Zebra S-Series
Maintenance Manual
Volume 1: General Maintenance
Zebra Technologies Corporation
Zebra Technologies Europe Limited
333 Corporate Woods Parkway
Vernon Hills, IL, USA 60061-3109
Zebra House
The Valley Centre, Gordan Road
High Wycombe, Buckinghamshire
HP13 6EQ, UK
Telephone:
Fax:
Telephone:
Fax:
+1 (847) 634-6700
+1 (847) 913-8766
38452L Rev. 3
+44 (0) 1494 472872
+44 (0) 1494 450103
Copyright 1995 Zebra Technologies Corporation. All rights reserved.
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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
R
Proprietary Statement
This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information
may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written
permission of Zebra Technologies Corporation.
Product Improvements
Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are
subject to change without notice.
FCC Compliance Statement
Note: This equipment has been tested and found to comply with the limits for a Class A digital Device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
In order to insure compliance, this printer must be used with a Shielded Power Cord and Shielded Communication
Cables.
“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation
could void the user’s authority to operate the equipment.”
Canadian DOC Compliance Statement
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out
in the radio interference regulations of the Canadian Department of Communications.
Liability Disclaimer
Zebra Technologies Corporation takes steps to assure that its published Engineering specifications and Manuals are
correct; however, errors do occur. Zebra Technologies Corporation has been advised of the possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.
Copyrights
The copyrights in this manual and the label printer described therein are owned by Zebra Technologies Corporation.
All rights are reserved. Unauthorized reproduction of this manual or the software in the label printer may result in
imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to
civil liability.
BAR-ONE®, SCAN-ONE®, TRACK-ONE®, Zebra®, ZPL®, and ZPL II® are registered
trademarks and WEDGE-ONE™ is a trademark of Zebra Technologies Corporation.
Centronics® is a registered trademark of Genicom Corporation.
IBM® is a registered trademark of IBM Corporation.
Windows™ is a trademark of Microsoft Corporation.
© Zebra Technologies Corporation. All rights reserved.
38452L Rev. 3
i
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ii
38452L Rev. 3
TABLE OF CONTENTS
Maintenance Manual (Volume 1) Registration Form
Compliance and Copyright Statements
. . . . . . . . . . . i
THE ZEBRA S-SERIES SYSTEM
Printer Specifications . . . . . . . . . . . . . .
Media Handling . . . . . . . . . . . . . . .
Printing Considerations . . . . . . . . . . .
Media Considerations . . . . . . . . . . . .
Ribbon Considerations . . . . . . . . . . .
Zebra Programming Language II (ZPL II®)
Bar Codes . . . . . . . . . . . . . . . . . .
Standard Printer Fonts . . . . . . . . . . . .
Physical Size . . . . . . . . . . . . . . . .
Electrical Requirements . . . . . . . . . . .
Cable Requirements . . . . . . . . . . . . .
115 VAC Applications . . . . . . . . . . .
230 VAC Applications . . . . . . . . . . .
Environmental Operating Range . . . . . .
Communication Specifications . . . . . . . . .
Serial Data Communications Overview . . .
Parallel Data Communications Overview . .
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1-1
1-1
1-2
1-2
1-3
1-3
1-3
1-4
1-5
1-6
1-6
1-6
1-6
1-6
1-7
1-7
1-9
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2-2
2-2
2-3
2-4
2-6
2-7
2-7
2-8
2-9
2-9
2-9
2-11
2-12
2-13
2-14
GETTING READY TO PRINT
Controls and Indicators . . . . . . . . . . . .
Front Panel Controls . . . . . . . . . . .
Front Panel LEDs . . . . . . . . . . . . .
Media Loading . . . . . . . . . . . . . . . .
Ribbon Loading . . . . . . . . . . . . . . . .
Media Calibration . . . . . . . . . . . . . . .
Adjusting the Print Darkness . . . . . . . . .
Adjusting the Tear-Off Position . . . . . . . .
Adjusting the Position of the Top of the Label
Adjusting the Media Sensor Positions . . . .
Upper Media Sensor . . . . . . . . . . . .
Lower Media Sensor . . . . . . . . . . .
Option Switches . . . . . . . . . . . . . . . .
Bank 1 . . . . . . . . . . . . . . . . . . .
Bank 2 . . . . . . . . . . . . . . . . . . .
38452L Rev. 3
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iii
PRINTER DIAGNOSTICS
Power ON Self Test . . . . . . . . . . .
Printer Self Tests . . . . . . . . . . . .
CANCEL Key Self Test . . . . . . .
PAUSE Key Self Test . . . . . . . .
FEED Key Self Test . . . . . . . . .
MODE Key Self Test . . . . . . . .
FEED, PAUSE and CANCEL Keys
PAUSE Key and CANCEL Key . .
FEED Key and CANCEL Key . . .
FEED Key and PAUSE Key . . . .
Extended Printer Diagnostics . . . . . .
PAUSE Key Loopback Test . . . . .
FEED Key Loopback Test . . . . .
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3-1
3-1
3-3
3-4
3-5
3-6
3-6
3-7
3-7
3-7
3-9
3-9
3-10
Field Maintenance Functions . . . . . . . . . . .
Tools Required . . . . . . . . . . . . . . . . . .
Cleaning the S-Series printer . . . . . . . . . . .
Cleaning the Printhead . . . . . . . . . . . . . .
Cleaning the Snap Plate . . . . . . . . . . . . . .
Cleaning the Cutter Module . . . . . . . . . . . .
Lubricating the Cutter Module . . . . . . . . . .
Recommended Preventive Maintenance Schedule
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4-1
4-1
4-1
4-2
4-2
4-4
4-4
4-5
Tools Required . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . .
105S Printhead Replacement . . . . . . . . . . . . . . .
160S Printhead Replacement . . . . . . . . . . . . . . .
Printhead Adjustments . . . . . . . . . . . . . . . . . .
Print Quality Adjustments . . . . . . . . . . . . . . .
Printhead Parallelism Adjustment . . . . . . . . . . .
Wear Plate Position Adjustment . . . . . . . . . . . .
Printhead Position Adjustment . . . . . . . . . . . .
Printhead Pressure Adjustment . . . . . . . . . . . .
Strip Plate Adjustment . . . . . . . . . . . . . . . .
Printhead Voltage Adjustment . . . . . . . . . . . . . . .
Adjustment Procedure . . . . . . . . . . . . . . . . .
Media Sensor Position Adjustment . . . . . . . . . . . .
Reflective Sensor Adjustment . . . . . . . . . . . . . . .
Media Sensor and Ribbon Sensor Sensitivity Adjustment
Take Label Sensor Alignment . . . . . . . . . . . . . . .
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5-2
5-2
5-3
5-5
5-7
5-7
5-8
5-9
5-10
5-11
5-12
5-12
5-13
5-15
5-17
5-17
5-19
PREVENTIVE MAINTENANCE
CORRECTIVE MAINTENANCE
iv
38452L Rev. 3
Media Tracking Adjustments . . . . . . . . . . . . . . . .
Rewind Mode . . . . . . . . . . . . . . . . . . . . . .
Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . .
Spindle Adjustment and Maintenance . . . . . . . . . . .
Tension Measurement Procedure . . . . . . . . . . . .
Spindle Tension Adjustment . . . . . . . . . . . . . .
Removing the Adapter Board . . . . . . . . . . . . . . . .
Installing the Adapter Board . . . . . . . . . . . . . . . .
Removing the Main Logic and Power Supply Boards . . .
Installing the Main Logic and Power Supply Boards . . . .
EPROM Software Installation . . . . . . . . . . . . . . . .
Main Drive Belt — Removal, Replacement & Adjustment .
Rewind Drive Belt — Removal, Replacement & Adjustment
AC Power Fuse Replacement . . . . . . . . . . . . . . . .
Battery Replacement . . . . . . . . . . . . . . . . . . . .
Cutter Adjustments and Replacement Instructiions . . . . .
Internal Access . . . . . . . . . . . . . . . . . . . . .
Cutter Motor Removal and Installation . . . . . . . . .
Cutter Mechanical Assembly Removal and Installation
Drive Link Assembly Installation . . . . . . . . . . . .
Cutter Circuit Board Removal and Installation . . . . .
Optical Sensor Removal and Installation . . . . . . . .
Lower Drive Arm Mechanical Alignment . . . . . . .
Upper Drive Arm Alignment . . . . . . . . . . . . . .
5-20
5-20
5-21
5-22
5-22
5-22
5-24
5-24
5-24
5-28
5-29
5-31
5-32
5-33
5-34
5-34
5-35
5-35
5-37
5-38
5-38
5-39
5-39
5-40
TROUBLESHOOTING
Troubleshooting . . . . . . . . . .
Power-ON Troubleshooting . .
General Troubleshooting . . .
Cutter Module Troubleshooting
Sample Labels . . . . . . . . . . .
Factory Assistance . . . . . . . .
Returning Equipment . . . . . . .
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6-1
6-1
6-2
6-4
6-5
6-11
6-11
105S and 160S MECHANICAL DRAWINGS and PARTS LISTS
Mechanical Parts and Assemblies . . . . . . . . . . . . . . . 7-1
105Se MECHANICAL DRAWINGS and PARTS LISTS
Mechanical Parts and Assemblies . . . . . . . . . . . . . . . 8-1
38452L Rev. 3
v
R
vi
38452L Rev. 3
1
The Zebra S-Series System
In this section...
Page
Printer Specifications .....................................................................1-1
Media Handling .........................................................................1-1
Printing Considerations............................................................1-2
Media Considerations ...............................................................1-2
Ribbon Considerations .............................................................1-3
Zebra Programming Language II (ZPL II ® ) .........................1-3
Bar Codes ...................................................................................1-3
Standard Printer Fonts..............................................................1-4
Physical Size ..............................................................................1-5
Electrical Requirements ...........................................................1-6
Cable Requirements ..................................................................1-6
115 VAC Applications ..............................................................1-6
230 VAC Applications..............................................................1-6
Environmental Operating Range ............................................1-6
Communication Specifications .....................................................1-7
Serial Data Communications Overview.................................1-7
Parallel Data Communications Overview .............................1-9
Printer Specifications
Media Handling
•
Tear-Off mode: Labels are produced in strips.
•
Rewind mode:
Requires Media Rewind option. Labels are rewound
internally onto a 3"-inner-diameter cardboard core.
•
Peel-Off mode:
Requires Peel-Off option or Media Rewind option.
Labels are dispensed and peeled from the liner. The
liner can be rewound directly onto the spindle using
the “J” Hook or onto a 3"-inner-diameter cardboard core.
•
Cutter mode
Requires Cutter Module option (105Se only). Media is cut
after printing; under software control.
38452L Rev. 3
Page 1-1
The S -Series System
S -Series Maintenance Manual: Volume 1
Printing Considerations
105S/105Se
Specification
Resolution (thermal transfer
or direct thermal)
203 dots per inch
(8 dots per mm)
Optional
152 dots per inch
(6 dots per mm)
Dot size (square)
0.00492"
(0.125 mm)
0.00656"
(0.167 mm)
Maximum print width
4.09" (104 mm)
4.09" (104 mm)
160S
Optional
300 dots per inch
(12 dots per mm)
203 dots per inch
(8 dots per mm)
0.0033" x 0.0039"
(0.083 x 0.100 mm)
0.00492"
(0.125 mm)
4.09" (104 mm)
6.30" (160 mm)
9.5" (241mm)
Standard 512 KB
memory
15" (381 mm)
26" (660 mm)
N/A
With 1 MG memory
39" (991 mm)
39" (991 mm)
18" (457 mm)
25" (635 mm)
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
Maximum
print length
Programmable constant
printing speeds
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.
Thin film printhead with Energy Control
Media Considerations
105S/105Se
Media Specifications
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
Label length
Minimum
160S
39" (991 mm)
25" (635 mm)
Tear-Off
0.63"
16.00 mm
0.63"
16.00 mm
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
0.012"
0.304 mm
0.012"
0.304 mm
Maximum (Printhead
Total thickness
(includes liner)
position may need adjustment
if thickness is above 0.01")
0.0023"
0.058 mm
0.0023"
0.058 mm
Core size
Minimum
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)
0.079" 0.157"
2 mm - 4 mm
0.079" 0.157"
2 mm - 4 mm
.118”
3 mm
.118”
3 mm
10 mm
.393”
10 mm
203 x 114
x 158 mm
8.0" x 7.2"
x 6.2"
203 x 183
x 158 mm
Black mark
sensing
Minimum mark length
(thickness)
Minimum mark width
.393”
(extending in from the liner
or tag stock edge)
Maximum internal fanfold media
pack size (L x W x H)
Page 1-2
8.0" x 4.5"
x 6.2"
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
The S -Series System
Ribbon Considerations
105S/105Se
Ribbon Specifications
160S
Ribbon width
Maximum 4.5"
114 mm
6.89"
175 mm
To protect the printhead from wear, Zebra recommends using
ribbon at least as wide as the media you are using.
Minimum
0.75"
19 mm
2.0"
50.8 mm
Standard
lengths
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
Roll size
Inner diameter of core
1.0"
25.4 mm
1.0"
25.4 mm
Outside diameter of full ribbon roll
3.2"
81.2 mm
3.2"
81.2 mm
Zebra Programming Language II (ZPL II ® )
•
Downloadable graphics
(with data compression)
•
Programmable quantity with print pause
•
Bit image data transfer and printing,
including mixing of text and graphics
•
Communicates in printable ASCII
characters
•
Format inversion
•
Controlled via mainframe, mini, PC,
Zebra-Mate or other data-entry device
•
Mirror image printing
•
Serialized fields
•
Four-position field rotation
(0, 90, 180, 270 degrees)
•
In-spec OCR-A and OCR-B
•
•
Slew command
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
•
Industrial 2 of 5, Standard 2 of 5
•
Code 39 (Supports ratios of 2:1, 3:1, 5:2,
and 7:3)
•
Plessey
•
•
MSI
Code 128 (Supports serialization in subsets B
and C and UCC Case C Codes)
•
CODABLOCK and MAXICODE
•
CODABAR (Supports ratios of 2:1, 3:1 and
5:2)
•
E/EAN-8, E/EAN-13, EAN EXTENSIONS
•
UPC-A, UPC-E, UPC EXTENSIONS
•
PDF 417 and POSTNET
•
Data Matrix
•
Interleaved 2 of 5 (Supports ratios of 2:1,
3:1 and 5:2; also supports Modulus 10
Check Digit)
38452L Rev. 3
Page 1-3
The S -Series System
S -Series Maintenance Manual: Volume 1
Standard Printer Fonts
Fonts A, B, C, D, E, F, G, H, and GS are expandable up to 10 times, height- and
width-independent. However, fonts E and H (OCR-A and OCR-B) are not
considered “in-spec” when expanded.
The scalable smooth font 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.
Figure 1.1 Sample of Default Fonts
Font Matrices for 6 dots/mm Printhead (105S/105Se only)
Font
Matrix
Type*
Character Size
Page 1-4
38452L Rev. 3
Char./mm
Char./inch
Width
0.039
0.059
0.079
0.085
0.105
0.315
0.098
0.157
Millimeters
Height
A
9
5
1
U-L-D
0.059
B
11
7
2
U
0.072
C, D
18
10
2
U-L-D
0.118
E
21
10
3
OCR-B
0.138
F
26
13
3
U-L-D
0.171
G
60
40
8
U-L-D
0.394
H
17
11
4
OCR-A
0.112
GS
24
24
0
SYMBOL 0.157
Ø
Default: 15 x 12
U-L-D
* U = Uppercase, L = Lowercase, D = Descenders
Width
Height
Intercharacter
gap
Width
Height
Inches
25.40
1.50
16.93
1.83
12.70
3.00
11.72
3.50
9.53
4.33
3.18 10.00
10.16
2.83
6.35
4.00
Scalable
1.00
1.50
2.00
2.17
2.67
8.00
2.50
4.00
1.00
0.67
0.50
0.46
0.38
0.13
0.40
0.25
S -Series Maintenance Manual: Volume 1
The S -Series System
Font Matrices for 8 dots/mm Printhead (105S, 105Se and 160S)
Font
Matrix
Type*
Character Size
Width
Char./mm
0.029
0.044
0.059
0.098
0.079
0.236
0.093
0.118
Height
A
9
5
1
U-L-D
0.044
B
11
7
2
U
0.054
C, D
18
10
2
U-L-D
0.088
E
28
15
5
OCR-B
0.138
F
26
13
3
U-L-D
0.128
G
60
40
8
U-L-D
0.295
H
21
13
6
OCR-A
0.103
GS
24
24
0
SYMBOL 0.118
Ø
Default: 15 x 12
U-L-D
* U = Uppercase, L = Lowercase, D = Descenders
Millimeters
Char./inch
Width
Height
Intercharacter
gap
Width
Height
Inches
33.90
1.13
22.60
1.38
16.95
2.25
10.17
3.50
12.71
3.25
4.24
7.50
10.71
2.63
8.48
3.00
Scalable
0.75
1.13
1.50
2.50
2.00
6.00
2.38
3.00
1.33
0.89
0.67
0.40
0.50
0.17
0.42
0.33
Font Matrices for 12 dots/mm Printhead (105S/105Se)
Font
Matrix
Type*
Character Size
Width
Char./mm
0.016
0.023
0.033
0.066
0.042
0.132
0.072
0.079
Height
A
9
5
1
U-L-D
0.029
B
11
7
2
U
0.036
C, D
18
10
2
U-L-D
0.059
E
42
20
6
OCR-B
0.138
F
26
13
3
U-L-D
0.185
G
60
40
8
U-L-D
0.198
H
34
22
8
OCR-A
0.112
GS
24
24
0
SYMBOL 0.079
Ø
Default: 15 x 12
U-L-D
* U = Uppercase, L = Lowercase, D = Descenders
Millimeters
Char./inch
Width
Height
Intercharacter
gap
Width
Height
Inches
50.80
0.73
33.86
0.91
25.40
1.49
23.44
3.50
19.06
2.15
6.36
5.02
20.32
2.84
12.70
2.00
Scalable
0.40
0.58
0.83
1.67
1.06
3.35
1.82
2.00
2.00
1.34
1.00
0.92
0.76
0.26
0.80
0.50
Physical Size
Physical
Characteristics
105S/105Se
160S
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
The S -Series System
S -Series Maintenance Manual: Volume 1
Electrical Requirements
•
115 VAC +15%/−20% or 230 VAC +15%/−15%, 48-62 Hz
•
5 Amps @ 115V, 3 Amps @ 230V
•
UL 1950 Listed - Certified to CAN/CSA-C22.2 No. 950-M89
•
Classified to IEC 950 and Complies with FCC and Canadian DOC class “A” rules
•
Carries the CE mark of compliance
Cable Requirements
The AC Power Cord has a three-prong female connector on one end. This
connector must be plugged into the mating connector at the rear of the S-Series
printer.
115 VAC Applications
A Standard US-style, three-prong grounded male plug is attached to the other
end of the AC Power Cord. This connector must be plugged into a nearby
electrical outlet.
230 VAC Applications
An AC Power Cord may or may not be included with the printer. For those
locations that cannot use either of the three power cords listed below, a proper
grounded AC Power Cord must be obtained and installed by the user (See Figure
2.2). The cable must then be plugged into a nearby electrical outlet.
Part Number
AC Power Cable Description
44618
Detachable Power Cord (US Standard 3-prong plug - 115 VAC)
44629
Detachable Power Cord (Continental Europe 3-prong plug - 230 VAC)
44637
Detachable Power Cord (British 3-prong plug - 230 VAC)
Figure 1.2
AC Power Cable
Environmental Ranges
Temperature
Non-condensing
relative humidity
Page 1-6
Operating
+41°F to +104°F (+5°C to +40°C)
Storage
-40°F to +158°F (-40°C to +70°C)
Operating
20% to 85%
Storage
20% to 85%
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
The S -Series System
Communication Specifications
Both serial and parallel data communication interfaces are available for the
S-Series printers. The S-Series printer sends and receives standard ASCII
(American Standard Code for Information Interchange) data characters.
With ZPL II ® , the Error Detection Protocol feature provides virtually error-free
communications. Refer to the user’s guide for further information.
Serial Data Communications Overview
The S-Series printers have a Data Terminal Equipment (DTE) port that supports
RS-232 serial data communications. The RS-232 interface has a standard 25-pin
DB25-S connector located at the rear of the printer. For all RS-232 input and
output signals, the S-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.
Figure 1.3 RS-232 Signal/ASCII Code Data Conditions
Serial Data Signal Levels
Serial data signals are defined as either MARK or SPACE, while control signals
are either ON or OFF. The output levels for the S-Series printers are as follows:
MARK or OFF = - 7 to - 10 Volts
SPACE or ON = +7 to +10 Volts
Serial Interface Connector Pinout and Description
A DB25-S connector is located at the rear of the Zebra S-Series printer and
provides serial data communications to a host using RS-232 signaling.
The pinouts and signal descriptions for the DTE port are as follows:
38452L Rev. 3
Page 1-7
The S -Series System
Pin No.
S -Series Maintenance Manual: Volume 1
Serial Data Port Signal Description
1
2
Frame Ground
Transmit Data: TXD is the serial data output of the Zebra S-Series printer.
It is on this lead that printer status information is transmitted
to the host.
3
Receive Data: RXD is the serial data input to the Zebra S-Series printer from
the host.
4
Request To Send: 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, Unterminated: These leads are not used.
21-25
RS-232
COMM PORT
J7
MAX232
11
12
9
14
13
8
+5 V F4
1 Amp
10
7
Figure 1.4
Page 1-8
1
Frame Ground
2
RS-232 Transmit
3
RS-232 Receive
4
Request To Send
6
Data Set Ready
7
Signal Ground
9
Reserved for
Future Use
20
Data Terminal
Ready
Serial DTE Port Interface
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
The S -Series System
Parallel Data Communications Overview
The S-Series printer may have a parallel data communications port instead of the
previously mentioned serial data port. The Parallel Interface has a standard
36-pin connector located at the rear of the printer. In this data communication
method, the bits of data which make up each character are sent all at one time
over several wires in the cable, one bit per wire.
Parallel Data Signal Levels
Parallel data signals are defined as either HIGH or LOW, while Control Signals
are either Active or Inactive. The distinction is due to the fact that some Control
Signals are active HIGH while others are active LOW. The voltage levels which
represent these conditions are:
Data Signal
Voltage Level
HIGH
+5 VDC
LOW
00 VDC
Parallel Interface Connector Pinout and Description
The following chart provides a description of each of the pins in the parallel
connector. A standard parallel data cable will provide the required
interconnection between the host and the S-Series printer.
Pin No.
Parallel Data Port Signal Description
1
The STROBE printer input has internal 3.3 kÙ pull-up resistors to 5V (IOL= 1.5mA) and is
designed to receive a signal driven open collector VOL <= 0.8V. This pin is a signal from the
host computer. Its LOW going edge will latch the data at the eight DATA inputs. Data is
non-transparently latched so as to avoid hold time requirements on the DATA signals. The
STROBE input is debounced to require an active width greater than 0.5 µsec before data is
latched.
2-9
DATA inputs have TTL input characteristics with internal 3.3 kÙ pullups and represent
1 TTL unit load or less. The DATA inputs are positive logic with a HIGH voltage level
corresponding to a logic 1. Pin 2 through Pin 9 = D0 through D7 respectively.
10
The ACK output is a 12 microsecond active LOW pulse indicating that the printer is ready to
accept data. The active LOW state precedes BUSY by 7 microseconds. ACK is driven open
collector with a 3.3 kÙ internal pull-up. The output sinks 7 mA to a VOL <= 0.4V.
11
The BUSY output is active HIGH whenever the printer cannot accept data due to any
normal or abnormal condition, including Buffer Overflow, Head Open, Over Temperature,
and Media Error conditions. BUSY is driven open collector with a 3.3 kÙ internal pull-up.
The output sinks 7 mA to a VOL <= 0.4V.
12
The PAPER OUT signal is active HIGH whenever the printer is out of media or ribbon.
13
The SELECT signal function is determined by an additional configuration option which
becomes active when the port is present. In the default condition, SELECT is active HIGH
whenever the parallel port is powered up and the parallel port is enabled. In the non-default
condition, SELECT will go active LOW whenever the printer is printing.
18
+5 VDC Supply provides an output of +5 VDC at a maximum current rating of 50 mA.
(Internal Fuse Protected)
32
The ERROR Output (Pin 15) is active LOW whenever any error condition is present.
ERROR is driven open collector with a 3.0 kÙ internal pull-up. The output sinks 7 mA to a
VOL <= 0.4V.
35
+5 VDC Pull-Up provides an output of +5 VDC through an internal 3.0 kÙ resistor.
16, 17, 19 - SIGNAL GROUNDS are the Logic Grounds and Returns for all Input and Output signals.
30, 33
14, 15, 31, NOT USED - These leads should be left unconnected.
34, 36
For an illustration of the parallel communication data and control circuits, refer
to the Main Logic Board Schematic in Volume 2 ( Part # 38453L).
38452L Rev. 3
Page 1-9
The S -Series System
S -Series Maintenance Manual: Volume 1
R
Page 1-10
38452L Rev. 3
2
Getting Ready to Print
In this section...
Page
Controls and Indicators ..................................................................2-2
Front Panel Controls.................................................................2-2
Front Panel LEDs ......................................................................2-3
Media Loading .................................................................................2-4
Ribbon Loading ...............................................................................2-6
Media Calibration ...........................................................................2-7
Adjusting the Print Darkness ........................................................2-7
Adjusting the Tear-Off Position....................................................2-8
Adjusting the Position of the Top of the Label ..........................2-9
Adjusting the Media Sensor Positions .........................................2-9
Upper Media Sensor .................................................................2-9
Lower Media Sensor .................................................................2-11
Option Switches ..............................................................................2-12
Bank 1 .........................................................................................2-13
Bank 2 .........................................................................................2-14
This section of the manual is intended to supplement the User’s Guide by
providing additional information to aid the service technician in
troubleshooting and maintaining the printer.
38452L Rev. 3
Page 2-1
Getting Ready to Print
S -Series Maintenance Manual: Volume 1
Controls and Indicators
All of the printer controls and indicators are located on the front of the unit except for the
Power ON/OFF Switch, which is located at the rear of the printer.
Front Panel Controls
AC Power ON/OFF Switch
Controls application of AC Power to
the printer. When powered ON, the
printer will perform a Power ON Self
Test as it begins operation. Turning the
printer ON while holding down certain
front panel keys will cause additional
printer self tests to occur once the
Power ON Self Test is complete. The
AC Power Switch should be turned
OFF prior to connecting or
disconnecting any cables.
PAUSE Key
The PAUSE Key stops and restarts the
printing process. If the printer is idle
(not printing) when the PAUSE Key is
pressed, no printing can take place. If
the PAUSE Key is pressed while
printing is in progress, the printing
stops once the current label is
completed.
Pressing the PAUSE Key a second time
resumes the printing process.
FEED Key
The FEED Key forces the printer to
feed one blank label. If the printer is
idle (not printing) or if the PAUSE
function is active when the FEED Key
is pressed, one blank label feeds from
the printer immediately. If the printer
is printing, one blank label feeds out
after completion of the current batch of
labels. After one blank label is fed out,
pressing the FEED Key again will
provide a second blank label.
CANCEL Key
The CANCEL Key is only recognized
when the PAUSE function is active.
Press the CANCEL Key and the current
label format will be canceled. If no
format is printing, the next one to be
printed will be canceled. If there are no
formats in the printer, the CANCEL
Key is ignored. If the CANCEL Key is
pressed for an extended period of time
(3 seconds), the printer will perform a
“Cancel All Formats” operation.
Page 2-2
38452L Rev. 3
Figure 2.1 Front Panel Controls
S -Series Maintenance Manual: Volume 1
Getting Ready to Print
MODE Key
The MODE Key causes the printer to enter the Configuration Mode. In this
Mode, the Print Darkness, Media Tear-Off Position, and Label Top Position
settings can be adjusted.
The Media Calibration procedure is also activated by the MODE key.
Refer to the user’s guide for details on the Configuration Mode and the Media
Calibration procedures.
Front Panel LEDs
Refer to Figure 2.1 for the location of the LEDs.
NOTE: If an operating condition which causes an LED to be ON constantly and
one which causes the same LED to flash occur at the same time, the LED will
flash.
LED Name
Status
Indication
POWER
ON
Printer is ON. The AC Power ON/OFF Switch is in the ON position
and the power cord is connected.
PRINTHEAD
OFF
Normal operation.
ON
Printhead Over Temperature condition. Printing stops until the
printhead cools down. Printing resumes automatically.
Printhead Under Temperature condition. Printing continues.
PAPER/
RIBBON
Flashing
Printhead Open.
OFF
Media and ribbon (if used) are properly loaded.
ON
Paper out.
Flashing
1. In Thermal Transfer Mode: Ribbon is out.
2. In Direct Thermal Mode: Ribbon is in the printer.
PAUSE
DATA
OFF
Normal operation.
ON
Printer has stopped all printing operations.
OFF
Idle, no data being received.
ON
Labels are printing.
Single
flash
The CANCEL key was pressed and a format was successfully
deleted from the print queue.
Flashing
Receiving data from host computer.
Slow
flashing
Printer sent a “stop transmitting data” (X-OFF) command to the host
computer.
DARKEN
ON
POSITION
ON
CALIBRATE
ON
Printer is in the Configuration Mode. See the Mode Key operation
for more information.
38452L Rev. 3
Page 2-3
Getting Ready to Print
S -Series Maintenance Manual: Volume 1
Media Loading
Figure 2.2 Roll Media Loading
PEEL-OFF
TEAR-OFF
REWIND
CUTTER
105Se
TEAR-OFF
PEEL-OFF
160S
Figure 2.3 Roll Media Loading Diagrams
Page 2-4
38452L Rev. 3
REWIND
S -Series Maintenance Manual: Volume 1
TEAR-OFF
Getting Ready to Print
BOTTOM SUPPLY
REAR SUPPLY
CUTTER
105Se
Figure 2.4 Fanfold Media Loading Diagrams
INTERNAL SUPPLY
BOTTOM SUPPLY
REAR SUPPLY
Figure 2.5 Fanfold Media Loading Diagrams (160S)
38452L Rev. 3
Page 2-5
Getting Ready to Print
S -Series Maintenance Manual: Volume 1
Ribbon Loading
Figure 2.6 105Se Ribbon Loading Diagram
Figure 2.7 160S Ribbon Loading Diagram
Page 2-6
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Getting Ready to Print
Media Calibration
IMPORTANT: Perform the media calibration procedure when media is
first installed or when a different type of media or ribbon is installed.
During this procedure, the printer automatically determines the media type, label
length, media and ribbon sensor settings, and printing method.
NOTE: Make sure that the media and ribbon rolls are positioned against the
inner spindle stops.
1.
2.
3.
Press the MODE key three times. The PAUSE and CALIBRATE lights turn
on.
Press FEED to calibrate. The printer feeds some media. The MODE lights
will flash on and off to indicate that the settings have been saved in memory.
Press PAUSE to exit PAUSE mode; the PAUSE light turns off.
Adjusting the Print Darkness
Due to differences in types of media/ribbon and the wear on the printhead, it
may be necesary to adjust the darkness setting (burn temperature) of the
S-Series printhead to achieve proper printing. Use the following procedure to
adjust the darkness; turning the printer OFF is not required for the new setting to
take effect.
CAUTION
Set the darkness to the lowest possible for the desired print
quality. Darkness set too high for a given ribbon may cause
printhead damage, ink smearing, ribbon wrinkle, and/or burning
through of the ribbon.
1.
2.
3.
4.
5.
6.
7.
8.
Begin printing a batch of labels. Use a self test label (see Printer
Diagnostics) or preferably, one of your own formats.
Pause the printing by pressing the PAUSE key.
Press the MODE key once to place the printer in “Darkness Adjust Mode.”
The DARKEN light turns on.
Press the UP or DOWN key to adjust the current setting.
Press PAUSE to ressume printing; check the new setting.
Repeat steps 2 through 5 for further adjustment.
When darkness is correct, press PAUSE once and MODE three times. The
MODE lights will flash on and off to indicate that the settings have been
saved in memory.
Press PAUSE to resume printing. Monitor the new setting, adjusting if
necessary.
38452L Rev. 3
Page 2-7
Getting Ready to Print
S -Series Maintenance Manual: Volume 1
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 configuration label reports the actual number of dot rows,
not the number of presses of the buttons used for adjustment.
1.
2.
3.
4.
Press the MODE key twice. The PAUSE and POSITION lights turn on.
Press the UP or DOWN key to adjust the current setting.
Press the MODE key twice. The MODE lights will flast on and off to
indicate that the settings have been saved in memory.
Press PAUSE to exit the PAUSE mode; the PAUSE light turns off.
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
S -Series Maintenance Manual: Volume 1
Getting Ready to Print
Adjusting the Position of the Top of the Label
1.
2.
3.
4.
Press the MODE key twice, then press and hold the MODE key for about
five seconds, until the lights change. PAUSE, DARKEN, and CALIBRATE
lights turn on.
Press the UP or DOWN key to adjust the current setting.
Press the MODE key twice. The MODE lights will flash on and off to
indicate that the settings have been saved in memory.
Press PAUSE to exit the PAUSE mode; the PAUSE light turns off.
Adjusting the Media Sensor Positions
This sensor is not used if Black Mark sensing is selected.
NOTE: If you’re using continuous media, do not perform this adjustment.
Leave the media sensor at the factory-set position.
Non-continuous media has a notch or opening between each label. To monitor
label movement you need to align the media sensor with this notch or opening.
The media sensor consists of two parts that must be properly aligned with the
notch or edge of the label. The factory-set position should be sufficient for most
applications. If not, perform the appropriate adjustments.
Adjusting the Upper Media Sensor
To adjust for the inside half of the media:
1.
2.
3.
4.
Remove the ribbon. Locate the upper media sensor (Figure 2.9-A).
Loosen, but do not remove, the Phillips head screw.
Slide the upper sensor along the slot to any position along the web, except
where the rounded corners of the label are detected. When using tag stock,
position the upper sensor directly over the hole or notch.
Tighten the screw.
38452L Rev. 3
Page 2-9
Getting Ready to Print
S -Series Maintenance Manual: Volume 1
To adjust for the outside half of the media (160S ONLY):
1.
2.
3.
4.
5.
6.
7.
Remove the ribbon. Locate the upper media sensor (Figure 2.9-A).
Remove the printer’s left side panel and reroute the media sensor cable to
provide additional slack.
Remove the Phillips head screw to release the upper section of the sensor
and wire cover.
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 adjustment is far to
the outside.
Replace and tighten the Phillips head screw.
Make sure the wires are routed back into the groove of the media sensor
bracket.
Replace the printer’s left side panel.
A
Figure 2.9 Upper Media Sensor
Page 2-10
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Getting Ready to Print
Lower Media Sensor Adjustment
1.
2.
3.
Locate the lower media sensor assembly under the rear idler roller
(Figure 2.10-A). (It is a spring clip holding a circuit board.)
Slide the sensor until the two brass-colored infrared emitters are under the
upper media sensor. Gently pull wires out as needed (wires should have a
little slack).
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.
A
Figure 2.10 Lower Media Sensor
38452L Rev. 3
Page 2-11
Getting Ready to Print
S -Series Maintenance Manual: Volume 1
Option Switches
These switches are located above the signal interface cable connector. See
Figure 2.11.
In the following tables, “R” means the switch is in the right position, while “L”
means the switch is in the left position. Refer to Figure 2.12.
BANK 2
BANK 2
BANK 1
(ONLY ON
SERIAL UNITS)
SIGNAL INTERFACE
CABLE CONNECTION
105Se and 160S
PARALLEL
105Se and 160S
SERIAL
Figure 2.11 Option Switch Locations
(L)(R)
1 2 3 4 5 6 7 8
Figure 2.12 Option Switches
Page 2-12
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Getting Ready to Print
Bank 1 (Serial interface printers only)
NOTE: Parallel interface printers do not have Bank 1 switches since they are
not required. Bank 1 switches must be properly positioned to establish serial
data communications with the host computer. Once communications are
established, do not change the position of these switches.
Bank 1
Switch
321
RRR
Baud Rate
9600
RRL
19200
RLR
110
RLL
300
LRR
600
LRL
1200
LLR
2400
LLL
4800
Switch
4
Data Bits
(Must be set to 8 data bits for Code Page 850)
R
7
L
8
Switch
65
Parity
RR
Even parity
RL
Parity disabled
LR
Odd parity
LL
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
38452L Rev. 3
Page 2-13
Getting Ready to Print
S -Series Maintenance Manual: Volume 1
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 the “R” position and
turn the power on. With these disabled, the printer will require ZPL commands
to set print mode, media mode, and/or media type.
To override, set the switches to one of the modes shown in the table. If you are
in the process of printing, this change takes affect on the next label printed. If
you change the switches from active to disabled after printer power-up, the
printer remains in the current mode until a ZPL command changes the mode.
Bank 2
Switch
321
RRL
Page 2-14
Print Mode
Cutter
RLL
Tear Off
LRL
Peel Off
LLL
Rewind
--R
Disabled
Switch
654
Media Mode
RRL
Non-continuous mark sense
RLL
Non-continuous web sense
LLL
Continuous
--R
Disabled
Switch
87
Media Type
RL
Thermal transfer
LL
Direct thermal
--R
Disabled
38452L Rev. 3
3
Printer Diagnostics
In this section...
Page
Power ON Self Test ........................................................................3-1
Printer Self Tests .............................................................................3-1
CANCEL Key Self Test ...........................................................3-3
PAUSE Key Self Test ...............................................................3-4
FEED Key Self Test..................................................................3-5
MODE Key Self Test ................................................................3-6
FEED, PAUSE and CANCEL Keys .......................................3-6
PAUSE Key and CANCEL Key ..............................................3-7
FEED Key and CANCEL Key ................................................3-7
FEED Key and PAUSE Key ....................................................3-7
Extended Printer Diagnostics ........................................................3-9
PAUSE Key Loopback Test .....................................................3-9
FEED Key Loopback Test .......................................................3-10
Built into the Zebra S-Series Printers are test routines to aid the technician in
diagnosing faults.
Power ON Self Test
A Power ON Self Test (POST) is performed each time the printer is turned ON.
This test checks for proper initialization of various electronic circuits and
establishes starting parameters as those stored in the printer’s memory. During
this test sequence, the front panel LEDs will turn ON and OFF to insure proper
operation.
At the end of this self test, only the POWER LED will remain lit. If other LEDs
remain lit, refer to Troubleshooting in this manual.
Printer Self Tests
These self tests produce sample labels and provide specific information which
helps determine the operating conditions for the printer.
Each self test is enabled when a front panel key is pressed while the printer’s
AC Power Switch is turned ON. Keep the key pressed until the front panel LEDs
turn ON.
When the Power On Self Test is completed, the selected printer self test will
start automatically.
38452L Rev. 3
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S -Series Maintenance Manual: Volume 1
Printer Diagnostics
NOTES: It is recommended that full width media be used when performing
these tests. Labels less than full width in size will lose printing on the right side.
Label length will determine the amount of printing starting at the top of the label.
When performing these self tests while in the Peel-Off Mode, the operator must
remove the labels as they become available.
When canceling a self test prior to its actual completion, always turn the printer
power OFF and then back ON to reset the printer.
Some of the 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.
Letter
Designation
Inches
per Second
Millimeters
per Second
A*
2"
51 mm
B
3"
76 mm
C
4"
102 mm
5"
127 mm
6"
152 mm
D
* Speed “A” for the 105S and 105Se with the optional 300 dots-per-inch
printhead is 2.4" (61 mm).
Page 3-2
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Printer Diagnostics
CANCEL Key Self Test
This self test prints a single label which contains a listing of the printer’s current
configuration parameters stored in Configuration (EEPROM) Memory. Press the
CANCEL Key while turning the AC Power Switch ON. A sample label is shown
in Figure 3.1.
The printer configuration may be changed temporarily for specific label formats
or ribbon and label stock, or permanently by saving the new parameters in
EEPROM Memory. Saving new parameters occurs whenever a printer
configuration procedure is performed. Refer to Getting Ready to Print for
further details on the Printer Configuration procedure.
Figure 3.1 CANCEL Key Self Test Label
38452L Rev. 3
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Printer Diagnostics
S -Series Maintenance Manual: Volume 1
PAUSE Key Self Test
Enter this self test mode by pressing the PAUSE Key while turning the AC
power ON.
This self test consists of eight separate test sequences, printing labels at both
Speed “A” and Speed “D” (“C” for the 300-dpi 105S and 105Se). During the
first four test sequences, the printer simulates the “Tear-Off” mode and
backfeeds the media prior to printing each label. During the last four test
sequences, the printer simulates the “Rewind” mode and does not backfeed the
media.
This self test can be used to print the test labels required when making
adjustments to the printer’s mechanical assemblies. These test labels can also
be printed when required during the Configuration and Calibration processes
described in Getting Ready to Print. See the label example in Figure 3.2.
NOTE: If the Take Label Sensor pair is mounted on the front of the printer,
“PEEL OPTION INSTALLED” will be printed on the first label. During the first
four test sequences, each label must be manually removed from the sensor path
before the next label will print. During test sequences five through eight, the
Take Label Sensor pair is not enabled and continuous printing occurs.
To bypass the first four sequences, press the PAUSE Key; then tear off the first
printed label. Once the label is removed, the printer will enter the PAUSE mode.
Press the CANCEL Key four times and make sure the Data LED flashes once
each time. Press the PAUSE Key once to start test sequence five.
1.
2.
3.
4.
5.
Page 3-4
The initial test sequence prints 15 labels at speed “A” then automatically
PAUSES the printer. Another 15 label sequence will start if the PAUSE Key
is pressed to permit printing.
While the printer is PAUSED, press the CANCEL Key once to select the
second self test sequence. Now each time the PAUSE Key is pressed, the
printer prints 15 labels at speed “D” (“C” for the 300-dpi 105S and 105Se).
Another 15 label sequence will start if the PAUSE Key is pressed to permit
printing.
While the printer is PAUSED, press the CANCEL Key once to select the
third self test sequence. Now each time the PAUSE Key is pressed, the
printer prints 50 labels at speed “A”. Another 50 label sequence will start if
the PAUSE Key is pressed to permit printing.
While the printer is PAUSED, press the CANCEL Key once to select the
fourth self test sequence. Now each time the PAUSE Key is pressed, the
printer prints 50 labels at speed “D” (“C” for the 300-dpi 105S and 105Se).
Another 50 label sequence will start if the PAUSE Key is pressed to permit
printing.
Self Test sequences five through eight are the same as sequences one
through four but simulate the “Rewind” mode of operation by not
backfeeding at the beginning of each label. In addition, the Take Label
Sensor pair is disabled during these test sequences so labels do not need to
be removed individually.
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Printer Diagnostics
Figure 3.2 PAUSE Key Self Test Label
FEED Key Self Test
The CANCEL Key Self Test should be performed prior to this Self Test.
Information on the printed “Configuration” Label (CANCEL Key Self Test) will
be used with the results of this self test to determine the best Darkness Setting
for a specific media/ribbon combination.
The FEED Key Self Test Label will print out at various PLUS or MINUS
darkness settings relative to the darkness value shown on the configuration
label. Inspect these labels and determine which one has the best darkness setting
for the application. See the example in Figure 3.3.
Figure 3.3 FEED Key Self Test Label
38452L Rev. 3
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Printer Diagnostics
S -Series Maintenance Manual: Volume 1
The value printed on that label is added to (plus) or subtracted from (minus) the
“Darkness” value specified on the Configuration Label.
The resulting numeric value (0 to 30) is the best darkness value for that specific
media/ribbon combination.
The value selected can be entered while performing a Media Darkness
Adjustment. The PLUS value can be entered by pressing the UP (FEED) Key,
while the MINUS value is entered by pressing the DOWN (CANCEL) Key the
appropriate number of times. Refer to the Calibration processes described in
Getting Ready to Print.
Optionally, the required relative darkness value can be programmed into the
ZPL II label formats sent to the printer.
MODE Key Self Test
This self test places the printer in the Communications Diagnostics Mode.
Press the MODE Key while turning the AC power switch ON, then send a label
format to the printer. In this mode, the printer prints the ASCII characters and
their corresponding hexadecimal values for any data received from the host
computer. See the example in Figure 3.4.
NOTE: Turn the printer’s power OFF to exit this self test.
Figure 3.4
MODE Key Self Test Label
FEED, PAUSE, and CANCEL Keys
If these three keys are held depressed at the same time and the power is turned
ON, the printer will enter the Media Sensor and Ribbon Sensor Sensitivity
Adjustment Mode. See Corrective Maintenance for these adjustments.
Page 3-6
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S -Series Maintenance Manual: Volume 1
Printer Diagnostics
PAUSE Key and CANCEL Key
This self test can be used to verify proper printer operation after parts have been
replaced or adjusted. When activated, the printer prints a maximum of 500 Head
Test Labels. Each label backfeeds prior to printing and feeds forward to the rest
position after printing. A serialized number will print on each label. Press the
PAUSE Key or turn the printer power OFF to stop printing. Refer to Figure 3.6.
FEED Key and CANCEL Key
This self test is normally performed during the manufacturing process or after a
major overhaul of the mechanical assemblies. This test prints seven
pre-programmed label formats, first at Speed “D,” then the same formats at
Speed “A.” The printer will automatically pause after each format. The sequence
of label formats is shown below. Refer to Figures 3.7 through 3.13.
FORMAT
PRINTING
TEST FUNCTION
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 Temperature 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 Temperature Test
13
10 at Speed A
Upper Smear Test
14
10 at Speed A
Lower Smear Test
FEED Key and PAUSE Key
Pressing these two keys at the same time, while turning the power ON,
temporarily resets the printer configuration to the factory default values. These
values will be active until power is turned OFF. If the factory default conditions
are to be used on a permanent basis, save them by pressing the MODE Key four
times - MODE LEDs cycle ON then OFF. A Media Calibration procedure
must be performed after factory default values are saved. Figure 3.5
indicates which printer function controls each of the configuration parameters.
38452L Rev. 3
Page 3-7
Printer Diagnostics
Parameter
Darkness
Tear Off Adjust
Web Sensor
Media Sensor
Ribbon Sensor
Mark Media Sensor
Mark Sensor
Media LED
Ribbon LED
Mark LED
Label Length
Max Label Length
Print Width
Print Mode
Media Type
Print Method
Host Port
Network Port
Baud
Data Bits
Parity
Stop Bits
Handshake
Protocol
Delimiter
Format Prefix
Control Prefix
Network ID
Modes Enabled
Modes Disabled
Resolution
Backfeed
Label Top
Left Position
Socket 1 ID
Socket 2 ID
Firmware
Configuration
Memory
B: Memory
Media Power Up
Media Head Close
S -Series Maintenance Manual: Volume 1
Controlled By
Front Panel Adjustment or ZPL II
Front Panel Adjustment
Front Panel Calibrate or ZPL II
Front Panel Calibrate or ZPL II
Front Panel Calibrate or ZPL II
DIP Switches or ZPL II
Front Panel Calibrate or ZPL II
Front Panel Calibrate or ZPL II
Front Panel Calibrate or ZPL II
Front Panel Calibrate or ZPL II
Front Panel Calibrate or ZPL II
ZPL II Controlled
ZPL II Controlled
DIP Switches or ZPL II Controlled
Front Panel Calibrate, DIP Switches or ZPL II
Front Panel Calibrate, DIP Switches or ZPL II
Firmware Controlled
Firmware Controlled
DIP Switches
DIP Switches
DIP Switches
Firmware Controlled
Dip Switches
Dip Switches
ZPL II Controlled
ZPL II Controlled
ZPL II Controlled
ZPL II Controlled
ZPL II Controlled
ZPL II Controlled
ZPL II Controlled
ZPL II Controlled
Front Panel Calibrate or ZPL II
ZPL II Controlled
EPROM
EPROM
Firmware Controlled
Firmware Controlled
Functioning Memory
Firmware Controlled
ZPL II Controlled
ZPL II Controlled
Figure 3.5 Configuration Parameter Controls
Page 3-8
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Printer Diagnostics
Extended Printer Diagnostics
Additional diagnostic tests are available for printhead assembly adjustments.
These diagnostics tests are only accessible when the data interface cable is
disconnected from the printer and a Loopback Connector is attached in its place.
The Serial Loopback Connector 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 Parallel Loopback Connector is a standard 36-pin parallel connector
mounted to a small circuit board. This connector is available from Zebra
Technologies as Part # 44680.
For each of these diagnostic tests, the printer will “transmit” the test label
format out of the Data Interface Connector to the Loopback Connector. The
Loopback Connector passes the test label format back to the printer as “receive”
Data and the test label is printed.
PAUSE Key Loopback Test
This test demonstrates the media movement capabilities of the printer and
provides a test label to view while making print quality adjustments.
With the Loopback Connector in place, press the PAUSE Key while turning the
AC Power Switch ON.
After the Power On Self Test, the printer will print 500 Head Test labels. Each
label will backfeed prior to printing and feed to the rest position after printing.
A serialized number will print on each label for label comparison purposes if
required. See the example in Figure 3.6.
The PAUSE Key can be used to stop and restart the printing operation.
Figure 3.6
PAUSE Key Loopback Test Label
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S -Series Maintenance Manual: Volume 1
Printer Diagnostics
FEED Key Loopback Test
With the Loopback Connector in place, press the FEED Key while turning the
AC Power Switch ON.
After the POST, the printer will begin printing a series of label formats as shown
in the chart below. The printer will PAUSE at the end of each printed format.
Press the PAUSE Key to begin printing the next format. Refer to the label
examples in Figures 3.7 through 3.13.
The PAUSE Key can be used to stop and restart the printing operation. When the
printer is paused, the CANCEL Key can be used to move to the next label format.
FORMAT
PRINTING
TEST FUNCTION
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
* “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
S -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
S -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
Preventive Maintenance
In this section...
Page
Field Maintenance Functions ........................................................4-1
Tools Required.................................................................................4-1
Cleaning the S-Series Printer ........................................................4-1
Cleaning the Printhead ...................................................................4-2
Cleaning the Snap Plate .................................................................4-2
Cleaning the Cutter Module ..........................................................4-4
Lubricating the Cutter Module......................................................4-4
Recommended Preventive Maintenance Schedule.....................4-5
Field Maintenance Functions
Field maintenance functions for the Zebra S-Series printer can be divided into
two basic categories.
• This section of the manual contains preventive maintenance procedures and
operator care instructions. Preventive maintenance consists of a visual
inspection and general cleaning of the interior and exterior of the unit and
printhead. These procedures may be performed by the operator and should
be performed on a regular basis.
•
Corrective maintenance, described in Corrective Maintenance, provides
detailed steps for resolving faults. Repairs are accomplished by replacement
of components or modules or by adjustments.
Tools Required
To properly perform the preventive maintenance tasks, the service technician
should be equipped with the following:
• Applicators
•
70% isopropyl alcohol
•
Citrus-based cleaner
WARNING
Unless indicated otherwise, turn power OFF before
performing maintenance procedures.
Cleaning the S-Series Printer
EXTERIOR — The exterior surfaces of the S-Series printer may be cleaned
with a lint-free cloth. DO NOT use solvents or harsh cleaning agents. If the unit
is excessively dirty, a mild detergent solution or desktop cleaner may be used
sparingly.
38452L Rev. 3
Page 4-1
Preventive Maintenance
S -Series Maintenance Manual: Volume 1
INTERIOR — As required, remove any dirt/lint accumulated in the interior of
the printer using a soft bristle brush and/or vacuum cleaner. It is a good practice
to inspect these areas after every fourth roll of media.
Cleaning the Printhead
Inconsistent print quality such as blank areas in the bar codes or graphics may
indicate a dirty printhead. For optimum performance, the printhead should be
cleaned regularly. When printing in direct thermal mode, perform the following
cleaning procedure after every roll of media (or 500 feet of fanfold media).
When printing in the thermal transfer mode, clean after every roll of ribbon.
NOTE: It is not necessary to turn the printer OFF prior to cleaning. All label
formats, images, and parameter settings stored in the printer’s memory will be
lost if the printer is turned OFF. If the printer is turned OFF, it may be necessary
to reload some items into the printer’s memory.
1. Open the printhead by moving the Latching Lever to the OPEN position.
2. Remove the media and ribbon (if present).
3. Use an applicator moistened with 70% isopropyl alcohol to wipe the print
elements from end to end. (Refer to Figure 4.1. The print elements are the
brown strip just behind the chrome strip.) Allow a few seconds for the
solvent to evaporate.
4. Rotate the Platen Roller and clean thoroughly with isopropyl alcohol.
5. Brush or vacuum any accumulated paper lint and dust away from the rollers
and the Media and Ribbon Sensors.
6. Reload ribbon and/or media, close and latch the printhead, and continue
printing.
Cleaning the Snap Plate
In the event of a label jam, the Media Guide Plate (Snap Plate) can be removed
and cleaned. Refer to Figure 4.2 and follow these steps.
1.
2.
3.
4.
Open the Printhead to its fully open position by rotating the Latching Lever
counterclockwise. The Printhead pivots to an almost vertical position.
From the front of the printer, pop up the front edge of the Snap Plate using
your fingernail or a flat-blade screwdriver.
Lift the front edge of the Snap Plate while pulling it up and out of the print
mechanism.
Clean the Snap Plate, including the raised area directly below the ribbon
sensor. Remove any stuck labels and use a citrus-based cleaner to remove
any built-up adhesive.
CAUTION
Incorrect installation of the Snap Plate can disable the
Ribbon Sensor or cause head pressure imbalance.
5.
Page 4-2
Replace the Snap Plate by placing the back legs in the openings in the Main
Media Guide while sliding it to the rear of the openings and snapping it
down into place. Refer to Figure 4.2.
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Preventive Maintenance
PRINTHEAD
RIBBON
SENSOR
LABEL
AVAILABLE
SENSORS
PLATEN
ROLLER
PEEL/TEAR
BAR
Figure 4.1
Printhead Cleaning
SNAP
PLATE
Figure 4.2
Snap Plate Cleaning
38452L Rev. 3
Page 4-3
Preventive Maintenance
S -Series Maintenance Manual: Volume 1
Cleaning the Cutter Module
Periodically, the Cutter Module should be cleaned to remove paper dust and
label residue. Refer to Figure 4.3.
Clean the stationary cutter blade with a cotton swab moistened with a
citrus-based cleaner when it becomes gummed up with label adhesive or paper
debris. After cleaning, apply a small amount of petroleum lubricating grease to
the moving cutter parts.
Figure 4.3 Cutter Blade Cleaning
Lubricating the Cutter Module
Certain applications or types of label stock may cause the cutter blades to
eventually start to squeak. This commonly occurs when less-than-full width
media is being used.
To eliminate the squeak and prolong cutter life, first turn off the printer. Next,
clean the lower cutter blade by following the above procedure. Then, coat a
cotton swab with a small amount of petroleum lubricating grease and wipe the
swab along the top of the lower cutter blade and on the surface of the ring at the
end of the rotary blade (refer to Figure 4.4).
DETAIL
Figure 4.4 Cutter Module Lubrication
Page 4-4
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Preventive Maintenance
Recommended Preventive Maintenance Schedule
AREA
METHOD
INTERVAL
PRINTHEAD
Isopropyl alcohol
PLATEN ROLLER
Isopropyl alcohol
MEDIA SENSOR
Air blow
When printing in the direct
thermal mode: after every roll
of media (or 500 feet of
fanfold media).
MEDIA PATH
Isopropyl alcohol and cloth
RIBBON SENSOR
Air blow
When printing in the thermal
transfer mode: after every roll
of ribbon.
PEEL ROLLER
Isopropyl alcohol
Once per month
LABEL AVAILABLE
SENSOR
Air blow
Once per six months
RIBBON FEEDING PATH
Visual
Once per three months
DRIVE BELTS
Visual
Six months or 500 rolls
CUTTER BLADES
Citrus-based cleaner and/or air
blow
As needed
MEDIA TAKE UP SPINDLE
Formal preventive maintenance is not required on these
spindles. Spindle tension should not be adjusted unless
the printer is malfunctioning (i.e., spindles not rotating
smoothly). The recommended tensions and adjustment
procedures are provided in Corrective Maintenance.
105S and 105Se printers: The spindles should be taken
apart and the felt pads replaced with new ones presoaked in
silicone oil (new felt pads and silicone oil are available in
kit # 01688-140) per the following schedule:
RIBBON SUPPLY SPINDLE
Media Supply and Take-Up Spindles - once per year or
after 500 media rolls of media
Ribbon Supply and Ribbon Take-Up Spindles - once per
year or after 200 rolls of ribbon.
160S printer: DO
RIBBON TAKE UP SPINDLE
NOT lubricate these spindles.
These spindles should only be disassembled and cleaned with
alcohol if they fail to rotate smoothly.
38452L Rev. 3
Page 4-5
Preventive Maintenance
S -Series Maintenance Manual: Volume 1
R
Page 4-6
38452L Rev. 3
5
Corrective Maintenance
In this section...
Page
Tools Required.................................................................................5-2
Test Equipment Required ...............................................................5-2
105S and 105Se Printhead Replacement .....................................5-3
160S Printhead Replacement.........................................................5-5
Printhead Adjustments ...................................................................5-7
Printhead Voltage Adjustment.......................................................5-12
Media Sensor Position Adjustment ..............................................5-15
Media Sensor and Ribbon Sensor Sensitivity Adjustment .......5-17
Take Label Sensor Alignment .......................................................5-19
Media Tracking Adjustments ........................................................5-20
Rewind Mode .............................................................................5-20
Peel-Off Mode ...........................................................................5-21
Spindle Adjustment and Maintenance .........................................5-22
Tension Measurement Procedure ............................................5-22
Spindle Tension Adjustment ...................................................5-22
Removing the Adapter Board ........................................................5-24
Installing the Adapter Board .........................................................5-24
Removing the Main Logic and Power Supply Boards ..............5-24
Installing the Main Logic and Power Supply Boards................5-28
EPROM Software Installation.......................................................5-29
Main Drive Belt - Removal, Replacement and Adjustment .....5-31
Rewind Drive Belt - Removal, Replacement and Adjustment .....5-32
AC Power Fuse Replacement ........................................................5-33
Battery Replacement.......................................................................5-34
Cutter Adjustments and Replacement Instructions....................5-34
Printer Disassembly ..................................................................5-34
Internal Access ..........................................................................5-35
Cutter Motor Removal..............................................................5-35
Cutter Motor Installation .........................................................5-35
Cutter Mechanical Assembly Removal..................................5-37
Cutter Mechanical Assembly Installation .............................5-37
Drive Link Assembly Installation ..........................................5-38
Cutter Circuit Board Removal ................................................5-38
Cutter Circuit Board Installation ............................................5-38
Optical Sensor Removal...........................................................5-39
Optical Sensor Installation ......................................................5-39
Lower Drive Arm Mechanical Alignment.............................5-39
Upper Drive Arm Alignment...................................................5-40
38452L Rev. 3
Page 5-1
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
When a problem is encountered with the S-Series printer, the service technician
should first insure the unit is being used properly, then exercise it to localize the
fault. Once localized, refer to the appropriate replacement or adjustment
procedure to correct the fault.
Tools Required
Screwdriver, flat blade, 1/4", 1/8" x 8", and 3/16" x 3"
Screwdriver, Phillips #1, #1 extended reach, and #2
Pliers, long-nose, small needle nose, utility, snap ring
Set of inch combination (open end/box end) wrenches (must include a 7/16")
Set of inch Allen wrenches (1/16", 3/32", 5/64", 7/64", 9/64")
Allen bit socket 5/32"
Allen hex key, 5/64"
Torque wrench calibrated in inch-pounds (drive size to fit 5/32" Allen bit socket)
Nut driver, 5/16"
Hex head drivers, 0.35", 1/16", 1/16" ball point, 3/32", 5/32", 5/64", 7/64", 7/64"
extended reach (minimum 10" shaft), 7/64" ball point, 9/64"
Metric hex head drivers, 1.5 mm, 2 mm, 3 mm, and 5 mm
Metric hex key set
0 – 1,000 g Spring Scale
0-2.25 Kg Spring Scale
Clip to clip (jumper) lead
Wire cutters
Soldering iron, 20-35W
Potentiometer adjustment tool
File
Metric/English ruler, metal scale
Fuse, 5 Amp, Slo Blo, 250V 3AG (115 VAC installations)
Fuse, 3 Amp, Slo Blo, 250V 3AG (230 VAC installations)
Spindle Torque Adjustment Kit, Part # 01773
Digital Voltmeter with Clip-On Leads
Test 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 maintenance procedures.
CAUTION
To prevent possible damage to EPROMs or the Main Logic
Board, please disconnect ALL communications cables before
performing maintenance procedures.
Page 5-2
38452L Rev. 3
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Corrective Maintenance
105S and 105Se Printhead Replacement
Refer to Figure 5.1 while performing the following procedure.
CAUTION
Observe proper electrostatic safety precautions when removing,
handling, and replacing the Printhead.
1.
2.
3.
4.
Turn the printer OFF and remove the Power Cord.
Remove media and ribbon.
Properly connect yourself to an anti-static protection system.
Remove the Printhead Pressure Plate and the Static Removal Brush by
removing the six (6) Allen head mounting screws. (Some printers may
require the removal of two additional screws that mount the Static Removal
Brush.)
5. Note the location of the grounding strap, and carefully hold the printhead
and remove the four Phillips screws that hold it to the Mounting Bracket.
6. Holding the printhead stable, remove the electrical connector mounted at
the back of the printhead.
7. Remove the old printhead.
8. Prior to installing the new printhead, note the resistance value shown
on the label located under the new printhead.
9. Reconnect the electrical connector to the new printhead.
10. Fit the new printhead into the mounting bracket.
CAUTION
Ensure that the grounding strap is reattached by the printhead
mounting screw.
11. Loosely install the four Phillips screws through the Printhead Bracket and
the Printhead’s aluminum body.
12. After verifying the Printhead is seated properly (Printhead Bracket Guide
Pins are fitted into the guide holes on the 12 dots/mm Printhead), tighten
the Phillips head mounting screws.
13. Reinstall the Pressure Plate and Static Removal Brush with the mounting
screws.
14. Use the Preventive Maintenance Kit to clean the new printhead thoroughly.
15. Reinstall media and ribbon.
16. Connect the AC Power Cord and turn the printer power ON.
17. After the printer completes the Power On Self Test, refer to the Printhead
Resistance value (noted in Step 8 above) and perform the Printhead Voltage
Adjustment on pages 5-12 through 5-14.
18. Press the PAUSE Key while turning the printer power ON, and check the
print quality of the test labels.
38452L Rev. 3
Page 5-3
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
PRESSURE
PLATE
MOUNTING
SCREWS
PRINTHEAD
PRESSURE
PLATE
STATIC
REMOVAL
BRUSH
GROUNDING
STRAP
PRINTHEAD
MOUNTING
SCREWS
PRINTHEAD
BRACKET
GUIDE PINS
(12 DOT/MM ONLY)
PRINTHEAD
PEM STUDS
(6 DOT/MM &
8 DOT/MM ONLY)
GUIDE HOLES
Figure 5.1 105S/105Se Printhead Replacement
Page 5-4
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
160S Printhead Replacement
Refer to Figure 5.2 while performing the following procedure.
CAUTION
Observe proper Electrostatic Safety Precautions when removing,
handling and replacing the Printhead.
1.
2.
3.
4.
5.
Turn the printer OFF and remove the Power Cord.
Open the Printhead Assembly and remove the media and ribbon; then close
the Printhead Assembly.
Properly connect yourself to an anti-static protection system.
Locate the Spring-loaded Printhead Mounting Screw on top of the Printhead Assembly.
Loosen the Mounting Screw until it disengages from the Printhead.
CAUTION
Use care to minimize any physical damage to the
Printhead during the remainder of this procedure.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Slowly open the Printhead Assembly. The Printhead will be resting on the
Platen while the rest of the Assembly pivots back.
Spread apart the holding tabs on the sides of the Printhead Data Connectors
to release the Data Cables.
Grasp the outside edges of the Printhead Power Cable Connector and press
down on the Power Cable Locking Tab.
While maintaining pressure on the locking tab, disconnect the Printhead
Power Cable and remove the Printhead through the front of the printer.
Prior to installing the new printhead, note the resistance value shown
on the label located under the new printhead.
Connect the Printhead Power Cable to the appropriate connector.
Spread apart the holding tabs on the sides of the two data connectors and
press the appropriate Printhead Data Cable into each connector. The
Holding Tabs must “snap” into place around the cable connectors. Dress
cables completely behind the printhead.
Carefully position the alignment slots in the new Printhead over the
alignment posts on the underside of the mounting bracket (refer to
Figure 5.2).
After ensuring that no cables are between the Printhead and the Printhead
Bracket and verifying the Printhead is seated properly, carefully tighten the
mounting screw. (If any problems occur during this installation process, contact
our Technical Support group.)
Refer to Figure 4.1. Use 70% isopropyl alcohol to thoroughly clean the print
element (brown area) of the new Printhead.
Reinstall media and ribbon.
Connect the AC Power Cord and turn the printer power ON.
38452L Rev. 3
Page 5-5
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
DO NOT LOOSEN
THESE SCREWS!!
PRINTHEAD
MECHANISM
ASSEMBLY
PRINTHEAD
MOUNTING
SCREW
PRINTHEAD
ALIGNMENT
POSTS
PRINTHEAD
DATA
CONNECTORS
POWER CABLE
LOCKING TAB
PRINTHEAD
ALIGNMENT
SLOTS
PRINTHEAD
PRINTHEAD
POWER
CONNECTOR
Figure 5.2 160S Printhead Replacement
Page 5-6
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
18. After completing the Power ON Self Test, refer to the Printhead Resistance
value (noted in Step 11 above) and perform the Printhead Voltage
Adjustment on pages 5-12 through 5-14.
19. After adjusting the printhead voltage, activate the PAUSE Key Self Test by
pressing the PAUSE Key while turning the printer power on. Check print
quality.
20. The printer should be ready for operation. If problems arise, refer to
Troubleshooting.
Printhead Adjustments
Print Quality Adjustments
There are five interrelated adjustments that lead to optimum print quality with
increased Printhead life:
•
Printhead Parallelism
•
Wear Plate (Balance) Position
•
Printhead Position
•
Printhead Pressure
• Strip Plate Positioning
To achieve optimum print quality, install full-width media and ribbon in the
printer while making the Printhead Adjustments.
1.
2.
Prior to performing Printhead Adjustments, activate the PAUSE Key Self
Test by pressing the PAUSE Key while turning the printer power ON.
Adjust the Toggle Spring(s) by turning the Knurled Adjusting Nut(s) so that
there is approximately 30 mm (1.2 inches) between the bottom of the
Knurled Adjusting Nut and the top of the black Toggle Button (refer to
Figure 5.3). Be sure the toggle is centered over the media (105S/105Se).
For the 160S, position both toggles so that they are half the distance
between the Printhead Attaching Screw and the outside edges of the
Printhead.
NOTES: The order in which the adjustments are performed depends on the print
quality of the labels printed during the PAUSE Test (see “Sample Labels” in
Troubleshooting).
The first two Printhead Adjustments (Parallelism and Wear Plate) must be
completed prior to attempting to locate the optimum print position. As with the
other adjustments, Parallelism and Wear Plate adjustments are interrelated.
Adjusting one may have an effect on the position of the other.
Excessive printhead pressure will lead to increased printhead wear and
decreased printhead life.
Increased printhead life is possible by combining minimum toggle pressure and
optimum printhead position over the Platen Roller.
38452L Rev. 3
Page 5-7
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
Printhead Parallelism Adjustment
This adjustment is performed in conjunction with the Wear Plate Position,
Printhead Position, and Printhead Pressure Adjustments.
Adjusting the printhead parallelism squares the printhead in reference to the media.
Refer to Figure 5.3 for location of adjustment screws used in the following
procedures.
Printhead Parallelism Test
1.
2.
3.
4.
Prior to starting this test, insure the installed media is “squared” with the
Tear-Off Bar.
When the printer begins printing PAUSE Key Self Test labels, refer to
Getting Ready to Print and adjust the Darkness for a clear presentation of
all lines on the test label.
The uppermost line on the test label should be parallel to the top edge of the
label within a tolerance of 0.020".
If the print lines are not parallel with the top of the label, proceed to the
Printhead Parallelism Adjustment. If parallelism is within tolerance,
proceed to the Wear Plate Position Adjustment.
Printhead Parallelism Adjustment
1.
2.
Using a 7/64" Allen wrench or 7/64" Hex driver, loosen the four Allen
screws at the top rear of the Print Mechanism.
Adjust the parallel location of the uppermost lines by turning one of the two
Parallelism Adjustment Screws located at the back of the Print Mechanism.
NOTE: Make adjustments in small adjustments (a fraction of a turn).
3.
4.
5.
6.
7.
Page 5-8
To move the printhead forward, turn the adjustment screw clockwise as
viewed from the rear of the printer.
To move the printhead backward, turn the adjustment screw
counterclockwise as viewed from the rear of the printer.
Adjust each side as necessary to align the uppermost line of the test label in
parallel with the top edge of the label.
To check the results of your adjustments, run additional PAUSE Key Self
Test labels and check for proper parallelism.
Tighten the four top Allen screws and run more PAUSE Key Self Test labels
to verify proper positioning.
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
NOTE: LOOSEN 4 HEX CAP SCREWS
BEFORE ADJUSTING HEAD
TOGGLE KNURLED
ADJUSTING NUT
30 mm
WEAR PLATE
ADJUSTMENT
SCREWS
PARALLELISM
ADJUSTMENT
SCREWS
STRIP
PLATE
NOTE: THE RIBBON TAKE-UP SPINDLE
IS NOT SHOWN IN THIS ILLUSTRATION
Figure 5.3 Printhead Adjustment Illustration
Wear Plate Position Adjustment
This adjustment is performed in conjunction with the Printhead Parallelism,
Printhead Position, and Printhead Pressure Adjustments.
Adjusting the Wear Plate position produces even pressure across the full width
of the Printhead and platen roller.
Refer to Figure 5.3 for the location of the adjustment screws used in the
following procedure.
1.
2.
3.
Position both Toggles (160S) so that they are half the distance between the
Printhead Attaching Screw and the outside edges of the Printhead. For the
105S/105Se, make sure the Toggle is centered over the media.
Adjust the Toggle Spring(s) by turning the Knurled Adjusting Nut(s) so that
there is approximately 30 mm (1.2 inches) between the bottom of the
Knurled Adjusting Nut and the top of the black Toggle Button.
Using a 3/32 ″ Allen wrench or Phillips head screwdriver, loosen the
two screws on the front of the Strip Plate.
4.
5.
6.
Activate the PAUSE Key Self Test by pressing the PAUSE Key while
turning the printer power ON.
As labels are printed, reduce the DARKNESS value until the test labels are
a charcoal gray color.
Print additional PAUSE Key Self Test labels and observe the print quality.
38452L Rev. 3
Page 5-9
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
7.
If lighter or no printing is observed on one side of the label as compared
with the other, continue with this adjustment.
8.
Using a 7/64 ″ Allen wrench, slightly loosen the two Allen set screws
mounted on the Wear Plate.
9.
Continue to print PAUSE Test labels while adjusting the Wear Plate
Eccentric for even printing.
10. Adjust the Wear Plate Eccentric by turning it by hand, or with a 7/16 ″ open
end wrench, or with a pair of utility pliers.
11. Adjust the Wear Plate Eccentric until uniform print density is achieved
across the label.
12. When even print quality is achieved, hold the Wear Plate in position and
tighten the two Wear Plate Set Screws.
13. Continue to print PAUSE Test labels and verify that parallelism is correct.
14. If parallelism is out of tolerance, perform the Printhead Parallelism
Adjustment.
15. If no other adjustment is required, follow the Strip Plate Adjustment
Procedure found later in this section, and tighten the two Allen screws.
Printhead Position Adjustment
This adjustment is performed in conjunction with the Printhead Parallelism,
Wear Plate Position, and Printhead Pressure Adjustments.
Adjusting the Printhead position aligns the head for optimum print quality.
Refer to Figure 5.3 for location of adjustment screws used in the following
procedure.
1.
2.
3.
4.
5.
The thermal elements of the printhead should be aligned just behind the
crest of the Platen Roller.
Print test labels using the PAUSE Key Self Test.
Using a 7/64" Allen wrench, loosen the four Allen screws at the top rear of
the Print Mechanism.
Position both Toggles (160S) so that they are half the distance between the
Printhead Attaching Screw and the outside edges of the Printhead. For the
105S/105Se, make sure the Toggle is centered over the media.
Set the Darkness to achieve the optimum print quality.
CAUTION
In step 6, to prevent printhead damage, loosen the four top
screws before turning the two rear adjustment screws.
6.
Page 5-10
Adjust the printhead position for optimum print quality by equally turning
the two Parallelism Adjustment Screws located at the back of the print
mechanism.
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
7.
Corrective Maintenance
Adjustments are made in very small increments.
Turn both Parallelism Adjustment Screws one eighth turn clockwise and
observe the changes in print quality. (Due to spring pressure, there may be
a dead spot in the actual printhead movement when switching adjustments
from one direction to the other.)
8. Decrease the Burn Temperature until the PAUSE Test labels are a charcoal
gray color.
9. Carefully look at the PAUSE Test labels for streaks, flouring, and other
print quality problems.
10. If required, adjust the hex head screws and observe if print quality problems
are corrected.
11. Increase Burn Temperature until the PAUSE Test labels are printed at
optimum resolution and contrast.
12. Since Printhead parallelism, Wear Plate position, and Printhead position are
interrelated, carefully look at the test labels for changes in these settings
and adjust if necessary.
Printhead Pressure Adjustment
Printhead Pressure is the fourth of the four interrelated adjustments. Using lower
Printhead Pressure and Darkness settings can extend printhead life. If printing is
too light on one side or if a thick media is used, printhead pressure may require
adjustment.
Refer to Figure 5.4 for the location of the Pressure Toggle for the 105S and
105Se printers. This toggle should be positioned over the center of the media
width. The 160S printer has two toggles. These toggles are typically positioned
at the 1/4 and 3/4 positions across the width of the media. If narrow media is
used on the 160S, the inside toggle should be centered above the media and the
pressure of the outside toggle should be reduced to zero.
1.
2.
3.
4.
5.
6.
7.
Print PAUSE Key Self Test labels to check print quality.
To increase printhead pressure, loosen the Upper Knurled Nut on the Toggle
and adjust the Lower Toggle Adjusting Nut downwards.
To decrease printhead pressure, loosen the Upper Knurled Nut and adjust
the Lower Toggle Adjusting Nut upwards.
Adjust printhead pressure for optimum print quality.
To lock-in printhead pressure, tighten the Upper Knurled Nut against the
Lower Toggle Adjusting Nut.
Though different media and ribbon combinations may require different
Toggle settings, a suggested initial distance between the bottom of the
Lower Toggle Adjusting Nut and the top of the black Toggle Button is
approximately 30 mm.
Adjust Burn Temperature to the optimum level for the installed media.
38452L Rev. 3
Page 5-11
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
TOGGLE
ADJUSTING
NUT
Figure 5.4 Printhead Pressure Adjustment
Strip Plate Adjustment
The Strip Plate is a very important part of the printhead adjustment procedure.
The Strip Plate can be adjusted for proper tracking and separation of the ribbon
from the media after printing.
1.
2.
3.
4.
5.
Print PAUSE Key Self Test labels.
Press the PAUSE Key and, after the printer pauses, observe the ribbon for
possible problems (wrinkling, etc.).
Refer to Figure 5.3, and loosen the two Allen screws holding the Strip Plate
to the front of the Printhead Assembly.
While running the PAUSE Key Self Test, lower the Strip Plate so the ribbon
is flat and smooth and tracks properly to the Ribbon Take-up Spindle.
Tighten the Strip Plate Allen screws and print a minimum of twenty-five
labels. Check for ribbon wrinkle, tracking, and noise problems. If ribbon
wrinkle and/or tracking problems persist, check the torque settings of the
Ribbon Supply Spindle and adjust tension if required.
Printhead Voltage Adjustment
When a printhead or the printer’s power supply is replaced, the printhead
Voltage must be adjusted for the proper value. This adjustment establishes the
voltage applied to the print elements during the printing process. When
adjustment is necessary, follow this procedure:
Page 5-12
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
CAUTION
This voltage adjustment is critical to the life of the
printhead. DO NOT use this adjustment in an attempt
to increase the printing darkness or burn temperature.
Adjustment Procedure
Calculate the proper Printhead Voltage using the appropriate formula below. The
formula to use depends on the type of Printhead used in the printer. In the formula, R
is the Print Element average resistance value as indicated on a label on the Printhead.
The label can be seen by releasing the Printhead latch, moving the ribbon (if any) to
the side and looking up at the underside of the Printhead.
(The charts in this section may be used instead of the formulas.)
1.
2.
3.
4.
5.
6.
6 dot/mm formula:
V = 0.978 × R + 0.48
8 dot/mm formula:
V = 0.64 × R + 0.479
12 dot/mm formula:
V = 0.4127 × R + 0.58
Remove the four mounting screws and the Left Side Panel to provide access
to the Main Logic Board.
Locate the Head Voltage Adjustment Potentiometer (RV2) below the
transformer and filter capacitors on the Power Supply Board.
(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, attach a voltmeter between
the left end of Diode Z3 and ground. Diode Z3 is located just to the right
of potentiometer RV2.
Turn the printer ON.
Adjust RV2 so the voltmeter reading matches the value determined at the
beginning of this procedure.
Turn the printer OFF, disconnect the voltmeter leads, and replace the
printer’s Left Side Panel.
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
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
8 Dot/mm Printhead Voltage Table
105S
105Se/
160S
105S
105Se/
160S
105S
105Se/
160S
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
Ω
Ω
12 Dot/mm Printhead Voltage Table
Page 5-14
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
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Media Sensor Position Adjustment
Transmissive Media Sensor
The Transmissive Media Sensor contains an upper section and a lower section.
The upper section senses the infrared light emitted by the components mounted
on the lower section. The amount of light passing between these two sections
determines when either the “web” between labels or a hole or notch in the media
is present. This sensing also determines the length of the label or ticket for
non-continuous media.
The factory-set position should be sufficient for any width label, so little or no
repositioning should be required when using media with a web. If it does
become necessary to reposition the Transmissive Media Sensor, perform the
Upper Section Adjustment first followed by the Lower Section Adjustment.
Upper Section Adjustment
To adjust the upper section of the Transmissive Media Sensor for the inside half
of the media width, refer to Figures 5.5 and 5.6 and follow these steps:
1. Remove the ribbon and locate the upper section of the Media Sensor.
2. Loosen the mounting screw holding this section in position.
3. Slide the upper section along the slot to any position along the web, except
where the rounded corners of the label are detected. (When using tag stock,
position the upper section directly over the hole or notch.)
4. Tighten the mounting screw.
(160S ONLY) To adjust the upper section of the Transmissive Media Sensor for
the outside half of the media width, refer to Figure 5.6 and the illustration on
page 7-13 and follow these steps:
1. Remove the ribbon and locate the upper section of the Media Sensor.
2. Remove the printer’s left side panel and reroute the media sensor cable to
provide additional slack.
3. Remove the mounting screw to release the upper section of the sensor and
the wire cover.
4. Carefully pull the wires through the tie wrap as you reposition the sensor
and the wire cover to the outside half of the mounting bracket.
5. Replace and tighten the mounting screw; then replace the printer’s left side
panel.
Lower Section Adjustment
To adjust the lower section of the Transmissive Media Sensor, refer to
Figure 5.7 and follow these steps:
1. Locate the lower section of the Transmissive Media Sensor (a spring clip
holding a printed circuit board) under the Rear Idler Roller.
2. Slide the lower section of the sensor across its mounting rail until the two
brass colored infrared emitters are centered under the upper section.
3. Gently pull wires out from the frame as required. (Wires should have a
little slack.)
NOTE: If the lower section is being moved inward and a large loop of wire
results, remove the printer’s left side panel and gently pull the wires through. It
is important that the wires be positioned away from the drive belts and pulleys.
38452L Rev. 3
Page 5-15
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
UPPER
MEDIA SENSOR
ADJUSTMENT
Figure 5.5 105S and 105Se Transmis sive Sensor (Upper)
Figure 5.6 160S Transmiss ive Sensor (Upper)
A
Page 5-16
Figure 5.7 Transmissive Sensor Lower Section
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Reflective Media Sensor Adjustment
The Reflective Media Sensor is placed into operation for those applications
where the sensing of Black Marks on the underside of the media is desired.
For the 105S printer, the Reflective Media Sensor is an option that is installed in
place of the lower section of the Transmissive Media Sensor. Position
adjustment is available across the total width of the media. With the Reflective
Media Sensor installed, the upper section of the Transmissive Media Sensor is
not operational.
For the 160S and 105Se printers, the position of the Reflective Media Sensor is
fixed against the Mainframe and has no adjustment. Switches on the rear of the
printers are used to configure the printers for operation with either the
Reflective Media Sensor or the Transmissive Media Sensor previously discussed.
Transmissive Media Sensor and Ribbon Sensor Sensitivity Adjustment
NOTE: This adjustment is initially performed by Zebra Technologies during
final printer inspection. Under normal circumstances, further adjustments should
not be necessary. The exception is when media with exceptionally thick or thin
backing material is being used in the printer.
Perform the following procedure if the Paper/Ribbon LED comes ON when:
a. In the thermal transfer printing mode, media and ribbon are properly installed
or
b. In the direct thermal printing mode, media only is properly installed.
Sensitivity Adjustment Procedure
1.
2.
3.
Turn the printer OFF.
Raise the Media Cover and open the Printhead.
Load at least 12 inches of blank backing material (no labels) under the
Printhead.
NOTE: Insure that blank backing material extends behind the Printhead and is
positioned between the upper and lower sections of the Transmissive Media
Sensor.
4. Remove the ribbon. (Sliding the ribbon as far to the right as possible will
have the same effect as removing it.)
5. Close the Printhead.
6. Press the Pause, Feed, and Cancel keys while turning the printer ON. Once
the printer is ON, release all three keys.
The following two sets of LEDs will begin flickering to signify that the
automatic sensor adjustment has been made.
The PRINTHEAD and PAPER/RIBBON LEDs.
The DARKEN and POSITION LEDs.
NOTE: If only one pair of LEDs is flickering, it indicates that the adjustment
was not successful. Go back to step 1 and start over.
38452L Rev. 3
Page 5-17
Corrective Maintenance
7.
8.
9.
S -Series Maintenance Manual: Volume 1
Open the Printhead and pull the media through the printer until a label is
positioned between the upper and lower sections of the Transmissive Media
Sensor. Move the ribbon back to its normal position.
Close the Printhead and press the MODE key to complete the automatic
adjustment process. A Media Sensor Profile will automatically print and
the new sensor settings will be automatically saved. (See Figure 5.8)
Perform the Media Calibration procedure located in Getting Ready to Print.
Figure 5.8 Media Sensor Profile Sample Label
Page 5-18
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Take Label Sensor Alignment
The Take Label Sensor pair is active only when the S-Series printer is set to
Peel-Off mode. To operate in this mode either the Rewind Option or the Backing
Only Rewind Option must be installed. The Take Label Sensor pair is not
included on S-Series printers unless one of these options is installed.
Refer to Figure 5.9 for the location of the Take-Label Sensor pair. When a label
printed in Peel-Off mode breaks the infrared light beam passing between the
sensors, further printing and feeding is inhibited. Additional label formats will
be accepted by the printer if the data buffer is not full. When the operator
removes the label from the sensor path, the next label will print. There is no
sensitivity adjustment for this sensor. If you encounter problems, make certain
the printer is set to Peel-Off mode and that the sensor pair are aligned. Sensors
are aligned when installed. No adjustments are required after installation.
TAKE
LABEL
SENSORS
Figure 5.9 Take Label Sensor Location
38452L Rev. 3
Page 5-19
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
Media Tracking Adjustments
Rewind Mode
If the media walks from side to side, or if it tears or wrinkles against the
Media Rewind Tracking Plate, it will be necessary to adjust the Rewind Plate
Assembly. Refer to Figures 5.10 and 5.11.
1.
2.
3.
4.
5.
Remove the Rewind Plate Assembly and loosen the 5/16” Hex nuts
attaching the Hook Plate to the Rewind Plate. Moving the outer end of the
Hook Plate up will force the media towards the Rewind Tracking Plate
while moving this end down will move the media away from the Tracking
Plate. (The opposite effect will occur if the same adjustments are performed
on the inner end of the Hook Plate.)
Tighten the Hex nuts, reinstall the Rewind Plate Assembly, and print several
test labels. If problems persist, readjust the Hook Plate.
(105S and 105Se Only) If the media cannot be made to track correctly with
the previous adjustment, check the distance from the outside of the Tracking
Plate to the Main Frame. This dimension is set at the factory and should be
0.530" (13.5 mm) to 0.570" (14.5 mm). If the distance needs to be reset,
refer to Figure 5.11 and proceed to step 4 below.
(105S and 105Se Only) Use a 1/16" Hex Allen Wrench to loosen the two
set screws in the Collar (located inside the Rewind Spindle Assembly). The
screws are accessible through a single hole in the Spindle Assembly, as
shown in Figure 5.11. Reposition the Spindle Assembly closer to or farther
from the Main Frame as required, and retighten the two set screws in the
collar.
Repeat steps 1 and 2 until the required results are achieved.
REWIND PLATE
HOOK PLATE
HOOK PLATE
OUTER END
HEX NUTS
Figure 5.10 Rewind Plate Assembly
Page 5-20
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Figure 5.11 105S/105Se Rewind Spindle Positioning
Peel-Off Mode
In “Peel-Off Mode”, the Lower Roller alignment has the same effect on media
tracking as the Rewind Plate alignment does in “Rewind Mode”. Refer to
Figure 5.12 and perform the following procedure.
1.
2.
3.
Use a 7/64″ Hex Allen wrench to loosen the (2) Allen screws that attach the
Platen Support Bracket to the Side Plate.
Moving the bracket toward the front of the machine moves the label backing
material away from the Rewind Tracking Plate. Moving the bracket toward
the rear of the machine moves the label backing toward the tracking plate.
Adjust the bracket position as required and tighten the Allen screws.
Print several labels and repeat steps 1 and 2 until proper tracking is
achieved.
7/64" HEX
ALLEN
SCREWS
LOWER
ROLLER
PLATEN
SUPPORT
BRACKET
Figure 5.12 Peel-Off Lower Roller Alignment
38452L Rev. 3
Page 5-21
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
Spindle Adjustment and Maintenance
There are three spindles which require periodic tension measurement and
adjustment. Measuring spindle tension should be done at least once each year
unless required more often due to high printer use. Tension should be adjusted
whenever it is not within the tolerance range associated with that spindle.
Tension Measurement Procedure
The procedure for measuring spindle tension is similar for all three spindles.
Refer to the Spindle Tension Adjustment Diagram in Figure 5.13 for specific
requirements.
1.
2.
3.
4.
Use adhesive tape to attach a 2" wide strip of polyester film (Part # 01776)
to the Spindle Shaft (or Core where required) as illustrated in Figure 5.13.
Wind the polyester film around the Spindle (or Core) about 5 times in the
direction indicated.
Slowly and evenly (2" per second) pull the strip of polyester film using the
Spring Scale. (The rotation of the spindle should be smooth and should not
cause the reading on the Spring Scale to “jump” excessively.)
Compare the Spring Scale reading with the load values provided in
Figure 5.13. Perform the Spindle Tension Adjustment only if the reading
is out of spec.
If adjustment is made, recheck the tension after running one full roll of
labels.
Spindle Tension Adjustment
Refer to the Spindle Tension Adjustment Diagram in Figure 5.13 and adjust the
Spindle Tension as follows:
1.
2.
3.
4.
5.
Page 5-22
Loosen the set screw(s) in the large Adjustment Nut at the end of the
spindle (End Cap of the Ribbon Supply Spindle).
Turn the Adjustment Nut inward to increase the tension or outward to
decrease the tension; then tighten the set screws.
If the Spindle Shaft turns when attempting to tighten or loosen the
Adjustment Nut, refer to Figure 5.11 and insert a 1/16" Allen wrench
through the access hole and into the set screw in the shaft collar
(105S/105Se ONLY) or into one of the slots in the plastic clutch
(160S ONLY). Hold the shaft in place with the Allen wrench while turning
the Hex nut.
Use adhesive tape to attach a 2" wide strip of polyester film (Part # 01776) to
the Spindle Shaft (or Core where required) as illustrated in Figure 5.13. Wind
the polyester film around the Spindle (or Core) about 5 times in the direction
indicated.
Slowly and evenly (2" per second) pull the strip of polyester film using the
Spring Scale. (The rotation of the spindle should be smooth and should not
cause the reading on the Spring Scale to “jump” excessively.)
Compare the tension reading on the Spring Scale with the appropriate load
values provided in Figure 5.13. Repeat steps 1 through 4 until the correct
tension is obtained.
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
105S/105Se RIBBON SUPPLY
SPINDLE ASSY
ALIGN ALL FLANGE SECTIONS
BEFORE INSTALLING RIBBON CORE.
F1
160S RIBBON SUPPLY
SPINDLE ASSY
SPINDLE
FORCE
LOAD
TOLERANCE
(GRAMS)
RIBBON SUPPLY
(ALL)
F1
450
±50
RIBBON TAKEUP
(ALL)
F2
450
±50
F3
F3
1300
1500
±100
±100
MEDIA
REWIND
105S/105Se
160S
ATTACH FILM STRIP
TO RIBBON CORE
WITH TAPE AS SHOWN
F2
DETAIL A
MORE LOAD
ATTACH FILM STRIP
TO SPINDLE WITH
TAPE AS SHOWN
SET
SCREW(S)
RIBBON TAKEUP
SPINDLE ASSY
F3
LESS
LOAD
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.
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
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
Removing the Adapter Board (105S-300 dpi and all 105Se)
The Adapter Board may require removal when replacement is necessary. Follow
the procedure below, and refer to Figure 5.14 to remove the Adapter Board.
CAUTION
Eliminate any static electricity by using an anti-static wrist strap
attached to the printer chassis. The printer electronics are
susceptible to static discharge.
Be sure the printer is OFF and the AC Power Cord and Signal Interface Cable
are disconnected.
CAUTION
Failure to disconnect power to the printer is a safety hazard and
could result in damage to the Printhead.
1.
2.
3.
4.
Remove the Left Side Panel of the printer by removing the Phillips screws
that hold it on.
Disconnect the Power Supply Cable and the Printhead Cable from the
Adapter Board.
Using a 7/64" Allen Wrench, remove the screw holding the Adapter Board
to the standoff that is mounted on the printer frame.
Using a gentle rocking motion, remove the Adapter Board from the socket
on the Main Logic Board.
Installing the Adapter Board (105S-300 dpi and all 105Se)
1.
2.
3.
4.
5.
Insert the Adapter Board into the socket on the Main Logic Board.
Using a 7/64" Allen wrench, attach the Adapter Board to the standoff with
the mounting screw; tighten the screw.
Attach the Power Supply Cable and the Printhead Cable. (The Printhead
Cable should be routed behind the drive belts and secured to the printer
frame with the clips mounted to the frame.)
Reattach the Left Side Panel to the printer.
Connect the AC Power Cord and Signal Interface Cable.
Removing the Main Logic and Power Supply Boards
The Main Logic Board or Power Supply Board may require removal when
replacement is necessary. The following procedure explains how to remove these
circuit boards.
Page 5-24
38452L Rev. 3
REAR PANEL
REAR PANEL
MOUNTING
SCREWS
38452L Rev. 3
POWER SUPPLY
PROTECTIVE COVER
HIGH VOLTAGE
DANGER
POWER SUPPLY BOARD
MOUNTING
SCREWS
MAIN LOGIC BOARD
MOUNTING
SCREWS
POWER
CABLE
ASSY
Figure 5.14 105S 12-Dot/105Se Electronics
POWER
SUPPLY
BOARD
MOUNTING
SCREWS
MAIN
LOGIC
BOARD
MOUNTING
SCREWS
STEPPER
MOTOR
ADAPTER
BOARD
PRINTHEAD
MEDIA
RIBBON
HEAD OPEN
TAKE LABEL
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Page 5-25
Page 5-26
REAR PANEL
REAR PANEL
MOUNTING
SCREWS
38452L Rev. 3
POWER SUPPLY
PROTECTIVE COVER
HIGH VOLTAGE
DANGER
POWER SUPPLY BOARD
MOUNTING
SCREWS
MAIN LOGIC BOARD
MOUNTING
SCREWS
Figure 5.15 105S 6- and 8-Dot Electronics
POWER
SUPPLY
BOARD
MOUNTING
SCREWS
MAIN
LOGIC
BOARD
MOUNTING
SCREWS
STEPPER
MOTOR
POWER
CABLE
ASSY
PRINTHEAD
MEDIA
RIBBON
HEAD OPEN
TAKE LABEL
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
REAR PANEL
REAR PANEL
MOUNTING
SCREWS
38452L Rev. 3
POWER SUPPLY
PROTECTIVE COVER
HIGH VOLTAGE
DANGER
POWER SUPPLY BOARD
MOUNTING
SCREWS
MAIN LOGIC BOARD
MOUNTING
SCREWS
POWER
SUPPLY
BOARD
Figure 5.16 160S Electronics
MOUNTING
SCREWS
MAIN
LOGIC
BOARD
MOUNTING
SCREWS
MEDIA REFLECTIVE SENSOR
MEDIA TRANSMISSIVE SENSOR
PRINTHEAD
STEPPER
MOTOR
POWER
CABLE
ASSY
RIBBON
HEAD OPEN
TAKE LABEL
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Page 5-27
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
CAUTION
Eliminate any static electricity by using an anti-static wrist strap
attached to the printer chassis. The printer electronics are
susceptible to static discharge.
1.
2.
3.
4.
5.
6.
7.
8.
Be sure printer is OFF and the AC Power Cord and Signal Interface Cable
are disconnected.
Remove the Left Side Panel of the printer by removing the Phillips screws
which hold it on.
Refer to Figures 5.14, 5.15 and 5.16. Unplug all Ribbon Cable Connectors,
Small Wire Connectors, and the Adaptor Board (if equipped) from the Main
Logic Board and the Power Supply Board.
Remove the two screws holding the cardboard cover over the high-voltage
section of the Power Supply, and remove the cover.
Remove the Mounting Screws that hold the Rear Panel to the Printer Frame.
Remove the four (105S/105Se) or five (160S) mounting screws holding the
Main Logic Board and the two mounting screws holding the Power Supply
against the Printer Frame Standoffs.
Carefully slide the Rear Panel and Circuit Board Assembly from the rear of
the printer.
To complete the circuit board removal process, either remove the two
mounting screws holding the Main Logic Board to the Rear Panel or remove
the three mounting screws holding the Power Supply Board to the Rear
Panel.
Installing the Main Logic and Power Supply Boards
If the Adaptor Board is installed in the printer, it is recommended that you
remove it before you perform this procedure (refer to page 5-24).
1.
2.
3.
4.
5.
6.
7.
8.
Page 5-28
Attach the Main Logic Board and/or the Power Supply Board to the Rear
Panel with the appropriate mounting screws. (Do not tighten these screws.)
Slide the Rear Panel and Circuit Board Assembly into the printer from the
rear.
Attach the Rear Panel to the Printer Frame with the mounting screws.
(Make sure the screws are snug.)
Attach the Main Logic Board and the Power Supply Board to the Printer
Frame Standoffs with the appropriate mounting screws. (Do not tighten
these screws.)
Tighten the circuit board mounting screws on the Rear Panel, then tighten
the mounting screws into the standoffs.
Reinstall the Adaptor Board (if equipped). Refer to page 5-24.
Attach all cables to the Main Logic Board and the Power Supply Board.
Replace the Power Supply Protective Cover.
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
WARNING
Dangerous voltage is present at the Power Supply Board
when the printer is ON. Keep clear of the Power Supply
Board when turning the printer ON.
1.
2.
3.
4.
Attach the AC Power Cord and the Data Cable to the appropriate rear panel
connectors.
Hold in the CANCEL Key while turning the printer power ON. After the
POST, a Printer Configuration Label should print.
If the printer does not operate properly, turn the power OFF and recheck all
connections.
When proper printer operation is achieved, complete this process by
reattaching the Left Side Panel on the printer.
EPROM Software Installation
To replace the EPROMs when installing firmware enhancements, read the
instructions included in the upgrade kit. The general upgrade procedure is as
follows:
1.
2.
Turn the AC Power OFF and disconnect the Power Cord.
Remove the Left Side Panel of the printer by removing the screws that hold
it on.
CAUTION
The printer electronics are susceptible to static discharge. Before
proceeding, it is recommended that the technician wear an
anti-static wrist strap connected to ground inside the printer.
3.
4.
(105S 6 Dots/mm and 8 Dots/mm Only) Refer to Figure 5.17 and gently
remove the EPROMs from positions U13 and U14 on the Main Logic Board.
(105S 12 Dots/mm, 105Se and 160S Only) Refer to Figure 5.18 and gently
remove the EPROMs from positions U13 and U14 on the Main Logic Board.
Insert the new EPROMs with the notches pointing UP. Match the Main
Logic Board “U” position with the position specified on each EPROM label.
Make sure all pins are properly aligned before pressing the chips into place.
CAUTION
Turning the S-Series printer ON with an EPROM installed in the
wrong direction will result in permanent damage to that EPROM.
5.
Before turning power ON, double-check that all EPROMs are in the proper
socket and that the notches are pointing UP.
38452L Rev. 3
Page 5-29
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
WARNING
When the printer power is turned ON in step 7, dangerous
voltage is present at the Power Supply Board.
Reconnect the AC Power Cord.
Press and hold the CANCEL Key while turning the printer AC Power
Switch ON. A Configuration Label will print.
8. Verify the “Firmware” version shown on the Configuration Label is the
same as the software just installed.
9. Complete the process by installing the Left Side Panel on the printer.
10. The printer is now ready to operate.
ZEBRA TECHNOLOGIES
CORPORATION
ZEBRA TECHNOLOGIES
CORPORATION
U13
U14
6.
7.
ZEBRA TECHNOLOGIES
CORPORATION
ZEBRA TECHNOLOGIES
CORPORATION
U14
U13
Figure 5.17 105S (6 and 8 Dots/mm) EPROM Locations
Figure 5.18 160S/105Se/105S (12 Dots/mm) EPROM Locations
Page 5-30
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Main Drive Belt — Removal, Replacement, and Adjustment
1.
2.
3.
4.
5.
6.
7.
Turn the printer OFF and remove the AC Power Cord.
Refer to Figure 5.19 and rotate the Ribbon Take-Up Pulley until the three
holes in the pulley are aligned with the three mounting screws which hold
the Ribbon Take-Up Spindle Assembly to the Printer Frame.
Use a 9/64” Allen wrench to reach through the holes in the Ribbon Take-Up
Pulley and loosen, but do not remove, the three Spindle Assembly mounting
screws.
Slide the Ribbon Take-Up Spindle Assembly to the right to relieve the
tension on the Main Drive Belt.
Remove the old Main Drive Belt and install the new one.
Hook a 2200 gram Spring Scale to the belt as shown in Figure 5.19, and
carefully slide the Ribbon Take-Up Spindle Assembly to the left to increase
belt tension.
When a scale reading of 2000 grams ± 250 grams (4.5 lbs ± 0.5 lbs) creates a
deflection of 1/4″, tighten the three mounting screws to a torque of 20
inch-pounds.
ACCESS TO
MOUNTING
SCREWS
3
2
22
00
20
18
00
I
1 S
HE
C
N
00
16
14
00
00
SPRING
SCALE
Figure 5.19 Main Drive Belt Replacement
38452L Rev. 3
Page 5-31
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
Rewind Drive Belt — Removal, Replacement and Adjustment
1.
2.
3.
4.
5.
6.
7.
Turn the printer OFF and remove the AC Power Cord.
Refer to Figure 5.20 and note the position of the Idler Gear used to adjust
the tension of the Rewind Drive Belt.
On the Media Side of the printer, locate the lower access hole in the Side
Frame and remove the hole plug. Use a 7/64″ Allen wrench with a 10″
minimum shaft length to reach through the hole and loosen the Idler Gear
Mounting Screw.
Slide the Idler Gear Assembly to the right to relieve the tension on the
Rewind Drive Belt.
Remove the old Rewind Drive Belt and install the new one.
Hook a 2200 gram spring scale to the belt as shown in Figure 5.20, and
carefully slide the Idler Gear Assembly to the left to increase belt tension.
When a scale reading of 2000 grams ± 250 grams (4.5 lbs ± 0.5 lbs) creates a
deflection of 1/4″, tighten the Idler Gear Mounting Screw to a torque of 20
inch-pounds.
1400
1600
1800
2000
IDLER
GEAR
2200
SPRING
SCALE
1
INCHES
2
3
Figure 5.20 Rewind Drive Belt Replacement
Page 5-32
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
AC Power Fuse Replacement
A user-replaceable AC Power Fuse is located just above the Power ON/OFF
Switch on the rear of the printer. For a 115 VAC installation, the replacement
fuse is a 3AG Fast Blow style rated at 5 Amp/250VAC. For a 230 VAC
installation, the fuse is the same style but rated at 3 Amp/250VAC.
CAUTION
Turn the printer’s AC Power Switch OFF and disconnect
the printer’s AC Power Cable before replacing the fuse.
To replace the fuse, insert the tip of a flatblade screwdriver into the slot
designed into the Fuse Holder’s End Cap. Press in slightly on the end cap and
turn the screwdriver slightly counter-clockwise. The end cap disengages from
the Fuse Holder and the fuse may be removed. To install a new fuse, reverse the
sequence.
VOLTAGE
SELECTION SWITCH
AC POWER FUSE
REPLACEMENT
AC POWER
ON/OFF SWITCH
AC POWER
CABLE CONNECTION
Figure 5.21 AC Fuse Replacement
38452L Rev. 3
Page 5-33
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
Battery Replacement
One of the factory-installed options for the 105S printer is the Battery
Backed-Up 256 KB RAM Memory. The Battery used with this option is a 3 VDC
Lithium Coin Battery type CR2477 (Zebra Part # 44641).
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended.
When discarding used batteries, do not incinerate.
The battery is located on the printer’s Main Logic Board. It is recommended that
a qualified Service Technician replace this battery since internal access to the
electronics area of the printer is required.
CAUTION
Turn the printer’s AC Power Switch OFF and disconnect
the printer’s AC Power Cable before replacing the battery.
Prior to removing and replacing the battery, observe proper
electrostatic and electrical safety precautions.
To remove the old battery, gently raise the right edge and slide the battery to the
right and out of the battery holder.
Insert the new battery with the negative (−) side toward the circuit board. The
positive (+) side should be visible when the battery is correctly installed.
To use the Battery Backed-Up RAM Memory, the “Battery Dead” condition must
be reset. The preferred method of resetting this condition is to send the “~JB”
ZPL II command to the printer.
A second method for resetting the “Battery Dead” condition is available at the
printer’s front panel. However, when this method is used, the printer
configuration is reset to the Factory Default condition. The printer must then be
reconfigured for the application and a Printer Calibration must be performed. To
reset the “Battery Dead” condition using this method, press and hold the PAUSE
and FEED Keys while turning the AC Power ON.
Cutter Adjustments and Replacement Instructions (105Se Only)
Printer Disassembly
The printer must be partially disassembled in order to remove and install parts.
Refer to the illustrations in this Section and follow the procedures that follow.
Page 5-34
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Internal Access
1.
2.
3.
Turn Printer Power OFF at the rear of the printer and disconnect the AC
Power Cord and all signal interface cables.
Remove all Media and Ribbon from the printer.
Access the Electronics Cabinet by removing the mounting screws in the left
side panel.
Cutter Motor Removal
1.
2.
3.
4.
5.
6.
7.
8.
9.
Refer to Figure 5.22. Remove the E-ring that attaches the Lower Drive Arm
to the Slotted Link.
Remove the screw that attaches the Mounting Post to the Main Frame.
Remove the cutter linkage, flat washer, and bearing from the printer.
Loosen the two set screws that attach the Lower Drive Arm to the Cutter
Motor shaft.
Pivot the Lower Drive Arm clockwise until the Lower Drive Arm flag
disengages the sensor.
Remove the Lower Drive Arm from the Cutter Motor shaft.
Disconnect the Cutter Motor Cable from the Cutter Board.
Remove the motor mounting screws that attach the Cutter Motor to the Main
Frame.
Pull the Cutter Motor away from the Main Frame, and the motor cable and
Grommet from the slot in the Main Frame.
Cutter Motor Installation
1.
2.
3.
4.
5.
6.
7.
8.
9.
Refer to Figure 5.22. Position the Cutter Motor near the mounting hole on
the mechanical side of the printer.
Pass the Cutter Motor Cable through the slit in the Rubber Grommet. Insert
the Grommet into the slot located in the lower right area of the motor
mounting hole, then slide it into the small hole. The electrical connector
must be positioned on the electronics side of the printer. (To prevent the
wires from coming out, rotate the Grommet so the cut is facing away from
the motor.)
Position the Cutter Motor against the printer frame so that the screw holes in
the motor line up with the holes in the frame, with the motor shaft toward the
front of the printer.
Use the two motor mounting screws to firmly attach the motor to the printer
frame.
Insert the Lower Drive Arm onto the Cutter Motor shaft.
Pivot the Lower Drive Arm counterclockwise until the Lower Drive Arm
flag engages the sensor.
Tighten the set screws that attach the Lower Drive Arm to the Cutter Motor
shaft.
Reinstall the cutter linkage, flat washer, and bearing.
Replace the screw that attaches the Mounting Post to the Main Frame.
38452L Rev. 3
Page 5-35
Page 5-36
38452L Rev. 3
LOWER DRIVE
ARM
CUTTER OPTICAL SENSOR
CLAMP
SLOTTED LINK
MOUNTING POST
LONG DRIVE
LINK
CUTTER OPTICAL
SENSOR
INSET
DETAIL A
LOWER CUTTER
BRACKET
CUTTER MOTOR
Figure 5.22 Cutter Installation
CUTTER MOTOR
SHAFT
UPPER DRIVE ARM
MEDIA GUIDE
UPPER CUTTER
BRACKET
STATIC BRUSH & MOUNTING
BRACKET
CUTTER
CUTTER BOARD
NUT PLATE
DETAIL A
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
10. Install the E-ring that attaches the Slotted Link to the Lower Drive Arm.
Cutter Mechanical Assembly Removal
NOTE: The Cutter Module should NOT be disassembled, but replaced as a unit.
Any disassembly of the Cutter Module will void the warranty.
1.
2.
3.
4.
5.
6.
7.
Refer to Figure 5.22. Remove the E-ring and washer from the top of the
Long Drive Link.
Refer to Figure 5.22, Detail A. At the Side Plate, remove the two socket
head cap screws from the Upper Cutter Bracket and Nut Plate.
Loosen the flat head screw that attaches the Upper Cutter Bracket to the
Cutter Module.
Remove the two socket head cap screws from the Lower Cutter Bracket.
Lift the outer end of the Cutter Module to remove the module.
Remove the two flat head screws that attach the Media Guide and Upper
Cutter Bracket to the Cutter Module.
Remove the four Phillips head screws that attach the Static Brush Mounting
Bracket too the bottom of the Cutter Module.
Cutter Mechanical Assembly Installation
1.
2.
3.
4.
5.
6.
Refer to Figure 5.22. Use the four Phillips head screws to attach the Static
Brush Mounting Bracket to the bottom of the Cutter Module.
Use the two flat head screws to mount the Media Guide and Upper Cutter
Bracket to the Cutter Module.
Carefully work the Cutter Module into position in the Main Frame in front
of the Printhead.
Loosely attach the Upper Cutter Bracket to the Side Plate with the Nut Plate
and two socket head cap screws.
Align the slots in the Lower Cutter Bracket with the threaded holes in the
Main Frame. Loosely attach the Lower Cutter Bracket with the two socket
head cap screws.
With the Cutter Module loosely installed, it is necessary to properly align it
and tighten all of the screws.
Open the Printhead and observe the position of the Tear-Off Bar (in front of
the Platen Roller) and the Rear Cutter Blade. Position the Cutter Module so
that the Rear Cutter Blade is parallel with the outer edge of the Tear-Off
Bar across the entire width of the media path. The Cutter Module should be
positioned as far forward as possible while maintaining parallelism with the
Tear-Off Bar. This should prevent interference of the Rear Cutter Blade
with the Tear-Off Bar.
After the above conditions are both met, tighten all mounting screws.
Carefully tighten the flat head screw that attaches the Upper Cutter Bracket
to the Cutter Module. Be careful not to disturb the position of the Media
Guide; if this part moves out of position, set its height so that its lower edge
is flush with the rear opening in the Cutter Module.
38452L Rev. 3
Page 5-37
Corrective Maintenance
7.
8.
9.
S -Series Maintenance Manual: Volume 1
The Rear Cutter Blade is held in position by two springs. If these springs
touch the Tear-Off Bar or other printer parts, the Rear Cutter Blade will not
float properly and will cause excessive wear and premature failure of the
Cutter Blades.
Check the clearance between the back of the Cutter Mechanism and the
Tear-Off Bar by inserting a screwdriver from the front of the Cutter
Mechanism and press the top of the Rear Cutter Blade toward the printer.
The blade should move a minimum of .030 inches. If necessary, loosen the
four Phillips head screws on the bottom of the Cutter Module and reposition
the Cutter Mechanism away from the Tear-Off Bar.
Attach the E-ring and washer to the Upper Drive Arm at the top of the Long
Drive Link.
Drive Link Assembly Installation
1.
2.
3.
4.
Refer to Figure 5.22. Remove the screw from the Mounting Post on the
Drive Link Assembly. Locate the Post in the mounting hole in the frame
and, from the media side of the frame, secure the Assembly with the screw.
The Upper Drive Arm is pre-assembled to the Cutter Module. Assemble the
Long Drive Link of the Drive Link Assembly over the connecting post on the
Upper Drive Arm and secure it with the washer and E-ring.
Attach the Lower Drive Arm of the Drive Link Assembly to the Cutter
Motor Shaft. Loosen the set screws to insure the Lower Drive Arm rotates
freely on the Motor shaft.
Apply a small amount of grease to the slot in the Slotted Link Assembly
where the Bearing will ride. Remove any excess grease to avoid damaging
the Cutter Optical Sensor.
Cutter Circuit Board Removal
1.
2.
3.
Refer to Figure 5.22. Disconnect all cables from the Cutter Board.
Remove the four socket head cap screws that mount the Cutter Board to the
standoffs.
Remove the Cutter Board.
Cutter Circuit Board Installation
1.
2.
3.
4.
5.
6.
7.
Page 5-38
Refer to Figure 5.23. Attach the power cable to J1 on the Cutter Circuit
Board.
Refer to Figure 5.23. Attach the data cable to J2 on the Cutter Circuit Board.
Locate the four (4) standoffs on the printer frame where the Cutter Board
will be mounted.
Route the Cutter Motor Wires between the two righthand standoffs and out
under the bottom of the Circuit Board.
Position the Cutter Circuit Board over all four standoffs.
Insert the screw through the lower right-hand Circuit Board mounting hole
(do not tighten at this time).
Install the three remaining mounting screws and tighten all four screws.
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Figure 5.23 Cutter Circuit Board
8.
Pass the Cutter Board Power Cable along the bottom of the printer frame
toward the Main Logic Board.
9. Plug the Cutter Motor leads into the Cutter Motor Connector, J3, on the
Cutter Circuit Board. (Black lead to the left. Note: This is a “polarized”
connector.)
10. Refer to Figure 5.23. Plug the Cutter Sensor wires into the Cutter OPTO
Connector, J6, on the Cutter Circuit Board.
11. Check the installation work and insure that during operation no wiring will
touch any moving parts.
Optical Sensor Removal
1.
2.
Refer to Figure 5.22. Remove the nut that holds the Cutter Optical Sensor
Assembly (wires, Sensor Clamp, and Optical Sensor) in position.
Lift the Cutter Optical Sensor Assembly off the Sensor Mounting Post.
Optical Sensor Installation
1.
2.
3.
Refer to Figure 5.22 and the Figure 5.22 inset. Install the Cutter Optical
Sensor Assembly on the Sensor Mounting Post. (The Sensor part of the
Assembly should be mounted toward the printer frame.)
Place the Sensor Clamp over the Optical Sensor and start the nut on the
Sensor Mounting Post. (DO NOT tighten the nut.)
Route the Sensor wires under the clamp and toward the rear of the printer,
and lightly tighten the nut to hold the wires in position. (DO NOT pinch
the wires.)
Lower Drive Arm Mechanical Alignment
1.
Connect the Power Cable from J1 on the Cutter Board to J4 on the Printhead
Adapter Board.
38452L Rev. 3
Page 5-39
Corrective Maintenance
2.
3.
S -Series Maintenance Manual: Volume 1
Connect the Data Ribbon Cable from J2 on the Cutter Board to J5 on the
Main Logic Board.
Attach the AC Power Cord and turn the printer ON. (If the Cutter Motor
starts, wait for it to stop.)
NOTE: A critical position adjustment is made in steps 4 and 5. The Cutter Motor
must be rotated until the two flat surfaces on the Cutter Motor shaft are
aligned with the set screws in the Lower Drive Arm, while the Lower Drive
Arm is in a vertical position (Sensor Flag down).
4.
5.
6.
7.
8.
9.
Refer to Figure 5.23. Attach a test clip at one end of a jumper cable to the
lead on the left end of Capacitor C6 (+5 VDC SOURCE) on the Cutter
Board.
Briefly touch the test clip at the other end of the jumper cable to Test Point
TP1 on the Cutter Board to “jog” the Cutter Motor to the desired position.
Position the Lower Drive Arm so the Sensor Flag is centered between the
front and back portions of the Cutter Optical Sensor, then tighten the two
set screws.
The set screws must be extremely tight to insure proper operation of the
Cutter Mechanism. Tighten the set screws with a 5/64" Allen Key. (As a
reference, when the set screws are tight, the Allen Key should deflect
approximately 0.6" (1.5 cm) past the point of tightness. The tightness
specification is 20 in. lbs. (2.3 N-m).
Activate the Cutter Motor, and make certain the Sensor Flag travels through
the slot in the Cutter Optical Sensor without touching it.
Turn the printer Power Switch OFF.
Upper Drive Arm Alignment
The Upper Drive Arm is part of the Cutter Mechanical Assembly and has been
properly aligned at the factory. If for some reason the factory position is altered,
the following procedure may be used to realign the Upper Drive Arm. The
printer must be programmed to operate in the Cutter Mode prior to performing
the following procedure.
1.
2.
Remove the printer’s Left Side Panel, if attached.
Loosen the Allen head cap screw that clamps the Upper Drive Arm to the
Rotary Cutter Blade shaft. (The Drive Arm may be snug on the shaft.)
3. Apply power to the printer. The Lower Drive Arm of the Drive Link
Assembly should rotate once and stop when the Sensor Flag activates the
Optical Sensor.
4. Refer to Figure 5.24. Only after the preceeding step, hold the Upper Drive
Arm in position and adjust the Rotary Cutter Blade so that the gap between
its cutting edge on the left end and the cutting edge of the Rear Cutter Blade
is approximately a .100" (2.5mm) as gauged by eye.
NOTE: If the gap between the cutting edges is too large, the cutter may not cut
properly across the entire media width. If the gap is too small, the media may
catch on the Rotary Cutter Blade edge and cause a jam.
5. Position the Upper Drive Arm out from the cutter frame so its flat surface is
flush with the end of the Rotary Cutter Blade shaft.
Page 5-40
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Corrective Maintenance
Tighten the Allen head cap screw with a 5/32 inch Allen bit socket on a
torque wrench until the slot closes or until a torque of 100 in. lbs.
(11.3 N-m) is reached.
NOTE: Overtightening the screw can damage the Drive Arm and can strip the
threads.
6. Test the Cutter alignment by feeding maximum-width label stock through
the printer and insuring that complete cutting of the label occurs. (If
necessary, repeat steps 4, 5, and 6 to achieve complete cutting of the labels.)
7. With a felt tip pen, draw a line across the outer face of the Upper Drive Arm
and the end of the cutter blade shaft. Should cutter operation problems ever
occur, this “witness mark” will show at a glance if the alignment of the
clamp and the cutter blade shaft has changed.
ROTARY CUTTER BLADE
UPPER CUTTER BRACKET
MOUNTING SCREW
MEDIA GUIDE
INSURE THE TOP OF THE TEAR
TEAR-OFF
OFF BAR IS POSITIONED ABOVE
BAR
OR LEVEL WITH THE TOP OF
THE REAR CUTTER BLADE
CLEARANCE OF .030"
MINIMUM BETWEEN
REAR CUTTER BLADE
AND TEAR-OFF BAR
RELATIVE POSITION OF THE ROTARY CUTTER
BLADE WHEN THE DRIVE LINK ASSEMBLY IS
STOPPED BY THE OPTICAL SENSOR, WHEN
THE POWER IS ON IN THE CUTTER MODE
.100"
(2.5 mm)
REAR CUTTER
BLADE
10421 SCREWS (4) CONTROL
POSITION OF CUTTER MODULE
& SQUARENESS TO MEDIA
Figure 5.24 Cutter Mechanical Assembly Positioning
38452L Rev. 3
Page 5-41
Corrective Maintenance
S -Series Maintenance Manual: Volume 1
R
Page 5-42
38452L Rev. 3
6
Troubleshooting
In this section...
Page
Troubleshooting...............................................................................6-1
Power-ON Troubleshooting.....................................................6-1
General Troubleshooting..........................................................6-2
Cutter Module Troubleshooting ..............................................6-4
Sample Labels..................................................................................6-5
Factory Assistance ..........................................................................6-11
Returning Equipment......................................................................6-11
Troubleshooting
Consult the Troubleshooting Tables which follow and compare the printer output
to the sample labels provided on the following pages to improve the quality of
your labels.
Table 6.1 Power-ON Troubleshooting
SYMPTOM
DIAGNOSIS
All LEDs light and
stay ON, or all LEDs
(except POWER
LED) never turn ON.
Main Logic Board or EPROM faulty
or loose interconnecting cables.
Insure cables are properly connected
and EPROMs are properly installed
or replace the Main Logic Board.
CALIBRATE LED
turns OFF after 5 sec.
but all other LEDs
stay ON.
Main Logic Board Dynamic RAM
faulty.
Replace Main Logic Board.
All LEDs Flash ON
and OFF.
No significant amount of DRAM
tested good.
Replace Main Logic Board.
All LEDs (except
POWER LED) are
OFF and no printer
operation possible.
Printer misconfigured for Peel-Off
Mode and Peel-Off Option not
installed.
If Peel-Off is installed, check Take
Label Sensor.
Printer locks up
while running Power
On Self Test.
Main Logic Board failure.
Replace Main Logic Board.
38452L Rev. 3
ACTION
Page 6-1
S -Series Maintenance Manual: Volume 1
Troubleshooting
Table 6.2 General Troubleshooting
SYMPTOM
Printer stops.
RIBBON LED and
PAUSE LED both
ON.
Printer stops.
PAPER/RIBBON
LED Flashes and the
PAUSE LED ON.
DIAGNOSIS
ACTION
Media not loaded or incorrectly loaded.
Load media correctly.
Misadjusted Media Sensor.
Check Media Sensor operation.
Adjust if necessary. (Run Printer
Calibration).
1. In continuous media mode,
non-continuous media is loaded.
2. In non-continuous media mode,
continuous media is loaded.
1. Calibrate.
2. Calibrate.
Ribbon not loaded or incorrectly
loaded.
Load ribbon correctly.
Ribbon Sensor not sensing ribbon that
is loaded correctly.
Check Ribbon Sensor operation.
Adjust if necessary. (Run Printer
Calibration).
Misadjusted Ribbon Sensor.
1. Calibrate.
1. In thermal transfer mode, ribbon is 2. Calibrate.
out.
2. In thermal direct mode, ribbon is in.
Printer stops. HEAD
OPEN LED Flashes
and PAUSE LED ON.
Printhead is not fully closed.
Close printhead completely.
Head Open Sensor not detecting Flag
or Flag not in proper position.
Check Head Open Sensor and Flag
for proper operation.
Printer stops and
HEAD LED ON.
Printhead element is overheated.
Printer resumes printing when the
printhead element cools.
Printer prints across
web or in wrong
position.
Loss of registration indicating a
Media Sensor problem.
Adjust Media Sensor position and
then, if needed, adjust the Media
Sensor sensitivity.
Printer set for continuous media, but
non-continuous media is loaded.
Set printer for correct type of media.
Continuous printing
occurring with the
HEAD LED ON.
Printhead under temperature.
Check print quality. Printhead will
heat up by printing, or move printer to
a warmer area.
Printer stops and
PAUSE LED lights.
Not enough memory to perform one
of the functions shown below.
You may do any of the following:
Functions:
1. Download Graphics.
2. Creating Bitmap
(not enough memory
for length of label).
3. Building Format
(label too complex).
Page 6-2
38452L Rev. 3
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.
S -Series Maintenance Manual: Volume 1
Troubleshooting
Table 6.2 General Troubleshooting (Cont'd)
SYMPTOM
Poor Print
Quality.
DIAGNOSIS
ACTION
Darkness too low.
Increase Burn Temp.
Incorrect Media and Ribbon
combination.
Replace Media or Ribbon.
Printhead Adjustments incorrect.
Perform required adjustments.
Label Length Parameter is set less
than the actual label length.
Set the correct label length.
Printer was powered ON in Peel-Off
mode without media being properly
loaded.
Load media correctly for Peel-Off
mode.
Printer is not calibrating media
properly.
Perform Media Adjustments.
Set value with the “^SS” ZPL II
command.
Long tracks of
missing print on
several labels.
Wrinkled ribbon.
See “Wrinkled Ribbon” below.
Print Element
damaged.
Replace printhead.
Fine gray lines
on blank labels
at angles.
Wrinkled ribbon.
See “Wrinkled Ribbon” below.
Wrinkled ribbon.
Ribbon fed through machine
incorrectly.
Load ribbon correctly.
Incorrect Darkness setting.
Set the Darkness to the lowest setting
possible for good print quality.
Incorrect printhead pressure
or balance.
Set the pressure to the minimum
needed. See Print Quality Adjustment
and Printhead Pressure Adjustment
procedures.
Media not feeding properly; it is
walking from side to side.
Make sure the media path remains
straight by positioning the Media
Guide closer to the media.
Strip Plate needs adjusting.
Perform adjustments.
Ribbon Supply Spindle needs
cleaning or tension needs adjusting.
Perform cleaning or adjustments.
Printhead needs realigning
with Platen Roller.
Perform adjustments.
Ribbon Take-up Spindle needs
cleaning or tension needs adjusting.
Perform cleaning or adjustments.
Printhead pressure needs balancing.
Adjust balance. See Printhead
Pressure Adjustment procedures.
Truncated print, no
print, or FEED Key
operates incorrectly
while using
non-continuous
media.
Light printing or no
printing on the left or
right side
of the label.
38452L Rev. 3
Page 6-3
S -Series Maintenance Manual: Volume 1
Troubleshooting
Table 6.2
SYMPTOM
Misregistration and
skips labels.
Misregistration and
misprint of
1 to 3 labels.
Vertical drift in
top-of-form
registration.
General Trou blesh ootin g
DIAGNOSIS
ACTION
Misadjusted Media Sensors.
Perform Media Sensor Adjustments.
Improper spindle tensions.
Perform Spindle Adjustments.
Improper ZPL II format.
Correct the ZPL II format.
Media was pulled when motor was
not moving.
Open and close the printhead.
Printer, that is in Peel-Off mode, was
powered ON without media being
properly loaded.
Load media correctly for
Peel-Off mode.
Misadjusted Media Sensor.
Place Media Sensor in the proper
position.
A plus or minus 4-6 dot row (approx.
1/2 mm) vertical drift is possible due
to the different tolerances and printer
modes.
Perform the “Tear-Off Position
Setting” front panel command
to correct.
Label jam in rear area Upper Media Plate needs cleaning.
of printhead.
Changes in parameter
settings did not take
effect.
(cont 'd)
Clean the Upper Media Plate.
All MODE LEDs must be OFF before The “^MPE” ZPL II command
turning the power OFF. A “^MPS”
enables all mode functions to be
ZPL II command disables Mode
front panel programmable.
Function Save.
If the problem continues, there may
be a problem on the Main Logic
Board.
Replace the Main Logic Board.
Table 6.3 Cutter Module Troubleshooting
SYMPTOM
Printing stops.
PAPER/RIBBON,
PAUSE, and
CANCEL LEDs on.
DIAGNOSIS
ACTION
Media jammed in Cutter.
Remove media, clean Cutter Module.
Connecting cables not connected to
Cutter Circuit Board.
Plug cables into Cutter Circuit Board.
Cutter Module is dirty.
Clean Cutter Module.
End of the media is not positioned
correctly on top of the platen.
Re-position media so that the end is
on top of the platen.
In Cutter Mode,
skewed or stuck
labels.
Cutter is dirty.
Clean the Cutter Module.
The Cutter is not
cutting labels cleanly.
Cutter is dirty.
Clean the Cutter Module.
Cutter blades are dull.
Replace the Cutter Module.
Labels jamming in
Cutter, or labels are
being cut more than
once.
Cutter is dirty.
Clean the Cutter Module.
Label length is too short.
Increase label length. See “Adjusting
the Tear-Off Position” in Getting
Ready to Print.
Page 6-4
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Troubleshooting
Sample Labels
The following pages contain sample labels to be used with the preceding
troubleshooting charts. These labels illustrate conditions which could be seen if
mechanical adjustments are necessary.
Zebra Z-Trans 3P media stock and type 5319 ribbon were used to obtain these
labels. Any other label and ribbon stock combinations may produce sample labels
with similar but not necessarily the same results.
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
S -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
S -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
Troubleshooting
S -Series Maintenance Manual: Volume 1
Unacceptable Label:
Darkness properly set
Printhead too far back
Breakup on trailing
edges of bars (opposite the direction
of movement)
Black is splotchy
Printhead needs to
come forward on
both sides
Toggles balanced
(equal pressure on left
and right sides)
Unacceptable Label:
Darkness properly set
Printhead way too far back
Breakup on trailing
edges of bars (opposite the direction
of movement)
Black is splotchy
Printhead needs to
come forward on
both sides
Toggles balanced
(equal pressure on left
and right sides)
Page 6-8
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Troubleshooting
Unacceptable Label:
Darkness properly set
Printhead position
correct on right side way
too far back on left side
Noisy printing
(breakup on trailing edges
of horizontal bars splotchy on left side)
Toggles balanced
(equal pressure on left
and right sides)
Unacceptable Label:
Darkness Properly Set
Printhead Position
Correct On Left Side Way
Too Far Back On Right
Side
Noisy Printing
(Breakup on Trailing
Edges of Horizontal Bars
- Splotchy On Right Side)
Toggles Balanced
(Equal Pressure On Left
and Right Sides)
38452L Rev. 3
Page 6-9
Troubleshooting
S -Series Maintenance Manual: Volume 1
Unacceptable Label:
Darkness properly set
Printhead position
correct on left side too far
forward on
right side
Noisy printing
(breakup on leading edges
of horizontal bars splotchy on right side)
Toggles balanced
(equal pressure on left
and right sides)
Unacceptable Label:
Darkness Properly Set
Printhead Position
Correct On Right Side
Way Too Far Forward
On Left Side
Noisy Printing
(Breakup on Leading
Edges of Horizontal Bars
- Splotchy On Left Side)
Toggles Balanced
(Equal Pressure On Left
and Right Sides)
Page 6-10
38452L Rev. 3
S -Series Maintenance Manual: Volume 1
Troubleshooting
Factory Assistance
Should any problem be encountered which cannot be corrected with the aid of this
manual, Technical Support should be contacted immediately to minimize or avoid
printer downtime. Technical Support can also assist in determining if the printer
should be returned for repair.
Returning Equipment
Should it become necessary to ship your printer, carefully pack the printer in a
suitable container to avoid damage during transit. A note describing the failure
must be enclosed with the unit. Whenever possible, the original shipping
container should be used. If other containers are used, a procedure similar to the
original factory packaging should be followed.
Enclose the unit in a protective, dust-proof bag and insure that the unit floats in
an outer carton of shock-absorbing material.
A Return Materials Authorization (RMA) number is required for all equipment
being returned. Contact Zebra Technologies Corporation’s Technical Support
Department to obtain an RMA number. Equipment returned for service without
prior authorization may be refused.
CAUTION
Remove any ribbon and paper rolls from the media compartment,
otherwise damage to the printer could result.
DO NOT package the printer in a rigid container without utilizing
shockmounts or shock-absorbing packing material. A rigid
container may cause damage to the printer by allowing shock on
the outside to be transmitted undamped to the unit.
38452L Rev. 3
Page 6-11
Troubleshooting
S -Series Maintenance Manual: Volume 1
R
Page 6-12
38452L Rev. 3
105S and 160S Parts Lists
7
In this section...
Page
Mechanical Parts and Assemblies ................................................7-1
Mechanical Parts and Assemblies Listing...................................7-1
Please note: This section contains common parts lists and drawings for
both the 105S and 105Se. For parts lists/drawings specific to the 105Se,
refer to Section 8.
Mechanical Parts and Assemblies
MECHANICAL PARTS AND ASSEMBLIES
Description
105S (6 and 8 Dot/mm) Final Assembly (Page 1 of 2)
105S (6 and 8 Dot/mm) Final Assembly (Page 2 of 2)
105S (12 Dot/mm) Final Assembly (Page 1 of 2)
105S (12 Dot/mm) Final Assembly (Page 2 of 2)
160S Final Assembly (Page 1 of 2)
160S Final Assembly (Page 2 of 2)
105S and 160S Base Assembly
105S Print Mechanism Assembly
160S Print Mechanism Assembly
105S (6 and 8 Dot/mm) Printhead Support Assembly
105S (12 Dot/mm) Printhead Support Assembly
160S Printhead Support Assembly
105S and 160S Media Guide Assembly
105S Ribbon Supply Spindle Assembly
160S Ribbon Supply Spindle Assembly
105S Ribbon Take-Up Spindle Assembly
160S Ribbon Take-Up Spindle Assembly
105S Peel-Off Rewind Spindle Assembly
160S Peel-Off Rewind Spindle Assembly
105S Media Rewind Spindle Assembly
160S Media Rewind Spindle Assembly
105S Peel-Off Option Assembly
160S Peel-Off Option Assembly
105S Media Rewind Option Assembly
160S Media Rewind Option Assembly
38452L Rev. 3
Page #
7-2/7-3
7-4/7-5
7-6/7-7
7-8/7-9
7-10/7-11
7-12/7-13
7-14/7-15
7-16/7-17
7-18/7-19
7-20/7-21
7-22/7-23
7-24/7-25
7-26/7-27
7-28/7-29
7-30/7-31
7-32/7-33
7-34/7-35
7-36/7-37
7-38/7-39
7-40/7-41
7-42/7-43
7-44/7-45
7-46/7-47
7-48/7-49
7-50/7-51
Page 7-1
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S (6 dot and 8 dot)
Final Assembly (Page 1 of 2)
PART NUMBER
DESCRIPTION
01130
01152
Nut, 6-32
Washer, Flat, .375 x .156 x .65
01155
01159
01448
01912
07435
07696
09367
30240
30256
30269
30391-004
30391-006
30392-004
30407-008
Washer, Lock, #4
Washer, External Lock, #6
Screw, 6-32 .37
Washer, External Lock, #4
Screw, 6-32 .37
Screw, 4-40 .31
Stand-Off, 4-40
Cover Plate with Opening (Serial)
Nut, Thumb, 6-32 .50
Pad, PVC, 4.0 x .37 .062
Screw, 4-40 .25
Screw, 4-40 .37
Screw, 6-32 .25
Screw, 6-32 .5
30916
31019
31020
31037
31038
31100M
31102
31103
31240
31517
31524M
31530M
31535M
31690M
31691M
31646M
35040
40342
45039
46325-3
Strap, Ground
Label, Logo, 105S
Label, Model Number
Cover, PCB, 105S
Panel, Left Side
Assembly, Membrane Switch, Front Panel
Panel, Rear PCB (Serial)
Panel, Rear PCB (Parallel)
Cover Plate with Opening (Parallel)
Shield, High Voltage
PCB, Front LED
PCB, Serial Main Logic
PCB, Serial Main Logic (w/Battery Backup)
PCB, Parallel Main Logic
PCB, Parallel Main Logic (w/Battery Backup)
Circuit Board, Power Supply
Door, Media Access
Bracket, Front Cover
Panel, Left Top
Spacer, 6-32
Page 7-2
38452L Rev. 3
QUANTITY
9
2
2
4
4
4
3
2
2
1
2
2
2
2
18
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
01159
01912
31102 (SERIAL)
31103 (PARALLEL)
30240 (SERIAL)
31240 (PARALLEL)
07696
01155
T
46325-3 (6)
F/R
F/R
S
B
S
B
T
30256
T
09367
S
S
T
E
01152
30391-006
30407-008
K
K
01130
07435
01448
30391-004
30392-004
Serial Only
P
Serial Only
F
Parallel Only
R
MOUNTING HARDWARE
E
E
E
E
E
E
J
J
J
J
31524M
E
40342
E
, L (2)
105S (6 & 8 Dot/mm) Final Assembly
Page 7-3
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S (6 dot and 8 dot)
Final Assembly (Page 2 of 2)
PART NUMBER
30257
30307
30336-1M
30336-2M
30355M
30357M
30914M
40355M
40357M
45189-2
45189-5
Page 7-4
DESCRIPTION
Pulley, Peel-Off Platen (6 Dots/mm)
Flag, Head Open
Pulley, Ribbon Take-Up
Pulley, Media Take-Up
Pulley, Main Platen (6 Dots/mm)
Pulley, Stepper Motor (6 Dots/mm)
Pulley, Peel-Off Platen (8 Dots/mm)
Pulley, Main Platen (8 Dots/mm)
Pulley, Stepper Motor (8 Dots/mm)
Belt, Media Rewind
Belt, Main Drive
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
105S Final Assembly (page 2 of 2)
Page 7-5
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S (12 dot)
Final Assembly (Page 1 of 2)
PART NUMBER
01130
01152
01155
01159
01448
01912
07435
07696
09367
30240
30256
30269
30391-004
30391-006
30392-004
30407-008
30916
31019
31020
31037
31038
31100M
31101
31103
31240
31517
31524M
31646M
35040
38530M
38691M
40342
45039
46325-3
Page 7-6
DESCRIPTION
Nut, 6-32
Washer, Flat, .375 x .156 x .65
Washer, Lock, #4
Washer, External Lock, #6
Screw, 6-32 .37
Washer, External Lock, #4
Screw, 6-32 .37
Screw, 4-40 .31
Stand-Off, 4-40
Cover Plate with Opening (Serial)
Nut, Thumb, 6-32 .50
Pad, PVC, 4.0 x .37 .062
Screw, 4-40 .25
Screw, 4-40 .37
Screw, 6-32 .25
Screw, 6-32 .5
Strap, Ground
Label, Logo, 105S
Label, Model Number
Cover, PCB, 105S
Panel, Left Side
Assembly, Membrane Switch, Front Panel
Panel, Rear PCB (Serial)
Panel, Rear PCB (Parallel)
Cover Plate with Opening (Parallel)
Shield, High Voltage
PCB, Front LED
Circuit Board, Power Supply
Door, Media Access
PCB, Serial Main Logic
PCB, Parallel Main Logic
Bracket, Front Cover
Panel, Left Top
Spacer, 6-32
QUANTITY
9
2
2
4
4
4
3
2
2
1
2
2
2
2
18
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
31526
A
38530M (SERIAL W/300 DPI HEAD)
38691M (PARALLEL W/300 DPI HEAD)
30240 (SERIAL)
31240 (PARALLEL)
46325-2
31101 (SERIAL W/300 DPI HEAD)
31103 (PARALLEL W/300 DPI HEAD)
01159
01912
07696
01155
T
46325-3 (6)
F/R
F/R
S
B
S
B
T
30256
T
09367
S
S
T
E
01152
30391-006
30407-008
K
K
01130
07435
01448
30391-004
30392-004
Serial Only
P
Serial Only
F
Parallel Only
R
MOUNTING HARDWARE
E
E
E
E
E
E
J
J
J
J
31524M
E
40342
E
, L (2)
105S(12
(12Dot/mm)
Dot/mm)Final
FinalAssembly
Assembly
105S
Page 7-7
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S (12 dot)
Final Assembly (Page 2 of 2)
PART NUMBER
30307
30336-1M
30336-2M
30357M
30914M
31526
40355M
45189-2
45189-5
Page 7-8
DESCRIPTION
Flag, Head Open
Pulley, Ribbon Take-Up
Pulley, Media Take-Up
Pulley, Stepper Motor (12 Dots/mm)
Pulley, Peel-Off Platen (12 Dots/mm)
Assembly, Adaptor Board
Pulley, Main Platen (12 Dots/mm)
Belt, Media Rewind
Belt, Main Drive
QUANTITY
1
1
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
105S (12 Dot/mm) Final Assembly
Page 7-9
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Final Assembly (Page 1 of 2)
PART NUMBER
01130
01152
01155
01159
01448
01912
07435
07696
09367
30240
30269
30391-004
30391-006
30392-004
30407-008
30916
31038
31100M
31240
31517
31524M
35040
38019
38020
38037
38039
38102
38103
38342
38530M
38646M
38691M
Page 7-10
DESCRIPTION
Nut, 6-32
Washer, Flat, .375 x .156 x .65
Washer, Lock, #4
Washer, External Lock, #6
Screw, 6-32 .37
Washer, External Lock, #4
Screw, 6-32 .37
Screw, 4-40, .31
Stand-Off, 4-40
Cover Plate with Opening (Serial)
Pad, PVC 4.00 x .37 x .062
Screw, 4-40 .25
Screw, 4-40 .37
Screw, 6-32 .25
Screw, 6-32 .5
Strap, Ground
Panel, Left Side
Assembly, Membrane Switch, Front Panel
Cover Plate with Opening (Parallel)
Shield, High Voltage
Circuit Board, Front LED
Door, Media Access
Label, Logo
Label, Logo
Panel, Right Top
Panel, Left Top
Panel, Rear PCB, Serial
Panel, Rear PCB, Parallel
Bracket, Front Cover
Circuit Board, Serial Main Logic
Circuit Board, Power Supply
Circuit Board, Parallel Main Logic
QUANTITY
4
2
2
4
4
4
3
2
2
1
2
2
2
19
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
C
38102 (SERIAL)
38103 (PARALLEL)
38530M (SERIAL)
38691M (PARALLEL)
31038
REMOVE MASKING DISC
C
C
A
31517
A
A
B
T
S
46325-3
(5 PLCS)
A
A
B
S
A
30916
S
L
K
K
35040
30269 (2)
A
A
K
30391-006
J
30407-008
G
T
C
01152
H
S
38646M
01155
M
T
30240
01912
N
A
A
01159
S
P
T
A
T
R
A
P
P
A
105 S and 160 S Parts Lists
30256
F
A
E
01130
D
07435
C
01448
B
30391-004
A
30392-004
CODE
PART NUMBER
SCREW LIST
E
E
E
E
E
38037
38039
J
J
E
A
A
A
38020
31524M
GROUND TAIL
J
D
A
J
38342
A
E
D
E
L
D
31100M
ALIGN W/FIXTURE
G
G
38019
DETAIL A
DETAIL A
160S Final Assembly (page 1 of 2)
Page 7-11
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Final Assembly (Page 2 of 2)
PART NUMBER
30307
30336-1M
30336-2M
30914M
40355M
40357M
45189-2
45189-5
Page 7-12
DESCRIPTION
Flag, Head Open
Pulley, Ribbon Take-Up
Pulley, Media Take-Up
Pulley, Peel-Off Platen (8 Dots/mm)
Pulley, Main Platen (8 Dots/mm)
Pulley, Stepper Motor (8 Dots/mm)
Belt, Media Rewind
Belt, Main Drive
QUANTITY
1
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
MEDIA REFLECTIVE SENSOR
MEDIA TRANSMISSIVE SENSOR
RIBBON SENSOR
HEAD OPEN SENSOR
TAKE LABEL SENSOR
30307
NOTE 3
NOTE 4
45189-5
MEMBRANE
SWITCH CABLE
4. TRANSMISSIVE SENSOR POSITION
WHEN EXTENDING THE MEDIA SENSOR POSITION TO THE OUTER HALF
OF THE MEDIA WIDTH, REROUTE THIS CABLE TO PROVIDE SUFFICIENT
SLACK FOR PULLING THROUGH THE MAIN FRAME.
45189-2
WHEN REPOSITIONING THE MEDIA SENSOR BACK TO THE INNER HALF
OF THE MEDIA WIDTH, PULL THIS CABLE BACK THROUGH THE MAIN
FRAME AND REROUTE THIS CABLE TO REMOVE ANY SLACK.
IN BOTH CASES, POSITION CABLES AWAY FROM ALL BELTS AND PULLEYS.
GROUND TAIL
160S Final Assembly (page 2 of 2)
Page 7-13
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S and 160S
Base Assembly
PART NUMBER
06576
07435
08754
46015
Page 7-14
DESCRIPTION
Guide, PCB, Nylon
Screw, 6-32, .37
Eyelet, .183 x .157 x .187
Bumper, Round, 1.09 x .62
QUANTITY
2
4
4
4
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
46015 (4)
105S and 160S Base Assembly
Page 7-15
105 S and 160 S Parts Lists
PART NUMBER
01130
01159
02252
06250
06268
06319
07229
30033
30104
30105
30106
30114
30115
30118
30239
30247
30256-B
30307
30336-1M
30353M
30355M
30357M
30392-004
30392-008
30393-006
30423-003
30466
30488
35020
35025
35082
35099M
35136
35137
35302RM
35909
PRINTER MODEL: 105S
Print Mechanism Assembly
DESCRIPTION
Nut, 6-32
Washer, Extended Lock, #6
Ring, Crescent, .250
E-Ring, External, .312
Washer, Lock, #6
Screw, 10-32 .37
Washer, Curved, .49 x .33 x .0075
Media Guide, Adjustable
Flange, Ball Bearing, .5 x .250 x .125
Bearing, Nylon, .312 x .251 x .078
Ring, Crescent, External, .312
Washer, Flat, .76 x .51 x .03
Washer, Wave, .740 x .520 x .080
Ring, “E”, External, .500 x .042
Washer, Crescent, .415 x .323 x .062
Washer, Flat, .42 x .260 x .0747
Nut, Thumb
Flag, Head Open
Assembly, Ribbon Take-Up Pulley
Assembly, Head Open Sensor
Assembly, Platen Pulley (6 Dots/mm)
Assembly, Stepper Motor Pulley (6 Dots/mm
and 12 Dots/mm)
Screw, 6-32 .25
Screw, 6-32 .50
Screw, 8-32 .37
Screw, Set, 8-32 .187
Washer, .26 x .63 x .06
Nut, 1/4-20
Bracket, Media Sensor
Roller Segment
Guide, Media
Assembly, Toggle
Washer, Nylon, .252 x .472 x .059
Ring, Retainer, .250
Assembly, Media Sensor
Handle, Printhead
QUANTITY
1
1
3
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
PART NUMBER
40001
40027
40050M
40051M
40154
40305RM
40355M
40357M
40444
40490-2
40808
40825
45025
45053M
45189-5
46196M
46904
Q10057
12
1
10
1
2
1
1
6
1
1
2
1
1
1
Page 7-16
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S
Print Mechanism Assembly
DESCRIPTION
Roller, Main Platen
Spring, Torsion
Spindle Assembly, Ribbon Take-Up
Spindle Assembly, Ribbon Supply
Pin, Eccentric
Assembly, Media Guide
Assembly, Platen Pulley (8 Dots/mm and
12 Dots/mm)
Assembly, Stepper Motor Pulley (8 Dots/mm)
Shaft, Pivot
Ribbon Take-Up Hook
Tear/Peel-Off Bar
Guide Plate, Upper Media (Snap Plate)
Roller, White Nylon, .62 .18
Hanger Assembly, Media Supply
Belt, Main Drive
Motor, Stepper
Assembly, Reflective Sensor (optional)
Washer, Flat, .372 x .158 x .032
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
01130
01159
Q10057
06250
30355M (6-DOT)
40355M ( 8 & 12 DOT)
40490-2
30357M (6 & 12 DOT)
40357M ( 8 DOT)
35020
30033
30256-B
40808
46196M
06268
40154
105S Print Mechanism Assembly
Page 7-17
105 S and 160 S Parts Lists
PART NUMBER
01130
01159
02252
06250
06319
07229
30033
30104
30105
30106
30114
30115
30118
30176
30239
30256-B
30260
30307
30336-1M
30353M
30392-004
30392-008
30393-006
30423-003
30488
30909
35082
35136
35137
38025
38053M
38099M
38151M
38226M
38302M
38825-1
PRINTER MODEL: 160S
Print Mechanism Assembly
DESCRIPTION
Nut, 6-32
Washer, External Lock, #6
Ring, Crescent, .250
Ring, “E” External, .312
Screw, 10-32 .37
Washer, Curved, .49 x .33 x .0075
Media Guide, Adjustable
Flange, Ball Bearing, .5 x .250 x .125
Bearing, Nylon, .312 x .251 x .078
Ring, Crescent, External, .312
Washer, Flat, .76 x .51 x .03
Washer, Wave, .740 x .520 x .080
Ring, “E”, External, .500 x .042
Plate, Media Supply (Supply Spindle Option)
Washer, Crescent, .415 x .323 x .062
Nut, Thumb
Washer, Crescent, .406 x .253 x .030
Flag, Head Open
Assembly, Ribbon Take-Up Pulley
Assembly, Head Open Sensor
Screw, 6-32 .25
Screw, 6-32 .50
Screw, 8-32 .37
Screw, Set, 8-32 .187
Nut 1/4-20 (Supply Spindle Option)
Handle, Printhead
Guide, Media
Washer, Nylon, .252 x .472 x .059
Ring, Retainer, .250
Roller Segment
Hanger Assembly, Media Supply
Assembly, Toggle
Spindle Assembly, Ribbon Supply
Assembly, Reflective Sensor (optional)
Assembly, Media Sensor
Guide Plate, Upper Media (Snap Plate)
QUANTITY
1
1
3
1
3
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
10
1
10
1
1
1
1
2
1
8
1
2
1
1
1
1
PART NUMBER
40027
40355M
40357M
40490-3
45189-5
46001-1
46105
46150M
46196M
46213M
46305M
46444
46808
48411
Q10057
Page 7-18
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Print Mechanism Assembly
DESCRIPTION
Spring, Torsion
Assembly, Platen Pulley (8 Dots/mm)
Assembly, Stepper Motor Pulley (8 Dots/mm)
Ribbon Take-Up Hook
Belt, Main Drive
Roller, Main Platen
Bearing, Nylon
Spindle Assembly, Ribbon Take-Up
Motor, Stepper
Assembly, Compliance
Assembly, Media Guide
Shaft, Pivot
Peel/Tear-Off Bar
Screw, Thumb
Washer, Flat, .372 x .158 x .032
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
S -Series Maintenance Manual: Volume 1
30336-1M
45189-5
30353M
30118
30114
30307
35082
30115
Q10057
01159
38151M
30392-004
01130
30392-004
P/O 46213M ASSY
30393-006
(3)
105 S and 160 S Parts Lists
30393-006
(3)
30392-004
40490-3
01159
40355M
06250
40027
38025
(8 PLCS)
46150M
30106
35136 (2)
38226M
48411
(2)
30466
40357M
46305M
35137
30392-004
30033
38053M
30256-B
46105
30239
30104
02252
38302M
46001-1
46444
46213M
02252
06319
(3)
46808
30260
30104
30105
30392-004
(5)
07229
38825-1
DETAIL C
COMPLIANT
ROLLER ASSY
30423-003
38099M
(2)
46196M
30909
30393-006
(4)
30392-004
30392-008
160S Print Mechanism Assembly
Page 7-19
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S (6 dot and 8 dot)
Printhead Support Assembly
PART NUMBER
01153
01159
10401
30391-003
30392-004
30402-006
30494
30531
30781
31521
31899
40014
40017
40193
40194
44000M
44200M
46481-1
48023
Page 7-20
DESCRIPTION
Washer, Flat, .250 x .125 x .028
Washer, Lock, #6
Screw, M3 x .5 x 4
Screw, 4-40 .19
Screw, 6-32 .25
Screw, 6-32 .37
Washer, .320 x .119 x .062
Assembly, Ribbon Sensor
Cable, Printhead, Ground
Assembly, Printhead Cable
Brush, Static Removal
Plate, Guide
Plate, Ribbon Strip
Washer, Felt, .406 x .172 x .048
Washer, Curved, .312 x .144 x .016
Printhead (8 Dots/mm)
Printhead (6 Dots/mm)
Screw, Adjustment, 6-32
Bearing, .313 x .190 x .375
QUANTITY
1
1
3
3
14
2
1
1
1
1
1
1
1
2
2
1
1
2
2
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30781
01159
10401 (3)
48023
45003 (6 & 8 DOT)
46481-1 (2)
40193 (2)
30494
40014
105S (6 & 8 Dot/mm)
Printhead Support Assembly
Page 7-21
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S (12 dot)
Printhead Support Assembly
PART NUMBER
01153
01159
30391-003
30392-004
30402-006
30494
30531
30781
31521
31899
40014
40017
40193
40194
44800M
45013
46481-1
48023
Page 7-22
DESCRIPTION
Washer, Flat, .250 x .125 x .028
Washer, Lock, #6
Screw, 4-40 .19
Screw, 6-32 .25
Screw, 6-32 .37
Washer, .320 x .119 x .062
Assembly, Ribbon Sensor
Cable, Printhead, Ground
Assembly, Printhead Cable
Brush, Static Removal
Plate, Guide
Plate, Ribbon Strip
Washer, Felt, ..406 x .172 x .048
Washer, Curved, .312 x .144 x .016
Printhead (12 Dots/mm)
Bracket
Screw, Adjustment, 6-32
Bearing, .313 x .190 x .375
QUANTITY
1
1
3
14
2
1
1
1
1
1
1
1
2
2
1
1
2
2
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30781
01159
10401 (3)
48023
45013 (12 DOT)
46481-1 (2)
40193 (2)
30494
40014
44800M (12 DOT)
105S (12
(12 Dot/mm)
Dot/mm)
105S
Printhead Support Assembly
Printhead
Page 7-23
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Printhead Support Assembly
PART NUMBER
01153
01159
01882
06268
30344
30391-003
30392-004
30402-006
30494
30781
38000M
38521
38601
40193
40194
46017
46022
46173
46174
46481-1
46605
Page 7-24
DESCRIPTION
Washer, Flat, .250 x .125 x .028
Washer, #6 Lock
Screw, 4-40 .25
Washer, #6 Split Lock
Assembly, Clutch Plate and Bearing
Screw, 4-40 .19
Screw, 6-32 .25
Screw, 6-32 .37
Washer, .320 x .119 x .062
Cable, Printhead Ground
Printhead (8 Dots/mm)
Assembly, Printhead Cable
Assembly, Printhead Cable, Power
Washer, Flat .406 x .172 x .048
Washer, Curved, .312 x .144 x .016
Plate, Ribbon Strip
Bearing, Rulon, .313 x .191 x .375
Brush, Static Removal
Plate, Guard
Screw, Adjustment, 6-32
Assembly, Ribbon Sensor
QUANTITY
1
2
2
4
1
1
12
2
1
1
1
1
1
2
2
1
2
1
1
2
1
S -Series Maintenance Manual: Volume 1
30392-004 (2)
105 S and 160 S Parts Lists
30392-004 (4)
01159 (2)
30781
01159
DETAIL
SCAL 2=1
FRONT SURFACE OF PRESSURE PLATE
SHOULD BE FLUSH TO BELOW ENDS
OF PRINTHEAD MOUNTING BRACKET
30392-004 (4)
06268 (4)
WRAP GROUND STRAP
AS SHOWN
46173
PRESSURE
PLATE
46022
(2)
PRINTHEAD
MOUNTING
BRACKET
46017
30402-006
(2)
01882
(2)
30494
30391-003
01153
46481-1 (2)
38521
46605
SEE NOTE 1
40194 (2)
40193 (2)
PRINTHEAD PIVOT BAR
46174
38601
38000M
NOTE:
1. POSITION RIBBON SENSOR (46605) TAB
FLUSH WITH TOP EDGE OF PRINTHEAD PIVOT BAR
30392-004 (2)
160S Printhead Support Assembly
Page 7-25
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S and 160S
Media Guide Assembly
PART NUMBER
30033
30256-B
Page 7-26
DESCRIPTION
Guide, Adjustable Media
Nut, Thumb, 6-32 .50 Brass
QUANTITY
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30033
30256-B
105S and 160S Media Guide Assembly
Page 7-27
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S
Ribbon Supply Spindle Assembly
PART NUMBER
07321
30041-4
30041-6
30042
30071
30097
30145
30146
30224
30344M
40070-1
40070-2
Page 7-28
DESCRIPTION
QUANTITY
Screw, Set, 6-32 .18
Washer, Felt, 29/32, 1/2, 3/32
Washer, Felt, 13/16, 13/32, 3/32
Spring, Torsion, .739 x .805
Housing, Ribbon Supply Spring
Spring, Compression, .660 x .528 x .066
Bearing, Thrust
Washer, Thrust, .687 x .375 x .093
Ring, Crescent, Ext. .375
Clutch Plate Bearing Maintenance Assembly
Blade, Ribbon Supply, Outer
Blade, Ribbon Supply, Inner
2
1
1
1
1
1
2
4
2
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
40070-1
BLADE
40070-2
BLADE
30145
30041-4
(SEE NOTE 1)
30146
30146
30041-6
(SEE NOTE 1)
30224
30224
30071
30146
LONG
END
30097
30344M
30146
07321
(2)
30145
30042
(SEE NOTES
2 & 3)
NOTES:
1. SOAK FELT WASHERS 30041-4 & 30041-6 WITH SILICONE OIL AND SQUEEZE OUT
2. SOAK SPRING 30042 IN SILICONE OIL & ASSEMBLE
3. LONG END OF TORSION SPRING 30042 FACES OUT
105S Ribbon Supply Spindle Assembly
Page 7-29
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Ribbon Supply Spindle Assembly
PART NUMBER
30042
30145
30146
40070-1
40070-2
46085
46211
47005
47171
Page 7-30
DESCRIPTION
Spring, Torsion, .739 x .805
Bearing, Thrust
Washer, Thrust, .687 x .375 x .093
Blade, Ribbon Supply, Outer
Blade, Ribbon Supply, Inner
Nut, Jam, 3/8 24
Spring, Compression, .53 x .660 x .62
Nut,Jam, 3/8 24
Housing, Ribbon Supply Spring
QUANTITY
1
2
4
2
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
Gray
40070-1
BLADE
White
40070-2
BLADE
30145
(NOTE 3)
30146
30146
LONG
END
47005
46085
47171
30146
30146
30042
40070-1
BLADE
30145
(NOTE 3)
46211
Black
NOTES:
1. ALL COMPONENTS MUST BE OIL FREE.
2. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE
HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION.
3. APPLY A LIGHT FILM OF GREASE (ZEBRA P/N 01660) TO PARTS 30145 (2).
160S Ribbon Supply Spindle Assembly
Page 7-31
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S
Ribbon Take-Up Spindle Assembly
PART NUMBER
07321
30073
30041-1
30058-2
30116
30118
30233
30422-002
Page 7-32
DESCRIPTION
Screw, Set, 6-32 .18
Collar
Washer, Felt, 1 1/4, 19/32, 3/32
Nut, Shoulder, .50-20, Hex
Spring, Compression, .720 x .610 x .625
E-Ring, Ext. .500 x .042
Spring, Compression, .088 x .012 x .312
Screw, Set, 6-32, .375
QUANTITY
4
2
2
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30422-002
30118
30233
07321 (2 PLCS)
A
.030 to
.080
30073
07321 (2 PLCS)
30073
POSITIONING
COLLAR
30041-1
30116
30041-1
NOTES:
30058-2
1) SOAK FELT WASHERS 30041-1 IN SILICONE OIL & SQUEEZE OUT.
(2) ASSEMBLY IS POSITIONED VIA POSITIONING COLLAR & SET SCREWS
AS SHOWN IN "A" - .030 TO .080 FROM EDGE OF 30118.
105S Ribbon Takeup Spindle Assembly
Page 7-33
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Ribbon Take-Up Spindle Assembly
PART NUMBER
30118
38015
38210
47158
Page 7-34
DESCRIPTION
E-Ring, Ext. .500 x .042
Screw, Set, #10-24 .187
Spring, Compression, .56 x .720 x 1.0
Nut, .50 .75
QUANTITY
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30118
47081
38015
NOTE:
47158
1. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE
HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION.
160S Ribbon Takeup Spindle Assembly
Page 7-35
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S
Peel-Off Rewind Spindle Assembly
PART NUMBER
07321
30041-7
30058-1
30110
30118
30422-006
Page 7-36
DESCRIPTION
Screw, Set, 6-32 .18
Washer, Felt, 1 5/8, 17/32, .093
Nut, Shoulder, .50-20, Hex
Spring, Compression, .85 x .67 x 1.12
E-Ring, Ext. .500 x .042
Screw, Set, 6-32, .375
QUANTITY
2
2
1
1
1
2
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30118
30422-006 (2 PLCS)
07321 (2 PLCS)
30041-7
30041-7
30110
30058-1
NOTES:
1) SOAK FELT WASHERS 30041-7 IN SILICONE OIL & SQUEEZE OUT.
105S Peel-Off Rewind Spindle Assembly
Page 7-37
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Peel-Off Rewind Spindle Assembly
PART NUMBER
30118
38015
38210
47158
Page 7-38
DESCRIPTION
E-Ring, Ext. .500 x .042
Screw, Set, #10-24 .187
Spring, Compression, .56 x .720 x 1.0
Nut, .50 .75
QUANTITY
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30118
38210
38015
NOTE:
47158
1. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE
HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION.
160S Peel-Off Rewind Spindle Assembly
Page 7-39
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S
Media Rewind Spindle Assembly
PART NUMBER
07321
30041-7
30433-008
30058-1
30118
30422-006
40110
45090-2
47062-2
Page 7-40
DESCRIPTION
Screw, Set, 6-32 .18
Washer, Felt, 1 5/8, 17/32, .093
Screw, 8-32 .500
Nut, Shoulder, .50-20, Hex
E-Ring, Ext. .500 x .042
Screw, Set, 6-32, .375
Spring, Compression, .85 x .67 x 1.12
Blade, Media Take-Up
Hook, Rewind
QUANTITY
2
2
6
1
1
2
1
3
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30422-006 (2 PLCS)
30118
30433-008 (6)
45090-2 (3)
30041-7
30041-7
40110
07321 (2 PLCS)
47062-2
30058-1
NOTES:
1) SOAK FELT WASHERS 30041-7 IN SILICONE OIL & SQUEEZE OUT.
105S Media Rewind Spindle Assembly
Page 7-41
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Media Rewind Spindle Assembly
PART NUMBER
30118
30433-004
38015
38210
46090
47062-1
47158
Page 7-42
DESCRIPTION
E-Ring, Ext. .500 x .042
Screw, 8-32 .250
Screw, Set, #10-24 .187
Spring, Compression, .56 x .720 x 1.0
Blade, Media Take-Up
Hook, Rewind
Nut, .50 .75
QUANTITY
1
6
1
1
3
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
30118
30433-004 (6)
46090 (3)
38210
46062
47062-1
38015
NOTE:
47158
1. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE
HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION.
160S Media Rewind Spindle Assembly
Page 7-43
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S
Peel-Off Option Assembly
PART NUMBER
02252
07435
30104
30114
30115
30118
30257
30265
30336-2M
30392-004
30393-006
30914M
31536M
40001
40490-2
45189-2
Page 7-44
DESCRIPTION
Ring, Crescent, .250
Screw, 6-32 .37
Flange, Ball Bearing, .5 x .250 x .125
Washer, Flat, .76 x .51 x .03
Washer, Save, .740 x .520 x .08
Ring, “E”, External, .500 x .042
Pulley Assembly, Rewind (6 Dots/mm)
Pulley, Idler
Pulley Assembly, Media Rewind
Screw, 6-32 .25
Screw, 8-32 .37
Pulley Assembly, Rewind (8 Dots/mm and
12 Dots/mm)
Sensor Assembly, Take-Label
Shaft, Platen
“L” Hook, Ribbon Assembly, 6 inches
Belt, Rewind
QUANTITY
2
2
2
1
1
1
1
1
1
3
3
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
40490-2
105S Peel-Off
Peel-Off Option
Option Assembly
105S
Assembly
Page 7-45
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Peel-Off Option Assembly
PART NUMBER
02252
07435
30104
30114
30115
30118
30247
30261
30265
30336-2M
30392-004
30392-006
30393-006
30914M
30536M
38055M
40490-3
45189-2
46001
46609M
Page 7-46
DESCRIPTION
Ring, Crescent, .250
Screw, 6-32 .37
Flange, Ball Bearing, .5 x .250 x .125
Washer, Flat, .76 x .51 x .03
Washer, Save, .740 x .520 x .08
Ring, “E”, External, .500 x .042
Washer, Flat, .42 x .260 x .0747
Washer, Flat, .442 x .255 x .020
Pulley, Idler
Pulley Assembly, Media Rewind
Screw, 6-32 .25
Screw, 6-32 .37
Screw, 8-32 .37
Pulley Assembly, Rewind (8 Dots/mm)
Sensor Assembly, Take-Label, Upper
Spindle, Media Rewind
“J” Hook
Belt, Rewind
Shaft, Platen
Sensor Assembly, Take-Label, Lower
QUANTITY
2
2
2
1
1
1
1
1
1
1
3
1
3
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
STEPPER MOTOR PULLEY (REF.)
105 S and 160 S Parts Lists
30536M
(BLK/BLU LEADS)
45189-5
MAIN DRIVE BELT (REF.)
30336-2M
NOTE: SPACERS MUST BE
POSITIONED ON BOTH SIDES
OF BELT 45189-5
30265
07435
30114
30118
30115
30393-006
45189-2
30914M
07435
38055M
46609M
(BLK/GRN LEADS)
30392-006
30104
30392-004
(2)
40490-3
02252
(2)
46001
30104
30261
30247
160S Peel-Off Option Assembly
Page 7-47
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105S
Media Rewind Option Assembly
PART NUMBER
02252
07435
30104
30114
30115
30118
30257
30265
30336-2M
30392-004
30393-006
30914M
31536M
40001
40055RM
40383RM
45189-2
45062
Page 7-48
DESCRIPTION
Ring, Crescent, .250
Screw, 6-32 .37
Flange, Ball Bearing, .5 x .250 x .125
Washer, Flat, .76 x .51 x .03
Washer, Save, .740 x .520 x .08
Ring, “E”, External, .500 x .042
Pulley Assembly, Rewind (6 Dots/mm)
Pulley, Idler
Pulley Assembly, Media Rewind
Screw, 6-32 .25
Screw, 8-32 .37
Pulley Assembly, Rewind (8 Dots/mm and
12 Dots/mm)
Sensor Assembly, Take-Label
Shaft, Platen
Spindle, Media Rewind
Assembly, Rewind Plate
Belt, Rewind
Media Take-Up “J” Hook
QUANTITY
2
2
2
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
12 & 8 DOT/MM 30914M
45062
105S Media Rewind Option Assembly
Page 7-49
105 S and 160 S Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 160S
Media Rewind Option Assembly
PART NUMBER
02252
07435
30104
30114
30115
30118
30247
30261
30265
30336-2M
30392-004
30392-006
30393-006
30536M
30914M
45189-2
46001
46062
46155M
46383M
46609M
Page 7-50
DESCRIPTION
Ring, Crescent, .250
Screw, 6-32 .37
Flange, Ball Bearing, .5 x .250 x .125
Washer, Flat, .76 x .51 x .03
Washer, Save, .740 x .520 x .08
Ring, “E”, External, .500 x .042
Washer, Flat, .42 x .260 x .0747
Washer, Flat, .442 x .255 x .020
Pulley, Idler
Pulley Assembly, Media Rewind
Screw, 6-32 .25
Screw. 6-32 .37
Screw, 8-32 .37
Sensor Assembly, Take-Label, Upper
Pulley Assembly, Rewind (8 Dots/mm)
Belt, Rewind
Shaft, Platen
Media Take-Up “J” Hook
Spindle, Media Rewind
Assembly, Rewind Plate
Sensor Assembly, Take-Label, Lower
QUANTITY
2
2
2
1
1
1
1
1
1
1
3
1
3
1
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 S and 160 S Parts Lists
STEPPER MOTOR PULLEY (REF.)
30536M
(BLK/BLU LEADS)
45189-5
MAIN DRIVE BELT (REF.)
30336-2M
NOTE: SPACERS MUST BE
POSITIONED ON BOTH SIDES
OF BELT 45189-5
30265
07435
30114
30118
30115
30393-006
45189-2
30914M
07435
46155M
46383M
46609M
(BLK/GRN LEADS)
30392-006
30392-004
(2)
30104
02252
(2)
46001
30104
30261
30247
160S Media Rewind Option Assembly
REWIND VERSION
Page 7-51
105 S and 160 S Parts Lists
R
Page 7-52
S -Series Maintenance Manual: Volume 1
105Se Parts Lists
8
In this section...
Page
Mechanical Parts and Assemblies ................................................8-1
Mechanical Parts and Assemblies Listing...................................8-2
Please note: This section contains parts lists and drawings that are specific
to the 105Se. For parts lists/drawings common for both the 105S and 105Se,
refer to Section 7.
Mechanical Parts and Assemblies
MECHANICAL PARTS AND ASSEMBLIES
Description
105Se Final Assembly (Page 1 of 2)
105Se Final Assembly (Page 2 of 2)
105Se Print Mechanism Assembly
105Se Printhead Support Assembly
105Se Peel-Off Option Assembly
105Se Media Rewind Option Assembly
105Se Cutter Option Assembly
38452L Rev. 3
Page #
8-2/8-3
8-4/8-5
8-6/8-7
8-8/8-9
8-10/8-11
8-12/8-13
8-14/8-15
Page 8-1
105 Se Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105Se
Final Assembly (Page 1 of 2)
PART NUMBER
DESCRIPTION
01130
01152
Nut, 6-32
Washer, Flat, .375 x .156 x .65
01155
01159
01448
01912
07435
30240
30256
30269
30391-004
30391-006
30392-004
30407-008
30916
31019
Washer, Lock, #4
Washer, External Lock, #6
Screw, 6-32, .37
Washer, External Lock, #4
Screw, 6-32, .37
Cover Plate with Opening (Serial)
Nut, Thumb, 6-32, .50
Pad, PVC, 4.0 x .37, .062
Screw, 4-40, .25
Screw, 4-40, .37
Screw, 6-32, .25
Screw, 6-32, .5
Strap, Ground
Label, Logo
31022
31038
31039
31040
31100M
31517
31524M
31532M
31646M
38102
38103
38037
38532M
38692M
40342
46325-3
Label, Model Number
Panel, Left Side
Panel, Media
Door, Media Access
Assembly, Membrane Switch, Front Panel
Shield, High Voltage
PCB, Front LED (supersedes 31520M)
PCB, Printhead Adaptor
PCB, Power Supply
Panel, Rear PCB (Serial)
Panel, Rear PCB (Parallel)
Cover, PCB
PCB, Serial, Main Logic
PCB, Parallel, Main Logic
Bracket, Front Cover
Spacer, 6-32
Page 8-2
38452L Rev. 3
QUANTITY
8
1
2
5
4
4
3
1
2
2
2
2
20
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7
S -Series Maintenance Manual: Volume 1
38102 (SERIAL)
38103 (PARALLEL)
38532M (SERIAL)
38692M (PARALLEL)
C
31038
C
C
31517
A
A
A
A
P
P
A
A
A
B
T
46325-3 (7)
REMOVE MASKING DISC
105 Se Parts Lists
S
B
S
A
A
T
30916
M
L
K
K
31040
A
A
31532M
C
31646M
01152
K
30391-006
J
30407-008
H
S
30269 (2)
01155
N
T
S
01912
P
T
30240
01159
S
R
A
A
T
G
A
T
30256
F
A
E
01130
D
07435
C
01448
B
30391-004
A
30392-004
CODE
PART NUMBER
SCREW LIST
E
E
E
E
E
38037
31039
J
J
E
A
A
A
31022
31524M
GROUND TAIL
J
L
D
31100M
ALIGN W/FIXTURE
31019
40342 (CUTTER OR
TEAR OFF VERSION)
D
D
E
A
J
A
E
G
G
DETAIL A
DETAIL A
105Se Final Assembly (page 1 of 2)
Page 8-3
105 Se Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105Se
Final Assembly (Page 2 of 2)
PART NUMBER
30257M
30307
30336-1M
30336-2M
30355M
30357M
30392-004
30914M
31528
31532M
40355M
40357M
45189-2
45189-5
Page 8-4
DESCRIPTION
Pulley, Peel-Off Platen (6 Dots/mm)
Flag, Head Open
Pulley, Ribbon Take-Up
Pulley, Media Take-Up
Pulley, Main Platen (6 Dots/mm)
Pulley, Stepper Motor (6 Dots/mm and 12
Dots/mm)
Screw, 6-32, .25
Pulley, Peel-Off Platen (8 Dots/mm and 12
Dots/mm)
Assembly, Power Cable
Assembly, Adaptor Board
Pulley, Main Platen (8 Dots/mm and 12
Dots/mm)
Pulley, Stepper Motor (8 Dots/mm)
Belt, Media Rewind
Belt, Main Drive
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 Se Parts Lists
M
M
M
M
M
M
M
M
31532M
105Se Final Assembly (page 2 of 2)
Page 8-5
105 Se Parts Lists
PART NUMBER
01130
01159
02252
06250
06319
07229
07321
30033
30104
30105
30106
30114
30115
30118
30239
30256-B
30260
30307
30336-1M
30353M
30355M
30357M
30392-004
30392-008
30393-006
30466
35020
35025
35082
35136
35137
35302RM
35909
38226M
38099M
38825-2
PRINTER MODEL: 105Se
Print Mechanism Assembly
DESCRIPTION
Nut, 6-32
Washer, External Lock, #6
Ring, Crescent, .250
Ring, “E” External, .312
Screw, 10-32, .37
Washer, Curved, .49 x .33 x .0075
Screw, 6-32, .18
Media Guide, Adjustable
Flange, Ball Bearing, .5 x .250 x .125
Bearing, Nylon, .312 x .251 x .078
Ring, Crescent, External, .312
Washer, Flat, .76 x .51 x .03
Washer, Wave, .740 x .520 x .080
Ring, “E”, External, .500 x .042
Washer, Crescent, .415 x .323 x .062
Nut, Thumb
Washer, Crescent, .406 x .253 x .030
Flag, Head Open
Assembly, Ribbon Take-Up Pulley
Assembly, Head Open Sensor
Assembly, Platen Pulley (6 Dots/mm)
Assembly, Stepper Motor Pulley (6 Dots/mm
and 12 Dots/mm)
Screw, 6-32, .25
Screw, 6-32, .50
Screw, 8-32, .37
Washer, .26 x .63 x .06
Bracket, Media Sensor
Roller Segment
Guide, Media
Washer, Nylon, .252 x .472 x .059
Ring, Retainer, .250
Assembly, Media Sensor
Handle, Printhead
Assembly, Reflective Sensor (optional)
Assembly, Toggle
Guide Plate, Upper Media (Snap Plate_
QUANTITY
1
2
3
1
3
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
PART NUMBER
40001
40027
40050M
40051M
40305RM
40355M
40357M
40444
40490-2
40808
45025
45053M
45189-5
46105
46196M
48411
12
1
10
2
1
6
1
2
1
1
1
1
1
1
Page 8-6
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105Se
Print Mechanism Assembly
DESCRIPTION
Roller, Main Platen
Spring, Torsion
Spindle Assembly, Ribbon Take-Up
Spindle Assembly, Ribbon Supply
Assembly, Media Guide
Assembly, Platen Pulley (8 Dots/mm and
12 Dots/mm)
Assembly, Stepper Motor Pulley (8 Dots/mm)
Shaft, Pivot
Ribbon Take-Up Hook
Tear/Peel-Off Bar
Roller, White Nylon, .62, .18
Assembly, Media Supply Maintenance
Belt, Main Drive
Bearing, Nylon, .312, .251, .140
Motor, Stepper
Thumb Screw
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
S -Series Maintenance Manual: Volume 1
105 Se Parts Lists
30336-1M
45189-5
30118
30393-006
(3)
30353M
01130
30307
30392-004
12/6 DOT 30355M
8DOT 40355M
30392-004 (2)
30114
Q10057
01159
40051M
30115
30393-006
(3)
35082
40490-2
30392-004
01159
45025
06250
40027
30106
40050M
35136 (2)
30466
35020
35137
38226M
12/6 DOT 30357
8 DOT 40357
30392-004 (3)
45053M
46105
35025
(6 PLCS)
01130
40305RM
(ASSY)
30033
30256-B
30392-004 (2)
30239
35302RM
30104
02252
40001
40444
02252
06319
(3)
40808
30260
30104
30105
30392-004
(5) 07229
38825-2
30423-003
38099M
46196M
35909
30393-006
(4)
40154
06268
40248
30392-004
30392-008
105Se Print Mechanism Assembly
Page 8-7
105 Se Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105Se
Printhead Support Assembly
PART NUMBER
01153
01159
01882
10401
30301-003
30392-004
30402-006
30494
30531
30781
31007
31521
31899
40014
40193
40194
44000M
44200M
44800M
45003
45013
Page 8-8
DESCRIPTION
Washer, Flat, .250 x .125 x .028
Washer, Lock, #6
Screw, 4-40, .19
Screw, M3 x .5 x 4
Screw, 4-40, .19
Screw, 6-32, .25
Screw, 6-32, .37
Washer, .320 x .119 x .062
Assembly, Ribbon Sensor
Cable, Printhead Ground
Plate, Ribbon Strip
Assembly, Printhead Cable
Brush, Static Removal
Guide Plate
Washer, Felt, .406 x .172 x .048
Washer, Curved, .312 x .144 x .016
Printhead (8 Dots/mm)
Printhead (6 Dots/mm)
Printhead (12 Dots/mm)
Bracket (6 Dots/mm and 8 Dots/mm)
Bracket (12 Dots/mm)
QUANTITY
1
1
2
3
1
14
2
1
1
1
1
1
1
1
2
2
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
105 Se Parts Lists
30392-004 (8)
30392-004 (4)
31899
30781
01159
10401 (3)
48023 (2)
45003 (6 & 8 DOT)
45013 (12 DOT)
46481-1 (2)
40194 (2)
40193 (2)
31007
01153
30301-003
30402-006 (2)
01882 (2)
30494
30531
SEE NOTE 1
PRINTHEAD
PIVOT BAR
40014
NOTE:
1. POSITION SENSOR (30531) TAB
FLUSH WITH TOP EDGE OF BAR
(40002).
31521
30392-004 (2)
44000M (8-DOT)
44200M (6-DOT)
44800M (12-DOT)
105Se Printhead Support Assembly
Page 8-9
105 Se Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105Se
Peel-Off Option Assembly
PART NUMBER
02252
07435
30104
30114
30115
30118
30257M
30265
30336-2M
30392-004
30393-006
30914M
40001
40490-2
45189-2
46609M
47062-2
Page 8-10
DESCRIPTION
QUANTITY
Ring, Crescent, .250
Screw, 6-32, .37
Flange, Ball Bearing, .5 x .250 x .125
Washer, Flat, .76 x .51 x .03
Washer, Save, .740 x .520 x .08
Ring, “E”, External, .500 x .042
Pulley Assembly, Rewind (6 Dots/mm)
Pulley, Idler
Pulley Assembly, Media Rewind
Screw, 6-32, .25
Screw, 8-32, .37
Pulley Assembly, Rewind (8 Dots/mm and
12 Dots/mm)
Shaft, Platen
Take-Up Hook
Belt, Rewind
Sensor Assembly, Take-Label, Upper/Lower
“L” Hook, Ribbon Assembly, 6 inches
2
2
2
1
1
1
1
1
1
3
3
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
STEPPER MOTOR PULLEY (REF.)
105 Se Parts Lists
P/O 46609M
(BLK/BLU LEADS)
45189-5
MAIN DRIVE BELT (REF.)
30336-2M
NOTE: SPACERS MUST BE
POSITIONED ON BOTH SIDES
OF BELT 45189-5
30265
IDLER PULLEY
07435
30114
30118
45189-2
REWIND PULLEY
6 DOT/ 30257M
12/8 DOT/ 30914M
30115
30393-006
(3)
07435
O2252
30104
P/O 46609M
(BLK/GRN LEADS)
30392-004
30392-004
(2)
47062-2
40001
30104
02252
105Se Peel-Off Option Assembly
Page 8-11
105 Se Parts Lists
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105Se
Media Rewind Option Assembly
PART NUMBER
02252
07435
30104
30114
30115
30118
30257M
30265
30336-2M
30392-004
30393-006
30914M
40001
40055RM
40383RM
45189-2
46609M
Page 8-12
DESCRIPTION
Ring, Crescent, .250
Screw, 6-32, .37
Flange, Ball Bearing, .5 x .250 x .125
Washer, Flat, .76 x .51 x .03
Washer, Save, .740 x .520 x .08
Ring, “E”, External, .500 x .042
Pulley Assembly, Rewind (6 Dots/mm)
Pulley, Idler
Pulley Assembly, Media Rewind
Screw, 6-32, .25
Screw, 8-32, .37
Pulley Assembly, Rewind (8 Dots/mm and
12 Dots/mm)
Shaft, Platen
Spindle, Media Rewind
Assembly, Rewind Plate
Belt, Rewind
Sensor Assembly, Take-Label
QUANTITY
2
2
2
1
1
1
1
1
1
3
3
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
STEPPER MOTOR PULLEY (REF.)
105 Se Parts Lists
P/O 46609M
(BLK/BLU LEADS)
45189-5
MAIN DRIVE BELT (REF.)
30336-2M
NOTE: SPACERS MUST BE
POSITIONED ON BOTH SIDES
OF BELT 45189-5
30265
07435
30114
30118
45189-2
30115
30393-006
(3)
REWIND PULLEY
12/6-DOT 30257
8-DOT 30914M
07435
02252
30104
40055RM
P/O 46609M
(BLK/GRN LEADS)
30392-004
30392-004
(2)
40001
30104
02252
REWIND VERSION
40383RM
105Se Media Rewind Option Assembly
Page 8-13
105 Se Parts Lists
PART NUMBER
01155
01822
02133
06224
08449
10421
10427
30133
30196-150
30198
30199
30208
30210
30214
30215
30216
30217-1
30219
30236
30313
30380M
30391-003
30392-004
30394-005
30405-006
30816
31024
31181
31374M
31730M
31807
S -Series Maintenance Manual: Volume 1
PRINTER MODEL: 105Se
PRINTER MODEL: 105Se
Cutter Option Assembly
Cutter Option Assembly
DESCRIPTION
Washer, Lock #4
Nut, 4-40
E-Ring, .188, Black
Grommet, Rubber
Tiewrap
Screw, M4 x .7 x 5
Screw, M4, .7
Bearing, Ball .375 x .187 x .125
Module, Cutter
Bearing
Bearing
Washer, Flat, .500 x .191 x .030
Washer, Flat, .564 x .384 x .060
Link, Main
Link, Slotted
Post, Pivot
Link, Pin
Flag, Sensor
Screw, 4-40
Clamp, Wire, Cutter
Assembly, Drive Arm
Screw, 4-40, .19
Screw, 6-32, .25
Screw, 10-32, .312
Screw, 1/4-20, .38
Bracket, Lower Cutter
Standoff
Guide, Upper Cutter
Assembly, Cutter Motor
Assembly, Cutter Printed Circuit Board
Bracket, Upper Cutter
QUANTITY
1
3
4
1
1
4
2
1
1
1
3
2
2
1
1
1
1
1
3
1
1
4
6
2
1
1
4
1
1
1
1
PART NUMBER
40193
40320
40819
46280M
46618
49600-012
49604-010
Q10019
Page 8-14
DESCRIPTION
Washer, Felt, .406 x .172 x .048
Brush, Anti-Static
Bracket, Cutter Support
Arm, Upper Drive
Assembly, Cutter Sensor
Assembly, Cable
Assembly, Power Cable
E-Ring, .250, Black
QUANTITY
2
1
1
1
1
1
1
1
S -Series Maintenance Manual: Volume 1
SET SCREWS TO ENGAGE FLATS
ON MOTOR SHAFT WHEN LOWER
ARM IS IN VERTICAL POSITION
MOTOR
ROTATION
DIRECTION
.100"
(2.5 mm)
MEDIA GUIDE
INSURE THE TOP OF THE TEAR
TEAR-OFF
OFF BAR IS POSITIONED ABOVE
BAR
OR LEVEL WITH THE TOP OF
THE REAR CUTTER BLADE
CLEARANCE OF .030"
REAR CUTTER
BLADE
MINIMUM BETWEEN
REAR CUTTER BLADE
AND TEAR-OFF BAR
BLACK FLAG TO BE
CENTERED IN OPTICAL
ASSY
SENSOR CLAMP
(30313) TO BE
SECURELY
OVER CABLES
FRONT VIEW
ROTARY CUTTER BLADE
UPPER CUTTER BRACKET
MOUNTING SCREW
MOTOR
SHAFT
10421 SCREWS (4) CONTROL
POSITION OF CUTTER MODULE
& SQUARENESS TO MEDIA
RELATIVE POSITION OF THE ROTARY CUTTER
BLADE WHEN THE DRIVE LINK ASSEMBLY IS
STOPPED BY THE OPTICAL SENSOR, WHEN
THE POWER IS ON IN THE CUTTER MODE
SIDE VIEW
105 Se Parts Lists
02133
49604-010
30199
30391-003 (4)
30214
02133
30199
Q10019
30210(2)
30217-1
02133
30208
30215
30198
30133
30380M
30219
01155
30236
30216
30199
02133
30313
49600-012
31024 (4)
31807
30392-004(2)
31730M
46280M
10427(2)
31081
01822
31181
01822(2)
30394-005(2)
46618
08449
06224
30236(2)
31374M
30816
NOTE
1. POSITION BRUSH SO THAT APPROXIMATELY
1/8" OF THE BRUSH'S BRISTLES RUB AGAINST EACH
MOVING LABEL AND THE BRUSH'S BRISTLES ARE
PARALLEL TO THE LABEL EDGE.
40320
30196-150
30405-006
40193 (2)
30392-004 (2)
10421 (4)
40819
30392-004 (2)
105Se Cutter Option Assembly
Page 8-15
105 Se Parts Lists
R
Page 8-16
S -Series Maintenance Manual: Volume 1