=HEUD 6/ 0DLQWHQDQFH 0DQXDO PREVIO US NEXT/SA VE SETUP/EX POWE TAKE LA ERRO PAPER FEED DATA CANC EL BEL R CHEC PAUSE IT R K RIBBO OUT N
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.
7$%/( 2) &217(176 LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x 6(&7,21 '(6&5,37,21 2) (48,30(17 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MEDIA HANDLING MODES . . . . .
TABLE OF CONTENTS LOADING MEDIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Rewind Mode — for Printers Without the Cutter Option . . . . . . . . . . . . . . . . Cutter Mode . . . . . . . . . . . .
TABLE OF CONTENTS Setting the Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Data Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Stop Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS FEED Key Loopback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 TECH TIPS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Factory Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Black Mark Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92 Media Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93 6(&7,21 0$,17(1$1&( $1' $66(0%/< '5$:,1*6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS /,67 2) ),*85(6 Figure 1-1. Default Fonts Examples .....................................................................................1-4 Figure 1-2. 105SL Printhead ................................................................................................1-7 Figure 1-3. Upper Media Sensor ..........................................................................................1-8 Figure 1-4. Lower Media Sensor and Bracket .........................................................
TABLE OF CONTENTS Figure 3-7. Format 1 and 4 Test Sample Label ................................................................... 3-9 Figure 3-8. Format 2 and 5 Test Sample Label ................................................................... 3-9 Figure 3-9. Format 3 and 6 Test Sample Label ................................................................. 3-10 Figure 3-10. Format 7 and 11 Test Sample Label ............................................................. 3-10 Figure 3-11.
TABLE OF CONTENTS Figure 4-35. Membrane Switch and Front Panel ...............................................................4-49 Figure 4-36. Remove/Install Membrane Switch and Front Panel Assembly ......................4-50 Figure 4-37. LCD PCB Removal/Installation ......................................................................4-51 Figure 4-38. Media Supply Hanger Tabs ...........................................................................4-52 Figure 4-40. International Safety Organizations ..
TABLE OF CONTENTS Figure 5-6. Main and Lower Platen Rollers ....................................................................... 5-15 Figure 5-7. Media Supply Hanger ...................................................................................... 5-17 Figure 5-8. Ribbon Supply Spindle .................................................................................... 5-19 Figure 5-9. Ribbon Take-up Spindle and Pulley ................................................................
TABLE OF CONTENTS /,67 2) 7$%/(6 Table 1-1. Font Matrices for 8 dot/mm (203 DPI) 105SL Printheads ........................... 1-3 Table 1-2. Font Matrices for 12 dot/mm (300 DPI) 105SL Printheads ......................... 1-4 Table 1-3. General Specifications ................................................................................ 1-5 Table 1-4. Printing Specifications ................................................................................. 1-5 Table 1-5. Ribbon Specifications ............
DESCRIPTION OF EQUIPMENT SECTION 1 6(&7,21 '(6&5,37,21 2) (48,30(17 '(6&5,37,21 The Zebra 105SL printer is a versatile label and ticket printer designed to print high quality bar codes, various sizes and styles of alphanumeric characters, and graphics in either the thermal transfer or direct thermal mode. The 105SL printer has the flexibility to meet a variety of applications. The Zebra Programming Language II (ZPL II) allows the programmer to format the printed material.
SECTION 1 DESCRIPTION OF EQUIPMENT In thermal transfer printing, the printhead is in contact with a ribbon that releases ink above a certain threshold temperature. The image is formed when heat from the printhead is transferred to the ribbon, releasing ink directly to the substrate (media) to produce the printed image. The resulting image is stable and is not affected by exposure to UV or sunlight as with direct thermal substrate. Direct Thermal method. Ribbon is not used in this method.
DESCRIPTION OF EQUIPMENT SECTION 1 %$5 &2'( 6<0%2/2*,(6 Bar code ratios — 2:1, 7:3, 5:2, & 3:1 2 dimensional bar codes: • CODABLOCK • PDF-417 • Micro PDF-417 • Code 49 • Data Matrix • Maxi Code • QR-Code • Code 128 (with subsets A, B, and C and UCC case C codes) Linear bar codes: • Code 11 • Code 39 • Code 93 • ISBT-128 • UPC-A, UPC Extensions • UPC-E • EAN-8 • EAN-13 • UPC and EAN 2 or 5 digit expressions • Plessey • Postnet • Standard 2 of 5 • Industrial 2 of 5 • Interleaved 2 of 5 • LOGMARS • MSI • Co
SECTION 1 DESCRIPTION OF EQUIPMENT Table 1-2. Font Matrices for 12 dot/mm (300 DPI) 105SL Printheads Character Size Font Matrix Type* Height Width Intercharacter gap A 9 5 1 B 11 7 C,D 18 E F G Inches Millimeters Height Width Char./ Inch Height Width Char./ mm U-L-D 0.030 0.020 50.0 0.76 0.51 1.97 2 U 0.037 0.030 33.3 0.93 0.76 1.31 10 2 U-L-D 0.060 0.040 25.0 1.53 1.02 0.98 41 20 6 OCR-B 0.137 0.087 11.5 3.47 2.20 0.45 26 13 3 U-L-D 0.087 0.
DESCRIPTION OF EQUIPMENT SECTION 1 63(&,),&$7,216 The following tables provide specifications for the printer, media, and ribbon. Using media or ribbon not designed for the printer can cause unsatisfactory results. Table 1-3. General Specifications Printer Physical Characteristics 105SL (203 dpi) 105SL (300 dpi) Height 15.5″ 394 mm 15.5″ 394 mm Width 11.2″ 284 mm 11.2″ 284 mm Depth 18.9″ 480 mm 18.9″ 480 mm Weight (without options) 55 lbs. 25 kg 55 lbs. 25 kg Table 1-4.
SECTION 1 DESCRIPTION OF EQUIPMENT Table 1-6. Media Specifications Minimum label length* Total media width (label + liner, if any) Total thickness (includes liner, if any) Tear-off 0.7″ (18 mm) Peel-off 0.5″ (13 mm) Cutter 1.5″ (38 mm) Rewind 0.25″ (6 mm) Minimum 0.79″ (20 mm) Maximum 4.52 mm (115 mm) Minimum 0.003″ (0.076 mm) Maximum 0.012″ (0.305 mm) 3″ (76 mm) Roll media core inside diameter 8.0″ (203 mm) Maximum roll diameter Inter-label gap Minimum 0.079″ (2 mm) Preferred 0.
DESCRIPTION OF EQUIPMENT SECTION 1 Table 1-7. Environmental Operating Ranges Thermal Transfer: +40°F to +104°F (+5°C to +40°C) Temperature Direct Thermal: +40°F to +104°F (+5°C to +40°C) Storage -40°F to +140°F (-40°C to +60°C) Non-condensing relative humidity Operating 20% to 85% Storage 5% to 85% (/(&75,&$/ 5(48,5(0(176 • • • Universal power supply with power factor correction 90-264VAC, 48-62Hz.
SECTION 1 DESCRIPTION OF EQUIPMENT 7UDQVPLVVLYH 0HGLD 6HQVRUV The upper and lower transmissive media sensor pair monitor the presence of media at the printhead. The bottom sensor is an infrared transmitter and the upper sensor is the receiver. Adjustment Screw Attaching Screws Figure 1-3. Upper Media Sensor Lower Media Sensor Grommet Figure 1-4. Lower Media Sensor and Bracket When the printer is using continuous media, the sensor pair merely confirm that there is media in the machine.
DESCRIPTION OF EQUIPMENT SECTION 1 on the information from the transmissive media sensor pair but starts based on information from another pair of media sensors, the take label or label available sensor pair. 7DNH /DEHO 6HQVRUV See Figure 1-5. This pair of sensors detects the absence of a label printed on non-continuous media in the peel off mode. When the label is removed, the sensor pair signals the processor and the processor starts printing the next label. Label Available Sensors Figure 1-5.
SECTION 1 DESCRIPTION OF EQUIPMENT 6SLQGOHV The105SL printer uses 4 different spindles. Refer to Section 5 for exploded view drawings of these spindles. RIBBON SUPPLY SPINDLE. Supports and dispenses ribbon to and through the printhead. Maintains a little back pressure on the ribbon to keep it from pulling off the spindle too fast. RIBBON TAKE-UP SPINDLE. Helps pull the ribbon through the printer. Maintains the correct ribbon tension for highest quality printing. Prevents ribbon from unwinding.
OPERATION OVERVIEW SECTION 2 6(&7,21 23(5$7,21 29(59,(: 23(5$725 &21752/6 This section discusses the functions of the various controls and indicators on the Zebra 105SL. Become familiar with each of the controls before servicing the printer. )URQW 3DQHO 'LVSOD\ The Front Panel Display, as shown in Figure 2-1, communicates operational and programming modes and parameters. 35(9,286 1(;7 6$9( 6(783 (;,7 32:(5 7$.( /$%(/ (5525 &+(&. 5,%%21 3$3(5 287 3$86( )((' '$7$ &$1&(/ Figure 2-1.
SECTION 2 OPERATION OVERVIEW )URQW 3DQHO .H\V For an explanation of the front panel controls, refer to the following table and to Figure 2-1. Table 2-1. Front Panel Keys Key Function Starts and stops the printing process. • If the printer is not printing: no printing can occur. • If the printer is printing: printing stops once the current label is complete. Press to remove error messages from the display. NOTE: Pause mode can also be activated via ZPL II (~PP, ^PP).
OPERATION OVERVIEW SECTION 2 )URQW 3DQHO ,QGLFDWRUV For an explanation of the front panel indicators, refer to the following table and to Figure 2-1. NOTE: If two operating conditions occur simultaneously (for example, one that causes a light to be on constantly and one that causes the same light to flash), the light flashes. Table 2-2. Front Panel Lights Light Status Power—green Off Indication The printer is off or power is not applied. The printer is on.
SECTION 2 OPERATION OVERVIEW 32:(5 &25' (OHFWULFDO 5HTXLUHPHQWV • • • Universal power supply with power factor correction 90–264 VAC, 48–62 Hz. Power Consumption Idle = 19 W Printing = 180 W (printing pause test label at speed A) Agency approvals: UL 1950, CISPR 22 (class B), IEC 950, 801-2, -3, and -4 standards, CSA 950, Canadian Doc. (class A), FCC (class A), CE compliance &DEOH 5HTXLUHPHQWV The AC power cord has a three-prong female connector on one end.
OPERATION OVERVIEW SECTION 2 ,17(5)$&( &211(&7,216 NOTE: Depending on the Configuration Number on the printer identification plate, the 105SL is equipped either with a DB-25 or a DB-9 serial connector. If the printer has a DB-9 connector, a 9-pin to 25-pin adapter and an RS-422/RS-485 adapter are available. The printer is equipped with a parallel interface connector and a serial interface connector, as shown in Figure 2-3. The interface cable is not supplied with the printer.
SECTION 2 OPERATION OVERVIEW RS-422/RS-485 Adapter DB-9 to DB-25 Adapter Female DB25 Connector on RS-422/RS-485 Adapter Female DB-25 Adapter Connector (plugs into cable) Male DB-9 Adapter Connector (plugs into printer) 2 RXD FG 1 3 TXD TXD 2 4 DTR RXD 3 Frame ground 9 Signal ground ref.
OPERATION OVERVIEW • • • SECTION 2 Keep data cables as short as possible. Do not bundle the data cables tightly with the power cords. Do not tie the data cables to power wire conduits. NOTE: Zebra printers comply with FCC “Rules and Regulations”, part 15, Subpart J, for Class A equipment, using fully shielded 6 foot long data cables. Use of longer cables or unshielded cables may increase radiated emissions above the Class A limits.
SECTION 2 OPERATION OVERVIEW The pin outs and signal descriptions for the DB-25 DTE port are as follows: Pin 1—FG (Frame ground) for cable shield.
OPERATION OVERVIEW NOTE: SECTION 2 Pin 9 is also available as a +5 VDC power source at 750 mA. To enable this capability, a jumper needs to be installed between pins 2 and 3 at JP1 on the Main Logic Board. The pin outs and signal descriptions for the RS-422/RS-485 adapter are as follows: Pin 1—FG (Frame ground) for cable shield.
SECTION 2 OPERATION OVERVIEW Logic 0 Stop Bit Logic 1 Mark (Idle) (+5 VDC) (Idle) 1 (0 VDC) Space 2 3 Start Bit 4 5 6 Data Bits 7 Parity Bit Figure 2-9. RS-422/RS-485 Signaling &RPPXQLFDWLRQ &RGH The 105SL printer sends and receives ASCII (American Standard Code for Information Interchange) characters in one of two formats, Serial Data or Parallel Data. NOTE: When using the serial data format, the baud rate, number of data and stop bits per character, and parity are selectable.
OPERATION OVERVIEW SECTION 2 3DUDOOHO 3RUW &RQQHFWRU The following table shows the pin configuration and function of a standard PC-to-Printer Centronics Parallel cable. Table 2-4.
SECTION 2 OPERATION OVERVIEW COAX Interface Board COAX From Host Computer 1 2 3 4 5 6 7 8 T EST B F PT L NG 8 L NG 4 L NG 2 L NG 1 INV R EPC 9 10 11 12 B F S2 B F S1 PA2 9Pin to COAX Adapter ATTN PA1 S YNC COAX Figure 2-11. Coax Adapter Cable and Interface Hook-up TWINAX Interface Board 9Pin to Twinax Adapter 1 2 3 4 5 6 7 8 EPC BF PT E MU 2 E MU 1 L NG 8 L NG 4 L NG 2 L NG 1 9 10 11 12 A DR 4 A DR 2 A DR 1 SPO ATTN T EST S YNC TWINAX Figure 2-12.
OPERATION OVERVIEW SECTION 2 /2$',1* 0(',$ Figure 2-13 provides a view of the printer with the media cover open. Become familiar with these components before loading the media or ribbon. Ribbon Take-up Spindle Spindle Hook Printhead Lever Platen Roller Printhead Tear-off/ Peel-off Bar Snap Plate Media Roller Ribbon supply Spindle Media Supply Guide Media Supply Hanger Media Guide Media Rewind Spindle Lower Roller Spindle Hook Figure 2-13.
SECTION 2 OPERATION OVERVIEW Printhead lever Media supply guide Open Media Media guide Figure 2-14. Roll Media Loading Tear-Off Mode 3HHO 0RGH NOTE: Liner rewind or media rewind option required. Refer to Figure 2-15. 1. Remove the rewind plate from the front of the printer, if installed. Store it on the two mounting screws on the inside of the front panel. 2. Open the printhead. 3. Slide the media guide and media supply guide as far from the printer frame as possible. 4. Load media as shown.
OPERATION OVERVIEW SECTION 2 Media supply guide Open Media Label Closed Media guide Tear-off/ peel-off bar Label backing Rewind spindle Rewind plate Hook Guide plate Figure 2-15. Peel and Liner Rewind Loading 0HGLD 5HZLQG 0RGH ³ IRU 3ULQWHUV :LWKRXW WKH &XWWHU 2SWLRQ NOTE: Media rewind option required. Refer to Figure 2-16. 1. Remove the rewind plate from its storage location in front of the print mechanism inside the media compartment. 2.
SECTION 2 OPERATION OVERVIEW Media supply guide Open Media Closed Media guide Rewind spindle Rewind plate Hook Guide plate Figure 2-16. Media Rewind w/o Cutter Option 9. Remove the hook from the rewind spindle. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate. 10. Wind the labels around either the 3″ (76 mm) core or the rewind spindle and reinstall the hook. 11.
OPERATION OVERVIEW SECTION 2 &XWWHU 0RGH NOTE: Factory installed only cutter option required. Refer to Figure 2-17. Printhead lever Media supply guide Open Cutter Media Media guide Figure 2-17. Cutter Mode Loading 1. Open the printhead. 2. Slide the media guide and media supply guide as far from the printer frame as possible. 3. Load media as shown. 4. Slide in the media guide and media supply guide so they just touch, but don’t restrict, the edge of the roll. 5. Close the printhead. 6.
SECTION 2 OPERATION OVERVIEW )DQIROG 0HGLD /RDGLQJ Refer to Figure 2-18. Fanfold media feeds through either the bottom or through a rear access slot from outside the printer. 1. Open the printhead. 2. Slide the media guide as far from the printer frame as possible. 3. Load media as shown. If in cutter mode, route media through the cutter. 4. Slide in the media guide so it just touches, but doesn’t restrict, the edge of the roll. 5. Close the printhead.
OPERATION OVERVIEW SECTION 2 5HPRYLQJ WKH /DEHO %DFNLQJ 0DWHULDO Since the rewind spindle holds the backing from a standard-size media roll, we recommend that you perform this procedure whenever you change the media. Use the following procedure to remove the backing material from the rewind spindle. NOTE: The printer does not need to be turned off for this procedure. 1. Unwind approximately 36″ (915 mm) of backing from the rewind spindle. Cut it off at the spindle. 2. Pull out the hook.
SECTION 2 3. OPERATION OVERVIEW To make ribbon loading and unloading easier, make a leader for your ribbon roll if it doesn’t already have one. Refer to Figure 2-20. Ribbon Label Strip of Media Backing 6-12 Inches Long Figure 2-20. Making a Ribbon Leader 4. Tear off a strip of media (labels and backing) about 6–12″ (150–300 mm) long from the roll. Peel off a label from this strip. Apply half of this label to the end of the strip and the other half to the end of the ribbon. This acts as a ribbon leader.
OPERATION OVERVIEW SECTION 2 Notch Hook Ribbon Take-up Spindle Figure 2-22. Ribbon Hook Fit 7. Place the ribbon with leader around the ribbon take-up spindle and wind counterclockwise for several turns. 8. Close the printhead. 5LEERQ 5HPRYDO To unload ribbon, refer to Figure 2-23 and follow the procedure below. 2 Notch 1 3 Hook 4 Ribbon Take-up Spindle Figure 2-23. Ribbon Removal 1. If the ribbon is not exhausted, break or cut the ribbon as close to the ribbon take-up spindle as possible.
SECTION 2 OPERATION OVERVIEW 326,7,21,1* 7+( 0(',$ 6(16256 7UDQVPLVVLYH 6HQVRU The “web” or “gap” sensor, also known as the “transmissive sensor,” detects the gap or hole/ notch between labels. The transmissive sensor consists of two sections: a light source (the lower media sensor) and a light sensor (the upper media sensor). The media passes between the two.
OPERATION OVERVIEW 5. SECTION 2 Secure the upper media sensor adjustment screw. Figure 2-25. Upper Media Sensor Location $GMXVWLQJ WKH /RZHU 0HGLD 6HQVRU Position the lower media sensor by sliding it in its slot until it is positioned under the upper media sensor. See Figure 2-24. %ODFN 0DUN 6HQVRU The black mark sensor is in a fixed position and enabled via the front panel. See “Configuring the Printer” in the User's Guide for details.
SECTION 2 OPERATION OVERVIEW ,1,7,$/ 32:(5 83 After you have correctly installed the media and ribbon, set the power switch to the on (1) position. The printer performs a Power On Self-Test (POST). When this is complete, the display shows, “PRINTER READY”. &$/,%5$7,21 NOTE: This procedure must be performed when the printer is first installed or if it does not properly detect the top of the label. To calibrate the printer, you must do the following: • Determine the type of media or labels being used.
OPERATION OVERVIEW 2. SECTION 2 Press the (+) key to start the calibration procedure. The front panel LCD should show: /2$' %$&.,1* &$1&(/ &217,18( 3. Press the (–) key to cancel the operation, or open the printhead and remove as many labels as needed to load a section of blank backing material under the media sensor. If you are unsure of the media sensor location, refer to Figure 2-24 and Figure 2-25. 4. Press the (+) key to continue. The front panel LCD should show: 5(029( 5,%%21 &$1&(/ &217,18( 5.
SECTION 2 OPERATION OVERVIEW 11. Press the (+) key to continue. The printer performs the second part of the calibration process and the front panel LCD shows: 0(',$ $1' 5,%%21 &$/,%5$7( The media sensor determines a new value based on the presence of media and backing and determines the label length. The ribbon sensor determines a new value based on the presence of ribbon. Once media stops feeding, the calibration process is complete! 12. Press the SETUP/EXIT key to leave the programming mode.
OPERATION OVERVIEW SECTION 2 The first attempt to change one of these parameters (pressing the (–) or (+) keys) requires you to enter a four-digit password. This is done via the “ENTER PASSWORD” display. The (–) key changes the selected digit position. The (+) key increases the selected digit value. After entering the password, press the NEXT/SAVE key. The parameter you are trying to change is displayed. If the password was entered correctly, you can now change the value.
SECTION 2 NOTE: OPERATION OVERVIEW The feed key self test described in “troubleshooting” can also be used to determine the best darkness setting. CAUTION: Set the darkness to the lowest setting possible for the desired print quality. Setting darkness too high for a given ribbon may cause ink smearing and/or printhead burning through the ribbon. If printing is too light, you should increase the darkness.
OPERATION OVERVIEW SECTION 2 6HOHFWLQJ WKH 3ULQW 0RGH Print Mode settings tell the printer the method of media delivery you wish to use. Be sure to select a print mode your hardware configuration supports, since some selections displayed are for optional printer features. 35,17 02'( ← 7($5 2)) → Press the right or left oval key to display other selections. Default: Tear Off Selections: Tear Off, Peel Off, Rewind, Cutter Press the NEXT key to display MEDIA TYPE.
SECTION 2 OPERATION OVERVIEW 6HOHFWLQJ WKH 3ULQW 0HWKRG The Print Method parameter specifies the method of printing: direct thermal (no ribbon) or thermal transfer (using thermal-transfer media and ribbon). CAUTION: Selecting direct thermal when using thermal transfer media and ribbon results in an error message, but printing continues. If the print method is not changed to thermal transfer or if the media is not changed, damage to the printhead may result.
OPERATION OVERVIEW SECTION 2 6HWWLQJ WKH 0D[LPXP /DEHO /HQJWK Maximum Label Length specifies the distance from the leading edge of one label to the leading edge of the next label. Refer to Figure 2-26. A considerable part of the interlabel gap is part of the label length. Setting this parameter serves two functions: • The value of this setting determines the maximum label length value to be used during the media portion of the calibration process.
SECTION 2 OPERATION OVERVIEW Press the left oval key to decrease the value or press the right oval key to increase the value. Default: 39.0 inches (988 mm) Range: 2.0 inches (50 mm) to 39.0 inches (988 mm) in 1.0 inch (25.4 mm) increments. Press the NEXT key to display LIST FONTS. /,67,1* 35,17(5 ,1)250$7,21 /LVW )RQWV Use this selection to print a label that lists all of the fonts currently available in the memory of the printer.
OPERATION OVERVIEW SECTION 2 /LVW )RUPDWV This selection is used to print a label that lists all of the formats currently stored in the memory of the printer’s RAM, optional EPROM, or on an optional memory card. /,67 )250$76 35,17 Press the right oval key to print a label listing all of the formats. Press the NEXT key to display LIST SETUP. /LVW 6HWXS This selection is used to print a label that lists the current printer’s configuration information (same as the CANCEL key self test).
SECTION 2 OPERATION OVERVIEW 1. Press the right oval key to select “YES”. If your printer is set to require a password, you are prompted to enter the password. 2. Enter the password then press the NEXT key. 3. The display shows “INITIALIZE CARD?” Press the right oval key to select “YES”. The display shows “ARE YOU SURE?” $5( <28 685( 12 <(6 4.
OPERATION OVERVIEW SECTION 2 3. Press the right oval key “YES” to begin initialization, or, press the left oval key “NO” to cancel the request and return to the “INITIALIZE FLASH” prompt. 4. Press the SETUP/EXIT key followed by the NEXT/SAVE key. If initialization is still in process, the display flashes back and forth between the two phrases “CHECKING E: MEMORY” and “PRINTER IDLE.” 5.
SECTION 2 OPERATION OVERVIEW 0HGLD DQG 5LEERQ 6HQVRU &DOLEUDWLRQ NOTES: Before you begin this procedure, make sure that the maximum length is set to a value greater than the length of the labels are using. If the maximum length is set to a lower value, the calibration process assumes that continuous media is in the printer. Ensure that the “Media Type” and “Maximum Length” values have been configured prior to performing this calibration process.
OPERATION OVERVIEW SECTION 2 6HWWLQJ WKH %DXG 5DWH The baud rate of the printer must match the baud rate of the host for communications to take place. Select the baud rate that matches the one used by the host. %$8' – Press the right oval key to increase the value, or press the left oval key to decrease the value. Default: 9600 Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600, 115200 Press the NEXT key to display DATA BITS.
SECTION 2 OPERATION OVERVIEW 6HWWLQJ WKH 6WRS %LWV The stop bits of the printer must match the stop bits of the host for communications to take place. Select the number of stop bits that match the quantity being used by the host. 6723 %,76 6723 %,7 Press the right or left oval key to display other selections. Default: 1 Stop Bit Selections: 1 Stop Bit, 2 Stop Bits Press the NEXT key to display HOST HANDSHAKE.
OPERATION OVERVIEW SECTION 2 6HWWLQJ WKH 1HWZRUN ,' Use Network ID to assign a unique number to a printer used in an RS-422/RS-485 network. This gives the host the means to address a specific printer. This does not affect TCP/IP or IPX networks. 1(7:25. ,' → Press the left oval key to move to the next digit position, and press the right oval key to increase the value of the selected digit. Default: Range: 000 000 – 999 Press the NEXT key to display COMMUNICATIONS.
SECTION 2 NOTE: OPERATION OVERVIEW On diagnostic printouts: FE indicates a framing error. OE indicates an overrun error. PE indicates parity error. NE indicates noise. For any errors, check that your communication parameters are correct. Set the print width equal to or less than the label width used for the test. Press the NEXT key to display CONTROL PREFIX. 7KH &RQWURO 3UHIL[ &KDUDFWHU The control prefix character is a two-digit hex value.
OPERATION OVERVIEW SECTION 2 7KH 'HOLPLWHU &KDUDFWHU The delimiter character is a two-digit hex value. Once configured, this character acts as a parameter place marker in ZPL/ZPL II. Refer to the “ZPL II Programming Guide” for more information. '(/,0,7(5 &+$5 → ! &+ Press the left oval key to move to the next digit position, and press the right oval key to increase the value of the digit. (The displayed “H” is not entered as part of the value.
SECTION 2 OPERATION OVERVIEW Press the NEXT key to display HEAD CLOSE. +HDG &ORVH This setting determines the action of the media after the opened printhead is closed. “Calibration” recalibrates the media and ribbon sensors, “Feed” feeds the label to the first web, “Length” calculates the length of the label, and “No Motion” means the media does not move. +($' &/26( ← &$/,%5$7,21 → Press the right or left oval key to display other selections.
OPERATION OVERVIEW SECTION 2 Press the right oval key to increase the value, or press the left oval key to decrease the value. Each positive number moves the label top position down by one dot row; each negative number moves the position up by one dot row. Default: Range: +0 –120 to +120 Press the NEXT key to display LEFT POSITION. LABEL TOP POSITION LABEL LENGTH LABEL FEED LABEL TOP POSITION +80 DOT ROWS LABEL LENGTH Figure 2-29.
SECTION 2 Default: Range: OPERATION OVERVIEW 0000 –9999 to +9999 (If a negative value is required, enter the numeric value first, then change the plus to a minus sign.) LABEL FEED LEFT POSITION DEFAULT LEFT POSITION -35 DOT ROWS LABEL LENGTH Figure 2-30. Left Position Press the NEXT key to display HEAD RESISTOR. 6HWWLQJ WKH +HDG 5HVLVWDQFH 9DOXH This value has been preset at the factory to match the resistance value of the printhead. It must not be changed, unless the printhead is replaced.
OPERATION OVERVIEW SECTION 2 +($' 5(6,6725 → 2+06 Press the left oval key to move to the next digit position, and press the right oval key to increase the value of the digit. Initial Value: Factory set Range: 0488 – 2415 Press the NEXT key to display WEB S.
SECTION 2 OPERATION OVERVIEW 6HWWLQJ WKH )RUPDW &RQYHUW This parameter selects the bitmap scaling factor. The first number is the original dots per inch (dpi) value; the second, the dpi to which you would like to scale. )250$7 &219(57 ← 121( → Press the right or left oval key to display other choices. Default: None Selections: None, 150 → 300, 150 → 600, 200 → 600, 300 → 600 Press the NEXT key to display IP Resolution.
OPERATION OVERVIEW SECTION 2 6XEQHW 0DVN This parameter selects the part of the IP address that is considered to be part of the local network. It can be reached without going through the default gateway. 68%1(7 0$6. Press the left oval key to move to the next digit position, press the right oval key to increase the value of the digit. Press the NEXT key to display DEFAULT GATEWAY.
SECTION 2 OPERATION OVERVIEW 3&0&,$ &$5' ,167$//$7,21 The PCMCIA card slot is a factory installed option. If your printer has that option, you may install or change the card at any time. Use the following procedure to install a PCMCIA card. CAUTION: OBSERVE PROPER ELECTROSTATIC SAFETY PRECAUTIONS WHEN HANDLING ANY STATIC-SENSITIVE COMPONENTS SUCH AS PRINTED CIRCUIT BOARDS AND PRINTHEADS. 1. Place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2.
TROUBLESHOOTING SECTION 3 6(&7,21 7528%/(6+227,1* 29(59,(: 2) =,3 6833257 If you have access to a PC and the Internet, go to http://www.zebra.com. Click on “Service and Support”. Then click on “On Line Technical Support” (ZIP Support). “Welcome to Zebra's ZIP Support” “Search our Knowledge Base of technical support and troubleshooting information for Zebra products. Our goal is to ensure that you receive prompt, courteous service and a solution that meets your needs.
SECTION 3 TROUBLESHOOTING The normal Power On Self Test sequence is as follows: 1. All lights turn on simultaneously and then turn off in sequence through the following steps. 2. SRAM functionality test performed. 3. Option ROM functionality test performed. The words “Not Installed” is added to the display if optional ROM is not used. 4. Printhead is checked for proper operation. 5. Processor functionality test performed. The word “Failed” is added to the display if the test fails. 6.
TROUBLESHOOTING SECTION 3 35,17(5 6(/) 7(676 ,QWURGXFWLRQ These self tests, illustrated on the following pages, produce sample labels and provide specific information that helps determine the operating conditions for the printer. Each self test is enabled by holding in a specific front panel key or keys while turning the power switch ON. Keep the key(s) pressed until the front panel LEDs turn ON. When the Power-On Self Test (POST) is completed, the selected printer self test starts automatically.
SECTION 3 TROUBLESHOOTING &$1&(/ .H\ 6HOI 7HVW This self test prints a single label which contains a listing of the current configuration parameters stored in configuration (EEPROM) memory. See Figure 3-1. To perform this self test, press the CANCEL key while turning the power switch ON. The configuration may be changed either temporarily for specific label formats or ribbon and label stock, or permanently by saving the new parameters in EEPROM memory.
TROUBLESHOOTING SECTION 3 3$86( .H\ 6HOI 7HVW 1. The initial self test prints 15 labels at a speed of 2″ per second, then automatically PAUSES the printer. When the PAUSE key is pressed, an additional 15 labels print. See Figure 3-2. 2. While the printer is PAUSED, press the CANCEL key once to alter the self test. When the PAUSE key is pressed, the printer prints the self test labels at 6″ per second. Fifteen additional labels are printed each time the PAUSE key is pressed. 3.
SECTION 3 TROUBLESHOOTING Figure 3-3. FEED Key Self Test Sample Label &RPPXQLFDWLRQV 'LDJQRVWLFV 7HVW This test is controlled by configuring the “Setting Communications Mode” parameter found in the configuration section of the printer’s User’s Guide. Refer to Figure 3-4 for a sample label resulting from this test. NOTE: This label is inverted when printed. Figure 3-4. Communications Diagnostics Self Test Page 3-6 105SL Maintenance Manual 32056L Rev.
TROUBLESHOOTING SECTION 3 )((' .H\ DQG 3$86( .H\ 6HOI 7HVW To reset the printer configuration to the factory default values, press these two keys at the same time, while turning the power ON. The printer performs a normal startup, resets to factory defaults, calibrates, and saves the settings. 3$86( .H\ DQG &$1&(/ .H\ 6HOI 7HVW This self test can be used to verify proper printer operation after parts have been replaced or adjusted. When activated, the printer prints a maximum of 500 head test labels.
SECTION 3 TROUBLESHOOTING (;7(1'(' 35,17(5 ',$*1267,&6 Additional diagnostic tests are available for printhead assembly adjustments. These diagnostic tests are only accessible when the data interface cable is disconnected from the printer and a loopback connector is attached in its place.
TROUBLESHOOTING SECTION 3 )((' .H\ /RRSEDFN 7HVW With the loopback connector in place, press the FEED key while turning the power switch ON. After the Power-On Self Test, the printer begins printing the same series of label formats as shown in Table 3-1 for FEED key/CANCEL key test. The printer pauses at the end of each series of labels. Press the PAUSE key to begin printing the next format. Sample labels are shown in Figure 3-7 through 3-13.
SECTION 3 TROUBLESHOOTING Figure 3-9. Format 3 and 6 Test Sample Label Figure 3-10. Format 7 and 11 Test Sample Label Figure 3-11. Format 8 and 12 Test Sample Label Page 3-10 105SL Maintenance Manual 32056L Rev.
TROUBLESHOOTING SECTION 3 Figure 3-12. Format 9 and 13 Test Sample Label Figure 3-13. Format 10 and 14 Test Sample Label %DVLF 7URXEOHVKRRWLQJ Refer to Table 3-2 and compare the printer output to the sample label to improve the quality of your labels. Table 3-2. Troubleshooting SYMPTOM Printer is dead. No LEDs light and no display. 32056L Rev. 2 12/4/01 DIAGNOSIS ACTION AC power source not live. Plug power cord into a live AC source.
SECTION 3 TROUBLESHOOTING Table 3-2. Troubleshooting (Continued) SYMPTOM DIAGNOSIS ACTION All LEDs light, but nothing displays on LCD and printer does not operate. Main logic board or Flash faulty. Download new Flash or replace the main logic board. All LEDs flash on and off. No significant amount of DRAM Replace the main logic board. tested good. Take Label LED flashing. Printer misconfigured for Peel-Off Mode. If peel-off is desired, check take label sensor.
TROUBLESHOOTING SECTION 3 Table 3-2. Troubleshooting (Continued) SYMPTOM WARNING HEAD COLD DIAGNOSIS Printhead element is not hot enough to print properly. Printhead data cable not properly connected. ACTION Environment too cold for proper printing. Relocate printer to warmer area. WARNING: The printhead can be very hot and can cause severe burns. Allow the printhead to cool. Disconnect and reconnect data cable to the printhead.
SECTION 3 TROUBLESHOOTING Table 3-2. Troubleshooting (Continued) SYMPTOM Poor Print Quality. Truncated print, no print, or feed button operates incorrectly while using non-continuous media. DIAGNOSIS ACTION Darkness set too low. Reconfigure darkness setting. Incorrect media and ribbon. Replace media and ribbon. Printhead just replaced. Ensure printhead is installed properly with no wires or debris caught underneath. Printhead adjustments incorrect. Perform required adjustments.
TROUBLESHOOTING SECTION 3 Table 3-2. Troubleshooting (Continued) SYMPTOM Misregistration/skips labels. Misregistration and misprint of 1 to 3 labels. DIAGNOSIS ACTION Improper sensor type selected. Select proper sensor type through front panel programming. Misadjusted media sensors. Adjust media sensors. Improper spindle tensions. Check and adjust spindle tension if necessary. Improper ZPL format. Correct ZPL format. Media was pulled when motor was not moving.
SECTION 3 TROUBLESHOOTING 5HWXUQLQJ (TXLSPHQW Should it become necessary to ship your 105SL printer, carefully pack it 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 the original shipping container is not available, a replacement can be ordered by contacting the Technical Support department.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 6(&7,21 35(9(17,9( $1' &255(&7,9( 0$,17(1$1&( 6$)(7< ,1)250$7,21 (48,30(17 6$)(7< 7,36 After reviewing each procedure, place a check in the box. The AC power plug and IEC 320 connectors on all Zebra Printers must bear the certification mark of at least one of the international safety organizations listed below. Unless indicated otherwise, turn the power OFF before performing any maintenance procedures to the printer.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE (48,30(17 6$)(7< 7,36 &RQWLQXHG To ensure that static-sensitive devices such as printhead and printed circuit boards are not damaged during disassembly and reassembly, observe proper electrostatic safety precautions when handling these components.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 3(5621$/ 6$)(7< 7,36 Danger of an explosion exists if the back-up battery is replaced incorrectly. Do not wear any jewelry such as rings, watches, bracelets, etc. and loose clothing when servicing the printers. Beware of “Pinch Points” on the printers. Be especially careful of: • Opening and closing of covers • Opening and closing of the printhead • Rewind Spindle • Platen Roller Wear protective eye wear when removing E-Rings, C-Clips and springs.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 0$,17(1$1&( &21&(376 This section of the maintenance manual is divided into two basic categories: preventive maintenance and corrective maintenance. Preventive maintenance procedures may be performed by the operator as well as the service technician and should be performed on a regular basis. Preventive maintenance consists of a visual inspection and general cleaning of the interior and exterior of the printer.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 WARNING: UNLESS INDICATED OTHERWISE, TURN PRINTER POWER OFF AND DISCONNECT THE PRINTER FROM THE POWER SOURCE BEFORE PERFORMING THE FOLLOWING MAINTENANCE PROCEDURES. CAUTION: USE ONLY THE CLEANING AGENTS DESCRIBED IN THE FOLLOWING PROCEDURES. ZEBRA TECHNOLOGIES WILL NOT BE RESPONSIBLE IF ANY OTHER FLUIDS ARE USED ON THIS PRINTER. EXTERIOR: The exterior surfaces of the 105SL printer may be cleaned as required by using a lint-free cloth.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Printhead Lever Printhead Black Mark Sensor Take-Label Sensors Ribbon Sensor Platen Roller Peel-off/Tear-off Bar Figure 4-1. Cleaning a Typical Printhead 3. Use a cleaning swab and wipe the print elements from end to end. The print elements are the grayish/black strip just behind the chrome strip on the underside of the printhead. Allow a few seconds for the solvent to evaporate. 4.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Loop Snap plate Loop Slot Removal Loop Tab Loop Slot Tab Installation Figure 4-2. Removal and Installation of Snap Plate 5. To reinstall the snap plate, insert the two tabs on the bottom of the snap plate into the two slots of the media pathway. 6. Slide the snap plate toward you. 7. Press down on the loops to lock the snap plate into place.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE WARNING: UNLESS INDICATED OTHERWISE, TURN PRINTER POWER OFF AND DISCONNECT THE PRINTER FROM THE POWER SOURCE BEFORE PERFORMING THE FOLLOWING MAINTENANCE PROCEDURES. 3ULQWHU 3DUWV DQG /RFDWLRQV 'LIIHUHQFHV LQ 3ULQWHU &RQILJXUDWLRQV The printer identification label on the rear of the unit identifies the configuration of the printer.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 (OHFWULFDO ,QWHUFRQQHFWLRQV Refer to Interconnection Diagram anytime you remove and replace circuit boards or disconnect and reconnect any electrical components. Use Figure 4-4 for printer configurations 10500-0XXX-XXXX and 10500-1XXX-XXXX. Use Figure 4-5 for printer configurations 10500-2XXX-XXXX and 10500-3XXX-XXXX.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE PCMCIA OPTION BOARD LCD Display Black Mark Sensor P25 MAIN LOGIC PCB Upper Media Sensor P27 P6 Lower Media Sensor P10 P8 P3 P5 Ribbon Sensor P2 P31 P32 P1 AC/DC POWER PCB P19 Head Open Sensor Front Panel Interface Printhead Data Cutter Option Upper Take-Label Sensor Lower Take-Label Sensor AC Power Fuse AC Input Printhead Power Main Logic Stepper Board Motor Power Cutter Option Figure 4-5.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 AC Power Switch = On = Off FUSE AC Power Cord Connection (See Note) Power Socket AC Power Cord Note: Depending on Configuration, the power entry module may not have a user-replaceable fuse. Figure 4-6. Power Switch and Power Cord Removal and Installation Parallel Data Port 36-pin male Serial Data Port (9-Pin or 25-Pin) Wire Retainers 9 Screw Fasteners 25 Printer Printer Parallel Data Cable Serial Data Cable Figure 4-7.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 5HFRQQHFWLQJ DQG 3RZHULQJ WKH 3ULQWHU Parallel Data Cable: To install the parallel data cable, push the 36-pin parallel data cable male connector into the parallel data port connector. Firmly seat the connector. Secure the connector with the two wire retainers. Serial Data Cable: If an adapter was connected to the serial data port, reinstall the adapter and secure it with the two screw fasteners.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 553 1R 5HPRYH DQG ,QVWDOO WKH '& 3RZHU 6XSSO\ NOTE: This procedure is used only for printer configurations 10500-0XXX-XXXX and 10500-1XXX-XXXX. CAUTION: OBSERVE PROPER ELECTROSTATIC SAFETY PRECAUTIONS WHEN HANDLING ANY STATIC-SENSITIVE COMPONENTS SUCH AS PRINTED CIRCUIT BOARDS AND PRINTHEADS. To remove the DC power supply: 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE NEXT/ PREVIO SETUP/ SAVE EXIT US POW TAKE ER LABE ERRO CH RIB ECK PAPE PAUS E L R R OU BON T FEED DATA CANC EL Screw DC Power Supply Assembly Heat Conduction Pad Hex Nut Figure 4-9. DC Power Supply Removal and Installation 553 1R 5HPRYH DQG ,QVWDOO WKH $& 3RZHU 6XSSO\ NOTE: This procedure is used only for printer configurations 10500-0XXX-XXXX and 10500-1XXX-XXXX.
PREVENTIVE AND CORRECTIVE MAINTENANCE NOTE: 3. SECTION 4 Retain all attaching hardware to use during reassembly. Refer to Figure 4-10. Remove the nut holding the ground lead from the power entry module to the printer chassis. Shield Main Logic Board and Rear Panel IT SETUP/EX VE NEXT/SA PREVIO US POWE TAKE R LABEL ERRO R CHEC PAPER PAUSE K RIB BON OUT FEED DATA Power Entry Module CANC EL AC Power Supply Assembly Heat Conduction Pad Figure 4-10.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 2. Reinstall the five nuts and two spacers that hold the AC power supply assembly against the printer chassis. Ensure the plastic spacers are installed on the two rear posts. 3. Reconnect the cable from the power switch to connector J2 on the AC power supply. 4. Slide the main logic board and rear panel assembly into the printer. 5.
PREVENTIVE AND CORRECTIVE MAINTENANCE 3. SECTION 4 Disconnect the cable tie and remove it from the insulation shield. WARNING: CERTAIN COMPONENTS LOCATED UNDER THE INSULATION SHIELD CAN STORE A RESIDUAL CHARGE FOR AS LONG AS TEN MINUTES AFTER POWER HAS BEEN REMOVED. USE EXTREME CARE WHEN REMOVING THE POWER SUPPLY. HANDLE THE BOARD ONLY AROUND THE OUTER EDGES. 4. Refer to Figure 4-11. Remove and retain the two screws securing the insulation shield to the standoffs on the power supply.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 3. Carefully connect all the cables to the correct connectors on the power supply board as shown in Figure 4-5. 4. Reinstall the insulation shield, making sure the top is dressed properly. Secure the insulation shield to the standoffs on the power supply with two screws. 5. Dress the wire harnesses across the top of the insulation shield, and secure them with the cable wrap. 6. Reinstall the electronics cover. 7.
PREVENTIVE AND CORRECTIVE MAINTENANCE Optional Interface Board SECTION 4 Option Card Shield Optional Memory Card IT SETUP/EX VE NEXT/SA US PREVIO R POWE TAKE LABE ERRO PAPE PAUS S2 Font ROMs (2) E L R CHEC K RIB R OU BON T FEED DATA CANC EL Rotary Switch Main Logic PCB Figure 4-12. Main Logic Board Removal and Installation (Printer Configurations 10500-0XXX-XXXX and 10500-1XXX-XXXX) 11. Flash memory is installed on the main logic board.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 1. Refer to Figure 4-12. Position the cables out of the way. Place the main logic board onto the plastic stand-offs attached to the aluminum mounting plate at the top and bottom right hand corners of the board. 2. At the rear of the printer, install the two screws and two hex head studs with their washers that hold the serial and parallel data connectors to the back of the printer. 3. Slide the main logic board and rear panel assembly into the printer.
PREVENTIVE AND CORRECTIVE MAINTENANCE NOTE: 3. SECTION 4 Retain all attaching hardware to use during reassembly. Refer to Figure 4-13. Remove the option card shield if installed. Press the card release the button to remove the PCMCIA card from the card slot located at the rear of the printer. Option Card Shield PCMCIA Option Board Optional Memory Card Optional Interface Board Plastic Standoffs Main Logic PCB Figure 4-13.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 2. Fasten the serial port connector to the rear panel with two studs and washers. 3. Fasten the parallel port connector to the rear panel with two screws. 4. If there is the PCMCIA option board, align the two connectors on the option board with P23 and P24 and align the two holes at the bottom with the two standoffs on the main logic board. Press the option board to engage the two connectors and capture the two standoffs.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Ribbon Take-up Pulley Main Drive Belt Access To Mounting Screws Platen Roller Pulley 3 2 Spring Scale 1 22 00 20 18 00 C IN HE S 00 16 14 00 00 Ruler Stepper Motor Pulley Figure 4-14. Main Drive Belt Adjustment 6. Slide the ribbon take-up spindle assembly to the right to relieve the tension on the main drive belt. 7.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 5. Refer to Figure 4-14. Rotate the ribbon take-up pulley until the three holes in the pulley align with the three mounting screws that hold the ribbon take-up spindle assembly to the printer frame. 6. Extend an Allen wrench through the holes in the ribbon take-up pulley and loosen the three spindle assembly mounting screws. 7. Slide the ribbon take-up spindle assembly to the right to relieve the tension on the main drive belt. 8.
PREVENTIVE AND CORRECTIVE MAINTENANCE 8. SECTION 4 Reconnect the power cable to the power source. Place the power switch in the On (I) position. 553 1R $GMXVW WKH 5HZLQG 'ULYH %HOW 7HQVLRQ 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Open the media cover. 3. Open the printhead and remove the media and ribbon. Close the printhead. 4. Refer to RRP No.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 10. When a scale reading of 2000 grams ±250 grams (4.5 lbs. ±0.5 lbs.) creates a deflection of 1/4 inch (6 mm), tighten the idler pulley mounting screw to a torque of 20 inch-pounds (2.3 Nm). 11. Reinstall the plug into the lower access hole. 12. Reinstall the DC power supply or the AC/DC power supply, depending on configuration. 13. Reinstall electronics cover. 14. Reinstall the media and ribbon. Close the media cover. 15.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Stepper Motor Pulley Rewind Drive Belt Rewind Spindle Pulley Idler Pulley Lower Peel Roller Pulley Figure 4-17. Rewind Drive Belt Removal and Installation 3ULQWKHDG 5HSODFHPHQW 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Open the media cover. 3. Open the printhead and remove the media and ribbon. Close the printhead.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Printhead Data Connector Do Not Loosen These Screws !! Printhead Mechanism Assembly Printhead Mounting Screw Printhead Alignment Slots 105SL Printhead Power Cable Locking Tab Printhead Power Connector Resistance Label Figure 4-18. Printhead Replacement 8. Remove the printhead through the front of the printer. CAUTION: THE PRINTHEAD IS VERY DELICATE AND SUSCEPTIBLE TO DAMAGE IF NOT HANDLED CAREFULLY.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 WARNING: IF THE DATA CABLE IS NOT CONNECTED SECURELY TO THE PRINTHEAD, A HEAD COLD WARNING MESSAGE MAY APPEAR ON THE DISPLAY EVEN THOUGH THE PRINTHEAD MAY BE VERY HOT. ACCIDENTLY TOUCHING A HOT PRINTHEAD CAN CAUSE SEVERE BURNS. 10. Refer to Figure 4-18 and connect the printhead data cable and the power cable to the replacement printhead. 11.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 18. Place the power switch in the Off (O) position. Perform the PAUSE Key Self Test and check print quality. If only half of a label is printed, the printhead is not seated properly. If the label printed properly, the printer is ready for operation. If print quality is not satisfactory, refer to Troubleshooting Table in Section 3 and proceed to Printhead Adjustments.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 4. Install media and ribbon, and position the toggle in the center of the print mechanism. 5. Perform the PAUSE Key Self Test by holding the PAUSE key while placing the power switch to the On (I) position. NOTE: 6. To increase printhead pressure, loosen the upper knurled nut on the toggle and adjust the lower toggle knurled nut downwards. To decrease printhead pressure, loosen the upper knurled nut and adjust the lower knurled nut upwards.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Loosen Four Screws Before Adjusting Head Position Wear Plate Screws Printhead Location Adjusting Screws Strip Plate Note: The Ribbon Take-up Spindle Is Not Shown In This Illustration Figure 4-22. Printhead Adjustment 5. Continue to make the small adjustments in both directions until the best quality is achieved. 6. Enter the Configuration mode and decrease the darkness setting until the PAUSE Key Self Test labels are a charcoal gray color. 7.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 :HDU 3ODWH %DODQFH 3RVLWLRQ $GMXVWPHQW CAUTION: WEAR PLATE POSITION ADJUSTMENT RARELY NEEDS TO BE PERFORMED. DO NOT PERFORM THIS ADJUSTMENT UNLESS YOU HAVE BEEN TRAINED TO DO SO. IF THE PROCEDURE IS NOT DONE CORRECTLY, PRINT QUALITY WILL BE ADVERSELY AFFECTED. Adjusting the wear plate position changes the pressure across the width of the printhead and platen roller.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 6. Continue to print PAUSE Key Self Test labels and verify even printing and parallelism. 7. If parallelism is out of tolerance, perform the “Printhead Parallelism Adjustment” on page 4-34. 8. If no other adjustment is required, tighten the two screws to lock the adjustment. 3ULQWKHDG 3DUDOOHOLVP 7HVW Adjusting the printhead parallelism squares the printhead with respect to the media path. 1.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 6WULS 3ODWH $GMXVWPHQW The strip plate can be adjusted to achieve proper tracking and separation of the ribbon from the media after printing. 1. Print PAUSE Key Self Test labels. 2. Press the PAUSE key. After the printer pauses, observe the ribbon for problems such as wrinkling. 3. Refer to Figure 4-23 and loosen, but do not remove, the two screws holding the strip plate to the front of the printhead assembly. 4.
SECTION 4 2. PREVENTIVE AND CORRECTIVE MAINTENANCE Refer to Figure 4-24 and locate the upper media sensor. Upper Media Sensor Adjustment Screw Figure 4-24. Upper Transmissive Media Sensor Position Adjustment 3. Carefully loosen, but do not remove, the screw at the top of the sensor. NOTE: When using label stock that has a web between labels, position the upper media sensor anywhere along the web, except where the rounded corners of the label are detected.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 7DNH /DEHO /DEHO $YDLODEOH 6HQVRU $OLJQPHQW The take label sensor activates only when the printer is set to peel-off mode. This mode requires the Rewind or Peel option. The media sensor pair is NOT installed on printers without this option. Refer to Figure 4-26 for the location of the take label sensor components. When the beam is broken, the printer will be inhibited from printing or feeding in peel-off mode only.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Figure 4-27. Rewind Plate Assembly 3HHO 2II 0RGH 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 4-28 and perform the following procedure. Side Plate Screws Platen Support Bracket Lower Roller Figure 4-28. Peel-Off Lower Roller Alignment Page 4-38 105SL Maintenance Manual 32056L Rev.
PREVENTIVE AND CORRECTIVE MAINTENANCE 1. SECTION 4 Loosen the two screws that attach the platen support bracket to the side plate. NOTE: 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. 2. Adjust the bracket position as required and tighten the screws. 3.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Spindle Force Load (grams) Ribbon Supply Ribbon Take-up F1 F2 450 450 ±50 ±50 Media Rewind F3 1450 ±100 Liner Rewind F4 1450 ±100 Align Both Sections Before Installing Ribbon Core.
PREVENTIVE AND CORRECTIVE MAINTENANCE NOTE: SECTION 4 The shaft in the spindle must be held stationary as the adjustment nut is adjusted. To hold the spindle, refer to Figure 4-30 and insert an Allen wrench through the access hole on the inner end of the spindle and into the set screw in the shaft collar. DO NOT TURN THE ALLEN WRENCH. Hold the shaft in place while turning the adjustment nut. Figure 4-30. Media Rewind Spindle 2.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Ribbon Supply Spindle WARNING: WEAR PROTECTIVE EYE WEAR WHEN REMOVING E-RINGS, C-CLIPS, SNAP RINGS AND SPRINGS. ALL OF THESE ARE UNDER TENSION AND COULD FLY OFF WHILE BEING REMOVED. 1. Refer to Figure 4-31. Carefully remove and retain the C-clip near the end of the shaft. Felt Washer Torsion Spring Inner Spindle Section Thrust Washers Allen Head Set Screws Outer Spindle Section Shaft Collar Compression Spring Bearing End Cap C-Clip Figure 4-31.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 11. Slide the shaft collar onto the shaft. 12. Install the thrust washers, bearing, and compression spring into the end cap. 13. Place the torsion spring into the end cap, making sure that the end of the spring extends through the small hole in the end of the cap. 14. Slide the end cap onto the shaft and insert the other end of the spring into the hole in the shaft collar.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 3. Slide the outer shaft collar off the shaft. 4. Remove and discard the felt washer. 5. Slide the spindle off the shaft. 6. Remove and discard the felt washer. 7. Slide the inner felt washer onto the shaft and insert it onto the lip of the inner shaft collar. 8. Slide the spindle onto the shaft. 9. Install the outer felt washer onto the outer shaft collar, making sure it is seated on the lip. 10.
PREVENTIVE AND CORRECTIVE MAINTENANCE Platen Roller Pulley Spacer SECTION 4 Main Frame Bearing Side Plate Platen Roller C-Clip Peel/Tear-Off Bar Bearing Washer Figure 4-33. Platen Roller Removal CAUTION: Never reuse the old bearings. Use only the new bearings that were provided with the replacement platen roller. 10. Orient the replacement platen roller so that the end of the roller with the flats for the pulley is on the left side when facing the front of the printer. 11.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 18. Replace the electronics cover. 19. Reinstall the media and ribbon. Close the printhead. 20. Close media cover. 21. Reconnect the data cables and the power cord. 22. Reconnect the power cable to the power source. Place the power switch in the On (I) position. /RZHU 3HHO 5ROOHU 5HPRYH DQG 5HSODFH WKH /RZHU 3HHO 5ROOHU 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord.
PREVENTIVE AND CORRECTIVE MAINTENANCE Peel Roller Pulley PREVIOUS NEXT/SAV E SETUP/EX IT POWE TAKE SECTION 4 R LABEL ERROR CHECK PAPER PAUSE RIBBO N OUT FEED DATA CANC EL Small Spacer Bearing C-Clip Peel Roller Roller Adjust Plate Bearing Figure 4-34. Peel Roller Kit Parts CAUTION: Never reuse the old bearings. Use only the new bearings that were provided with the replacement platen roller. 14.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 23. Replace the electronics cover. 24. Reinstall the media and ribbon. Close the printhead. 25. Close the media cover. 26. Reconnect the data cables and the power cord. 27. Reconnect the power cable to the power source. Place the power switch in the On (I) position. 28. Perform a PAUSE Key Self Test and observe the tracking of the rewind drive belt and the tracking of the label backing material.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Ribbon Cable Connectors Twisted Wire Connector Pem LCD PCB Hex nut Membrane Switch Panel and Front Cover Assembly Ferrite Bead on Frame (If Present) Opening for Cables Ground Tail Nut Washer Figure 4-35. Membrane Switch and Front Panel ,QVWDOO WKH 1HZ 0HPEUDQH 6ZLWFK DQG )URQW 3DQHO 1. Insert two ribbon cables and ground cable through hole in front of printer. 2. Position the new membrane switch and front panel to the front of printer.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Membrane Switch Panel and Front Cover Assembly Nut PREVIOUS NEXT/ SAVE SETUP /EXIT POWER TAKE LABEL ERROR CHECK PAPER PAUSE RIBBON OUT FEED DATA CANCEL Nut Nut Figure 4-36. Remove/Install Membrane Switch and Front Panel Assembly 9. Reconnect the power cable to the power source. Place the power switch in the On (I) position. 10.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Ribbon Cable Connectors Aluminum Spacers Twisted Wire Connector Pem LCD PCB Hex nut Front Panel Figure 4-37. LCD PCB Removal/Installation 5. Connect the twisted wire connector to the LCD PCB. 6. Connect the two ribbon cable connectors to the LCD PCB. 7. Replace the electronics cover. 8. Reconnect the data cables and the power cord. 9. Reconnect the power cable to the power source. Place the power switch in the On (I) position. 10.
SECTION 4 5. PREVENTIVE AND CORRECTIVE MAINTENANCE For printers with configuration number 10500-0XXX-XXXX or 10500-1XXX-XXXX, refer to RRP No. 6 on page 4-18 and remove the Main Logic Board. Refer to RRP No. 4 on page 4-14 and remove the AC power supply. or For printers with configuration number 10500-2XXX-XXXX or 10500-3XXX-XXXX, refer to RRP No. 7 on page 4-20 and remove the Main Logic Board. 6. Refer to Figure 4-38.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Figure 4-39. Media Supply Hanger Installation 10. Reconnect the power cable to the power source. Place the power switch in the On (I) position. $& 3RZHU )XVH 5HSODFHPHQW The 105SL printer uses a metric-style fuse, 5 x 20 mm IEC, rated at F5A, 250V. The end caps of the fuse must bear the certification mark of a known international safety organization as shown in Figure 4-40. Figure 4-40.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE To replace a faulty fuse, use the following procedure. WARNING: TURN THE PRINTER’S AC POWER SWITCH OFF AND DISCONNECT THE PRINTER’S AC POWER CABLE BEFORE REPLACING ANY FUSES. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. 2. Refer to Figure 4-41.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 3ULQWHU &RQILJXUDWLRQV ;;; ;;;; DQG ;;; ;;;; The AC fuse is located on the power supply. To replace a faulty fuse, use the following procedure. WARNING: TURN THE PRINTER’S AC POWER SWITCH OFF AND DISCONNECT THE PRINTER’S AC POWER CABLE BEFORE REPLACING ANY FUSES. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. 2. Refer to RRP No.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 5. Fold the top of the insulation shield back into place and dress the harness so it does not interfere with the reinstallation of the electronics cover. 6. Reinstall the electronics cover. 7. Reconnect the power cable to the power source. Place the power switch in the On (I) position. NOTE: If AC power is not restored to the printer, make sure that the power cable is connected to a live power source.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Cutter Assembly Notch E-Ring Upper Drive Arm Lower Drive Arm Main Link Slotted Link Bearing Washer E-Ring E-Ring Post Pivot Stud Pivot Pin E-Ring Washer E-Ring Figure 4-43. Cutter Main Link and Slotted Removal and Installation &XWWHU 6ORWWHG /LQN 5HSODFHPHQW 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Refer to RRP No.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 4. Refer to Figure 4-43. Remove the E-ring that attaches the cutter main link to the mounting pin in the cutter slotted link. 5. Remove the E-ring, flat washer and bearing that attach the cutter slotted link to the pin on the lower drive arm. 6. Remove the E-ring and two flat washers that attach the cutter slotted link to the pivot post. 7. Remove the slotted link. 8. Position the new slotted link as shown in Figure 4-43. 9.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Allen Screw J4 Pems Cutter PCB Ribbon Cable Cutter Motor Power Cable Figure 4-44. Cutter PCB Removal and Installation 8. Refer to Figure 4-45. Attach the cutter power cable to connector J2 on the new cutter board. 9. Attach the cutter data cable to connector J1 on the new cutter PCB. NOTE: The cutter motor leads have a polarized connector. 10.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE J2 to DC Power Supply +5 VDC C1 J1 to Main Logic Board J3 to Cutter Optical Sensor TP1 J4 to Stepper Motor Figure 4-45. Cutter PCB Connections /RZHU 'ULYH $UP $OLJQPHQW The alignment of the lower drive arm must be checked and possibly adjusted any time the cutter PCB is replaced. To perform the lower drive arm mechanical alignment, some but not all cables must be connected between the power supply(ies), and the cutter PCB.
PREVENTIVE AND CORRECTIVE MAINTENANCE 2. SECTION 4 For printer configurations 10500-2XXX-XXXX and 10500-3XXX-XXXX, reinstall the insulation shield on the AC/DC power supply. WARNING: USE EXTREME CARE WHEN WORKING NEAR LIVE POWER. THE POWER SUPPLIES ARE LIVE AND HAVE POTENTIALLY LETHAL CURRENT. KEEP CLEAR OF THE POWER SUPPLY WHEN WORKING WITH THE CUTTER COMPONENTS. SOURCE VOLTAGE CAN CAUSE SERIOUS INJURY OR DEATH. 3. Reconnect the AC power cord. Reconnect the power cable to the power source.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 14. Reinstall the electronics cover. 15. Reconnect data cables. Place the power switch in the On (I) position. 8SSHU 'ULYH $UP $OLJQPHQW If the media hits either cutter blade or if the cutter does not cut through the label material completely, the upper drive arm alignment must be checked. NOTE: The upper drive arm is part of the cutter mechanical assembly and has been aligned at the factory.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Rotary Cutter Blade Upper Cutter Bracket Mounting Screw Media Guide Ensure the Top of the Tear-Off Bar is Positioned Above or Level With the Top of the Rear Cutter Blade Tear-Off 0.100 (2.5 mm) Rear Cutter Blade Bar Clearance of 0.030 (0.
SECTION 4 5. PREVENTIVE AND CORRECTIVE MAINTENANCE Refer to Figure 4-44. On the electronics side of the printer, disconnect the cutter motor power cable from the cutter PCB connector J4. Loosen the screws that attach the cutter PCB. Remove the one Allen screw in the lower right corner of the cutter PCB so you can remove the cutter motor power lead. WARNING: WEAR PROTECTIVE EYE WEAR WHEN REMOVING E-RINGS, C-CLIPS, SNAP RINGS AND SPRINGS.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 E-Ring Long Drive Link Flat Washer Slotted Link Bearing Lower Drive Arm E-Ring Pivot Pin E-Ring Mounting Post Clamp Motor Mounting Allen Screws Cutter Optical Sensor Cutter Motor Allen Screw Ferrite Ring Cutter Motor Shaft Grommet Figure 4-47. Cutter Motor Replacement 8. Tighten the two set screws that secure the lower drive arm to the shaft of the new cutter motor.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 14. Refer to Figure 4-4 or Figure 4-5. Carefully connect the remaining cables/connectors to the power supply and verify proper placement and orientation. 15. Ensure that the power switch is in the Off (O) position. Reconnect the AC power cord. Connect the power cord to a live AC source. Place the power switch in the On (I) position. Enter configuration mode and set the printer for cutter mode.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 5. Install new platen pulley on end of platen shaft so that the set screws align with the flats of the platen shaft. 6. Tighten the two set screws in the new platen pulley assembly. 7. Reinstall and adjust the tension of main drive belt. 8. Reinstall the electronics cover. 9. Reconnect the data cables and the power cord. 10. Reconnect the power cable to the power source. Place the power switch in the On (I) position.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Linen Thread Figure 4-50. Linen Thread Placement 7. Refer to Figure 4-51. Remove the screw attaching the upper media sensor to the bracket. Set aside the bracket. Phillips Head Screw Washer Upper Media Sensor Bracket Linen Thread Sensor Wire Cover Lower Media Sensor Red & Black Upper Media Sensor Connectors Red & Brown Grommet Figure 4-51.
PREVENTIVE AND CORRECTIVE MAINTENANCE Lower Media Sensor SECTION 4 Grommet Figure 4-52. Lower Media Sensor and Bracket 10. Remove these electrical lead connectors. From the media side of the printer, remove the grommet from the slot in the printer main frame. Gently pull on the sensors while guiding the wires through the hole in the main frame. 11. Remove the upper and lower sensors and electrical leads with the connectors. ,QVWDOO 1HZ 6HQVRUV 1. Refer to Figure 4-51.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 8. Connect upper sensor green and yellow leads to the main logic board. Connect lower sensor red and black leads to the main logic board. 9. Close the white plastic clamps. Secure the clamps with hex nuts. Adjust the wire tie to secure the wires. 10. Reinstall the electronics cover. 11. Refer to “Transmissive Media Sensor Position Adjustment” on page 4-35 and adjust the position of the sensors. 12. Reinstall the media and ribbon. Close the media cover.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 E-Ring Spacer Rewind Pulley Bearing Housing Flat Washer Rewind Spindle Wave Washer Screws (3) Washers (3) Figure 4-53. Media Rewind Spindle Replacement 13. Secure the new media rewind spindle assembly with the E-ring. 14. Reinstall the rewind drive belt. Reinstall the main drive belt. 15. Refer to RRP No. 8 on page 4-22 and adjust the tension on the main drive belt. 16. Refer to RRP No. 10 on page 4-25 and adjust the tension on the rewind drive belt. 17.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 5LEERQ 6XSSO\ 6SLQGOH 5HSODFHPHQW CAUTION: NEVER TURN THE RIBBON SUPPLY SPINDLE COUNTERCLOCKWISE AS VIEWED FROM THE END. DOING SO CAN DISCONNECT THE TENSION SPRING AND REQUIRE THE SPINDLE TO BE REBUILT. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Open the media cover. 3. Open the printhead and remove the media and ribbon. Close the printhead. 4.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 7. On the right hand side of the printer, pull out the old ribbon supply spindle and bearing housing, as an assembly. 8. Install the new ribbon supply spindle and bearing housing, as an assembly, through the mounting hole in the printer main frame. 9. Attach the bearing housing with three screws. Tighten the screws to 18–20 inch-pounds. (2.0–2.3 Nm). 10. Install the new nut and washer that secures the new ribbon supply spindle. 11.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Allen Screws (3) Wave Washer Pulley Washers (3) E-Ring Spacer Bearing Housing Flat Washer PREVIOUS NEXT/SAV E SETUP/EX POWE TAKE Ribbon Take-up Spindle IT R LABEL ERROR CHEC PAPER PAUSE K RIBBO N OUT FEED DATA CANC EL Figure 4-55. Ribbon Take-up Spindle 11. Install the wave washer, flat washer, spacer and belt pulley. Secure the new spindle assembly with the E-ring. 12. Reinstall and adjust the tension of the main drive belt. 13.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Allen Screw Phillips Screw Phillips Screw PCMCIA Allen Screw Phillips Screws (3) PCMCIA Phillips Screws (3) Parallel Interface Connector Parallel Interface Connector Phillips Screws (2) Phillips Screws (2) Phillips Screw Phillips Screw 3/16 Hex Studs (2) 3/16 Hex Studs (2) DB-25 Serial Interface Connector DB-9 Serial Interface Connector AC Power On/off Switch AC Power On/off Switch AC Power Cable Connection AC Power Cable Connection Prin
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Power Switch Brown Brown Blue Brown Blue Blue Green W/Yellow Tracer Ground Wire Green W/Yellow Tracer Ground Wire Power Entry Module Hex Nut Figure 4-57. Rear Panel Wiring 13. Snap the power switch assembly into the replacement rear panel. 14. Install the AC power entry module into the replacement rear panel and secure with two screws. 15. Position the replacement rear panel to the back of the printer.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 were made correctly. Replace the fuse and reconnect the power cord. Place the power switch in the On (I) position. 5LEERQ 7DNH 8S 3XOOH\ 5HSODFHPHQW 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Refer to RRP No. 2 on page 4-12 and remove the electronics cover. 3. Refer to RRP No. 9 on page 4-23 and remove the main drive belt.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 7. Reinstall the E-ring to retain the pulley. 8. Install the main drive belt. Refer to RRP No. 8 on page 4-22 and adjust the tension on the main drive belt. 9. Reinstall the electronics cover. 10. Reconnect the data cables and the power cord. 11. Reconnect the power cable to the power source. Place the power switch in the On (I) position. 0HGLD 7DNH 8S 3XOOH\ 5HSODFHPHQW 1. Refer to RRP No.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Wave Washer Media Take-Up Pulley PREVIO US NEXT/SA VE E-Ring SETUP/EX POWE TAKE LABEL ERRO R CHEC Spacer PAPER PAUSE Flat Washer IT R K RIBBO N OUT FEED DATA CANC EL Figure 4-59. Media Take-up Pulley Replacement 16. Reconnect the power cable to the power source. Place the power switch in the On (I) position. 3HHO 5ROOHU 3XOOH\ 5HSODFHPHQW 1. Refer to RRP No.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Stepper Motor Pulley Rewind Drive Belt Media Take-Up Pulley Idler Gear Set Screws Peel Roller Pulley Figure 4-60. Peel Roller Pulley Replacement 10. Tighten the two set screws to secure the pulley. 11. Reinstall the rewind drive belt. Refer to RRP No. 10 on page 4-25 to adjust the tension on the rewind drive belt. 12. Reinstall the main drive belt. Refer to RRP No. 8 on page 4-22 to adjust the tension on the main drive belt. 13.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Flag Slot Shield Trimount Retainer Back of Printer Flag Retaining Screw PREVIOUS NEXT/SAVE SETUP /EXIT POWER TAKE LABEL ERROR CHECK PAPER Pivot Bar PAUSE Wave Washer RIBBON OUT FEED DATA Toggle Assembly CANCEL Plastic Bearing Printhead Lever Figure 4-61. Pivot Bar, Handle and Toggle Parts 7. On the left side of the printer, pry off the shield trimount retainer that retains the printhead open flag. 8.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 15. With the printhead lever facing down, slide it onto the shaft far enough to compress the wave washer. NOTE: The retaining screw screws through the handle into the shaft. 16. Tighten the retaining screw so it threads into the pivot shaft. 17. Check the orientation and operation of the printhead lever, toggle, and head open flag. 18. Reinstall the electronics cover. 19. Open the printhead and reinstall media and ribbon. Close the printhead. 20.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Rewind Plate Slot Lip Adjustable Hook Plate Figure 4-62. Rewind Plate Replacement 5LEERQ 6HQVRU 5HSODFHPHQW 5HPRYH WKH 2OG 5LEERQ 6HQVRU 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Open the media cover. 3. Open the printhead and remove the media and ribbon. Close the printhead.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Do Not Loosen These Screws !! Printhead Mechanism Assembly Printhead Mounting Screw Power Cable Locking Tab Printhead Data Connector Printhead Alignment Slots 105SL Printhead Printhead Power Connector Resistance Label Figure 4-63. Printhead Replacement CAUTION: THE PRINTHEAD IS VERY DELICATE AND SUSCEPTIBLE TO DAMAGE IF NOT HANDLED CAREFULLY. USE PARTICULAR CARE TO ENSURE THAT THE PRINTHEAD IS NOT DAMAGED WHEN HANDLING IT. 6.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Printhead Assembly Screw Pivot Bar Flat Washer Washer Split Grommet Ribbon Sensor (See Note) Guard Plate Note: Position Ribbon Sensor Tab So It Is Not Flush With Top Edge of Pivot Bar. The Gap Should be 0.010 Min./0.030 Max. Below Top Edge. Screws Figure 4-64. Guard Plate and Sensor Wire Tie Figure 4-65. Wire Tie Removal and Installation ,QVWDOO WKH 1HZ 5LEERQ 6HQVRU 1.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE 5. Refer to Figure 4-65. Bunch the printhead power and data cables along with the ribbon sensor cable. Install a tie wrap around all three cables and the printhead pivot shaft. Snug it up and cut off the excess. 6. Carefully position the alignment slots in the new printhead over the alignment posts on the underside of the mounting bracket. 7. Seat the printhead completely and hold it in place.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 18. If you receive a Ribbon Error, check all the steps of the installation procedure. Make sure that the sensor power connector is fully seated into the connector on the logic board. 7DNH /DEHO 6HQVRU 5HSODFHPHQW 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Open the media cover. 3. Refer to RRP No. 2 on page 4-12 and remove the electronics cover.
SECTION 4 9. PREVENTIVE AND CORRECTIVE MAINTENANCE Refer to Figure 4-4 or Figure 4-5. Route the wires through the cable clamps and bring them to the main logic board. Make sure that the wires do not come in contact with any moving parts. 10. Connect the take label sensor connectors to the main logic board. NOTE: In the Peel-Off mode, if the two sensors are not aligned with each other, the take label LED illuminates, and the printer does not operate.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Main Frame Side Plate Platen Roller C-Clip Peel/Tear-Off Bar Bearing Washer Figure 4-68. Freeing Side Plate for Removal 10. Refer to Figure 4-69. Remove screw 12, the printhead lever, and the wave washer, as shown in Detail A. NOTE: To ensure that the side plate is reinstalled in the exact position, paint two thin lines from the side plate to the stepper motor housing. 11.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE Pivot Shaft 12 7 7 Wave Washer 12 11 3 PREVI OUS NEXT/ SAVE SETUP /EXIT POWER TAKE 8 LABEL ERROR CHECK PAPER Detail A PAUSE 8 RIBBON 10 OUT Printhead Lever FEED DATA CANCEL Detail A 1 4 9 2 5 6 Side Plate Stepper Motor Housing Figure 4-69. Side Plate Removal and Installation NOTE: 3. After the side plate is reinstalled, there are many parts that need to be reinstalled and a series of adjustments that need to be made.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 Main Frame Grommet PREVIOUS NEXT/SAVE Connector SETUP/EXIT POWER TAKE LABEL ERROR Stepper Motor Electrical Lead CHECK RIBBON PAPER OUT PAUSE FEED DATA Stepper Motor CANCEL Side Plate Stepper Motor Housing Screws (4) Figure 4-70. DC Stepper Motor Removal and Installation 10. Ensure that the peel roller extends through the bearing in the side plate, and secure with the C-clip. 11.
SECTION 4 PREVENTIVE AND CORRECTIVE MAINTENANCE %ODFN 0DUN 6HQVRU 5HSODFHPHQW 5HSODFH %ODFN 0DUN 6HQVRU 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Refer to RRP No. 2 on page 4-12 and remove the electronics cover. 3. Refer to Figure 4-71. Remove two screws that secure the black mark sensor, and remove the sensor. Black Mark Sensor Allen Screws (2) Figure 4-71. Black Mark Sensor Installation 4.
PREVENTIVE AND CORRECTIVE MAINTENANCE SECTION 4 12. Reconnect the power cable to the power source. Place the power switch in the On (I) position. 13. Enter Printer Configuration and select MARK for sensor type. 0HGLD &RYHU 5HSODFHPHQW 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2. Open the media cover. 3. Refer to Figure 4-72.
SECTION 4 Page 4-94 PREVENTIVE AND CORRECTIVE MAINTENANCE 105SL Maintenance Manual 32056L Rev.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 6(&7,21 0$,17(1$1&( $1' $66(0%/< '5$:,1*6 '(6&5,37,21 Use the mechanical assembly drawings when troubleshooting or replacing components. Use the associated parts list when ordering replacement parts. Item parts that do not have associated part numbers are not available and need to be ordered using the next highest assembly number.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS /,67 2) 7$%/(6 Table 5-1 Final Assembly (View 1). ................................................................................... 5-4 Table 5-2 Final Assembly (View 2). ................................................................................... 5-6 Table 5-3 Final Assembly (View 3) for Configuration Numbers 10500-0XXX-XXXX and 10500-1XXX-XXX. .....................................................................................
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 /,67 2) ),*85(6 Figure 5-1. Final Assembly (View 1) ..................................................................................5-5 Figure 5-2. Final Assembly (View 2) ..................................................................................5-7 Figure 5-3. Final Assembly (View 3 ) for Configuration Numbers 10500-0XXX-XXXX and 10500-1XXX-XXXX ..................................................................................5-9 Figure 5-4.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-1. Final Assembly (View 1) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part Number 31040 30269 01861 32039M 30407-008 01130 40051M 40050M 32038M 46396-006 32034M 46609-4M 48808 30023 46198M 46199M 30826 %† 48342 32053M Description Panel, Media Side Pad, PVC 4.00 x 0.037 x 0.62 Label, Supplies Kit, Maintenance, Media Cover . Screw, 6-32 x 0.5 Nut, 6-32 Assy.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 1 3 2 4 6 8 7 9 5 11 12 10 13 14 15 PREVI OUS NEXT/ SAVE 23 SETUP /EXIT POWER TAKE LABEL ERROR CHECK PAPER PAUSE RIBBON OUT FEED DATA CANCEL 16 22 20 17 18 19 21 Figure 5-1. Final Assembly (View 1) 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-2. Final Assembly (View 2) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number 01130 22613M 38226M 46091 40305RM 32028M 30236 30494 35020 40031 40248 40154 † 30956 30007-3 48011-5 Description Screw, 6-32 x 0.25 Nut, 6-32 Kit, Maintenance, Head Open Sensor Kit, Maintenance, Reflective Sensor (Includes Tiewrap Q06020) Grommet, Rubber 1.25 x 0.625 Assy.
MAINTENANCE AND ASSEMBLY DRAWINGS 1 (2) 2 SECTION 5 8 9 6 3 10 4 5 11 Upper Media Sensor Sub Assembly 7 1 1 (2) 17 18 12 13 14 1 15 16 1 Figure 5-2. Final Assembly (View 2) 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-3. Final Assembly (View 3) for Configuration Numbers 10500-0XXX-XXXX and 10500-1XXX-XXX Item 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Ref. 21 22 23 24 25 Ref.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 17 3 2 24 16 1 18 15 10 10 4 23 13 14 12 11 5 10 12 9 BLUE 6 7 8 BROWN 25 28 30 22 19 20 26 21 31 32 27 29 Figure 5-3. Final Assembly (View 3 ) for Configuration Numbers 10500-0XXX-XXXX and 10500-1XXX-XXXX SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-4. Final Assembly (View 4) for Configuration Numbers 10500-2XXX-XXXX and 10500-3XXX-XXXX Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number 22416 33000M 07696 46396-006 30236 46616 30236 33123 33124 33127-012 33050M 46396-006 01130 33059 46396-012 ** † Description Assembly, PCB PCMCIA Option Standoff, 4-40 Hex Washer, Lock #4 Kit, Maintenance MLB Screw, 4-40 x 0.31 Screw, 6-32 x 0.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 7 6 (3) 5 (2) 8 4 9 2 (2) 3 (2) 1 10 10 11 13 12 14 15 21 (4) 16 19 DAN HIGH GER VOLT AGE 17 20 (4) 18 Figure 5-4. Final Assembly (View 4) for Configuration Numbers 10500-2XXX-XXXX and 10500-3XXX-XXXX 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-5. Printhead Support Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number 30781 † 31899 †† ‡ ‡‡ ³ § §§ ¶ 48162 48014 30494 ¶¶ « 46665M 22 22 23 23 32432M 32433M 24 24 25 26 27 28 48017 46882-003 48099-5 30007-4 Description Rivet, Snap 0.138 x 0.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS 6 1 7 5 8 6 4 2 7 3 28 11 27 9 10 26 25 12 24 18 19 20 13 22 23 14 21 (See Note 1) 7 15 16 17 Wrap Ground Strap As Shown Resistance Value XXXXXXXXXXXXXX R=XXXX XXXXXXXXXXX XXXXXX Note: 1. Position Ribbon Sensor Tab not to be Flush With Top Edge of Pivot Bar. Gap 0.010 Min./0.030 Max. Below Top Edge 2. Remove Tab as Shown from Printhead Data Connector.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-6. Main and Lower Platen Rollers Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number 32011M 02252 22004-2 32101M 02252 22004-1 40019 40355M † 30914M † Description Kit, Maintenance, Platen Roller (Main) . Assembly, Platen Roller . Bearing, Flanged Ball . Washer, Flat 0.42 x 0.260 x 0.0747 . Ring, Crescent External 0.250 .
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 1 6 2 3 4 5 7 12 8 13 14 15 9 10 17 11 20 16 19 18 21 Figure 5-6. Main and Lower Platen Rollers 32056L Rev.
SECTION 5 Page 5-16 MAINTENANCE AND ASSEMBLY DRAWINGS 105SL Maintenance Manual 32056L Rev.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 Table 5-7. Media Supply Hanger Item 1 2 3 4 5 6 Part Number 32053M 35082 35136* 30466** 35137† Description Kit, Maintenance, Media Supply Hanger . Guide, Media . Washer, Nylon 0.252 x 0.472 x 0.059 . Bracket, Media Hanger . Washer, 0.26 x 0.63 x 0.06 . Ring, Retainer 0.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-8. Ribbon Supply Spindle Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 N/S Part Number 40051M 40066 † 40333M 40070-2 30401-002 †† 40068 40070-1 30401-002 ‡ 30344M ‡‡ § 30071 §§ 40067 ¶ Description Assembly, Maintenance, Ribbon Supply Spindle . Ring, Crescent External 0.375 . Support, Spindle Ribbon Supply . Washer, Thrust 0.687 x 0.375 x 0.093 . Bearing, Thrust .
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 1 11 15 6 10 7 13 12 8 5 14 3 9 2 4 4 2 21 19 20 5 17 18 16 Figure 5-8. Ribbon Supply Spindle 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-9. Ribbon Take-up Spindle and Pulley Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 N/S Part Number 40050M 30422-002 30438 30112 40057 30422-006 30073 † †† ‡ 30058-2 40490-2 31336M 30080-4 ‡‡ Description Kit, Maintenance, Ribbon Take-up . Assembly, Bearing Support . . Bearing Support . . Screw, 6-32 x 0.25 . . Spring, Compression 0.088 x 0.250 . . Spring Support . .
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 1 2 4 5 3 6 7 8 10 11 9 13 15 17 12 Notes: 14 1) Soak Felt Washers 30041-1 in Silicone Oil & Squeeze Out. 16 (2) Assembly is Positioned via Positioning Collar & Set Screws Collar should be 0.030 to 0.080 from Edge of 30118. 19 20 21 18 Figure 5-9. Ribbon Take-up Spindle and Pulley 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-10. Media Guide Assembly Item 1 2 3 4 5 6 7 Part Number 40305RM 30153 01130 40252R 30033 % Description Kit, Maintenance, Media Guide . Guide, Stationary Media . Nut, 6-32 . Support, Media Guide . Guide, Adjustable Media . Nut, Thumb 6-32 x 0.50, Brass . Screw, Cap 6-32 x 0.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 Table 5-11. Front Panel and LCD Display Item 1 2 3 4 5 6 7 Part Number 32021M 5HI 01130 32043M 01130 Qty Description Kit, Maintenance, Front Membrane Switch . Front Panel and Membrane Switch Assy. . Nut, 6-32 . Washer, Flat 0.500 x 0.191 x 0.030 Kit, Maintenance, LCD . LCD Display .
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-12. AC and DC Power Supplies Item 1 2 3 Part Number 32060M 49285 32070M 4 5 6 7 8 49286 01130 46392-006 9 33050M 10 11 Description Kit, Maintenance AC Power Supply (Configuration Numbers 10500-0XXX-XXXX and 10500-1XXX-XXXX) . Assembly, AC Power Supply . Pad, Insulation Kit, Maintenance DC Power Supply (Configuration Numbers 10500-0XXX-XXXX and 10500-1XXX-XXXX) . Assembly, DC Power Supply . Pad, Insulation . Nut, 6-32 .
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 Table 5-13. Pivot Bar Assembly Item 1 2 3 4 5 6 7 8 9 Part Number 32034M 35099M 30391-006 † Description Kit, Maintenance Pivot Bar . Shield, Tri-mount . Flag, Sensor . Assembly, Maintenance, Toggle Move . Screw, 4-40 x 0.37 . Washer, Wave 0.49 x 0.33 x 0.0075 . Printhead Lever Bearing, Nylon 0.312 x 0.251 x 0.140 Bearing, Nylon 0.312 x 0.251 x 0.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-14. Backing Rewind Assembly Item Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 N/S Part Number 33180 02252 22004-1 40019 † 40490-2 †† 45189-5 ‡ ‡‡ 30257 46609-4M § 30265 30207 11301 §§ Description Kit, Option Backing Rewind . Screw, 8-32, Socket Head Cap . Washer, Flat 0.406 x 0.172 x 0.048 .
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 4 2 3 Stepper Motor Pulley (Not Included) 7 1 8 10 9 4 5 19 12 20 17 16 2 21 11 13 14 22 23 18 6 2 15 8 Figure 5-14. Backing Rewind Assembly 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-15. Media Rewind Option Item Ref 1 2 3 4 5 6 7 8 9 10 11 12 Part Number 33181 22004-1 02252 40019 † 40055RM 47062-2 46609-4M †† ‡ ‡‡ § 45189-2 30265 30207 30257 22 23 40383RM 24 11301 N/S §§ N/S ¶ N/S - Not Shown 13 14 15 16 17 18 19 20 21 Description Qty Kit, Option Media Rewind . Screw, 8-32, Socket Head Cap . Washer, Flat 0.406 x 0.172 x 0.048 .
MAINTENANCE AND ASSEMBLY DRAWINGS 3 SECTION 5 6 2 4 5 1 Stepper Motor Pulley (Not Included) 7 9 8 5 12 11 14 13 18 17 2 10 20 15 16 22 21 2 19 8 24 23 Figure 5-15. Media Rewind Option 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-16. Cutter Option Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Part Number 30378M 30199 Q10019 30210 30217-1 30379M 30133 30198 30380M 30219 † 30236 30216 01822 46618M 30394-005 30405-006 46224 08449 31374M 10421 30816 †† ‡ 40819 30196-150 46280M ‡‡ 49730M 49604-010 49600-012 40320 40181 Q10011 46807 48459 Description E-Ring, 0.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS 2 1 32 33 3 31 1 6 34 8 9 10 11 37 12 13 38 14 27 15 3 4 5 (2) 30 7 2 37 16 16 1 6 17 36 18 14 19 39 29 35 24 20 21 28 22 23 25 26 27 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. Figure 5-16. Cutter Option (View 1) 32056L Rev.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Rotary Cutter Blade Upper Cutter Bracket Mounting Screw Insure the Top of the Tear off Bar is Positioned Above or Level With the Top of the Rear Cutter Blade 0.100" (2.5 mm) Media Guide Tear-off Bar Rear Cutter Blade Clearance of 0.030" (0.
MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5 SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-17. Communication Options Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number 48924 30757 30753 48925 30757 48753 46692 46689 ³ 46709 47210 Description Kit, Field Upgrade IBM Twinax . Assembly, PCB IBM Twinax . AP Cable, Ribbon 40 Option Signal . Assembly, Cable IBM Twinax Kit, Field Upgrade IBM Coax . Assembly, PCB IBM Coax . AP Cable, Ribbon 40 Option Signal . Cable, Coax Ext.
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS Table 5-18. Fanfold Bin Option Item 1 2 3 4 5 6 7 Part Number 40457 30278 30277 40276 30956 01130 Description Kit, Fanfold Upgrade . Bracket, End, Fanfold . Bracket, Side, Fanfold . Bin, Fanfold . Screw, 6-32 x 0.37 . Washer, Flat 0.207 x 0.146 x 0.030 .
OPTION KITS SECTION 6 6(&7,21 237,21 .,76 %$&.,1* 5(:,1' 237,21 .,7 /,1(5 5(:,1' This kit (part # 33180) includes the parts necessary to install the backing rewind option into the 105SL. The kit includes all the parts listed in Table 6-1 and shown in Figure 6-1. Table 6-1.
SECTION 6 OPTION KITS 3 2 4 1 5 10 Stepper Motor Pulley (Not Included) 7 8 3 9 17 11 18 15 14 2 19 6 12 23 22 13 21 16 20 2 8 Figure 6-1. Backing Rewind Option Kit ,QVWDOODWLRQ The printer must be partially disassembled in order to install the various parts provided in this kit. Use the following procedure to install the kit. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2.
OPTION KITS SECTION 6 1 2 Rewind Spindle Mounting Hole 10 3 5 Rewind Platen Mounting Hole 2 Lower Access Hole 4 8 7 Stepper Motor Pulley 12 22 11 14 15 9 3 18 6 Part of 17 Upper Take Label Sensor (Green/Yellow Wires) 18 19 21 3 16 20 Upper Take Label Sensor Mounting Hole Lower Take Label Sensor Mounting Hole 2 8 Lower Access Hole Part of 17 Lower Take Label Sensor (Black/Red Wires) Figure 6-2. Liner Rewind Assembly Installation 32056L Rev.
SECTION 6 7. OPTION KITS Position the idler shaft in the middle of the mounting slot and tighten the mounting screw. NOTE: Avoid getting grease anywhere except on the idler shaft. 8. With a toothpick or small screwdriver, apply a very small amount of grease (provided in kit) to the idler shaft. 9. Orient the idler pulley (19) as shown, and slide it onto the idler shaft. 10. Remove and discard the plastic plug from the rewind spindle mounting hole near the bottom of the side plate. 11.
OPTION KITS SECTION 6 25. Leave approximately a 0.020 in. (0.5 mm) gap between the C-ring and platen support bracket. Tighten the two pulley set screws. 26. Remove the plastic plugs from the upper and lower take-label sensor mounting holes. NOTE: The upper take-label sensor has green/yellow wires. 27. Refer to Figure 6-3. Insert the upper take label sensor connector and cable through the upper hole in the main frame. Figure 6-3. Take-Label Sensors 28. Position the sensor with the window facing down.
SECTION 6 OPTION KITS S2 J7 J8 J9 Main Logic PCB J10 J11 Lower Take Label Sensor (J15) J12 J13 J14 J15 J16 J17 J18 J19 J20 Upper Take Label Sensor (J16) J21 J11 J1 J9 J10 J8 J7 J6 J5 J4 AC Power PCB J3 J1 J2 DC Power PCB Figure 6-4.
OPTION KITS NOTE: SECTION 6 In peel off mode, if the two sensors are not aligned with each other, the take label LED illuminates, and the printer does not operate. 33. Refer to RRP No. 9 on page 4-23 and remove the main drive belt. 34. Refer to Figure 6-6. Route the rewind drive belt around the inside stepper motor pulley, rewind spindle pulley, rewind platen pulley and the idler pulley.
SECTION 6 OPTION KITS 44. Reconnect the power cable to the power source. Place the power switch in the On (I) position. 45. Perform a PAUSE Key Self Test and observe the tracking of the liner. If the liner does not track properly, proceed to “Adjusting the Roller Adjust Plate.” 5HFRQILJXUH WKH 3ULQWHU IRU 3HHO 2SHUDWLRQ 1. Enter the Configuration mode by pressing the Setup/Exit key at the Printer Ready display. 2. Press Next/Save until you get to Print Mode. 3.
OPTION KITS SECTION 6 3. Tighten the two screws. Check label backing tracking again. 4. Repeat the procedure until the required results are achieved. 0(',$ 5(:,1' 237,21 .,7 This kit (part # 33181) includes the parts necessary to install the media rewind option into the 105SL. The kit includes all the parts listed in Table 6-2 and shown in Figure 6-8. Table 6-2.
SECTION 6 OPTION KITS 3 2 4 1 Stepper Motor Pulley (Not Included) 7 5 8 3 9 11 18 12 19 16 15 2 6 20 13 23 5 22 17 2 21 14 8 24 10 Figure 6-8. Media Rewind Option Kit ,QVWDOODWLRQ The printer must be partially disassembled in order to install the various parts provided in this kit. Use the following procedure to install the kit. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord. Disconnect the data cables. 2.
OPTION KITS SECTION 6 1 2 Rewind Spindle Mounting Hole 10 3 5 Rewind Platen Mounting Hole 2 Lower Access Hole 4 8 7 Stepper Motor Pulley 12 22 11 14 15 9 3 18 6 Part of 17 Upper Take Label Sensor (Green/Yellow Wires) 18 19 21 3 16 20 Upper Take Label Sensor Mounting Hole Lower Take Label Sensor Mounting Hole 2 8 Lower Access Hole Part of 17 Lower Take Label Sensor (Black/Red Wires) Figure 6-9. Media Rewind Installation 32056L Rev.
SECTION 6 OPTION KITS 6. Place a flat washer (2) onto one of the screws (8). Using the Allen wrench provided with this kit, place this mounting screw through the lower access hole in the side plate and through the idler pulley mounting slot in the printer main frame. On the electronics side of the printer main frame, attach the idler shaft (22) to the mounting screw. 7. Position the idler shaft in the middle of the mounting slot and tighten the mounting screw.
OPTION KITS SECTION 6 23. Slide spacer (21) onto the platen roller. NOTE: Use part # 30257 for 300-dpi printers or part # 48018M for 203-dpi printers. 24. Slide rewind platen pulley (17) onto the platen roller and align the two set screws with the flat surfaces of the platen roller. 25. Leave approximately a 0.020″ (0.5 mm) gap between the C-ring and platen support bracket. Tighten the two pulley set screws. 26.
SECTION 6 NOTE: OPTION KITS Figure 6-4 illustrates 105SL printers with configuration numbers 10500-0XXX-XXXX and 10500-1XXX-XXXX. Figure 6-5 illustrates 105SL printers with configuration numbers 10500-2XXX-XXXX and 10500-3XXX-XXXX. 33. Refer to Figure 6-4 or Figure 6-5. Route the sensor wires through the cable clamps and bring them to the main logic board. Make sure that the wires do not come in contact with any moving parts. 34. Connect the sensor connectors to the main logic board as shown.
OPTION KITS SECTION 6 3. Press (+) or (–) key until you select REWIND. 4. Pressing the Setup/Exit key to leave the Configuration mode. Press the (+) or (–) key to select Permanent. Press Next/Save to accept and make permanent. $GMXVWLQJ WKH 3ODWHQ 6XSSRUW %UDFNHW If the liner is tracking off to one side, perform the following procedure to position the roller adjust plate. 1. Refer to Figure 6-7. Loosen, but do not remove, the two screws holding the platen support bracket to the side plate.
SECTION 6 OPTION KITS Figure 6-11. Cutter Catch Tray Installation ,17(51$/ )$1)2/' 6833/< %,1 237,21 This kit (part # 40457) includes the parts necessary to install the internal fanfold supply bin option into the 105SL. Use the following procedure to install the internal fanfold supply bin. NOTE: The Internal Fanfold Supply Bin cannot be installed in a printer that contains a Media Rewind Option or a Peel-off Option. 1. Refer to RRP No.
OPTION KITS SECTION 6 Figure 6-12. Cutter Catch Tray Length and Width Adjustments 7. Load the fanfold media as illustrated on the media loading label in the printer or in the User’s Guide. 8. Make sure the upper and lower media sensors are positioned to read the end of label indicator on the new fanfold media. 9. Close the media cover. 10. Reconnect the power cord to the printer. 11. Reconnect the power cord to the power source. Place the power switch in the On (I) position. 12.
SECTION 6 OPTION KITS Media Cover Fanfold Supply Bin End Bracket Fanfold Supply Bin Side Bracket Fanfold Supply Bin Screw 6-32 x 0.37 Hex Cap (3) Flat Washer (3) PREVIO US NEXT/ SAVE SETUP /EXIT POWER TAKE LABEL ERROR CHECK PAPER PAUSE RIBBON OUT FEED DATA CANCEL Frame Support Nut 6-32 (3) Figure 6-13. Internal Fanfold Supply Bin Installation NOTES: The parallel port on the back of the printer is not operational when the internal PrintServer II is installed.
OPTION KITS SECTION 6 Parallel Interface Connector Serial Interface Connector Allen Screws and Plate AC Power On/Off Switch AC Power Cable Connection Note: Depending on configuration, the Serial Interface may be a DB-25 or a DB-9 connector. Figure 6-14. Rear Panel 4. Insert the ribbon cable and PrintServer II through the mounting slot. NOTE: Figure 6-15 illustrates 105SL printers with configuration numbers 10500-0XXX-XXXX and 10500-1XXX-XXXX.
SECTION 6 OPTION KITS Figure 6-15. Internal PrintServer ll Installation (Printer Configurations 10500-0XXX-XXXX and 10500-1XXX-XXXX) (;7(51$/ =(%5$1(7 35,176(59(5 ,, 237,21 External ZebraNet PrintServer II (part # 46692), as shown in Figure 6-17, plugs directly into the printer’s parallel port. Use the following procedure to install and test the ZebraNet PrintServer II. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position and disconnect the AC power cord.
OPTION KITS SECTION 6 Ferrite Bead Data Cable Connector Ribbon Cable Ribbon Cable Ferrite Bead Figure 6-16. Internal PrintServer ll Installation (Printer Configurations 10500-2XXX-XXXX and 10500-3XXX-XXXX) 5. Reconnect the power cord to the power source. Place the power switch in the On (I) position. 6. The status indicator flashes orange during the POST (Power-On Self Test) phase and changes to green when stabilized.
SECTION 6 OPTION KITS Figure 6-17. External PrintServer &2$; &20081,&$7,216 ,17(5)$&( %2$5' 237,21 This kit (part # 48925) includes all the parts necessary to install the Coax Communications Interface Board option into the 105SL. Use the following procedure to install and set up the interface board. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position. Disconnect the AC power cord. 2. Refer to RRP No. 2 on page 4-12 and remove the electronics cover. 3.
OPTION KITS SECTION 6 Figure 6-18. Coax Communications Interface Board Installation (Printer Configurations 10500-0XXX-XXXX and 10500-1XXX-XXXX) Interface Board Data Cable Connector Interface Data Cable Figure 6-19. Coax Communications Interface Board Installation (Printer Configurations 10500-2XXX-XXXX and 10500-3XXX-XXXX) 10. Connect the coax cable from the host computer to the mating connector on the adapter cable. 32056L Rev.
SECTION 6 OPTION KITS Figure 6-20. Coax Adapter Cable and Interface Hook up NOTE: After setting the DIP switches, turn the printer power off (O) and back on (I). With the exception of DIP switch number 2, the printer monitors the positions of the DIP switches only during the Power-On Self Test (POST). The EBCDIC buffer print function is enabled whenever DIP switch number 2 is placed in the “Right” position. 11. Refer to Table 6-3. Set the dip switches in the correct position for this application.
OPTION KITS SECTION 6 Table 6-3. Coax Dip Switch Setting (Continued) Right Left Left Left 8 - France Right Left Left Right 9 - Italy Right Left Right Left A - Japan Right Left Right Right B -Japan (English) Right Right Left Left C - Portugal Right Right Left Right D - Spain Right Right Right Left E - Spanish Speaking Right Right Right Right F - United Kingdom NOTE: The language character sets 1 - US/Canada and B - Japan (English) are the same.
SECTION 6 OPTION KITS 7:,1$; &20081,&$7,216 ,17(5)$&( %2$5' 237,21 This kit (part # 48924)includes the parts necessary to install the Twinax Communications Interface Board option into the 105SL. Use the following procedure to install and set up the interface board. 1. Refer to RRP No. 1 on page 4-10 and place the power switch in the Off (O) position. Disconnect the AC power cord. 2. Refer to Figure 6-14.
OPTION KITS SECTION 6 Interface Board Data Cable Connector Interface Data Cable Figure 6-22. Twinax Interface Board Installation (Printer Configurations 10500-2XXX-XXXX and 10500-3XXX-XXXX) 6. Dress the ribbon cable behind the twinax interface board as you slide the board completely into the printer. 7. Fasten the twinax interface board in place with the two screws used for the blank cover. 8. Reinstall the electronics cover. 9. Refer to Figure 6-23.
SECTION 6 OPTION KITS Figure 6-23. Twinax Connections Table 6-5. Twinax Dip Switch Setting Switch #1 Left Right Switch #2 Left Right Switch #3 Left Left Right Right Switch #5 Left Left Left Left Left Page 6-28 Print complete Description An “Operation Complete” status message is sent to the host after a label format is completely printed. The host can then send the next label format to be printed. Enables the “Early Print Complete” function.
OPTION KITS SECTION 6 Table 6-5.
SECTION 6 Page 6-30 OPTION KITS 105SL Maintenance Manual 32056L Rev.
3URGXFW 6XSSRUW 6HUYLFHV Which Department Do You Need? Zebra’s Corporate Offices Zebra Technologies Corporation, USA 333 Corporate Woods Parkway Vernon Hills, Illinois 60061-3109 Phone: +1 847.634.6700 Fax: +1 847.913.
5HJLRQDO 6DOHV 2IILFHV $VLD 3DFLILF Zebra Technologies Corporation Singapore Phone: +65 8420322 Fax: +65 8420366 )UDQFH Zebra Technologies Europe Ltd. Paris, France Phone: +33 (0)155 209393 Fax: +33 (0)155 209399 *HUPDQ\ Zebra Technologies Europe Ltd. Obertshausen, Germany Phone: +49 (0) 6104 709900 Fax: +49 (0) 6104 709922 +RQJ .RQJ Zebra Technologies Corporation Hong Kong Phone: +852 2111.0210 Fax: +852 2235.9098 ,WDO\ Zebra Technologies Europe Ltd.
