Solving Mechanical Errors on Value Class Card Printers

Details

Symptoms

• Cards will not feed or print properly
• Loud grinding noises coming from the printer
• Printer will display "Mechanical Error" on the LCD

Applies To

Zebra Value Class Printers Including ZXP Series 1 & 3

Cause

Mechanical errors are caused because a part internal to the printer (usually a drive component) fails to operate properly. Sensors inside the printer are able to detect this along when cards are not feeding through the card path.

Card jams is the most common cause for mechanical errors. However, when using an incorrect power supply, the printer may not have enough power to operate at all.

Solution

Here are some common causes and solutions to this problem. If you have any questions, please contact Zebra Technical Support.

Mechanical Error Cause and Solution
Possible Cause	Solution
Card has jammed inside the printer	Open the printer and clear any card jams Read More>> To prevent further jams: Make sure the cards being used meet the specifications required by your printer according to the user's manual Make sure cards are loaded properly Read More>> Perform a complete cleaning procedure so the driver rollers can feed the cards properly.  Read More>>
Feeder did not align to the correct starting position	Inspect the flipper area (the mechanism underneath the card hopper) for objects blocking the gears Turn the printer off, open the print cover, and remove the ribbon. Pull on the tab holding the feeder and then move the feeder up (see picture). Inspect for any foreign objects (plastics, pieces of ribbon, etc.) in the flipper area and remove them. Place everything back to normal and restart the printer.
Power supply is not the correct one or may be defective	Verify the power supply being used is the right one for this printer. Value class printers require a 24V DC Output power supply. Some users may have access to multiple printers. If the power supply is the correct one, try a different one and see if problems go away
Belt, rollers, or stepper motor have failed to operate	Contact a Card Service Provider or send the printer in for service Read More>>