ZEBRA ZXP Series 7™ · ZXP7 P1037750-061 Yes Replace the upper feed roller, available in ZXP7...

ZEBRA

P1069160-002

ZXP Series 7™

Cover

Troubleshooting Guide

P1069160-002 Rev. A

The troubleshooting procedures presented in this document are intended for use by Zebra trained and certified personnel, or under the specific direction of Zebra trained and certified personnel. Attempts to perform troubleshooting procedures by non-Zebra trained and certified personnel may void the product warranty and may cause damage to the equipment.

Copyright Notice© 2014 ZIH Corp.

This document contains information proprietary to Zebra Technologies Corporation. This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra.

While every effort has been made to keep the information contained within current and accurate as of the date of publication, no guarantee is given that the document is error-free or that it is accurate with regard to any specification. Zebra Technologies Corporation reserves the right to make changes, for the purpose of product improvement, at any time.

TrademarksZXP Series 7 is a trademark and Zebra is a registered trademark of Zebra Technologies Corporation. Windows is a registered trademark of Microsoft Corporation in the United States and other countries. All other trademarks or registered trademarks are marks of their respective holders.

Electrostatic Discharge Caution • For any of these procedures that involve touching internal components of the printer, the procedure must be performed at a static-free workstation, an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used.

Electric Shock Hazard • Some troubleshooting procedures direct the use of bypassing inserts (also called "cheaters") to enable troubleshooting with power on and the covers open. For these procedures, use extreme caution to avoid touching any internal parts of the printer with your hands or any tools, and be sure to remove any bypassing inserts before placing equipment back into service.

Contents

Card Errors Error 1- Card Feed Error 4014………………………………………………………………………………………………3

Error 2- Flipper Card Jam 7026…………………………………………………………………………………………….9

Error 3- MAG Card Jam 7035………………………………………………………………………………………………17

Error 4- Options Card Jam 7024…………………………………………………………………………………………17

Error 5- Out of Ribbon 5001………………………………………………………………………………………………..24

Error 6- Ribbon Jam 5003……………………………………………………………………………………………………..24

Error 7- Ribbon Color Detect Error 5007…………………………………………………………………………24

Error 8- Top/ Bottom Laminate Feed Fail 17005/ 17006………….……………………………..34

Error 9- Top/ Bottom Heater Fail 17013/ 17014…….…………………………………………………..34

Error 10- Top/ Bottom Cutter Fail 17019/ 17020………………………………………………………..34

Image Quality Image Placement………………………………………………………………………………………………………………………43

Monochrome and K Panel Printing……………………………………………………………………………………47

Misregistration……………………………………………………………….…………………………………………………………51

Ribbon Wrinkle………………………………………………………….………………………………………………………………56

White Line On Card………………………………………..………………………………………………………………………..60

Scratch Off Gray and KdO Image Issues………………………………………………………….64

Card Feed Error 4014

Pg. 4 Feeding Into Flipper?- No

Pg. 5 Feeding Into Flipper?- Yes

Pg. 6 Service Center Instructions

Pg. 7 Reference Page Part 1


3

44014 Card Feed Error

Are cards feeding into the

flipper area?Instructions

Open the options door and remove

the cleaning cartridge

Yes

Are the cards the

correct thickness?

No

Are the cards a

supported card type?Yes

Are the cards

warped?Yes

Are the cards

sticking together?No

Are the proper # of

cards being used?

(less than 200)

No

Are the cards

uneven in the

feeding cassette?

(See Pic 1.0)

Yes

Select the retry

button on the OCP

to retry the card.

The card thicknesses

currently supported are

10 mil - 50 mil

Not

Sure

Reference the next page

for a complete list of

supported card types

Not

Sure

If they do not lay flush

against the table, replace

with new unwarped cards

Not

Sure

Pull stack out of feeder

and fan out cards, being

careful not to touch front

surface of the cards

Yes

Is card feeding cassette

locked in place?

(See Pic 1.1)

Take out cards so that

there is less than 200 of

the 30 mil cards in feeder

No

Open the feeding

cartridge lid and

straighten out the cards

YNeos

Check: Cassette is down and

all the way to the left. It should

lock into place.

Not

Sure

Are the cards on the left

side of the pusher plate?

Yes

Is the pusher plate

properly released and

the cassette lid closed?

Yes

Check: That the pusher plate is

not locked in the back of the

cassette when the lid is down.

(See Pic 1.3)

Not

Sure

Check: Picture 1.2 for

correct card location

Not

Sure

Select the retry

button on the OCP

to Retry the card.

Is the card feed path clean? Is

the feed roller clean?

Yes

Is the feed roller moving?

Yes

Remove the feeder cartridge and

select the retry button on the OCP.

Watch the lower feed drive roller for

movement (see pic)

To

Check

Is the Card Feed Motor

running? To Check: press the

retry button on the OCP and

listen for the card feed motor

No

Run a feeder cleaning cycle through the

OCP. Clean the feeder drive rollers and

feeder pinch rollers with alcohol swab.

No

Replace the feeder

cartridge securely with

cards properly loaded.

Retry Card on OCP

Yes

Printer Requires

Service

Go To Pg. 6

No Yes

Printer Requires

Service

Go To Pg. 6

Card Still

Fails

Card Still

Fails

Card Still Fails

Still

No

Send Feeder

Cartridge For

Replacement

Go To Pg. 6

Go to Pg. 5

CheckCheck

No

Pg 4: Feeding Into Flipper? – No

Pg 5: Feeding Into Flipper?- Yes

Pg 6: Service Center Instructions

Pg 7: Reference Page Part 1


DoneCard Feeds

Correctly

DoneCard Feeds

Correctly

5

Are there less than 200 cards in the

feeding cassette? Over 200 of the

30 mil cards might not create

enough pressure for the cards to

feed.

Are the cleaning cassette and

cleaning rollers properly

installed? (See Pic 1.5) Tape

removed from the cleaning

rollers?

Are the feeding rollers

dirty?

Clean the feeding rollers with the

feeder cleaning cards through the

OCP cleaning cycle. Press card retry

button.

Yes

Is the card reaching the sensor

on the flipper deck

(See Pic 2.0)

Open ZXP Toolbox, go to printer sensors

and check whether flipper sensor is

seeing card (changing from 0 to 1)

Yes

Send Printer For

Service

Goto Pg. 6

No

No

Remove cards so that

there are less than 200 in

feeder. Press card retry

button.

Remove tape from the cleaning

rollers and properly insert the

cleaning cartridge. Press card

retry button.

No






Is the card feeding

behind the flipper deck?

(See Pic 2.1)

Send Printer For

Service

Go to Pg. 6

Go to

page 4

Go to

Pg. 4No

Is the Singulation Roller

worn? (See Pic 1.4)

Send Printer For

Service

Go To Pg. 6

Yes

Yes

No

Yes

No

Yes

Yes

Card Still Fails

Card Still Fails

No

Card Still Partial Feeds

DoneCard

Feeds

DoneCard

Feeds

DoneCard

Feeds

No

Toolbox Register Sensor






6

Printer Returned with no

Feed or Partial Feed into

Flipper?

No Feed Partial Feed

Is Pusher Plate Applying

enough Pressure to

Card?

Is the Bottom Feed

Roller skidding on the

card or showing signs of

wear? (see Pic 2.5)

Replace Feeder

Cartridge No


Worn/ old? (See Pic 2.2)

Yes

Replace the Bottom feed

Roller, available in Kit

Drive Assembly Feeder

ZXP7 P1037750-061

Yes


Worn or skidding on the

card? (See Pic 2.2)

No

Yes

Is the upper feed drive

roller moving without

difficulty and is not worn

out or squeaky?

No

Replace the Singulation Roller (See Pic

2.3), available in Kit Drive Assembly

Feeder ZXP7 P1037750-061

Yes Replace the Singulation

Roller, available in ZXP7


Kit, P1037750-061

Is the Top Feed Roller

skidding on the card or

showing signs of wear

(See Pic 2.4)?

No

Replace the Top feed

roller, available in Kit


ZXP7 P1037750-061

YesReplace the upper feed

roller, available in ZXP7


Kit, P1037750-061

Yes

Is the card feeding


NoInspect the feeder drive belt

and gears for damage or

improper assembly. Listen

for grinding, teeth/ belt

slipping. Feeder Clutch

failing?

No

Replace the feeder drive

belt/ gears/ clutch,

available in Kit Drive

Assembly Feeder ZXP7

P1037750-061

Yes

Is the ZXP Toolbox

registering the sensor?

No

Perform a flipper

Calibration using the

flipper calibration tool

(refer to the service

manual)

Yes

Check the sensors

connection to board for

loose wires at SEN FLCD

J11. (See Pic 2.6) If

connection is loose or out of

order, repair connection and

check. See Picture for

correct wire order.

No

If the connector SEN FLCD

J11 is still not registering in

the toolbox after the loose

wire is fixed or no loose wire

was found, replace the

sensor and rewire the

connector.

Is feeder motor not

making noise or feed

rollers not moving?

No

Yes

Check the connector JB

FCBA_FLIP for signal using

a voltmeter. (See Pic 2.7) If

a signal is not detected,

replace the connector.

Yes

Check the card feed

motor connections for

any loose wires. If found,

repair connections and

check for connectivity.

Motor Still Malfunctioning

Still Malfunctioning






Contact Zebra/

Elevate to Tech

Support Level 3

Contact Zebra/

Elevate to Tech

Support Level 3

No

Contact Zebra/

Elevate to Tech

Support Level 3

4014

Card Feed Error

Service Center

Reference Page Part 1

Pusher Plate Released Feeding Cassette Closed and

Pusher Plate Released

Cards On Correct Side Of Pusher PlateCards on wrong side of pusher plate






1.0 Cards Uneven in Feeding Cartridge

1.1 Loading the Feeding Cassette

1.2 Cards on wrong side of pusher plate

1.3 Pusher plate properly released 1.4 Worn Singulation Roller

Cleaning Cassette Location

2Cleaning Cassette and

Cleaning Rollers With Tape

Still On

Cleaning Cassette Being

Inserted Into Proper Location

1.5 Cleaning Cassette location and Proper installation


Press the Feeding Cassette DownSlide the Cassette All the Way to the Left Until The Cassette Locks Into Place

7





Pg 8: Reference Page Part 2Reference Page Part 2

Obsolete, replaced by black singulation roller

2.7 Correct order for Feeder Motor wires2.6 Correct order for SEN FLCD J11

2.0 Card Feed Sensor on Flipper Deck2.1 Card Feeding Behind

Flipper Deck

Worn Singulation Roller

2.2 Old and Worn Singulation Roller Respectively

2.3 Black Singulation Roller 2.4 Top Feed Roller

2.5 Worn Bottom Feed Roller

8

Flipper Card Jam 7026

Pg. 10 Flipper Jam When Initializing

Pg. 11 Flipper Jam When Feeding Part 1


Pg. 13 Flipper Jam When Printing

Pg. 14 Service Center Instructions



9

10

7026

Flipper Card Jam

What Was The Printer Doing

When The Problem

Occurred?

Feeding?

Pg.11

Is the Flipper Roller Popped

Out Of Place On the Flipper

Deck

(See Pic 1.0)?

No

Refer to the Service Manual

to Replace Flipper Roller

Yes Printing?

Pg. 13Initializing

Is There A Card In

The Flipper Deck?

Is There A Card

Jammed In The

Reject Bin Blocking

The Flipper?

Is There A Card In

The Card Path

Blocking The Flipper?

(See Pic 1.1)

Is There A Card

Jammed Under The

MAG Head Blocking

The Flipper?

No

No

No

No

Yes

DoneCard

Prints

Send Printer For

Service Pg. 14

Turn Printer Off,

Remove Card,

Restart Printer.

Yes

Turn Printer Off,

Remove Card,

Restart Printer.

Card

Prints Done

Done

Turn Printer Off,

Remove Card,

Restart Printer.

YesCard

Prints

Card Still

Jams

Card Still

Jams

Card Still

Jams

Turn Printer Off,

Remove Card,

Restart Printer.

DoneYesCard

Prints

Card Still

Jams


Pg.11 Flipper Jam When Feeding Part 1


Pg.13 Flipper Jam When Printing

Pg.14 Service Center Instructions



11

7026

Flipper Card Jam

What Was The Printer Doing

When The Problem

Occurred?

Is the Flipper Roller Popped

Out Of Place On the Flipper

Deck?

(See Pic 1.0)

No

Refer to the Service

Manual to Replace

Flipper Roller

Yes

Initializing?

Pg. 10

Manual Card Feed

Slot

Card

Feeder

Is The Flipper

Deck Level w/ The

Card Path?

Are The Cards

Trying To Feed At

The Same Time?

Is the Card

Jamming Between

the Feeder and

the Flipper?

(See Pic 1.2)

Is The Flipper Deck Level w/

Feeder Position? (Cards

Feeding Either In Front Of Or

Behind Flipper Deck)

Yes

No

No

Turn Off Printer, Remove Card

From Flipper, Then Restart

Printer And Feed Cards

YesNo

Turn Printer Off, Remove

Feeder Cartridge And Open

Options Door. Remove Jammed

Card. Restart Printer and Print

card again.

Yes

Turn Printer Off, Open Options

Door, Remove Cleaning

Cartridge, Clear Flipper Jam,

and Fan Out Remaining Cards

to Separate them. Restart Job

Yes

Done

Card

Jams

Card

Prints

Make Sure Feeder Cartridge Is

Pushed All The Way To The

Left (See Pic 1.3)

Make Sure The Cleaning

Cartridge Is Inserted Correctly,

(See Pic 1.4) Then Print Card

Again

Then

Check To See If Singulation

Roller Is Worn.

(See Pic 2.0)

AlsoStill

Jams

Card

Prints

No

Attempting to feed cards

.

How Were You Feeding The

Cards?

Printing?

Pg. 13

Card

Prints

Card Jams

Send Printer For

Service Pg. 14

Done

Card

Feeds Flipper

Jams

Flipper

Jams

Continue

on Pg. 12

Done

Done

Continue

on Pg. 12








12

Continued From

Pg. 11

Manual Feed Slot

Is the Platen

Roller on the

Flipper Deck

Worn?

Is the Platen Roller on

the Flipper Deck

Turning? (Remove

Flipper Roller and check

to see if platen is turning)

No

Send Printer For

Service Pg. 14

Yes

Send Printer For

Service Pg. 14No

Is the Flipper Roller on

the Flipper Deck Worn?Yes

Send Printer For

Service Pg. 14Yes

Send Printer For

Service Pg. 14

No

Continued From

Pg. 11

Card Feeder

Is the Platen

Roller on the

Flipper Deck

Worn?

Is the Platen Roller on

the Flipper Deck

Turning? (Remove

Flipper Roller and check

to see if platen is turning)

Is the Flipper

Roller on the

Flipper Deck

Worn?

No

Yes

Open options Door

and clear cards.

Power cycle printer

and feed cards

again

No

Done

Cards Feed

Send Printer For

Service Pg. 14

Still

Jams

Yes

No

Yes








13

From Print

Module

From Options

Module

Where Is The

Card Coming

From?

Is the Card

Stalled/ Jammed

Btwn the Print

Module and

Flipper?

Is the Card

Stalled/ Jammed

Btwn the Options

Module and the

Flipper?

Is the Platen Roller

on the Flipper Deck

Worn?

Is the Platen Roller

on the Flipper Deck

Turning?

Is the Flipper Roller

on the Flipper Deck

worn?

Is The Flipper Deck

Level w/ The Card

Path?

Is The Flipper Deck

Level w/ The Card

Path?

No No

No

No

Yes

No

Turn Off Printer. Remove

Card From Flipper.

Restart Printer.

Yes Yes

Turn Off Printer, Open Options

Door, Remove Cleaning Cartridge

and Remove Jammed Card.

Restart Printer and Print card

again.

Yes Yes

Yes

No

Yes

Card

Prints

Card

Jams

7026

Flipper Card Jam

What Was The Printer

Doing When The

Problem Occurred?

Is the Flipper Roller

Popped Out Of Place On

the Flipper Deck?

No

Refer to the Service

Manual to Replace

Flipper Roller

Yes

Initializing?

Pg. 10Printing

Feeding?

Pg. 11

DoneCard

Prints

Card

Jams

Send Printer For

Service Pg. 14

No

Send Printer For

Service Pg. 14

Send Printer For

Service Pg. 14

Send Printer For

Service Pg. 14

Done

Card

Jams

Send Printer For

Service Pg. 14








14

Replace/Reinstall

New Flipper Roller

w/ O ring

Replace Flipper Platen

Roller From Kit Platen

Rollers ZXP7 P1037750-

050

Flipper Deck Motor is

Malfunctioning. Replace

Flipper Motor or Kit Flipper

Assembly ZXP7 P1037750-

075

7026

Flipper Card Jam

Service Center

Closeout Misaligned/

Overtightened. Remove

and Reinsert Closeout.

Replace If Necessary.

MAG Head Malfunction.

Remove Head From Options

Module and Reseat. If Still

Fails, Replace MAG Head

with

Use The Flipper Calibration Tool

(See Pic 2.1) to Recalibrate the

Flipper Through the Toolbox

Initialize the printer and check to

see if the flipper deck is aligned

with the card path.

Did the printer come in with a

reported missing/ worn/broken

Flipper Roller?

Yes

Did the printer come

in with reports of

stalling in the Flipper?

Turn Off The Printer, Cheat The Options

Door Open, Remove the Flipper Roller,

And Initialize Printer. Check To See If

Platen On Flipper Deck Is Moving

YesPlaten Not

Moving

When Printing, Is The

Card Jamming

Coming From The

Print Module Going

Into The Flipper?

When Encoding, Is

The Card Jamming

Coming From The

Encoding Module

Going Into The

Flipper?

On Printer

Initialization, The

Flipper Has Difficulty

Turning Or Doesn’t

Turn at All.

Turn Off The Printer,

Open The Printer

Door, Remove The

Ribbon. Where is the

Card?

Yes

Flipper

Misaligned…

Recalibrate

Flipper

Completely Under Closeout

Little Under Flipper Deck

Turn Off The Printer,

Open The Printer Door,

Remove The Ribbon.

Where is the Card?

Flipper Jammed… Remove

Card, Recalibrate Flipper If

Necessary.

HHaallff UUnnddeerr CClloosseeoouutt

HHaallff IInn FFlliippppeerr

Half Under Closeout

Half In Flipper

Completely Under Closeout

Against Flipper Deck

Cheat Open the Options

Door, Remove the Cleaning

Cartridge, Initialize The

Printer And Observe Flipper

Deck Motion.

Not

Sure?

Check To Make Sure The Flipper

Position Sensor Is Functioning In the

ZXP Toolbox. If Not, Replace With Kit

Flipper Position Sensor ZXP7

P1037750-034

Flipper Won’t

Calibrate

No

No

No

Yes

No

No

Flipper Still

Won’ Calibrate

Contact Zebra/

Elevate to Tech

Support Level 3

Done

Card Prints

DoneCard Prints

Done

Card Prints

Done

Card

Prints

Done

Contact Zebra/

Elevate to Tech

Support Level 3

Flipper

Still

Jams

Contact Zebra/

Elevate to Tech

Support Level 3

Flipper

Still

Stalls

DoneCard Prints

Still Jams

DoneCard

Prints

Contact Zebra/

Elevate to Tech

Support Level 3

Flipper

Still

Jams

Contact Zebra/

Elevate to Tech

Support Level 3

No

Flipper Still Jams

Contact Zebra/

Elevate to Tech

Support Level 3

Flipper

Still

Jams

DoneCard

Prints

Done

Card

Prints

Done

Card

Prints

Contact Zebra/

Elevate to Tech

Support Level 3

Flipper

Still

Jams








Flipper Calibrates

Cards Still Jam

Card Prints


1.0 Flipper Roller on

Flipper Deck

1.1 Card in card path

blocking the flipper

1.2 Card Jammed between

the Flipper and the Feeder

1.3 Proper Way to insert the Feeder Cartridge into the printer

1.4 Properly inserted

Cleaning Cartridge









15


2.0 Worn Singulation Roller








2.1 Flipper Calibration tool

16

MAG Card Jam 7035+Options Card Jam 7024

Pg. 18 Card Jam MAG

Pg. 19 Options Card Jam

Pg. 20 Service Center Card Jam MAG

Pg. 21 Service Center Options Card Jam



17

18

Card Jam MAG

7035

Print job will be

automatically retried after

options door is closed, or

click “cancel” on the OCP

to cancel to the print job.

Card

Cleared

Card Didn’t

Clear

Turn printer off, open options door,

remove the input hopper, remove

plastic MAG encoder cover (See

Pic 1.1), unscrew and lift MAG

encoder out of printer.

Inspect card path for any

obstructions and clear them.

Return everything into printer in

reverse order and close the

options cover. Turn printer on.

Print job will automatically

resume after successful

initialization.

Card Removed

From Card Path

Done

Card Jam MAG

Still Occurs

Done

Card

Prints

Card Jam MAG

Error Again

Clear print queue, power

cycle printer, and print

card again.

Hear Motor

Moving Platen

DoneCard Prints w/

Correct Card

Send to Service

Center

Pg. 20

Card Still Jams

Under MAG

Done

Card Prints

Open Card feeder and

remove cards.

Thumb through or fan

cards to better separate

cards to prevent multiple

feeds from cards sticking

Multiple Cards

Under MAG Head

Check and make sure

cards being used meets

Zebra Spec range

(10 mi l- 50 mil)

Is there a card jammed

under the MAG head?Yes

Card Still Jams

Under MAG

No

Open the options door and

check for a card jammed under

the MAG encoder (See Pic 1.0).

If card present, close options

door. Printer will attempt to

clear additional card in system.

Cheat options door open (See

Pic 1.2). Remove plastic cover

over magnetic head. When

attempting to print, listen for

platen motor moving when card

passes under magnetic head.

Pg. 18 Card Jam MAG

Pg.19 Options Card Jam

Pg.20 Service Center Card Jam MAG

Pg.21 Service Center Options Card Jam



Card Prints

19

Options Card

Jam 7024

Print job will be

automatically retried after

options door is closed, or

click “cancel” on the OCP

to cancel the print job.

Card

Cleared

Card Didn’t

Clear

Turn printer off, open options door,

remove the input hopper, remove

plastic MAG encoder cover

(See Pic 2.1), unscrew and lift the

smart card encoder out of printer.

Inspect card path for any obstructions

and clear them.

Return everything into printer in

reverse order and close the

options cover. Turn printer on.

Print job will automatically

resume after successful

initialization.

Did Card Jump

Card Path?

Done

Card Prints

Options Card Jam

Still Occurs

DoneCard

Prints

Options Card

Jam

Error AgainClear print queue, power

cycle printer, and print

card again.

DoneCard Prints w/

Correct Card

Send to Service

Center

Pg. 21

Options Card Jam

Error Again

Done

Card Prints

Open Card feeder and

remove cards. Thumb

through or fan cards to

better separate cards to

prevent multiple feeds

from cards sticking

Multiple Cards

In Options Module?

Check and make sure

cards being used meets

Zebra Spec range (10

mil- 50 mil)

Is there a card jammed

In the Options Module?Yes

Card Still Jams

In Option Module

No

Open the options door and check

for a card jammed under the smart

card encoder (See Pic 2.0). If card

present, close options door.

Printer will attempt to clear

additional card in system.

Possibly caused by flipper deck

misaligned. Power cycle printer

to initialize the flipper and

encode the card again.

(See Pic 2.2)

Send to Service

Center

Pg. 21

Card Still

Jams Under

Options Module

Done

Card

Prints

Pg. 18 Card Jam MAG






Make sure the Manual

feed slot cleaning

cartridge is installed and

the roller paper is

properly removed.

Card Still Jams

In Option Module

Card Prints w/

Correct CardDone

20

Pg. 18 Card Jam MAG






7035

Card Jam MAG

Service Center

Use Kit Pressure Roller

Assembly MAG ZXP7

P1037750-048

MAG Printer

Use Kit Pressure Roller

Assembly Non-MAG

ZXP7 P1037750-086Non MAG Printer

Remove MAG encoder

and check Pressure

roller assembly for

contamination or breaks/

wear?

Is the MAG Head Bad/

Faulty? Restart the

printer and see if the

OCP registers a MAG

head error.

No

Replace MAG Head with

Kit MAG Head

Replacement ZXP7

P1037750-017

Yes

No

MAG Board may have

malfunctioned. Replace

MAG Board with Kit

PCBA MAG Control

ZXP7 P1037750-016

Card Still Jams/

MAG Error on OCP

Replace Pressure

Roller Assembly for

either MAG or Non-

MAG printers

Yes

DoneCard

Prints

Contact Zebra/

Elevate to Tech

Support Level 3

DoneCard

Prints

Card Still Jams/

MAG Error on OCP

DoneCard

Prints

DoneCard

Prints

Is the MAG Head Sensor

misaligned? Remove MAG

Encoder and Check Alignment.

Is the Sensor not flush against

the Encoder housing?

No

Adjust Sensor or replace

MAG Head with Kit MAG

Head Replacement ZXP7

P1037750-017 if needed.

Yes DoneCard

Prints

Card Still Jams

Card Still Jams

21

Pg. 18 Card Jam MAG






7024

Options Card Jam

Service Center

Open options door. Is the

flipper deck misaligned

with card path?

Recalibrate Flipper Deck

Using Flipper Calibration

Tool through the

Toolbox. Attempt to

encode card again.Yes

Remove SC encoder and

check SC Connection

pins on SC fixture and

connection on printer.

No

Check To Make Sure

The Flipper Position

Sensor Is Functioning In

the ZXP ToolBox. If Not,

Replace With Kit Flipper

Position Sensor ZXP7

P1037750-034

Flipper Won’t

Calibrate

Done

Card Encodes

Card Still Jams

Under Options Module

Flipper Still

Wont Calibrate

Contact Zebra/

Elevate to Tech

Support Level 3

Is SC Encoder Bad/

Faulty? Restart the

printer and see if the

OCP registers a SC

module error.

No

Replace SC encoder with

Kit Mifare Contact Smart

Card Module ZXP7

P1037750-087

Yes

No

SC Board may have

malfunctioned. Replace

SC Board with Kit PCBA

Smart Card ZXP7

P1037750-015

Card Still Jams/

SC Error on OCP

Replace SC encoder with Kit Mifare

Contact Smart Card Module ZXP7

P1037750-087 if connection pins on

SC Module broken. Replace SC board

with kit PCBA Smart Card ZXP7

P1037750-015 if SC module

connection on printer is broken.

Yes

Card Still Jams Under Options Module

DoneCard

Prints

Contact Zebra/

Elevate to Tech

Support Level 3

DoneCard

Prints

Card Still Jams/

SC Error on OCP

DoneCard

Prints

Is the Mag Belt

tensioning loose? “Pinch”

the belt to check it’s

tautness.

(See Pic 2.3)

No

To tighten the belt

and the motor to the

fixture, turn the

screws till the belt is

no longer loose.

(See Pic 2.4)

Yes DoneCard

Encodes

Card Still Jams

Pg. 18 Card Jam MAG







1.0 Card Jammed under

MAG Endcoder Head

1.1 Remove Plastic

MAG Cover

1.2 How to operate the printer with the options cover open

22

Pg. 18 Card Jam MAG







2.2 Card hops the card path under the smart card encoder. Tends

to hop the card path from flipper deck being out of calibration.

2.0 Card Jammed under Smart Card Module 2.1 Remove Plastic MAG Cover

2.3 Mag Belt In Options Module

With Possible Loose Tension2.4 Screws That Need To Be

Tightened to Secure MAG Motor

And Tigheten Loose Belt

23

Out of Ribbon 5001,Ribbon Jam 5003,Ribbon Color Detect Error5007

Pg. 25 Out of Ribbon

Pg. 26 Ribbon Jam

Pg. 27 Ribbon Color Detect Error

Pg. 28 Service Center Out of Ribbon

Pg. 29 Service Center Ribbon Jam

Pg. 30 Service Center Ribbon Color Detect Error




24

25Pg. 25 Out of Ribbon

Pg.26 Ribbon Jam

Pg.27 Ribbon Color Detect Error

Pg.28 Service Center Out of Ribbon

Pg.29 Service Center Ribbon Jam

Pg.30 Service Center Ribbon Color Detect Error




5001

Out of Ribbon

Is the Ribbon Physically

out? (All the ribbon will be

on the blue spindle on the

left side)

Open Printer Cover And

Pull Open Ribbon Drawer

Is the ribbon broken or

ripped in half?

(See Pic 1.0)

No

Replace With

New Ribbon.

Close Printer

Door. Job Should

Restart.

Yes DoneCards

Print

Out Of Ribbon Error

No

Take the ribbon out of the printer, lay both

sides flat on the table and line the two sides

up as best you can, cutting jagged edges as

needed. Tape two ends together and roll

tapped ribbon onto take up (blue) core.

Reinsert into ribbon drawer, close printer. Job

will try to resume. (See Pic 1.1)

Yes DoneCards

Print

Out Of Ribbon Error

Go into the toolbox and on the left

side menu look under Information.

Select Media. In the Media window,

make sure the Images remaining is

correct and matches the OCP

Ribbon count.

Put a different ribbon in

and make sure it can be

read. If it can be read,

issue closed.

Yes

Is The Tricolor Sensor Malfunctioning? Go into

the toolbox and on the left side menu look under

Information. Select Printer Sensors. In the Printer

Sensors window, look under Sensor Values for

the Tri-Color Information. If the values read

unknown for Any, Red, Green or Blue, the

sensor may be malfunctioning.

No

Yes

No

Send to Service

Center

Pg. 28

Using cleaning

card to clean

printhead of any

debris through the

OCP Cleaning

Cycle.

Still Rips

Ribbon

Done

Stops

Ripping

Send to Service

Center

Pg. 28

Still

Rips

Is Image printed

extremely dark or

dense? If so,

reduce power in

the toolbox

advance settings

tab.

Still Rips/

Not Dark

Image

Done

Stops

Ripping

Perform a tri-color sensor calibration. Go

into the toolbox. Under the tab Printer

Setting, select the advance menu and

under diagnostics select Tricolor in the

calibration window. Make sure the Ribbon

is not in the printer when you perform the

calibration. (See Pic 3.4)

DoneSensor

Working

Sensor Still Malfunctioning

Check to make sure you are

at the most up to date

version of FW. If not,

Upgrade.

26

5003

Ribbon Jam


Pg.26 Ribbon Jam








Is the ribbon broken or snapped in

half? (See pic 2.0 ) Does it appear

baggy or “fluffy” in the ribbon

drawer, like it barely fits in the

printer housing?

(See Pic 2.1)

Take the ribbon out of the printer, lay both sides flat on the table

and line the two sides up as best you can, cutting jagged edges as

needed. Tape the two ends together and roll tapped ribbon onto

take up (blue) core. Reinsert into ribbon drawer, close printer. Job

will try to resume. (See taped Pic 2.2). If Baggy Roll, discard

current roll and check color settings in step below with new ribbon.

Yes

Is the ribbon stuck to the card and

jammed under the ribbon closeout

in front of or behind the Print Head

along the card path?

(See Pic 2.6)

No

Pull out card and remove card and

ribbon if necessary from under

closeout. Repair ribbon if needed.

Replace ribbon in printer and close

printer door. Job should restart.

YesDoneCard Prints

Ribbon Still Jams

Is the card sticking to the

Print Head?

Is the ribbon stuck to/

wrapped around the

platen roller?

(See Pic 2.3)

No

No

No

Send to Service

Center

Pg. 29

Pull the ribbon off the Print Head. If the ribbon

rips, repair with tape and replace ribbon in the

printer. Job should restart.

Yes

Turn printer off. Remove ribbon drawer by depressing tabs on

bottom of sliders. (See Pic 2.4) Grab ribbon close to platen and

attempt to gently pull ribbon in smooth motion away from platen

roller. Try not to rip ribbon as you unwind it. If the platen roller is

able to move freely and ribbon unwinds from platen, repair ribbon

with tape, replace ribbon, turn printer on and job will auto-retry.

DoneCard Prints

DoneCard Prints

Ribbon Breaks Again

Yes

Send To Service

Center

Pg. 29

Card Prints Done

Can’t Unwind Ribbon

From Platen Roller

Is the peel bar worn out on the print

head? (Check # of cards printed on

OCP and open printer door, pull out

print head and visually inspect peel

bar for signs of wear).

(See Pic 2.5)

No

Check color settings on card. If printing is

to dark, ribbon might be getting to hot and

sticking to card. Reduce power in toolbox

and try printing again.

Is the Print Head worn down? Are

any of the pixels missing on printed

cards? Or when you remove the

print head and look at the printing

surface (See Pic 3.4), is there

debris that won’t come off or signs

of wear to the print surface?

Customer can, if

comfortable using the

printer, replace the Print

Head themselves.

Otherwise, have the

customer send the

printer in for Service

Yes

Replace with Kit

Printhead Assembly

ZXP7 P1037750-006.

Kit comes with

directions for

replacement.

Customer

Replaces

PH

Customer Can’t Replace

Print Head

Send To Service

Center

Pg. 29

No

Check to make sure

you are at the most

up to date version of

FW. If not, Upgrade.

Ribbon Still Jams

27

5007

Ribbon Color Detect Error


Pg.26 Ribbon Jam








Is there ribbon (or other debris) in the

system blocking the Tri-color sensor?

(See Pic 3.3)

Open Printer Cover And

Pull Open Ribbon Drawer

Is the ribbon broken or snapped

in half?

(See Pic 3.0)

Take the ribbon out of the printer, lay both sides flat on the

table and line the two sides up as best you can, cutting jagged

edges as needed. Tape the two ends together and roll tapped

ribbon onto take up (blue) core. Reinsert into ribbon drawer,

close printer. Job will try to resume. (See taped Pic 3.1)

Yes

No

DoneCard Prints

Check color settings. If printing is to dark, the ribbon is

getting too hot and sticking to card. Reduce power in

toolbox and try printing again.

Ribbon Sticks to Card Again

DoneCard PrintsError Still Occurs

Remove ribbon debris from tricolor sensor and

card path. Replace ribbon in drawer and close

printer. Job will restart.

Yes

No

DoneCard Prints

Error Still Occurs

Does the ribbon have the correct RFID Tag? Open

drawer and pull out ribbon. Check white label on top

of purple ribbon core for ribbon type. (See Pic 3.2).

Also Check OCP menu for Media information. Do

they match the ribbon you have?

Yes

Is The Tricolor Sensor Malfunctioning? Go into

the toolbox and on the left side menu look under

Information. Select Printer Sensors. In the Printer

Sensors window, look under Sensor Values for

the Tri-Color Information. If the values read

unknown for Any, Red, Green or Blue, the sensor

may be malfunctioning.

No

Send to Service

Center

Pg. 30

Use a different Ribbon. If different Ribbon works,

ribbon supplier problem. Printer problem closed.No

Yes

DoneSensor

Working

Sensor Still Malfunctioning

Perform a tri-color sensor

calibration. Go into the toolbox.

Under the tab Printer Setting,

select the advance menu and

under diagnostics select Tricolor in

the calibration window. Make sure

the Ribbon is not in the printer

when you perform the calibration.

(See Pic 3.4)

Check to make sure you

are at the most up to

date version of FW. If

not, Upgrade.

28


Pg.26 Ribbon Jam








5001

Out of Ribbon

Service Center

Replace Ribbon sensor

using Kit Ribbon Sensor

ZXP7 P1037750-028. Put a

ribbon in and see if the FW

correctly sees the ribbon.

Replace the Tricolor

sensor using Kit Ribbon

Tricolor Sensor ZXP7

P1037750-040

Check to see if the Media Authentication

board may have be damaged. Replace

the board using Kit PCBA Media

Authentication ZXP7 P1037750-020. Put

a new ribbon in the printer and see if it’s

properly recognized.

Is the ribbon

still ripping?

Go into the final test software

and adjust the color density.

Attempt to print the card again.

Note: Do not reduce density

more than 3% or to the point

where the image appears

washed out.

Yes

In the final test software, check the

print tension settings against the ones

in the service manual and make sure

they match. If the print tensions don’t

match the ones in the service manual,

change the numbers so they match.

Attempt to print again.

Error

Does the FW register

the same type of

ribbon the customer

is using in the printer?

Error

Replace the PH using Kit

Printhead Assembly

ZXP7 P1037750-006.

Refer to the service

manual for instrucations.

Attempt to print

Make sure the ribbon

and ribbon RFID tag

match. Recalibrate

the Tricolor sensor in

the ZXP7 Final test

software. Try printing

several cards.

Try a different ribbon in

the printer to see if it

registers correctly in the

OCP and the ZXP

Toolbox. Does a different

ribbon register correctly?

No No

Is the printer

registering the wrong

ribbon during

initialization?

Yes Error

Ribbon

Not

Recognized

Contact Zebra/

Elevate to Tech

Support Level 3

No

Yes

No

Card Prints

Done

Card Prints

Done

DoneCard

Prints

Error

Contact Zebra/

Elevate to Tech

Support Level 3

Yes

The Ribbon is

incompatible.

Issue closed.

Ribbon Recognized

Done

DoneRibbon

Recognized

Ribbon Still Not Recognized

Done

Cards Print

DoneCards

Print

Error Still Occurs

Check to make sure

you are at the most



First

Next

29


Pg.26 Ribbon Jam








5003

Ribbon Jam

Service Center

Replace the PH using Kit Printhead

Assembly ZXP7 P1037750-006.

Refer to the service manual for

install instructions.

Replace the peel bar by replacing

using the Kit Housing for Printhead

ZXP7 P1037750-007. Refer to the

service manual for install

instructions.

Is the customer

reporting Baggy Roll

even after power

reduction?

Is the peel bar worn

out, preventing the

ribbon from cleanly

peeling off of the

card?

Pull the PH assembly

out of the Printer and

examine the PH for

any debris that could

be tearing the ribbon.

Is there burned on

Debris?

No

No

Yes

Use the ZXP7 test software to

check the ribbon tension settings. If

out, reset them according to

currently accepted tensions. Print a

full roll and see if the ribbon is still

baggy.

Yes

Done

Ribbon

Peels

Cleanly

Contact Zebra/

Elevate to Tech

Support Level 3

No

Yes

Done

Card Prints

Use the ZXP7 test

software to perform a

dampening calibration.

Print a full roll and see if

the ribbon is still baggy.

Still Baggy

Done

No Baggy RollNo Baggy Roll

Done

Still Baggy

Contact Zebra/

Elevate to Tech

Support Level 3

Ribbon Still Sticks to Card

Still Rips

Ribbon

Contact Zebra/

Elevate to Tech

Support Level 3

Contact Zebra/

Elevate to Tech

Support Level 3

Check to make sure

you are at the most




Pg.26 Ribbon Jam








5007

Ribbon Color Detect

Error

Service Center




P1037750-040. Refer to

the service manual for

installation instructions.

Make sure nothing is

blocking the tricolor

sensor and the sensor

isn’t visibly damaged.

Clean the printer if

necessary.

Are the tricolor sensor

cables loose? Check,

and tighten cables if

necessary.

Recalibrate the Tricolor

sensors in the ZXP7

final test software.

Does the error still

appear?

Is the Tricolor Sensor

Blocked? Open the

printer cover and remove

the ribbon drawer. (See

Pic 3.3 for Tricolor

sensor location)

Yes

Is the Tricolor sensor registering

in the driver? Open the Tool

Box and make the Tricolor

sensors indicators are switching

from 0 to 1 and back.

No

In the Tool Box, are the

Tricolor readings normal?

(Normal readings when

there is no ribbon in are 0

across the sensors)

Contact Zebra/

Elevate to Tech

Support Level 3




P1037750-040. Refer to






P1037750-040. Refer to



Are the tricolor sensor

cables loose? Check,

and tighten cables if

necessary.

No

Error

Still

Occurs

No

Yes

No Yes No

Yes

Done

Error Gone

Done

Error Gone

Contact Zebra/

Elevate to Tech

Support Level 3

Error

Still

Occurs

Done

Error Gone

Done

Error Gone

Contact Zebra/

Elevate to Tech

Support Level 3

Error

Still

Occurs

Done

Error Gone

Done

Error Gone

Contact Zebra/

Elevate to Tech

Support Level 3

Error

Still

Occurs

Done

Error Gone

Check to make

sure you are at the

most up to date

version of FW. If

not, Upgrade.

30


Pg.26 Ribbon Jam









1.0 Ripped Ribbon

1.1 Repairing a Ripped Ribbon

31


Pg.26 Ribbon Jam









2.0 Ripped Ribbon


2.1 Baggy/ Fluffy Roll in Housing

2.3 Ribbon Going Under the Platen Roller

2.4 Depressing Tabs on side of Ribbon Drawer to Remove it.

2.5 Worn Peel Bar on Print Head

2.6 Ribbon Closeouts In Front and Behind the Print Head

32


Pg.26 Ribbon Jam









3.0 Ripped Ribbon


3.2 Picture of RFID Tag on a Ribbon

Core

3.3 Picture of the Tri- Color Sensor

3.4 Tricolor Calibration in Toolbox Advanced Settings

33

Top/ Bottom Laminate Feed Fail17005/ 17006,Top/ Bottom Heater Fail 17013/17014,Top/Bottom Cutter Fail 17019/ 1720

Pg. 35 Top/ Bottom Laminate Feed Fail

Pg. 36 Top/ Bottom Heater Fail

Pg. 37 Top/ Bottom Cutter Fail

Pg. 38 Service Center Laminate Feed Fail

Pg. 39 Service Center Heater Fail

Pg. 40 Service Center Cutter Fail



34

35

17005/17006

Top/Bottom Laminate Feed

Fail

Is the top/ bottom cartridge

properly installed/ locked in

position? In order to check you

must open the laminator door.

(See Pic 1.0)

Do you have a cartridge

installed that isn’t in use?

If you are laminating only

on the top or only on the

bottom, then both

cartridges can’t be

installed.

Are there flakes of media

blocking the media

sensor? (See Pic1.2)

Open the laminate door

and remove the top and

bottom laminate cartridge

to check.

Visually inspect the area and

remove flakes or pieces of

media. Replace cartridges

and resume laminating.

Use cleaning card to

clean the laminator.

Use the cleaning

cycle prompts found

in the OCP.

Feed Fail

Still Occurs

Send to Service

Center

Pg. 38

No

Send to Service

Center

Pg. 38

Feed Fail

Still OccursYes

Yes

No

Card Laminates

DoneDone

Card Laminates

Open the laminator door and

remove the top or bottom

laminator cartridge that isn’t

being used in the print job.

Close the laminator door

and allow the job to resume

Yes DoneCard

Laminates

Still Feed Fail

Remove the top or bottom

cartridge, reinsert it and turn it until

the cartridge snaps fully into

position. Make sure the laminate is

properly aligned before reinserting

the cartridge. (See Pic 1.1)

No DoneCard

Laminates

Still Feed Fail

Pg. 35 Laminate Feed Fail

Pg. 36 Laminate Heater Fail

Pg. 37 Laminate Cutter Fail

Pg. 38 Service Center Feed Fail

Pg.39 Service Center Heater Fail

Pg.40 Service Center Cutter Fail



Is the laminator

reading the

laminate

correctly?

No

Open the ZXP toolbox

and under media, check

to see if the laminate is

registering correctly.

(See Pic 1.3)

Check to make sure the

laminate tag isn’t bad.

Try putting another

laminate in the laminator.

Not

Registering

Different Laminate

Works

Tag was bad. Use

Different laminate.

Issue Closed.

Send to Service

Center

Pg. 38

Not

Registering

Yes

36

17013/ 17014

Top/ Bottom Heater Fail

Turn the printer off and back

on. Allow the printer and

laminator to reinitialize and

the job to restart.

Re-seat the laminator oven. To do this, turn off

the printer. Open the laminator doors and

remove the 4 screws holding the laminator oven

in the laminator (See Pic 2.1). Pull the laminator

oven out and put it back in. Replace the screws,

close the laminator doors and turn the printer on.

Job should resume.

Send to Service

Center

Pg. 39

DoneCard

Laminates

Error Comes Back

Error Comes Back

DoneCard

Laminates

Make sure path under

heater is clear. (See Pic

2.0). If card or laminate

debris found, power cycle

the printer and resume

laminating job.

Error Comes Back

DoneCard

Laminates









Replace heater using Kit

Heater Assembly ZXP7

105936G-519. Refer to


instructions. Attempt to print

and laminate a card.

DoneNo Heater Fail

Error Comes Back

Make sure the most up to

date laminator FW is

installed. If not, load it, then

power cycle printer. Attempt

a printing and laminating job.

DoneNo Heater Fail

Error Comes Back

37

17019/ 17020

Top/ Bottom Cutter

Fail

Turn the printer off and

back on. Allow the printer

and laminator to

reinitialize and the job to

restart.

DoneCard

Laminates

Error Comes Back

Check to see if the top or

bottom cutter blade is

obstructed. Open the laminator

doors and remove the top and

bottom cartridge. Check the

area for loose media blocking

the sensor and remove it.

Top or bottom

cutter blade or

connection could

be damaged or

failed.

Error Comes Back

DoneCard

Laminates

Send to Service

Center

Pg. 40









Update the printer to the

latest version of FW for

the laminator. Attempt to

print and laminate a card,

does the cutter still fail?

DoneNo

Yes

38

17005/17006

Top/Bottom Laminate Feed Fail

Service Center

Replace the upper

spindle using Kit

Spindle for Upper

Cassette ZXP7

105936G-527. Refer

to the service manual

for install instructions.

Replace the lower

spindle using Kit

Spindle for Lower

Cassette ZXP7

105936G-528. Refer



Replace the Upper

Laminator cassette

with Kit Upper

Cassette ZXP7

105936G-516

Kit Lower

Laminator Control

Motor ZXP7

10536G-513

Kit Upper

Laminator Control

Motor ZXP7

10536G-512

When received the

printer, did the tech

report a problem with the

cartridges latching or

staying latched/ is their a

problem?

Is the laminator reading the

laminate correctly? Use same

type of laminate as the

customer, but a different roll.

No

Is the top or

bottom cartridge

not latching on the

spindle correctly?

Yes

Yes Upper

Yes Lower

No

Does the top

cartridge latch

properly but

unlatch when you

close the

laminator door?

Is the laminator moving the laminate

into the system? Operate the laminator

with the door open, (See Pic 1.4) and

power cycle the printer. Watch to see if

laminator top and bottom spindle move

and listen for motor movement.

Yes

Contact Zebra/

Elevate to Tech

Support Level 3

Yes

No

Open the ZXP toolbox

and under media, check

to see if the laminate is

registering correctly.

(See Pic 1.3)

Check to make sure

the laminate tag isn’t

bad. Try putting

another laminate in

the laminator.

Not

Registering

Different Laminate

Works

Tag was bad. Tell customer

that laminate is not

supported and return printer

to customer.

Issue Closed

Sensor is malfunctioning/

shorted. Replace with Kit

Card Laminate Sensor

ZXP7 10523G-533

Different Laminate

Doesn’t Work

Still Doesn’t

Register

Contact Zebra/

Elevate to Tech

Support Level 3

Still

Doesn’t

Latch

Contact Zebra/

Elevate to Tech

Support Level 3

Replace either the

Upper or lower

laminator control

motor as needed.

No Movement/

No Noise

Upper

Lower









39

17013/ 17014

Top/ Bottom Heater Fail

Service Center

Replace heater using Kit

Heater Assembly ZXP7

105936G-519. Refer to


instructions. Attempt to print

and laminate a card.

Make sure the most up to

date laminator FW is

installed. If not, load it, then

power cycle printer. Attempt

a printing and laminating job.

DoneNo Heater Fail

Heater Still Fails

Heater Still Fails

DoneNo Heater Fail

Contact Zebra/

Elevate to Tech

Support Level 3

Replace the top or bottom

halogen bulb for heather

using Kit Halogen Bulbs for

Heater (Quantity of 2) ZXP7

105936G-509

Heater Still Fails

DoneNo Heater Fail









40

17019/ 17020

Top/ Bottom Cutter Fail

Service Center

Kit Upper Cutter

Assembly ZXP7

105936G-522

Kit Lower Cutter

Assembly ZXP7

105936G-508

Update the printer to the

latest version of FW for

the laminator. Attempt to

print and laminate a card,

does the cutter still fail?

DoneNo

Replace the upper or

lower cutter as needed

using the Upper or Lower

Kit Assembly. Refer to

the service manual to

install. Restart the printer

and attempt to print and

laminate again.

Yes

Upper Cutter

Lower Cutter

Contact Zebra/

Elevate to Tech

Support Level 3









Check the upper or lower

cutter cable connection

for loose connections.

Any loose connections?

Reconnect loose cables

and power cycle the

printer. Attempt to print

and laminate a card, does

the cutter still fail?

Yes

No

DoneNo

Yes


1.0 Laminator Door 1.1 Laminator Cartridge Snapped Correctly in Place

1.2 Path to Unblock for Media Sensor

1.3 Screen Shot of ZXP Toolbox Laminate Media 1.03

1.4 Four Steps to Make a Cheater to Cheat the Laminator Door Open









41










2.0 Path Under The Heater/ Oven

2.1 Oven Held in place with 4 Screws

42

Image Placement

Pg. 44 Image Placement

Pg. 45 Service Center Image Placement

Pg. 46 Reference Page 1

43

44

Image Placement

See Ref Pg. 1

Adjust the Offset

Manually

Send the Printer in

For Service

Open the ZXP7

Toolbox and select

the Printer Settings

Tab. Toward the

bottom of the window

you can adjust the X

and Y offset.

Increasing the # of pixels in the

X directions shifts the image to

the right. Decreasing the # of

pixels in the X direction shifts

the image to the Left. Align the

front of the image with the

Leading edge of the card.

Front to

Back

Shift

Increasing the # of pixels

in the Y directions shifts

the image UP.

Decreasing the # of

Pixels in the Y direction

shifts the image Down.

Up And

Down

Shift

Image Shifts Over Printing

Print 10 of the

customer card and

see if the image stays

correctly centeredNext

DoneCards

Print




Is your image

sized correctly?

1006 by 640?

Have the customer adjust the

image dimensions and attempt to

print 10 cards again.

No

DoneCards Print

If the customer can’t alter the

image, send them a test image

that’s the correct dimensions and

have them print 10 cards to make

sure the printer is the problem.

Customer Can’t

Alter ImageDone

Cards

Print

Is the customer

changing between

a high capacity

and small capacity

roll, causing the

image placement

difference?

Yes

After aligning the

card, us the Image

Fill slider in the

same window to

stretch the Image to

fill the card.

Warning: Do not move or

stretch the image over the edge

of the card. The printer was not

meant to print off the edge of

the cards.

Next

Next

No

Make sure the customer uses

either a small capacity roll only or a

large capacity roll only during and

after adjustments. Continue on to

adjustments.

Yes

Image

Still

Offset

45

Image Placement

Service Center

Adjust Customer

Image on card

Print at least 50

cards and make

sure image

doesn’t shift over

the 50 cards.

Next

Run a Print Speed

Calibration

If Image

Shifts

Run a Ribbon

Torque Calibration

If Image

Shifts

If Image

Shifts

Contact Zebra/

Elevate to Tech

Support Level 3

Open the ZXP7

Toolbox and

select the Printer

Settings Tab.

Toward the

bottom of the

window you can

adjust the X and Y

offset.

Open the ZXP 7 Test

software. Select station

from the upper left hand

and select Service from

the drop down list.

To Calibrate

Input the Printer serial

number and model number

in the space provided. When

the list populates, select

Print Speed Calibration.

Follow the on screen

directions.

Next

Open the ZXP 7 Test

software. Select station

from the upper left hand

and select Service from

the drop down list.

Input the Printer serial number and

model number in the space

provided. When the list populates,

select Ribbon Torque Calibration.

Follow the on screen directions.

Use Torque Calibration Tools

(See Pics 1.1)

NextTo Calibrate

DoneImage Is

Centered

DoneImage Is

Centered

DoneImage Stays

Centered




Increasing the # of pixels in the X

directions shifts the image to the

right. Decreasing the # of pixels in

the X direction shifts the image to

the Left. Align the front of the

image with the Leading edge of the

card.Front to

Back

Shift

Increasing the # of pixels

in the Y directions shifts

the image UP.

Decreasing the # of

Pixels in the Y direction

shifts the image Down.

Up And

Down

Shift

Print 10 copies of

the customer card

and see if the

image stays

correctly centered

Next

Done

Image

Stays

Centered

After aligning the

card, us the Image

Fill slider in the same

window to stretch the

Image to fill the card.

Warning: Do not move or stretch

the image over the edge of the

card. The printer was not meant

to print off the edge of the cards.

Next

Next

46




Reference Page 1

X-X+

Y-

Y+

Positive and Negative Pixel Movement in the X and Y Direction

Example of Image Shifted In the -X Direction

Leading Edge

Front of Printing

Trailing Edge

End Of Printing

Misregistration

Pg. 52 Color Misregistration

Pg. 53 K Panel Misregistration

Pg. 54 Service Center Misregistration


47

48

Misregistration

See Ref Pg. 1

Go into the ZXP 7 toolbox and

select the Printer Settings tab.

Select the Advanced Settings

button in the bottom right hand

corner. The Password is

ZebraZXPS7 (Case sensitive)

Select the Diagnostics

tab and under the

Calibration section select

the tricolor command.

Press Run, but make

sure you remove the

ribbon before performing

the calibration.

Perform a

tricolor

calibration.

Print 10 cards that

were previously

showing

misregistration.

Replace the

Print Head

Send the customer a new Print head for

them to do a Print head replacement,

unless the are not comfortable doing it

themselves. Then have the customer

send the printer into a service center to

have the Print head replaced. Kit

Printhead Assembly ZXP7 P1037750-006.

Print 10 cards that

were previously

showing

misregistration.

Send Printer In For

Service

To Calibrate

Calibration

Fails

Next Next

New PH To Check

Still Misregistered

New Print

Head Fails

Misregistration

GoneDone

Misregistration

GoneDone

Is the Color or

the K Panel

misregistered?

Color

Misregistered

K Panel Misregistered

First

Go To

Pg. 53

Pg. 52 Misregistration (Color)

Pg. 53. Misregistration (K Panel)



Adjust the

YMC Preheat

Level

Open the driver by opening

the start menu and select

Devices and Printers. Right

click on the ZXP 7 Printer

and select Printing

Preferences from the drop

down menu.

To Adjust

Select the Color

(YMC) Optimization

tab and increase or

decrease the Preheat

slider as is needed.

Next

Print 10 cards that

were previously

showing

misregistration.

Next DoneMisregistration

Gone

Color Still

Misregistered

49




Pg. 55 Reference Page 1Misregistration

See Ref Pg. 1

Is the Color or

the K Panel

misregistered?

K Panel

Misregistered

Color Misregistered

First

Go To

Pg. 52

If possible, have the

customer change or

reduce the density of

their image, if they

have the capability.

Making the card image

less dense could solve

the k panel

misregistration problem

since is can be image

dependant.

Change

Image

K Panel Still

Misregistered

Send Printer In For

Service

Go into the ZXP 7 toolbox and

select the Printer Settings tab.

Select the Advanced Settings

button in the bottom right hand

corner. The Password is

ZebraZXPS7 (Case sensitive)

Select the Mech and

Power Adjustments tab

and you will find two

sliders at the bottom.

Adjust the the K Panel

Slider to adjust the

alignment between YMC

and the K Panel.

Print 10 cards that

were previously

showing K Panel

misregistration.

To Adjust Next NextMisregistration

GoneDone

Go into the

Advanced

Settings Menu

and adjust the K

Panel

K Panel Still

Misregistered

Replace

the Print

Head

Send the customer a new Print head for them

to do a Print head replacement, unless the

are not comfortable doing it themselves. Then

have the customer send the printer into a

service center to have the Print head

replaced. Kit Printhead Assembly ZXP7

P1037750-006.

Print 10 cards that

were previously

showing K Panel

misregistration.

New PH To Check

New Print

Head Fails

Misregistration

GoneDone

Note: If you are printing YMC with K

extracted and seeing an outline of

white around text (See Pic 1.0), an

easy way to get rid of the white outline

is to change the printing to YMC+K

instead.

50

Misregistration

Service Center

Run a Tricolor

Calibration

Run a Print Speed

Calibration

Still

Misregisters

Replace Tricolor

Sensor

Still Misregisters

Go into the ZXP 7 toolbox

and select the Printer

Settings tab. Select the

Advanced Settings button in

the bottom right hand corner.

The Password is

ZebraZXPS7 (Case

sensitive)

Select the Diagnostics

tab and under the

Calibration section select

the tricolor command.

Press Run, but make

sure you remove the

ribbon before performing

the calibration.

Print 50 cards that

were previously

showing

misregistration.

To Calibrate Next NextMisregistration

GoneDone

First

Open the ZXP 7 Test

software. Select

station from the upper

left hand and select

Service from the drop

down list.

To Calibrate

Input the Printer serial

number and model

number in the space

provided. When the list

populates, select Print

Speed Calibration.

Follow the on screen

directions.

Next DoneImage Is

Registered




P1037750-040

DoneCards

PrintFirst

Contact Zebra/

Elevat to Tech

Support Level 3

Still

Misregisters

Print 50 cards that

were previously

showing

misregistration.

Next

Print 50 cards that

were previously

showing

misregistration.

Next





Make sure the

Tricolor sensor is

securely mounted

Print 50 cards that

were previously

showing

misregistration.

Check DoneImage Is

Registered

Still

Misregisters

Replace the

Print Head

Replace the Print Head using

Kit Printhead Assembly ZXP7

P1037750-006. Refer to the

Service Manual for replacement

Instructions.

Print 10 cards that

were previously

showing

misregistration.

New PH To Check

New Print

Head Fails

Misregistration

GoneDone

51




Pg. 55 Reference Page 1Reference Page 1

Misregistration in the Y Direction

Misregistration in the X Direction

1.0 YMC w/ K extracted, white shadow around black text. 1.0 YMC+K, no white shadow around black text.

Mono Printing

Pg. 48 Monochrome and K Panel Printing

Pg. 49 Service Center Mono Printing


52

53

Monochrome

And K Panel Printing

See Ref Pg. 1

Is the card printing

black too light or

too dark and

bleeding black.

Send the customer a new

Print head for them to do a

Print head replacement,

unless the are not

comfortable doing it

themselves. Then have the

customer send the printer

into a service center to have

the Print head replaced.

Have the customer go

into the ZXP 7 toolbox

and go to the Printer

Settings section. Select

the Advanced Menu in

the lower right hand

corner. The password is

ZebraZXPS7 and is case

sensitive.

Under the tab mechanical adjustments, decrease

the K mono Font and K mono Back power by

increments of 2%, printing 5 cards after each

reduction to see if the problem has disappeared.

Replace the Print

HeadNew PH

Send the Printer in

for Service

Still To Light Or

Too Dark/

Bleeding

Print 10 cards that were

previously showing

monochorome printing

issues. Adujust k panel

power as needed (see first

block for power adjustment

Info)

To Check

Mono

Issues

Gone

Done

Bleeding

GoneDone

Monochrome Issues Remain

Is the ribbon

Monocrome or

the K panel in

a color ribbon?

Too Light

Is the ribbon

Monocrome or the

K panel in a color

ribbon?

Bleeding/ Too Dark

Adjust

Power

Setting

Under the tab mechanical adjustments, increase the

K mono Font and K mono Back power by




K Panel power by increments of 2%, printing 5

cards after each reduction to see if the problem has

disappeared.


the K Panel power by increments of 2%, printing 5


disappeared.

DoneBleeding

Gone

K Panel

Mono

Mono

K Panel DoneBlack

Darker

DoneBlack

Darker

Still To Light Or

Too Dark/

Bleeding

Replace the PH using

Kit Printhead

Assembly ZXP7

P1037750-006. Refer



Pg. 48 Mono and K Panel Printing

Pg. 49 Service Center Mono and K Panel


Is the Printer in

the correct mode

for what the

customer is

printing?

Check





and select Printing


down menu.

Select the tab Black

Panel (K)

Optimization to select

the correct K panel

mode for printing.

Barcode, Text or

Mixed.

Next DoneMono Printing

Optimized

Adjust the YMC

Preheat Level





and select Printing


down menu.

To Adjust

Select the Color

(YMC) Optimization

tab and increase or

decrease the Preheat

slider as is needed.

Next

Print 10 cards that

were previously

showing

misregistration.

Next DoneMono Printing

Optimized

Still To Light Or

Too Dark/

Bleeding

Still To Light Or

Too Dark/

Bleeding

54

Monochrome

And K Panel Printing

Service Center

Cards

bleeding/ too

dark or too

light.

Go into the ZXP 7

toolbox and go to the

Printer Settings section.

Select the Advanced

Menu in the lower right

hand corner. The

password is

ZebraZXPS7 and is case

sensitive.


the K mono Font and K mono Back power by



Bleeding

GoneDone

Is the ribbon

Monocrome or the

K panel in a color

ribbon?

Too Light

Is the ribbon

Monocrome or the

K panel in a color

ribbon?

Bleeding/

Too Dark


K mono Font and K mono Back power by



Under the tab mechanical adjustments, increase

the K Panel power by increments of 2%,

printing 5 cards after each reduction to see if the

problem has disappeared.


the K Panel power by increments of 2%, printing 5


disappeared.

DoneBleeding

Gone

K Panel

Mono

Mono

K Panel DoneBlack

Darker

DoneBlack

Darker

Adjust

Power

Setting

Mono Still Too

Dark Or Too

Light

The K panel or mono

printing power

sometimes increase over

time. Decrease the K

panel or Mono power in

the toolbox (See above

block for decreasing

power)

Replace the

Print Head, If

the customer

hasn’t already

done so.

Has the Printer run a lot of

cards? If densitometer is

available, check mono

density. Target is between

.97 and 1.03 on Density

setup Card in OCP

Yes Next


Assembly ZXP7 P1037750-006. Refer

to the service manual for install

instructions.

Next Done

Mono

Issues

Fixed

Mono Still Too

Dark Or Too

Light

Contact Zebra/

Elevate to Tech

Support Level 3




55




Too Light Mono Printing

Too Dark/ Bleeding Mono Printing

Ribbon Wrinkle

Pg. 57 Ribbon Wrinkle

Pg. 58 Service Center Ribbon Wrinkle


56

57

Ribbon Wrinkle

See Ref Pg. 1


into the toolbox and go

into the advanced menu

under the Printer

Settings. The Password

is ZebraZXPS7

Under the tab mechanical

adjustments, decrease the

Yellow, Magenta, and Cyan

power by increments of 2%,

printing 5 cards after each

reduction to see if the problem

has disappeared.

Is the printer and

Print head clean

and all debris

removed from

print path?

Run a cleaning cycle with

the long cleaning card

through the OCP. The

cycle is called the

cleaning path.

No

Yes

Open the Printer Cover

and pull out the ribbon

drawer. Check the card

path under the print head

for debris and clear any if

found.

Next

Send the customer a new Print head

for them to do a Print head

replacement, unless the are not

comfortable doing it themselves. Then

have the customer send the printer

into a service center to have the Print

head replaced.

Next

Ribbon Wrinkle

Still Present

Is the image being

printed too dark or

is the ribbon

having difficulty

printing?

Yes

No

Send the Printer in

For Service

DoneRibbon

Wrinkle Gone

Done

Done

Ribbon

Wrinkle Gone

Ribbon

Wrinkle Gone




instructions.

New PH




58

Are the Printer

and Print Head

Clean?

Yes

Has the ribbon

torque calibration

drifted?

Has the Ribbon

Dampening

Calibration

drifted?

Replace Print Head (If not

already done by customer).

Directions are in the print head

No

Contact Zebra/

Elevate to Tech

Support Level 3

Wrinkle Still

Present

Ribbon Wrinkle

Service Center

No

Run a cleaning cycle

with the long cleaning

card through the

OCP. The cycle is

called the cleaning

path.






found.

Next DoneRibbon

Wrinkle GoneNo

Enter the ZXP7 test

software. In the top

left hand side select

the station drop down

and check service.

Yes

Enter the ZXP7 test

software. In the top

left hand side select

the station drop down

and check service.

Yes

Enter the printer code

and serial number in the

requested box. When the

list populates, select the

Ribbon Torque

Calibration

Next

Enter the printer code

and serial number in the

requested box. When the

list populates, select the

Ribbon Dampening

Calibration

Next

Follow the

directions on

screen to run the

Ribbon

Dampening

calibration.

Next

Follow the

directions on

screen and use

the torque

calibration tools

(See Pic 1.0) to

run the calibration.

Next DoneRibbon

Wrinkle Gone

DoneRibbon

Wrinkle Gone

DoneRibbon

Wrinkle Gone




instructions.

New PH





into the toolbox and

go into the advanced

menu under the

Printer Settings

Under the tab mechanical

adjustments, decrease the

Yellow, Magenta, and Cyan

power by increments of 2%,

printing 5 cards after each

reduction to see if the

problem has disappeared.

Next

Is the image being printed too dark or is

the ribbon having difficulty printing? Check

if Service Center or Partner has access to

a densitometer, check color setting. Btwn

.94 and 1.06 on Density card from OCP

(See Pic 1.1)

Yes DoneRibbon

Wrinkle Gone

No

59




Reference Page 1

Color Ribbon Wrinkle Examples

Mono Ribbon Wrinkle Examples

1.0 Ribbon Torque Calibration Tools 1.1 Density Card From OCP

White Line On Card

Pg. 61 White Line On Card

Pg. 62 Service Center White Line On Card


60

61

White Line On Card

See Ref Pg. 1

Send the customer a new Print

head for them to do a Print

head replacement, unless the

are not comfortable doing it


customer send the printer into a

service center to have the Print

head replaced.

Replace the

Print HeadNew PH

Send the Printer in

for Service

White Line

Remains

Print 10 cards that

were previously

showing a missing

pixel.

To CheckWhite Line

GoneDone

Is the print head

clean and all

debris removed

from print path?

Run a cleaning cycle

with the long cleaning

card through the

OCP. The cycle is

called the cleaning

path.

No






found.

Next

Yes

Pull Print Head

out of printer and

check head

surface for build

up or debris

Next DoneWhite Line

Gone

Replace the PH using

Kit Printhead

Assembly ZXP7

P1037750-006. Refer







green ESD wire on the Print

Head is properly connected.

(See Pic 1.0) If off, most

likely reason for ESD build

up and pixel failure

No

Connect the green

wire to the ground

on the Print Head

Fixture

(See Pic 1.0)

Yes

Go to next step

to replace the

Print Head

Next

62

White Line On Card

Service Center

Check for

Debris and

Clean Head


green ESD wire on the Print

Head is properly connected.

(See Pic 1.0) If off, most

likely reason for ESD build

up and pixel failure

White Line

Still Present

Possible Blown

Pixel. Replace

Head (Be Extra

careful for ESD)

White Line

Still Present

New PH

Print 10 cards that

were previously

showing a missing

pixel.

To CheckWhite Line

GoneDone



through the OCP. The

cycle is called the

cleaning path.

No






found.

Next

Pull Print Head out of

printer and check

head surface for build

up or debris

Next DoneWhite Line

Gone



Refer to the service manual for

install instructions.




Contact Zebra/

Elevate to Tech

Support Level 3

White Line

Still Present

Connect the green

wire to the ground

on the Print Head

Fixture

(See Pic 1.0)

Yes

Go to next step

to replace the

Print Head

Next




Reference Page 1

1.0 Green Ground Wire on Print Head Fixture

Attached Wire Detached Wire

Blown Pixen

63

Scratch Off Gray and KdOImage Quality Issues

Pg. 65 KdO and SoG Ribbon Issues

Pg. 66 Service Center KdO and SoG Ribbon Issues


64

65

KdO and SoG Ribbon

Issues

Is the Ribbon Baggy or

(Fluffy), creating Panel

Sync, or Ripping Ribbon

(Out of Ribbon Error

5001)?

(See Pic 1.1 on Pg. 67)

Is the OCP

Showing an 5002

INVALID RIBBON

Error Message?

Is the Card’s

Image Showing

Ribbon Wrinkle?

(See Pic 1.2 on

Pg. 65)

Is Scratch Off

Gray Missing The

Image At the

Leading Edge?

(See Ref 1.3 on

Pg. 65)

No

No

No

Have the

customer go into

the toolbox and

select the

Firmware and

Lookup Tables tab

on the left. (See

Pic 1.0 on Pg. 67)

The Customer’s FW

may be an old version

that doesn’t support

the new ribbons.

Send the Customer

the Newest FW.

Yes Next

In the Select Firmware to Download

Section at the top, have the Customer

browse to the new FW and follow the

prompts to install it.

Next

Restart the printer once the FW has

loaded with the new Ribbon in. Check

that the OCP goes to READY.

Next

DoneOCP Says

READY

The RFID tag on the KdO or

the SoG Ribbon may be

bad. Replace the ribbon.

OCP Still Says

Invalid Ribbon

Yes

No

Send the Printer in

for Service

Send the Customer a new

Printhead kit for them to do a

PrintHead replacement, unless

they are not comfortable doing it


customer send the printer into a

service center to have the

PrintHead replaced. Kit PrintHead


Restart the printer and

place a brand new roll

into the printer. Print a

full roll, monitoring for

Bagginess, Panel Sync,

and Ribbon Ripping.

To Check

Issues

Remain

Done

Send Printer in For

Service

Yes

Have the customer go into the

Driver and select the Black Panel

(K) Optimization Tab. Select the

Advanced Button on the Front of

card or Back of card Section to

enter the Monocrome Printing

Screen. Select the side of the card

that is showing ribbon wrinkle.

Next

At the bottom under the tab Intensity, decrease the slider

by increments of 2; print 5 cards after each reduction to

see if the problem has disappeared.

Ribbon

Wrinkle GoneDone

Send the Customer a new PrintHead kit for them to do a

PrintHead replacement, unless they are not comfortable doing it

themselves. Then have the customer send the printer into a

service center to have the PrintHead replaced. Kit PrintHead


Wrinkle Remains

Have the customer

print 50 cards using

the image that had

previously shown

ribbon wrinkle.

To Check DoneRibbon

Wrinkle Gone

Wrinkle

Remains

Send Printer in For

Service

Send the Customer a new PrintHead kit for them

to do a PrintHead replacement, unless they are

not comfortable doing it themselves. Then have

the customer send the printer into a service

center to have the PrintHead replaced. Kit

PrintHead Assembly ZXP7 P1037750-005.

Yes

Have the customer print

50 cards using the image

that had previously had

missing parts at the

Leading Edge.

DoneLeading Edge

Issue Gone

Leading Edge

Issue Remains

To Check




Issues

Gone

66

KdO and SoG

Service Center




Clean the Printer

and the Print

Head



through the OCP from the

Advanced menu. The cycle

is called the cleaning path.

Follow the prompts on the

OCP.






found.

Next DoneRibbon

Issues GoneSteps

Upgrade the FW

to the Newest

Version

Go into the toolbox and select the

Firmware and Lookup Tables tab on

the left. In the Select Firmware to

Download Section at the top, browse

to the newest FW and follow the

prompts to install it.

(See Pic 1.0 on Pg. 67)

FW

Upgrade

Restart the printer and place a

brand new roll into the printer.

Print a full roll, monitoring for

Ribbon Issue Reported.

Next DoneRibbon

Issues Gone

Is the image being

printed too dark or is the

ribbon having difficulty

printing, causing baggy

roll, panel sync or ripped

ribbon? Is it the image

too dark ?

Go into the toolbox and

go into the advanced

menu under the Printer

Settings. The Password

is ZebraZXPS7

Yes

Under the tab mechanical adjustments,

decrease the K Panel power by increments

of 2%; printing 5 cards after each reduction to

see if the problem has disappeared.

Next

Replace

the

PrintHead

Ribbon

Issues Remain

Send the Customer a new PrintHead kit for them

to do a PrintHead replacement, unless they are

not comfortable doing it themselves. Then have

the customer send the printer into a service

center to have the PrintHead replaced. Kit

PrintHead Assembly ZXP7 P1037750-005.

Have the customer print

50 cards using the image

that previously had the

reported ribbon issue

DoneRibbon

Issue GoneTo CheckNew PH

DoneRibbon

Issues Gone

Contact Zebra/

Elevate to Tech

Support Level 3

Ribbon

Issues Remain

Ribbon

Issues Remain

Ribbon

Issues Remain




Pic 1.0 Toolbox Firmware Tab

Pic 1.1 Baggy Roll, Panel Sync and Ripped Ribbon

1.3 SoG Missing Image @ Leading Edge

1.2 KdO Ribbon Wrinkle

67






Yes

Are the cards the

correct thickness?

No

Are the cards a

supported card type?Yes

Are the cards

warped?Yes

Are the cards

sticking together?No

Are the proper # of

cards being used?

(less than 200)

No

Are the cards

uneven in the

feeding cassette?

(See Pic 1.0)

Yes

Select the retry

button on the OCP

to retry the card.

The card thicknesses

currently supported are

10 mil - 50 mil

Not

Sure

Reference the next page

for a complete list of

supported card types

Not

Sure

If they do not lay flush

against the table, replace

with new unwarped cards

Not

Sure

Pull stack out of feeder

and fan out cards, being

careful not to touch front

surface of the cards

Yes

Is card feeding cassette

locked in place?

(See Pic 1.1)

No

Take out cards so that

there is less than 200 of

the 30 mil cards in feeder

No

Open the feeding

cartridge lid and

straighten out the cards

Yes

Check: Cassette is down and

all the way to the left. It should

lock into place.

Not

Sure

Are the cards on the left

side of the pusher plate?

Yes

Is the pusher plate

properly released and

the cassette lid closed?

Yes

Check: That the pusher plate is

not locked in the back of the

cassette when the lid is down.

(See Pic 1.3)

Not

Sure

Check: Picture 1.2 for

correct card location

Not

Sure

Select the retry

button on the OCP

to Retry the card.

Is the card feed path clean? Is

the feed roller clean?

Yes

Is the feed roller moving?

Yes

Remove the feeder cartridge and

select the retry button on the OCP.

Watch the lower feed drive roller for

movement (see pic)

To

Check

Is the Card Feed Motor

running? To Check: press the

retry button on the OCP and

listen for the card feed motor

No

Run a feeder cleaning cycle through the

OCP. Clean the feeder drive rollers and

feeder pinch rollers with alcohol swab.

No

Replace the feeder

cartridge securely with

cards properly loaded.

Retry Card on OCP

Yes

Printer Requires

Service

Go To Pg. 6

No Yes

Printer Requires

Service

Go To Pg. 6

Card Still

Fails

Card Still

Fails

Card Still Fails

Still

No

Send Feeder

Cartridge For

Replacement

Go To Pg. 6

Go to Pg. 5

CheckCheck

No






DoneCard Feeds

Correctly

DoneCard Feeds

Correctly

Are there less than 200 cards in the

feeding cassette? Over 200 of the

30 mil cards might not create

enough pressure for the cards to

feed.

Are the cleaning cassette and

cleaning rollers properly

installed? (See Pic 1.5) Tape

removed from the cleaning

rollers?

Are the feeding rollers

dirty?

Clean the feeding rollers with the

feeder cleaning cards through the

OCP cleaning cycle. Press card retry

button.

Yes

Is the card reaching the sensor

on the flipper deck

(See Pic 2.0)

Open ZXP Toolbox, go to printer sensors

and check whether flipper sensor is

seeing card (changing from 0 to 1)

Yes

Send Printer For

Service

Goto Pg. 6

No

No

Remove cards so that

there are less than 200 in

feeder. Press card retry

button.

Remove tape from the cleaning

rollers and properly insert the

cleaning cartridge. Press card

retry button.

No






Is the card feeding


(See Pic 2.1)

Send Printer For

Service

Go to Pg. 6

Go to

page 4

Go to

Pg. 4No


worn? (See Pic 1.4)

Send Printer For

Service

Go To Pg. 6

Yes

Yes

No

Yes

No

Yes

Yes

Card Still Fails

Card Still Fails

No

Card Still Partial Feeds

DoneCard

Feeds

DoneCard

Feeds

DoneCard

Feeds

No

Toolbox Register Sensor






Printer Returned with no

Feed or Partial Feed into

Flipper?

No Feed Partial Feed

Is Pusher Plate Applying

enough Pressure to

Card?

Is the Bottom Feed

Roller skidding on the

card or showing signs of

wear? (see Pic 2.5)

Replace Feeder

Cartridge No


Worn/ old? (See Pic 2.2)

Yes

Replace the Bottom feed

Roller, available in Kit


ZXP7 P1037750-061

Yes


Worn or skidding on the

card? (See Pic 2.2)

No

Yes

Is the upper feed drive

roller moving without

difficulty and is not worn

out or squeaky?

No

Replace the Singulation Roller (See Pic

2.3), available in Kit Drive Assembly

Feeder ZXP7 P1037750-061

Yes Replace the Singulation

Roller, available in ZXP7


Kit, P1037750-061

Is the Top Feed Roller

skidding on the card or

showing signs of wear

(See Pic 2.4)?

No

Replace the Top feed

roller, available in Kit


ZXP7 P1037750-061

YesReplace the upper feed

roller, available in ZXP7


Kit, P1037750-061

Yes

Is the card feeding


NoInspect the feeder drive belt

and gears for damage or

improper assembly. Listen

for grinding, teeth/ belt

slipping. Feeder Clutch

failing?

No

Replace the feeder drive

belt/ gears/ clutch,

available in Kit Drive

Assembly Feeder ZXP7

P1037750-061

Yes

Is the ZXP Toolbox

registering the sensor?

No

Perform a flipper

Calibration using the

flipper calibration tool

(refer to the service

manual)

Yes

Check the sensors

connection to board for

loose wires at SEN FLCD

J11. (See Pic 2.6) If

connection is loose or out of

order, repair connection and

check. See Picture for

correct wire order.

No

If the connector SEN FLCD

J11 is still not registering in

the toolbox after the loose

wire is fixed or no loose wire

was found, replace the

sensor and rewire the

connector.

Is feeder motor not

making noise or feed

rollers not moving?

No

Yes

Check the connector JB

FCBA_FLIP for signal using

a voltmeter. (See Pic 2.7) If

a signal is not detected,

replace the connector.

Yes

Check the card feed

motor connections for

any loose wires. If found,

repair connections and

check for connectivity.

Motor Still Malfunctioning

Still Malfunctioning






Contact Zebra/

Elevate to Tech

Support Level 3

Contact Zebra/

Elevate to Tech

Support Level 3

No

Contact Zebra/

Elevate to Tech

Support Level 3

4014

Card Feed Error

Service Center


Pusher Plate Released Feeding Cassette Closed and

Pusher Plate Released

Cards On Correct Side Of Pusher PlateCards on wrong side of pusher plate






1.0 Cards Uneven in Feeding Cartridge

1.1 Loading the Feeding Cassette

1.2 Cards on wrong side of pusher plate

1.3 Pusher plate properly released 1.4 Worn Singulation Roller


2Cleaning Cassette and

Cleaning Rollers With Tape

Still On

Cleaning Cassette Being

Inserted Into Proper Location

1.5 Cleaning Cassette location and Proper installation







Pg 8: Reference Page Part 2Reference Page Part 2

Obsolete, replaced by black singulation roller

2.7 Correct order for Feeder Motor wires2.6 Correct order for SEN FLCD J11

2.0 Card Feed Sensor on Flipper Deck2.1 Card Feeding Behind

Flipper Deck

Worn Singulation Roller

2.2 Old and Worn Singulation Roller Respectively

2.3 Black Singulation Roller 2.4 Top Feed Roller

2.5 Worn Bottom Feed Roller

ZEBRA ZXP Series 7™ · ZXP7 P1037750-061 Yes Replace the upper feed roller, available in ZXP7...

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Transcript of ZEBRA ZXP Series 7™ · ZXP7 P1037750-061 Yes Replace the upper feed roller, available in ZXP7...