. Replace the four corner mounting screws securing the print engine to
the applicator.

Resume Printer Operation

1. Open the front cover, unlatch the printhead lever, and reinsert media and ribbon in
the print engine.
2. Close and latch the printhead lever.
3. Reconnect the AC power cord and interface cables.
4. Turn On (l) the print engine.

Final Conversion Procedures

Caution • Do not set the printhead resistance value higher than that shown on the printhead. Doing so may damage the printhead.
1. Press Setup/Exit. Press Next until you see +HDG5HVLVWRU, and then press the Up
oval key.
2. The print engine will display
password is 1234.
3DVVZRUG. Type in the Password Code. The default
3. Enter the resistance value of the new printhead. Save the new setting as permanent.
4. Turn the prin t eng ine Of f (O) and hold t he left oval ar row key. Turn the pri nt engi ne
On (l).
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5. The front panel will display 32:(5837(67&21),*/$%(/. Press the Previous key twice. The front panel will display
 (300 dpi) LH or RH. Press the left or right oval arrow key until you see the
desired setting.
6. Press Next twice and then turn the print engine Off (O). Turn the print engine back On (l) to automatically save the setting.
02'(/6(/(&73D[ (200 dpi) or
Page 12 of 12 57600L-001 Rev. 1 9/17/04
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