Zebra 105S, 105SE, 160S Maintenance Manual

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Zebra S-Series

Maintenance Manual

Volume 1: General Maintenance

Zebra Technologies Corporation

333 Corporate Woods Parkway Vernon Hills, IL, US A 60061-3109

Telephone: +1 (847) 634-6700 Fax: +1 (847) 913-8766

Zebra Technologies Europe Limited

Zebra House The Valley Cen tre, Gordan R oad High Wycombe, Buckinghamshire HP13 6EQ, UK

Telephone: +44 (0) 1494 472872 Fax: +44 (0) 1494 450103

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

ii 38452L Rev. 3

TABLEOFCONTENTS

ComplianceandCopyrightStatements ..........i

THEZEBRAS-SERIESSYSTEM

Printer Specifications.....................1-1

MediaHandling......................1-1

PrintingConsiderations..................1-2

MediaConsiderations...................1-2

RibbonConsiderations..................1-3

Zebra Programming LanguageII(ZPLII

BarCodes.........................1-3

Standard Printer Fonts...................1-4

Physical Size.......................1-5

ElectricalRequirements..................1-6

CableRequirements....................1-6

115 VAC Applications..................1-6

230VAC Applications..................1-6

Environmental OperatingRange.............1-6

Communication Specifications................1-7

SerialDataCommunications Overview..........1-7

ParallelDataCommunicationsOverview.........1-9

).......1-3

GETTINGREADYTOPRINT

Controls andIndicators....................2-2

FrontPanelControls...................2-2

FrontPanelLEDs.....................2-3

MediaLoading........................2-4

RibbonLoading........................2-6

MediaCalibration.......................2-7

AdjustingthePrint Darkness.................2-7

AdjustingtheTear-Off Position................2-8

AdjustingthePosition of theTopof theLabel........2-9

AdjustingtheMediaSensor Positions............2-9

Upper MediaSensor....................2-9

Lower MediaSensor..................2-11

OptionSwitches.......................2-12

Bank 1..........................2-13

Bank 2..........................2-14

38452L Rev.3 iii

PRINTERDIAGNOSTICS

Power ON SelfTest......................3-1

Printer SelfTests.......................3-1

CANCELKeySelf Test..................3-3

PAUSEKeySelfTest...................3-4

FEED KeySelf Test....................3-5

MODE KeySelfTest...................3-6

FEED, PAUSEand CANCEL Keys...........3-6

PAUSEKeyand CANCEL Key.............3-7

FEED Keyand CANCELKey..............3-7

FEED Keyand PAUSEKey...............3-7

ExtendedPrinterDiagnostics.................3-9

PAUSEKeyLoopbackTest................3-9

FEED KeyLoopbackTest...............3-10

PREVENTIVEMAINTENANCE

Field MaintenanceFunctions.................4-1

Tools Required........................4-1

CleaningtheS-Seriesprinter.................4-1

CleaningthePrinthead....................4-2

CleaningtheSnapPlate....................4-2

CleaningtheCutterModule..................4-4

Lubricating theCutterModule................4-4

RecommendedPreventiveMaintenanceSchedule......4-5

CORRECTIVEMAINTENANCE

Tools Required........................5-2

TestEquipment Required...................5-2

105SPrintheadReplacement.................5-3

160SPrintheadReplacement.................5-5

Printhead Adjustments....................5-7

PrintQualityAdjustments.................5-7

Printhead Parallelism Adjustment.............5-8

Wear PlatePositionAdjustment..............5-9

Printhead Position Adjustment.............5-10

Printhead PressureAdjustment.............5-11

StripPlateAdjustment.................5-12

Printhead VoltageAdjustment................5-12

AdjustmentProcedure..................5-13

MediaSensor Position Adjustment.............5-15

ReflectiveSensorAdjustment................5-17

MediaSensor andRibbonSensorSensitivityAdjustment.5-17

TakeLabelSensor Alignment................5-19

iv 38452L Rev.3

MediaTrackingAdjustments................5-20

Rewind Mode......................5-20

Peel-Off Mode......................5-21

SpindleAdjustment and Maintenance...........5-22

TensionMeasurement Procedure............5-22

SpindleTensionAdjustment..............5-22

Removing theAdapterBoard................5-24

InstallingtheAdapterBoard................5-24

Removing theMain LogicandPower SupplyBoards...5-24

InstallingtheMainLogic and PowerSupplyBoards....5-28

EPROMSoftwareInstallation................5-29

MainDriveBelt— Removal, Replacement& Adjustment.5-31 Rewind DriveBelt—Removal,Replacement & Adjustment5-32

AC Power FuseReplacement................5-33

BatteryReplacement....................5-34

CutterAdjustmentsand Replacement Instructiions.....5-34

InternalAccess.....................5-35

CutterMotor Removal andInstallation.........5-35

CutterMechanicalAssemblyRemoval and Installation 5-37

Drive Link AssemblyInstallation............5-38

CutterCircuitBoardRemoval and Installation.....5-38

OpticalSensorRemoval andInstallation........5-39

Lower Drive Arm MechanicalAlignment.......5-39

Upper DriveArmAlignment..............5-40

TROUBLESHOOTING

Troubleshooting........................6-1

Power-ON Troubleshooting................6-1

GeneralTroubleshooting.................6-2

CutterModule Troubleshooting..............6-4

SampleLabels.........................6-5

FactoryAssistance.....................6-11

Returning Equipment....................6-11

105Sand160SMECHANICALDRAWINGSandPARTSLISTS

MechanicalPartsand Assemblies...............7-1

105SeMECHANICALDRAWINGSandPARTSLISTS

MechanicalPartsand Assemblies...............8-1

38452L Rev.3 v

vi 38452L Rev. 3

1 TheZebraS-SeriesSystem

Inthissection... Page

PrinterSpecifications.....................................................................1-1

MediaHandling.........................................................................1-1

PrintingConsiderations............................................................1-2

MediaConsiderations...............................................................1-2

RibbonConsiderations.............................................................1-3

ZebraProgrammingLanguageII(ZPLII

BarCodes...................................................................................1-3

StandardPrinterFonts..............................................................1-4

PhysicalSize..............................................................................1-5

ElectricalRequirements...........................................................1-6

CableRequirements..................................................................1-6

115VACApplications..............................................................1-6

230VACApplications..............................................................1-6

EnvironmentalOperatingRange............................................1-6

CommunicationSpecifications.....................................................1-7

SerialDataCommunicationsOverview.................................1-7

ParallelDataCommunicationsOverview.............................1-9

).........................1-3

PrinterSpecifications

Media Handling

• Tear-Offmode:Labelsareproducedinstrips.

• Rewindmode: RequiresMediaRewindoption.Labelsarer ewound

• Peel-Offmode: RequiresPeel-OffoptionorMediaRewindoption.

• Cuttermode RequiresCutterModuleoption(105Seonly).Mediaiscut

internallyontoa3"-inner-diametercardboardcore.

Labelsaredispensedandpeeledfromtheliner.The linercanberewounddirectlyontothespindleusing the“J”Hookorontoa3"-inner-diametercar dboardcore.

afterprinting;undersoftwarecontrol.

38452L Rev.3 Page1-1

-Series Maintenance Manual: Volume 1 TheS-Series System

Ribbon Considerations

Ribbon Specifications 105S/105

Ribbon width

To protect the printhead fromwear, Zebra recommends using ribbon at least as wide as the media you are using.

Standard lengths

Roll size Inner diameter of core 1.0" 25.4 mm 1.0" 25.4 mm

2:1 media to ribbon roll ratio 984 ft 300 m 984 ft 300 m 3:1 media to ribbon roll ratio 1476 ft 450 m 1476 ft 450 m

Outside diameter of full ribbon roll 3.2" 81.2 mm 3.2" 81.2 mm

Maximum 4.5" 114 mm 6.89" 175 mm

Minimum 0.75" 19 mm 2.0" 50.8 mm

160

Zebra Programming Language II (ZPL II®)

• Downloadable graphic s

(with data compression)

• Bit image data transfer and printing,

including mixing of text and graphics

• Format inversion

• Mirror image printing

• Four-position field rotation

(0, 90, 180, 270 degrees)

• Slew command

• Programmable quantity with print pause

• Communicates in p rintable ASCII

characters

• Controlled via m ainframe, mini, PC,

Zebra-Mate or other data-entry device

• Serialized fields

• In-spec OCR-A and OCR-B

• UPC/EAN at nominal 100% magnification

(6 dot/mm and 12 dot/mm printheads only)

Bar Codes

The following bar codes are available:

• Code 11, Code 49, Code 93

• Code 39 (Supports ratios of 2:1, 3:1, 5:2,

and 7:3)

• Code 128 (Supports serialization in subsets B

and C and UCC Case C C o d es )

• CODABAR (Supports ratios of 2:1, 3:1 and

5:2)

• Interleaved 2 of 5 (Supports ratios of 2:1,

3:1 and 5:2; also supports Modulus 10 Check Digit)

• Industrial 2 of 5, Standard 2 of 5

• Plessey

• MSI

• CODABLOCK and MAXICODE

• E/EAN-8, E/EAN-13, EAN EXTENSIONS

• UPC-A, UPC-E, UPC EXTENSIONS

• PDF 417 and POSTNET

• Data Matrix

38452L Rev. 3 Page 1-3

TheS-Series System

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 scal able smooth font Ø (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 Ø through software control.

-Series Maintenance Manual: Volume 1

Figure 1.1 Sample of Default Fonts

Font Matrices for 6 dots/mm Printhead (105S/105Seonly)

Font Matrix Type* Character Size

Inches Millimeters

gap

Height

A 9 5 1 U-L-D 0.059 0.039 25.40 1.50 1.00 1.00 B 11 7 2 U 0.072 0.059 16.93 1.83 1.50 0.67

C, D 18 10 2 U-L-D 0.118 0.079 12.70 3.00 2.00 0.50

E 21 10 3 OCR-B 0.138 0.085 11.72 3.50 2.17 0.46

F 26 13 3 U-L-D 0.171 0.105 9.53 4.33 2.67 0.38 G 60 40 8 U-L-D 0.394 0.315 3.18 10.00 8.00 0.13 H 17 11 4 OCR-A 0.112 0.098 10.16 2.83 2.50 0.40

GS 24 24 0 SYMBOL 0.157 0.157 6.35 4.00 4.00 0.25

Ø Default: 15 x 12 U-L-D Scalable

* U = Uppercase, L = Lowercase, D = Descenders

Page 1-4 38452L Rev. 3

Width

Inter-

character

Height

Width

Char./inch

Height

Width

Char./mm

-Series Maintenance Manual: Volume 1 TheS-Series System

Font Matrices for 8 dots/mm Printhead (105S, 105Seand 160S)

Font Matrix Type* Character Size

Inches Millimeters

gap

Height

A 9 5 1 U-L-D 0.044 0.029 33.90 1.13 0.75 1.33 B 11 7 2 U 0.054 0.044 22.60 1.38 1.13 0.89

C, D 18 10 2 U-L-D 0.088 0.059 16.95 2.25 1.50 0.67

E 28 15 5 OCR-B 0.138 0.098 10.17 3.50 2.50 0.40

F 26 13 3 U-L-D 0.128 0.079 12.71 3.25 2.00 0.50 G 60 40 8 U-L-D 0.295 0.236 4.24 7.50 6.00 0.17 H 21 13 6 OCR-A 0.103 0.093 10.71 2.63 2.38 0.42

GS 24 24 0 SYMBOL 0.118 0.118 8.48 3.00 3.00 0.33

Ø Default: 15 x 12 U-L-D Scalable

* U = Uppercase, L = Lowercase, D = Descenders

Width

Inter-

character

Height

Width

Char./inch

Height

Width

Char./mm

Font Matrices for 12 dots/mm Printhead (105S/105Se)

Font Matrix Type* Character Size

Inches Millimeters

gap

Height

A 9 5 1 U-L-D 0.029 0.016 50.80 0.73 0.40 2.00

B 11 7 2 U 0.036 0.023 33.86 0.91 0.58 1.34

C, D 18 10 2 U-L-D 0.059 0.033 25.40 1.49 0.83 1.00

E 42 20 6 OCR-B 0.138 0.066 23.44 3.50 1.67 0.92

F 26 13 3 U-L-D 0.185 0.042 19.06 2.15 1.06 0.76 G 60 40 8 U-L-D 0.198 0.132 6.36 5.02 3.35 0.26 H 34 22 8 OCR-A 0.112 0.072 20.32 2.84 1.82 0.80

GS 24 24 0 SYMBOL 0.079 0.079 12.70 2.00 2.00 0.50

Ø Default: 15 x 12 U-L-D Scalable

* U = Uppercase, L = Lowercase, D = Descenders

Width

Inter-

character

Height

Width

Char./ inch

Height

Physical Size

Physical

Characteristics 105

/105

160S

Width

Char./mm

Height 15.4" 391 mm 15.4" 391 mm Width 10.5" 267 mm 13.1" 333 mm Depth 18.9" 480 mm 18.9" 480 mm Weight (without options) 43 lbs. 19.5 kg 55 lbs. 24.9 kg

38452L Rev. 3 Page 1-5

TheS-Series System

Electrical Requirements

• 115VAC+15%/−20%or230VAC+15%/−15%,48-62Hz

• 5Amps@115V,3Amps@230V

• UL1950Listed-Certifiedt oCAN/CSA- C22.2No.950-M89

• ClassifiedtoIEC950andComplieswithFCCandCanadianDOCclass“A”rules

• CarriestheCEmarkofcompliance

Cable Requirements

TheACPowerCordhasathree-prongfemaleconnectorononeend.This connectormustbepluggedintothematingcon nectorattherearoftheS-Seri es printer.

115 VAC Applications

AStandardUS-style,three-pronggroundedmaleplugisattachedtotheother endoftheACPowerCord.Thisconnectormustbepluggedintoanearby electricaloutlet.

-Series Maintenance Manual: Volume 1

230 VAC Applications

AnACPowerCordmayormaynotbeincludedwiththeprinter.Forthose locationsthatcannotuseeitherofthethreepowercordslistedbelow,aproper groundedACPowerCordmustbeobtainedandinstalledbytheuser(SeeFigure

1.2).Thecablemustthenbepluggedintoanearbyelectricaloutlet.

Part Number ACPowerCableDescription

44618 Detachable Power Cord(US Standard 3-prongplug -115VAC) 44629 Detachable Power Cord(ContinentalEurope3-prongplug-230VAC) 44637 Detachable Power Cord(British 3-prongplug- 230VAC)

Figure1.2ACPowerCable

Environmental Ranges

Operating +41°Fto +104°F(+5°C to +40°C)

Temperature Non-condensing

relativehumidity

Page1-6 38452L Rev.3

Storage -40°Fto +158°F(-40°Cto +70°C) Operating 20%to 85% Storage 20%to 85%

-Series Maintenance Manual: Volume 1 TheS-Series System

Communication Specifications

Both serial and parallel dat a 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 II communications. Refer to the user’s gui de for further information.

Serial Data Communications Overview

The S-S eries printers have a D ata Terminal Equipment (DTE) port that supports RS-232 serial data communications. The RS-232 interf ace 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-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.

, the Error Det ection Protocol feature provides virtually error-free

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-S eries printers are as follow s:

MARK or OFF = - 7 to - 10 Volts

SPACE or ON = +7 to +10 Volts

Serial Interface Connector Pinout and Description

A D B25-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 pinout s and signal descriptions for the DTE port are as follows:

38452L Rev. 3 Page 1-7

TheS-Series System

Pin No. Serial Data Port Signal Description

1 Frame Ground 2 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.

3 Receive Data: RXD is the serial data input to the Zebra S-Series printer from

the host.

4 Request ToSend: RTS is an output from the Zebra S-Series printer.

It is a constantly active output to the host computer.

6 Data Set Ready: DSR is an input to the Zebra S-Series printer from the host. 7 Signal Ground: Tied to logic ground. This lead serves as the voltage

reference between the two communicating devices.

9 Reserved: For Future Use.

20 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,

21-25

Unterminated: These leads are not used.

-Series Maintenance Manual: Volume 1

COMM PORT

MAX232

+5 V

1 Amp

Figure 1.4 Serial DTE Port Interface

RS-232

1 2 3 4 6 7 9

Frame Ground

RS-23 2

Request To Send Data Set Ready Signal Ground

Reserved for Future Use

Data Terminal Ready

Transmit

Receive

Page 1-8 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 TheS-Series System

Parallel Data Communications Overview

TheS-Seriesprintermayhaveaparalleldatacommunicationsportinsteadofthe previouslymentionedserialdataport.TheParallelInterfacehasastandard 36-pinconnectorlocatedattherearoftheprinter.Inthisdatacommunica tion method,thebitsofdatawhichmakeupeachcharacteraresentallatonetime overseveralwiresinthecable,onebitperwire.

ParallelDataSignalLevels

ParalleldatasignalsaredefinedaseitherHIGHorLOW,whileControlSignals areeitherActiveorInactive.ThedistinctionisduetothefactthatsomeControl SignalsareactiveHIGHwhileothersareactiveLOW.Thevoltagelevelswhich representtheseconditionsare:

DataSignal Voltage Level

HIGH +5VDC

LOW 00 VDC

ParallelInterfaceConnectorPinoutandDescription

Thefollowingchartprovidesadesc riptionofeachofthepinsintheparallel connector.Astandardparalleldatacablewillprovidetherequired interconnectionbetweenthehostandtheS-Seriesprinter.

Pin No. ParallelDataPort Signal Description

1 The

STROBEprinter input has internal3.3kÙpull-upresistorsto 5V (IOL=1.5mA) and is

designed to receive a signaldriven opencollector V

<=0.8V.This pin is a signalfromthe

host computer.Its LOW goingedge willlatch the dataat theeight DATA inputs.Datais non-transparentlylatched soas to avoid hold time requirementsonthe DATA signals. The STROBEinput isdebounced torequirean activewidthgreaterthan 0.5µsecbefore datais latched.

2-9 DATAinputshave TTL input characteristicswith internal3.3k

pullups andrepresent 1TTLunit load orless.The DATAinputs arepositivelogicwith a HIGHvoltagelevel corresponding toa logic1.Pin 2throughPin 9= D0throughD7respectively.

10 The

ACKoutput is a 12microsecondactiveLOWpulse indicating thatthe printer is readyto

accept data. The active LOW state precedesBUSY by7 microseconds.

collector with a 3.3k

internalpull-up.The output sinks 7 mA to a VOL<=0.4V.

ACKis driven open

11 The BUSY output is active HIGHwheneverthe printercannotaccept datadueto any

normalorabnormal condition,includingBufferOverflow,Head Open,Over Temperature, and Media Error conditions.BUSYis driven opencollector with a 3.3k The output sinks 7mAto a V

<=0.4V.

internalpull-up.

12 ThePAPEROUTsignalisactiveHIGHwhenevertheprinterisoutofmediaorribbon. 13 The SELECT signal function is determined byanadditional configuration option which

becomes active when the portispresent. Inthe default condition,SELECT is active HIGH whenever theparallel portis powered upand the parallelportis enabled.Inthe non-default condition, SELECT willgoactive LOW whenever the printeris printing.

18 +5VDC Supplyprovidesan output of +5VDCat a maximum currentrating of 50mA.

(InternalFuse Protected)

32 The

ERROROutput (Pin 15)is active LOW whenever anyerrorconditionis present.

ERRORis driven opencollector witha 3.0kÙinternalpull-up. The output sinks 7mAto a

<=0.4V.

35 +5VDC Pull-Up provides an output of +5VDC throughan internal 3.0k

16,17,19-

SIGNALGROUNDSaretheLogicGroundsandReturnsforallInputandOutpu tsignals.

resistor.

30,33

14,15,31,

NOT USED-Theseleadsshouldbe left unconnected.

34,36

38452L Rev.3 Page1-9

TheS-Series System

-Series Maintenance Manual: Volume 1

Page 1-10 38452L Rev. 3

2 GettingReadytoPrint

Inthissection... Page

ControlsandIndicators..................................................................2-2

FrontPanelControls.................................................................2-2

FrontPanelLEDs......................................................................2-3

MediaLoading.................................................................................2-4

RibbonLoading...............................................................................2-6

MediaCalibration...........................................................................2-7

AdjustingthePrintDarkness........................................................2-7

AdjustingtheTear-OffPosition....................................................2-8

AdjustingthePositionoftheTopoftheLabel..........................2-9

AdjustingtheMediaSensorPositions.........................................2-9

UpperMediaSensor.................................................................2-9

LowerMediaSensor.................................................................2-11

OptionSwitches..............................................................................2-12

Bank1.........................................................................................2-13

Bank2.........................................................................................2-14

ThissectionofthemanualisintendedtosupplementtheUser’sGuideby providingadditionalinformationtoaidtheservicetechnicianin troubleshootingandmaintainingtheprinter.

38452L Rev.3 Page2-1

Getting Ready to Print

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,whichis located at the rear of the printer.

Front Panel Controls

AC Power ON/OFF Switch

Controls appli cation of AC Power t o 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 Ke y 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 onc e the current label is completed.

-Series Maintenance Manual: Volume 1

FEED Key

CANCEL Key

Pressing the PAUSE Key a second time resumes the printing process.

The FEED Key forces the printer to feed one blank label. If the printer is idle (not pri nting) or if the PAUSE function is active when the FEED Key is pressed, one blank label feeds from the pri nter 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 FEED Key again will provide a second blank label.

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 cancel ed. If there are no formats in the printer, the CANCEL Key is ignored. If the CANCEL Key is pressed f or an extended period of time (3 seconds), the printer will perform a “Cancel All Formats” operation.

Figure 2.1 Front Panel Controls

Page 2-2 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 GettingReadytoPrint

MODEKey

TheMODEKeycausestheprintertoentertheConfigurationMode.Inthis Mode,thePrintDarkness,MediaTear-OffPosition,andLabelTopPosition settingscanbeadjusted.

TheMediaCalibrationprocedureisalsoactivatedbytheMODEkey. Refertotheuser’sguidefordetailsontheConfigurationModeandtheMedia

Calibrationprocedures.

Front Panel LEDs

RefertoFigure2.1forthelocationoftheLEDs. NOTE:IfanoperatingconditionwhichcausesanLEDtobeONconstantlyand

onewhichcausesthesameLEDtoflashoccuratthesametime,theLEDwill flash.

LED Name Status Indication

POWER ON Printer isON.The AC Power ON/OFF Switch isintheONposition

and the powercord is connected.

PRINTHEAD OFF Normaloperation.

ON PrintheadOverTemperature condition.Printing stops untilthe

printheadcools down.Printingresumes automatically. PrintheadUnderTemperature condition.Printingcontinues.

Flashing PrintheadOpen.

PAPER/ RIBBON

PAUSE OFF Normaloperation.

DATA OFF Idle, nodatabeing received.

DARKEN ON POSITION ON CALIBRATE ON

OFF Mediaandribbon (if used) are properlyloaded. ON Paper out. Flashing 1.InThermal TransferMode: Ribbon is out.

2.InDirectThermalMode: Ribbon is in the printer.

ON Printer has stopped allprintingoperations.

ON Labelsareprinting. Single

flash Flashing Receiving datafromhost computer. Slow

flashing

TheCANCELkeywas pressed and a format was successfully deleted fromthe print queue.

Printer senta “stoptransmitting data”(X-OFF)commandtothehost computer.

Printer isintheConfiguration Mode.See theModeKeyoperation for moreinformation.

38452L Rev.3 Page2-3

GettingReadytoPrint

MediaLoading

-Series Maintenance Manual: Volume 1

TEAR-OFF

Figure2.2 RollMedia Loading

PEEL-OFF

105Se

TEAR-OFF PEEL-OFF

REWIND CUTTER

REWIND

160S

Figure 2.3 RollMedia LoadingDiagrams

Page2-4 38452L Rev.3

-SeriesMaintenanceManual:Volume1 GettingReadytoPrint

TEAR-OFF

REARSUPPLY

BOTTOMSUPPLY

CUTTER

INTERNALSUPPLY

105Se

Figure2.4 Fanfold MediaLoadingDiagrams

BOTTOMSUPPLY

Figure 2.5 FanfoldMedia LoadingDiagrams (160S)

REARSUPPLY

38452L Rev.3 Page2-5

GettingReadytoPrint

RibbonLoading

-Series Maintenance Manual: Volume 1

Figure 2.6 105Se RibbonLoadingDiagram

Figure 2.7160S RibbonLoadingDiagram

Page2-6 38452L Rev.3

-SeriesMaintenanceManual:Volume1 GettingReadytoPrint

MediaCalibration

IMPORTANT:Performthemediacalibrationprocedurew henmediais firstinstalledorwhenadifferenttypeofmediaorribbonisinstalled.

Duringthisprocedure,theprinterautomaticallydeterminesthemediatype,label length,mediaandribbonsensorsettings,andprintingmethod.

NOTE:Makesurethatthemediaandribbonrollsarepositionedagainstthe innerspindlestops.

1. PresstheMODEkeythreetimes.ThePAUSEandCALIBRATElightsturn

on.

2. PressFEEDtocalibrate.Theprinterfeedssomemedia.TheMODElights

willflashonandofftoindicatethatthesettingshavebeensavedinmemory.

3. PressPAUSEtoexitPAUSEmode;thePAUSElightturnsoff.

AdjustingthePrintDarkness

Duetodifferencesintypesofmedia/ribbonandthewearontheprinthead,it maybenecesarytoadjustthedarknesssetting(burntemperature)ofthe S-Seriesprintheadtoachieveproperprinting.Usethefollowingprocedureto adjustthedarkness;turningtheprinterOFFisnotrequiredforthenewsettingto takeeffect.

CAUTION

Setthedarknesstothelowestpossibleforthedesiredprint

quality.Darknesssettoohighforagivenribbonmaycause

printheaddamage,inksmearing,ribbonwrin kle,and/orburning

throughoftheribbon.

1. Beginprintingabatchoflabels.Useaselftestlabel(seePrinter

Diagnostics)orpreferably,oneofyourownformats.

2. PausetheprintingbypressingthePAUSEkey.

3. PresstheMODEkeyoncetoplacetheprinterin“DarknessAdjustMode.”

TheDARKENlightturnson.

4. PresstheUPorDOWNkeytoadjustthecurrentsetting.

5. PressPAUSEtoressumeprinting;checkthenewsetting.

6. Repeatsteps2through5forfurtheradjustment.

7. Whendarknessiscorrect,pressPAUSEonceandMODEthreetimes.The

MODElightswillflashonandofftoindicatethatthesettingshavebeen savedinmemory.

8. PressPAUSEtoresumeprinting.Monitorthenewsetting,adjustingif

necessary.

38452L Rev.3 Page2-7

TheS-Series System

Printing C onsiderations

-Series Maintenance Manual: Volume 1

Specification 105S/105

Resolution (thermal transfer

or direct thermal)

Dot size (square) 0.00492"

Maximum print width 4.09" (104 mm) 4.09" (104 mm) 4.09" (104 mm) 6.30" (160 mm)

Standard 512 KB

Maximum

print length

Bar code modulus (“X”) 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 printing speeds

Thin film printhead with Energy Control

memory With 1 MG memory 39" (991 mm) 39" (991 mm) 18" (457 mm) 25" (635 mm)

203 dots per inch

(8 dots per mm)

(0.125 mm)

15" (381 mm) 26" (660 mm) N/A 9.5" (241mm)

2" (51 mm), 3" (76 mm), 4" (102 mm), 5" (127 mm), or 6" (152 mm) per second.

The 105S and 105Se with optional 300 dots/inch resolution support

2.4" (61 mm), 3" (76 mm), and 4" (102 mm) per second.

Optional

152 dots per inch

(6 dots per mm)

0.00656"

(0.167 mm)

Optional 300 dots per inch (12 dots per mm)

0.0033" x 0.0039" (0.083 x 0.100 mm)

160

203 dots per inch

(8 dots per mm)

0.00492"

(0.125 mm)

Media Considerations

Media Specifications 105S/105

160

Total media width Maximum 4.5" 114.3 mm 7.2" 182.9 mm

Minimum 0.75" 19.05 mm 2.0" 50.8 mm

Maximum 39" (991 mm) 25" (635 mm)

Tear-Off 0.63" 16.00 mm 0.63" 16.00 mm

Label length

Minimum

Peel-Off 0.50" 12.8 mm 0.50" 12.8 mm

Rewind 0.50" 12.8 mm 0.50" 12.8 mm

Cutter 1.25" 31.75 mm N/A N/A

Total thickness (includes liner)

Maximum

position may need adjustment if thickness is above 0.01")

(Printhead

0.012" 0.304 mm 0.012" 0.304 mm

Minimum 0.0023" 0.058 mm 0.0023" 0.058 mm Core size 3.0" 76.2 mm 3.0" 76.2 mm Maximum roll diameter 8.0" 203 mm 8.0" 203 mm Interlabel gap

(0.115"/3 mm preferred)

Minimum mark length Black mark sensing

(thickness)

Minimum mark width

0.079" -

0.157"

2 mm - 4 mm 0.079" -

0.157"

2 mm - 4 mm

.118” 3 mm .118” 3 mm

.393” 10 mm .393” 10 mm (extending in from the liner or tag stock edge)

Maximum internal fanfold media pack size (L x W x H)

8.0" x 4.5"

x 6.2"

203 x 114 x 158 mm

8.0" x 7.2" x 6.2"

203 x 183 x 158 mm

Page 1-2 38452L Rev. 3

Getting Ready to Print

Adjusting the Tear-Off Position

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 configura tion label reports the actual number of dot rows, not the number of presses of the buttons used for adjustment.

1. Press the MODE key twice. The PAUSE and POSITION lights turn on.

2. 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.

-Series Maintenance Manual: Volume 1

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

Page 2-8 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 GettingReadytoPrint

AdjustingthePositionoftheTopoftheLabel

1. PresstheMODEkeytwice,thenpressandholdt heMODEkeyforabout fiveseconds,untilthelightsc hange.PAUSE,D ARKEN,andCAL IBRATE lightsturnon.

2. PresstheUPorDOWNkeytoadjustthecurrentsetting.

3. PresstheMODEkeytwice.TheMODElightswillflashonandoffto indicatethatthesettingshavebeensavedinmemory.

4. PressPAUSEtoexitthePAUSEmode;thePAUSElightturnsoff.

AdjustingtheMediaSensorPositions

ThissensorisnotusedifBlackMarksens ingisselected. NOTE:Ifyou’reusingcontinuousmedi a,donotperformt hisadjustment.

Leavethemediasensoratthefactory-setposition. Non-continuousmediahasanotchoropeningbetweeneachlabel.Tomonitor

labelmovementyouneedtoalignthemediasensorwiththisnotchoropening. Themediasensorconsistsoftwopartsthatmustbeproperlyalignedwiththe

notchoredgeofthelabel.Thefactory-setpositionshouldbesufficientformost applications.Ifnot,performtheappropriateadjustments.

Adjusting the Upper Media Sensor

Toadjustfortheinsidehalfofthemedia:

1. Removetheribbon.Locatetheuppermediasensor(Figure2.9-A).

2. Loosen,butdonotremove,thePhillipsheadscrew.

3. Slidetheuppersensoralongtheslottoanypositionalongtheweb,except wheretheroundedcornersofthelabelaredetected.Whenusingtagstock, positiontheuppersensordirectlyovertheholeornotch.

4. Tightenthescrew.

38452L Rev.3 Page2-9

Getting Ready to Print

To adjust for the outside half of the media (160S ONLY):

1. R emove the ribbon. Locate the upper media sensor (Figure 2.9-A).

2. R emove the printer’s left side panel and reroute the media sensor cable to provide a dditional slack.

3. R emove 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 aside the sensor wire cover if the adj ustment is far to the outside.

5. Replace and tighten the Phillips head screw.

6. Make sure the wires are routed back into the g roove of the media sensor bracket.

7. Replace the printer ’s left side panel.

-Series Maintenance Manual: Volume 1

Figure 2.9 Upper Media Sensor

Page 2-10 38452L Rev. 3

-Series Maintenance Manual: Volume 1 Getting Ready 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 boa rd.)

2. Slide the sensor until the two brass-colored infrared emitters are under the upper medi a 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

Getting Ready to Print

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.

-Series Maintenance Manual: Volume 1

BANK 2BANK 2

BANK 1

(ONLY ON

SERIAL UNITS)

SIGNAL INTERFACE

CABLE CONNECTION

105 and 160

Se S

PARALLEL

Figure 2.11 Option Switch Locations

105 and 160

Se S

SERIAL

(L)(R)

1 2 3 4 5 6 7 8

Figure 2.12 Option Switches

Page 2-12 38452L Rev. 3

-Series Maintenance Manual: Volume 1 Getting Ready to Print

Bank 1 (Serial interface printers only)

NOTE: Parallel interf ace 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 th ese switches.

Bank 1

Switch

321

R R R 9600 R R L 19200 R L R 110 R L L 300 L R R 600 L R L 1200 L L R 2400 L L L 4800

Switch

R7 L8

Switch

6 5 Parity

R R Even parity R L Parity disabled L R Odd parity L L Parity disabled

Switch

7 Communication Handshake Control

R XON/XOFF control L DTR/DSR control

Switch

8 Error Detection Protocol

R No error detection L Error detection active

(Must be set to 8 data bits for Code Page 850)

Baud Rate

Data Bits

38452L Rev. 3 Page 2-13

Getting Ready to Print

Bank 2

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 t he “R” position and turn the power on. With these disabled, the printer will requi re 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 table. If you a re 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.

Switch

321

R R L Cutter R L L Tear Off L R L Peel Off L L L Rewind

- - R Disabled

Switch

6 5 4 Media Mode

R R L Non-continuous mark sense

R L L Non-continuous web sense

L L L Continuous

- - R Disabled

Switch

8 7 Media Type

R L Thermal transfer L L Direct thermal

- - R Disabled

-Series Maintenance Manual: Volume 1

Bank 2

Print Mode

Page 2-14 38452L Rev. 3

3 PrinterDiagnostics

Inthissection... Page

PowerONSelfTest........................................................................3-1

PrinterSelfTests.............................................................................3-1

CANCELKeySelfTest...........................................................3-3

PAUSEKeySelfTest...............................................................3-4

FEEDKeySelfTest..................................................................3-5

MODEKeySelfTest................................................................3-6

FEED,PAUSEandCANCELKeys.......................................3-6

PAUSEKeyandCANCELKey..............................................3-7

FEEDKeyandCANCELKey................................................3-7

FEEDKeyandPAUSEKey....................................................3-7

ExtendedPrinterDiagnostics........................................................3-9

PAUSEKeyLoopbackTest.....................................................3-9

FEEDKeyLoopbackTest.......................................................3-10

BuiltintotheZebraS-SeriesPrintersa retestroutinestoaidthetechnicianin diagnosingfaults.

Power ONSelfTest

APowerONSelfTest(POST)isperformedeachtimetheprinteristurnedON. Thistestchecksforproperinitializationofvariouselectroniccircuitsand establishesstartingparametersasthosestoredintheprinter’smemory.During thistestsequence,thefrontpanelLEDswillturnONandOFFtoinsureproper operation.

Attheendofthisselftest,onlythePOWERLEDwillremainlit.IfotherLEDs remainlit,refertoTroubleshootinginthismanual.

PrinterSelf Tests

Theseselftestsproducesamplelabelsandprovidespecificinformationwhich helpsdeterminetheoperatingconditionsfortheprinter.

Eachselftestisenabledwhenafr ontpanelkeyispressedwhilethepri nter’s ACPowerSwitchisturnedON.KeepthekeypresseduntilthefrontpanelLEDs turnON.

WhenthePowerOnSelfTestiscompleted,theselectedprinterselftestwill startautomatically.

38452L Rev.3 Page3-1

Printer Diagnostics

NOTES: It is r ecommended that full width media be used when performing these t ests. Labels less than full w idth in size will lose printing on the right side. Label length will determine the amount of pr inting starting at the top of th e label.

When performi ng these self tests while in the Peel-Off Mode, the operator must remove t he labels as they become available.

When canceling a self test prior to its actual completion, always turn the printer power O FF and then back ON to reset the printer.

Some of the printer 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 (i.e., “A,” “B,” “C,” etc.). The following chart shows the relationships between the different speeds.

-Series Maintenance Manual: Volume 1

Letter

Designation

A* 2" 51 mm B3"76mm C 4" 102 mm

D 6" 152 mm

* S peed “A” for the 105S and 105Se with the optional 300 dots-per-inch printhead is 2.4" (61 mm).

Inches

per Second

5" 127 mm

Millimeters

per Second

Page 3-2 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 PrinterDiagnostics

CANCEL Key Self Test

Thisselftestprintsasinglelabelwhichcontainsalistingoftheprinter’scurrent configurationparametersstoredinConfiguration(EEPROM)Memory.Pressthe CANCELKeywhileturningtheACPowerSwitchON.Asamplelabelisshown inFigure3.1.

Theprinterconfigurationmaybechangedtemporarilyforspecificlabelformats orribbonandlabelstock,orpermanentlybysavingthenewparametersin EEPROMMemory.Savingnewparametersoccurswheneveraprinter configurationprocedureisperformed.RefertoGettingReadytoPrintfor furtherdetailsonthePrinterConfigurationprocedure.

Figure 3.1 CANCELKey Self Test Label

38452L Rev.3 Page3-3

PrinterDiagnostics

PAUSE Key Self Test

EnterthisselftestmodebypressingthePAUSEKeywhileturningtheAC powerON.

Thisselftestconsistsofeightseparatetestsequences,printinglabelsatboth Speed“A”andSpeed“D”(“C”forthe300-dpi105Sand105Se).Duringthe firstfourtestsequences,theprintersimulatesthe“Tear-Off”modeand backfeedsthemediapriortoprintingeachlabel.Duringthelastfourtest sequences,theprintersimulatesthe“Rewind”modeanddoesnotbackfeedthe media.

Thisselftestcanbeusedtoprintthetestlabelsrequiredwhenmaking adjustmentstotheprinter’smechanicalassemblies.Thesetestlabelscanalso beprintedwhenrequiredduringtheConfigurationandCalibrationprocesses describedinGettingReadytoPrint.SeethelabelexampleinFigure3.2.

NOTE:IftheTakeLabelSensorpairismountedonthefrontoftheprinter, “PEELOPTIONINSTALLED”willbeprintedonthefirstlabel.Duringthefirst fourtestsequences,eachlabelmustbemanuallyremovedfromthesensorpath beforethenextlabelwillprint.Duringtestsequencesfivethrougheight,the TakeLabelSensorpairisnotenabledandcontinuousprintingoccurs.

-Series Maintenance Manual: Volume 1

Tobypassthefirstfoursequences,pressthePAUSEKey;thentearoffthefirst printedlabel.Oncethelabelisremoved,theprinterwillenterthePAUSEmode.

PresstheCANCELKeyfourtimesandmakesuretheDataLEDflashesonce eachtime.PressthePAUSEKeyoncetostarttestsequencefive.

1. Theinitialtestsequenceprints15labelsatspeed“A”thenautomatically PAUSEStheprinter.Another15la belsequencewillstartifthePA USEKey ispressedtopermitprinting .

2. WhiletheprinterisPAUSED,presstheCANCELKeyoncetoselectthe secondselftestsequence.NoweachtimethePAUSEKeyispressed,the printerprints15labelsatspeed“D”(“C”forthe300-dpi105Sand105Se). Another15labelsequencewillstartifthePAUSEKeyispressedtopermit printing.

3. WhiletheprinterisPAUSED,presstheCANCELKeyoncetoselectthe thirdselftestsequence.NoweachtimethePAUSEKeyispressed,the printerprints50labelsatspeed“A”.Another50labelsequencewillstartif thePAUSEKeyispressedtopermitprinting.

4. WhiletheprinterisPAUSED,presstheCANCELKeyoncetoselectthe fourthselftestsequence.NoweachtimethePAUSEKeyispressed,the printerprints50labelsatspeed“D”(“C”forthe300-dpi105Sand105Se). Another50labelsequencewillstartifthePAUSEKeyispressedtopermit printing.

5. SelfTestsequencesfivethrougheightarethesameassequencesone throughfourbutsimulatethe“Rewind”modeofoperationbynot backfeedingatthebeginningofeachlabel.Inaddition,theTakeLabel Sensorpairisdisabledduringthesetestsequencessolabelsdonotneedto beremovedindividually.

Page3-4 38452L Rev.3

-Series Maintenance Manual: Volume 1 Printer Diagnostics

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 t he application. See the example in Figure 3.3.

Figure 3.3 FEED Key Self Test Label

38452L Rev. 3 Page 3-5

PrinterDiagnostics

Thevalueprintedonthatlabelisaddedto(plus)orsubtractedfrom(minus)the “Darkness”valuespecifiedontheConfigurationLabel.

Theresultingnumericvalue(0to30)ist hebestdarknessvalueforthatspec ific media/ribboncombination.

ThevalueselectedcanbeenteredwhileperformingaMediaDarkness Adjustment.ThePLUSvaluecanbeenteredbypressingtheUP(FEED)Key, whiletheMINUSvalueisenteredbypressingtheDOWN(CANCEL)Keythe appropriatenumberoftimes.RefertotheCalibrationprocessesdescribedin

GettingReadytoPrint.

Optionally,therequiredrelativedarknessvaluecanbeprogrammedintothe ZPLIIlabelformatssenttotheprinter.

MODE Key Self Test

ThisselftestplacestheprinterintheCommunicationsDiagnosticsMode. PresstheMODEKeywhileturningtheACpowerswitchON,thensendalabel

formattotheprinter.Inthismode,theprinterprintstheASCIIcharactersand theircorrespondinghexadecimalvaluesforanydatareceivedfromthehost computer.SeetheexampleinFigure3.4.

-Series Maintenance Manual: Volume 1

NOTE:Turntheprinter’spowerOFFtoexitthisselftest.

Figure3.4MODEKeySelfTestLabel

FEED, PAUSE, and CANCEL Keys

Ifthesethreekeysarehelddepressedatthesametimeandthepoweristurned ON,theprinterwillentertheMediaSensorandR ibbonSensorSensi tivity AdjustmentMode.SeeCorrectiveMaintenancefortheseadjustments.

Page3-6 38452L Rev.3

-SeriesMaintenanceManual:Volume1 PrinterDiagnostics

PAUSE Key and CANCEL Key

Thisselftestcanbeusedtoverifyproperprinteroperationafterpartshavebeen replacedoradjusted.Whenactivated,theprinterprintsamaximumof500Head TestLabels.Eachlabelbackfeedspriortoprintingandfeedsforwardtotherest positionafterprinting.Aserializednumberwillprintoneachlabel.Pressthe PAUSEKeyorturntheprinterp owerOFFtostopprint ing.RefertoFigure3 .6.

FEED Key and CANCEL Key

Thisselftestisnormallyperformedduringthemanufacturingprocessoraftera majoroverhaulofthemechanicalassemblies.Thistestprintsseven pre-programmedlabelformats,firstatSpeed“D,”thenthesameformatsat Speed“A.”Theprinterwillautomaticallypauseaftereachformat.Thesequence oflabelformatsisshownbelow.RefertoFigures3.7through3.13.

FORMAT PRINTING TEST FUNCTION

1 20atSpeed D LeftRibbonWrinkle Test 2 20atSpeed D RightRibbon WrinkleTest 3 20atSpeed D Bar CodeWrinkleTest(Code-39) 4 20atSpeed A LeftRibbonWrinkle Test 5 20atSpeed A RightRibbon WrinkleTest 6 20atSpeed A Bar CodeWrinkleTest(Code-39) 7 10atSpeed D UsableArea Test 8 10atSpeed D Head TemperatureTest

9 10atSpeed D UpperSmear Test 10 10atSpeed D Lower SmearTest 11 10atSpeed A UsableArea Test 12 10atSpeed A Head TemperatureTest 13 10atSpeed A UpperSmear Test 14 10atSpeed A Lower SmearTest

FEED Key and PAUSE Key

Pressingthesetwokeysatthesametime,whileturningthepowerON, temporarilyresetstheprinterconfigurationtothefactorydefaultvalues.These valueswillbeactiveuntilpoweristurnedOFF.Ifthefactorydefaultconditions aretobeusedonapermanentbasis,savethembypressingtheMODEKeyfour times-MODELEDscycleONthenOFF.AMediaCalibrationprocedure

mustbeperformedafterfactorydefaultvalu esaresaved.Figure3.5

indicateswhichprinterfunctioncontrolseachoftheconfigurationparameters.

38452L Rev.3 Page3-7

Printer Diagnostics

Parameter Controlled By

Darkness Front Panel Adjustment or ZPL II Tear Off Adjust Front Panel Adjustment Web Sensor Front Panel Calibrate or ZPL II Media Sensor Front Panel Calibrate or ZPL II Ribbon Sensor Front Panel Calibrate or ZPL II Mark Media Sensor DIP Switches or ZPL II Mark Sensor Front Panel Calibrate or ZPL II Media LED Front Panel Calibrate or ZPL II Ribbon LED Front Panel Calibrate or ZPL II Mark LED Front Panel Calibrate or ZPL II Label Length Front Panel Calibrate or ZPL II Max Label Length ZPL II 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 Functioning Memory B: Memory Firmware Controlled Media Power Up ZPL II Controlled Media Head Close ZPL II Controlled

-Series Maintenance Manual: Volume 1

Figure 3.5 Configuration Parameter Controls

Page 3-8 38452L Rev. 3

-Series Maintenance Manual: Volume 1 Printer Diagnostics

Extended Printer Diagnostics

Additional diagnostic tests are available for printhead assembly adjustments. These diagnost ics tests are only accessible when the data interface cable is disconnected fr om the printer and a Loopback Connector i s attached in its place.

The Serial Loopback Connector is a 25-pin “D” type (DB25P-Male ) style with the following pins tied together.

• pins 2 and 3

• pins 6 and 20

• pins 13 and 14

• pins 16 and 19

The Par allel 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 C onnector 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 t est 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 label s. Each label will backfeed prior to printing and feed to the rest position after printing.

A s erialized 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.

Figure 3.6 PAUSE Key Loopback Test Label

38452L Rev. 3 Page 3-9

Printer Diagnostics

FEED Key Loopback Test

With the Loopback Connector in place, press the F EED 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. R efer 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 p aused, the CANCEL Key can be used to move to the next label format.

FORMAT PRINTING TEST FUNCTION

1 20 at Speed D* Left Ribbon Wrinkle Test 2 20 at Speed D* Right Ribbon Wrinkle Test 3 20 at Speed D* Bar Code Wrinkle Test (Code-39) 4 20 at Speed A Left Ribbon Wrinkle Test 5 20 at Speed A Right Ribbon Wrinkle Test 6 20 at Speed A Bar Code Wrinkle Test (Code-39) 7 10 at Speed D* Usable Area Test 8 10 at Speed D* Head Temp Test

9 10 at Speed D* Upper Smear Test 10 10 at Speed D* Lower Smear Test 11 10 at Speed A Usable Area Test 12 10 at Speed A Head Temp Test 13 10 at Speed A Upper Smear Test 14 10 at Speed A Lower Smear Test

-Series Maintenance Manual: Volume 1

* “C ” for the 105S and 105Se with the 300 dots/inch printhead

Figure 3.7 Format 1 (8) Test Label

Page 3-10 38452L Rev. 3

-Series Maintenance Manual: Volume 1 Printer Diagnostics

Figure 3.8 Format 2 (9) Test Label

Figure 3.9 Format 3 (10) Test Label

Figure 3.10 Format 4 (11) Test Label

38452L Rev. 3 Page 3-11

Printer Diagnostics

-Series Maintenance Manual: Volume 1

Figure 3.11 Format 5 (12) Test Label

Figure 3.12 Format 6 (13) Test Label

Figure 3.13 Format 7 (14) Test Label

Page 3-12 38452L Rev. 3

4 PreventiveMaintenance

Inthissection... Page

FieldMaintenanceFunctions........................................................4-1

ToolsRequired.................................................................................4-1

CleaningtheS-SeriesPrinter........................................................4-1

CleaningthePrinthead...................................................................4-2

CleaningtheSnapPlate.................................................................4-2

CleaningtheCutterModule..........................................................4-4

LubricatingtheCutterModule......................................................4-4

RecommendedPreventiveMaintenanceSchedule.....................4-5

FieldMaintenanceFunctions

FieldmaintenancefunctionsfortheZebraS-Seriesprintercanbedivide dinto twobasiccategories.

• Thissectionofthemanualcontainspreventivemaintenanceproceduresand

operatorcareinstructions.Preventivemaintenanceconsistsofavisual inspectionandgeneralcleaningoftheinteriorandexterioroftheunitand printhead.Theseproceduresmaybeperformedbytheoperatorandshould beperformedonaregularbasis.

• Correctivemaintenance,describedinCorrectiveMaintenance,provides

detailedstepsforresolvingfaults.Repairsareaccomplishedbyreplacement ofcomponentsormodulesorbyadjustments.

ToolsRequired

Toproperlyperformthepreventivemaintenancetasks,theservicetechnician shouldbeequippedwiththefoll owing:

• Applicators

• 70%isopropylalcohol

• Citrus-basedcleaner

Unlessindicatedotherwise,turnpowerOFFbefore

performingmaintenanceprocedures.

CleaningtheS-SeriesPrinter

EXTERIOR—TheexteriorsurfacesoftheS-Seriesprintermaybecl eaned withalint-freecloth.DONOTusesolventsorharshcleaningagents.Iftheunit isexcessivelydirty,amilddetergentsolutionordesktopcleanermaybeused sparingly.

WARNING

38452L Rev.3 Page4-1

PreventiveMaintenance

INTERIOR—Asrequired,removeanydirt/lintaccumulatedintheinteriorof theprinterusingasoftbristlebrushand/orvacuumcleaner.Itisagoodpractice toinspecttheseareasaftereveryfourthrollofmedia.

CleaningthePrinthead

Inconsistentprintqualitysuchasblankareasinthebarcodesorgraphicsmay indicateadirtyprinthead.Foroptimumperformance,theprintheadshouldbe cleanedregularly.Whenprintingindirectthermalmode,performthefollowing cleaningprocedureaftereveryrollofmedia(or500feetoffanfoldmedia). Whenprintinginthethermaltransfermode,cleanaftereveryrollofribbon.

NOTE:ItisnotnecessarytoturntheprinterOFFpriortocleaning.Alllabel formats,images,andparametersettingsstoredintheprinter’smemorywillbe lostiftheprinteristurnedOFF.IftheprinteristurnedOFF,itmaybenecessary toreloadsomeitemsintotheprinter’smemory.

1. OpentheprintheadbymovingtheLatchingLevertotheOPENposition.

2. Removethemediaandribbon(ifpresent).

3. Useanapplicatormoistenedwith70%isopropylalcoholtowipetheprint elementsfromendtoend.(RefertoFigure4.1.Theprintelementsarethe brownstripjustbehindthechromestrip.)Allowafewsecondsforthe solventtoevaporate.

4. RotatethePlatenRollerandcleanthoroughlywithisopropylalcohol.

5. Brushorvacuumanyaccumulatedpaperlintanddustawayfromtherollers andtheMediaandRibbonSensors.

6. Reloadribbonand/ormedia,closeandlatchtheprinthead,andcontinue printing.

-Series Maintenance Manual: Volume 1

CleaningtheSnapPlate

Intheeventofalabeljam,theMediaGuidePlate(SnapPlate)canberemoved andcleaned.RefertoFigure4.2andfollowthesesteps.

1. OpenthePrintheadtoitsfullyopenpositionbyrotatingtheLatchingLever counterclockwise.ThePrintheadpivotstoanalmostverticalposition.

2. Fromthefrontoftheprinter,po pupthefrontedgeo ftheSnapPlateusing yourfingernailoraflat-bladescrewdriver.

3. LiftthefrontedgeoftheSnapPlatewhilepullingitupandoutoftheprint mechanism.

4. CleantheSnapPlate,includingtheraisedareadirectlybelowtheribbon sensor.Removeanystucklabelsanduseacitrus-basedcleanertoremove anybuilt-upadhesive.

IncorrectinstallationoftheSnapPlatecandisablethe

5. ReplacetheSnapPlatebyplacingthebacklegsintheopeningsintheMain MediaGuidewhileslidingittotherearoftheopeningsandsnappingit downintoplace.RefertoFigure4.2.

CAUTION

RibbonSensororcauseheadpressureimbalance.

Page4-2 38452L Rev.3

-SeriesMaintenanceManual:Volume1 PreventiveMaintenance

PRINTHEAD

RIBBON

SENSOR

LABEL

AVAILABLE

SENSORS

PLATEN

ROLLER

Figure4.1PrintheadCleaning

PEEL/TEAR

BAR

SNAP

PLATE

Figure4.2SnapPlateCleaning

38452L Rev.3 Page4-3

Preventive Maintenance

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.

-Series Maintenance Manual: Volume 1

Figure 4.3 Cutter Blade Cleaning

Lubricating the Cutter Module

Certain applications or types of label stock may cause the cutter blades to eventually st art to squeak. This commonly occurs when less-than-full width media is being used.

To eli minate 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 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

-SeriesMaintenanceManual:Volume1 PreventiveMaintenance

RecommendedPreventiveMaintenanceSchedule

AREA METHOD INTERVAL

PRINTHEAD Isopropyl alcohol When printinginthedirect

PLATEN ROLLER Isopropyl alcohol

MEDIASENSOR Airblow

MEDIA PATH Isopropyl alcoholandcloth

RIBBON SENSOR Airblow

PEELROLLER Isopropyl alcohol Once per month

LABELAVAILABLE

SENSOR

RIBBONFEEDING PATH Visual Once per three months

DRIVE BELTS Visual Six monthsor500rolls

CUTTER BLADES Citrus-based cleanerand/or air

Formalpreventivemaintenance is not required onthese spindles. Spindletension should notbe adjustedunless the printer ismalfunctioning(i.e.,spindlesnot rotating

MEDIA TAKE UPSPINDLE

smoothly).Therecommendedtensionsandadjustment procedures are provided inCorrectiveMaintenance.

Airblow Once per six months

blow

thermalmode:after everyroll ofmedia (or500feet of fanfold media).

When printinginthethermal transfer mode:after everyroll ofribbon.

As needed

RIBBONSUPPLY SPINDLE

RIBBONTAKE UPSPINDLE

105Sand105Seprinters:Thespindles should be taken apart and the felt pads replaced with new ones presoaked in silicone oil (new feltpads and silicone oil are availablein kit #01688-140)per the followingschedule:

Media SupplyandTake-Up Spindles - once per yearor after500media rollsof media

Ribbon Supplyand Ribbon Take-Up Spindles-once per yearorafter 200rolls of ribbon.

160Sprinter:

Thesespindles should onlybe disassembled andcleaned with alcoholiftheyfail torotate smoothly.

DONOTlubricatethesespindles.

38452L Rev.3 Page4-5

Preventive Maintenance

-Series Maintenance Manual: Volume 1

Page 4-6 38452L Rev. 3

5 CorrectiveMaintenance

Inthissection... Page

ToolsRequired.................................................................................5-2

TestEquipmentRequired...............................................................5-2

105Sand105SePrintheadReplacement.....................................5-3

160SPrintheadReplacement.........................................................5-5

PrintheadAdjustments...................................................................5-7

PrintheadVoltageAdjustment.......................................................5-12

MediaSensorPositionAdjustment..............................................5-15

MediaSensorandRibbonSensorSensitivityAdjustment.......5-17

TakeLabelSensorAlignment.......................................................5-19

MediaTrackingAdjustments........................................................5-20

RewindMode.............................................................................5-20

Peel-OffMode...........................................................................5-21

SpindleAdjustmentandMaintenance.........................................5-22

TensionMeasurementProcedure............................................5-22

SpindleTensionAdjustment...................................................5-22

RemovingtheAdapterBoard........................................................5-24

InstallingtheAdapterBoard.........................................................5-24

RemovingtheMainLogicandPowerSupplyBoards..............5-24

InstallingtheMainLogicandPowerSupplyBoards................5-28

EPROMSoftwareInstallation.......................................................5-29

MainDriveBelt-Removal,ReplacementandAdjustment.....5-31

RewindDriveBelt-Removal,ReplacementandAdjustment.....5-32

ACPowerFuseReplacement........................................................5-33

BatteryReplacement.......................................................................5-34

CutterAdjustmentsandReplacementInstructions....................5-34

PrinterDisassembly..................................................................5-34

InternalAccess..........................................................................5-35

CutterMotorRemoval..............................................................5-35

CutterMotorInstallation.........................................................5-35

CutterMechanicalAssemblyRemoval..................................5-37

CutterMechanicalAssemblyInstallation.............................5-37

DriveLinkAssemblyInstallation..........................................5-38

CutterCircuitBoardRemoval................................................5-38

CutterCircuitBoardInstallation............................................5-38

OpticalSensorRemoval...........................................................5-39

OpticalSensorInstallation......................................................5-39

LowerDriveArmMechanicalAlignment.............................5-39

UpperDriveArmAlignment...................................................5-40

38452L Rev.3 Page5-1

Corrective Maintena nce

When a problem is encountered with the S-Ser ies printer, the service technician should first insure the unit is being used properly, then exercise i t to localize the fault. Onc e localized, refer to the appr opriate replacement or adjustment procedure t o correct the fault.

Tools Required

Screwdriver, flat blade, 1/4", 1/8" x 8", and 3/16" x 3" Screwdriver, Phillips #1, #1 extended r each, and #2 Pliers, long-nose, small needle nose, utility, snap ring Set of inch combination (open end/box end) w renches (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", 7/6 4"

extended r each (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 0–1,000gSpringScale 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 w ith Clip-On Leads

-Series Maintenance Manual: Volume 1

Test Equipment 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 main tenance procedures.

CAUTION

To prevent possible damage to EPR OMs or the Main Logic

Board, please disconnect ALL communications cables before

performing maintenance procedures.

Page 5-2 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

105Sand 105

RefertoFigure5.1whileperformingthefollowingprocedure.

1. TurntheprinterOFFandremovethePowerCord.

2. Removemediaandribbon.

3. Properlyconnectyourselftoananti-staticprotectionsystem.

4. RemovethePrintheadPressurePlateandtheStaticRemovalBrushby

5. Notethelocationofthegroundingstrap,andcarefullyholdtheprinthead

6. Holdingtheprintheadstable,removetheelectricalconnectormountedat

7. Removetheoldprinthead.

8. Priortoinstallingthenewprinthead,notetheresistancevalueshown

9. Reconnecttheelectricalconnectortothenewprinthead.

10.Fitthenewprintheadintothemountingbracket.

Printhead Replacement

CAUTION

Observeproperelectrostaticsafetyprecautionswhenremoving,

handling,andreplacingthePrinthead.

removingthesix(6)Allenheadmountingscrews.(Someprintersmay requiretheremovaloftwoadditionalscrewsthatmounttheStaticRemoval Brush.)

andremovethefourPhillipsscrewsthatholdittotheMountingBracket.

thebackoftheprinthead.

onthelabellocatedunderthenewprint head.

CAUTION

Ensurethatthegroundingstrapisreattachedbytheprinthead

mountingscrew.

11.LooselyinstallthefourPhillipsscrewsthroughthePrintheadBracketand

thePrinthead’saluminumbody.

12.AfterverifyingthePrintheadisseatedproperly(PrintheadBracketGuide

Pinsarefittedintotheguideholesonthe12dots/mmPrinthead),tighten thePhillipsheadmountingscrews.

13.ReinstallthePressurePlateandStaticRemovalBrushwiththemounting

screws.

14.UsethePreventiveMaintenanceKittocleanthenewprintheadthoroughly.

15.Reinstallmediaandribbon.

16.ConnecttheACPowerCordandturntheprinterpowerON.

17.AftertheprintercompletesthePowerOnSelfTest,refertothePrinthead

Resistancevalue(notedinStep8above)andperformthePrintheadVoltage Adjustmentonpages5-12through5-14.

18.PressthePAUSEKeywhileturningtheprinterpowerON,andcheckthe

printqualityofthetestlabels.

38452L Rev.3 Page5-3

Corrective Maintena nce

PRESSURE

PLATE

MOUNTING

SCREWS

PRINTHEAD

PRESSURE

PLATE

GROUNDING

STRAP

PRINTHEAD MOUNTING

SCREWS

-Series Maintenance Manual: Volume 1

STATIC

REMOVAL

BRUSH

PRINTHEAD

BRACKET

GUIDE PINS

(12 DOT/MM ONLY)

PRINTHEAD

GUIDE HOLES

PEM STUDS

(6 DOT/MM

8 DOT/MM ONLY)

Figure 5.1 105S/105Se Printhead Replacement

Page 5-4 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

160SPrintheadReplacement

RefertoFigure5.2whileperformingthefollowingprocedure.

CAUTION

ObserveproperElectrostaticSafetyPrecautionswhenremoving,

handlingandreplacingthePrinthead.

1. TurntheprinterOFFandremovethePowerCord.

2. OpenthePrintheadAssemblyandremovethemediaandribbon;thenclose

thePrintheadAssembly.

3. Properlyconnectyourselftoananti-staticprotectionsystem.

4. LocatetheSpring-loadedPrintheadMountingScrewontopofthePrintheadAssembly.

5. LoosentheMountingScrewuntilitdisengagesfr omthePrinthead.

CAUTION

Usecaretominimizeanyphysicaldamagetothe Printheadduringtheremainderofthisprocedure.

6. SlowlyopenthePrintheadAssembly.ThePrintheadwillberestingonthe

PlatenwhiletherestoftheAssemblypivotsback.

7. SpreadaparttheholdingtabsonthesidesofthePrintheadDataConnectors

toreleasetheDataCables.

8. GrasptheoutsideedgesofthePrintheadPowerCableConnectorandpress

downonthePowerCableLockingTab.

9. Whilemaintainingpressureonthelockingtab,disconnectthePrinthead

PowerCableandremovethePrintheadthroughthefrontoftheprinter.

10.Priortoinstallingthenewprinthead,notetheresistancevalueshown

onthelabellocatedunderthenewprint head.

11.ConnectthePrintheadPowerCabletotheappropriateconnector.

12.Spreadaparttheholdingtabsonthesidesofthetwodataconnectorsand

presstheappropriatePr intheadDataCableint oeachconnector.T he HoldingTabsmust“snap”intoplacearoundthecableconnectors.Dress cablescompletelybehindtheprint head.

13.CarefullypositionthealignmentslotsinthenewPrintheadoverthe

alignmentpostsontheundersideofthemountingbracket(referto

Figure5.2).

14.AfterensuringthatnocablesarebetweenthePrintheadandthePrinthead

BracketandverifyingthePrintheadisseatedproperly,carefullytightenthe mountingscrew.(Ifanyproblemsoccurduringthisinstallationprocess,contact

ourTechnicalSupportgroup.)

15.RefertoFigure4.1.Use70%isopropylalcoholtothoroughlycleantheprint

element(brownarea)ofthenewPrinthead.

16.Reinstallmediaandribbon.

17.ConnecttheACPowerCordandturntheprinterpowerON.

38452L Rev.3 Page5-5

Corrective Maintena nce

PRINTHEAD

MECHANISM

ASSEMBLY

PRINTHEAD

MOUNTING

SCREW

-Series Maintenance Manual: Volume 1

DO NOT LOOSEN

THESE SCREWS!!

PRINTHEAD

DATA

CONNECTORS

PRINTHEAD ALIGNMENT

SLOTS

PRINTHEAD

PRINTHEAD ALIGNMENT

POSTS

POWER CABLE

LOCKING TAB

PRINTHEAD

POWER

CONNECTOR

Figure 5.2 160S Printhead Replacement

Page 5-6 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

18.AftercompletingthePowerONSelfTest,refertothePrintheadResistance

value(notedinStep11above)andperformthePrintheadVoltage Adjustmentonpages5-12through5-14.

19.Afteradjustingtheprintheadvoltage,activatethePAUSEKeySelfTestby

pressingthePAUSEKeywhileturningtheprinterpoweron.Checkprint quality.

20.Theprintershouldbereadyforoperation.Ifproblemsarise,referto

Troubleshooting.

PrintheadAdjustments

Print Quality Adjustments

Therearefiveinterrelatedadjustmentsthatleadtooptimumprintqualitywith increasedPrintheadlife:

• PrintheadParallelism

• WearPlate(Balance)Position

• PrintheadPosition

• PrintheadPressure

• StripPlatePositioning

Toachieveoptimumprintquality,installfull-widthmediaandribboninthe printerwhilemakingthePrintheadAdjustments.

1. PriortoperformingPrintheadAdjustments,activatethePAUSEKeySelf

TestbypressingthePAUSEKeywhil eturningtheprinterpo werON.

2. AdjusttheToggleSpring(s)byturningtheKnurledAdjustingNut(s)sothat

thereisapproximately30mm(1.2inches)betweenthebottomofthe KnurledAdjustingNutandthetopoftheblackToggleButton(referto Figure5.3).Besurethetoggleiscenteredoverthemedia(105S/105Se).

Forthe160S,positionbothtoggle ssothattheyarehalfthedist ance betweenthePrintheadAttachingScrewandtheoutsideedgesofthe Printhead.

NOTES:Theorderinwhichtheadjustmentsareperformeddependsontheprint qualityofthelabelsprintedduringthePAUSETest(see“SampleLabels”in

Troubleshooting).

ThefirsttwoPrintheadAdjustments(ParallelismandWearPlate)mustbe completedpriortoattemptingtolocatetheoptimumprintposition.Aswiththe otheradjustments,ParallelismandWearPlateadjustmentsareinter related. Adjustingonemayhaveaneffectonthepositionoftheother.

Excessiveprintheadpressurewillleadtoincreasedprintheadwearand decreasedprintheadlife.

Increasedprintheadlifeispossiblebycombin ingminimumtogglepressureand optimumprintheadpositionoverthePlatenRoller.

38452L Rev.3 Page5-7

CorrectiveMaintenance

Printhead Parallelism Adjustment

ThisadjustmentisperformedinconjunctionwiththeWearPlatePosition, PrintheadPosition,andPrintheadPressureAdjustments.

Adjustingtheprintheadparallelismsquarestheprintheadinreferencetothemedia. RefertoFigure5.3forlocationofadjustmentscrewsusedinthefollowing

procedures.

PrintheadParallelismTest

1. Priortostartingthistest,insuretheinstalledmediais“squared”withthe Tear-OffBar.

2. WhentheprinterbeginsprintingPAUSEKeySelfTestlabels,referto

GettingReadytoPrintandadjusttheDarknessforaclearpresentationof

alllinesonthetestlabel.

3. Theuppermostlineonthetestlabelshouldbeparalleltothetopedgeofthe labelwithinatoleranceof0.02 0".

4. Iftheprintlinesarenotparallelwiththetopofthelabel,proceedtothe PrintheadParallelismAdjustment.Ifparallelismiswithintolerance, proceedtotheWearPlatePositionAdjustment.

-Series Maintenance Manual: Volume 1

PrintheadParallelismAdjustment

1. Usinga7/64"Allenwrenchor7/64"Hexdriver,loosenthefourAllen screwsatthetoprearofthePrintMechanism.

2. Adjusttheparallellocationoftheuppermostlinesbyturningoneofthetwo ParallelismAdjustmentScrewslocatedatthebackofthePrintMechanism.

NOTE:Makeadjustmentsinsmalladjustm ents(afractionofaturn).

3. Tomovetheprintheadforward,turntheadjustmentscrewclockwiseas viewedfromtherearoftheprinter.

4. Tomovetheprintheadbackward,turntheadjustme ntscrew counterclockwiseasviewedfromtherearoftheprinter.

5. Adjusteachsideasnecessarytoaligntheuppermostlineofthetestlabelin parallelwiththetopedgeofthelabel.

6. Tochecktheresultsofyouradjustments,runadditionalPAUSEKeySelf Testlabelsandcheckforproperparallelism.

7. TightenthefourtopAllenscrewsandrunmorePAUSEKeySelfTestlabels toverifyproperpositioni ng.

Page5-8 38452L Rev.3

-Series Maintenance Manual: Volume 1 Corrective Maintenance

TOGGLE KNURLED

ADJUSTING NUT

WEAR PLATE

ADJUSTMENT

SCREWS

STRIP

PLATE

NOTE: LOOSEN 4 HEX CAP SCREWS

BEFORE ADJUSTING HEAD

30 mm

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 Print head and platen roller.

Refer t o Figure 5.3 for the location of t he adjustment screws used in the following procedure.

1. Position both Toggles (160S) so that they are half the dista nce 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 b ottom of the Knurled Adjusti ng Nut and the top of the black Toggle Button.

Using a 3/32

″ Allen wrench o r 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. As 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

CorrectiveMaintenance

7. Iflighterornoprintingisobservedononesideofthelabelascompared withtheother,continuewiththisadjustment.

Usinga7/64

″Allenwrench,slightlyloosenthetwoAllensetscrews

mountedontheWearPlate.

9. ContinuetoprintPAUSETestlabelswhileadjustingtheWearPlate Eccentricforevenprinting.

10.

AdjusttheWearPlateEccentricbyturningitbyhand,orwitha7/16

endwrench,orwithapairofutilityp liers.

11.AdjusttheWearPlateEccentricuntiluniformprintdensityisachieved acrossthelabel.

12.Whenevenprintqualityisachieved,holdtheWearPlateinpositionand tightenthetwoWearPlateSetScrews.

13.ContinuetoprintPAUSETestlabelsandverifythatparallelismiscorrect.

14.Ifparallelismisoutoftolerance,performthePrintheadParallelism Adjustment.

15.Ifnootheradjustmentisrequired,followtheStripPlateAdjustment Procedurefoundlaterinthissection,andtightenthetwoAllenscrews.

Printhead P osition Adjustment

-Series Maintenance Manual: Volume 1

″open

ThisadjustmentisperformedinconjunctionwiththePrintheadParallelism, WearPlatePosition,andPrintheadPressureAdjustments.

AdjustingthePrintheadpositionalignstheheadforoptimumprintquality. RefertoFigure5.3forlocationofadjustmentscrewsusedinthefollowing

procedure.

1. Thethermalelementsoftheprintheadshouldbealignedjustbehindthe crestofthePlatenRoller.

2. PrinttestlabelsusingthePAUSEKeySelfTest.

3. Usinga7/64"Allenwrench,loosenthefourAllenscrewsatthetoprearof thePrintMechanism.

4. PositionbothToggles(160S)sothattheyar ehalfthedistancebetweenthe PrintheadAttachingScrewandtheoutsideedgesofthePrinthead.Forthe 105S/105Se,makesuretheToggleiscenteredoverthemedia.

5. SettheDarknesstoachievetheoptimumprintquality.

CAUTION

Instep6,topreventprintheaddamage,loosenthefourtop

screwsbeforeturningthetworearadjustmentscrews.

6. Adjusttheprintheadpositionforoptimumprintqualitybyequallyturning thetwoParallelismAdjustmentScrewslocatedatthebackoftheprint mechanism.

Page5-10 38452L Rev.3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

7. Adjustmentsaremadeinverysmallincrements.

TurnbothParallelismAdjustmentScrewsoneeighthturnclockwiseand observethechangesinprintquality.(Duetospringpressure,theremaybe adeadspotintheactualprintheadmovementwhenswitchingadjustments fromonedirectiontotheother.)

8. DecreasetheBurnTemperatureuntilthePAUSETestlabelsareachar coal graycolor.

9. CarefullylookatthePAUSETestlabelsforstreaks,flouring,andother printqualityproblems.

10.Ifrequired,adjustthehexheadscrewsandobserveifprintqualityproblems arecorrected.

11.IncreaseBurnTemperatureuntilthePAUSETestlabelsareprintedat optimumresolutionandcontrast.

12.SincePrintheadparallelism,WearPlateposition,andPrintheadpositionare interrelated,carefullylookatthetestlabelsforchangesinthesesettings andadjustifnecessary.

Printhead Pressure Adjustment

PrintheadPressureisthefourthofthefourinterr elatedadjustments.Usinglower PrintheadPressureandDarknesssettingscanextendprintheadlife.Ifprintingis toolightononesideorifathickmediaisused,printheadpressuremayrequire adjustment.

RefertoFigure5.4forthelocationo fthePressureTog gleforthe105Sand 105Seprinters.Thistoggleshouldbeposit ionedoverthecenteroft hemedia width.The160Sprinterhastwotoggl es.Thesetogglesaretyp icallypositioned atthe1/4and3/4positionsacrossthewidthofthemedia.Ifnarrowmediais usedonthe160S,theinsidetogglesho uldbecenteredabovet hemediaandthe pressureoftheoutsidetoggleshouldbereducedtozero.

1. PrintPAUSEKeySelfTestlabelstochec kprintquality.

2. Toincreaseprintheadpressure,loosent heUpperKnurledNutontheToggle andadjusttheLowerToggl eAdjustingNutdo wnwards.

3. Todecreaseprintheadpressure,loo sentheUpperKnu rledNutandadjust theLowerToggleAdjustingNutupwards.

4. Adjustprintheadpressureforoptimumprintquality.

5. Tolock-inprintheadpressure,tightentheUpperKnurledNutagainstthe LowerToggleAdjustingNut.

6. Thoughdifferentmediaandribboncom binationsmayrequired ifferent Togglesettings,asuggestedinitialdistancebetweenthebottomofthe LowerToggleAdjustingNutandthetopoftheblackToggleButtonis approximately30mm.

7. AdjustBurnTemperaturetotheoptimumlevelfortheinstalledmedia.

38452L Rev.3 Page5-11

CorrectiveMaintenance

-Series Maintenance Manual: Volume 1

TOGGLE

ADJUSTING

NUT

Figure 5.4 Printhead PressureAdjustment

Strip Plate Adjustment

TheStripPlateisaveryimportantpartoftheprintheadadjustmentprocedure. TheStripPlatecanbeadjustedforpropertrackingandseparationoftheribbon

fromthemediaafterprinting.

1. PrintPAUSEKeySelfTestlabels.

2. PressthePAUSEKeyand,aftertheprinterpauses,observetheribbonfor possibleproblems(wrinkling,etc.).

3. RefertoFigure5.3,andloosenthetwoAllenscrewsholdingtheStripPlate tothefrontofthePrintheadAssembly.

4. WhilerunningthePAUSEKeySelfTest,lowertheStripPlatesotheribbon isflatandsmoothandtracksproperlytotheRibbonTake-upSpindle.

5. TightentheStripPlateAllenscrewsandprintaminimumoftwenty-five labels.Checkforribbonwrinkle,track ing,andnoiseproblems.I fribbon wrinkleand/ortrackingproblemspersist,checkthetorquesettingsofthe RibbonSupplySpindleandadjusttensionifreq uired.

PrintheadVoltageAdjustment

Whenaprintheadortheprinter’spowersupplyisreplaced,theprint head Voltagemustbeadjustedforthepropervalue.T hisadjustmentestablishesthe voltageappliedtotheprintelementsduringtheprintingprocess.When adjustmentisnecessary,followthisprocedure:

Page5-12 38452L Rev.3

-Series Maintenance Manual: Volume 1 Corrective Maintenance

CAUTION

This voltage adjustment is critical to the life of the

printhead.

to increase the printing darkness or burn temperature.

DO NOT use this adjustment in an attempt

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 P rint 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:

8 dot/mm formula:

12 dot/mm formula:

1. Remove the four mounting scr ews 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. (105S and 105Se Only) On the Main Logic Board, attach a voltmeter between test point TP8 and Ground. TP8 is located to the left of the DC Power Cable Connector J9. (160S Only) On the Power Supply Board, at tach a voltmeter between the left end of Diode Z3 and ground. Diode Z3 is located just t o the right of potent iometer RV2.

4. Turn the printer ON.

5. Adjust RV2 so the voltmeter reading matches the value determi ned at the beginning of this procedure.

6. Turn the printer OFF, disconnect the voltmeter leads, and replace the printer’s Left Side Panel.

VR=×+0978 048..

VR=×+064 0479..

VR=×+04127 058..

6 Dot/mm Printhead Voltage Table

Ω Volts Ω Volts Ω Volts

315 18 355 19.1 395 20.1 320 18.2 360 19.2 400 20.3 325 18.3 365 19.4 405 20.4 330 18.4 370 19.5 410 20.5 335 18.6 375 19.6 415 20.6 340 18.7 380 19.8 420 20.7 345 18.8 385 19.9 425 20.9 350 19 390 20

38452L Rev. 3 Page 5-13

Corrective Maintena nce

8 Dot/mm Printhead Voltage Table

-Series Maintenance Manual: Volume 1

105Se/

Ω 105S

Volts Volts Volts Volts Volts Volts

535 19.0 18.95 600 20.1 20.04 665 21.1 21.07 540 19.1 19.04 605 20.2 20.12 670 21.2 21.14 545 19.2 19.12 610 20.2 20.20 675 21.3 21.22 550 19.2 19.21 615 20.3 20.28 680 21.3 21.30 555 19.3 19.29 620 20.4 20.36 685 21.4 21.37 560 19.4 19.38 625 20.5 20.44 690 21.5 21.45 565 19.5 19.46 630 20.6 20.52 695 21.6 21.52 570 19.6 19.54 635 20.6 20.60 700 21.6 21.60 575 19.7 19.63 640 20.7 20.68 705 21.7 21.67 580 19.7 19.71 645 20.8 20.76 710 21.8 21.75 585 19.8 19.79 650 20.9 20.83 715 21.9 21.82 590 19.9 19.88 655 21.0 20.91 720 21.9 21.90

Ω Volts Ω Volts Ω Volts

810 18.86 910 19.96 1010 21.00 815 18.92 915 20.01 1015 21.05 820 18.98 920 20.07 1020 21.10 825 19.03 925 20.12 1025 21.15 830 19.09 930 20.17 1030 21.20 835 19.14 935 20.22 1035 21.25 840 19.20 940 20.28 1040 21.30 845 19.25 945 20.33 1045 21.35 850 19.31 950 20.38 1050 21.40 855 19.36 955 20.43 1055 21.45 860 19.42 960 20.48 1060 21.50 865 19.47 965 20.54 1065 21.54 870 19.53 970 20.59 1070 21.59 875 19.58 975 20.64 1075 21.64 880 19.64 980 20.69 1080 21.69 885 19.69 985 20.74 1085 21.74 890 19.75 990 20.79 1090 21.79 895 19.80 995 20.84 1095 21.84 900 19.85 1000 20.90 1100 21.89 905 19.91 1005 20.95

160S Ω 105S

12 Dot/mm Printhead Voltage Table

105Se/

160S Ω 105S

105Se/

160S

Page 5-14 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

MediaSensorPositionAdjustment

Transmissive Media Sensor

TheTransmissiveMediaSensorcontainsanuppersectionandalowersection. Theuppersectionsensestheinfraredlightemittedbythecomponentsmounted onthelowersection.Theamountoflightpassingbetweenthesetwosections determineswheneitherthe“web”betweenlabelsoraholeornotchinthemedia ispresent.Thissensingalsodeterminesthelengthofthelabelorticketfor non-continuousmedia.

Thefactory-setpositionshouldbesufficientforanywidthlabel,solittleorno repositioningshouldberequiredwhenusingmediawithaweb.Ifitdoes becomenecessarytorepositiontheTransmissiveMediaSensor,performthe UpperSectionAdjustmentfirstfollowedbytheLowerSectionAdjustment.

UpperSectionAdjustment

ToadjusttheuppersectionoftheTransmissiveMediaSensorfortheinsidehalf ofthemediawidth,refertoFigures5.5and5.6andfollowthesesteps:

1. RemovetheribbonandlocatetheuppersectionoftheMediaSensor.

2. Loosenthemountingscrewholdingthissectioninposition.

3. Slidetheuppersectionalongtheslottoanypositionalongtheweb,except wheretheroundedcornersofthelabelaredetected.(Whenusingtagstock, positiontheuppersectiondirectlyovertheholeornotch.)

4. Tightenthemountingscrew.

(160SONLY)ToadjusttheuppersectionoftheTransmissiveMediaSensorfor theoutsidehalfofthemediawidth,refertoFigure5.6andtheillustrationon

page7-13andfollowthesest eps:

1. RemovetheribbonandlocatetheuppersectionoftheMediaSensor.

2. Removetheprinter’sleftsidepanelandreroutethemediasensorcableto provideadditionalslack.

3. Removethemountingscrewtoreleasetheuppersectionofthesensorand thewirecover.

4. Carefullypullthewiresthroughthetiewrapasyourepositionthesensor andthewirecovertotheoutsidehalfofthemountingbracket.

5. Replaceandtightenthemountingscrew;thenreplacetheprint er’sleftside panel.

LowerSectionAdjustment

ToadjustthelowersectionoftheTransmissiveMediaSensor,referto

Figure5.7andfollowthesesteps:

1. LocatethelowersectionoftheTransmissiveMediaSensor(aspringclip holdingaprintedcircuitboard)undertheRearIdlerRoller.

2. Slidethelowersectionofthesensoracrossitsmountingrailuntilthetwo brasscoloredinfraredemittersarecenteredundertheuppersection.

3. Gentlypullwiresoutfromtheframeasrequired.(Wiresshouldhavea littleslack.)

NOTE:Ifthelowersectionisbeingmovedinwardandalargeloopofwire results,removetheprinter’sleftsidepanelandgentlypullthewiresthrough.It isimportantthatthewiresbepositionedawayfromthedrivebeltsandpulleys.

38452L Rev.3 Page5-15

Corrective Maintena nce

Figure 5.5 105S and 105Se Transmissive Sensor (Upper)

-Series Maintenance Manual: Volume 1

UPPER

MEDIA SENSOR

ADJUSTMENT

Figure 5.6 160S Transmissive Sensor (Upper)

Figure 5.7 Transmissive Sensor Lower Section

Page 5-16 38452L Rev. 3

-Series Maintenance Manual: Volume 1 Corrective Maintenance

Reflective Media Sensor Adjustment

The R eflective 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, the upper secti on 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 o n 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 necessar y. The exception is when media with e xceptionally thick or thin backing mate rial is being used in the printer.

Perform t he following procedure if the Paper/Ribbon LED comes ON when: a. In the thermal transfer printing mode, media and ribbon are properly installed

b. In the direct thermal printing mode, media only is properly installed.

Sensitivity Adjustment Procedure

1. Turn the printer OFF.

2. Raise the Media Cover and open the Printhead.

3. Load at least 12 inches of blank backing materi al (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 a s far to the right as possible wi ll have the same effect as removing it.)

5. Close the Printhead.

6. Press the Pause, Feed, and Cancel keys while turning the printer ON. Once the pri nter is ON, re lease all three keys.

The foll owing 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 is flickering, it indicates that the adjustment was not successful. Go back to step 1 and start over.

38452L Rev. 3 Page 5-17

CorrectiveMaintenance

7. OpenthePrintheadandpullthemediathroughtheprinteruntilalabelis positionedbetweentheupperandlowersectionso ftheTransmissiveMedia Sensor.Movetheribbonbacktoitsnormalposition.

8. ClosethePrintheadandpresstheMODEkeytocompletetheautomatic adjustmentprocess.AMediaSensorProfilewillautomaticallyprintand thenewsensorsettingswillbeautomaticallysaved.(SeeFigure5.8)

9. PerformtheMediaCalibrationpr ocedurelocatedinG ettingReadytoPr int.

-Series Maintenance Manual: Volume 1

Figure 5.8Media Sensor Profile SampleLabel

Page5-18 38452L Rev.3

-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 Opt ion or the Backing Only Rewind Option must be installed. The Take Label Sensor pair 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 P eel-Off mode breaks the infr ared light beam passing between the sensors, further printing and feeding is inhibited. Additional label formats will be accept ed by the printer i f 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 adj ustment for this sensor. If you encounter problems, make certain the p rinter is set to Peel-Off mode and that the sensor pair are aligned. Sensors are aligned when installed. No adjustments are required after installation.

is not

TAKE

LABEL

SENSORS

Figure 5.9 Take Label Sensor Location

38452L Rev. 3 Page 5-19

CorrectiveMaintenance

MediaTrackingAdjustments

Rewind Mode

Ifthemediawalksfromsidetoside,orifittearsorwrinklesagainstthe MediaRewindTrackingPlate,itwillbenecessarytoadjusttheRewindPlate Assembly.RefertoFigures5.1 0and5.11.

1. RemovetheRewindPlateAssemblyandloosenthe5/16”Hexnuts attachingtheHookPlatetotheRewindPlate.Movingtheouterendofthe HookPlateupwillforcethemediatowardstheRewindTrackingPlate whilemovingthisenddownwillmovethemediaawayfromtheTracking Plate.(Theoppositeeffectwilloccurifthesameadjustmentsarepe rformed ontheinnerendoftheHookPlate.)

2. TightentheHexnuts,reinstalltheR ewindPlateAss embly,andprintsever al testlabels.Ifproblemspersist,readjusttheHookPlate.

3. (105Sand105SeOnly)Ifthemediacannotbemadetotrackcorrectlywith thepreviousadjustment,checkthedistancefromtheoutsideoftheTracking PlatetotheMainFrame.Th isdimensionisse tatthefactoryands houldbe

0.530"(13.5mm)to0.570"(14.5mm).Ifthedist anceneedstobereset, refertoFigure5.11andproceedtostep4below.

4. (105Sand105SeOnly)Usea1/16"HexAllenWrenchtoloosenthetw o setscrewsintheCollar(locatedinsidetheRewindSpindleAssembly).The screwsareaccessiblethroughasingleholeintheSpindleAssembly,as showninFigure5.11.Reposi tiontheSpindleA ssemblyclosertoorf arther fromtheMainFrameasrequired,andretightenthetwosetscrewsinthe collar.

5. Repeatsteps1and2untiltherequiredresultsareachieved.

-Series Maintenance Manual: Volume 1

HOOKPLATE OUTEREND

Figure5.10RewindPlateAssembly

Page5-20 38452L Rev.3

REWINDPLATE

HOOKPLATE

HEXNUTS

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

Figure5.11105S/105SeRewindSpindlePositioning

Peel-Off Mode

In“Peel-OffMode”,theLowerRolleralignmenthasthesameeffectonmedia trackingastheRewindPlatealignmentdoesin“RewindMode”.Referto Figure5.12andperformthef ollowingprocedure.

Usea7/64″HexAllenwrenchtoloosenthe(2)Allenscrewsthatattachthe PlatenSupportBrackettotheSidePlate.

2. Movingthebrackettowardthefrontofthemachinemovesthelabelbacking materialawayfromtheRewindTrackingPlate.Movingthebrackettoward therearofthemachinemovesthelabelbackingtowardthetrackingplate. AdjustthebracketpositionasrequiredandtightentheAllenscrews.

3. Printseverallabelsandrepeatst eps1and2untilpropertr ackingis achieved.

LOWER

ROLLER

Figure 5.12 Peel-Off Lower RollerAlignment

38452L Rev.3 Page5-21

7/64"HEX

ALLEN

SCREWS

PLATEN SUPPORT BRACKET

CorrectiveMaintenance

-Series Maintenance Manual: Volume 1

SpindleAdjustmentandMaintenance

Therearethreespindleswhichrequireperiodictensionmeasurementand adjustment.Measuringspindletensionshouldbedoneatl eastonceeachyear unlessrequiredmoreoftenduetohighprinteruse.Tensionshouldbeadjusted wheneveritisnotwithinthetolerancerangeassociatedwiththatspindle.

Tension Measurement Procedure

Theprocedureformeasuringspindletensionissimilarforallthreespindles. RefertotheSpindleTensi onAdjustmentDiagrami nFigure5.13forspec ific requirements.

1. Useadhesivetapetoattacha2"widestripofpolyesterfilm(Part#01776) totheSpindleShaft(orCorewhererequired)asillustratedinFigure5.13. WindthepolyesterfilmaroundtheSpindle(orCore)about5timesinthe directionindicated.

2. Slowlyandevenly(2"persecond)pullthestripofpolyesterfilmusingthe SpringScale.(Therotationofthespindleshouldbesmoothandshouldnot causethereadingontheSpringScaleto“jump”excessively.)

3. ComparetheSpringScalereadingwiththeloadvaluesprovidedin

Figure5.13.PerformtheSpindleTensionAdjustmentonlyifthereading

isoutofspec.

4. Ifadjustmentismade,recheckthetensionafterrunningonefullrollof labels.

Spindle Tension Adjustment

RefertotheSpindleTensi onAdjustmentDiagrami nFigure5.13andadjus tthe SpindleTensionasfollows:

1. Loosenthesetscrew(s)inthelargeAdjustmentNutattheendofthe spindle(EndCapoftheRibbonSupplySpindle).

2. TurntheAdjustmentNutinwardtoincreasethetensionoroutwardto decreasethetension;thentightenthesetscrews.

IftheSpindleShaftturnswhenattemptingtotightenorloosenthe AdjustmentNut,refertoFigure5.11andinserta1/16"Allenwrench throughtheaccessholeandintothesetscrewintheshaftcollar

(105S/105SeONLY)orintooneoftheslotsintheplasticclutch (160SONLY).HoldtheshaftinplacewiththeAllenwrenchwhileturning

theHexnut.

3. Useadhesivetapetoattacha2"widestripofpolyesterfilm(Part#01776)to theSpindleShaft(orCorewhererequired)asillustratedinFigure5.13.Wind thepolyesterfilmaroundtheSpindle(orCore)about5timesinthedirection indicated.

4. Slowlyandevenly(2"persecond)pullthestripofpolyesterfilmusingthe SpringScale.(Therotationofthespindleshouldbesmoothandshouldnot causethereadingontheSpringScaleto“jump”excessively.)

5. ComparethetensionreadingontheSpringScalewiththeappropriateload valuesprovidedinFigur e5.13.Repeatsteps1throug h4untilthecorrect tensionisobtained.

Page5-22 38452L Rev.3

-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

RIBBON SUPPLY

RIBBON TAKEUP

MEDIA REWIND

(ALL)

105S/105Se 160S

ATTACH FILM STRIP TO SPINDLE WITH TAPE AS SHOWN

(GRAMS)

450

1300

1500

RIBBON TAKEUP

SPINDLE ASSY

±50

±100 ±100

ATTACH FILM STRIP TO RIBBON CORE WITH TAPE AS SHOWN

DETAIL A

MORE LOAD

SET

SCREW(S)

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.

LESS LOAD

MEDIA REWIND

SPINDLE ASSY

ATTACH FILM STRIP TO MEDIA CORE WITH TAPE AS SHOWN

Figure 5.13 Spindle Tension Adjustments

38452L Rev. 3 Page 5-23

CorrectiveMaintenance

-Series Maintenance Manual: Volume 1

RemovingtheAdapterBoard(105S-300dpiandall105Se)

TheAdapterBoardmayrequireremovalwhenreplacementisnecessary.Follow theprocedurebelow,andrefertoFigur e5.14toremovetheAdapterBoard.

CAUTION

Eliminateanystaticelectricitybyusingananti-staticwriststrap

attachedtotheprinterchassis.Theprinterelectronicsare

susceptibletostaticdischarge.

BesuretheprinterisOFFandtheACPowerCordandSignalInterfaceCable aredisconnected.

CAUTION

Failuretodisconnectpowertotheprinterisasafetyhazardand

couldresultindamagetothePrinthead.

1. RemovetheLeftSidePaneloftheprinterbyremovingthePhillipsscrews thatholditon.

2. DisconnectthePowerSupplyCableandthePrin theadCablefromthe AdapterBoard.

3. Usinga7/64"AllenWrench,removethescre wholdingtheAdapte rBoard tothestandoffthatismountedontheprinterf rame.

4. Usingagentlerockingmotion,removetheAdapterBoardfromthesocket ontheMainLogicBoard.

InstallingtheAdapterBoard(105S-300dpiandall105Se)

1. InserttheAdapterBoardintothesocketontheMainLogicBoard.

2. Usinga7/64"Allenwrench,attachtheAdapterBoardtothestandoffwith themountingscrew;tightenthescrew.

3. AttachthePowerSupplyCableandthePrintheadCable.(ThePr inthead Cableshouldberoutedbehindthedrivebeltsandsecuredtotheprinter framewiththeclipsmountedtotheframe.)

4. ReattachtheLeftSidePaneltotheprinter.

5. ConnecttheACPowerCordandSignalInterfaceCable.

RemovingtheMainLogicandPowerSupplyBoards

TheMainLogicBoardorPowerSupplyBoardmayrequireremovalwhen replacementisnecessary.Thefollowingprocedureexplainshowtoremovethese circuitboards.

Page5-24 38452L Rev.3

-Series Maintenance Manual: Volume 1 Corrective Maintenance

PRINTHEAD

BOARD

ADAPTER

MEDIA

RIBBON

HEAD OPEN

TAKE LABEL

MOTOR

STEPPER

SCREWS

MOUNTING

MAIN LOGIC BOARD

MAIN

LOGIC

BOARD

SCREWS

MOUNTING

SCREWS

MOUNTING

POWER SUPPLY BOARD

SCREWS

MOUNTING

DANGER

BOARD

POWER

SUPPLY

HIGH VOLTAGE

ASSY

CABLE

POWER

Figure 5.14 105S 12-Dot/105Se Electronics

POWER SUPPLY

PROTECTIVE COVER

SCREWS

MOUNTING

REAR PANEL

38452L Rev. 3 Page 5-25

Corrective Maintena nce

-Series Maintenance Manual: Volume 1

MEDIA

RIBBON

HEAD OPEN

TAKE LABEL

SCREWS

MOUNTING

MAIN

LOGIC

BOARD

ASSY

CABLE

POWER

PRINTHEAD

SCREWS

MOUNTING

BOARD

POWER

SUPPLY

MOTOR

STEPPER

Figure 5.15 105S 6- and 8-Dot Electronics

SCREWS

MOUNTING

MAIN LOGIC BOARD

SCREWS

MOUNTING

REAR PANEL

Page 5-26 38452L Rev. 3

SCREWS

MOUNTING

POWER SUPPLY BOARD

DANGER

HIGH VOLTAGE

POWER SUPPLY

PROTECTIVE COVER

REAR PANEL

-Series Maintenance Manual: Volume 1 Corrective Maintenance

RIBBON

HEAD OPEN

MEDIA REFLECTIVE SENSOR

MEDIA TRANSMISSIVE SENSOR

TAKE LABEL

SCREWS

MOUNTING

MAIN

LOGIC

BOARD

POWER

CABLE

ASSY

PRINTHEAD

SCREWS

MOUNTING

POWER

SUPPLY

BOARD

STEPPER

MOTOR

Figure 5.16 160S Electronics

SCREWS

MOUNTING

REAR PANEL

SCREWS

MOUNTING

MAIN LOGIC BOARD

SCREWS

MOUNTING

POWER SUPPLY BOARD

38452L Rev. 3 Page 5-27

DANGER

HIGH VOLTAGE

POWER SUPPLY

PROTECTIVE COVER

REAR PANEL

CorrectiveMaintenance

Eliminateanystaticelectricitybyusingananti-staticwriststrap

attachedtotheprinterchassis.Theprinterelectronicsare

1. BesureprinterisOFFandtheACPowerCordandSignalInterfaceCa ble aredisconnected.

2. RemovetheLeftSidePaneloftheprinterbyremovingthePhillipsscrews whichholditon.

3. RefertoFigures5.14,5.1 5and5.16.UnplugallRibbonC ableConnectors , SmallWireConnectors,andtheAdaptorBoard(ifequipped)fromtheMain LogicBoardandthePowerS upplyBoard.

4. Removethetwoscrewsholdingthecardboardcoveroverthehigh-voltage sectionofthePowerSupply,andr emovethecover.

5. RemovetheMountingScrewsthatholdtheRearPaneltothePrinterFrame.

6. Removethefour(105S/105Se)orfive(160S)mountingscrewsholdingthe MainLogicBoardandthetwomountingscrewshold ingthePowerSupply againstthePrinterFrameStandoffs.

7. CarefullyslidetheRearPanelandCircuitBoardAssemblyfromtherearof theprinter.

8. Tocompletethecircuitboardremovalprocess,eitherremovethetwo mountingscrewsholdingtheMainLogicBoardtotheRearPanelorremove thethreemountingscrewsholdingthePowerSupplyBoardtotheRe ar Panel.

-Series Maintenance Manual: Volume 1

CAUTION

susceptibletostaticdischarge.

InstallingtheMainLogicandPower SupplyBoards

IftheAdaptorBoardisinstalledintheprinter,itisrecommendedthatyou removeitbeforeyouperformthisprocedure(refertopage5-24).

1. AttachtheMainLogicBoardand/orthePowerSupplyBoardtotheRear Panelwiththeappropriatemountingscrews.(Donottightenthesescrews.)

2. SlidetheRearPanelandCircuitBoardAssemblyintotheprinterfromt he rear.

3. AttachtheRearPaneltothePrinterFramewiththemountingscrews. (Makesurethescrewsaresnug.)

4. AttachtheMainLogicBoardandthePowerSupplyBoardtothePrinter FrameStandoffswiththeappropriatemountingscrews.(Donottighten thesescrews.)

5. TightenthecircuitboardmountingscrewsontheR earPanel,thentighten themountingscrewsintothestandoffs.

6. ReinstalltheAdaptorBoard(ifequipped).Refertopage5-24.

7. AttachallcablestotheMainLogicBoardandthePowerSupplyBoard.

8. ReplacethePowerSupplyProtectiveCover.

Page5-28 38452L Rev.3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

WARNING

DangerousvoltageispresentatthePowerSupplyBoard

whentheprinterisON.KeepclearofthePowerSupply

BoardwhenturningtheprinterON.

1. AttachtheACPowerCordandtheDataCabletotheappropri aterearpanel connectors.

2. HoldintheCANCELKeywhileturningtheprinterpowerON.Afterthe POST,aPrinterConfigurationLabelshouldprint.

3. Iftheprinterdoesnotoperateproperly,turnthepowerOFFandrecheckall connections.

4. Whenproperprinteroperationisachieved,completethisprocessby reattachingtheLeftSidePanelonthepri nter.

EPROMSoftwareInstallation

ToreplacetheEPROMswheninstallingfirmwareenhancements,readthe instructionsincludedintheupgradekit.Thegeneralupgradeprocedureisas follows:

1. TurntheACPowerOFFanddisconnectthePowerCord.

2. RemovetheLeftSidePaneloftheprinterbyremovingthescrewsthathold iton.

CAUTION

Theprinterelectronicsaresusceptibletostaticdischarge.Before

proceeding,itisrecommendedthatthetechnicianwearan

anti-staticwriststrapconnectedtogroundinsidetheprinter.

3. (105S6Dots/mmand8Dots/mmOnly)RefertoFigure5.17andgently removetheEPROMsfrompositionsU13andU14ontheMainLogicBoard. (105S12Dots/mm,105Seand160SOnly)RefertoFigure5.18andgently removetheEPROMsfrompositionsU13andU14ontheMainLogicBoard.

4. InsertthenewEPROMswiththenotchespointingUP.MatchtheMain LogicBoard“U”positionwitht hepositionspecifiedone achEPROMlabel. Makesureallpinsareproperlyalignedbeforepressingthechipsintoplace.

CAUTION

TurningtheS-SeriesprinterONwithanEPROMinstalledinthe

wrongdirectionwillresultinpermanentdamagetothatEPROM.

5. BeforeturningpowerON,double-checkthatallEPROMsareintheproper socketandthatthenotchesarepointingUP.

38452L Rev.3 Page5-29

Corrective Maintena nce

When the printer power is turned ON in step 7, dangerous

voltage is present at th e Power Supply Board.

6. R econnect the AC Power Cord.

7. Press and hold the CANCEL Key while turning the printer A C Power Switch O N. A Configuration Label will print.

8. Verify the “Firmware” version shown on the Configuration Label is the same as the software just installed.

9. C omplete the process by install ing the Left Side Panel on the printer.

10. The p rinter is now ready to operate.

-Series Maintenance Manual: Volume 1

WARNING

U13

CORPORATION

ZEBRA TECHNOLOGIES

U14

CORPORATION

ZEBRA TECHNOLOGIES

Figure 5.17 105S (6 and 8 Dots/mm) EPROM Locations

U13

CORPORATION

ZEBRA TECHNOLOGIES

U14

ZEBRA TECHNOLOGIES

CORPORATION

Figure 5.18 160S/105Se/105S (12 Dots/mm) EPROM Locations

Page 5-30 38452L Rev. 3

-Series Maintenance Manual: Volume 1 Corrective Maintenance

Main Drive Belt — Removal, Replacement, and Adjustment

1. Turn the printer OFF and remove the AC Power Cord.

2. 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 R ibbon Take-Up Spindle Assembly to the Printer Frame.

3. 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.

4. Slide the Ribbon Take-Up Spindle Assembly to the right to relieve the tension on the Main Drive Belt.

5. R emove the old Main Dri ve Belt and install the new one.

6. Hook a 2200 gram Spring Scale to the belt as shown in Figure 5.19, and carefully sli de the Ribbon Take-Up Spindle 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″, t ighten the three mounting screws to a torque of 20

inch-pounds.

ACCESS TO

MOUNTING

SCREWS

SPRING

SCALE

INCHES

1400

1600

1800

2000

2200

Figure 5.19 Main Drive Belt Replacement

38452L Rev. 3 Page 5-31

Corrective Maintena nce

-Series Maintenance Manual: Volume 1

Rewind Drive Belt — Removal, Replacement and Adjustment

1. Turn the printer OFF and remove the AC Power Cord.

2. Refer to Figure 5.20 and note the posit ion of the Idler Gear used to adjust the t ension of the Rewind D rive Belt.

3. 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 r each through the hole and loosen the Idler Gear Mounting S crew.

4. Slide the Idler Gear Assembly to the right to relieve t he tension on the Rewind Drive Belt.

5. R emove the old Rewind Drive Belt and install the new one.

6. Hook a 2200 gram spring scale to the belt as show n 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″, t ighten the Idler Gear Mounting Screw to a torque of 20

inch-pounds.

1400 1600 1800 2000

2200

SPRING

SCALE

INCHES

Figure 5.20 Rewind Drive Belt Replacement

Page 5-32 38452L Rev. 3

IDLER GEAR

-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 ra ted 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 slot designed into the Fuse Holder’s End Cap. Press in slightly on the end cap and turn the scr ewdriver slightly counter-clockwise. The end cap disengages from the Fuse Holder and the fuse may be removed. To install a new fuse, rev erse 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 Maintena nce

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 a 3 VDC Lithium Coin Battery type CR2477 (Zebra Part # 44641).

Danger of explosion if battery is incorrectly replaced.

Replace only with the same or equivalent type recommended.

The battery is located on the printer’s Mai n L ogic Board. It is recommended that a qualified Service Technician replace this battery since internal access to the electronics area of t he printer is required.

Turn the printer’s AC Power Switch OFF and disconnect

the printer ’s AC Power Cable before replacing the battery.

-Series Maintenance Manual: Volume 1

CAUTION

When discarding used batteries, do not incinerate.

CAUTION

Prior to removing and replacing the battery, obser ve proper

electrostatic and electrical safety precautions.

To remove the old battery, gently raise the ri ght edge and slide the battery to the right and out of the battery holder.

Insert the new battery with the negative (−) side toward the circuit board. The positive (+) side shoul d be visible when the battery is correctl y installed.

To use the Batt ery Backed-Up RAM Memory, the “Battery Dead” condition must be reset. The preferred method of resetting this condition is to send the “~JB” ZPL I I 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 i s 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” conditi on using this method, press and hold the PAUSE and FEED Keys while turning the AC Power ON.

Cutter Adjustments and Replacement Instructions (105

Printer Disassembly

Only)

The printer must be partially disassembled in order to remove and i nstall parts. Refer to the illustrations in this Section and follow the procedures that follow.

Page 5-34 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

Internal Access

1. TurnPrinterPowerOFFattherearoftheprinteranddisconnecttheAC PowerCordandallsignalinterfacecables.

2. RemoveallMediaandRibbonfromtheprinter.

3. AccesstheElectronicsCabinetbyremovingthemountingscrewsintheleft sidepanel.

Cutter Motor Removal

1. RefertoFigure5.22.RemovetheE-ringthatattachestheLowerDriveArm totheSlottedLink.

2. RemovethescrewthatattachestheMountingPosttotheMainFrame.

3. Removethecutterlinkage,flatwasher,andbearingfromtheprinter.

4. LoosenthetwosetscrewsthatattachtheLowerDriveArmtotheCutter Motorshaft.

5. PivottheLowerDriveArmclockwiseuntiltheLowerDriveArmflag disengagesthesensor.

6.RemovetheLowerDriveArmfromtheCutterMotorshaft.

7. DisconnecttheCutterMotorCablefromtheCutterBoard.

8. RemovethemotormountingscrewsthatattachtheCutterMotortotheMain Frame.

9. PulltheCutterMotorawayfromtheMainFrame,andthemotorcableand GrommetfromtheslotintheMainFrame.

Cutter Motor Installation

1. RefertoFigure5.22.PositiontheCutterMotornearthemountingholeon themechanicalsideoftheprinter.

2. PasstheCutterMotorCablethroughtheslitintheRubberGrommet.Insert theGrommetintotheslotlocatedinthelowerrightareaofthemotor mountinghole,thenslideitintothesmallhole.Theelectricalconnector mustbepositionedontheelectronicssideoftheprinter.(Topreventthe wiresfromcomingout,rotatetheGrommetsothecutisfacingawayfrom themotor.)

3. PositiontheCutterMotoragainsttheprinterframesothatthescrewholesin themotorlineupwiththeholesintheframe,withthemotorshafttowardthe frontoftheprinter.

4. Usethetwomotormountingscrewstofirmlyattachthemotortotheprinter frame.

5. InserttheLowerDriveArmontotheCutterMotorshaft.

6. PivottheLowerDriveArmcount erclockwiseuntiltheLow erDriveArm flagengagesthesensor.

7. TightenthesetscrewsthatattachtheLowerDriveArmtotheCutterMotor shaft.

8. Reinstallthecutterlinkage,flatwasher,andbearing.

9. ReplacethescrewthatattachestheMountingPosttotheMainF rame.

38452L Rev.3 Page5-35

Corrective Maintena nce

-Series Maintenance Manual: Volume 1

BRACKET

DETAIL A

NUT PLATE

CUTTER BOARD

UPPER DRIVE ARM

UPPER CUTTER

MEDIA GUIDE

BRACKET

STATIC BRUSH MOUNTING

CUTTER

INSET

SENSOR

CUTTER OPTICAL

CUTTER MOTOR

BRACKET

LOWER CUTTER

SHAFT

CUTTER MOTOR

Figure 5.22 Cutter Installation

DETAIL A

ARM

LOWER DRIVE

LINK

LONG DRIVE

Page 5-36 38452L Rev. 3

CUTTER OPTICAL SENSOR

CLAMP

SLOTTED LINK

MOUNTING POST

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

10.InstalltheE-ringthatattachestheSlottedLinktotheLowerDriveArm.

Cutter Mechanical Assembly Removal

NOTE:TheCutterModuleshouldNO Tbedisassembled,butreplacedasaunit. AnydisassemblyoftheCutterModulewillvoidthewarranty.

1. RefertoFigure5.22.RemovetheE-ringandwasherfromthetopofthe LongDriveLink.

2. RefertoFigure5.22,DetailA.AttheSidePlate,removethetwosocket headcapscrewsfromtheUpperCutterBracketandNutPlate.

3. LoosentheflatheadscrewthatattachestheUpperCutterBrackettothe CutterModule.

4. RemovethetwosocketheadcapscrewsfromtheLowerCutterBracket.

5. LifttheouterendoftheCutterModuletoremo vethemodule.

6. RemovethetwoflatheadscrewsthatattachtheMediaGuideandUpper CutterBrackettotheCutterModule.

7. RemovethefourPhillipsheadscrewsthatattachtheStaticBrushMounting BrackettoothebottomoftheCutterModule.

Cutter Mechanical Assembly Installation

1. RefertoFigure5.22.UsethefourPhillipsheadscrewstoattachtheStatic BrushMountingBrackettothebottomoftheCutterModule.

2. Usethetwoflatheadscrewstomountt heMediaGuideandUpperC utter BrackettotheCutterModule.

3. CarefullyworktheCutterModuleintopositionintheMainFrameinfront ofthePrinthead.

4. LooselyattachtheUpperCutterBrackettotheSidePlatewiththeNutPlate andtwosocketheadcapscrews.

5. AligntheslotsintheLowerCutterBracketwiththethreadedholesinthe MainFrame.LooselyattachtheLowerCutterBracketwiththetwosocket headcapscrews.

6. WiththeCutterModulelooselyinstalled,itisnecessarytoproperlyalignit andtightenallofthescrews.

OpenthePrintheadandobservethepositionoftheTear-OffBar(infrontof thePlatenRoller)andtheRearCutterBlade.Posi tiontheCutterModuleso thattheRearCutterBladeisparallelwiththeouteredgeoftheTear-Off Baracrosstheentirewidthofthemediapath.TheCutterModuleshouldbe positionedasfarforwardaspossiblewhilemaintainingparallelismwiththe Tear-OffBar.ThisshouldpreventinterferenceoftheRearCutterBlade withtheTear-OffBar.

Aftertheaboveconditionsarebothmet,tightenallmountingscrews. CarefullytightentheflatheadscrewthatattachestheUpperCutterBracket

totheCutterModule.BecarefulnottodisturbthepositionoftheMedia Guide;ifthispartmovesoutofposition,setitsheightsothatitsloweredge isflushwiththerearopeningintheCutterModule.

38452L Rev.3 Page5-37

CorrectiveMaintenance

7. TheRearCutterBladeisheldinpositionbytwosprings.Ifthesesprings touchtheTear-OffBarorotherprinterparts,theRearCutterBladewillnot floatproperlyandwillcauseexcessivewearandprematurefailureofthe CutterBlades.

8. ChecktheclearancebetweenthebackoftheCutterMechanismandthe Tear-OffBarbyinsertingascrewdr iverfromthefronto ftheCutter MechanismandpressthetopoftheRearCutterBladetowardtheprinter. Thebladeshouldmoveaminimumof.030inches.Ifnecessary,loosenthe fourPhillipsheadscrewsonthebottomoftheCutterModuleandreposition theCutterMechanismawayfromtheTear-OffBar.

9. AttachtheE-ringandwashertotheUpperDriveArmatthetopoftheLong DriveLink.

Drive Link A ssembly Installation

1. RefertoFigure5.22.RemovethescrewfromtheMountingPostonthe DriveLinkAssembly.LocatethePostinthemountingholeintheframe and,fromthemediasideoftheframe,securetheAssemblywiththescrew.

2. TheUpperDriveArmispre-assembledtotheCutterModule.Assemblethe LongDriveLinkoftheDriveLinkAssemblyovertheconnectingpostonthe UpperDriveArmandsecureitwiththewasherandE-ring .

3. AttachtheLowerDriveArmoftheDriveLinkAssemblytotheCutter MotorShaft.Loosenthesetscr ewstoinsuret heLowerDri veArmrotates freelyontheMotorshaft.

4. ApplyasmallamountofgreasetotheslotintheSlottedLinkAssembly wheretheBearingwillride.Removeanyexcessgreasetoavoiddamaging theCutterOpticalSensor.

-Series Maintenance Manual: Volume 1

Cutter Circuit Board Removal

1. RefertoFigure5.22.Discon nectallcablesfromtheC utterBoard.

2. RemovethefoursocketheadcapscrewsthatmounttheCutterBoardtothe standoffs.

3. RemovetheCutterBoard.

Cutter Circuit Board Installation

1. RefertoFigure5.23.AttachthepowercabletoJ1ontheCutterCircuit Board.

2. RefertoFigure5.23.AttachthedatacabletoJ2ontheCutterCircuitBoard.

3. Locatethefour(4)standoffsontheprinterframew heretheCutterBoar d willbemounted.

4. RoutetheCutterMotorWiresbetwee nthetworighthandstand offsandout underthebottomoftheCircuitBoard.

5. PositiontheCutterCircuitBoardoverallfourstandoffs.

6. Insertthescrewthroughthelowerright-handCircuitBoardmountinghole (donottightenatthistime).

7. Installthethreeremainingmountingscrewsandtightenallfourscrews.

Page5-38 38452L Rev.3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

Figure 5.23 CutterCircuit Board

8. PasstheCutterBoardPowerCablealongthebottomoftheprinterframe towardtheMainLogicBoard.

9. PlugtheCutterMotorleadsintotheCutterMotorConnector,J3,onthe CutterCircuitBoard.(Blackleadtotheleft.Note:Thisisa“polarized” connector.)

10.RefertoFigure5.23.PlugtheCutterSensorwiresintotheCutterOPTO Connector,J6,ontheCutterCircuitBoard.

11.Checktheinstallationworkandinsurethatduringoperationnowiringwill touchanymovingparts.

Optical Sensor Removal

1. RefertoFigure5.22.RemovethenutthatholdstheCutterOpticalSensor Assembly(wires,SensorClamp,andOpticalSensor)inposition.

2. LifttheCutterOpticalSensorAssemblyofftheSensorMountingPost.

Optical Sensor Installation

1. RefertoFigure5.22andtheFigure5.22inset.InstalltheCutterOptical SensorAssemblyontheSensorMounti ngPost.(TheSensorparto fthe Assemblyshouldbemountedtowardtheprinterframe.)

2. PlacetheSensorClampovertheOpticalSensorandstartthenutonthe SensorMountingPost.(D ONOTtightenthenut.)

3. RoutetheSensorwiresundertheclampandtowardtherearoftheprinter, andlightlytightenthenuttoholdthewiresinposition.(DONOTpinch

thewires.)

Lower Drive Arm Mechanical Alignment

1. ConnectthePowerCablefromJ1ontheCutterBoardtoJ4onthePrinthead AdapterBoard.

38452L Rev.3 Page5-39

CorrectiveMaintenance

2. ConnecttheDataRibbonCablefromJ2ontheCutterBoardtoJ5onthe MainLogicBoard.

3. AttachtheACPowerCordandturntheprinterON.(IftheCutterMotor

starts,waitforittost op.)

NOTE:A criticalposition adjustmentis made in steps4and 5.TheCutter Motor

must be rotateduntil the twoflat surfacesonthe Cutter Motor shaftare alignedwith the set screwsin theLowerDriveArm,whilethe LowerDrive Arm is in a verticalposition (SensorFlag down).

4. RefertoFigure5.23.Attachatestclipatoneendofajumpercabletothe leadontheleftendofCapacitorC6(+5VDCSOURCE)ontheCutter Board.

5. BrieflytouchthetestclipattheotherendofthejumpercabletoTestPoint TP1ontheCutterBoardto“jog”theCutterMotortothedesiredposition.

6. PositiontheLowerDriveArmsotheSensorFlagiscenteredbetweenthe frontandbackportionsoftheCutterOpticalSensor,thentig htenthetwo setscrews.

7. Thesetscrewsmustbeextremelytighttoinsureproperoperationofthe CutterMechanism.Tightenthesetscrewswitha5/64"AllenKey.(Asa reference,whenthesetscrewsaretight,theAllenKeyshoulddeflect approximately0.6"(1.5cm)pastthepointoftightness.Thetig htness specificationis20in.lbs.(2.3N-m).

8. ActivatetheCutterMotor,andmakecertaintheSensorFlagtravelsthrough theslotintheCutterOpticalSensorwithouttouchingit.

9. TurntheprinterPowerSwitchOFF.

-Series Maintenance Manual: Volume 1

Upper Drive Arm Alignment

TheUpperDriveArmispartoftheCutterMechanicalAssemblyandhasbeen properlyalignedatthefactory.Ifforsom ereasonthefactoryposit ionisaltered, thefollowingproceduremaybeusedtorealigntheUpperDriveArm.The printermustbeprogrammedtooperateintheCutterModepriortoperforming thefollowingprocedure.

1. Removetheprinter’sLeftSidePanel,ifattached.

2. LoosentheAllenheadcapscrewthatclampstheUpperDriveArmtothe RotaryCutterBladeshaft.(TheDriveArmmaybesnugontheshaft.)

3. Applypowertotheprinter.TheLowerDri veArmoftheDriveLi nk AssemblyshouldrotateonceandstopwhentheSensorFlagactivatesthe OpticalSensor.

4. RefertoFigure5.24.Onlyaft erthepreceedingstep,holdtheUpperDrive ArminpositionandadjusttheRotaryCutterBladesothatthegapbetween itscuttingedgeontheleftendandthecuttingedgeoftheRearCutterBlade isapproximatelya.100"(2.5mm)asgaugedbyeye.

NOTE:Ifthegapbetweenthecuttingedgesistoolarge,thecuttermaynotcut properlyacrosstheentiremediawidth.Ifthegapistoosmall,themediamay catchontheRotaryCutterBladeedgeandcauseajam.

5. PositiontheUpperDriveArmoutfromthecutterframesoitsflatsurfaceis flushwiththeendoftheRotaryCutterBladeshaft.

Page5-40 38452L Rev.3

-SeriesMaintenanceManual:Volume1 CorrectiveMaintenance

TightentheAllenheadcapscrewwitha5/32inchAllenbitsocketona torquewrenchuntiltheslotclosesoruntilatorqueof100in.lbs. (11.3N-m)isreached.

NOTE:OvertighteningthescrewcandamagetheDriveArmandcanstripthe threads.

6. TesttheCutteralignmentbyfeedingmaximum-widthlabelstockthrough theprinterandinsuringthatcomp letecuttingofthelabeloccurs.( If necessary,repeatsteps4,5,and6toachievecompletecuttingofthelabels.)

7. Withafelttippen,drawalineacrosstheouterfaceoftheUpperDriveArm andtheendofthecutterbladeshaft.Shouldcutteroperationproblemsever occur,this“witnessmark”willshowataglancei fthealignmentofthe clampandthecutterbladeshafthaschanged.

UPPERCUTTERBRACKET

INSURETHETOPOFTHETEAR OFFBARISPOSITIONEDABOVE ORLEVELWITHTHETOPOF THEREARCUTTERBLADE

Figure 5.24 CutterMechanical AssemblyPositioning

ROTARYCUTTERBLADE

MOUNTINGSCREW

MEDIAGUIDE

TEAR-OFF

BAR

CLEARANCEOF.030" MINIMUMBETWEEN REARCUTTERBLADE ANDTEAR-OFFBAR

RELATIVEPOSITIONOFTHEROTARYCUTTER BLADEWHENTHEDRIVELINKASSEMBLYIS STOPPEDBYTHEOPTICALSENSOR,WHEN THEPOWERISONINTHECUTTERMODE

.100"

(2.5mm)

REARCUTTER BLADE

10421SCREWS(4)CONTROL POSITIONOFCUTTERMODULE &SQUARENESSTOMEDIA

38452L Rev.3 Page5-41

Corrective Maintena nce

-Series Maintenance Manual: Volume 1

Page 5-42 38452L Rev. 3

6 Troubleshooting

Inthissection... Page

Troubleshooting...............................................................................6-1

Power-ONTroubleshooting.....................................................6-1

GeneralTroubleshooting..........................................................6-2

CutterModuleTroubleshooting..............................................6-4

SampleLabels..................................................................................6-5

FactoryAssistance..........................................................................6-11

ReturningEquipment......................................................................6-11

Troubleshooting

ConsulttheTroubleshootingTableswhichfollowandcomparetheprinteroutput tothesamplelabelsprovidedonthefollowingpagestoimprovethequalityof yourlabels.

Table 6.1 Power-ONTroubleshooting

SYMPTOM DIAGNOSIS ACTION

All LEDs lightand stayON,orallLEDs (exceptPOWER LED) never turnON.

CALIBRATE LED turnsOFF after5 sec. butallother LEDs stayON.

All LEDs FlashON andOFF.

All LEDs (except POWER LED) are OFFand noprinter operation possible.

Printer locks up while runningPower OnSelfTest.

Main Logic BoardorEPROM faulty orloose interconnecting cables.

Main Logic BoardDynamicRAM faulty.

Nosignificantamountof DRAM testedgood.

Printer misconfiguredfor Peel-Off Modeand Peel-Off Option not installed.

Main Logic Boardfailure. ReplaceMain Logic Board.

Insure cablesare properlyconnected and EPROMs areproperlyinstalled orreplace the MainLogic Board.

ReplaceMain Logic Board.

If Peel-Off is installed, checkTake LabelSensor.

38452L Rev.3 Page6-1

Troubleshooting

Table 6.2 General Troubleshooting

SYMPTOM DIAGNOSIS ACTION

-Series Maintenance Manual: Volume 1

Printer stops. RIBBON LED and PAUSE LED both ON.

Printer stops. PAPER/RIBBON LED Flashes and the PAUSE LED ON.

Printer stops. HEAD OPEN LED Flashes and PAUSE LED ON.

Printer stops and HEAD LED ON.

Printer prints across web or in wrong position.

Continuous printing occurring with the HEAD LED ON.

Printer stops and PAUSE LED lights.

Media notloadedor incorrectlyloaded. Load media correctly. Misadjusted Media Sensor.

1. In continuous media mode, non-continuous media is loaded.

2. In non-continuous media mode, continuous media is loaded.

Ribbon not loaded or incorrectly loaded.

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. Printhead is not fully closed. Close printhead completely. Head Open Sensor not detecting Flag

or Flag not in proper position. Printhead element is overheated. Printer resumes printing when the

Loss of registration indicating a Media Sensor problem.

Printer set for continuous media, but non-continuous media is loaded.

Printhead under temperature. Check print quality. Printhead will

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).

3. Building Format (label too complex).

Check Media Sensor operation. Adjust if necessary. (Run Printer Calibration).

1. Calibrate.

2. Calibrate. Load ribbon correctly.

Check Ribbon Sensor operation. Adjust if necessary. (Run Printer Calibration).

1. Calibrate.

2. Calibrate.

Check Head Open Sensor and Flag for proper operation.

printhead element cools. Adjust Media Sensor position and

then, if needed, adjust the Media Sensor sensitivity.

Set printer for correct type of media.

heat up by printing, or move printer to a warmer area.

You may do any of the following:

1. Check for proper Communication Configuration.

2. With PAUSE ON, use the “~HM” ZPL II Command to display the amount of memory free.

3. With PAUSE ON, press CANCEL to skip that label format and continue to the next one.

4. Cycle Power OFF and back ON to clear printer memory and start again.

Page 6-2 38452L Rev. 3

-SeriesMaintenanceManual:Volume1 Troubleshooting

Table 6.2 General Troubleshooting(Cont'd)

SYMPTOM DIAGNOSIS ACTION

PoorPrint Quality.

Truncatedprint,no print, orFEED Key operates incorrectly whileusing non-continuous media.

Long tracksof missing print on several labels.

Finegraylines on blank labels atangles.

Wrinkled ribbon. Ribbonfedthroughmachine

Lightprinting orno printingonthe left or right side ofthe label.

Darknesstoolow. IncreaseBurn Temp. IncorrectMediaand Ribbon

combination. PrintheadAdjustmentsincorrect. Performrequired adjustments. Label Length Parameteris setless

thanthe actual labellength. Printerwas powered ONin Peel-Off

modewithoutmedia being properly loaded.

Printeris not calibrating media properly.

Wrinkled ribbon. See “WrinkledRibbon” below. PrintElement

damaged. Wrinkled ribbon. See “WrinkledRibbon” below.

incorrectly. IncorrectDarkness setting. Set theDarkness to the lowestsetting

Incorrectprintheadpressure or balance.

Medianot feedingproperly; itis walkingfromsideto side.

StripPlateneeds adjusting. Performadjustments. RibbonSupplySpindle needs

cleaning ortensionneeds adjusting. Printheadneedsrealigning

withPlatenRoller. RibbonTake-up Spindle needs

cleaning ortensionneeds adjusting. Printheadpressure needsbalancing. Adjust balance.SeePrinthead

Replace MediaorRibbon.

Set thecorrectlabellength.

Load media correctlyfor Peel-Off mode.

PerformMedia Adjustments. Set valuewith the“^SS” ZPL II command.

Replace printhead.

Load ribboncorrectly.

possiblefor goodprint quality. Set thepressure to the minimum

needed. See PrintQualityAdjustment and Printhead PressureAdjustment procedures.

Make sure the mediapath remains straightbypositioningthe Media Guide closerto the media.

Performcleaningoradjustments.

Performadjustments.

Performcleaningoradjustments.

Pressure Adjustmentprocedures.

38452L Rev.3 Page6-3

Troubleshooting

Table6.2GeneralTroubleshooting(cont'd)

SYMPTOM DIAGNOSIS ACTION

-Series Maintenance Manual: Volume 1

Misregistrationand skips labels.

Misregistrationand misprint of 1to 3 labels.

Verticaldriftin top-of-form registration.

Labeljamin rear area of printhead.

Changesin parameter settings didnot take effect.

Misadjusted MediaSensors. PerformMediaSensor Adjustments. Improper spindletensions. PerformSpindleAdjustments. Improper ZPLIIformat. Correctthe ZPL IIformat. Mediawas pulledwhenmotorwas

not moving. Printer,thatis in Peel-Off mode,was

powered ONwithoutmedia being properlyloaded.

Misadjusted MediaSensor. PlaceMediaSensor intheproper

A plusor minus4-6dotrow (approx. 1/2 mm) vertical driftis possibledue to the different tolerancesandprinter modes.

Upper Media Plate needs cleaning. Cleanthe Upper MediaPlate.

AllMODELEDsmustbe OFFbefore turning the power OFF.A“^MPS” ZPL IIcommanddisables Mode Function Save.

If theproblemcontinues, theremay be a problemontheMain Logic Board.

Openand closethe printhead.

Load media correctlyfor Peel-Off mode.

position. Performthe“Tear-Off Position

Setting”frontpanel command

tocorrect.

The “^MPE” ZPL II command enablesallmodefunctionsto be front panelprogrammable.

Replace the MainLogic Board.

Table 6.3 CutterModuleTroubleshooting

SYMPTOM DIAGNOSIS ACTION

Printingstops. PAPER/RIBBON, PAUSE,and CANCEL LEDs on.

InCutter Mode, skewedorstuck labels.

The Cutter is not cuttinglabels cleanly.

Labels jammingin Cutter,orlabels are being cutmorethan once.

Page6-4 38452L Rev.3

Mediajammed inCutter. Remove media, cleanCutterModule. Connecting cablesnot connectedto

Cutter CircuitBoard. Cutter Module is dirty. CleanCutter Module. End of the media isnotpositioned

correctlyontopofthe platen. Cutter is dirty. CleantheCutterModule.

Cutter is dirty. CleantheCutterModule. Cutter blades aredull. Replace theCutterModule. Cutter is dirty. CleantheCutterModule. Labellengthis too short. Increaselabellength. See “Adjusting

Plugcables into CutterCircuit Board.

Re-positionmedia so thatthe end is ontop of the platen.

the Tear-Off Position”inGetting

Ready to Print.

-Series Maintenance Manual: Volume 1 Troubleshooting

Sample Labels

The foll owing pages contain sample labels to be used with t he preceding troubleshooting charts. These labels illustrate condit ions which could be seen if mechanical adjustments are necessary.

Zebra Z-Trans 3P media stock and type 5319 ribbon were used to obtain t hese labels. Any other label and ribbon stock combinations may produce sample labels with simi lar but not necessarily the same res ults.

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)

38452L Rev. 3 Page 6-5

Troubleshooting

-Series Maintenance Manual: Volume 1

Unacceptable Label:

Darkness low Printhead positioned

correctly Toggles balanced

(equal pressure on left and right sides)

Unacceptable Label:

Darkness very low Printhead positioned

correctly. Toggles balanced

(equal pressure on left and right sides)

Page 6-6 38452L Rev. 3

-Series Maintenance Manual: Volume 1 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)

38452L Rev. 3 Page 6-7

Zebra 105S, 105SE, 160S Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual