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Use the mechanical assembly drawings when troubleshooting or replacing components and use the associated parts list when ordering replacement parts. Item parts that do not have associated part numbers are not available and need to be ordered using the next highest assembly number.
Caution Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
77259L Rev. 4 12/16/03
Z4M/Z6M Maintenance Manual
Page 5-1
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Table 5-1. Main Printer Assemblies
ITEM PART NUMBER

1 2 3 3 4 4 5 5 6 6 7 7 8 8 9 77695M 77667M 77302M 77302-6M 77629 77704 77100M 77117M 77380M 77381M 77085M 77082M 77238M 77331 77171M
DESCRIPTION
Electronics Cover Front Panel Assembly Maintenance Kit Static Brush Assembly Kit (Z4M) (See Figure 5-7) Kit, Maintenance Static Brush (Z6M) (See Figure 5-7) Cover, Rear (Z4M) Cover, Rear (Z6M) Kit, Maintenance Ribbon Take-Up (Z4M) Kit, Maintenance Ribbon Take-Up (Z6M) Kit, Maintenance Hanger (Z4M) Kit, Maintenance Hanger (Z6M) Assembly, Ribbon Supply Maintenance Kit (Z4M) Assembly, Ribbon Supply Maintenance Kit (Z6M) Kit, Maintenance Dancer (See Figure 5-8) (Z4M) Kit, Maintenance Dancer (See Figure 5-8) (Z6M) Kit, Maintenance Printhead Mechanism w/ Printhead (203 dpi) (Z4M) (See Figure 5-6. ) Kit, Maintenance Optical Media Sensor (Transmissive) Kit, Maintenance Ribbon/Head Open Sensor Kit, Maintenance Media Door (Z4M) Kit, Maintenance Media Door (Z6M) Kit, Maintenance Shaft Platen (Z4M) (See Figure 5-4) Kit, Maintenance Shaft Platen (Z6M) (See Figure 5-4) Plate, Ribbon Stripe (Z4M) Plate, Ribbon Stripe (Z6M) Rubber Bumper Base Mainframe Cover, Front (Z4M) Cover, Front (Z6M) Print Mechanism Latch Kit (See Figure 5-10 for Assembly breakdown) Cutter Kit Option (Z4M) (See Figure 5-12) Cutter Kit Option (Z6M) (See Figure 5-12) Flash Memory Kit Option (1 Mb) (See Figure 5-17) Flash Memory Kit Option (2 Mb) (See Figure 5-17) Memory Card (PCMCIA) Interface Option (See Figure 5-2) Z Series Hardware Kit (Not Illustrated)
QTY
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1
10 77752M 11 77765M 12 77034M 12 77035M 13 77023M 13 77022M 14 77049-104 14 77049-168 15 44014 16 N/A 17 N/A 18 77665 18 77702 N/S 77112M N/S 77971 N/S 77972 N/S 77817 N/S 77818 N/S 77819 N/S 77800M N/S: Not Shown N/A: Not Available Separately
Page 5-2
77259L Rev. 4 12/16/03
Maintenance and Assembly Drawings
Section 5
4 2 3 6
7 8
10
17 16 15 18
14 11
12 13
Figure 5-1. Main Printer Assemblies
77259L Rev. 4 12/16/03
5-3
Section 5
Maintenance and Assembly Drawings
Table 5-2. Electronics Maintenance Kits
Item
1 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 *N/S
Part Number
77186 77185 77237 77715M 77550 77282 77571 77016 49185 **N/A 77187 Q06020 77904M 07696 01153 22416 07808 **N/A 77819 **N/A **N/A **N/A **N/A **N/A 77520 77315 77600
Description
Plate, Back Cover, w/PCMCIA Port Plate, Back Cover, w/o PCMCIA Port Screw, M4 X 10 Power Supply Board Maintenance Kit Insulator, Pad Pad, Clamp Insulator, Electric Barrier Clamp, Heatsink Power Supply Screw, M3 X 14 Screw, M4 x 16 Bracket, CPU Support Tie Wrap Main Logic Board Maintenance Kit Screw, 4-40, Pan Head Washer, Flat Standoff Clamp, Cable Flat Screw, Hex M4 x 0.7 x 8 Memory Card (PCMCIA) Interface Option Kit Washer, Insulated Standoff Memory Card (PCMCIA) Interface Plate, Stud Fastener, Push-In Connector, Elastomeric for PCMCIA Interface Nut, Thumb for PCMCIA Interface Cable, PSU-MLB
Quantity
1 1 8 1 1 1 1 1 3 3 1 2 1 2 4 2 6 1 1 3 1 1 1 1 1 3 1
PCMCIA Kit (Optional)

2
20 21 22
1 23 2
19
25
24 3 4 18 2 8
12 13 15 14 2 11 8 10 7 2
16 17
16
9 6
*N/S: Not Shown **N/A: Not Available Separately
Figure 5-2. Electronics Maintenance Kits
5-4
12/16/03 77259L Rev. 4

Table 5-3. (Reflective) Media Sensor Assembly Maintenance Kit
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ITEM
PART NUMBER
DESCRIPTION
Kit, Maintenance Media Sensor Assembly (Reflective) . Media Sensor Assembly . Tie Wrap
QTY
1 1 3
REF 77807M 1 N/A 2 Q06020 N/A: Not Available Separately
1 2
Figure 5-3. (Reflective) Media Sensor Assembly Maintenance Kit
77259L Rev. 4 12/16/03
Page 5-5
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Table 5-4. Platen Assembly
ITEM PART NUMBER
DESCRIPTION
QTY
1 1 1 1 1 1 1 1 2 3 1 1 2 1 1 1 1 1
1 HW44216 Screw, M4.2 x 1.41 2 77752M Kit, Maintenance Optical (Transmissive) Media Sensor 3 77935M Kit, Maintenance Media Edge Guide 4 HW46128 Washer, Nylon 5 77807M Kit, Assembly (Reflective) Media Sensor (See Figure 5-3. ) 6 77023M Kit, Maintenance Platen Roller Shaft (Z4M) (See Figure 5-5. ) 6 77022M Kit, Maintenance Platen Roller Shaft (Z6M) (See Figure 5-5. ) 7 77765M Kit, Maintenance Ribbon/Head Open Sensor 8 77078 Washer, Flat, 0.500 x 0.191 x 0.090 9 *HW77237 Screw, M4 x 0.7 x 10 10 77625M Peel Tear Bar (Z4M) 10 77799M Peal Tear Bar (Z6M) 11 77231 Screw, M3 x 8 mm 12 N/A Washer, Nylon 0.2 x 0.625 x 0.020 13 HW30208 Washer, Flat .500 x .191 x .030 14 N/A Screw, M4 x 0.7 x 12 mm Hex Head 14 *HW77237 Screw, M4 x 0.7 x 10 mm Thread 15 77112M Kit, Maintenance Latch (See Figure 5-10. ) N/A: Not Available Separately
*Minimum Quantity of 5 Minimum Quantity of 25
Page 5-6
77259L Rev. 4 12/16/03

3 1 2
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6 5 8 9 7 10
11 12 13 14
15
Figure 5-4. Platen Assembly
77259L Rev. 4 12/16/03
Page 5-7
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Table 5-5. Platen Roller Shaft Maintenance Kit
ITEM
PART NUMBER
DESCRIPTION
QTY
1 1 1 1 2 1
REF 77023M Kit, Maintenance Platen Roller, Z4M REF 77022M Kit, Maintenance Platen Roller, Z6M 1 N/A Roller, Platen Shaft 2 N/A Bearing, Platen 3 N/A Spring, Clip 4 N/A Washer, Spring N/A: Not Available Separately
1 2
4 2
Figure 5-5.
Platen Roller Shaft Maintenance Kit
Page 5-8
77259L Rev. 4 12/16/03

Table 5-6. Printhead Housing Maintenance Kit
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ITEM PART NUMBER
DESCRIPTION
QTY
1 1 1 1 1 1 1 1 1 1 1 1 1
1 77171M Kit, Maintenance Printhead Housing (203 dpi printhead) Z4M 2 77804M Kit, Maintenance Cable Printhead 4 inch 2 77831M Kit, Maintenance Cable Printhead 6 inch 3 77500M Kit, Maintenance Printhead 300 dpi (Z4M) 3 77000M Kit, Maintenance Printhead 203 dpi (Z4M) 3 77001M Kit, Maintenance Printhead 203 dpi (Z6M) 3 77501M Kit, Maintenance Printhead 300 dpi (Z6M) 4 *HW77047 . Screw, Printhead Mounting N/S 77802M Kit, Maintenance Printhead Hardware 4 inch N/S N/A . Cable, Braid 4 inch N/S N/A . Spring, Compression 0.21 x .030 x 1.5 N/S 77049-104 . Plate, Ribbon Strip (Z4M) N/S 77049-168 . Plate, Ribbon Strip (Z6M) N/S: Not Shown N/A: Not Available Separately
*Minimum Quantity of 5
4 Printhead Ground
Printhead Data
Printhead Power
Figure 5-6. Printhead Housing Maintenance Kit
77259L Rev. 4 12/16/03
Page 5-9
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Table 5-7. Static Brush Assembly Maintenance Kit
ITEM
PART NUMBER
DESCRIPTION
Kit, Maintenance Static Brush Assembly (Z4M) Kit, Maintenance Static Brush Assembly (Z6M) . Screw, M3 x 0.5 . Washer, Star M3 . Brush, Ribbon Static Brush, Ribbon Static . Bracket, Ribbon Static Brush . Screw, M4 x 0.7 x 10 mm
QTY
1 1 2 2 1 1 1 2
REF 77302M REF 77303M 1 HW10401 2 10472 3 77318 3 77319 4 N/A 5 *HW77237 N/A: Not Available Separately
Figure 5-7. Static Brush Assembly Maintenance Kit
Page 5-10
77259L Rev. 4 12/16/03

Table 5-8. Dancer Assembly Maintenance Kit
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ITEM PART NUMBER
DESCRIPTION
QTY
1 1 2 1 1 2 1 1 1
Kit, Maintenance Dancer Assembly (Z6M) 1 77331M (Sold as a Complete Assembly only for Z6M) 2 77238M Kit, Maintenance Dancer Assembly (Z4M) 3 N/A . Bearing, 0.38 x 0.63 x 0.50 4 N/A . Spring, Torsion 5 N/A . Dancer 6 HW30224 . Ring, External Crescent, 0.375 7 N/A Shaft, Dancer 8 HW44356 Washer, 0.198 x 0.75 x 0.085 9 HW10432 Screw, Cap M4 x 0.7 N/A: Not Available Separately Minimum Quantity of 25 Minimum Quantity of 50
8 7
Figure 5-8. Dancer Assembly Maintenance Kit
77259L Rev. 4 12/16/03
Page 5-11
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Table 5-9. Ribbon Supply Assembly Maintenance Kit
ITEM
PART NUMBER
DESCRIPTION
Kit, Maintenance Ribbon Supply, Z4M Kit, Maintenance Ribbon Supply, Z6M Screw, Cap, M4 x 0.7 Washer, 0.198 x 0.75 x 0.085 Shaft, Ribbon Supply Washer, 0.500 x 0.377 x 0.020 Ring, Crescent, Ext. Spindle, Inner Blade, Spindle Spring, Tension Screw, Set Cup, M3 x 0.5 Cup, Spring Clutch Screw, M3 x 0.5 Blade Spindle, Inner Spindle, Outer
QTY
1 1 1 1 1 1 1 1 2 2 4 2 2 1 1 1
REF 77085M REF 77082M 1 HW10432 2 HW44356 3 N/A 4 44390 5 HW30224 6 N/A 7 N/A 8 N/A 9 HW44147 10 N/A 11 HW10401 12 N/A 13 N/A 14 N/A N/A: Not Available Separately Minimum Quantity of 25 Minimum Quantity of 50
2 1 5 6 7 3 4 7
14 9 9 11 12
8 10
13 8 10
11 12 14 9 13 8 10
Z4M Z6M
Figure 5-9. Ribbon Supply Maintenance Kit
Page 5-12
77259L Rev. 4 12/16/03

Table 5-10. Print Mechanism Latch Kit
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ITEM
REF 1 2 3 4 5 6 7 8 9
PART NUMBER
77112M 77276 N/A 10473 Q10011 *HW77237 77236 N/A N/A N/A . Cap, Strike Plate . Latch, Strike Plate . Washer, Flat M4
DESCRIPTION
Kit, Latch Print Mechanism
QTY
REF 1 1 1 1 1 1 1 1 1
. Screw, M4 x 10 Cp Hx H Bo . Screw, M4 x 0.7 x 10 mm . Cover, Latch Plate . Latch . Spring, Compression . Pin, Slot Spring
N/A: Not Available Separately

2 3
8 7 6
Figure 5-10. Print Mechanism Latch Kit
77259L Rev. 4 12/16/03
Page 5-13
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Table 5-11. Drive System Belts/Pulleys
ITEM
PART NUMBER
DESCRIPTION
Kit, Maintenance Clutch Ribbon Take-Up . Hub, Clutch . Gear, Clutch . Bearing, Clutch . Spring, Return Washer, Nylon Flat, 0.375 x 0.75 x 0.062 Washer, Flat 0.379 x 0.53 x 0.056 Collar, Shaft 0.377 x 0.750 . Screw, Set, M3 X 0.5 Kit, Maintenance Drive System . Gear, Compound . Gear, Intermediate . Belt, 080P 144Tcndtv PU . Pulley, Compound . Screw, Set M4 x 0.7 x 10 mm Nut, Adjusting Screw, M4 x 0.7 Screw, Cap, M4 x 0.7 x 12 mm Kit, Maintenance Stepper Motor Screw, M3 x 0.5 x 8 mm Screw, M6 x 20
QTY
1 1 1 1 1 1 2 1 2 1 1 1 1 1 2 1 2 1 1 1 1
1 77814M 2 N/A 3 N/A 4 N/A 5 N/A 6 N/A 7 N/A 8 44118 9 HW4147 10 77803M 11 N/A 12 N/A 13 77396 14 N/A 15 HW10856 16 N/A 17 *HW77237 18 HW10432 19 77813M 20 HW44924 21 N/A N/A: Not Available Separately
Page 5-14
77259L Rev. 4 12/16/03
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2 8 11
12 5 4 6 21 15 9 20 19 16 13 14
10
Note: Gear #11 and Pulley #14 are Pictured for 203 dpi. The Small Part Facing Out. 18 17 For 300 dpi they must be turned around. The Large Part Facing Out.
Figure 5-11. Drive System Belts/Pulleys
77259L Rev. 4 12/16/03
Page 5-15
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Table 5-12. Cutter Kit (Option)
ITEM
PART NUMBER
DESCRIPTION
Kit, Optional Cutter, (Z4M) Kit, Optional Cutter, (Z6M) . Tray, Catch (Z4M) . Tray, Catch (Z6M) . Cutter Cover and PC Board Assembly (Z4M) . . Cutter Cover (Z4M) . Cutter Cover and PC Board Assembly (Z6M) . Cutter Cover (Z6M) . Kit, Module Cutter (Z4M) . Kit, Module Cutter (Z6M) . Screw, M3 . Cable, Cutter . Screw, Socket Head M4 x 10 . Static Brush, Cutter (Z4M) . Static Brush, Cutter (Z6M)
QTY
1 1 1 1 1 1 1 1 1 1 2 1 1 1 1
1 77971 1 77972 2 77041 2 77997 3 77973M 3 77697 3 77974M 3 77698 4 77990M 4 77401M 5 N/A 6 77630 7 77427 8 77408 8 77409 N/A: Not Available Separately
3 Motor Connector 7
Figure 5-12. Cutter Kit (Optional)
Page 5-16
77259L Rev. 4 12/16/03

Table 5-13. Value Peel Assembly (Optional)
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ITEM PART NUMBER

1 78002M 1 78002-6M 2 77231 3 77197M 3 77727M 4 10094 5 N/A 6 N/A N/S 77222 N/S 77738 N/S: Not Shown
DESCRIPTION
Kit, Maintenance Value Peel, Z4M Kit, Maintenance Value Peel, Z6M . Screw, M3 x 8 mm Kit, Maintenance Value Peel Pinch Roller, Z4M Kit, Maintenance Value Peel Pinch Roller, Z6M . E-Ring, 3 mm . Bearing . Roller, Pinch . Brush, Value Peel Static Z4M . Brush, Value Peel Static Z6M
QTY
1 1 2 1 1 2 2 1 1 1
1 2
Figure 5-13. Value Peel Assembly
77259L Rev. 4 12/16/03
Page 5-17
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Table 5-14. Liner Take-up Assembly (Z4M Only)
ITEM
1 2 3 4
PART NUMBER
77347M 77648 *HW77237 06313 Kit, Z4M Liner Take-up . Cable, Motor . Screw, M4 x 10 mm . E-ring
DESCRIPTION
QTY
1 1 2 1
NOTE: The Liner Take-up is Only Available for the Z4M!!!
Figure 5-14. Liner Take-up Assembly (Z4M Only)
Page 5-18
77259L Rev. 4 12/16/03

Table 5-15. Power Rewind/Peel (Option)
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ITEM
PART NUMBER
DESCRIPTION
Kit, Power Rewind/Peel, Z4M Kit, Power Rewind/Peel, Z6M . Kit, Maintenance Motor/Spindle Z4M . Kit, Maintenance Motor/Spindle Z6M . Kit, Maintenance PCB DC Motor . Cable, Media Rewind . . Cable Tie 0.09 W x 3.63 L . Kit, Maintenance Power Peel, Z4M . Kit, Maintenance Power Peel, Z6M . Screw, M4 x 0.7 x 10 mm . Pan
QTY
1 1 1 1 1 1 1 1 1 8 1
1 77058 1 77059 2 77498M 3 77898M 3 77740M 4 77648M 5 Q06020 6 77247M 6 77257M 7 *HW77237 8 N/A N/A: Not Available Separately
1 2 4 3
Figure 5-15. Power Rewind/Peel Option
77259L Rev. 4 12/16/03
Page 5-19
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Table 5-16. Value Peel Rewind Kit (Released in Fourth Quarter 2001)
ITEM
PART NUMBER
DESCRIPTION
Kit, Rewind/Peel, Z4M Kit, Power Rewind/Peel, Z6M . Kit, Maintenance Motor/Spindle Z4M . Kit, Maintenance Motor/Spindle Z6M . Kit, Maintenance Value Peel Rewind PCB . Cable, Media Rewind . . Cable Tie 0.09 W x 3.63 L . Kit, Peel, Z4M . Kit, Peel, Z6M . Screw, M4 x 0.7 x 10 mm . Pan
QTY
1 1 1 1 1 1 1 1 1 8 1
1 78005 1 Factory Install Only 2 78007M 3 78007-6M 3 78010M 4 77648M 5 Q06020 6 78002 7 78002-6 8 *HWW77237 9 N/A N/A: Not Available Separately
1 2 4 3
8 9
Figure 5-16. Value Peel Rewind Kit
Page 5-20
77259L Rev. 4 12/16/03

Table 5-17. Miscellaneous Options
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Item Part Number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 N/S N/S N/S N/S N/S: 48924 48752 30757 30753 48925 48761 30757 48753 46692 46689 46709 47210 46686 77823 77824 77978 77978 Not Shown
Description
Kit, Field Upgrade IBM Twinax . Assembly, PCB IBM Twinax . AP Cable, Ribbon 40 Option Signal . Assembly, Cable IBM Twinax Kit, Field Upgrade IBM Coax . Assembly, PCB IBM Coax . AP Cable, Ribbon 40 Option Signal . Cable, Coax Ext. IBM Kit, Upgrade ZebraNet II External Kit, Upgrade ZebraNet II Internal . PA Cable, Internal . PA Cable Tape ZebraNet II . Grommet, Strip 2-1/8 . PA 10 Base T Web Internal Kit, Upgrade 300 dpi Z4M Kit, Upgrade 203 dpi Z4M Kit, Upgrade 203 dpi Z6M Kit, Upgrade 300 dpi Z6M
Qty
1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 3
5 7
1 2 3 4 5 6 7 8 9 10 11 12
EPC BF P T EMU 2 EMU 1 LNG 8 LNG 4 LNG 2 LNG 1 ADR 4 ADR 2 ADR 1 SPO
1 2 3 4 5 6 7 8 9 10 11 12
EPC BF P T EMU 2 EMU 1 LNG 8 LNG 4 LNG 2 LNG 1 ADR 4 ADR 2 ADR 1 SPO
CANCE ATT N T ES T S YN
C
CANCE ATT N T ES T S YN
C
TWIN
AX
COA
8 13
10
11 12 14
Figure 5-17. Miscellaneous Options
77259L Rev. 4 12/16/03
Page 5-21
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Page 5-22
77259L Rev. 4 12/16/03

Zebra z4m Schematic

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6HFWLRQ  0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV

77259L Rev. 4 12/16/03

Z4M/Z6M Maintenance Manual

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ITEM PART NUMBER

Z4M/Z6M Maintenance Manual

77259L Rev. 4 12/16/03

Maintenance and Assembly Drawings

Figure 5-1. Main Printer Assemblies

77259L Rev. 4 12/16/03

Z4M/Z6M Maintenance Manual

Maintenance and Assembly Drawings

Table 5-2. Electronics Maintenance Kits

PCMCIA Kit (Optional)

*N/S: Not Shown **N/A: Not Available Separately

Figure 5-2. Electronics Maintenance Kits

Z4M/Z6M Maintenance Manual

12/16/03 77259L Rev. 4

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REF 77807M 1 N/A 2 Q06020 N/A: Not Available Separately

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

77259L Rev. 4 12/16/03

Z4M/Z6M Maintenance Manual

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ITEM PART NUMBER

Z4M/Z6M Maintenance Manual

77259L Rev. 4 12/16/03

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Figure 5-4. Platen Assembly

77259L Rev. 4 12/16/03

Z4M/Z6M Maintenance Manual

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Platen Roller Shaft Maintenance Kit

Z4M/Z6M Maintenance Manual

77259L Rev. 4 12/16/03

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ITEM PART NUMBER

Figure 5-6. Printhead Housing Maintenance Kit

77259L Rev. 4 12/16/03

Z4M/Z6M Maintenance Manual

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Figure 5-7. Static Brush Assembly Maintenance Kit

Z4M/Z6M Maintenance Manual

77259L Rev. 4 12/16/03

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ITEM PART NUMBER

Figure 5-8. Dancer Assembly Maintenance Kit

77259L Rev. 4 12/16/03

Z4M/Z6M Maintenance Manual

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Figure 5-9. Ribbon Supply Maintenance Kit

Z4M/Z6M Maintenance Manual

77259L Rev. 4 12/16/03

0DLQWHQDQFH DQG $VVHPEO\ 'UDZLQJV

N/A: Not Available Separately

Figure 5-10. Print Mechanism Latch Kit

77259L Rev. 4 12/16/03

Z4M/Z6M Maintenance Manual

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Z4M/Z6M Maintenance Manual

77259L Rev. 4 12/16/03

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