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Zebra 30344M

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1. 1 4 1 4 1 4 Page 7 18 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists P e 25 49 L COMPLIANT 22 22 Di NI ROLLER ASSY i 160S Print Mechanism Assembly Page 7 19 1055 and 1605 Parts Lists PRINTER MODEL 105S 6 dot and 8 dot S Series Maintenance Manual Volume 1 PART NUMBER Printhead Support Assembly DESCRIPTION QUANTITY 01153 Washer Flat 250 x 125 x 028 1 01159 Washer Lock 6 1 10401 Screw M3 x 5 x 4 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 30402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30531 Assembly Ribbon Sensor 30781 Cable Printhead Ground 31521 Assembly Printhead Cable 31899 Brush Static Removal 40014 Plate Guide 40017 Plate Ribbon Strip 40193 Washer Felt 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 44000M Printhead 8 Dots mm 44200M Printhead 6 Dots mm 46481 1 Screw Adjustment 6 32 48023 Page 7 20 Bearing 313 x 190 x 375 S Series Maintenance Manual Volume 1
2. 1 Attach the AC Power Cord and the Data Cable to the appropriate rear panel connectors 2 Hold in the CANCEL Key while turning the printer power ON After the POST a Printer Configuration Label should print 3 If the printer does not operate properly turn the power OFF and recheck all connections 4 When proper printer operation is achieved complete this process by reattaching the Left Side Panel on the printer EPROM Software Installation To replace the EPROMs when installing firmware enhancements read the instructions included in the upgrade kit The general upgrade procedure is as follows Turnthe AC Power OFF and disconnect the Power Cord 2 Remove the Left Side Panel of the printer by removing the screws that hold it on CAUTION The printer electronics are susceptible to static discharge Before proceeding it is recommended that the technician wear an anti static wrist strap connected to ground inside the printer 3 105S 6 Dots mm and 8 Dots mm Only Refer to Figure 5 17 and gently remove the EPROMs from positions U13 and U14 on the Main Logic Board 105S 12 Dots mm 105Se and 160S Only Refer to Figure 5 18 and gently remove the EPROMs from positions U13 and 914 on the Main Logic Board 4 Insert the new EPROMs with the notches pointing UP Match the Main Logic Board U position with the position specified on ea
3. 5 24 Installing the Adapter BOAT 5 24 Removing the Main Logic and Power Supply Boards 5 24 Installing the Main Logic and Power Supply Boards 5 28 EPROM Software Installation iere reis PERDE 5 29 Main Drive Belt Removal Replacement and Adjustment 5 31 Rewind Drive Belt Removal Replacement and Adjustment 5 32 AC Power Fuse Replacement ee tut bus 5 33 Battery su dead 5 34 Cutter Adjustments and Replacement Instructions 5 34 Printer Disassemb lyu iade tpud dmn 5 34 1 10 101 eor PI 5 35 Cutter Motor Removal ierra 5 35 Cutter Motor Installation ioo sob Lice 5 35 Cutter Mechanical Assembly Removal 5 37 Cutter Mechanical Assembly Installation 5 37 Drive Link Assembly Installation 5 38 Cutter Circuit Board Removal e eei 5 38 Cutter Circuit Board Installation 5 38 Optical Sensor u u uma iR aa qas al 5 39 Optical Sensor Installation iiec 5 39 Lower Drive Arm Mechanical Alignment 5 39 Upper Drive Arm Alignmetnt
4. 47158 1 O RINGS WEAR PLATES AND FRICTION CLUTCHES MUST BE HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION 160S Peel Off Rewind Spindle Assembly Page 7 39 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S Media Rewind Spindle Assembly PART NUMBER DESCRIPTION QUANTITY 07321 Screw Set 6 32 18 30041 7 Washer Felt 1 5 8 17 32 093 30433 008 Screw 8 32 500 30058 1 Nut Shoulder 50 20 Hex 30118 E Ring Ext 500 x 042 30422 006 Screw Set 6 32 375 40110 Spring Compression 85 x 67 x 1 12 45090 2 Blade Media Take Up 47062 2 Hook Rewind NIe Page 7 40 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30433 008 6 30041 7 i NOTES 1 SOAK FELT WASHERS 30041 7 IN SILICONE OIL 8 SQUEEZE OUT 105S Media Rewind Spindle Assembly Page 7 41 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S Media Rewind Spindle Assembly PART NUMBER DESCRIPTION QUANTITY 30118 E Ring Ext 500 x 042 1 30433 004 Screw 8 32 250 38015 Screw Set 10 24 187 38210 Spring Compression 56 x 720 x 1 0 46090 Blade Media Take Up 47062 1 Hook Rewind 47158 Nut 50 75 Page 7 42 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30118 06 30433 0
5. PRESSURE 4 ied PLATE a wa PRINTHEAD MOUNTING BRACKET gt 30402 006 2 aS 40194 2 40193 2 PRINTHEAD PIVOT BAR 46174 38000M 30392 004 2 1 POSITION RIBBON SENSOR 46605 TAB FLUSH WITH TOP EDGE OF PRINTHEAD PIVOT BAR 160S Printhead Support Assembly Page 7 25 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S and 160S Media Guide Assembly PART NUMBER DESCRIPTION QUANTITY 30033 Guide Adjustable Media 1 30256 B Nut Thumb 6 32 50 Brass 1 Page 7 26 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30256 B 105S and 160S Media Guide Assembly Page 7 27 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S Ribbon Supply Spindle Assembly PART NUMBER DESCRIPTION QUANTITY 07321 Screw Set 6 32 18 30041 4 Washer Felt 29 32 1 2 3 32 30041 6 Washer Felt 13 16 13 32 3 32 30042 Spring Torsion 739 x 805 30071 Housing Ribbon Supply Spring 30097 Spring Compression 660 x 528 x 066 30145 Bearing Thrust 30146 Washer Thrust 687 x 375 x 093 30224 Ring Crescent Ext 375 30344M Clutch Plate Bearing Maintenance Assembly 40070 1 Blade Ribbon Supply Outer 400
6. Page 7 34 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30118 AE 47081 38015 NOTE 47158 1 O RINGS WEAR PLATES AND FRICTION CLUTCHES MUST BE HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION 160S Ribbon Takeup Spindle Assembly Page 7 35 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S PART NUMBER DESCRIPTION QUANTITY 07321 Screw Set 6 32 18 2 30041 7 Washer Felt 1 5 8 17 32 093 30058 1 Nut Shoulder 50 20 Hex 2 1 30110 Spring Compression 85 x 67 x 1 12 1 1 2 30118 E Ring Ext 500 x 042 30422 006 Screw Set 6 32 375 Page 7 36 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30118 30422 006 2 5 ac e 07321 2 PLCS 301 n 30058 1 105S Peel Off Rewind Spindle Assembly 30041 7 j Sa NOTES 1 SOAK FELT WASHERS 30041 7 IN SILICONE OIL amp SQUEEZE OUT Page 7 37 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S Peel Off Rewind Spindle Assembly PART NUMBER DESCRIPTION QUANTITY 30118 E Ring Ext 500 x 042 1 38015 Screw Set 10 24 187 1 38210 Spring Compression 56 x 720 x 1 0 1 47158 Nut 50 75 1 Page 7 38 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30118 9 4 38210
7. Printhead Voltage Adjustment Adjustment Procedure 245444444844 ws Media Sensor Position Adjustment Reflective Sensor Adjustment Media Sensor and Ribbon Sensor Sensitivity Adjustment Take Label Sensor Alignment 38452L Rev 3 Media Tracking Adjustments 5 20 Rewind Mode 244464 5 20 5 21 Spindle Adjustment and Maintenance 5 22 Tension Measurement Procedure 2 5 22 Spindle Tension Adjustment 5 22 Removing the Adapter Board 5 24 Installing the Adapter Board 5 24 Removing the Main Logic and Power Supply Boards 5 24 Installing the Main Logic and Power Supply Boards 5 28 EPROM Software Installation 5 29 Main Drive Belt Removal Replacement amp Adjustment 5 31 Rewind Drive Belt Removal Replacement amp Adjustment 5 32 AC Power Fuse Replacement 5 33 Battery Replacement 5 34 Cutter Adjustments and Replacement Instructiions 5 34 Internal ACCESS 44642444458 HoH eS SES 5 35 Cutter Motor Removal and Installation 5 35 Cutter Mechanical Assembly Removal and Installation 5 37 Drive Link Assembly Installation 5 38 Cutter Circuit Board Removal and Installation 5 38 Optical Sensor Removal and Installation
8. 555 5 59 wst 28 50 50 5 ogg S 55 opg 23 A 8 0 HOS 2 e A o Hos T gt e 2 d 2 CIE 1 TORRA Troubleshooting 38452L Rev 3 Page 6 6 S Series Maintenance Manual Volume 1 38452L Rev 3 Troubleshooting Unacceptable Label Darkness properly set Printhead too far forward Scratch flowers on black area foggy appearance Printhead needs to be moved rearward Walk out wrinkle with feed button and readjust Toggles balanced equal pressure on left and right sides Unacceptable Label Darkness properly set Printhead way too far forward Scratch flowers on black area washed out appearance Printhead needs to be moved rearward Walk out wrinkle with feed button and readjust Toggles balanced equal pressure on left and right sides Page 6 7 Troubleshooting H si H 21628 6 8 384521 3 S Series Maintenance Manual Volume 1 Unacceptable Label Darkness properly set Printhead too far back Breakup on trailing edges of bars op posite the direction of movement Black is splotchy Printhead needs to come forward on both sides Toggles ba
9. 30392 004 Screw 6 32 25 30392 008 Screw 6 32 50 30393 006 Screw 8 32 37 30423 003 Screw Set 8 32 187 30466 Washer 26 x 63 x 06 30488 Nut 1 4 20 35020 Bracket Media Sensor 35025 Roller Segment 35082 Guide Media 35099M Assembly Toggle 35136 Washer Nylon 252 x 472 x 059 35137 Ring Retainer 250 35302RM Assembly Media Sensor 35909 Handle Printhead Q10057 Page 7 16 Washer Flat 372 x 158 x 032 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30488 30393 006 3 50 Q 30106 99 2 30393 006 3 30392 004 gt 30355 6 DOT 40355 8 8 12 DOT 30357 6 amp 12 DOT 40357M 8 DOT 30104 S 5 i gt 2 742744 30239 45025 E 45053 02252 e 40305RM 30033 02252 12 20 30247 30392 004 30104 1055 Print Mechanism Assembly Page 7 17 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S PRINTER MODEL 160S PART NUMBER DESCRIPTION QUANTITY PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 1 40027 Spring Torsion 01159 Washer External Lock 6 40355M Assembly Platen Pulley 8 Dots mm 02252 Ring Crescent 250 40357M Assembly Stepper Motor Pulley 8 Dots mm 062
10. 5 39 Lower Drive Arm Mechanical Alignment 5 39 Upper Drive Arm Alignment 5 40 TROUBLESHOOTING Troubleshooting 42442545045 44 8G 408584 6 1 Power ON Troubleshooting 6 1 General Troubleshooting o RR S 6 2 Cutter Module Troubleshooting 6 4 Sample oan PONE 6 5 Factory Assistance 4 4 4 6 11 Returning Equipment 6 11 105S and 160S MECHANICAL DRAWINGS and PARTS LISTS Mechanical Parts and Assemblies 7 1 1055 MECHANICAL DRAWINGS and PARTS LISTS Mechanical Parts and Assemblies 8 1 384521 3 1 my Zebra The Zebra S Series System In this section Page Printer Specifications 1 1 M dia OT 1 1 Printing iaasa 1 2 Media Considerations u 1 2 Ribbon Consideration S osi 1 3 Zebra Programming Language II ZPL 1 3 cadi 1 3 Standard Printer Polls uis ede 1 4 Physical SIZO M 1 5 Electrical Requirements eoo cose Geste Od p edu 1 6 Cable deines 1 6 115 VAC 1 6 230 VAC Appli C ONS Q
11. 30392 004 Screw 6 32 25 30392 008 Screw 6 32 50 30393 006 Screw 8 32 37 30466 Washer 26 x 63 x 06 35020 Bracket Media Sensor 35025 Roller Segment 35082 Guide Media 35136 Washer Nylon 252 x 472 x 059 35137 Ring Retainer 250 35302RM Assembly Media Sensor 35909 Handle Printhead 38226M Assembly Reflective Sensor optional 38099M Assembly Toggle 38825 2 Guide Plate Upper Media Snap 105Se Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105Se Print Mechanism Assembly PART NUMBER DESCRIPTION QUANTITY 40001 Roller Main Platen 40027 Spring Torsion 40050M Spindle Assembly Ribbon Take Up 40051M Spindle Assembly Ribbon Supply 40305RM Assembly Media Guide 40355M Assembly Platen Pulley 8 Dots mm and 12 Dots mm 40357M Assembly Stepper Motor Pulley 8 Dots mm 40444 Shaft Pivot 40490 2 Ribbon Take Up Hook 40808 Tear Peel Off Bar 45025 Roller White Nylon 62 18 45053M Assembly Media Supply Maintenance 45189 5 Belt Main Drive 46105 Bearing Nylon 312 251 140 46196M Motor Stepper 48411 Page 8 6 Thumb Screw N 1 4 1 4 lt lt S Series Maintenanc
12. 30240 SERIAL N M L K J H G F E D 31240 PARALLEL 31102 SERIAL 31103 PARALLEL 30256 09367 1130 07435 01448 30391 004 30392 004 CODE PART NUMBER SCREW LIST P SeralOny Parle Only 105S 6 amp 8 Dot mm Final Assembly Page 7 3 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S 6 dot and 8 dot Final Assembly Page 2 of 2 PART NUMBER DESCRIPTION QUANTITY 30257 Pulley Peel Off Platen 6 Dots mm 30307 Flag Head Open 30336 1M Pulley Ribbon Take Up 30336 2M Pulley Media Take Up 30355M Pulley Main Platen 6 Dots mm 30357M Pulley Stepper Motor 6 Dots mm 30914M Pulley Peel Off Platen 8 Dots mm 40355M Pulley Main Platen 8 Dots mm 40357M Pulley Stepper Motor 8 Dots mm 45189 2 Belt Media Rewind 45189 5 Belt Main Drive Page 7 4 PRINT HEAD MEDIA RIBBIIN HEAD DPEN TAKE LABEL S Series Maintenance Manual Volume 1 1055 and 160 Parts Lists MEMBRANE SWITCH CABLE LOOP EXCESS CABLE GROUND TAIL DIMENSIONS FROM MAIN LOCATION PULLEY FRAME TO INSIDE GUIDING EDGE OF PULLEY D RIBBON TAKEUP 30336 1 FIXED IN SUB ASSY 40355 8 001 AX MAIN PLATEN ood ppp MM 433 IN 40357M 8 DUT N 3 STEPPER 303578
13. PARALLELISM ADJUSTMENT SCREWS NOTE THE RIBBON TAKE UP SPINDLE IS NOT SHOWN IN THIS ILLUSTRATION Figure 5 3 Printhead Adjustment Illustration Wear Plate Position Adjustment This adjustment is performed in conjunction with the Printhead Parallelism Printhead Position and Printhead Pressure Adjustments Adjusting the Wear Plate position produces even pressure across the full width of the Printhead and platen roller Refer to Figure 5 3 for the location of the adjustment screws used in the following procedure 1 Position both Toggles 1605 so that they are half the distance between the Printhead Attaching Screw and the outside edges of the Printhead For the 105S 105Se make sure the Toggle is centered over the media 2 Adjust the Toggle Spring s by turning the Knurled Adjusting Nut s so that there is approximately 30 mm 1 2 inches between the bottom of the Knurled Adjusting Nut and the top of the black Toggle Button 3 Using a 3 32 Allen wrench or Phillips head screwdriver loosen the two screws on the front of the Strip Plate 4 Activate the PAUSE Key Self Test by pressing the PAUSE Key while turning the printer power ON 5 labels are printed reduce the DARKNESS value until the test labels are a charcoal gray color 6 Print additional PAUSE Key Self Test labels and observe the print quality 38452L Rev 3 Page 5 9 Corrective Maintenance S Series Maintenance Manual Volume 1 10 11 1
14. GAP PRINTHEAD MEMBRANE PEELOFF BAR TU PLATEN GAP SHOULD BE SET TO 005 015 MAX GAP SWITCH CABLE ALONG THE LENGTH OF THE PLATEN GAP BE SET WITH A 004 005 THICK BY 3 WIDE SHIM 3 HEAD OPEN CLOSED FLAG WITH HEAD CLOSED FLAG TO BE TIGHTENED IN POSITION AS SHOWN GROUND TAIL 105Se Final Assembly page 2 of 2 Page 8 5 PRINTER MODEL 105Se Print Mechanism Assembly QUANTITY PART NUMBER DESCRIPTION 01130 Nut 6 32 01159 Washer External Lock 6 02252 Ring Crescent 250 06250 Ring E External 312 06319 Screw 10 32 37 07228 Washer Curved 49 x 33 x 0075 07321 Screw 6 32 18 30033 Media Guide Adjustable 30104 Flange Ball Bearing 5 x 250 x 125 30105 Bearing Nylon 312 x 251 x 078 30106 Ring Crescent External 312 30114 Washer Flat 76 x 51 x 03 30115 Washer Wave 740 x 520 x 080 30118 Ring E External 500 x 042 30239 Washer Crescent 415 x 323 x 062 30256 B Nut Thumb 30260 Washer Crescent 406 x 253 x 030 30307 Flag Head Open 30336 1M Assembly Ribbon Take Up Pulley 30353M Assembly Head Open Sensor 30355M Assembly Platen Pulley 6 Dots mm 30357M Assembly Stepper Motor Pulley 6 Dots mm and 12 Dots mm a7 N N
15. J L D 0 198 6 36 CR A 0 112 20 32 GS 00 00 2 Ow S 2 character S MBOL 0 079 12 70 Default 15 x 12 U L D Scalable U Uppercase L Lowercase D Descenders Physical Size Physical Characteristics Height 1055 1055 Width Depth Weight without options 38452L Rev 3 Page 1 5 The S Series System S Series Maintenance Manual Volume 1 Electrical Requirements 115 VAC 15 20 or 230 VAC 15 15 48 62 Hz e 5 Amps 115 3 Amps 230V e UL 1950 Listed Certified to CAN CSA C22 2 No 950 M89 e Classified to IEC 950 and Complies with FCC and Canadian DOC class rules e Carries the mark of compliance Cable Requirements The AC Power Cord has a three prong female connector on one end This connector must be plugged into the mating connector at the rear of the S Series printer 115 VAC Applications A Standard US style three prong grounded male plug is attached to the other end of the AC Power Cord This connector must be plugged into a nearby electrical outlet 230 VAC Applications An AC Power Cord may or may not be included with the printer For those locations that cannot use either of the three power cords listed below a proper grounded AC Power Cord must be obtained and installed by the user See Figure 2 2 The cable must then be plugged
16. Printer Self Tests 4 0 5 oe ooo x ea x CANCEL Key Self Test 8 PAUSE Key Self Test PEED Key Self Testo MODE Key Self ya eos s FEED PAUSE and CANCEL Keys PAUSE Key and CANCEL Key FEED Key and CANCEL Key FEED Key and PAUSE Key Extended Printer Diagnostics 5254 4454 5 4 o 44 4 PAUSE Key Loopback FEED Key Loopback Test PREVENTIVE MAINTENANCE Field Maintenance Functions Toole m 3 99 y 398 9 808 Cleaning the S Series printer Cleaning the Printhead Cleaning the Snap Pl t gee SS ee See a Cleaning the Cutter Lubricating the Cutter Module Recommended Preventive Maintenance Schedule CORRECTIVE MAINTENANCE Tools Required Test Equipment Required 1055 Printhead Replacement 1605 Printhead Replacement 5 Printhead Adjustments _ Print Quality Printhead Parallelism Adjustment Wear Plate Position Adjustment Printhead Position Adjustment Printhead Pressure Adjustment Strip Plate Adjustment
17. DOT 10 MM 393 IN 4 MEDIA TAKEUP 30336 2M FIXED IN SUB ASSY r 30914M 8 DUT 5 PEELDF 30257 8 W 3 15 IN NOTE BELT TENSION TO SET BELT TENSIONS PULL ON BELTS WITH SPRING SCALE AT LOCATIONS SHOWN WITH AND IN THE DIRECTION SHOWN UNTIL BELT IS DEFLECTED 1 4 SPRING SCALE SHOULD READ AS FOLLOWS BELT SCALE READING POUNDS GRAMS 45189 5 4 5 1800 2200 45189 2 4 5 1800 2200 PEEL TEAR BAR PLATEN GAP PEELOFF BAR PLATEN GAP SHOULD BE SET TD 005 TO 015 MAX GAP ALONG THE LENGTH OF THE PLATEN GAP BE SET WITH 004 005 THICK BY 3 WIDE SHIM HEAD OPEN CLOSED FLAG WITH HEAD CLOSED FLAG TO BE TIGHTENED IN POSITION AS SHOWN 105S Final Assembly page 2 of 2 Page 7 5 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S 12 dot Final Assembly Page 1 of 2 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 01152 Washer Flat 375 x 156 x 65 01155 Washer Lock 4 01159 Washer External Lock 6 01448 Screw 6 32 37 01912 Washer External Lock 4 07435 Screw 6 32 37 07696 Screw 4 40 31 09367 Stand Off 4 40 30240 Cover Plate with Opening Serial 30256 Nut Thumb 6 32 50 30269 Pad PVC 4 0 x 37 062 30391 004 Screw 4 40 25 30391 006 Screw 4 40 37 30392 004 Screw 6 32 25 30407 008 Screw 6 32 5 30916 Strap Ground 31019 Label Logo 105S 31020 Label Model Number 31037 Cover PCB 105S 31038 Panel Le
18. 1055 and 1605 Parts Lists PRINTER MODEL 105S S Series Maintenance Manual Volume 1 PART NUMBER Media Rewind Option Assembly DESCRIPTION QUANTITY 02252 Ring Crescent 250 07435 Screw 6 32 37 30104 Flange Ball Bearing 5 x 250 x 125 30114 Washer Flat 76 x 51 x 03 30115 Washer Save 740 x 520 x 08 30118 Ring E External 500 x 042 30257 Pulley Assembly Rewind 6 Dots mm 30265 Pulley Idler 30336 2M Pulley Assembly Media Rewind 30392 004 Screw 6 32 25 30393 006 Screw 8 32 37 30914M Pulley Assembly Rewind 8 Dots mm and 12 Dots mm 31536 Sensor Assembly Take Label 40001 Shaft Platen 40055RM Spindle Media Rewind 40383RM Assembly Rewind Plate 45189 2 Belt Rewind 45062 Page 7 48 Media Take Up J Hook S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 45189 5 REF STEPPER MOTOR PULLEY 30118 NOTE SPACERS MUST P O 31536M POSITIONED ON BOTH 30336 2M BLK BLUE SIDES OF BELT 45189 5 30393006 SY PULLEY e 30114 c ouse NG 80115 REWIND PULLEY E 6 DOT MM 30257 451892 12 amp 8 DOT MM 30914M 02252 2 30104 31536 40383RM BLK GRN REWIND PLATE 105S Media Rewind Option As
19. Final Assembly Page 2 of 2 PART NUMBER DESCRIPTION QUANTITY 30307 Flag Head Open 30336 1M Pulley Ribbon Take Up 30336 2 Pulley Media Take Up 30357M Pulley Stepper Motor 12 Dots mm 30914M Pulley Peel Off Platen 12 Dots mm 31526 Assembly Adaptor Board 40355M Pulley Main Platen 12 Dots mm 45189 2 Belt Media Rewind 45189 5 Belt Main Drive Page 7 8 160 Parts Lists S Series Maintenance Manual Volume 1 105S and MEDIA 38530 SERIAL amp 38691 PARALLEL RIBBON MAIN LOGIC BOARD HEAD OPEN TAKE LABEL 31526 ADAPTER BOARD ASSEMBLY 31101 SERIAL amp 38103 PARALLEL REAR PCB PANEL 30392 004 CAP SCREW 46325 2 SPACER 31528 POWER CABLE ASSEMBLY S E OEE EEEE EEEE EE E LOCATION PULLEY DIMENSIONS FROM MAIN FRAME TO INSIDE GUIDING EDGE OF PULLEY 0 RIBBON TAKEUP 30336 1M 2 MAIN PLATEN 40355 12 DOT FIXED IN SUB ASSY 11 C 433 IN 3 STEPPER 30357 12 007 10 393 2 MEDIA TAKEUP 30336 2 FIXED IN SUB ASSY 5 PEELOFF 30914M 12 007 8 MM 3 15 IN NOTE 1 BELT TENSION TO SET BELT TENSIONS PULL ON BELTS WITH SPRING SCALE AT LOCATIONS SHOWN WITH AND IN TH
20. In this section Page Field Maintenance Functions 4 1 Tools 9 4 1 Cleaning the S Series PUTHEGE 4 1 Cleaning the Printhead racine bildet dene ibas 4 2 Cleaning the Snap u aaa assaka sawa qyanaaqnaqha shayan akay 4 2 Cleaning the Cutter 4 4 Lubricating the Cutter Module 2 4 4 Recommended Preventive Maintenance Schedule 4 5 Field Maintenance Functions Field maintenance functions for the Zebra S Series printer can be divided into two basic categories e This section of the manual contains preventive maintenance procedures and operator care instructions Preventive maintenance consists of a visual inspection and general cleaning of the interior and exterior of the unit and printhead These procedures may be performed by the operator and should be performed on a regular basis e Corrective maintenance described in Corrective Maintenance provides detailed steps for resolving faults Repairs are accomplished by replacement of components or modules or by adjustments Tools Required To properly perform the preventive maintenance tasks the service technician should be equipped with the following e Applicators e 70 isopropyl alcohol e Citrus based cleaner WARNING U
21. become necessary to reposition the Transmissive Media Sensor perform the Upper Section Adjustment first followed by the Lower Section Adjustment Upper Section Adjustment To adjust the upper section of the Transmissive Media Sensor for the inside half of the media width refer to Figures 5 5 and 5 6 and follow these steps 1 Remove the ribbon and locate the upper section of the Media Sensor 2 Loosen the mounting screw holding this section in position 3 Slide the upper section along the slot to any position along the web except where the rounded corners of the label are detected When using tag stock position the upper section directly over the hole or notch 4 Tighten the mounting screw 1605 ONLY To adjust the upper section of the Transmissive Media Sensor for the outside half of the media width refer to Figure 5 6 and the illustration on page 7 13 and follow these steps 1 Remove the ribbon and locate the upper section of the Media Sensor 2 Remove the printer s left side panel and reroute the media sensor cable to provide additional slack 3 Remove the mounting screw to release the upper section of the sensor and the wire cover 4 Carefully pull the wires through the tie wrap as you reposition the sensor and the wire cover to the outside half of the mounting bracket 5 Replace and tighten the mounting screw then replace the printer s left side panel Lower Section Adjustment To adjust the lower section
22. di R66 4 Fo 4 8155 Of o Lo 1 T mE o Ocee O o RA Lo O 114 95 88 o 961 L o ezip o 6 o 55 o E ES o 9 EB o o opo uo a R68 olo Log 2 C66 204 Logo 5 9 Loll o o R94 RI7L 8 o o o 4 LO o4 C60 rr R173 Fog01 77 c19 c51 R160 of Ono L OR6 of o 0 4 H z cis RI63 17 957 C117 C70 ewm 4 Lo Of Fo u24 055 18 113 Figure 5 17 105S 6 and 8 Dots mm EPROM Locations U13 ZEBRA TECHNOLOGIES CORPORATION ZEBRA TECHNOLOGIES CORPORATION Figure 5 18 160S 105Se 105S 12 Dots mm EPROM Locations Page 5 30 38452L Rev 3 S Series Maintenance Manual Volume 1 Correct
23. 5 40 38452L Rev 3 Page 5 1 Corrective Maintenance S Series Maintenance Manual Volume 1 When a problem is encountered with the S Series printer the service technician should first insure the unit is being used properly then exercise it to localize the fault Once localized refer to the appropriate replacement or adjustment procedure to correct the fault Tools Required Screwdriver flat blade 1 4 1 8 x 8 and 3 16 x 3 Screwdriver Phillips 1 1 extended reach and 2 Pliers long nose small needle nose utility snap ring Set of inch combination open end box end wrenches must include a 7 16 Set of inch Allen wrenches 1 16 3 32 5 64 7 64 9 64 Allen bit socket 5 32 Allen hex key 5 64 Torque wrench calibrated in inch pounds drive size to fit 5 32 Allen bit socket Nut driver 5 16 Hex head drivers 0 35 1 16 1 16 ball point 3 32 5 32 5 64 7 64 7 64 extended reach minimum 10 shaft 7 64 ball point 9 64 Metric hex head drivers 1 5 mm 2 mm 3 mm and 5 mm Metric hex key set 0 1 000 g Spring Scale 0 2 25 Kg Spring Scale Clip to clip jumper lead Wire cutters Soldering iron 20 35W Potentiometer adjustment tool File Metric English ruler metal scale Fuse 5 Amp Slo Blo 250V 3AG 115 VAC installations Fuse 3 Amp Slo Blo 250V 3AG 230 VAC installations Spindle Torque Adjustment Kit Part 01773 Digital Voltmeter with Clip On Leads Test Equipme
24. Media Guide while sliding it to the rear of the openings and snapping it down into place Refer to Figure 4 2 38452L Rev 3 Preventive Maintenance T gt 3 e o 42 PRINTHEAD 47 7 2 PEEL TEAR BAR PLATEN ROLLER LABEL AVAILABLE SENSORS Figure 4 1 Printhead Cleaning G So 5 7m Figure 4 2 Snap Plate Cleaning Page 4 3 38452L Rev 3 Preventive Maintenance S Series Maintenance Manual Volume 1 Cleaning the Cutter Module Periodically the Cutter Module should be cleaned to remove paper dust and label residue Refer to Figure 4 3 Clean the stationary cutter blade with a cotton swab moistened with a citrus based cleaner when it becomes gummed up with label adhesive or paper debris After cleaning apply a small amount of petroleum lubricating grease to the moving cutter parts Figure 4 3 Cutter Blade Cleaning Lubricating the Cutter Module Certain applications or types of label stock may cause the cutter blades to eventually start to squeak This commonly occurs when less than full width media is being used To eliminate the squeak and prolong cutter life first turn off the printer Next clean the lower cutter blade by following the above procedure Then coat a cotton swab with a small amount of petroleum lubricating grease and wipe the swab along the top
25. a suggested initial distance between the bottom of the Lower Toggle Adjusting Nut and the top of the black Toggle Button is approximately 30 mm 7 Adjust Burn Temperature to the optimum level for the installed media 38452L Rev 3 Page 5 11 Corrective Maintenance S Series Maintenance Manual Volume 1 TOGGLE ADJUSTING NUT Figure 5 4 Printhead Pressure Adjustment Strip Plate Adjustment The Strip Plate is a very important part of the printhead adjustment procedure The Strip Plate can be adjusted for proper tracking and separation of the ribbon from the media after printing Print PAUSE Key Self Test labels 2 Press the PAUSE Key and after the printer pauses observe the ribbon for possible problems wrinkling etc 3 Refer to Figure 5 3 and loosen the two Allen screws holding the Strip Plate to the front of the Printhead Assembly 4 While running the PAUSE Key Self Test lower the Strip Plate so the ribbon is flat and smooth and tracks properly to the Ribbon Take up Spindle 5 Tighten the Strip Plate Allen screws and print a minimum of twenty five labels Check for ribbon wrinkle tracking and noise problems If ribbon wrinkle and or tracking problems persist check the torque settings of the Ribbon Supply Spindle and adjust tension if required Printhead Voltage Adjustment When a printhead or the printer s power supply is replaced the printhead Voltage must be adjusted for the proper value This adjust
26. on the label located under the new printhead Reconnect the electrical connector to the new printhead Fit the new printhead into the mounting bracket CAUTION Ensure that the grounding strap is reattached by the printhead mounting screw 11 12 13 14 15 16 17 18 Loosely install the four Phillips screws through the Printhead Bracket and the Printhead s aluminum body After verifying the Printhead is seated properly Printhead Bracket Guide Pins are fitted into the guide holes on the 12 dots mm Printhead tighten the Phillips head mounting screws Reinstall the Pressure Plate and Static Removal Brush with the mounting Screws Use the Preventive Maintenance Kit to clean the new printhead thoroughly Reinstall media and ribbon Connect the AC Power Cord and turn the printer power ON After the printer completes the Power On Self Test refer to the Printhead Resistance value noted in Step 8 above and perform the Printhead Voltage Adjustment on pages 5 12 through 5 14 Press the PAUSE Key while turning the printer power ON and check the print quality of the test labels 38452L Rev 3 Page 5 3 Corrective Maintenance S Series Maintenance Manual Volume 1 PRESSURE PLATE MOUNTING SCREWS PRINTHEAD PRESSURE PLATE STATIC GROUNDING REMOVAL STRAP BRUSH PRINTHEAD MOUNTING SCREWS PRINTHEAD BRACKET GUIDE PINS 12 DOT MM ONLY PRINTHEAD PEM
27. the upper section of the Transmissive Media Sensor is not operational For the 160S and 105Se printers the position of the Reflective Media Sensor is fixed against the Mainframe and has no adjustment Switches on the rear of the printers are used to configure the printers for operation with either the Reflective Media Sensor or the Transmissive Media Sensor previously discussed Transmissive Media Sensor and Ribbon Sensor Sensitivity Adjustment NOTE This adjustment is initially performed by Zebra Technologies during final printer inspection Under normal circumstances further adjustments should not be necessary The exception is when media with exceptionally thick or thin backing material is being used in the printer Perform the following procedure if the Paper Ribbon LED comes ON when a In the thermal transfer printing mode media and ribbon are properly installed or b In the direct thermal printing mode media only is properly installed Sensitivity Adjustment Procedure Turn the printer OFF Raise the Media Cover and open the Printhead 3 Load at least 12 inches of blank backing material no labels under the Printhead NOTE Insure that blank backing material extends behind the Printhead and is positioned between the upper and lower sections of the Transmissive Media Sensor 4 Remove the ribbon Sliding the ribbon as far to the right as possible will have the same effect as removing it 5 Close the Printhead
28. 160S PARALLEL SERIAL Figure 2 11 Option Switch Locations Figure 2 12 Option Switches Page 2 12 38452L Rev 3 S Series Maintenance Manual Volume 1 Getting to Print Bank 1 Serial interface printers only NOTE Parallel interface printers do not have Bank 1 switches since they are not required Bank 1 switches must be properly positioned to establish serial data communications with the host computer Once communications are established do not change the position of these switches Baud Rate Switch Data Bits 4 Must be set to 8 data bits for Code Page 850 Even parity Parity disabled Odd parity Parity disabled Communication Handshake Control XON XOFF control DTR DSR control Error Detection Protocol No error detection Error detection active 38452L Rev 3 Page 2 13 Page 2 14 to Print S Series Maintenance Manual Volume 1 These switches can manually override any ZPL commands that affect print mode media mode and media type They can also override settings established during the calibration procedure If you do not want to override ZPL or the calibration settings disable one or more of the options by setting switches 1 4 and or 7 to the R position and turn the power on With these disabled the printer will require ZPL commands to set print mode media mode and or media type To override set the switches to one of the modes shown in the
29. As a reference when the set screws are tight the Allen Key should deflect approximately 0 6 1 5 cm past the point of tightness The tightness specification is 20 in lbs 2 3 N m Activate the Cutter Motor and make certain the Sensor Flag travels through the slot in the Cutter Optical Sensor without touching it Turn the printer Power Switch OFF Upper Drive Arm Alignment Page 5 40 The Upper Drive Arm is part of the Cutter Mechanical Assembly and has been properly aligned at the factory If for some reason the factory position is altered the following procedure may be used to realign the Upper Drive Arm The printer must be programmed to operate in the Cutter Mode prior to performing the following procedure Remove the printer s Left Side Panel if attached Loosen the Allen head cap screw that clamps the Upper Drive Arm to the Rotary Cutter Blade shaft The Drive Arm may be snug on the shaft Apply power to the printer The Lower Drive Arm of the Drive Link Assembly should rotate once and stop when the Sensor Flag activates the Optical Sensor Refer to Figure 5 24 Only after the preceeding step hold the Upper Drive Arm in position and adjust the Rotary Cutter Blade so that the gap between its cutting edge on the left end and the cutting edge of the Rear Cutter Blade is approximately a 100 2 5mm as gauged by eye NOTE If the gap between the cutting edges is too large the cutter may not cut properly across the
30. BY THE OPTICAL SENSOR WHEN THE POWER 1 ON IN THE CUTTER MODE REAR CUTTER BLADE 10421 SCREWS 4 CONTROL POSITION OF CUTTER MODULE amp SQUARENESS TO MEDIA Figure 5 24 Cutter Mechanical Assembly Positioning 38452L Rev 3 Page 5 41 Corrective Maintenance S Series Maintenance Manual Volume 1 Page 5 42 38452L Rev 3 6 Troubleshooting In this section Page Troubleshooting cnisia 6 1 Power On Troublesh otin gissingen 6 1 General TOM eS 6 2 Cutter Module Troubleshooting 6 4 Sample uuu aa 6 5 Factory t rp Pe 6 11 6 11 Troubleshooting Consult the Troubleshooting Tables which follow and compare the printer output to the sample labels provided on the following pages to improve the quality of your labels Table 6 1 Power ON Troubleshooting symptom DacNoss ACTION All LEDs light and Main Logic Board or EPROM faulty Insure cables are properly connected stay ON or all LEDs or loose interconnecting cables 5 are properly installed except POWER or replace the Main Logic Board LED never turn ON CALIBRATE LED Main Logic Board Dynamic RAM Replace Main Logic Board turns OFF after 5 sec faulty but all other LEDs stay ON All LEDs Flash ON No significant amount of DRAM Replace M
31. Final Assembly Page 2 of 2 PART NUMBER DESCRIPTION QUANTITY 30257M Pulley Peel Off Platen 6 Dots mm 30307 Flag Head Open 30336 1M Pulley Ribbon Take Up 30336 2M Pulley Media Take Up 30355M Pulley Main Platen 6 Dots mm 30357M Pulley Stepper Motor 6 Dots mm and 12 Dots mm 30392 004 Screw 6 32 25 30914M Pulley Peel Off Platen 8 Dots mm and 12 Dots mm 31528 Assembly Power Cable 31532M Assembly Adaptor Board 40355M Pulley Main Platen 8 Dots mm and 12 Dots mm 40357M Pulley Stepper Motor 8 Dots mm 45189 2 Belt Media Rewind 45189 5 Belt Main Drive Page 8 4 S Series Maintenance Manual Volume 1 105Se Parts Lists MEDIA RIBBON HEAD TAKE LABEL DIMENSIONS FROM MAIN LOCATION PULLEY FRAME TO INSIDE GUIDING EDGE OF PULLEY RIBBON TAKEUP 30336 1M FIXED IN SUB ASSY 40355 8 12 DOT MAIN PLATEN 30355M 6 DOT 11 MM 433 IN 30357 6 12 DOT STEPPER DDD 10 C393 IN 30392 004 MEDIA TAKEUP 30336 2M FIXED IN SUB ASSY 30914M 8712 DDD PEELIFF DOD 8 MM 3 15 IN NOTE 1 BELT TENSION TO CHECK BELT TENSIONS PULL ON BELTS WITH SPRING SCALE AT LOCATIONS SHOWN WITH AND IN THE DIRECTION SHOWN UNTIL SRM BELT IS DEFLECTED 1 4 SPRING SCALE SHOULD READ AS FOLLOWS BELT SCALE READING POUNDS GRAMS 45189 5 4 5 1800 2200 45189 2 4 5 1800 2200 2 PEEL TEAR OFF BAR
32. Handling Printing Considerations Media Considerations lt 4 48644 24 Ribbon Considerations Zebra Programming Language II ZPL 1 Bat COUGS ece i qos E uox ues AUR qi eS d Standard Printer 8 Physical Size ux emos Wawas ES ee oe pres Electrical Requirements 4 Cable Requirements 5 939 939 oe 115 VAC Applications 230 VAC Applications Environmental Operating Range Communication Specifications Serial Data Communications Overview Parallel Data Communications Overview GETTING READY TO PRINT Controls and Indicators Front Panel Controls 2 Front Panel LEDs Media L adine s lt ses RP Rx xw Ribbon Loading 540x499 woe om Pour Media Calibration Adjusting the Print Darkness Adjusting the Tear Off Position Adjusting the Position of the Top of the Label Adjusting the Media Sensor Positions Upper Media Sensor 2 253644 x o o m RR Lower Media Sensor Option SO p q 5 384521 3 iii PRINTER DIAGNOSTICS Power ON Self Testa us gom oe 3
33. Link Drive Link Assembly Installation Refer to Figure 5 22 Remove the screw from the Mounting Post on the Drive Link Assembly Locate the Post in the mounting hole in the frame and from the media side of the frame secure the Assembly with the screw The Upper Drive Arm is pre assembled to the Cutter Module Assemble the Long Drive Link of the Drive Link Assembly over the connecting post on the Upper Drive Arm and secure it with the washer and E ring Attach the Lower Drive Arm of the Drive Link Assembly to the Cutter Motor Shaft Loosen the set screws to insure the Lower Drive Arm rotates freely on the Motor shaft Apply a small amount of grease to the slot in the Slotted Link Assembly where the Bearing will ride Remove any excess grease to avoid damaging the Cutter Optical Sensor Cutter Circuit Board Removal 3 Refer to Figure 5 22 Disconnect all cables from the Cutter Board Remove the four socket head cap screws that mount the Cutter Board to the standoffs Remove the Cutter Board Cutter Circuit Board Installation Page 5 38 Refer to Figure 5 23 Attach the power cable to J1 on the Cutter Circuit Board Refer to Figure 5 23 Attach the data cable to J2 on the Cutter Circuit Board Locate the four 4 standoffs on the printer frame where the Cutter Board will be mounted Route the Cutter Motor Wires between the two righthand standoffs and out under the bottom of the Circuit Board Position the Cutter Cir
34. MUST BE HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION 3 APPLY ALIGHT FILM OF GREASE ZEBRA P N 01660 TO PARTS 30145 2 160S Ribbon Supply Spindle Assembly Page 7 31 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S PART NUMBER DESCRIPTION QUANTITY 07321 Screw Set 6 32 18 4 30073 Collar 30041 1 Washer Felt 1 1 4 19 32 3 32 2 2 30058 2 Nut Shoulder 50 20 Hex 1 1 1 1 1 30116 Spring Compression 720 x 610 x 625 30118 E Ring Ext 500 x 042 30233 Spring Compression 088 x 012 x 312 30422 002 Screw Set 6 32 375 Page 7 32 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists S 30422 002 30118 8 30233 07321 2 PLCS e 030 to 080 0 30073 1 POSITIONING COLLAR 07321 2 PLCS 30041 1 one 30041 1 30058 2 NOTES 1 SOAK FELT WASHERS 30041 1 IN SILICONE OIL amp SQUEEZE OUT 2 ASSEMBLY IS POSITIONED VIA POSITIONING COLLAR amp SET SCREWS AS SHOWN IN A 030 TO 080 FROM EDGE OF 30118 105S Ribbon Takeup Spindle Assembly Page 7 33 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S Ribbon Take Up Spindle Assembly PART NUMBER DESCRIPTION QUANTITY 30118 E Ring Ext 500 x 042 38015 Screw Set 10 24 187 38210 Spring Compression 56 x 720 x 1 0 47158 Nut 50 75
35. ON IN THE CUTTER MODE REAR CUTTER BLADE 10421 SCREWS 4 CONTROL POSITION OF CUTTER MODULE amp SQUARENESS TO MEDIA 49604 010 ne 30391 003 4 I 31024 4 V lt 30392 004 2 se 10427 2 46280 y m o E 5 9 I T aed Pg 4 a 1 m 5 4 01822 2 31181 pg jd 30196 150 40320 T UG 30236 2 223 5 w 30816 40819 10421 4 40193 2 14 4 30392 004 2 E 30392 004 2 105Se Cutter Option Assembly Page 8 15 105Se Parts Lists S Series Maintenance Manual Volume 1 Page 8 16
36. Rewind Drive Belt On the Media Side of the printer locate the lower access hole in the Side Frame and remove the hole plug Use a 7 64 Allen wrench with a 10 minimum shaft length to reach through the hole and loosen the Idler Gear Mounting Screw Slide the Idler Gear Assembly to the right to relieve the tension on the Rewind Drive Belt Remove the old Rewind Drive Belt and install the new one Hook a 2200 gram spring scale to the belt as shown in Figure 5 20 and carefully slide the Idler Gear Assembly to the left to increase belt tension When a scale reading of 2000 grams 250 grams 4 5 lbs 0 5 lbs creates a deflection of 1 4 tighten the Idler Gear Mounting Screw to a torque of 20 inch pounds _ SPRING SCALE Figure 5 20 Rewind Drive Belt Replacement 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance AC Power Fuse Replacement A user replaceable AC Power Fuse is located just above the Power ON OFF Switch on the rear of the printer For a 115 VAC installation the replacement fuse is a 3AG Fast Blow style rated at 5 Amp 250VAC For a 230 VAC installation the fuse is the same style but rated at 3 Amp 250VAC CAUTION Turn the printer s AC Power Switch OFF and disconnect the printer s AC Power Cable before replacing the fuse To replace the fuse insert the tip of a flatblade screwdriver into the
37. Sensor wires under the clamp and toward the rear of the printer and lightly tighten the nut to hold the wires in position DO NOT pinch the wires Lower Drive Arm Mechanical Alignment Connect the Power Cable from J1 on the Cutter Board to J4 on the Printhead Adapter Board 38452L Rev 3 Page 5 39 Corrective Maintenance 4 S Series Maintenance Manual Volume 1 Connect the Data Ribbon Cable from J2 on the Cutter Board to J5 on the Main Logic Board Attach the AC Power Cord and turn the printer ON If the Cutter Motor starts wait for it to stop NOTE A critical position adjustment is made in steps 4 and 5 The Cutter Motor must be rotated until the two flat surfaces on the Cutter Motor shaft are aligned with the set screws in the Lower Drive Arm while the Lower Drive Arm is in a vertical position Sensor Flag down Refer to Figure 5 23 Attach a test clip at one end of a jumper cable to the lead on the left end of Capacitor C6 5 VDC SOURCE on the Cutter Board Briefly touch the test clip at the other end of the jumper cable to Test Point on the Cutter Board to jog the Cutter Motor to the desired position Position the Lower Drive Arm so the Sensor Flag is centered between the front and back portions of the Cutter Optical Sensor then tighten the two set screws The set screws must be extremely tight to insure proper operation of the Cutter Mechanism Tighten the set screws with a 5 64 Allen Key
38. Test Using a 7 64 Allen wrench loosen the four Allen screws at the top rear of the Print Mechanism Position both Toggles 1605 so that they are half the distance between the Printhead Attaching Screw and the outside edges of the Printhead For the 1055 1055 make sure the Toggle is centered over the media Set the Darkness to achieve the optimum print quality CAUTION In step 6 to prevent printhead damage loosen the four top screws before turning the two rear adjustment screws Adjust the printhead position for optimum print quality by equally turning the two Parallelism Adjustment Screws located at the back of the print mechanism 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance 7 Adjustments are made in very small increments Turn both Parallelism Adjustment Screws one eighth turn clockwise and observe the changes in print quality Due to spring pressure there may be a dead spot in the actual printhead movement when switching adjustments from one direction to the other 8 Decrease the Burn Temperature until the PAUSE Test labels are a charcoal gray color 9 Carefully look at the PAUSE Test labels for streaks flouring and other print quality problems 10 If required adjust the hex head screws and observe if print quality problems are corrected 11 Increase Burn Temperature until the PAUSE Test labels are printed at optimum resolution and contrast 12 Since Printhe
39. amp 8 DOT 45013 12 DOT QU YS 46481 1 2 40194 2 40193 2 01882 2 PRINTHEAD PIVOT BAR 40014 NOTE 1 POSITION SENSOR 30531 TAB FLUSH WITH TOP EDGE OF BAR 40002 30392 004 2 44000M 8 DOT 44200M 6 DOT 44800M 12 DOT 105Se Printhead Support Assembly Page 8 9 105Se Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105Se Peel Off Option Assembly PART NUMBER DESCRIPTION QUANTITY 02252 Ring Crescent 250 07435 Screw 6 32 37 30104 Flange Ball Bearing 5 x 250 x 125 30114 Washer Flat 76 x 51 x 03 30115 Washer Save 740 x 520 x 08 30118 Ring E External 500 x 042 30257M Pulley Assembly Rewind 6 Dots mm 30265 Pulley Idler 30336 2M Pulley Assembly Media Rewind 30392 004 Screw 6 32 25 30393 006 Screw 8 32 37 30914M Pulley Assembly Rewind 8 Dots mm and 12 Dots mm 40001 Shaft Platen 40490 2 Take Up Hook 45189 2 Belt Rewind 46609M Sensor Assembly Take Label Upper Lower 47062 2 L Hook Ribbon Assembly 6 inches k k gt oh Page 8 10 STEPPER MOTOR PULLEY REF 45189 5 MAIN DRIVE BELT N NOTE SPACERS MUST BE POSITIONED ON BOTH SIDES OF BELT 45189 5 30265 IDLER PULLEY 6 DOT 30257M 12 8 DOT 30914M P O 46609M BLK GRN LEADS S Series Maintenance Manual Volume 1 105Se
40. and out of the battery holder Insert the new battery with the negative side toward the circuit board The positive side should be visible when the battery is correctly installed To use the Battery Backed Up RAM Memory the Battery Dead condition must be reset The preferred method of resetting this condition is to send the JB ZPL II command to the printer A second method for resetting the Battery Dead condition is available at the printer s front panel However when this method is used the printer configuration is reset to the Factory Default condition The printer must then be reconfigured for the application and a Printer Calibration must be performed To reset the Battery Dead condition using this method press and hold the PAUSE and FEED Keys while turning the AC Power ON Cutter Adjustments and Replacement Instructions 105Se Only Printer Disassembly The printer must be partially disassembled in order to remove and install parts Refer to the illustrations in this Section and follow the procedures that follow Page 5 34 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance Internal Access 1 Turn Printer Power OFF at the rear of the printer and disconnect the AC Power Cord and all signal interface cables Remove all Media and Ribbon from the printer 3 Access the Electronics Cabinet by removing the mounting screws in the left side panel Cutter Motor Rem
41. connector located at the rear of the printer In this data communication method the bits of data which make up each character are sent all at one time over several wires in the cable one bit per wire Parallel Data Signal Levels Parallel data signals are defined as either HIGH or LOW while Control Signals are either Active or Inactive The distinction is due to the fact that some Control Signals are active HIGH while others are active LOW The voltage levels which represent these conditions are Data Signal Voltage Level HIGH 5 VDC LOW 0 VDC Parallel Interface Connector Pinout and Description The following chart provides a description of each of the pins in the parallel connector A standard parallel data cable will provide the required interconnection between the host and the S Series printer Pin No Parallel Data Port Signal Description The STROBE printer input has internal 3 3 pull up resistors to 5V IoL 1 5mA and is designed to receive a signal driven open collector VoL lt 0 8V This pin is a signal from the host computer Its LOW going edge will latch the data at the eight DATA inputs Data is non transparently latched so as to avoid hold time requirements on the DATA signals The STROBE input is debounced to require an active width greater than 0 5 usec before data is latched DATA inputs have TTL input characteristics with internal 3 3 kQ pullups and represent 1 TTL unit load or less The DATA inputs are posit
42. do not perform this adjustment Leave the media sensor at the factory set position Non continuous media has a notch or opening between each label To monitor label movement you need to align the media sensor with this notch or opening The media sensor consists of two parts that must be properly aligned with the notch or edge of the label The factory set position should be sufficient for most applications If not perform the appropriate adjustments Adjusting the Upper Media Sensor To adjust for the inside half of the media Remove the ribbon Locate the upper media sensor Figure 2 9 A Loosen but do not remove the Phillips head screw 3 Slide the upper sensor along the slot to any position along the web except where the rounded corners of the label are detected When using tag stock position the upper sensor directly over the hole or notch 4 Tighten the screw 38452L Rev 3 Page 2 9 to Print S Series Maintenance Manual Volume 1 To adjust for the outside half of the media 160S ONLY Remove the ribbon Locate the upper media sensor Figure 2 9 A 2 Remove the printer s left side panel and reroute the media sensor cable to provide additional slack 3 Remove the Phillips head screw to release the upper section of the sensor and wire cover 4 Lift the upper media sensor assembly and move the sensor and the wire cover to the outside half Carefully pull the wires through the tie wrap You may need to set a
43. entire media width If the gap is too small the media may catch on the Rotary Cutter Blade edge and cause a jam 2 Position the Upper Drive Arm out from the cutter frame so its flat surface is flush with the end of the Rotary Cutter Blade shaft 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance Tighten the Allen head cap screw with 5 32 inch Allen bit socket on a torque wrench until the slot closes or until a torque of 100 in lbs 11 3 N m is reached NOTE Overtightening the screw can damage the Drive Arm and can strip the threads 6 Test the Cutter alignment by feeding maximum width label stock through the printer and insuring that complete cutting of the label occurs If necessary repeat steps 4 5 and 6 to achieve complete cutting of the labels 7 With a felt tip pen draw a line across the outer face of the Upper Drive Arm and the end of the cutter blade shaft Should cutter operation problems ever occur this witness mark will show at a glance if the alignment of the clamp and the cutter blade shaft has changed UPPER CUTTER BRACKET ROTARY CUTTER BLADE MOUNTING SCREW N MEDIA GUIDE j INSURE THE TOP OF THE TEAR OFF BAR IS POSITIONED ABOVE TERE OR LEVEL WITH THE BAR THE REAR CUTTER BLADE CLEARANCE OF 030 MINIMUM BETWEEN REAR CUTTER BLADE AND TEAR OFF BAR RELATIVE POSITION OF THE ROTARY CUTTER BLADE WHEN THE DRIVE LINK ASSEMBLY IS STOPPED
44. host Request To Send RTS is an output from the Zebra S Series printer It is a constantly active output to the host computer Data Set Ready DSR is an input to the Zebra S Series printer from the host Signal Ground Tied to logic ground This lead serves as the voltage reference between the two communicating devices Reserved For Future Use Data Terminal Ready DTR is an output from the Zebra S Series printer and is the control line between the printer and the host When the DTR control line from the printer is in the ON condition the host is allowed to send data to the printer When DTR is in the OFF condition the host is not allowed to send data This condition occurs when the printer is configured for DTR DSR data flow control and the communication buffer is within 512 characters of its capacity 5 8 10 19 1 Unterminated These leads not used 2 1 25 RS 232 COMM PORT J7 A Frame Ground RS 232 Transmit RS 232 Receive Request To Send Data Set Ready Signal Ground Reserved for Future Use Data Terminal Ready Figure 1 4 Serial DTE Port Interface Page 1 8 38452L Rev 3 S Series Maintenance Manual Volume 1 The S Series System Parallel Data Communications Overview The S Series printer may have a parallel data communications port instead of the previously mentioned serial data port The Parallel Interface has a standard 36 pin
45. is dirty Clean the Cutter Module Label length is too short 38452L Rev 3 Increase label length See Adjusting the Tear Off Position in Getting Ready to Print S Series Maintenance Manual Volume 1 Sample Labels Troubleshooting The following pages contain sample labels to be used with the preceding troubleshooting charts These labels illustrate conditions which could be seen if mechanical adjustments are necessary Zebra Z Trans 3P media stock and type 5319 ribbon were used to obtain these labels Any other label and ribbon stock combinations may produce sample labels with similar but not necessarily the same results 1234587890 12345678901 2345578901 23456789012345678901234567890123456 _ 1234567890123456789012345678901234567890123455678901234557890123456 38452L Rev 3 Acceptable Label Darkness properly set Printhead positioned correctly Toggles balanced equal pressure on left and right sides Unacceptable Label Darkness too high Printhead positioned correctly Toggles balanced equal pressure on left and right sides Page 6 5 a a m o 5 8 4 2 8 o 9 o 2 7 o gt a aso a aso SZ Ss T 485 5 9 amp 528 72 n Q a 55 Qn vy 529 a 2 2 Py 05 oS GO
46. is in the ON position and the power cord is connected PRINTHEAD Normal operation Printhead Over Temperature condition Printing stops until the printhead cools down Printing resumes automatically Printhead Under Temperature condition Printing continues Flashing Printhead Open PAPER OFF Media and ribbon if used are properly loaded RIBBON ON Paper out Flashing 1 In Thermal Transfer Mode Ribbon is out 2 In Direct Thermal Mode Ribbon is in the printer OFF Normal operation ON Printer has stopped all printing operations OFF Idle no data being received ON Labels are printing Single The CANCEL key was pressed and a format was successfully flash deleted from the print queue Flashing Receiving data from host computer Slow Printer sent a stop transmitting data X OFF command to the host flashing computer DARKEN ON POSITION ON CALIBRATE ON Printer is in the Configuration Mode See the Mode Key operation for more information 38452L Rev 3 Page 2 3 S Series Maintenance Manual Volume 1 MEDIA MEDIA SUPPLY SUPPLY GUIDE PLATEN ROLLER REWIND SPINDLE SPINDLE HOOK Figure 2 2 Roll Media Loading TEAR OFF PEEL OFF REWIND CUTTER REWIND Figure 2 3 Roll Media Loading Diagrams Page 2 4 38452L Rev 3 Figure 2 4 Fanfold Media Loading Diagrams INTERNAL SUPPLY BOTTOM SUPPLY REAR S
47. length Standard 512 KB memory 15 381 mm 26 660 mm N A 9 5 241mm With 1 MG memory 39 991 mm 39 991 mm 18 457 mm 25 635 mm Bar code modulus dimension 5 mil to 50 mil 6 6 mil to 66 mil 3 33 mil to 33 3 mil 5 mil to 50 mil Programmable constant 2 51 mm 3 76 mm 4 102 mm 5 127 mm or 6 152 mm per second printing speeds The 105 105Se with optional 300 dots inch resolution support 2 4 61 mm 3 76 mm and 4 102 mm per second Thin film printhead with Energy Control Media Considerations 105S 105Se 114 3 mm 19 05 mm 39 991 mm 16 00 mm 12 8 mm 12 8 mm 31 75 mm Media Specifications 1 2 20 4 5 0 75 182 9 mm 50 8 mm 25 635 mm 16 00 mm 12 8 mm 12 8 mm Total media width Maximum Minimum Maximum 0 63 0 50 0 50 N A Tear Off Peel Off Rewind 0 63 0 50 0 50 1 25 Label length Minimum Cutter Maximum Printhead position may need adjustment if thickness is above 0 01 Total thickness 0 012 0 304 mm 0 012 0 304 mm includes liner 0 0023 3 0 8 0 0 079 0 157 118 0 058 mm 776 2 mm 203 mm 2mm 4mm 0 0023 3 0 8 0 0 079 0 157 118 0 058 76 2 mm 203 2 mm 4 mm Minimum Core size Maximum roll diameter Interlabe
48. of the Transmissive Media Sensor refer to Figure 5 7 and follow these steps 1 Locate the lower section of the Transmissive Media Sensor a spring clip holding a printed circuit board under the Rear Idler Roller 2 Slide the lower section of the sensor across its mounting rail until the two brass colored infrared emitters are centered under the upper section 3 Gently pull wires out from the frame as required Wires should have a little slack NOTE If the lower section is being moved inward and a large loop of wire results remove the printer s left side panel and gently pull the wires through It is important that the wires be positioned away from the drive belts and pulleys 38452L Rev 3 Page 5 15 Corrective Maintenance S Series Maintenance Manual Volume 1 MEDIA SENSOR ADJUSTMENT UPPER MEDIA SENSOR ADJUSTMENT 2 2 Ei Figure 5 7 Transmissive Sensor Lower Section Page 5 16 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance Reflective Media Sensor Adjustment The Reflective Media Sensor is placed into operation for those applications where the sensing of Black Marks on the underside of the media is desired For the 105S printer the Reflective Media Sensor is an option that is installed in place of the lower section of the Transmissive Media Sensor Position adjustment is available across the total width of the media With the Reflective Media Sensor installed
49. of the lower cutter blade and on the surface of the ring at the end of the rotary blade refer to Figure 4 4 DETAIL Figure 4 4 Cutter Module Lubrication Page 4 4 38452L Rev 3 S Series Maintenance Manual Volume 1 Preventive Maintenance Recommended Preventive Maintenance Schedule PRINTHEAD METHOD Isopropyl alcohol INTERVAL When printing in the direct PLATEN ROLLER thermal mode after every roll MEDIA SENSOR of media or 500 feet of Air blow fanfold media MEDIA PATH Isopropyl alcohol and cloth When printing in the thermal RIBBON SENSOR transfer mode after every roll Air blow of ribbon PEEL ROLLER Isopropyl alcohol Once per month LABEL AVAILABLE SENSOR Air blow Once per six months RIBBON FEEDING PATH Visual Once per three months DRIVE BELTS Visual Six months or 500 rolls CUTTER BLADES Citrus based cleaner and or air As needed blow MEDIA TAKE UP SPINDLE RIBBON SUPPLY SPINDLE RIBBON TAKE UP SPINDLE Formal preventive maintenance is not required on these spindles Spindle tension should not be adjusted unless the printer 1 malfunctioning i e spindles not rotating smoothly The recommended tensions and adjustment procedures are provided in Corrective Maintenance 1055 and 105Se printers The spindles should be taken apart and the felt pads replaced with new ones presoaked in
50. removal when replacement is necessary The following procedure explains how to remove these circuit boards 38452L Rev 3 L d gt Volume 1 S Series Maintenance Manual 4 59010 21 5901 911614 H3AOO 3AIL93 LO08d 5 16 25 YOLOW AlddNS 3 FOVLIOA DI SM3H2S ONILNNOW SA3H2S ONILNNOW Qquvoa AlddNS H3MOd 9995 ONILNNOW 21901 NIV SM3H2S ONILNNOW TANVd 5 448525 ONILNNOW TANVd HV38 Page 5 25 38452L Rev 3 Corrective Maintenance S Series Maintenance Manual Volume 1 PRINTHEAD MOUNTING SCREWS MOUNTING SCREWS Figure 5 15 105S 6 and 8 Dot Electronics P MAIN LOGIC BOARD MOUNTING SCREWS i E lt lt gt Z i o E gt gt o LL M T POWER SUPPLY PROTECTIVE COVER REAR PANEL REAR PANEL MOUNTING SCREWS iut 384521 3 L d gt Volume 1 S Series Maintenance Manual s3Iu0429 3 5091 91 5 AAILOALOYd AlddflS H3MOd a oo 2 ADVLIO
51. resistor 16 17 19 J SIGNAL GROUNDS are the Logic Grounds and Returns for all Input and Output signals 30 33 NOT USED These leads should be left unconnected For an illustration of the parallel communication data and control circuits refer to the Main Logic Board Schematic in Volume 2 Part 38453L 38452L Rev 3 Page 1 9 The S Series System S Series Maintenance Manual Volume 1 Page 1 10 38452L Rev 3 Getting Ready to Print In this section Page Controls and 2 2 Front Panel uu an up OR Pr EE 2 2 Front Pane 519 M Hm 2 3 Media Loa diht 2 4 Ribbon WE iiic 2 6 Media Calibra utis d ic 2 7 Adjusting the Print Darkness 2 7 Adjusting the Tear Off POSIUO 2 tenerentur ted treu adea 2 8 Adjusting the Position of the Top of the Label 2 9 Adjusting the Media Sensor Positions 2 9 Mp et Media coute va ier iamen ase n latas 2 9 Lower 2 11 aberat ami S RUN eR ad 2 12 B nk eT m H 2 13 lou er fr 2 14 This section of the manual is intended to supplement the User s Guide by providing additional information to aid the service technician in troubleshooting and m
52. slot designed into the Fuse Holder s End Cap Press in slightly on the end cap and turn the screwdriver slightly counter clockwise The end cap disengages from the Fuse Holder and the fuse may be removed To install a new fuse reverse the sequence VOLTAGE SELECTION SWITCH AC POWER FUSE REPLACEMENT AC POWER ON OFF SWITCH AC POWER CABLE CONNECTION Figure 5 21 AC Fuse Replacement 38452L Rev 3 Page 5 33 Corrective Maintenance S Series Maintenance Manual Volume 1 Battery Replacement One of the factory installed options for the 105S printer is the Battery Backed Up 256 KB RAM Memory The Battery used with this option is a3 VDC Lithium Coin Battery type CR2477 Zebra Part 44641 CAUTION Danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended When discarding used batteries do not incinerate The battery is located on the printer s Main Logic Board It is recommended that a qualified Service Technician replace this battery since internal access to the electronics area of the printer is required CAUTION Turn the printer s AC Power Switch OFF and disconnect the printer s AC Power Cable before replacing the battery Prior to removing and replacing the battery observe proper electrostatic and electrical safety precautions To remove the old battery gently raise the right edge and slide the battery to the right
53. table If you are in the process of printing this change takes affect on the next label printed If you change the switches from active to disabled after printer power up the printer remains in the current mode until a ZPL command changes the mode Print Mode Cutter Tear Off Peel Off Rewind Disabled Non continuous mark sense Non continuous web sense Continuous Disabled Thermal transfer Direct thermal Disabled 38452L Rev 3 3 Printer Diagnostics In this section Page Power ON Self TOS ciam ni QUON 3 1 PNET Seli 3 1 CANCEL Key Self 3 3 PAUSE Key Self 3 4 PEED Key Self qasa qasa 3 5 MODE Key Self 3 6 FEED PAUSE and CANCEL Keys 3 6 PAUSE Key and CANCEL Key 3 7 FEED Key and CANCEL Key 3 7 PEED Key and PAUSE 3 7 Extended Printer uuu to ei RS P ut ion muda 3 9 PAUSE Key Loopback Test 3 9 FEED Key Loopback Test onte en t anto 3 10 Built into the Zebra S Series Printers are test routines to aid the technician in diagnosing faults Power ON Self Test A Power ON Self Test POS
54. the different tolerances and printer modes Perform the Tear Off Position Setting front panel command to correct Label jam in rear area of printhead Upper Media Plate needs cleaning Clean the Upper Media Plate Changes in parameter settings did not take effect Printing stops PAPER RIBBON PAUSE and CANCEL LEDs on All MODE LEDs must be OFF before turning the power OFF A AMPS ZPL command disables Mode Function Save The ZPL II command enables all mode functions to be front panel programmable If the problem continues there may be a problem on the Main Logic Board Replace the Main Logic Board Table 6 3 Cutter Module Troubleshooting symptom ACTION Media jammed in Cutter Remove media clean Cutter Module Connecting cables not connected to Cutter Circuit Board Plug cables into Cutter Circuit Board Cutter Module is dirty Clean Cutter Module End of the media is not positioned correctly on top of the platen Re position media so that the end is on top of the platen In Cutter Mode skewed or stuck labels Cutter is dirty Clean the Cutter Module The Cutter is not cutting labels cleanly Cutter is dirty Clean the Cutter Module Cutter blades are dull Replace the Cutter Module Labels jamming in Cutter or labels are being cut more than once Page 6 4 Cutter
55. the two motor mounting screws to firmly attach the motor to the printer frame 5 Insert the Lower Drive Arm onto the Cutter Motor shaft Pivot the Lower Drive Arm counterclockwise until the Lower Drive Arm flag engages the sensor 7 Tighten the set screws that attach the Lower Drive Arm to the Cutter Motor shaft 8 Reinstall the cutter linkage flat washer and bearing 9 Replace the screw that attaches the Mounting Post to the Main Frame 38452L Rev 3 Page 5 35 Corrective Maintenance S Series Maintenance Manual Volume 1 BRACKET DETAIL A MEDIA GUIDE STATIC BRUSH amp MOUNTING BRACKET CUTTER CUTTER BOARD CUTTER MOTOR LOWER CUTTER BRACKET Figure 5 22 Cutter Installation CUTTER MOTOR DETAIL A SENSOR CUTTER OPTICAL CUTTER OPTICAL SENSOR 5 2 5 gE 5 2 5 5 2 So gt Page 5 36 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance 10 Install the E ring that attaches the Slotted Link to the Lower Drive Arm Cutter Mechanical Assembly Removal NOTE The Cutter Module should NOT be disassembled but replaced as a unit Any disassembly of the Cutter Module will void the warranty 1 Refer to Figure 5 22 Remove the E ring and washer from the top of the Long Drive Link 2 Refer to Figure 5 22 Detail A At the Side Plate remove the two socket head cap screws from
56. 0193 Washer Felt 406 x 172 x 048 2 40320 Brush Anti Static 40819 Bracket Cutter Support 46280M Arm Upper Drive 46618 Assembly Cutter Sensor 49600 012 Assembly Cable 49604 010 Assembly Power Cable Q10019 Page 8 14 E Ring 250 Black I I SET SCREWS ENGAGE FLATS ON MOTOR SHAFT WHEN LOWER ARM IS IN VERTICAL POSITION MOTOR ROTATION MOTOR DIRECTION 1 lt BLACK FLAG TO SENSOR CLAMP rZ l CENTERED IN OPTICAL 30313 TOBE C 7 ASSY SECURELY OVER CABLES FRONT VIEW SIDE VIEW 02133 _ 30199 7 9 30214 Q10019 30210 2 30217 1 30216 4 D 01822 1 46618 1 POSITION BRUSH SO THAT APPROXIMATELY 1 8 OF THE BRUSH S BRISTLES RUB AGAINST EACH MOVING LABEL AND THE BRUSH S BRISTLES ARE PARALLEL TO THE LABEL EDGE S Series Maintenance Manual Volume 1 105Se Parts Lists UPPER CUTTER BRACKET ROTARY CUTTER BLADE INSURE THE TOP OF THE TEAR MOUNTING SCREW MEDIA GUIDE OFF BAR IS POSITIONED ABOVE TEAR OFF gt Al OR LEVEL WITH THE TOP OF BAR G THE REAR CUTTER BLADE CLEARANCE OF 030 2 MINIMUM BETWEEN REAR CUTTER BLADE AND TEAR OFF BAR RELATIVE POSITION OF THE ROTARY CUTTER BLADE WHEN THE DRIVE LINK ASSEMBLY 1 STOPPED BY THE OPTICAL SENSOR WHEN THE POWER 1
57. 04 6 38210 47062 1 47158 1 O RINGS WEAR PLATES AND FRICTION CLUTCHES MUST HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION 160S Media Rewind Spindle Assembly Page 7 43 1055 and 1605 Parts Lists PRINTER MODEL 105S S Series Maintenance Manual Volume 1 PART NUMBER Peel Off Option Assembly DESCRIPTION QUANTITY 02252 Ring Crescent 250 07435 Screw 6 32 37 30104 Flange Ball Bearing 5 x 250 x 125 30114 Washer Flat 76 x 51 x 03 30115 Washer Save 740 x 520 x 08 30118 Ring E External 500 x 042 30257 Pulley Assembly Rewind 6 Dots mm 30265 Pulley Idler 30336 2M Pulley Assembly Media Rewind 30392 004 Screw 6 32 25 30393 006 Screw 8 32 37 30914M Pulley Assembly Rewind 8 Dots mm and 12 Dots mm 31536 Sensor Assembly Take Label 40001 Shaft Platen 40490 2 L Hook Ribbon Assembly 6 inches 45189 2 Page 7 44 Belt Rewind 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 REF STEPPER MOTOR PULLEY POSITIONED ON BOTH SIDES OF BELT 45189 5 45189 5 MAIN DRIVE BELT 30118 NOTE SPACERS MUST 31536 245 30336 2 BLK BLUE 30393 006 3 30265 IDLER PULLEY REWIND PULLEY W 6 DOT MM 30257 45189 2 N B 1
58. 105S and 160S Parts Lists 30392 004 4 c 46481 1 2 40194 2 40193 2 2 1 1 POSITION SENSOR 30531 TAB 40014 FLUSH WITH TOP EDGE OF PRINTHEAD PIVOT BAR 44000M 8 DOT 44200M 6 DOT La 30392 004 2 105S 6 amp 8 Dot mm Printhead Support Assembly Page 7 21 1055 and 1605 Parts Lists PRINTER MODEL 105S 12 dot S Series Maintenance Manual Volume 1 PART NUMBER Printhead Support Assembly DESCRIPTION QUANTITY 01153 Washer Flat 250 x 125 x 028 01159 Washer Lock 6 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 30402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30531 Assembly Ribbon Sensor 30781 Cable Printhead Ground 31521 Assembly Printhead Cable 31899 Brush Static Removal 40014 Plate Guide 40017 Plate Ribbon Strip 40193 Washer Felt 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 44800M Printhead 12 Dots mm 45013 Bracket 46481 1 Screw Adjustment 6 32 48023 Page 7 22 Bearing 313 x 190 x 375 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30392 004 4 J e A 46481 1 2 40194 2 40193 2 a 3039 1 003 2 30402 006 2 NOTE 1 POSITION SEN
59. 12007 8 DOT MM 30914M P O 31536M BLK GRN 40490 2 105S Peel Off Option Assembly Page 7 45 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S Peel Off Option Assembly PART NUMBER DESCRIPTION QUANTITY 02252 Ring Crescent 250 2 07435 Screw 6 32 37 2 30104 Flange Ball Bearing 5 x 250 x 125 2 30114 Washer Flat 76 x 51 x 03 1 30115 Washer Save 740 x 520 x 08 1 30118 Ring E External 500 x 042 1 30247 Washer Flat 42 x 260 x 0747 1 30261 Washer Flat 442 x 255 x 020 1 30265 Pulley Idler 1 30336 2M Pulley Assembly Media Rewind 1 30392 004 Screw 6 32 25 3 1 3 1 1 1 1 1 1 1 30392 006 Screw 6 32 37 30393 006 Screw 8 32 37 30914M Pulley Assembly Rewind 8 Dots mm 30536M Sensor Assembly Take Label Upper 38055M Spindle Media Rewind 40490 3 J Hook 45189 2 Belt Rewind 46001 Shaft Platen 46609M Sensor Assembly Take Label Lower Page 7 46 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists STEPPER MOTOR PULLEY 45189 5 MAIN DRIVE BELT REF 30536M BLK BLU LEADS NOTE SPACERS MUST BE AV POSITIONED ON BOTH SIDES OF BELT 45189 5 30914M BLK GRN LEADS 30392 006 Is _ a 30392 004 40490 3 1605 Peel Off Option Assembly Page 7 47
60. 2 13 14 15 If lighter or no printing is observed on one side of the label as compared with the other continue with this adjustment Using a 7 64 Allen wrench slightly loosen the two Allen set screws mounted on the Wear Plate Continue to print PAUSE Test labels while adjusting the Wear Plate Eccentric for even printing Adjust the Wear Plate Eccentric by turning it by hand or with a 7 16 open end wrench or with a pair of utility pliers Adjust the Wear Plate Eccentric until uniform print density is achieved across the label When even print quality is achieved hold the Wear Plate in position and tighten the two Wear Plate Set Screws Continue to print PAUSE Test labels and verify that parallelism is correct If parallelism is out of tolerance perform the Printhead Parallelism Adjustment If no other adjustment is required follow the Strip Plate Adjustment Procedure found later in this section and tighten the two Allen screws Printhead Position Adjustment Page 5 10 This adjustment is performed in conjunction with the Printhead Parallelism Wear Plate Position and Printhead Pressure Adjustments Adjusting the Printhead position aligns the head for optimum print quality Refer to Figure 5 3 for location of adjustment screws used in the following procedure The thermal elements of the printhead should be aligned just behind the crest of the Platen Roller Print test labels using the PAUSE Key Self
61. 32 5 30916 Strap Ground 31019 Label Logo 31022 Label Model Number 31038 Panel Left Side 31039 Panel Media 31040 Door Media Access 31100M Assembly Membrane Switch Front Panel 31517 Shield High Voltage 31524M PCB Front LED supersedes 31520M 31532M PCB Printhead Adaptor 31646M PCB Power Supply 38102 Panel Rear PCB Serial 38103 Panel Rear PCB Parallel 38037 Cover PCB 38532M PCB Serial Main Logic 38692M PCB Parallel Main Logic 40342 Bracket Front Cover 46325 3 Spacer 6 32 S Q Q N e c Page 8 2 384521 Rev 3 GROUND TAIL E 31100 L ALIGN W FIXTURE DETAIL A DETAIL 207 7 31524M 40342 CUTTER OR TEAR OFF VERSION 31532M S Series Maintenance Manual Volume 1 105Se Parts Lists 38102 SERIAL 38103 PARALLEL wl B 38532M SERIAL 38692M PARALLEL 01159 01152 30391 006 J 30407 008 REMOVE MASKING DISC 5 L K H G F E D 31646M 30391 004 30392 004 PART NUMBER SCREW LIST P 105Se Final Assembly page 1 of 2 Page 8 3 105Se Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105Se
62. 50 Ring E External 312 40490 3 Ribbon Take Up Hook 06319 Screw 10 32 37 45189 5 Belt Main Drive 07229 Washer Curved 49 x 33 x 0075 46001 1 Roller Main Platen 30033 Media Guide Adjustable 46105 Bearing Nylon 30104 Flange Ball Bearing 5 x 250 x 125 46150M Spindle Assembly Ribbon Take Up 30105 Bearing Nylon 312 x 251 x 078 46196M Motor Stepper 30106 Ring Crescent External 312 46213M Assembly Compliance 30114 Washer Flat 76 x 51 x 03 46305M Assembly Media Guide 30115 Washer Wave 740 x 520 x 080 46444 Shaft Pivot 30118 Ring External 500 x 042 46808 Peel Tear Off Bar 30176 Plate Media Supply Supply Spindle Option 48411 Screw Thumb 30239 Washer Crescent 415 x 323 x 062 Q10057 Washer Flat 372 x 158 x 032 30256 B Nut Thumb 30260 Washer Crescent 406 x 253 x 030 30307 Flag Head Open 30336 1M Assembly Ribbon Take Up Pulley 30353M Assembly Head Open Sensor 30392 004 Screw 6 32 25 30392 008 Screw 6 32 50 30393 006 Screw 8 32 37 30423 003 Screw Set 8 32 187 30488 Nut 1 4 20 Supply Spindle Option 30909 Handle Printhead 35082 Guide Media 35136 Washer Nylon 252 x 472 x 059 35137 Ring Retainer 250 38025 Roller Segment 38053M Hanger Assembly Media Supply 38099M Assembly Toggle 38151M Spindle Assembly Ribbon Supply 38226M Assembly Reflective Sensor optional 38302M Assembly Media Sensor 38825 1 Guide Plate Upper Media Snap
63. 70 2 Page 7 28 Blade Ribbon Supply Inner N ID ae a S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 40070 1 me 40070 2 BLADE 2959 30145 30146 4 5 1 30146 E 6 46 X SEE NOTE 1 5 N B 30224 2 48 LA 30071 pm AS X N eno 30145 Ni SEE NOTES 30344M 283 NOTES 1 SOAK FELT WASHERS 30041 4 amp 30041 6 WITH SILICONE OIL AND SQUEEZE OUT 2 SOAK SPRING 30042 IN SILICONE OIL amp ASSEMBLE 3 LONG END OF TORSION SPRING 30042 FACES OUT 105S Ribbon Supply Spindle Assembly Page 7 29 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S Ribbon Supply Spindle Assembly PART NUMBER DESCRIPTION QUANTITY 30042 Spring Torsion 739 x 805 30145 Bearing Thrust 30146 Washer Thrust 687 x 375 x 093 40070 1 Blade Ribbon Supply Outer 40070 2 Blade Ribbon Supply Inner 46085 Nut Jam 3 8 24 46211 Spring Compression 53 x 660 x 62 47005 Nut Jam 3 8 24 47171 Housing Ribbon Supply Spring Page 7 30 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 40070 1 Gray BLADE oe gle 47005 g a ag 30146 30145 N 30042 NOTE 3 46211 NOTES 1 ALL COMPONENTS MUST BE OIL FREE 2 O RINGS WEAR PLATES AND FRICTION CLUTCHES
64. 7435 Screw 6 32 37 07696 Screw 4 40 31 09367 Stand Off 4 40 30240 Cover Plate with Opening Serial 30256 Nut Thumb 6 32 50 30269 Pad PVC 4 0 x 37 062 3039 1 004 Screw 4 40 25 30391 006 Screw 4 40 37 30392 004 Screw 6 32 25 30407 008 Screw 6 32 5 30916 Strap Ground 31019 Label Logo 105S 31020 Label Model Number 31037 Cover PCB 105S 31038 Panel Left Side 31100M Assembly Membrane Switch Front Panel 31102 Panel Rear PCB Serial 31103 Panel Rear PCB Parallel 31240 Cover Plate with Opening Parallel 31517 Shield High Voltage 31524M PCB Front LED 31530M PCB Serial Main Logic 31535M PCB Serial Main Logic w Battery Backup 31690M PCB Parallel Main Logic 31691M PCB Parallel Main Logic w Battery Backup 31646M Circuit Board Power Supply 35040 Door Media Access 40342 Bracket Front Cover 45039 Panel Left Top 46325 3 Spacer 6 32 N IN no 1 1 1 01 41 41 1 1 1 4 1 4 1 4 PL Page 7 2 38452L Rev 3 2 31019 7 GROUND TAIL E WASHERS L 2 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 31530M SERIAL 31535M SERIAL W BATTERY BACKUP 31690M PARALLEL 31691M PARALLEL W BATTERY BACKUP 01159 07696 01152 30391 006 5
65. A 35 ONILNNOW 5 44265 ONILNNOW AlddNS 6 44265 ONILNNOW QHVO8 21901 NIYIN SM3H2S 4 ONILNNOW N3dO QV3H NO88IH HOSN3S 3AISSIASNVH L VIO3IN YOSNAS 3AILO3 133H VIAJN T3NVd HV3H 5 448425 ONILNNOW TANVd HV3H Page 5 27 38452L Rev 3 Corrective Maintenance S Series Maintenance Manual Volume 1 CAUTION Eliminate any static electricity by using an anti static wrist strap attached to the printer chassis The printer electronics are susceptible to static discharge 1 sure printer is OFF and the AC Power Cord and Signal Interface Cable are disconnected 2 Remove the Left Side Panel of the printer by removing the Phillips screws which hold it on 3 Refer to Figures 5 14 5 15 and 5 16 Unplug all Ribbon Cable Connectors Small Wire Connectors and the Adaptor Board if equipped from the Main Logic Board and the Power Supply Board 4 Remove the two screws holding the cardboard cover over the high voltage section of the Power Supply and remove the cover 5 Remove the Mounting Screws that hold the Rear Panel to the Printer Frame 6 Remove the four 105S 105Se or five 160S mounting screws holding the Main Logic Board and the two mounting screws holding the Power Supply against the Printer Frame Standoffs 7 Carefully slide the Rear Panel and Circuit Board Assembly from the rear of the printer 8 To complete the circuit bo
66. ARK S MARK MED S MODES ENABLED MODES DISABLED FIRMWARE IN THIS PRINTER IS COPYRIGHTED Figure 3 1 CANCEL Key Self Test Label 38452L Rev 3 Page 3 3 Printer Diagnostics S Series Maintenance Manual Volume 1 PAUSE Key Self Test Page 3 4 Enter this self test mode by pressing the PAUSE Key while turning the AC power ON This self test consists of eight separate test sequences printing labels at both Speed A and Speed D C for the 300 dpi 105S and 105Se During the first four test sequences the printer simulates the Tear Off mode and backfeeds the media prior to printing each label During the last four test sequences the printer simulates the Rewind mode and does not backfeed the media This self test can be used to print the test labels required when making adjustments to the printer s mechanical assemblies These test labels can also be printed when required during the Configuration and Calibration processes described in Getting Ready to Print See the label example in Figure 3 2 NOTE If the Take Label Sensor pair is mounted on the front of the printer PEEL OPTION INSTALLED will be printed on the first label During the first four test sequences each label must be manually removed from the sensor path before the next label will print During test sequences five through eight the Take Label Sensor pair is not enabled and continuous printing occurs To bypass the first four sequences press th
67. B Parallel 38342 Bracket Front Cover 38530M Circuit Board Serial Main Logic 38646M Circuit Board Power Supply 38691M Circuit Board Parallel Main Logic N N N k 5 Page 7 10 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 38102 SERIAL 38103 PARALLEL 38530M SERIAL 38691M PARALLEL REMOVE MASKING DISC 46325 3 5 PLCS 31517 30391 006 30407 008 01448 30391 004 A 30392 004 CODE PART NUMBER SCREW LIST GROUND TAIL 31524M E NU 31100M 5 ALIGN W FIXTURE DETAIL A 160S Final Assembly page 1 of 2 DETAIL A Page 7 11 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S PART NUMBER DESCRIPTION QUANTITY 30307 Flag Head Open 1 30336 1M Pulley Ribbon Take Up 30336 2M Pulley Media Take Up 30914M Pulley Peel Off Platen 8 Dots mm 40355M Pulley Main Platen 8 Dots mm 40357M Pulley Stepper Motor 8 Dots mm 45189 2 Belt Media Rewind 45189 5 Belt Main Drive Page 7 12 Maintenance Manual Volume 1 105S and 160S Parts Lists MEDIA REFLECTIVE SENSOR ME
68. Core about 5 times in the direction indicated Slowly and evenly 2 per second pull the strip of polyester film using the Spring Scale The rotation of the spindle should be smooth and should not cause the reading on the Spring Scale to jump excessively Compare the Spring Scale reading with the load values provided in Figure 5 13 Perform the Spindle Tension Adjustment only if the reading is out of spec If adjustment is made recheck the tension after running one full roll of labels Spindle Tension Adjustment Page 5 22 Refer to the Spindle Tension Adjustment Diagram in Figure 5 13 and adjust the Spindle Tension as follows 1 Loosen the set screw s in the large Adjustment Nut at the end of the spindle End Cap of the Ribbon Supply Spindle Turn the Adjustment Nut inward to increase the tension or outward to decrease the tension then tighten the set screws If the Spindle Shaft turns when attempting to tighten or loosen the Adjustment Nut refer to Figure 5 11 and insert a 1 16 Allen wrench through the access hole and into the set screw in the shaft collar 1055 1055 ONLY or into one of the slots in the plastic clutch 160S ONLY Hold the shaft in place with the Allen wrench while turning the Hex nut Use adhesive tape to attach a 2 wide strip of polyester film Part 01776 to the Spindle Shaft or Core where required as illustrated in Figure 5 13 Wind the polyester film around the Spindle or Core a
69. DIA TRANSMISSIVE SENSOR RIBBON SENSOR HEAD OPEN SENSOR TAKE LABEL SENSOR 2 DIMENSIONS FROM MAIN LOCATION PULLEY FRAME INSIDE GUIDING EDGE OF PULLEY 0 RIBBON TAKEUP 30336 1 FIXED IN SUB ASSY 1 main PLarEN 435 8 DDD 433 IN 1 X n 3 STEPPER 40357M 810 395 IN 1 1 1 2 Si EI cH E X ADM 4 MEDIA TAKEUP 30336 2M FIXED IN SUB ASSY iss 27 30914 8 07 2 _ Z 17249 5 PEELOFF 8 3 15 IN 1 19 1 27 E H 1 22 gaer NOTE 1 BELT TENSION TO CHECK BELT TENSIONS PULL ON BELTS WITH SPRING SCALE AT LOCATIONS SHOWN WITH AND IN THE DIRECTION SHOWN UNTIL BELT IS DEFLECTED 1 4 SPRING SCALE SHOULD READ AS FOLLOWS 45189 5 BELT SCALE READING POUNDS GRAMS 45189 5 4 5 1800 2200 45189 2 4 5 1800 2200 2 PEEL TEAR IFF BAR PLATEN GAP 1 MEMBRANE PEELOFF BAR TO PLATEN GAP SHOULD BE SET TO 005 TO 015 MAX GAP SWITCH CABLE ALONG THE LENGTH THE PLATEN GAP BE SET WITH A 004 005 THICK BY 3 WIDE SHIM 3 HEAD OPEN CLOSED FLAG WITH HEAD CLOSED FLAG TO BE TIGHTENED IN POSITION AS SHOWN 4 TRANSMISSIVE SENSOR POSITION 1 1 1 1 1 r 45189 2 WHEN EXTENDING THE MEDIA SENSOR POSITION THE OUTER HALF OF THE MEDIA WIDTH REROUTE THIS CABLE TO PROVIDE SUFFICIENT SLACK FOR PULLING T
70. E DIRECTION SHOWN UNTIL BELT IS DEFLECTED 1 4 SPR ING SCALE SHOULD READ AS FOLLOWS BELT SCALE READING POUNDS GRAMS 45189 5 4 5 1800 2200 45189 2 4 5 1800 2200 2 PEEL TEAR OFF BAR PLATEN GAP PEELOFF BAR TO PLATEN GAP SHOULD BE SET TO 005 TO 015 MAX GAP ALONG THE LENGTH OF THE PLATEN GAP TO BE SET WITH A 004 005 THICK BY 3 WIDE SHIM 3 HEAD OPEN CLOSED FLAG WITH HEAD CLOSED FLAG TO BE TIGHTENED IN POSITION AS SHOWN MEMBRANE SWITCH CABLE GROUND 105S 12 Dot mm Final Assembly Page 7 9 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S Final Assembly Page 1 of 2 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 01152 Washer Flat 375 x 156 x 65 01155 Washer Lock 4 01159 Washer External Lock 6 01448 Screw 6 32 37 01912 Washer External Lock 4 07435 Screw 6 32 37 07696 Screw 4 40 31 09367 Stand Off 4 40 30240 Cover Plate with Opening Serial 30269 Pad PVC 4 00 x 37 x 062 30391 004 Screw 4 40 25 30391 006 Screw 4 40 37 30392 004 Screw 6 32 25 30407 008 Screw 6 32 5 30916 Strap Ground 31038 Panel Left Side 31100M Assembly Membrane Switch Front Panel 31240 Cover Plate with Opening Parallel 31517 Shield High Voltage 31524M Circuit Board Front LED 35040 Door Media Access 38019 Label Logo 38020 Label Logo 38037 Panel Right Top 38039 Panel Left Top 38102 Panel Rear PCB Serial 38103 Panel Rear PC
71. FEED Key again will provide a second blank label CANCEL Key The CANCEL Key is only recognized when the PAUSE function is active Press the CANCEL Key and the current label format will be canceled If no format is printing the next one to be printed will be canceled If there are no formats in the printer the CANCEL Key is ignored If the CANCEL Key is pressed for an extended period of time 3 seconds the printer will perform a Cancel All Formats operation Page 2 2 38452L Rev 3 O POWER O PRINTHEAD O PAPER RIBBON PAUSE Q Qe DATA CANCEL O ZV DARKEN Oe NZ POSITION CALIBRATE MODE O Figure 2 1 Front Panel Controls S Series Maintenance Manual Volume 1 Getting to Print MODE Key The MODE Key causes the printer to enter the Configuration Mode In this Mode the Print Darkness Media Tear Off Position and Label Top Position settings can be adjusted The Media Calibration procedure is also activated by the MODE key Refer to the user s guide for details on the Configuration Mode and the Media Calibration procedures Front Panel LEDs Refer to Figure 2 1 for the location of the LEDs NOTE If an operating condition which causes an LED to be ON constantly and one which causes the same LED to flash occur at the same time the LED will flash LED Name Status Indication POWER Printer is ON The AC Power ON OFF Switch
72. HROUGH THE MAIN FRAME WHEN REPOSITIONING THE MEDIA SENSOR BACK TO THE INNER HALF OF THE MEDIA WIDTH PULL THIS CABLE BACK THROUGH THE MAIN FRAME AND REROUTE THIS CABLE REMOVE ANY SLACK 1 1 1 1 BOTH CASES POSITION CABLES AWAY FROM ALL BELTS AND PULLEYS GROUND TAIL T j 1 11 b a 2 L 160S Final Assembly page 2 of 2 Page 7 13 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S and 160S Base Assembly PART NUMBER DESCRIPTION QUANTITY 06576 Guide PCB Nylon 07435 Screw 6 32 37 08754 Eyelet 183 x 157 x 187 46015 Bumper Round 1 09 x 62 Page 7 14 S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 46015 4 08754 4 07435 4 105S and 160S Base Assembly Page 7 15 1055 and 1605 Parts Lists PRINTER MODEL 105S S Series Maintenance Manual Volume 1 PRINTER MODEL 105S Print Mechanism Assembly PART NUMBER DESCRIPTION QUANTITY PART NUMBER Print Mechanism Assembly DESCRIPTION QUANTITY 01130 Nut 6 32 40001 Roller Main Platen 01159 Washer Extended Lock 6 40027 Spring Torsion 02252 Ring Crescent 250 40050M Spindle Assembly Ribbon Take Up 06250 E Ring External 312 40051M Spindle Assembly
73. Parts Lists P O 46609M BLK BLU LEADS 40001 30104 30392 004 2 105Se Peel Off Option Assembly Page 8 11 105Se Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105Se Media Rewind Option Assembly PART NUMBER DESCRIPTION QUANTITY 02252 Ring Crescent 250 07435 Screw 6 32 37 30104 Flange Ball Bearing 5 x 250 x 125 30114 Washer Flat 76 x 51 x 03 30115 Washer Save 740 x 520 x 08 30118 Ring E External 500 x 042 30257M Pulley Assembly Rewind 6 Dots mm 30265 Pulley Idler 30336 2M Pulley Assembly Media Rewind 30392 004 Screw 6 32 25 30393 006 Screw 8 32 37 30914M Pulley Assembly Rewind 8 Dots mm and 12 Dots mm 40001 Shaft Platen 40055RM Spindle Media Rewind 40383RM Assembly Rewind Plate 45189 2 Belt Rewind 46609M Page 8 12 Sensor Assembly Take Label STEPPER MOTOR PULLEY 30336 2M 45189 5 M BLK BLU LEADS MAIN DRIVE BELT REF NOTE SPACERS MUST POSITIONED ON BOTH SIDES OF BELT 45189 5 07435 30114 30265 EN _ mo FT Y X 30393 006 JN N 6 REWIND PULLEY N 12 6 DOT 30257 07435 12 6 DOT 30257 x I 8 DOT 30914M 46609 BLK GRN LEADS REWIND VERSION 40383RM S Series Maintena
74. Press the Pause Feed and Cancel keys while turning the printer ON Once the printer is ON release all three keys The following two sets of LEDs will begin flickering to signify that the automatic sensor adjustment has been made The PRINTHEAD and PAPER RIBBON LEDs The DARKEN and POSITION LEDs NOTE If only one pair of LEDs 1 flickering it indicates that the adjustment was not successful Go back to step 1 and start over 38452L Rev 3 Page 5 17 Corrective Maintenance S Series Maintenance Manual Volume 1 7 Open the Printhead and pull the media through the printer until a label is positioned between the upper and lower sections of the Transmissive Media Sensor Move the ribbon back to its normal position 8 Close the Printhead and press the MODE key to complete the automatic adjustment process A Media Sensor Profile will automatically print and the new sensor settings will be automatically saved See Figure 5 8 9 Perform the Media Calibration procedure located in Getting Ready to Print RIBBON RIBBON RIBBON MEDIA MEDIA Figure 5 8 Media Sensor Profile Sample Label Page 5 18 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance Take Label Sensor Alignment The Take Label Sensor pair is active only when the S Series printer is set to Peel Off mode To operate in this mode either the Rewind Option or the Backing Only Rewind Option must be installed The Take Label Sensor pair is not
75. Ribbon Supply 06268 Washer Lock 6 40154 Pin Eccentric 06319 Screw 10 32 37 40305RM Assembly Media Guide 07229 Washer Curved 49 x 33 x 0075 30033 Media Guide Adjustable 40355M Assembly Platen Pulley 8 Dots mm and 12 Dots mm nd 30104 Flange Bearing 5 x 250 x 125 40357M Assembly Stepper Motor Pulley 8 Dots mm 30105 Bearing Nylon 312 x 251 x 078 40444 Shaft Pivot 30106 Ring Crescent External 312 40490 2 Ribbon Take Up Hook 30114 Washer Flat 76 x 51 x 03 40808 Tear Peel Off Bar 30115 Washer Wave 740 x 520 x 080 40825 Guide Plate Upper Media Snap Plate 30118 Ring E External 500 x 042 45025 Roller White Nylon 62 18 30239 Washer Crescent 415 x 323 x 062 45053M Hanger Assembly Media Supply 30247 Washer Flat 42 x 260 x 0747 45189 5 Belt Main Drive 30256 B Nut Thumb 46196M Motor Stepper 30307 Flag Head Open 46904 Assembly Reflective Sensor optional 30336 1M Assembly Ribbon Take Up Pulley 30353 Assembly Head Open Sensor 30355M Assembly Platen Pulley 6 Dots mm 30357M Assembly Stepper Motor Pulley 6 Dots mm and 12 Dots mm 4 1 4 N N O
76. SOR 30531 TAB FLUSH WITH TOP EDGE OF PRINTHEAD PIVOT BAR PIVOT BAR 40014 105S 12 Dot mm Printhead Support Assembly Page 7 23 1055 and 1605 Parts Lists PRINTER MODEL 160S S Series Maintenance Manual Volume 1 PART NUMBER Printhead Support Assembly DESCRIPTION QUANTITY 01153 Washer Flat 250 x 125 x 028 1 01159 Washer 6 Lock 01882 Screw 4 40 25 06268 Washer 6 Split Lock 30344 Assembly Clutch Plate and Bearing 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 30402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30781 Cable Printhead Ground 38000M Printhead 8 Dots mm 38521 Assembly Printhead Cable 38601 Assembly Printhead Cable Power 40193 Washer Flat 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 46017 Plate Ribbon Strip 46022 Bearing Rulon 313 x 191 x 375 46173 Brush Static Removal 46174 Plate Guard 46481 1 Screw Adjustment 6 32 46605 Page 7 24 Assembly Ribbon Sensor S Series Maintenance Manual Volume 1 105S and 160S Parts Lists 30392 004 2 30392 004 4 01159 2 DETAIL FRONT SURFACE OF PRESSURE PLATE SHOULD BE FLUSH TO BELOW ENDS OF PRINTHEAD MOUNTING BRACKET 30392 004 4 06268 4 N WRAP GROUND STRAP AS SHOWN
77. STUDS 6 DOT MM amp 8 DOT MM ONLY GUIDE HOLES Figure 5 1 105S 105Se Printhead Replacement Page 5 4 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance 160S Printhead Replacement Refer to Figure 5 2 while performing the following procedure CAUTION Observe proper Electrostatic Safety Precautions when removing handling and replacing the Printhead Turn the printer OFF and remove the Power Cord Open the Printhead Assembly and remove the media and ribbon then close the Printhead Assembly Properly connect yourself to an anti static protection system Locate the Spring loaded Printhead Mounting Screw on top of the Printhead Assembly Loosen the Mounting Screw until it disengages from the Printhead CAUTION Use care to minimize any physical damage to the Printhead during the remainder of this procedure 10 11 12 13 14 15 16 17 Slowly open the Printhead Assembly The Printhead will be resting on the Platen while the rest of the Assembly pivots back Spread apart the holding tabs on the sides of the Printhead Data Connectors to release the Data Cables Grasp the outside edges of the Printhead Power Cable Connector and press down on the Power Cable Locking Tab While maintaining pressure on the locking tab disconnect the Printhead Power Cable and remove the Printhead through the front of the printer Prior to installing the new printhead note the r
78. Series printer follows the EIA RS 232 and CCITT V 24 specifications for signal levels The baud rate number of data bits and parity are user selectable via DIP switches at the rear of the printer Parity only applies to data transmitted by the printer The parity associated with received data is ignored Further information on the settings of these switches is contained in the printer s user s guide START PARITY BIT DATA BITS BIT 7 25 LOGIC 1 STOP LOGIC BIT Figure 1 3 RS 232 Signal ASCII Code Data Conditions Serial Data Signal Levels Serial data signals are defined as either MARK or SPACE while control signals are either ON or OFF The output levels for the S Series printers are as follows MARK or OFF 7 to 10 Volts SPACE or ON 7 to 10 Volts Serial Interface Connector Pinout and Description A DB25 S connector is located at the rear of the Zebra S Series printer and provides serial data communications to a host using RS 232 signaling The pinouts and signal descriptions for the DTE port are as follows 38452L Rev 3 Page 1 7 The S Series System S Series Maintenance Manual Volume 1 Pin Serial Data Port Signal Description 1 Frame Ground Transmit Data TXD is the serial data output of the Zebra S Series printer It is on this lead that printer status information is transmitted to the host Receive Data RXD is the serial data input to the Zebra S Series printer from the
79. T is performed each time the printer is turned ON This test checks for proper initialization of various electronic circuits and establishes starting parameters as those stored in the printer s memory During this test sequence the front panel LEDs will turn ON and OFF to insure proper operation At the end of this self test only the POWER LED will remain lit If other LEDs remain lit refer to Troubleshooting in this manual Printer Self Tests These self tests produce sample labels and provide specific information which helps determine the operating conditions for the printer Each self test is enabled when a front panel key is pressed while the printer s AC Power Switch is turned ON Keep the key pressed until the front panel LEDs turn ON When the Power On Self Test is completed the selected printer self test will start automatically 38452L Rev 3 Page 3 1 Printer Diagnostics S Series Maintenance Manual Volume 1 NOTES It is recommended that full width media be used when performing these tests Labels less than full width in size will lose printing on the right side Label length will determine the amount of printing starting at the top of the label When performing these self tests while in the Peel Off Mode the operator must remove the labels as they become available When canceling a self test prior to its actual completion always turn the printer power OFF and then back ON to reset the printer Some of the prin
80. UA FII REE 1 6 Environmental Operating 1 6 Communication aum 1 7 Serial Data Communications OVvervIew 1 7 Parallel Data Communications OvervIiew 1 9 Printer Specifications Media Handling Tear Off mode Rewind mode Peel Off mode Cutter mode Labels are produced in strips Requires Media Rewind option Labels are rewound internally onto a 3 inner diameter cardboard core Requires Peel Off option or Media Rewind option Labels are dispensed and peeled from the liner The liner can be rewound directly onto the spindle using the J Hook or onto a 3 inner diameter cardboard core Requires Cutter Module option 105Se only Media is cut after printing under software control 38452L Rev 3 Page 1 1 The S Series System S Series Maintenance Manual Volume 1 Printing Considerations Specification Resolution thermal transfer or direct thermal 203 dots per inch 8 dots per mm 105S 105Se Optional 152 dots per inch 6 dots per mm Optional 300 dots per inch 12 dots per mm 203 dots per inch 8 dots per mm Dot size square 0 00492 0 125 mm 0 00656 0 167 mm 0 0033 x 0 0039 0 083 x 0 100 mm 0 00492 0 125 mm Maximum print width 4 09 104 mm 4 09 104 mm 4 09 104 mm 6 30 160 mm Maximum print
81. UPPLY Figure 2 5 Fanfold Media Loading Diagrams 160S 38452L Rev 3 Page 2 5 to Print S Series Maintenance Manual Volume 1 Ribbon Loading RIBBON RIBBON TAKE UP SUPPLY SPINDLE 2 PLATEN ROLLER LOWER ROLLER UPPER ROLLER Figure 2 6 105Se Ribbon Loading Diagram RIBBON RIBBON TAKE UP SUPPLY SPINDLE 2 PLATEN ROLLER ROLLERS LOWER ROLLER UPPER ROLLER Figure 2 7 160S Ribbon Loading Diagram Page 2 6 38452L Rev 3 S Series Maintenance Manual Volume 1 Getting Ready to Print Media Calibration IMPORTANT Perform the media calibration procedure when media is first installed or when a different type of media or ribbon is installed During this procedure the printer automatically determines the media type label length media and ribbon sensor settings and printing method NOTE Make sure that the media and ribbon rolls are positioned against the inner spindle stops 1 Press the MODE key three times The PAUSE and CALIBRATE lights turn on 2 Press FEED to calibrate The printer feeds some media The MODE lights will flash on and off to indicate that the settings have been saved in memory 3 Press PAUSE to exit PAUSE mode the PAUSE light turns off Adjusting the Print Darkness Due to differences in types of media ribbon and the wear on the printhead it may be necesary to adjust the darkness setting burn temperature of the S Series printhead to achieve proper printing Us
82. USE LED ON Head Open Sensor not detecting Flag or Flag not in proper position Check Head Open Sensor and Flag for proper operation Printer stops and HEAD LED ON Printhead element is overheated Printer resumes printing when the printhead element cools Printer prints across web or wrong position Loss of registration indicating a Media Sensor problem Adjust Media Sensor position and then if needed adjust the Media Sensor sensitivity Printer set for continuous media but non continuous media is loaded Set printer for correct type of media Continuous printing occurring with the HEAD LED ON Printhead under temperature Check print quality Printhead will heat up by printing or move printer to a warmer area Printer stops and PAUSE LED lights Page 6 2 Not enough memory to perform one of the functions shown below Functions 1 Download Graphics 2 Creating Bitmap not enough memory for length of label Building Format label too complex 38452L Rev 3 You may do any of the following 1 Check for proper Communication Configuration 2 With PAUSE ON use the ZPL Command to display the amount of memory free With PAUSE ON press CANCEL to skip that label format and continue to the next one Cycle Power OFF and back ON to clear printer memory and start again S Series Maintenance Manual Volume 1 SYMPTOM Poo
83. Unacceptable Label Darkness properly set Printhead position correct on left side too far forward on right side 1234567892 123456 78901 23456 78321 Noisy printing breakup on leading edges of horizontal bars splotchy on right side Toggles balanced equal pressure on left and right sides Unacceptable Label Darkness Properly Set Printhead Position 9 91234567889 4567890 Correct On Right Side Way Too Far Forward On Left Side Noisy Printing Breakup on Leading Edges of Horizontal Bars Splotchy On Left Side Toggles Balanced Equal Pressure On Left and Right Sides Page 6 10 38452L Rev 3 S Series Maintenance Manual Volume 1 Troubleshooting Factory Assistance Should any problem be encountered which cannot be corrected with the aid of this manual Technical Support should be contacted immediately to minimize or avoid printer downtime Technical Support can also assist in determining if the printer should be returned for repair Returning Equipment Should it become necessary to ship your printer carefully pack the printer in a suitable container to avoid damage during transit A note describing the failure must be enclosed with the unit Whenever possible the original shipping container should be used If other containers are used a procedure similar to the original factory packaging should be followed Encl
84. Zebra S Series Maintenance Manual Volume 1 General Maintenance TIU 33189 3337489 15 wn _ Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills IL USA 60061 3109 Telephone 1 847 634 6700 Fax 1 847 913 8766 Zebra 1055c Wi 999 TT Zebra Technologies Europe Limited Zebra House The Valley Centre Gordan Road High Wycombe Buckinghamshire HP13 6EQ UK Telephone 44 0 1494 472872 Fax 44 0 1494 450103 38452L Rev 3 Copyright 1995 Zebra Technologies Corporation rights reserved 7 Zebra Zebra S Series Printer Maintenance Manual Volume 1 Rev 3 Registration Form ZEBRA TECHNOLOGIES CORPORATION To receive Maintenance Manual revisions and updates complete this form and fax or mail it to Zebra Technologies at the fax number or address shown below Company Address City_ State Zip Phone Contact Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills Illinois USA 60061 3109 ATTN Technical Training FAX Number 1 847 913 8766 7 Zebra Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation It is intended solely for the infor mation and use of parties operating and maintaining the equipment described herein Such proprietary information may not be used reproduced or disclosed to any other part
85. ad parallelism Wear Plate position and Printhead position are interrelated carefully look at the test labels for changes in these settings and adjust if necessary Printhead Pressure Adjustment Printhead Pressure is the fourth of the four interrelated adjustments Using lower Printhead Pressure and Darkness settings can extend printhead life If printing is too light on one side or if a thick media is used printhead pressure may require adjustment Refer to Figure 5 4 for the location of the Pressure Toggle for the 105S and 105Se printers This toggle should be positioned over the center of the media width The 160S printer has two toggles These toggles are typically positioned at the 1 4 and 3 4 positions across the width of the media If narrow media is used on the 160S the inside toggle should be centered above the media and the pressure of the outside toggle should be reduced to zero Print PAUSE Key Self Test labels to check print quality 2 increase printhead pressure loosen the Upper Knurled Nut on the Toggle and adjust the Lower Toggle Adjusting Nut downwards 3 decrease printhead pressure loosen the Upper Knurled Nut and adjust the Lower Toggle Adjusting Nut upwards Adjust printhead pressure for optimum print quality 5 To lock in printhead pressure tighten the Upper Knurled Nut against the Lower Toggle Adjusting Nut 6 Though different media and ribbon combinations may require different Toggle settings
86. age 7 51 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 Page 7 52 8 1055 Parts Lists In this section Page Mechanical Parts Assemblies 8 1 Mechanical Parts and Assemblies Listing 8 2 Please note This section contains parts lists and drawings that are specific to the 105Se For parts lists drawings common for both the 1055 105Se refer to Section 7 Mechanical Parts and Assemblies MECHANICAL PARTS AND ASSEMBLIES Description Page 105Se Final Assembly Page 1 of 2 8 2 8 3 105Se Final Assembly Page 2 of 2 8 4 8 5 105Se Print Mechanism Assembly 8 6 8 7 105Se Printhead Support Assembly 8 8 8 9 105Se Peel Off Option Assembly 8 10 8 11 105Se Media Rewind Option Assembly 8 12 8 13 105Se Cutter Option Assembl 8 14 8 15 38452L Rev 3 Page 8 1 105Se Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105Se Final Assembly Page 1 of 2 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 01152 Washer Flat 375 x 156 x 65 01155 Washer Lock 4 01159 Washer External Lock 6 01448 Screw 6 32 37 01912 Washer External Lock 4 07435 Screw 6 32 37 30240 Cover Plate with Opening Serial 30256 Nut Thumb 6 32 50 30269 Pad PVC 4 0 x 37 062 30391 004 Screw 4 40 25 30391 006 Screw 4 40 37 30392 004 Screw 6 32 25 30407 008 Screw 6
87. ain Logic Board and OFF tested good All LEDs except Printer misconfigured for Peel Off If Peel Off is installed check Take POWER LED are Mode and Peel Off Option not Label Sensor OFF and no printer installed operation possible Printer locks up Main Logic Board failure Replace Main Logic Board while running Power On Self Test 38452L Rev 3 Page 6 1 S Series Maintenance Manual Volume 1 Troubleshooting Table 6 2 General Troubleshooting symptom DuGNOSS ACTION Printer stops Media not loaded or incorrectly loaded Load media correctly RIBBON LED and PAUSE LED both ON Misadjusted Media Sensor 1 In continuous media mode non continuous media is loaded 2 In non continuous media mode continuous media is loaded Check Media Sensor operation Adjust if necessary Run Printer Calibration 1 Calibrate 2 Calibrate Printer stops PAPER RIBBON Ribbon not loaded or incorrectly loaded Load ribbon correctly LED Flashes and the PAUSE LED ON Ribbon Sensor not sensing ribbon that is loaded correctly Misadjusted Ribbon Sensor 1 In thermal transfer mode ribbon is out 2 In thermal direct mode ribbon is in Check Ribbon Sensor operation Adjust if necessary Run Printer Calibration 1 Calibrate 2 Calibrate Printer stops HEAD Printhead is not fully closed Close printhead completely OPEN LED Flashes and PA
88. aintaining the printer 38452L Rev 3 Page 2 1 Getting Ready to Print S Series Maintenance Manual Volume 1 Controls and Indicators All of the printer controls and indicators are located on the front of the unit except for the Power ON OFF Switch which is located at the rear of the printer Front Panel Controls AC Power ON OFF Switch Controls application of AC Power to the printer When powered ON the printer will perform a Power ON Self Test as it begins operation Turning the printer ON while holding down certain front panel keys will cause additional printer self tests to occur once the Power ON Self Test is complete The AC Power Switch should be turned OFF prior to connecting or disconnecting any cables PAUSE Key The PAUSE Key stops and restarts the printing process If the printer is idle not printing when the PAUSE Key is pressed no printing can take place If the PAUSE Key is pressed while printing is in progress the printing stops once the current label is completed Pressing the PAUSE Key a second time resumes the printing process FEED Key The FEED Key forces the printer to feed one blank label If the printer is idle not printing or if the PAUSE function is active when the FEED Key is pressed one blank label feeds from the printer immediately If the printer is printing one blank label feeds out after completion of the current batch of labels After one blank label is fed out pressing the
89. allel with the outer edge of the Tear Off Bar across the entire width of the media path The Cutter Module should be positioned as far forward as possible while maintaining parallelism with the Tear Off Bar This should prevent interference of the Rear Cutter Blade with the Tear Off Bar After the above conditions are both met tighten all mounting screws Carefully tighten the flat head screw that attaches the Upper Cutter Bracket to the Cutter Module Be careful not to disturb the position of the Media Guide if this part moves out of position set its height so that its lower edge is flush with the rear opening in the Cutter Module 38452L Rev 3 Page 5 37 Corrective Maintenance S Series Maintenance Manual Volume 1 The Rear Cutter Blade is held in position by two springs If these springs touch the Tear Off Bar or other printer parts the Rear Cutter Blade will not float properly and will cause excessive wear and premature failure of the Cutter Blades Check the clearance between the back of the Cutter Mechanism and the Tear Off Bar by inserting a screwdriver from the front of the Cutter Mechanism and press the top of the Rear Cutter Blade toward the printer The blade should move a minimum of 030 inches If necessary loosen the four Phillips head screws on the bottom of the Cutter Module and reposition the Cutter Mechanism away from the Tear Off Bar Attach the E ring and washer to the Upper Drive Arm at the top of the Long Drive
90. ard removal process either remove the two mounting screws holding the Main Logic Board to the Rear Panel or remove the three mounting screws holding the Power Supply Board to the Rear Panel Installing the Main Logic and Power Supply Boards Page 5 28 If the Adaptor Board is installed in the printer it is recommended that you remove it before you perform this procedure refer to page 5 24 1 Attach the Main Logic Board and or the Power Supply Board to the Rear Panel with the appropriate mounting screws Do not tighten these screws 2 Slide the Rear Panel and Circuit Board Assembly into the printer from the rear 3 Attach the Rear Panel to the Printer Frame with the mounting screws Make sure the screws are snug 4 Attach the Main Logic Board and the Power Supply Board to the Printer Frame Standoffs with the appropriate mounting screws Do not tighten these screws 5 Tighten the circuit board mounting screws on the Rear Panel then tighten the mounting screws into the standoffs Reinstall the Adaptor Board if equipped Refer to page 5 24 7 Attach all cables to the Main Logic Board and the Power Supply Board Replace the Power Supply Protective Cover 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance s WARNING Dangerous voltage is present at the Power Supply Board when the printer is ON Keep clear of the Power Supply Board when turning the printer
91. bout 5 times in the direction indicated Slowly and evenly 2 per second pull the strip of polyester film using the Spring Scale The rotation of the spindle should be smooth and should not cause the reading on the Spring Scale to jump excessively Compare the tension reading on the Spring Scale with the appropriate load values provided in Figure 5 13 Repeat steps 1 through 4 until the correct tension is obtained 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance 105S 105Se RIBBON SUPPLY SPINDLE ASSY ALIGN ALL FLANGE SECTIONS BEFORE INSTALLING RIBBON CORE 160S RIBBON SUPPLY SPINDLE ASSY SPINDLE FORCE LOAD TOLERANCE GRAMS RIBBON SUPPLY Wn RIBBON TAKEUP ALL MEDIA 105S 105Se ATTACH FILM STRIP REWIND 160S RIBBON CORE WITH TAPE AS SHOWN DETAIL A ATTACH FILM STRIP TO SPINDLE WITH TAPE AS SHOWN RIBBON TAKEUP SPINDLE ASSY LOOSEN THE SET SCREW S ON NUT ADJUST NUT IN OUT TO INCREASE DECREASE FORCE SECURE NUT TO SHAFT WITH SET SCREW S AFTER ADJUSTMENT SPINDLE ASSY A ATTACH FILM STRIP TO MEDIA CORE WITH TAPE AS SHOWN Figure 5 13 Spindle Tension Adjustments 38452L Rev 3 Page 5 23 Corrective Maintenance S Series Maintenance Manual Volume 1 Removing the Adapter Board 105S 300 dpi and all 105Se The Adapter Board may require removal when replacement is necessary Follow the procedure below and refer to Figure 5 14 to remove the Adap
92. ch EPROM label Make sure all pins are properly aligned before pressing the chips into place CAUTION Turning the S Series printer ON with an EPROM installed in the wrong direction will result in permanent damage to that EPROM 5 Before turning power ON double check that all EPROMs are in the proper socket and that the notches are pointing UP 38452L Rev 3 Page 5 29 Corrective Maintenance S Series Maintenance Manual Volume 1 WARNING When the printer power is turned ON in step 7 dangerous voltage is present at the Power Supply Board Reconnect the AC Power Cord 7 Press and hold the CANCEL Key while turning the printer AC Power Switch ON A Configuration Label will print 8 Verify the Firmware version shown on the Configuration Label is the same as the software just installed 9 Complete the process by installing the Left Side Panel on the printer 10 The printer is now ready to operate vu99 Dus om e o ESO 865 Fo el ooooooo R64 04 FO 0000000 jiz
93. cuit Board over all four standoffs Insert the screw through the lower right hand Circuit Board mounting hole do not tighten at this time Install the three remaining mounting screws and tighten all four screws 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance 5 VDC Figure 5 23 Cutter Circuit Board 8 Pass the Cutter Board Power Cable along the bottom of the printer frame toward the Main Logic Board 9 Plug the Cutter Motor leads into the Cutter Motor Connector J3 on the Cutter Circuit Board Black lead to the left Note This is a polarized connector 10 Refer to Figure 5 23 Plug the Cutter Sensor wires into the Cutter OPTO Connector J6 on the Cutter Circuit Board 11 Check the installation work and insure that during operation no wiring will touch any moving parts Optical Sensor Removal 1 Refer to Figure 5 22 Remove the nut that holds the Cutter Optical Sensor Assembly wires Sensor Clamp and Optical Sensor in position 2 Lift the Cutter Optical Sensor Assembly off the Sensor Mounting Post Optical Sensor Installation 1 Refer to Figure 5 22 and the Figure 5 22 inset Install the Cutter Optical Sensor Assembly on the Sensor Mounting Post The Sensor part of the Assembly should be mounted toward the printer frame 2 Place the Sensor Clamp over the Optical Sensor and start the nut on the Sensor Mounting Post DO NOT tighten the nut 3 Route the
94. e Manual Volume 1 105Se Parts Lists 30393 006 35 9 30392 004 2 TN 12 6 DOT d 8DOT 40355M 45025 35025 6 PLCS 12 6 DOT 30357 Ss N 8 DOT 40357 30392 004 3 30392 004 5 07229 i 30423 003 9 9 1055 Print Mechanism Assembly Page 8 7 105Se Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105Se Printhead Support Assembly PART NUMBER DESCRIPTION QUANTITY 01153 Washer Flat 250 x 125 x 028 01159 Washer Lock 6 01882 Screw 4 40 19 10401 Screw 5 x 4 30301 003 Screw 4 40 19 30392 004 Screw 6 32 25 30402 006 Screw 6 32 37 30494 Washer 320 x 119 x 062 30531 Assembly Ribbon Sensor 30781 Cable Printhead Ground 31007 Plate Ribbon Strip 31521 Assembly Printhead Cable 31899 Brush Static Removal 40014 Guide Plate 40193 Washer Felt 406 x 172 x 048 40194 Washer Curved 312 x 144 x 016 44000M Printhead 8 Dots mm 44200M Printhead 6 Dots mm 44800M Printhead 12 Dots mm 45003 Bracket 6 Dots mm and 8 Dots mm 45013 Page 8 8 Bracket 12 Dots mm S Series Maintenance Manual Volume 1 105Se Parts Lists 30392 004 4 45003 6
95. e PAUSE Key then tear off the first printed label Once the label is removed the printer will enter the PAUSE mode Press the CANCEL Key four times and make sure the Data LED flashes once each time Press the PAUSE Key once to start test sequence five 1 The initial test sequence prints 15 labels at speed A then automatically PAUSES the printer Another 15 label sequence will start if the PAUSE Key 15 pressed to permit printing 2 While the printer is PAUSED press the CANCEL Key once to select the second self test sequence Now each time the PAUSE Key is pressed the printer prints 15 labels at speed D C for the 300 dpi 1055 and 1055 Another 15 label sequence will start if the PAUSE Key is pressed to permit printing 3 While the printer is PAUSED press the CANCEL Key once to select the third self test sequence Now each time the PAUSE Key is pressed the printer prints 50 labels at speed Another 50 label sequence will start if the PAUSE Key is pressed to permit printing 4 While the printer is PAUSED press the CANCEL Key once to select the fourth self test sequence Now each time the PAUSE Key is pressed the printer prints 50 labels at speed D C for the 300 dpi 1055 and 1055 Another 50 label sequence will start if the PAUSE Key is pressed to permit printing 5 Self Test sequences five through eight are the same as sequences one through four but simulate the Rewind mode of operation by not backf
96. e Test 20 at Speed A Bar Code Wrinkle Test Code 39 10 at Speed D Usable Area Test 10 at Speed D Head Temperature Test 10 at Speed Upper Smear Test 10 at Speed Lower Smear Test E 10 at Speed A Usable Area Test N 10 at Speed A Head Temperature Test 10 at Speed Upper Smear Test AR 10 at Speed A FEED Key and PAUSE Key Lower Smear Test Pressing these two keys at the same time while turning the power ON temporarily resets the printer configuration to the factory default values These values will be active until power is turned OFF If the factory default conditions are to be used on a permanent basis save them by pressing the MODE Key four times MODE LEDs cycle ON then OFF A Media Calibration procedure must be performed after factory default values are saved Figure 3 5 indicates which printer function controls each of the configuration parameters 38452L Rev 3 Page 3 7 Printer Diagnostics Parameter S Series Maintenance Manual Volume 1 Controlled By Darkness Front Panel Adjustment or ZPL Tear Off Adjust Front Panel Adjustment Web Sensor Front Panel Calibrate or ZPL Media Sensor Front Panel Calibrate or ZPL II Ribbon Sensor Front Panel Calibrate or ZPL Mark Media Sensor DIP Switches or ZPL II Mark Senso
97. e the following procedure to adjust the darkness turning the printer OFF is not required for the new setting to take effect CAUTION Set the darkness to the lowest possible for the desired print quality Darkness set too high for a given ribbon may cause printhead damage ink smearing ribbon wrinkle and or burning through of the ribbon l Begin printing a batch of labels Use a self test label see Printer Diagnostics or preferably one of your own formats 2 Pause the printing by pressing the PAUSE key 3 Press the MODE key once to place the printer in Darkness Adjust Mode The DARKEN light turns on 4 Press the UP or DOWN key to adjust the current setting 5 Press PAUSE to ressume printing check the new setting 6 Repeat steps 2 through 5 for further adjustment 7 When darkness is correct press PAUSE once and MODE three times The MODE lights will flash on and off to indicate that the settings have been saved in memory 8 Press PAUSE to resume printing Monitor the new setting adjusting if necessary 38452L Rev 3 Page 2 7 to Print S Series Maintenance Manual Volume 1 Adjusting the Tear Off Position Page 2 8 This procedure sets the rest position of the media over the Tear Bar after printing The possible adjustment range is approximately plus or minus 80 dot rows Power need not be turned off to reset this parameter NOTE The printer configuration label reports the actual number of dot
98. ead NOTES The order in which the adjustments are performed depends on the print quality of the labels printed during the PAUSE Test see Sample Labels in Troubleshooting The first two Printhead Adjustments Parallelism and Wear Plate must be completed prior to attempting to locate the optimum print position As with the other adjustments Parallelism and Wear Plate adjustments are interrelated Adjusting one may have an effect on the position of the other Excessive printhead pressure will lead to increased printhead wear and decreased printhead life Increased printhead life is possible by combining minimum toggle pressure and optimum printhead position over the Platen Roller 38452L Rev 3 Page 5 7 Corrective Maintenance S Series Maintenance Manual Volume 1 Printhead Parallelism Adjustment This adjustment is performed in conjunction with the Wear Plate Position Printhead Position and Printhead Pressure Adjustments Adjusting the printhead parallelism squares the printhead in reference to the media Refer to Figure 5 3 for location of adjustment screws used in the following procedures Printhead Parallelism Test 1 Prior to starting this test insure the installed media is squared with the Tear Off Bar 2 When the printer begins printing PAUSE Key Self Test labels refer to Getting Ready to Print and adjust the Darkness for a clear presentation of all lines on the test label 3 The uppermost line
99. ed on that label is added to plus or subtracted from minus the Darkness value specified on the Configuration Label The resulting numeric value 0 to 30 is the best darkness value for that specific media ribbon combination The value selected can be entered while performing a Media Darkness Adjustment The PLUS value can be entered by pressing the UP FEED Key while the MINUS value is entered by pressing the DOWN CANCEL Key the appropriate number of times Refer to the Calibration processes described in Getting Ready to Print Optionally the required relative darkness value can be programmed into the ZPL label formats sent to the printer MODE Key Self Test This self test places the printer in the Communications Diagnostics Mode Press the MODE Key while turning the AC power switch ON then send a label format to the printer In this mode the printer prints the ASCII characters and their corresponding hexadecimal values for any data received from the host computer See the example in Figure 3 4 NOTE Turn the printer s power OFF to exit this self test AFSAFO394 255 SE 46 53 5E 46 4F 33 39 34 2 32 35 41 N 18 10 FDCOOOO0 4E 20 31 38 2C 31 38 5E 46 44 28 30 30 30 30 3772 7797 FS 29 39 39 39 2D 39 39 39 39 5E 45 53 0 BA FOO 50 AAN 18 46 38 20 35 38 41 41 2C 31 38 2C 10 FDCENTER STA 31 30 46 44 43 45 4E 54 45 52 20 53 54 41 Figure 3 4 MODE Key Self T
100. edure l Usea 7 64 Hex Allen wrench to loosen the 2 Allen screws that attach the Platen Support Bracket to the Side Plate 2 Moving the bracket toward the front of the machine moves the label backing material away from the Rewind Tracking Plate Moving the bracket toward the rear of the machine moves the label backing toward the tracking plate Adjust the bracket position as required and tighten the Allen screws 3 Print several labels and repeat steps 1 and 2 until proper tracking is achieved 7 64 HEX ALLEN SCREWS ROLLER aL PLATEN SUPPORT BRACKET Figure 5 12 Peel Off Lower Roller Alignment 38452L Rev 3 Page 5 21 Corrective Maintenance S Series Maintenance Manual Volume 1 Spindle Adjustment and Maintenance There are three spindles which require periodic tension measurement and adjustment Measuring spindle tension should be done at least once each year unless required more often due to high printer use Tension should be adjusted whenever it is not within the tolerance range associated with that spindle Tension Measurement Procedure The procedure for measuring spindle tension is similar for all three spindles Refer to the Spindle Tension Adjustment Diagram in Figure 5 13 for specific requirements 1 Use adhesive tape to attach 2 wide strip of polyester film Part 01776 to the Spindle Shaft or Core where required as illustrated in Figure 5 13 Wind the polyester film around the Spindle or
101. eed A Usable Area Test E O E N 10 at Speed A Head Temp Test 10 at Speed Upper Smear Test 10 at Speed Lower Smear Test for the 1055 and 105Se with the 300 dots inch printhead LEFT WRINKLE TEST PRINTING SPEED D X68Z9SPECT Ox Figure 3 7 Format 1 8 Test Label 38452L Rev 3 S Series Maintenance Manual Volume 1 Printer Diagnostics RIGHT WRINKLE TEST PRINTING SPEED D 6829SPEcT OX Figure 3 8 Format 2 9 Test Label CODE 39 CODE 32 EUM E cd EIL s i ci aS 620 x x a tl B e T m m H H Figure 3 9 Format 3 10 Test Label USEABLE AREA 012345678901234567890123456 PRINTING AT SPEED D Figure 3 10 Format 4 11 Test Label 38452L Rev 3 Page 3 11 Printer Diagnostics S Series Maintenance Manual Volume 1 HEAD TEMP TEST PRINTING AT SPEED D COUNT 0001 Figure 3 11 Format 5 12 Test Label x012345678901234 UPPER SMEAR TEST PRINTING AT SPEED D Figure 3 12 Format 6 13 Test Label LOWER SMEAR TEST PRINTING AT SPEED D 012345678901234 Figure 3 13 Format 7 14 Test Label Page 3 12 38452L Rev 3 4 Preventive Maintenance
102. eeding at the beginning of each label In addition the Take Label Sensor pair is disabled during these test sequences so labels do not need to be removed individually 38452L Rev 3 S Series Maintenance Manual Volume 1 Printer Diagnostics 12345678961234567890 1234567890 1234567896123456789612345678961234567 Figure 3 2 PAUSE Key Self Test Label FEED Key Self Test The CANCEL Key Self Test should be performed prior to this Self Test Information on the printed Configuration Label CANCEL Key Self Test will be used with the results of this self test to determine the best Darkness Setting for a specific media ribbon combination The FEED Key Self Test Label will print out at various PLUS or MINUS darkness settings relative to the darkness value shown on the configuration label Inspect these labels and determine which one has the best darkness setting for the application See the example in Figure 3 3 Relative Darkness 0 Print Speed 2 ZAXMANLSHOAONN TAP IHS 430284 zAxman subdouw Tf 6 sepoqe pd 125456789 ABCDEFGHIJKLMNOPQRSTUVWKYZ abcdefghi jklmnopqrstuvwxyz Figure 3 3 FEED Key Self Test Label 38452L Rev 3 Page 3 5 Printer Diagnostics S Series Maintenance Manual Volume 1 The value print
103. esistance value shown on the label located under the new printhead Connect the Printhead Power Cable to the appropriate connector Spread apart the holding tabs on the sides of the two data connectors and press the appropriate Printhead Data Cable into each connector The Holding Tabs must snap into place around the cable connectors Dress cables completely behind the printhead Carefully position the alignment slots in the new Printhead over the alignment posts on the underside of the mounting bracket refer to Figure 5 2 After ensuring that no cables are between the Printhead and the Printhead Bracket and verifying the Printhead is seated properly carefully tighten the mounting screw If any problems occur during this installation process contact our Technical Support group Refer to Figure 4 1 Use 70 isopropyl alcohol to thoroughly clean the print element brown area of the new Printhead Reinstall media and ribbon Connect the AC Power Cord and turn the printer power ON 38452L Rev 3 Page 5 5 S Series Maintenance Manual Volume 1 Corrective Maintenance DO NOT LOOSEN THESE SCREWS PRINTHEAD MECHANISM ASSEMBLY PRINTHEAD MOUNTING SCREW PRINTHEAD ALIGNMENT PRINTHEAD DATA CONNECTORS POWER CABLE LOCKING TAB PRINTHEAD ALIGNMENT SLOTS PRINTHEAD POWER PRINTHEAD CONNFCIOR Figure 5 2 160S Printhead Replacement Page 5 6 38452L Rev 3 S Series Maintenance Man
104. est Label FEED PAUSE and CANCEL Keys If these three keys are held depressed at the same time and the power is turned ON the printer will enter the Media Sensor and Ribbon Sensor Sensitivity Adjustment Mode See Corrective Maintenance for these adjustments Page 3 6 38452L Rev 3 S Series Maintenance Manual Volume 1 Printer Diagnostics PAUSE Key and CANCEL Key This self test can be used to verify proper printer operation after parts have been replaced or adjusted When activated the printer prints a maximum of 500 Head Test Labels Each label backfeeds prior to printing and feeds forward to the rest position after printing A serialized number will print on each label Press the PAUSE Key or turn the printer power OFF to stop printing Refer to Figure 3 6 FEED Key and CANCEL Key This self test is normally performed during the manufacturing process or after a major overhaul of the mechanical assemblies This test prints seven pre programmed label formats first at Speed D then the same formats at Speed A The printer will automatically pause after each format The sequence of label formats is shown below Refer to Figures 3 7 through 3 13 FORMAT PRINTING TEST FUNCTION E 20 at Speed D Left Ribbon Wrinkle Test 20 at Speed D Right Ribbon Wrinkle Test 20 at Speed D Bar Code Wrinkle Test Code 39 20 at Speed A Left Ribbon Wrinkle Test 20 at Speed A Right Ribbon Wrinkl
105. ft Side 31100M Assembly Membrane Switch Front Panel 31101 Panel Rear PCB Serial 31103 Panel Rear PCB Parallel 31240 Cover Plate with Opening Parallel 31517 Shield High Voltage 31524M PCB Front LED 31646M Circuit Board Power Supply 35040 Door Media Access 38530M PCB Serial Main Logic 38691M PCB Parallel Main Logic 40342 Bracket Front Cover 45039 Panel Left Top 46325 3 Spacer 6 32 N N N N N N OQ AININ L Page 7 6 GROUND TAIL E WASHERS L 2 S Series Maintenance Manual Volume 1 46325 2 31526 38530M SERIAL W 300 DPI HEAD 38691M PARALLEL W 300 DPI HEAD 30240 SERIAL 31240 PARALLEL 31101 SERIAL W 300 DPI HEAD 01159 01912 07696 01155 01152 31103 PARALLEL W 300 DPI HEAD 30391 006 30407 008 30256 09367 01130 07435 01448 T 5 L K J H G F E D CODE 30391 004 30392 004 PART NUMBER P R REW LIST 1055 and 160 Parts Lists 105S 12 Dot mm Final Assembly Page 7 7 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S 12 dot
106. gnification e Slew command 6 dot mm and 12 dot mm printheads only Bar Codes The following bar codes are available Code 11 Code 49 Code 93 e Industrial 2 of 5 Standard 2 of 5 Code 39 Supports ratios of 2 1 3 1 5 2 e Plessey and 7 3 e MSI Code 128 Supports serialization in subsets and and UCC Case C Codes e CODABLOCK and MAXICODE e CODABAR Supports ratios of 2 1 3 1 and s S D 5 2 e UPC A UPC E UPC EXTENSIONS e Interleaved 2 of 5 Supports ratios of 2 1 e PDF 417 and POSTNET 3 1 and 5 2 also supports Modulus 10 Check Digit e Data Matrix 38452L Rev 3 Page 1 3 The S Series System S Series Maintenance Manual Volume 1 Standard Printer Fonts Fonts A B C D E F G H and GS are expandable up to 10 times height and width independent However fonts E and H OCR A and OCR B are not considered in spec when expanded The scalable smooth font CG Triumvirate Bold Condensed is expandable on a dot by dot basis height and width independent while maintaining smooth edges Maximum character size depends on the available memory IBM Code Page 850 international character sets are available in fonts A B C D E F G and through software control FONT A ABCDuxyz 12345 FONT B ABCDWXY2 12345 FONT D AByz 123 FONT E OCR B ABCxyz 123 FONT F ABCDwxyz 12345 FONT C Az4 FONT H UPPER CASE FONT 0 Scalable ABCDwxyz 12345 FONT GS Fi
107. gure 1 1 Sample of Default Fonts Font Matrices for 6 dots mm Printhead 105S 105Se only Matrix Character Size Inches Millimeters Char inch 5 J L D 0 059 25 40 1 50 7 U 0 072 16 93 1 83 10 L D 0 118 12 70 3 00 10 CR B 0 138 11 72 3 50 13 J L D 0 171 9 53 4 33 40 L D 0 394 3 18 10 00 CR A 0 112 10 16 2 83 GS tS character SYMBOL 0 157 6 35 4 00 Default 15 x 12 U L D Scalable U Uppercase L Lowercase D Descenders Page 1 4 38452L Rev 3 S Series Maintenance Manual Volume 1 The S Series System Font Matrices for 8 dots mm Printhead 105S 105Se and 160S Matrix 5 J L D Character Size Inches Millimeters 0 044 Char inch 33 90 7 U 0 054 22 60 10 J L D 0 088 16 95 15 CR B 0 138 10 17 13 J L D 0 128 12 71 40 J L D 0 295 4 24 13 CR A 0 103 10 71 GS SIA r2 tS character 24 SYMBOL 0 118 8 48 Default 15 x 12 U L D Scalable U Uppercase L Lowercase D Descenders J L D Character Size Inches Millimeters 0 029 50 80 U 0 036 33 86 L D 0 059 25 40 CR B 0 138 23 44 J L D 0 185 19 06
108. gure 3 5 Configuration Parameter Controls 38452L Rev 3 S Series Maintenance Manual Volume 1 Printer Diagnostics Extended Printer Diagnostics Additional diagnostic tests are available for printhead assembly adjustments These diagnostics tests are only accessible when the data interface cable is disconnected from the printer and a Loopback Connector is attached in its place The Serial Loopback Connector 15 25 pin D type DB25P Male style with the following pins tied together pins 2 and 3 Solder Side of Connector e pins 20 e pins 13 and 14 e pins 16 and 19 The Parallel Loopback Connector is a standard 36 pin parallel connector mounted to a small circuit board This connector is available from Zebra Technologies as Part 44680 For each of these diagnostic tests the printer will transmit the test label format out of the Data Interface Connector to the Loopback Connector The Loopback Connector passes the test label format back to the printer as receive Data and the test label is printed PAUSE Key Loopback Test This test demonstrates the media movement capabilities of the printer and provides a test label to view while making print quality adjustments With the Loopback Connector in place press the PAUSE Key while turning the AC Power Switch ON After the Power On Self Test the printer will print 500 Head Test labels Each label will backfeed prior to printing and feed t
109. he inner end of the Hook Plate 2 Tighten the Hex nuts reinstall the Rewind Plate Assembly and print several test labels If problems persist readjust the Hook Plate 3 1055 105Se Only If the media cannot be made to track correctly with the previous adjustment check the distance from the outside of the Tracking Plate to the Main Frame This dimension is set at the factory and should be 0 530 13 5 mm to 0 570 14 5 mm If the distance needs to be reset refer to Figure 5 11 and proceed to step 4 below 4 1055 and 105Se Only Use a 1 16 Hex Allen Wrench to loosen the two set screws in the Collar located inside the Rewind Spindle Assembly The screws are accessible through a single hole in the Spindle Assembly as shown in Figure 5 11 Reposition the Spindle Assembly closer to or farther from the Main Frame as required and retighten the two set screws in the collar 5 Repeat steps 1 and 2 until the required results are achieved REWIND PLATE a HOOK PLATE HOOK PLATE OUTER END Figure 5 10 Rewind Plate Assembly 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance 1 16 Hex Allen Wrench Tracking Plate Figure 5 11 105S 105Se Rewind Spindle Positioning Peel Off Mode In Peel Off Mode the Lower Roller alignment has the same effect on media tracking as the Rewind Plate alignment does in Rewind Mode Refer to Figure 5 12 and perform the following proc
110. ies for any other purpose without the expressed written permission of Zebra Technologies Corporation Product Improvements Continuous improvement of products is a policy of Zebra Technologies Corporation All specifications and signs are subject to change without notice FCC Compliance Statement Note This equipment has been tested and found to comply with the limits for a Class A digital Device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual may cause harmful inter ference to radio communications Operation of this equipment in a residential area is likely to cause harmful interfer ence in which case the user will be required to correct the interference at his own expense In order to insure compliance this printer must be used with a Shielded Power Cord and Shielded Communication Cables The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation could void the user s authority to operate the equipment Canadian DOC Compliance Statement This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio interference regulations of the Ca
111. included on S Series printers unless one of these options is installed Refer to Figure 5 9 for the location of the Take Label Sensor pair When a label printed in Peel Off mode breaks the infrared light beam passing between the sensors further printing and feeding is inhibited Additional label formats will be accepted by the printer if the data buffer is not full When the operator removes the label from the sensor path the next label will print There is no sensitivity adjustment for this sensor If you encounter problems make certain the printer is set to Peel Off mode and that the sensor pair are aligned Sensors are aligned when installed No adjustments are required after installation SENSORS Figure 5 9 Take Label Sensor Location 38452L Rev 3 Page 5 19 Corrective Maintenance S Series Maintenance Manual Volume 1 Media Tracking Adjustments Rewind Mode Page 5 20 If the media walks from side to side or if it tears or wrinkles against the Media Rewind Tracking Plate it will be necessary to adjust the Rewind Plate Assembly Refer to Figures 5 10 and 5 11 1 Remove the Rewind Plate Assembly and loosen the 5 16 Hex nuts attaching the Hook Plate to the Rewind Plate Moving the outer end of the Hook Plate up will force the media towards the Rewind Tracking Plate while moving this end down will move the media away from the Tracking Plate The opposite effect will occur if the same adjustments are performed on t
112. into a nearby electrical outlet Part Number AC Power Cable Description 44618 Detachable Power Cord US Standard 3 prong plug 115 VAC 44629 Detachable Power Cord Continental Europe 3 prong plug 230 VAC 44637 Detachable Power Cord British 3 prong plug 230 VAC CEE22 TYPE 5 3 SN NEUTRAL n PLUG CAP FOR EARTH YOUR COUNTRY LIVE Figure 1 2 AC Power Cable Environmental Ranges Operating 41 F to 104 F 5 C to 40 Temperature Storage 40 F to 158 F 40 C to 70 Non condensing Operating 20 to 85 relative humidity Storage 20 to 85 Page 1 6 38452L Rev 3 S Series Maintenance Manual Volume 1 The S Series System Communication Specifications Both serial and parallel data communication interfaces are available for the S Series printers The S Series printer sends and receives standard ASCII American Standard Code for Information Interchange data characters With ZPL i the Error Detection Protocol feature provides virtually error free communications Refer to the user s guide for further information Serial Data Communications Overview The S Series printers have a Data Terminal Equipment DTE port that supports RS 232 serial data communications The RS 232 interface has a standard 25 pin DB25 S connector located at the rear of the printer For all RS 232 input and output signals the S
113. ive Maintenance Main Drive Belt Removal Replacement and Adjustment Turn the printer OFF and remove the AC Power Cord Refer to Figure 5 19 and rotate the Ribbon Take Up Pulley until the three holes in the pulley are aligned with the three mounting screws which hold the Ribbon Take Up Spindle Assembly to the Printer Frame Use a 9 64 Allen wrench to reach through the holes in the Ribbon Take Up Pulley and loosen but do not remove the three Spindle Assembly mounting Screws Slide the Ribbon Take Up Spindle Assembly to the right to relieve the tension on the Main Drive Belt Remove the old Main Drive Belt and install the new one Hook a 2200 gram Spring Scale to the belt as shown in Figure 5 19 and carefully slide the Ribbon Take Up Spindle Assembly to the left to increase belt tension When a scale reading of 2000 grams 250 grams 4 5 108 0 5 165 creates a deflection of 1 47 tighten the three mounting screws to a torque of 20 inch pounds IN SA 21 ACCESS TO MOUNTING SCREWS SPRING Figure 5 19 Drive Belt Replacement 38452L Rev 3 Page 5 31 Corrective Maintenance S Series Maintenance Manual Volume 1 Rewind Drive Belt Removal Replacement and Adjustment Turn the printer OFF and remove the AC Power Cord Refer to Figure 5 20 and note the position of the Idler Gear used to adjust the tension of the
114. ive logic with a HIGH voltage level corresponding to a logic 1 Pin 2 through Pin 9 DO through D7 respectively The ACK output is a 12 microsecond active LOW pulse indicating that the printer is ready to accept data The active LOW state precedes BUSY by 7 microseconds ACK is driven open collector with a 3 3 k internal pull up The output sinks 7 mA to a Vor lt 0 4V The BUSY output is active HIGH whenever the printer cannot accept data due to any normal or abnormal condition including Buffer Overflow Head Open Over Temperature and Media Error conditions BUSY is driven open collector with 3 3 internal pull up The output sinks 7 mA to a VoL lt 0 4V The PAPER OUT signal is active HIGH whenever the printer is out of media or ribbon The SELECT signal function is determined by an additional configuration option which becomes active when the port is present In the default condition SELECT is active HIGH whenever the parallel port is powered up and the parallel port is enabled In the non default condition SELECT will go active LOW whenever the printer is printing 5 VDC Supply provides an output of 5 VDC at a maximum current rating of 50 mA Internal Fuse Protected The ERROR Output Pin 15 is active LOW whenever any error condition is present ERROR is driven open collector with a 3 0 kQ internal pull up The output sinks 7 mA to a VoL lt 0 4V 5 VDC Pull Up provides an output of 5 VDC through an internal 3 0
115. l gap 0 115 3 mm preferred Minimum mark length 3mm 3mm thickness Minimum mark width extending in from the liner or tag stock edge Black mark sensing 3937 10 393 10 mm 203 x 183 x 158 mm 8 0 x 4 5 x 6 2 203 x 114 x 158 mm 8 0 x 7 2 x 6 2 Maximum internal fanfold media pack size L x W x H Page 1 2 38452L Rev 3 S Series Maintenance Manual Volume 1 The S Series System Ribbon Considerations Ribbon Specifications 105S 105Se Ribbon width Maximum 4 5 6 89 To protect the printhead from wear Zebra recommends usin 4 2 Minimum 0 75 2 0 ribbon at least as wide as the media you are using Standard 2 1 media to ribbon roll ratio 984 ft 984 ft lengths 3 1 media to ribbon roll ratio 1476 ft 1476 ft Roll size Inner diameter of core 1 0 1 0 Outside diameter of full ribbon roll 3 27 2 2 Zebra Programming Language ZPL Downloadable graphics Programmable quantity with print pause e Communicates in printable ASCII e Bit image data transfer and printing characters ineluding rong OL text and graphies e Controlled via mainframe mini e Format inversion Zebra Mate or other data entry device Mirror image printing e Serialized fields Four position field rotation e OCR A and OCR B 195905 UPC EAN at nominal 100 ma
116. lanced equal pressure on left and right sides Unacceptable Label Darkness properly set Printhead way too far back Breakup on trailing edges of bars op posite the direction of movement Black is splotchy Printhead needs to come forward on both sides Toggles balanced equal pressure on left and right sides S Series Maintenance Manual NI RI Sr ec TO pm gem e O e wW 4 325228801234567890123455789012345578901234567 89012 4567890 5 A 2 5 7 3 123456783012345678501234567820125 384521 3 Volume 1 i i i i 2 89012 Troubleshooting Unacceptable Label Darkness properly set Printhead position correct on right side way too far back on left side Noisy printing breakup on trailing edges of horizontal bars splotchy on left side Toggles balanced equal pressure on left and right sides Unacceptable Label Darkness Properly Set Printhead Position Correct On Left Side Way Too Far Back On Right Side Noisy Printing Breakup on Trailing Edges of Horizontal Bars Splotchy On Right Side Toggles Balanced Equal Pressure On Left and Right Sides Page 6 9 Troubleshooting S Series Maintenance Manual Volume 1
117. media and ribbon if present 3 Use an applicator moistened with 70 isopropyl alcohol to wipe the print elements from end to end Refer to Figure 4 1 The print elements are the brown strip just behind the chrome strip Allow a few seconds for the solvent to evaporate Rotate the Platen Roller and clean thoroughly with isopropyl alcohol 5 Brush or vacuum any accumulated paper lint and dust away from the rollers and the Media and Ribbon Sensors 6 Reload ribbon and or media close and latch the printhead and continue printing Cleaning the Snap Plate Page 4 2 In the event of a label jam the Media Guide Plate Snap Plate can be removed and cleaned Refer to Figure 4 2 and follow these steps 1 Open the Printhead to its fully open position by rotating the Latching Lever counterclockwise The Printhead pivots to an almost vertical position 2 From the front of the printer pop up the front edge of the Snap Plate using your fingernail or a flat blade screwdriver 3 Liftthe front edge of the Snap Plate while pulling it up and out of the print mechanism 4 Clean the Snap Plate including the raised area directly below the ribbon sensor Remove any stuck labels and use a citrus based cleaner to remove any built up adhesive CAUTION Incorrect installation of the Snap Plate can disable the Ribbon Sensor or cause head pressure imbalance 5 Replace the Snap Plate by placing the back legs in the openings in the Main
118. ment establishes the voltage applied to the print elements during the printing process When adjustment is necessary follow this procedure Page 5 12 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance CAUTION This voltage adjustment is critical to the life of the printhead DO NOT use this adjustment in an attempt to increase the printing darkness or burn temperature Adjustment Procedure Calculate the proper Printhead Voltage using the appropriate formula below The formula to use depends on the type of Printhead used in the printer In the formula R is the Print Element average resistance value as indicated on a label on the Printhead The label can be seen by releasing the Printhead latch moving the ribbon if any to the side and looking up at the underside of the Printhead The charts in this section may be used instead of the formulas 6 dot mm formula V 40 978 x R 0 48 8 dot mm formula V 0 64x R 0 479 12 dot mm formula V 40 4127 x R 0 58 1 Remove the four mounting screws and the Left Side Panel to provide access to the Main Logic Board 2 Locate the Head Voltage Adjustment Potentiometer RV2 below the transformer and filter capacitors on the Power Supply Board 3 1055 and 105Se Only On the Main Logic Board attach a voltmeter between test point TP8 and Ground 8 is located to the left of the DC Power Cable Connector J9 160S Only On the Power Supply Board a
119. nadian Department of Communications Liability Disclaimer Zebra Technologies Corporation takes steps to assure that its published Engineering specifications and Manuals are correct however errors do occur Zebra Technologies Corporation has been advised of the possibility of such dam ages Because some states do not allow the exclusion or limitation of liability for consequential or incidental dam ages the above limitation may not apply to you Copyrights The copyrights in this manual and the label printer described therein are owned by Zebra Technologies Corporation All rights are reserved Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of up to one year and fines of up to 10 000 17 U S C 506 Copyright violators may be subject to civil liability SCAN ONE TRACK ONE Zebra ZPL and ZPL II are registered trademarks and WEDGE ONE is a trademark of Zebra Technologies Corporation Centronics is a registered trademark of Genicom Corporation IBM is a registered trademark of IBM Corporation Windows is a trademark of Microsoft Corporation Zebra Technologies Corporation All rights reserved 38452L Rev 3 1 my Zebra TABLE CONTENTS Maintenance Manual Volume 1 Registration Form Compliance and Copyright Statements THE ZEBRA S SERIES SYSTEM Printer Specifications 55299 ee ed 404 Media
120. nce Manual Volume 1 105Se Parts Lists P O 46609M 2 30392 004 2 lt 40001 105Se Media Rewind Option Assembly Page 8 13 PRINTER MODEL 105Se Cutter Option Assembly PART NUMBER DESCRIPTION QUANTITY 01155 Washer Lock 4 01822 Nut 4 40 02133 E Ring 188 Black 06224 Grommet Rubber 08449 Tiewrap 10421 Screw M4 x 7x5 10427 Screw M4 7 30133 Bearing Ball 375 x 187 125 30196 150 Module Cutter 30198 Bearing 30199 Bearing 30208 Washer Flat 500 x 191 x 030 30210 Washer Flat 564 x 384 x 060 30214 Link Main 30215 Link Slotted 30216 Post Pivot 30217 1 Link Pin 30219 Flag Sensor 30236 Screw 4 40 30313 Clamp Wire Cutter 30380M Assembly Drive Arm 30391 003 Screw 4 40 19 30392 004 Screw 6 32 25 30394 005 Screw 10 32 312 30405 006 Screw 1 4 20 38 30816 Bracket Lower Cutter 31024 Standoff 31181 Guide Upper Cutter 31374M Assembly Cutter Motor 31730M Assembly Cutter Printed Circuit Board 31807 Bracket Upper Cutter 105Se Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105Se Cutter Option Assembly PART NUMBER DESCRIPTION QUANTITY 4
121. nless indicated otherwise turn power OFF before performing maintenance procedures Cleaning the S Series Printer EXTERIOR The exterior surfaces of the S Series printer may be cleaned with a lint free cloth DO NOT use solvents or harsh cleaning agents If the unit is excessively dirty a mild detergent solution or desktop cleaner may be used sparingly 38452L Rev 3 Page 4 1 Preventive Maintenance S Series Maintenance Manual Volume 1 INTERIOR As required remove any dirt lint accumulated in the interior of the printer using a soft bristle brush and or vacuum cleaner It is a good practice to inspect these areas after every fourth roll of media Cleaning the Printhead Inconsistent print quality such as blank areas in the bar codes or graphics may indicate a dirty printhead For optimum performance the printhead should be cleaned regularly When printing in direct thermal mode perform the following cleaning procedure after every roll of media or 500 feet of fanfold media When printing in the thermal transfer mode clean after every roll of ribbon NOTE It is not necessary to turn the printer OFF prior to cleaning All label formats images and parameter settings stored in the printer s memory will be lost if the printer is turned OFF If the printer is turned OFF it may be necessary to reload some items into the printer s memory 1 Open the printhead by moving the Latching Lever to the OPEN position 2 Remove the
122. ns straight by positioning the Media Guide closer to the media Strip Plate needs adjusting Perform adjustments Ribbon Supply Spindle needs cleaning or tension needs adjusting Perform cleaning or adjustments Printhead needs realigning with Platen Roller Perform adjustments Ribbon Take up Spindle needs cleaning or tension needs adjusting Perform cleaning or adjustments Light printing or no printing on the left or right side of the label Printhead pressure needs balancing 38452L Rev 3 Adjust balance See Printhead Pressure Adjustment procedures Page 6 3 S Series Maintenance Manual Volume 1 Troubleshooting Misregistration and skips labels Table 6 2 General Troubleshooting cont d symptom ACTION Misadjusted Media Sensors Perform Media Sensor Adjustments Improper spindle tensions Perform Spindle Adjustments Improper ZPL II format Correct the ZPL format Misregistration and misprint of 1 to 3 labels Media was pulled when motor was not moving Open and close the printhead Printer that is in Peel Off mode was powered ON without media being properly loaded Load media correctly for Peel Off mode Misadjusted Media Sensor Place Media Sensor in the proper position Vertical drift in top of form registration A plus or minus 4 6 dot row approx 1 2 mm vertical drift is possible due to
123. nt Required Multimeter and test leads Anti static mat and anti static wrist strap used when removing electronic circuit boards or updating firmware WARNING Unless indicated otherwise turn printer power OFF before performing maintenance procedures CAUTION To prevent possible damage to or the Main Logic Board please disconnect ALL communications cables before performing maintenance procedures 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance 105S and 105Se Printhead Replacement Refer to Figure 5 1 while performing the following procedure CAUTION Observe proper electrostatic safety precautions when removing handling and replacing the Printhead 10 Turn the printer OFF and remove the Power Cord Remove media and ribbon Properly connect yourself to an anti static protection system Remove the Printhead Pressure Plate and the Static Removal Brush by removing the six 6 Allen head mounting screws Some printers may require the removal of two additional screws that mount the Static Removal Brush Note the location of the grounding strap and carefully hold the printhead and remove the four Phillips screws that hold it to the Mounting Bracket Holding the printhead stable remove the electrical connector mounted at the back of the printhead Remove the old printhead Prior to installing the new printhead note the resistance value shown
124. o the rest position after printing A serialized number will print on each label for label comparison purposes if required See the example in Figure 3 6 The PAUSE Key can be used to stop and restart the printing operation 1234567890123456789012345678901234567890123456789012345678901234567 Figure 3 6 PAUSE Key Loopback Test Label 38452L Rev 3 Page 3 9 Printer Diagnostics S Series Maintenance Manual Volume 1 FEED Key Loopback Test Page 3 10 With the Loopback Connector in place press the FEED Key while turning the AC Power Switch ON After the POST the printer will begin printing a series of label formats as shown in the chart below The printer will PAUSE at the end of each printed format Press the PAUSE Key to begin printing the next format Refer to the label examples in Figures 3 7 through 3 13 The PAUSE Key can be used to stop and restart the printing operation When the printer is paused the CANCEL Key can be used to move to the next label format FORMAT PRINTING TEST FUNCTION 20 at Speed D Left Ribbon Wrinkle Test 20 at Speed D Right Ribbon Wrinkle Test 20 at Speed D Bar Code Wrinkle Test Code 39 20 at Speed A Left Ribbon Wrinkle Test 20 at Speed A Right Ribbon Wrinkle Test 20 at Speed A Bar Code Wrinkle Test Code 39 10 at Speed D Usable Area Test 10 at Speed D Head Temp Test 10 at Speed D Upper Smear Test 10 at Speed D Lower Smear Test 10 at Sp
125. on the test label should be parallel to the top edge of the label within a tolerance of 0 020 4 Ifthe print lines are not parallel with the top of the label proceed to the Printhead Parallelism Adjustment If parallelism is within tolerance proceed to the Wear Plate Position Adjustment Printhead Parallelism Adjustment 1 Using a 7 64 Allen wrench or 7 64 Hex driver loosen the four Allen screws at the top rear of the Print Mechanism 2 Adjust the parallel location of the uppermost lines by turning one of the two Parallelism Adjustment Screws located at the back of the Print Mechanism NOTE Make adjustments in small adjustments a fraction of a turn 3 To move the printhead forward turn the adjustment screw clockwise as viewed from the rear of the printer 4 move the printhead backward turn the adjustment screw counterclockwise as viewed from the rear of the printer 5 Adjust each side as necessary to align the uppermost line of the test label in parallel with the top edge of the label 6 check the results of your adjustments run additional PAUSE Key Self Test labels and check for proper parallelism 7 Tighten the four top Allen screws and run more PAUSE Key Self Test labels to verify proper positioning Page 5 8 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance TOGGLE KNURLED NOTE LOOSEN 4 HEX CAP SCREWS ADJUSTING NUT BEFORE ADJUSTING HEAD WEAR PLATE ADJUSTMENT SCREWS
126. ose the unit in a protective dust proof bag and insure that the unit floats in an outer carton of shock absorbing material A Return Materials Authorization RMA number is required for all equipment being returned Contact Zebra Technologies Corporation s Technical Support Department to obtain an RMA number Equipment returned for service without prior authorization may be refused CAUTION Remove any ribbon and paper rolls from the media compartment otherwise damage to the printer could result DO NOT package the printer in a rigid container without utilizing shockmounts or shock absorbing packing material A rigid container may cause damage to the printer by allowing shock on the outside to be transmitted undamped to the unit 38452L Rev 3 Page 6 11 Troubleshooting S Series Maintenance Manual Volume 1 Page 6 12 38452L Rev 3 7 1055 and 1605 Parts Lists In this section Page Mechanical Parts and Assemblies enses 7 1 Mechanical Parts and Assemblies Listing 7 1 Please note This section contains common parts lists and drawings for both the 105S and 105Se For parts lists drawings specific to the 105Se refer to Section 8 Mechanical Parts and Assemblies MECHANICAL PARTS AND ASSEMBLIES Description Page 105S 6 and 8 Dot mm Final Assembly Page 1 of 2 7 2 7 3 105S 6 and 8 Dot mm Final Assembly Page 2 of 2 7 4 7 5 105 12 Dot mm Final A
127. oval 1 Refer to Figure 5 22 Remove the E ring that attaches the Lower Drive Arm to the Slotted Link Remove the screw that attaches the Mounting Post to the Main Frame 3 Remove the cutter linkage flat washer and bearing from the printer Loosen the two set screws that attach the Lower Drive Arm to the Cutter Motor shaft 5 Pivot the Lower Drive Arm clockwise until the Lower Drive Arm flag disengages the sensor Remove the Lower Drive Arm from the Cutter Motor shaft 7 Disconnect the Cutter Motor Cable from the Cutter Board 8 Remove the motor mounting screws that attach the Cutter Motor to the Main Frame 9 Pull the Cutter Motor away from the Main Frame and the motor cable and Grommet from the slot in the Main Frame Cutter Motor Installation 1 Refer to Figure 5 22 Position the Cutter Motor near the mounting hole on the mechanical side of the printer 2 Pass the Cutter Motor Cable through the slit in the Rubber Grommet Insert the Grommet into the slot located in the lower right area of the motor mounting hole then slide it into the small hole The electrical connector must be positioned on the electronics side of the printer To prevent the wires from coming out rotate the Grommet so the cut is facing away from the motor 3 Position the Cutter Motor against the printer frame so that the screw holes in the motor line up with the holes in the frame with the motor shaft toward the front of the printer 4 Use
128. r Front Panel Calibrate or ZPL Media LED Front Panel Calibrate or ZPL Ribbon LED Front Panel Calibrate or ZPL II Mark LED Front Panel Calibrate or ZPL II Label Length Front Panel Calibrate ZPL Max Label Length ZPL Controlled Print Width ZPL II Controlled Print Mode DIP Switches or ZPL II Controlled Media Type Front Panel Calibrate DIP Switches or ZPL II Print Method Front Panel Calibrate DIP Switches or ZPL II Host Port Firmware Controlled Network Port Firmware Controlled Baud DIP Switches Data Bits DIP Switches Parity DIP Switches Stop Bits Firmware Controlled Handshake Dip Switches Protocol Dip Switches Delimiter ZPL II Controlled Format Prefix ZPL II Controlled Control Prefix ZPL II Controlled Network ID ZPL II Controlled Modes Enabled ZPL II Controlled Modes Disabled ZPL II Controlled Resolution ZPL II Controlled Backfeed ZPL II Controlled Label Top Front Panel Calibrate or ZPL II Left Position ZPL II Controlled Socket 1 ID EPROM Socket 2 ID EPROM Firmware Firmware Controlled Configuration Firmware Controlled Memory B Memory Functioning Memory Firmware Controlled Media Power Up ZPL II Controlled Media Head Close ZPL II Controlled Fi
129. r Print Quality Troubleshooting Table 6 2 General Troubleshooting Cont d DIAGNOSIS Darkness too low ACTION Increase Burn Temp Incorrect Media and Ribbon combination Replace Media or Ribbon Printhead Adjustments incorrect Perform required adjustments Truncated print no print or FEED Key operates incorrectly while using non continuous media Label Length Parameter is set less than the actual label length Set the correct label length Printer was powered ON in Peel Off mode without media being properly loaded Load media correctly for Peel Off mode Printer is not calibrating media properly Perform Media Adjustments Set value with the ASS ZPL II command Long tracks of missing print on several labels Wrinkled ribbon See Wrinkled Ribbon below Print Element damaged Replace printhead Fine gray lines on blank labels at angles Wrinkled ribbon See Wrinkled Ribbon below Wrinkled ribbon Ribbon fed through machine incorrectly Load ribbon correctly Incorrect Darkness setting Set the Darkness to the lowest setting possible for good print quality Incorrect printhead pressure or balance Set the pressure to the minimum needed See Print Quality Adjustment and Printhead Pressure Adjustment procedures Media not feeding properly it is walking from side to side Make sure the media path remai
130. rows not the number of presses of the buttons used for adjustment Press the MODE key twice The PAUSE and POSITION lights turn on Press the UP or DOWN key to adjust the current setting 3 Press the MODE key twice The MODE lights will flast on and off to indicate that the settings have been saved in memory 4 Press PAUSE to exit the PAUSE mode the PAUSE light turns off Nominal factory set tear line location will usually be 00 LABEL MOTION This illustration shows how higher values move the label further out from the printer moves the tear line closer to the leading edge of the next label while lower values move the label into the printer moves the tear line closer to the edge of the printed label Figure 2 8 Tear Off Position Adjustment 38452L Rev 3 S Series Maintenance Manual Volume 1 Getting to Print Adjusting the Position of the Top of the Label 1 Press the MODE key twice then press and hold the MODE key for about five seconds until the lights change PAUSE DARKEN and CALIBRATE lights turn on Press the UP or DOWN key to adjust the current setting 3 Press the MODE key twice The MODE lights will flash on and off to indicate that the settings have been saved in memory 4 Press PAUSE to exit the PAUSE mode the PAUSE light turns off Adjusting the Media Sensor Positions This sensor is not used if Black Mark sensing is selected NOTE If you re using continuous media
131. sembly Page 7 49 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 160S Media Rewind Option Assembly PART NUMBER DESCRIPTION QUANTITY 02252 Ring Crescent 250 2 07435 Screw 6 32 37 30104 Flange Ball Bearing 5 x 250 x 125 30114 Washer Flat 76 x 51 x 03 30115 Washer Save 740 x 520 x 08 30118 Ring E External 500 x 042 30247 Washer Flat 42 x 260 x 0747 30261 Washer Flat 442 x 255 x 020 30265 Pulley Idler 30336 2M Pulley Assembly Media Rewind 30392 004 Screw 6 32 25 30392 006 Screw 6 32 37 30393 006 Screw 8 32 37 30536M Sensor Assembly Take Label Upper 30914M Pulley Assembly Rewind 8 Dots mm 45189 2 Belt Rewind 46001 Shaft Platen 46062 Media Take Up J Hook 46155M Spindle Media Rewind 46383M Assembly Rewind Plate 46609M Page 7 50 Sensor Assembly Take Label Lower 2 2 1 1 1 1 1 1 1 3 1 3 1 1 1 1 1 1 1 1 STEPPER MOTOR PULLEY REF 45189 5 MAIN DRIVE BELT REF NOTE SPACERS MUST BE POSITIONED ON BOTH 510 OF BELT 45189 5 30914M REWIND VERSION S Series Maintenance Manual Volume 1 30536M BLK BLU LEADS 105S and 160S Parts Lists 160S Media Rewind Option Assembly P
132. side the sensor wire cover if the adjustment is far to the outside 5 Replace and tighten the Phillips head screw 6 Make sure the wires are routed back into the groove of the media sensor bracket 7 Replace the printer s left side panel Figure 2 9 Upper Media Sensor Page 2 10 38452L Rev 3 S Series Maintenance Manual Volume 1 Getting to Print Lower Media Sensor Adjustment 1 Locate the lower media sensor assembly under the rear idler roller Figure 2 10 A It is a spring clip holding a circuit board 2 Slide the sensor until the two brass colored infrared emitters are under the upper media sensor Gently pull wires out as needed wires should have a little slack 3 NOTE If the sensor is being moved inward and a large loop of wire develops remove the cover from the electronics side of the printer and gently pull the wires through Clamp the wires so that they do not rub any belts Figure 2 10 Lower Media Sensor 38452L Rev 3 Page 2 11 to Print S Series Maintenance Manual Volume 1 Option Switches These switches are located above the signal interface cable connector See Figure 2 11 In the following tables R means the switch is in the right position while L means the switch is in the left position Refer to Figure 2 12 BANK 2 BANK 2 BANK 1 ONLY ON SERIAL UNITS SIGNAL INTERFACE CABLE CONNECTION 105Se and 160S 105Se and
133. silicone oil new felt pads and silicone oil are available in kit 01688 140 per the following schedule Media Supply and Take Up Spindles once per year or after 500 media rolls of media Ribbon Supply and Ribbon Take Up Spindles once per year or after 200 rolls of ribbon 160S printer DO NOT lubricate these spindles These spindles should only be disassembled and cleaned with alcohol if they fail to rotate smoothly 38452L Rev 3 Page 4 5 Preventive Maintenance S Series Maintenance Manual Volume 1 Page 4 6 38452L Rev 3 Corrective Maintenance In this section Page Tools 5 2 Test Equipment 5 2 1055 and 10556 Printhead Replacement 5 3 160S Printhead 5 5 Printhead And STC 5 7 Printhead Voltage Ac 5 12 Media Sensor Position Adjustment 5 15 Media Sensor and Ribbon Sensor Sensitivity Adjustment 5 17 Take Label Sensor Aligntnent 5 19 Media Tracking Adjustments 5 20 Rewind reri Fr 5 20 Peel Off M de AT ds 5 21 Spindle Adjustment and Maintenance 5 22 Tension Measurement Procedutre 5 22 Spindle Tension Adjustment 5 22 Removing the Adapter Board
134. ssembly Page 1 of 2 7 6 7 7 105S 12 Dot mm Final Assembly Page 2 of 2 7 8 7 9 160S Final Assembly Page 1 of 2 7 10 7 11 160S Final Assembly Page 2 of 2 7 12 7 13 105S and 160S Base Assembly 7 14 7 15 105S Print Mechanism Assembly 7 16 7 17 1605 Print Mechanism Assembly 7 18 7 19 105S 6 and 8 Dot mm Printhead Support Assembly 7 20 7 21 105S 12 Dot mm Printhead Support Assembly 7 22 7 23 160S Printhead Support Assembly 7 24 7 25 105S and 160S Media Guide Assembly 7 26 7 27 105S Ribbon Supply Spindle Assembly 7 28 7 29 160S Ribbon Supply Spindle Assembly 7 30 7 31 1055 Ribbon Take Up Spindle Assembly 7 32 7 33 160S Ribbon Take Up Spindle Assembly 7 34 7 35 105S Peel Off Rewind Spindle Assembly 7 36 7 37 160S Peel Off Rewind Spindle Assembly 7 38 7 39 105S Media Rewind Spindle Assembly 7 40 7 41 1605 Media Rewind Spindle Assembly 7 42 7 43 1055 Peel Off Option Assembly 7 44 7 45 160S Peel Off Option Assembly 7 46 7 47 105S Media Rewind Option Assembly 7 48 7 49 1605 Media Rewind Option Assembl 7 50 7 51 38452L Rev 3 Page 7 1 1055 and 1605 Parts Lists S Series Maintenance Manual Volume 1 PRINTER MODEL 105S 6 dot and 8 dot Final Assembly Page 1 of 2 PART NUMBER DESCRIPTION QUANTITY 01130 Nut 6 32 01152 Washer Flat 375 x 156 x 65 01155 Washer Lock 4 01159 Washer External Lock 6 01448 Screw 6 32 37 01912 Washer External Lock 4 0
135. ter Board CAUTION Eliminate any static electricity by using an anti static wrist strap attached to the printer chassis The printer electronics are susceptible to static discharge Be sure the printer is OFF and the AC Power Cord and Signal Interface Cable are disconnected CAUTION Failure to disconnect power to the printer is a safety hazard and could result in damage to the Printhead 1 Remove the Left Side Panel of the printer by removing the Phillips screws that hold it on 2 Disconnect the Power Supply Cable and the Printhead Cable from the Adapter Board 3 Using a 7 64 Allen Wrench remove the screw holding the Adapter Board to the standoff that is mounted on the printer frame 4 Using a gentle rocking motion remove the Adapter Board from the socket on the Main Logic Board Installing the Adapter Board 105S 300 dpi and all 105Se Insert the Adapter Board into the socket on the Main Logic Board 2 Using 7 64 Allen wrench attach the Adapter Board to the standoff with the mounting screw tighten the screw 3 Attach the Power Supply Cable and the Printhead Cable The Printhead Cable should be routed behind the drive belts and secured to the printer frame with the clips mounted to the frame Reattach the Left Side Panel to the printer 5 Connect the AC Power Cord and Signal Interface Cable Removing the Main Logic and Power Supply Boards The Main Logic Board or Power Supply Board may require
136. ter self tests produce labels at varying print speeds These speeds may be referred to as inches per second millimeters per second or by alphabetic letter designation 1 A etc The following chart shows the relationships between the different speeds Letter Inches Millimeters Designation per Second per Second Speed A for the 105S and 105Se with the optional 300 dots per inch printhead is 2 4 61 mm Page 3 2 38452L Rev 3 S Series Maintenance Manual Volume 1 Printer Diagnostics CANCEL Key Self Test This self test prints a single label which contains a listing of the printer s current configuration parameters stored in Configuration EEPROM Memory Press the CANCEL Key while turning the AC Power Switch ON A sample label is shown in Figure 3 1 The printer configuration may be changed temporarily for specific label formats or ribbon and label stock or permanently by saving the new parameters in EEPROM Memory Saving new parameters occurs whenever a printer configuration procedure is performed Refer to Getting Ready to Print for further details on the Printer Configuration procedure PRINTER CONFIGURATION DARKNESS TEAR OFF PRINT MODE LABEL LENGTH MAXIMUM LENGTH HOST PORT 2 PORT BAUD DATA BITS PARITY P BITS HOST HANDSHAKE PROTOCOL COMMUNICATIONS CONTROL PREFIX FORMAT PREFIX DELIMITER CHAR MEDIA POWER UP M
137. the Upper Cutter Bracket and Nut Plate 3 Loosen the flat head screw that attaches the Upper Cutter Bracket to the Cutter Module Remove the two socket head cap screws from the Lower Cutter Bracket 5 Lift the outer end of the Cutter Module to remove the module Remove the two flat head screws that attach the Media Guide and Upper Cutter Bracket to the Cutter Module 7 Remove the four Phillips head screws that attach the Static Brush Mounting Bracket too the bottom of the Cutter Module Cutter Mechanical Assembly Installation 1 Refer to Figure 5 22 Use the four Phillips head screws to attach the Static Brush Mounting Bracket to the bottom of the Cutter Module 2 Use the two flat head screws to mount the Media Guide and Upper Cutter Bracket to the Cutter Module 3 Carefully work the Cutter Module into position in the Main Frame in front of the Printhead 4 Loosely attach the Upper Cutter Bracket to the Side Plate with the Nut Plate and two socket head cap screws 5 Align the slots in the Lower Cutter Bracket with the threaded holes in the Main Frame Loosely attach the Lower Cutter Bracket with the two socket head cap screws 6 With the Cutter Module loosely installed it is necessary to properly align it and tighten all of the screws Open the Printhead and observe the position of the Tear Off Bar in front of the Platen Roller and the Rear Cutter Blade Position the Cutter Module so that the Rear Cutter Blade is par
138. ttach a voltmeter between the left end of Diode Z3 and ground Diode Z3 is located just to the right of potentiometer RV2 4 Turn the printer ON Adjust RV2 so the voltmeter reading matches the value determined at the beginning of this procedure 6 Turn the printer OFF disconnect the voltmeter leads and replace the printer s Left Side Panel 6 Dot mm Printhead Voltage Table Volts Volts 384521 3 Page 5 13 Corrective Maintenance S Series Maintenance Manual Volume 1 8 Dot mm Printhead Voltage Table 12 Dot mm Printhead Voltage Table Page 5 14 38452L Rev 3 S Series Maintenance Manual Volume 1 Corrective Maintenance Media Sensor Position Adjustment Transmissive Media Sensor The Transmissive Media Sensor contains an upper section and a lower section The upper section senses the infrared light emitted by the components mounted on the lower section The amount of light passing between these two sections determines when either the web between labels or a hole or notch in the media is present This sensing also determines the length of the label or ticket for non continuous media The factory set position should be sufficient for any width label so little or no repositioning should be required when using media with a web If it does
139. ual Volume 1 Corrective Maintenance 18 After completing the Power ON Self Test refer to the Printhead Resistance value noted in Step 11 above and perform the Printhead Voltage Adjustment on pages 5 12 through 5 14 19 After adjusting the printhead voltage activate the PAUSE Key Self Test by pressing the PAUSE Key while turning the printer power on Check print quality 20 The printer should be ready for operation If problems arise refer to Troubleshooting Printhead Adjustments Print Quality Adjustments There are five interrelated adjustments that lead to optimum print quality with increased Printhead life e Printhead Parallelism e Wear Plate Balance Position e Printhead Position e Printhead Pressure e Strip Plate Positioning To achieve optimum print quality install full width media and ribbon in the printer while making the Printhead Adjustments 1 Prior to performing Printhead Adjustments activate the PAUSE Key Self Test by pressing the PAUSE Key while turning the printer power ON 2 Adjust the Toggle Spring s by turning the Knurled Adjusting Nut s so that there is approximately 30 mm 1 2 inches between the bottom of the Knurled Adjusting Nut and the top of the black Toggle Button refer to Figure 5 3 Be sure the toggle is centered over the media 105S 105Se For the 1605 position both toggles so that they are half the distance between the Printhead Attaching Screw and the outside edges of the Printh

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