Zebra S-Series Maintenance Manual Volume 1: General Maintenance Zebra Technologies Corporation Zebra Technologies Europe Limited 333 Corporate Woods Parkway Vernon Hills, IL, USA 60061-3109 Zebra House The Valley Centre, Gordan Road High Wycombe, Buckinghamshire HP13 6EQ, UK Telephone: Fax: Telephone: Fax: +1 (847) 634-6700 +1 (847) 913-8766 38452L Rev. 3 +44 (0) 1494 472872 +44 (0) 1494 450103 Copyright 1995 Zebra Technologies Corporation. All rights reserved.
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Zebra S-Series Printer Maintenance Manual (Volume 1, Rev. 3) Registration Form ZEBRA TECHNOLOGIES CORPORATION To receive Maintenance Manual revisions and updates, complete this form and fax or mail it to Zebra Technologies at the fax number or address shown below.
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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.
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TABLE OF CONTENTS Maintenance Manual (Volume 1) Registration Form Compliance and Copyright Statements . . . . . . . . . . . i THE ZEBRA S-SERIES SYSTEM Printer Specifications . . . . . . . . . . . . . . Media Handling . . . . . . . . . . . . . . . Printing Considerations . . . . . . . . . . . Media Considerations . . . . . . . . . . . . Ribbon Considerations . . . . . . . . . . . Zebra Programming Language II (ZPL II®) Bar Codes . . . . . . . . . . . . . . . . . . Standard Printer Fonts . . . . . . . . .
PRINTER DIAGNOSTICS Power ON Self Test . . . . . . . . . . . Printer Self Tests . . . . . . . . . . . . CANCEL Key Self Test . . . . . . . PAUSE Key Self Test . . . . . . . . FEED Key Self Test . . . . . . . . . MODE Key Self Test . . . . . . . . FEED, PAUSE and CANCEL Keys PAUSE Key and CANCEL Key . . FEED Key and CANCEL Key . . . FEED Key and PAUSE Key . . . . Extended Printer Diagnostics . . . . . . PAUSE Key Loopback Test . . . . . FEED Key Loopback Test . . . . . . . . . . . . . . . . . . . . . . . .
Media Tracking Adjustments . . . . . . . . . . . . . . . . Rewind Mode . . . . . . . . . . . . . . . . . . . . . . Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . Spindle Adjustment and Maintenance . . . . . . . . . . . Tension Measurement Procedure . . . . . . . . . . . . Spindle Tension Adjustment . . . . . . . . . . . . . . Removing the Adapter Board . . . . . . . . . . . . . . . . Installing the Adapter Board . . . . . . . . . . . . . . . . Removing the Main Logic and Power Supply Boards . . .
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1 The Zebra S-Series System In this section... Page Printer Specifications .....................................................................1-1 Media Handling .........................................................................1-1 Printing Considerations............................................................1-2 Media Considerations ...............................................................1-2 Ribbon Considerations .............................................................
The S -Series System S -Series Maintenance Manual: Volume 1 Printing Considerations 105S/105Se Specification Resolution (thermal transfer or direct thermal) 203 dots per inch (8 dots per mm) Optional 152 dots per inch (6 dots per mm) Dot size (square) 0.00492" (0.125 mm) 0.00656" (0.167 mm) Maximum print width 4.09" (104 mm) 4.09" (104 mm) 160S Optional 300 dots per inch (12 dots per mm) 203 dots per inch (8 dots per mm) 0.0033" x 0.0039" (0.083 x 0.100 mm) 0.00492" (0.125 mm) 4.
S -Series Maintenance Manual: Volume 1 The S -Series System Ribbon Considerations 105S/105Se Ribbon Specifications 160S Ribbon width Maximum 4.5" 114 mm 6.89" 175 mm To protect the printhead from wear, Zebra recommends using ribbon at least as wide as the media you are using. Minimum 0.75" 19 mm 2.0" 50.8 mm Standard lengths 2:1 media to ribbon roll ratio 984 ft 300 m 984 ft 300 m 3:1 media to ribbon roll ratio 1476 ft 450 m 1476 ft 450 m Roll size Inner diameter of core 1.
The S -Series System S -Series Maintenance Manual: Volume 1 Standard Printer Fonts Fonts A, B, C, D, E, F, G, H, and GS are expandable up to 10 times, height- and width-independent. However, fonts E and H (OCR-A and OCR-B) are not considered “in-spec” when expanded. The scalable smooth font Ø (CG Triumvirate™ Bold Condensed) is expandable on a dot-by-dot basis, height- and-width independent, while maintaining smooth edges. Maximum character size depends on the available memory.
S -Series Maintenance Manual: Volume 1 The S -Series System Font Matrices for 8 dots/mm Printhead (105S, 105Se and 160S) Font Matrix Type* Character Size Width Char./mm 0.029 0.044 0.059 0.098 0.079 0.236 0.093 0.118 Height A 9 5 1 U-L-D 0.044 B 11 7 2 U 0.054 C, D 18 10 2 U-L-D 0.088 E 28 15 5 OCR-B 0.138 F 26 13 3 U-L-D 0.128 G 60 40 8 U-L-D 0.295 H 21 13 6 OCR-A 0.103 GS 24 24 0 SYMBOL 0.118 Ø Default: 15 x 12 U-L-D * U = Uppercase, L = Lowercase, D = Descenders Millimeters Char.
The S -Series System S -Series Maintenance Manual: Volume 1 Electrical Requirements • 115 VAC +15%/−20% or 230 VAC +15%/−15%, 48-62 Hz • 5 Amps @ 115V, 3 Amps @ 230V • UL 1950 Listed - Certified to CAN/CSA-C22.2 No. 950-M89 • Classified to IEC 950 and Complies with FCC and Canadian DOC class “A” rules • Carries the CE mark of compliance Cable Requirements The AC Power Cord has a three-prong female connector on one end.
S -Series Maintenance Manual: Volume 1 The S -Series System Communication Specifications Both serial and parallel data communication interfaces are available for the S-Series printers. The S-Series printer sends and receives standard ASCII (American Standard Code for Information Interchange) data characters. With ZPL II ® , the Error Detection Protocol feature provides virtually error-free communications. Refer to the user’s guide for further information.
The S -Series System Pin No. S -Series Maintenance Manual: Volume 1 Serial Data Port Signal Description 1 2 Frame Ground Transmit Data: TXD is the serial data output of the Zebra S-Series printer. It is on this lead that printer status information is transmitted to the host. 3 Receive Data: RXD is the serial data input to the Zebra S-Series printer from the host. 4 Request To Send: RTS is an output from the Zebra S-Series printer. It is a constantly active output to the host computer.
S -Series Maintenance Manual: Volume 1 The S -Series System Parallel Data Communications Overview The S-Series printer may have a parallel data communications port instead of the previously mentioned serial data port. The Parallel Interface has a standard 36-pin connector located at the rear of the printer. In this data communication method, the bits of data which make up each character are sent all at one time over several wires in the cable, one bit per wire.
The S -Series System S -Series Maintenance Manual: Volume 1 R Page 1-10 38452L Rev.
2 Getting Ready to Print In this section... Page Controls and Indicators ..................................................................2-2 Front Panel Controls.................................................................2-2 Front Panel LEDs ......................................................................2-3 Media Loading .................................................................................2-4 Ribbon Loading .........................................................................
Getting Ready to Print S -Series Maintenance Manual: Volume 1 Controls and Indicators All of the printer controls and indicators are located on the front of the unit except for the Power ON/OFF Switch, which is located at the rear of the printer. Front Panel Controls AC Power ON/OFF Switch Controls application of AC Power to the printer. When powered ON, the printer will perform a Power ON Self Test as it begins operation.
S -Series Maintenance Manual: Volume 1 Getting Ready to Print MODE Key The MODE Key causes the printer to enter the Configuration Mode. In this Mode, the Print Darkness, Media Tear-Off Position, and Label Top Position settings can be adjusted. The Media Calibration procedure is also activated by the MODE key. Refer to the user’s guide for details on the Configuration Mode and the Media Calibration procedures. Front Panel LEDs Refer to Figure 2.1 for the location of the LEDs.
Getting Ready to Print S -Series Maintenance Manual: Volume 1 Media Loading Figure 2.2 Roll Media Loading PEEL-OFF TEAR-OFF REWIND CUTTER 105Se TEAR-OFF PEEL-OFF 160S Figure 2.3 Roll Media Loading Diagrams Page 2-4 38452L Rev.
S -Series Maintenance Manual: Volume 1 TEAR-OFF Getting Ready to Print BOTTOM SUPPLY REAR SUPPLY CUTTER 105Se Figure 2.4 Fanfold Media Loading Diagrams INTERNAL SUPPLY BOTTOM SUPPLY REAR SUPPLY Figure 2.5 Fanfold Media Loading Diagrams (160S) 38452L Rev.
Getting Ready to Print S -Series Maintenance Manual: Volume 1 Ribbon Loading Figure 2.6 105Se Ribbon Loading Diagram Figure 2.7 160S Ribbon Loading Diagram Page 2-6 38452L Rev.
S -Series Maintenance Manual: Volume 1 Getting Ready to Print Media Calibration IMPORTANT: Perform the media calibration procedure when media is first installed or when a different type of media or ribbon is installed. During this procedure, the printer automatically determines the media type, label length, media and ribbon sensor settings, and printing method. NOTE: Make sure that the media and ribbon rolls are positioned against the inner spindle stops. 1. 2. 3. Press the MODE key three times.
Getting Ready to Print S -Series Maintenance Manual: Volume 1 Adjusting the Tear-Off Position This procedure sets the rest position of the media over the Tear Bar after printing. The possible adjustment range is approximately plus or minus 80 dot rows. Power need not be turned off to reset this parameter. NOTE: The printer configuration label reports the actual number of dot rows, not the number of presses of the buttons used for adjustment. 1. 2. 3. 4. Press the MODE key twice.
S -Series Maintenance Manual: Volume 1 Getting Ready to Print Adjusting the Position of the Top of the Label 1. 2. 3. 4. Press the MODE key twice, then press and hold the MODE key for about five seconds, until the lights change. PAUSE, DARKEN, and CALIBRATE lights turn on. Press the UP or DOWN key to adjust the current setting. Press the MODE key twice. The MODE lights will flash on and off to indicate that the settings have been saved in memory.
Getting Ready to Print S -Series Maintenance Manual: Volume 1 To adjust for the outside half of the media (160S ONLY): 1. 2. 3. 4. 5. 6. 7. Remove the ribbon. Locate the upper media sensor (Figure 2.9-A). Remove the printer’s left side panel and reroute the media sensor cable to provide additional slack. Remove the Phillips head screw to release the upper section of the sensor and wire cover. Lift the upper media sensor assembly and move the sensor and the wire cover to the outside half.
S -Series Maintenance Manual: Volume 1 Getting Ready to Print Lower Media Sensor Adjustment 1. 2. 3. Locate the lower media sensor assembly under the rear idler roller (Figure 2.10-A). (It is a spring clip holding a circuit board.) Slide the sensor until the two brass-colored infrared emitters are under the upper media sensor. Gently pull wires out as needed (wires should have a little slack).
Getting Ready to Print S -Series Maintenance Manual: Volume 1 Option Switches These switches are located above the signal interface cable connector. See Figure 2.11. In the following tables, “R” means the switch is in the right position, while “L” means the switch is in the left position. Refer to Figure 2.12. BANK 2 BANK 2 BANK 1 (ONLY ON SERIAL UNITS) SIGNAL INTERFACE CABLE CONNECTION 105Se and 160S PARALLEL 105Se and 160S SERIAL Figure 2.
S -Series Maintenance Manual: Volume 1 Getting Ready to Print Bank 1 (Serial interface printers only) NOTE: Parallel interface printers do not have Bank 1 switches since they are not required. Bank 1 switches must be properly positioned to establish serial data communications with the host computer. Once communications are established, do not change the position of these switches.
Getting Ready to Print S -Series Maintenance Manual: Volume 1 Bank 2 These switches can manually override any ZPL commands that affect print mode, media mode, and media type. They can also override settings established during the calibration procedure. If you do not want to override ZPL or the calibration settings, disable one or more of the options by setting switches 1, 4, and/or 7 to the “R” position and turn the power on.
3 Printer Diagnostics In this section... Page Power ON Self Test ........................................................................3-1 Printer Self Tests .............................................................................3-1 CANCEL Key Self Test ...........................................................3-3 PAUSE Key Self Test ...............................................................3-4 FEED Key Self Test..................................................................
S -Series Maintenance Manual: Volume 1 Printer Diagnostics NOTES: It is recommended that full width media be used when performing these tests. Labels less than full width in size will lose printing on the right side. Label length will determine the amount of printing starting at the top of the label. When performing these self tests while in the Peel-Off Mode, the operator must remove the labels as they become available.
S -Series Maintenance Manual: Volume 1 Printer Diagnostics CANCEL Key Self Test This self test prints a single label which contains a listing of the printer’s current configuration parameters stored in Configuration (EEPROM) Memory. Press the CANCEL Key while turning the AC Power Switch ON. A sample label is shown in Figure 3.1. The printer configuration may be changed temporarily for specific label formats or ribbon and label stock, or permanently by saving the new parameters in EEPROM Memory.
Printer Diagnostics S -Series Maintenance Manual: Volume 1 PAUSE Key Self Test Enter this self test mode by pressing the PAUSE Key while turning the AC power ON. This self test consists of eight separate test sequences, printing labels at both Speed “A” and Speed “D” (“C” for the 300-dpi 105S and 105Se). During the first four test sequences, the printer simulates the “Tear-Off” mode and backfeeds the media prior to printing each label.
S -Series Maintenance Manual: Volume 1 Printer Diagnostics Figure 3.2 PAUSE Key Self Test Label FEED Key Self Test The CANCEL Key Self Test should be performed prior to this Self Test. Information on the printed “Configuration” Label (CANCEL Key Self Test) will be used with the results of this self test to determine the best Darkness Setting for a specific media/ribbon combination.
Printer Diagnostics S -Series Maintenance Manual: Volume 1 The value printed on that label is added to (plus) or subtracted from (minus) the “Darkness” value specified on the Configuration Label. The resulting numeric value (0 to 30) is the best darkness value for that specific media/ribbon combination. The value selected can be entered while performing a Media Darkness Adjustment.
S -Series Maintenance Manual: Volume 1 Printer Diagnostics PAUSE Key and CANCEL Key This self test can be used to verify proper printer operation after parts have been replaced or adjusted. When activated, the printer prints a maximum of 500 Head Test Labels. Each label backfeeds prior to printing and feeds forward to the rest position after printing. A serialized number will print on each label. Press the PAUSE Key or turn the printer power OFF to stop printing. Refer to Figure 3.6.
Printer Diagnostics Parameter Darkness Tear Off Adjust Web Sensor Media Sensor Ribbon Sensor Mark Media Sensor Mark Sensor Media LED Ribbon LED Mark LED Label Length Max Label Length Print Width Print Mode Media Type Print Method Host Port Network Port Baud Data Bits Parity Stop Bits Handshake Protocol Delimiter Format Prefix Control Prefix Network ID Modes Enabled Modes Disabled Resolution Backfeed Label Top Left Position Socket 1 ID Socket 2 ID Firmware Configuration Memory B: Memory Media Power Up Media
S -Series Maintenance Manual: Volume 1 Printer Diagnostics Extended Printer Diagnostics Additional diagnostic tests are available for printhead assembly adjustments. These diagnostics tests are only accessible when the data interface cable is disconnected from the printer and a Loopback Connector is attached in its place. The Serial Loopback Connector is a 25-pin “D” type (DB25P-Male) style with the following pins tied together.
S -Series Maintenance Manual: Volume 1 Printer Diagnostics FEED Key Loopback Test With the Loopback Connector in place, press the FEED Key while turning the AC Power Switch ON. After the POST, the printer will begin printing a series of label formats as shown in the chart below. The printer will PAUSE at the end of each printed format. Press the PAUSE Key to begin printing the next format. Refer to the label examples in Figures 3.7 through 3.13.
S -Series Maintenance Manual: Volume 1 Printer Diagnostics Figure 3.8 Format 2 (9) Test Label Figure 3.9 Format 3 (10) Test Label Figure 3.10 Format 4 (11) Test Label 38452L Rev.
Printer Diagnostics S -Series Maintenance Manual: Volume 1 Figure 3.11 Format 5 (12) Test Label Figure 3.12 Format 6 (13) Test Label Figure 3.13 Format 7 (14) Test Label Page 3-12 38452L Rev.
4 Preventive Maintenance In this section... Page Field Maintenance Functions ........................................................4-1 Tools Required.................................................................................4-1 Cleaning the S-Series Printer ........................................................4-1 Cleaning the Printhead ...................................................................4-2 Cleaning the Snap Plate .................................................................
Preventive Maintenance S -Series Maintenance Manual: Volume 1 INTERIOR — As required, remove any dirt/lint accumulated in the interior of the printer using a soft bristle brush and/or vacuum cleaner. It is a good practice to inspect these areas after every fourth roll of media. Cleaning the Printhead Inconsistent print quality such as blank areas in the bar codes or graphics may indicate a dirty printhead. For optimum performance, the printhead should be cleaned regularly.
S -Series Maintenance Manual: Volume 1 Preventive Maintenance PRINTHEAD RIBBON SENSOR LABEL AVAILABLE SENSORS PLATEN ROLLER PEEL/TEAR BAR Figure 4.1 Printhead Cleaning SNAP PLATE Figure 4.2 Snap Plate Cleaning 38452L Rev.
Preventive Maintenance S -Series Maintenance Manual: Volume 1 Cleaning the Cutter Module Periodically, the Cutter Module should be cleaned to remove paper dust and label residue. Refer to Figure 4.3. Clean the stationary cutter blade with a cotton swab moistened with a citrus-based cleaner when it becomes gummed up with label adhesive or paper debris. After cleaning, apply a small amount of petroleum lubricating grease to the moving cutter parts. Figure 4.
S -Series Maintenance Manual: Volume 1 Preventive Maintenance Recommended Preventive Maintenance Schedule AREA METHOD INTERVAL PRINTHEAD Isopropyl alcohol PLATEN ROLLER Isopropyl alcohol MEDIA SENSOR Air blow When printing in the direct thermal mode: after every roll of media (or 500 feet of fanfold media). MEDIA PATH Isopropyl alcohol and cloth RIBBON SENSOR Air blow When printing in the thermal transfer mode: after every roll of ribbon.
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5 Corrective Maintenance In this section... Page Tools Required.................................................................................5-2 Test Equipment Required ...............................................................5-2 105S and 105Se Printhead Replacement .....................................5-3 160S Printhead Replacement.........................................................5-5 Printhead Adjustments ...................................................................
Corrective Maintenance S -Series Maintenance Manual: Volume 1 When a problem is encountered with the S-Series printer, the service technician should first insure the unit is being used properly, then exercise it to localize the fault. Once localized, refer to the appropriate replacement or adjustment procedure to correct the fault.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance 105S and 105Se Printhead Replacement Refer to Figure 5.1 while performing the following procedure. CAUTION Observe proper electrostatic safety precautions when removing, handling, and replacing the Printhead. 1. 2. 3. 4. Turn the printer OFF and remove the Power Cord. Remove media and ribbon. Properly connect yourself to an anti-static protection system.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 PRESSURE PLATE MOUNTING SCREWS PRINTHEAD PRESSURE PLATE STATIC REMOVAL BRUSH GROUNDING STRAP PRINTHEAD MOUNTING SCREWS PRINTHEAD BRACKET GUIDE PINS (12 DOT/MM ONLY) PRINTHEAD PEM STUDS (6 DOT/MM & 8 DOT/MM ONLY) GUIDE HOLES Figure 5.1 105S/105Se Printhead Replacement Page 5-4 38452L Rev.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance 160S Printhead Replacement Refer to Figure 5.2 while performing the following procedure. CAUTION Observe proper Electrostatic Safety Precautions when removing, handling and replacing the Printhead. 1. 2. 3. 4. 5. Turn the printer OFF and remove the Power Cord. Open the Printhead Assembly and remove the media and ribbon; then close the Printhead Assembly. Properly connect yourself to an anti-static protection system.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 DO NOT LOOSEN THESE SCREWS!! PRINTHEAD MECHANISM ASSEMBLY PRINTHEAD MOUNTING SCREW PRINTHEAD ALIGNMENT POSTS PRINTHEAD DATA CONNECTORS POWER CABLE LOCKING TAB PRINTHEAD ALIGNMENT SLOTS PRINTHEAD PRINTHEAD POWER CONNECTOR Figure 5.2 160S Printhead Replacement Page 5-6 38452L Rev.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance 18. After completing the Power ON Self Test, refer to the Printhead Resistance value (noted in Step 11 above) and perform the Printhead Voltage Adjustment on pages 5-12 through 5-14. 19. After adjusting the printhead voltage, activate the PAUSE Key Self Test by pressing the PAUSE Key while turning the printer power on. Check print quality. 20. The printer should be ready for operation. If problems arise, refer to Troubleshooting.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 Printhead Parallelism Adjustment This adjustment is performed in conjunction with the Wear Plate Position, Printhead Position, and Printhead Pressure Adjustments. Adjusting the printhead parallelism squares the printhead in reference to the media. Refer to Figure 5.3 for location of adjustment screws used in the following procedures. Printhead Parallelism Test 1. 2. 3. 4.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance NOTE: LOOSEN 4 HEX CAP SCREWS BEFORE ADJUSTING HEAD TOGGLE KNURLED ADJUSTING NUT 30 mm WEAR PLATE ADJUSTMENT SCREWS PARALLELISM ADJUSTMENT SCREWS STRIP PLATE NOTE: THE RIBBON TAKE-UP SPINDLE IS NOT SHOWN IN THIS ILLUSTRATION Figure 5.3 Printhead Adjustment Illustration Wear Plate Position Adjustment This adjustment is performed in conjunction with the Printhead Parallelism, Printhead Position, and Printhead Pressure Adjustments.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 7. If lighter or no printing is observed on one side of the label as compared with the other, continue with this adjustment. 8. Using a 7/64 ″ Allen wrench, slightly loosen the two Allen set screws mounted on the Wear Plate. 9. Continue to print PAUSE Test labels while adjusting the Wear Plate Eccentric for even printing. 10.
S -Series Maintenance Manual: Volume 1 7. Corrective Maintenance Adjustments are made in very small increments. Turn both Parallelism Adjustment Screws one eighth turn clockwise and observe the changes in print quality. (Due to spring pressure, there may be a dead spot in the actual printhead movement when switching adjustments from one direction to the other.) 8. Decrease the Burn Temperature until the PAUSE Test labels are a charcoal gray color. 9.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 TOGGLE ADJUSTING NUT Figure 5.4 Printhead Pressure Adjustment Strip Plate Adjustment The Strip Plate is a very important part of the printhead adjustment procedure. The Strip Plate can be adjusted for proper tracking and separation of the ribbon from the media after printing. 1. 2. 3. 4. 5. Print PAUSE Key Self Test labels. Press the PAUSE Key and, after the printer pauses, observe the ribbon for possible problems (wrinkling, etc.).
S -Series Maintenance Manual: Volume 1 Corrective Maintenance CAUTION This voltage adjustment is critical to the life of the printhead. DO NOT use this adjustment in an attempt to increase the printing darkness or burn temperature. Adjustment Procedure Calculate the proper Printhead Voltage using the appropriate formula below. The formula to use depends on the type of Printhead used in the printer. In the formula, R is the Print Element average resistance value as indicated on a label on the Printhead.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance 8 Dot/mm Printhead Voltage Table 105S 105Se/ 160S 105S 105Se/ 160S 105S 105Se/ 160S Volts Volts Volts Volts Volts Volts 535 19.0 18.95 600 20.1 20.04 665 21.1 21.07 540 19.1 19.04 605 20.2 20.12 670 21.2 21.14 545 19.2 19.12 610 20.2 20.20 675 21.3 21.22 550 19.2 19.21 615 20.3 20.28 680 21.3 21.30 555 19.3 19.29 620 20.4 20.36 685 21.4 21.37 560 19.4 19.38 625 20.5 20.44 690 21.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Media Sensor Position Adjustment Transmissive Media Sensor The Transmissive Media Sensor contains an upper section and a lower section. The upper section senses the infrared light emitted by the components mounted on the lower section. The amount of light passing between these two sections determines when either the “web” between labels or a hole or notch in the media is present.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 UPPER MEDIA SENSOR ADJUSTMENT Figure 5.5 105S and 105Se Transmis sive Sensor (Upper) Figure 5.6 160S Transmiss ive Sensor (Upper) A Page 5-16 Figure 5.7 Transmissive Sensor Lower Section 38452L Rev.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Reflective Media Sensor Adjustment The Reflective Media Sensor is placed into operation for those applications where the sensing of Black Marks on the underside of the media is desired. For the 105S printer, the Reflective Media Sensor is an option that is installed in place of the lower section of the Transmissive Media Sensor. Position adjustment is available across the total width of the media.
Corrective Maintenance 7. 8. 9. S -Series Maintenance Manual: Volume 1 Open the Printhead and pull the media through the printer until a label is positioned between the upper and lower sections of the Transmissive Media Sensor. Move the ribbon back to its normal position. Close the Printhead and press the MODE key to complete the automatic adjustment process. A Media Sensor Profile will automatically print and the new sensor settings will be automatically saved. (See Figure 5.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Take Label Sensor Alignment The Take Label Sensor pair is active only when the S-Series printer is set to Peel-Off mode. To operate in this mode either the Rewind Option or the Backing Only Rewind Option must be installed. The Take Label Sensor pair is not included on S-Series printers unless one of these options is installed. Refer to Figure 5.9 for the location of the Take-Label Sensor pair.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 Media Tracking Adjustments Rewind Mode If the media walks from side to side, or if it tears or wrinkles against the Media Rewind Tracking Plate, it will be necessary to adjust the Rewind Plate Assembly. Refer to Figures 5.10 and 5.11. 1. 2. 3. 4. 5. Remove the Rewind Plate Assembly and loosen the 5/16” Hex nuts attaching the Hook Plate to the Rewind Plate.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Figure 5.11 105S/105Se Rewind Spindle Positioning Peel-Off Mode In “Peel-Off Mode”, the Lower Roller alignment has the same effect on media tracking as the Rewind Plate alignment does in “Rewind Mode”. Refer to Figure 5.12 and perform the following procedure. 1. 2. 3. Use a 7/64″ Hex Allen wrench to loosen the (2) Allen screws that attach the Platen Support Bracket to the Side Plate.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 Spindle Adjustment and Maintenance There are three spindles which require periodic tension measurement and adjustment. Measuring spindle tension should be done at least once each year unless required more often due to high printer use. Tension should be adjusted whenever it is not within the tolerance range associated with that spindle. Tension Measurement Procedure The procedure for measuring spindle tension is similar for all three spindles.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance 105S/105Se RIBBON SUPPLY SPINDLE ASSY ALIGN ALL FLANGE SECTIONS BEFORE INSTALLING RIBBON CORE.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 Removing the Adapter Board (105S-300 dpi and all 105Se) The Adapter Board may require removal when replacement is necessary. Follow the procedure below, and refer to Figure 5.14 to remove the Adapter Board. CAUTION Eliminate any static electricity by using an anti-static wrist strap attached to the printer chassis. The printer electronics are susceptible to static discharge.
REAR PANEL REAR PANEL MOUNTING SCREWS 38452L Rev. 3 POWER SUPPLY PROTECTIVE COVER HIGH VOLTAGE DANGER POWER SUPPLY BOARD MOUNTING SCREWS MAIN LOGIC BOARD MOUNTING SCREWS POWER CABLE ASSY Figure 5.
Page 5-26 REAR PANEL REAR PANEL MOUNTING SCREWS 38452L Rev. 3 POWER SUPPLY PROTECTIVE COVER HIGH VOLTAGE DANGER POWER SUPPLY BOARD MOUNTING SCREWS MAIN LOGIC BOARD MOUNTING SCREWS Figure 5.
REAR PANEL REAR PANEL MOUNTING SCREWS 38452L Rev. 3 POWER SUPPLY PROTECTIVE COVER HIGH VOLTAGE DANGER POWER SUPPLY BOARD MOUNTING SCREWS MAIN LOGIC BOARD MOUNTING SCREWS POWER SUPPLY BOARD Figure 5.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 CAUTION Eliminate any static electricity by using an anti-static wrist strap attached to the printer chassis. The printer electronics are susceptible to static discharge. 1. 2. 3. 4. 5. 6. 7. 8. Be sure printer is OFF and the AC Power Cord and Signal Interface Cable are disconnected. Remove the Left Side Panel of the printer by removing the Phillips screws which hold it on. Refer to Figures 5.14, 5.15 and 5.16.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance WARNING Dangerous voltage is present at the Power Supply Board when the printer is ON. Keep clear of the Power Supply Board when turning the printer ON. 1. 2. 3. 4. Attach the AC Power Cord and the Data Cable to the appropriate rear panel connectors. Hold in the CANCEL Key while turning the printer power ON. After the POST, a Printer Configuration Label should print.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 WARNING When the printer power is turned ON in step 7, dangerous voltage is present at the Power Supply Board. Reconnect the AC Power Cord. Press and hold the CANCEL Key while turning the printer AC Power Switch ON. A Configuration Label will print. 8. Verify the “Firmware” version shown on the Configuration Label is the same as the software just installed. 9. Complete the process by installing the Left Side Panel on the printer. 10.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Main Drive Belt — Removal, Replacement, and Adjustment 1. 2. 3. 4. 5. 6. 7. Turn the printer OFF and remove the AC Power Cord. Refer to Figure 5.19 and rotate the Ribbon Take-Up Pulley until the three holes in the pulley are aligned with the three mounting screws which hold the Ribbon Take-Up Spindle Assembly to the Printer Frame.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 Rewind Drive Belt — Removal, Replacement and Adjustment 1. 2. 3. 4. 5. 6. 7. Turn the printer OFF and remove the AC Power Cord. Refer to Figure 5.20 and note the position of the Idler Gear used to adjust the tension of the Rewind Drive Belt. On the Media Side of the printer, locate the lower access hole in the Side Frame and remove the hole plug.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance AC Power Fuse Replacement A user-replaceable AC Power Fuse is located just above the Power ON/OFF Switch on the rear of the printer. For a 115 VAC installation, the replacement fuse is a 3AG Fast Blow style rated at 5 Amp/250VAC. For a 230 VAC installation, the fuse is the same style but rated at 3 Amp/250VAC. CAUTION Turn the printer’s AC Power Switch OFF and disconnect the printer’s AC Power Cable before replacing the fuse.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 Battery Replacement One of the factory-installed options for the 105S printer is the Battery Backed-Up 256 KB RAM Memory. The Battery used with this option is a 3 VDC Lithium Coin Battery type CR2477 (Zebra Part # 44641). CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended. When discarding used batteries, do not incinerate.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Internal Access 1. 2. 3. Turn Printer Power OFF at the rear of the printer and disconnect the AC Power Cord and all signal interface cables. Remove all Media and Ribbon from the printer. Access the Electronics Cabinet by removing the mounting screws in the left side panel. Cutter Motor Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. Refer to Figure 5.22. Remove the E-ring that attaches the Lower Drive Arm to the Slotted Link.
Page 5-36 38452L Rev. 3 LOWER DRIVE ARM CUTTER OPTICAL SENSOR CLAMP SLOTTED LINK MOUNTING POST LONG DRIVE LINK CUTTER OPTICAL SENSOR INSET DETAIL A LOWER CUTTER BRACKET CUTTER MOTOR Figure 5.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance 10. Install the E-ring that attaches the Slotted Link to the Lower Drive Arm. Cutter Mechanical Assembly Removal NOTE: The Cutter Module should NOT be disassembled, but replaced as a unit. Any disassembly of the Cutter Module will void the warranty. 1. 2. 3. 4. 5. 6. 7. Refer to Figure 5.22. Remove the E-ring and washer from the top of the Long Drive Link. Refer to Figure 5.22, Detail A.
Corrective Maintenance 7. 8. 9. S -Series Maintenance Manual: Volume 1 The Rear Cutter Blade is held in position by two springs. If these springs touch the Tear-Off Bar or other printer parts, the Rear Cutter Blade will not float properly and will cause excessive wear and premature failure of the Cutter Blades.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Figure 5.23 Cutter Circuit Board 8. Pass the Cutter Board Power Cable along the bottom of the printer frame toward the Main Logic Board. 9. Plug the Cutter Motor leads into the Cutter Motor Connector, J3, on the Cutter Circuit Board. (Black lead to the left. Note: This is a “polarized” connector.) 10. Refer to Figure 5.23. Plug the Cutter Sensor wires into the Cutter OPTO Connector, J6, on the Cutter Circuit Board. 11.
Corrective Maintenance 2. 3. S -Series Maintenance Manual: Volume 1 Connect the Data Ribbon Cable from J2 on the Cutter Board to J5 on the Main Logic Board. Attach the AC Power Cord and turn the printer ON. (If the Cutter Motor starts, wait for it to stop.) NOTE: A critical position adjustment is made in steps 4 and 5.
S -Series Maintenance Manual: Volume 1 Corrective Maintenance Tighten the Allen head cap screw with a 5/32 inch Allen bit socket on a torque wrench until the slot closes or until a torque of 100 in. lbs. (11.3 N-m) is reached. NOTE: Overtightening the screw can damage the Drive Arm and can strip the threads. 6. Test the Cutter alignment by feeding maximum-width label stock through the printer and insuring that complete cutting of the label occurs.
Corrective Maintenance S -Series Maintenance Manual: Volume 1 R Page 5-42 38452L Rev.
6 Troubleshooting In this section... Page Troubleshooting...............................................................................6-1 Power-ON Troubleshooting.....................................................6-1 General Troubleshooting..........................................................6-2 Cutter Module Troubleshooting ..............................................6-4 Sample Labels..................................................................................6-5 Factory Assistance ......
S -Series Maintenance Manual: Volume 1 Troubleshooting Table 6.2 General Troubleshooting SYMPTOM Printer stops. RIBBON LED and PAUSE LED both ON. Printer stops. PAPER/RIBBON LED Flashes and the PAUSE LED ON. DIAGNOSIS ACTION Media not loaded or incorrectly loaded. Load media correctly. Misadjusted Media Sensor. Check Media Sensor operation. Adjust if necessary. (Run Printer Calibration). 1. In continuous media mode, non-continuous media is loaded. 2.
S -Series Maintenance Manual: Volume 1 Troubleshooting Table 6.2 General Troubleshooting (Cont'd) SYMPTOM Poor Print Quality. DIAGNOSIS ACTION Darkness too low. Increase Burn Temp. Incorrect Media and Ribbon combination. Replace Media or Ribbon. Printhead Adjustments incorrect. Perform required adjustments. Label Length Parameter is set less than the actual label length. Set the correct label length. Printer was powered ON in Peel-Off mode without media being properly loaded.
S -Series Maintenance Manual: Volume 1 Troubleshooting Table 6.2 SYMPTOM Misregistration and skips labels. Misregistration and misprint of 1 to 3 labels. Vertical drift in top-of-form registration. General Trou blesh ootin g DIAGNOSIS ACTION Misadjusted Media Sensors. Perform Media Sensor Adjustments. Improper spindle tensions. Perform Spindle Adjustments. Improper ZPL II format. Correct the ZPL II format. Media was pulled when motor was not moving. Open and close the printhead.
S -Series Maintenance Manual: Volume 1 Troubleshooting Sample Labels The following pages contain sample labels to be used with the preceding troubleshooting charts. These labels illustrate conditions which could be seen if mechanical adjustments are necessary. Zebra Z-Trans 3P media stock and type 5319 ribbon were used to obtain these labels. Any other label and ribbon stock combinations may produce sample labels with similar but not necessarily the same results.
Troubleshooting S -Series Maintenance Manual: Volume 1 Unacceptable Label: Darkness low Printhead positioned correctly Toggles balanced (equal pressure on left and right sides) Unacceptable Label: Darkness very low Printhead positioned correctly. Toggles balanced (equal pressure on left and right sides) Page 6-6 38452L Rev.
S -Series Maintenance Manual: Volume 1 Troubleshooting Unacceptable Label: Darkness properly set Printhead too far forward “Scratch flowers” on black area (foggy appearance) Printhead needs to be moved rearward Walk out wrinkle with feed button and readjust Toggles balanced (equal pressure on left and right sides) Unacceptable Label: Darkness properly set Printhead way too far forward “Scratch flowers” on black area (washed out appearance) Printhead needs to be moved rearward Walk out wrinkle with feed b
Troubleshooting S -Series Maintenance Manual: Volume 1 Unacceptable Label: Darkness properly set Printhead too far back Breakup on trailing edges of bars (opposite the direction of movement) Black is splotchy Printhead needs to come forward on both sides Toggles balanced (equal pressure on left and right sides) Unacceptable Label: Darkness properly set Printhead way too far back Breakup on trailing edges of bars (opposite the direction of movement) Black is splotchy Printhead needs to come forward on bot
S -Series Maintenance Manual: Volume 1 Troubleshooting Unacceptable Label: Darkness properly set Printhead position correct on right side way too far back on left side Noisy printing (breakup on trailing edges of horizontal bars splotchy on left side) Toggles balanced (equal pressure on left and right sides) Unacceptable Label: Darkness Properly Set Printhead Position Correct On Left Side Way Too Far Back On Right Side Noisy Printing (Breakup on Trailing Edges of Horizontal Bars - Splotchy On Right Side)
Troubleshooting S -Series Maintenance Manual: Volume 1 Unacceptable Label: Darkness properly set Printhead position correct on left side too far forward on right side Noisy printing (breakup on leading edges of horizontal bars splotchy on right side) Toggles balanced (equal pressure on left and right sides) Unacceptable Label: Darkness Properly Set Printhead Position Correct On Right Side Way Too Far Forward On Left Side Noisy Printing (Breakup on Leading Edges of Horizontal Bars - Splotchy On Left Side)
S -Series Maintenance Manual: Volume 1 Troubleshooting Factory Assistance Should any problem be encountered which cannot be corrected with the aid of this manual, Technical Support should be contacted immediately to minimize or avoid printer downtime. Technical Support can also assist in determining if the printer should be returned for repair. Returning Equipment Should it become necessary to ship your printer, carefully pack the printer in a suitable container to avoid damage during transit.
Troubleshooting S -Series Maintenance Manual: Volume 1 R Page 6-12 38452L Rev.
105S and 160S Parts Lists 7 In this section... Page Mechanical Parts and Assemblies ................................................7-1 Mechanical Parts and Assemblies Listing...................................7-1 Please note: This section contains common parts lists and drawings for both the 105S and 105Se. For parts lists/drawings specific to the 105Se, refer to Section 8.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S (6 dot and 8 dot) Final Assembly (Page 1 of 2) PART NUMBER DESCRIPTION 01130 01152 Nut, 6-32 Washer, Flat, .375 x .156 x .65 01155 01159 01448 01912 07435 07696 09367 30240 30256 30269 30391-004 30391-006 30392-004 30407-008 Washer, Lock, #4 Washer, External Lock, #6 Screw, 6-32 .37 Washer, External Lock, #4 Screw, 6-32 .37 Screw, 4-40 .31 Stand-Off, 4-40 Cover Plate with Opening (Serial) Nut, Thumb, 6-32 .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 01159 01912 31102 (SERIAL) 31103 (PARALLEL) 30240 (SERIAL) 31240 (PARALLEL) 07696 01155 T 46325-3 (6) F/R F/R S B S B T 30256 T 09367 S S T E 01152 30391-006 30407-008 K K 01130 07435 01448 30391-004 30392-004 Serial Only P Serial Only F Parallel Only R MOUNTING HARDWARE E E E E E E J J J J 31524M E 40342 E , L (2) 105S (6 & 8 Dot/mm) Final Assembly Page 7-3
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S (6 dot and 8 dot) Final Assembly (Page 2 of 2) PART NUMBER 30257 30307 30336-1M 30336-2M 30355M 30357M 30914M 40355M 40357M 45189-2 45189-5 Page 7-4 DESCRIPTION Pulley, Peel-Off Platen (6 Dots/mm) Flag, Head Open Pulley, Ribbon Take-Up Pulley, Media Take-Up Pulley, Main Platen (6 Dots/mm) Pulley, Stepper Motor (6 Dots/mm) Pulley, Peel-Off Platen (8 Dots/mm) Pulley, Main Platen (8 Dots/mm) Pulley, Stepper Motor (8 Dots
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 105S Final Assembly (page 2 of 2) Page 7-5
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S (12 dot) Final Assembly (Page 1 of 2) PART NUMBER 01130 01152 01155 01159 01448 01912 07435 07696 09367 30240 30256 30269 30391-004 30391-006 30392-004 30407-008 30916 31019 31020 31037 31038 31100M 31101 31103 31240 31517 31524M 31646M 35040 38530M 38691M 40342 45039 46325-3 Page 7-6 DESCRIPTION Nut, 6-32 Washer, Flat, .375 x .156 x .65 Washer, Lock, #4 Washer, External Lock, #6 Screw, 6-32 .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 31526 A 38530M (SERIAL W/300 DPI HEAD) 38691M (PARALLEL W/300 DPI HEAD) 30240 (SERIAL) 31240 (PARALLEL) 46325-2 31101 (SERIAL W/300 DPI HEAD) 31103 (PARALLEL W/300 DPI HEAD) 01159 01912 07696 01155 T 46325-3 (6) F/R F/R S B S B T 30256 T 09367 S S T E 01152 30391-006 30407-008 K K 01130 07435 01448 30391-004 30392-004 Serial Only P Serial Only F Parallel Only R MOUNTING HARDWARE E E E E E E J J J J 31524M E 403
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S (12 dot) Final Assembly (Page 2 of 2) PART NUMBER 30307 30336-1M 30336-2M 30357M 30914M 31526 40355M 45189-2 45189-5 Page 7-8 DESCRIPTION Flag, Head Open Pulley, Ribbon Take-Up Pulley, Media Take-Up Pulley, Stepper Motor (12 Dots/mm) Pulley, Peel-Off Platen (12 Dots/mm) Assembly, Adaptor Board Pulley, Main Platen (12 Dots/mm) Belt, Media Rewind Belt, Main Drive QUANTITY 1 1 1 1 1 1 1 1 1
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 105S (12 Dot/mm) Final Assembly Page 7-9
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Final Assembly (Page 1 of 2) PART NUMBER 01130 01152 01155 01159 01448 01912 07435 07696 09367 30240 30269 30391-004 30391-006 30392-004 30407-008 30916 31038 31100M 31240 31517 31524M 35040 38019 38020 38037 38039 38102 38103 38342 38530M 38646M 38691M Page 7-10 DESCRIPTION Nut, 6-32 Washer, Flat, .375 x .156 x .65 Washer, Lock, #4 Washer, External Lock, #6 Screw, 6-32 .37 Washer, External Lock, #4 Screw, 6-32 .
S -Series Maintenance Manual: Volume 1 C 38102 (SERIAL) 38103 (PARALLEL) 38530M (SERIAL) 38691M (PARALLEL) 31038 REMOVE MASKING DISC C C A 31517 A A B T S 46325-3 (5 PLCS) A A B S A 30916 S L K K 35040 30269 (2) A A K 30391-006 J 30407-008 G T C 01152 H S 38646M 01155 M T 30240 01912 N A A 01159 S P T A T R A P P A 105 S and 160 S Parts Lists 30256 F A E 01130 D 07435 C 01448 B 30391-004 A 30392-004 CODE PART NUMBER SCREW LIST E E E E E
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Final Assembly (Page 2 of 2) PART NUMBER 30307 30336-1M 30336-2M 30914M 40355M 40357M 45189-2 45189-5 Page 7-12 DESCRIPTION Flag, Head Open Pulley, Ribbon Take-Up Pulley, Media Take-Up Pulley, Peel-Off Platen (8 Dots/mm) Pulley, Main Platen (8 Dots/mm) Pulley, Stepper Motor (8 Dots/mm) Belt, Media Rewind Belt, Main Drive QUANTITY 1 1 1 1 1 1 1 1
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists MEDIA REFLECTIVE SENSOR MEDIA TRANSMISSIVE SENSOR RIBBON SENSOR HEAD OPEN SENSOR TAKE LABEL SENSOR 30307 NOTE 3 NOTE 4 45189-5 MEMBRANE SWITCH CABLE 4. TRANSMISSIVE SENSOR POSITION WHEN EXTENDING THE MEDIA SENSOR POSITION TO THE OUTER HALF OF THE MEDIA WIDTH, REROUTE THIS CABLE TO PROVIDE SUFFICIENT SLACK FOR PULLING THROUGH THE MAIN FRAME.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S and 160S Base Assembly PART NUMBER 06576 07435 08754 46015 Page 7-14 DESCRIPTION Guide, PCB, Nylon Screw, 6-32, .37 Eyelet, .183 x .157 x .187 Bumper, Round, 1.09 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 46015 (4) 105S and 160S Base Assembly Page 7-15
105 S and 160 S Parts Lists PART NUMBER 01130 01159 02252 06250 06268 06319 07229 30033 30104 30105 30106 30114 30115 30118 30239 30247 30256-B 30307 30336-1M 30353M 30355M 30357M 30392-004 30392-008 30393-006 30423-003 30466 30488 35020 35025 35082 35099M 35136 35137 35302RM 35909 PRINTER MODEL: 105S Print Mechanism Assembly DESCRIPTION Nut, 6-32 Washer, Extended Lock, #6 Ring, Crescent, .250 E-Ring, External, .312 Washer, Lock, #6 Screw, 10-32 .37 Washer, Curved, .49 x .33 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 01130 01159 Q10057 06250 30355M (6-DOT) 40355M ( 8 & 12 DOT) 40490-2 30357M (6 & 12 DOT) 40357M ( 8 DOT) 35020 30033 30256-B 40808 46196M 06268 40154 105S Print Mechanism Assembly Page 7-17
105 S and 160 S Parts Lists PART NUMBER 01130 01159 02252 06250 06319 07229 30033 30104 30105 30106 30114 30115 30118 30176 30239 30256-B 30260 30307 30336-1M 30353M 30392-004 30392-008 30393-006 30423-003 30488 30909 35082 35136 35137 38025 38053M 38099M 38151M 38226M 38302M 38825-1 PRINTER MODEL: 160S Print Mechanism Assembly DESCRIPTION Nut, 6-32 Washer, External Lock, #6 Ring, Crescent, .250 Ring, “E” External, .312 Screw, 10-32 .37 Washer, Curved, .49 x .33 x .
S -Series Maintenance Manual: Volume 1 30336-1M 45189-5 30353M 30118 30114 30307 35082 30115 Q10057 01159 38151M 30392-004 01130 30392-004 P/O 46213M ASSY 30393-006 (3) 105 S and 160 S Parts Lists 30393-006 (3) 30392-004 40490-3 01159 40355M 06250 40027 38025 (8 PLCS) 46150M 30106 35136 (2) 38226M 48411 (2) 30466 40357M 46305M 35137 30392-004 30033 38053M 30256-B 46105 30239 30104 02252 38302M 46001-1 46444 46213M 02252 06319 (3) 46808 30260 30104 30105 30392-004 (5
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S (6 dot and 8 dot) Printhead Support Assembly PART NUMBER 01153 01159 10401 30391-003 30392-004 30402-006 30494 30531 30781 31521 31899 40014 40017 40193 40194 44000M 44200M 46481-1 48023 Page 7-20 DESCRIPTION Washer, Flat, .250 x .125 x .028 Washer, Lock, #6 Screw, M3 x .5 x 4 Screw, 4-40 .19 Screw, 6-32 .25 Screw, 6-32 .37 Washer, .320 x .119 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30781 01159 10401 (3) 48023 45003 (6 & 8 DOT) 46481-1 (2) 40193 (2) 30494 40014 105S (6 & 8 Dot/mm) Printhead Support Assembly Page 7-21
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S (12 dot) Printhead Support Assembly PART NUMBER 01153 01159 30391-003 30392-004 30402-006 30494 30531 30781 31521 31899 40014 40017 40193 40194 44800M 45013 46481-1 48023 Page 7-22 DESCRIPTION Washer, Flat, .250 x .125 x .028 Washer, Lock, #6 Screw, 4-40 .19 Screw, 6-32 .25 Screw, 6-32 .37 Washer, .320 x .119 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30781 01159 10401 (3) 48023 45013 (12 DOT) 46481-1 (2) 40193 (2) 30494 40014 44800M (12 DOT) 105S (12 (12 Dot/mm) Dot/mm) 105S Printhead Support Assembly Printhead Page 7-23
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Printhead Support Assembly PART NUMBER 01153 01159 01882 06268 30344 30391-003 30392-004 30402-006 30494 30781 38000M 38521 38601 40193 40194 46017 46022 46173 46174 46481-1 46605 Page 7-24 DESCRIPTION Washer, Flat, .250 x .125 x .028 Washer, #6 Lock Screw, 4-40 .25 Washer, #6 Split Lock Assembly, Clutch Plate and Bearing Screw, 4-40 .19 Screw, 6-32 .25 Screw, 6-32 .37 Washer, .320 x .119 x .
S -Series Maintenance Manual: Volume 1 30392-004 (2) 105 S and 160 S Parts Lists 30392-004 (4) 01159 (2) 30781 01159 DETAIL SCAL 2=1 FRONT SURFACE OF PRESSURE PLATE SHOULD BE FLUSH TO BELOW ENDS OF PRINTHEAD MOUNTING BRACKET 30392-004 (4) 06268 (4) WRAP GROUND STRAP AS SHOWN 46173 PRESSURE PLATE 46022 (2) PRINTHEAD MOUNTING BRACKET 46017 30402-006 (2) 01882 (2) 30494 30391-003 01153 46481-1 (2) 38521 46605 SEE NOTE 1 40194 (2) 40193 (2) PRINTHEAD PIVOT BAR 46174 38601 38000M NOTE:
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S and 160S Media Guide Assembly PART NUMBER 30033 30256-B Page 7-26 DESCRIPTION Guide, Adjustable Media Nut, Thumb, 6-32 .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30033 30256-B 105S and 160S Media Guide Assembly Page 7-27
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S Ribbon Supply Spindle Assembly PART NUMBER 07321 30041-4 30041-6 30042 30071 30097 30145 30146 30224 30344M 40070-1 40070-2 Page 7-28 DESCRIPTION QUANTITY Screw, Set, 6-32 .18 Washer, Felt, 29/32, 1/2, 3/32 Washer, Felt, 13/16, 13/32, 3/32 Spring, Torsion, .739 x .805 Housing, Ribbon Supply Spring Spring, Compression, .660 x .528 x .066 Bearing, Thrust Washer, Thrust, .687 x .375 x .093 Ring, Crescent, Ext. .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 40070-1 BLADE 40070-2 BLADE 30145 30041-4 (SEE NOTE 1) 30146 30146 30041-6 (SEE NOTE 1) 30224 30224 30071 30146 LONG END 30097 30344M 30146 07321 (2) 30145 30042 (SEE NOTES 2 & 3) NOTES: 1. SOAK FELT WASHERS 30041-4 & 30041-6 WITH SILICONE OIL AND SQUEEZE OUT 2. SOAK SPRING 30042 IN SILICONE OIL & ASSEMBLE 3.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Ribbon Supply Spindle Assembly PART NUMBER 30042 30145 30146 40070-1 40070-2 46085 46211 47005 47171 Page 7-30 DESCRIPTION Spring, Torsion, .739 x .805 Bearing, Thrust Washer, Thrust, .687 x .375 x .093 Blade, Ribbon Supply, Outer Blade, Ribbon Supply, Inner Nut, Jam, 3/8 24 Spring, Compression, .53 x .660 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists Gray 40070-1 BLADE White 40070-2 BLADE 30145 (NOTE 3) 30146 30146 LONG END 47005 46085 47171 30146 30146 30042 40070-1 BLADE 30145 (NOTE 3) 46211 Black NOTES: 1. ALL COMPONENTS MUST BE OIL FREE. 2. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION. 3. APPLY A LIGHT FILM OF GREASE (ZEBRA P/N 01660) TO PARTS 30145 (2).
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S Ribbon Take-Up Spindle Assembly PART NUMBER 07321 30073 30041-1 30058-2 30116 30118 30233 30422-002 Page 7-32 DESCRIPTION Screw, Set, 6-32 .18 Collar Washer, Felt, 1 1/4, 19/32, 3/32 Nut, Shoulder, .50-20, Hex Spring, Compression, .720 x .610 x .625 E-Ring, Ext. .500 x .042 Spring, Compression, .088 x .012 x .312 Screw, Set, 6-32, .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30422-002 30118 30233 07321 (2 PLCS) A .030 to .080 30073 07321 (2 PLCS) 30073 POSITIONING COLLAR 30041-1 30116 30041-1 NOTES: 30058-2 1) SOAK FELT WASHERS 30041-1 IN SILICONE OIL & SQUEEZE OUT. (2) ASSEMBLY IS POSITIONED VIA POSITIONING COLLAR & SET SCREWS AS SHOWN IN "A" - .030 TO .080 FROM EDGE OF 30118.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Ribbon Take-Up Spindle Assembly PART NUMBER 30118 38015 38210 47158 Page 7-34 DESCRIPTION E-Ring, Ext. .500 x .042 Screw, Set, #10-24 .187 Spring, Compression, .56 x .720 x 1.0 Nut, .50 .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30118 47081 38015 NOTE: 47158 1. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S Peel-Off Rewind Spindle Assembly PART NUMBER 07321 30041-7 30058-1 30110 30118 30422-006 Page 7-36 DESCRIPTION Screw, Set, 6-32 .18 Washer, Felt, 1 5/8, 17/32, .093 Nut, Shoulder, .50-20, Hex Spring, Compression, .85 x .67 x 1.12 E-Ring, Ext. .500 x .042 Screw, Set, 6-32, .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30118 30422-006 (2 PLCS) 07321 (2 PLCS) 30041-7 30041-7 30110 30058-1 NOTES: 1) SOAK FELT WASHERS 30041-7 IN SILICONE OIL & SQUEEZE OUT.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Peel-Off Rewind Spindle Assembly PART NUMBER 30118 38015 38210 47158 Page 7-38 DESCRIPTION E-Ring, Ext. .500 x .042 Screw, Set, #10-24 .187 Spring, Compression, .56 x .720 x 1.0 Nut, .50 .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30118 38210 38015 NOTE: 47158 1. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S Media Rewind Spindle Assembly PART NUMBER 07321 30041-7 30433-008 30058-1 30118 30422-006 40110 45090-2 47062-2 Page 7-40 DESCRIPTION Screw, Set, 6-32 .18 Washer, Felt, 1 5/8, 17/32, .093 Screw, 8-32 .500 Nut, Shoulder, .50-20, Hex E-Ring, Ext. .500 x .042 Screw, Set, 6-32, .375 Spring, Compression, .85 x .67 x 1.
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30422-006 (2 PLCS) 30118 30433-008 (6) 45090-2 (3) 30041-7 30041-7 40110 07321 (2 PLCS) 47062-2 30058-1 NOTES: 1) SOAK FELT WASHERS 30041-7 IN SILICONE OIL & SQUEEZE OUT.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Media Rewind Spindle Assembly PART NUMBER 30118 30433-004 38015 38210 46090 47062-1 47158 Page 7-42 DESCRIPTION E-Ring, Ext. .500 x .042 Screw, 8-32 .250 Screw, Set, #10-24 .187 Spring, Compression, .56 x .720 x 1.0 Blade, Media Take-Up Hook, Rewind Nut, .50 .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 30118 30433-004 (6) 46090 (3) 38210 46062 47062-1 38015 NOTE: 47158 1. O-RINGS, WEAR PLATES AND FRICTION CLUTCHES MUST BE HANDLED WITH CARE TO PREVENT OIL OR GREASE CONTAMINATION.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S Peel-Off Option Assembly PART NUMBER 02252 07435 30104 30114 30115 30118 30257 30265 30336-2M 30392-004 30393-006 30914M 31536M 40001 40490-2 45189-2 Page 7-44 DESCRIPTION Ring, Crescent, .250 Screw, 6-32 .37 Flange, Ball Bearing, .5 x .250 x .125 Washer, Flat, .76 x .51 x .03 Washer, Save, .740 x .520 x .08 Ring, “E”, External, .500 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 40490-2 105S Peel-Off Peel-Off Option Option Assembly 105S Assembly Page 7-45
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Peel-Off Option Assembly PART NUMBER 02252 07435 30104 30114 30115 30118 30247 30261 30265 30336-2M 30392-004 30392-006 30393-006 30914M 30536M 38055M 40490-3 45189-2 46001 46609M Page 7-46 DESCRIPTION Ring, Crescent, .250 Screw, 6-32 .37 Flange, Ball Bearing, .5 x .250 x .125 Washer, Flat, .76 x .51 x .03 Washer, Save, .740 x .520 x .08 Ring, “E”, External, .500 x .042 Washer, Flat, .42 x .260 x .0747 Washer, Flat, .
S -Series Maintenance Manual: Volume 1 STEPPER MOTOR PULLEY (REF.) 105 S and 160 S Parts Lists 30536M (BLK/BLU LEADS) 45189-5 MAIN DRIVE BELT (REF.
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105S Media Rewind Option Assembly PART NUMBER 02252 07435 30104 30114 30115 30118 30257 30265 30336-2M 30392-004 30393-006 30914M 31536M 40001 40055RM 40383RM 45189-2 45062 Page 7-48 DESCRIPTION Ring, Crescent, .250 Screw, 6-32 .37 Flange, Ball Bearing, .5 x .250 x .125 Washer, Flat, .76 x .51 x .03 Washer, Save, .740 x .520 x .08 Ring, “E”, External, .500 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists 12 & 8 DOT/MM 30914M 45062 105S Media Rewind Option Assembly Page 7-49
105 S and 160 S Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 160S Media Rewind Option Assembly PART NUMBER 02252 07435 30104 30114 30115 30118 30247 30261 30265 30336-2M 30392-004 30392-006 30393-006 30536M 30914M 45189-2 46001 46062 46155M 46383M 46609M Page 7-50 DESCRIPTION Ring, Crescent, .250 Screw, 6-32 .37 Flange, Ball Bearing, .5 x .250 x .125 Washer, Flat, .76 x .51 x .03 Washer, Save, .740 x .520 x .08 Ring, “E”, External, .500 x .042 Washer, Flat, .42 x .260 x .
S -Series Maintenance Manual: Volume 1 105 S and 160 S Parts Lists STEPPER MOTOR PULLEY (REF.) 30536M (BLK/BLU LEADS) 45189-5 MAIN DRIVE BELT (REF.
105 S and 160 S Parts Lists R Page 7-52 S -Series Maintenance Manual: Volume 1
105Se Parts Lists 8 In this section... Page Mechanical Parts and Assemblies ................................................8-1 Mechanical Parts and Assemblies Listing...................................8-2 Please note: This section contains parts lists and drawings that are specific to the 105Se. For parts lists/drawings common for both the 105S and 105Se, refer to Section 7.
105 Se Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105Se Final Assembly (Page 1 of 2) PART NUMBER DESCRIPTION 01130 01152 Nut, 6-32 Washer, Flat, .375 x .156 x .65 01155 01159 01448 01912 07435 30240 30256 30269 30391-004 30391-006 30392-004 30407-008 30916 31019 Washer, Lock, #4 Washer, External Lock, #6 Screw, 6-32, .37 Washer, External Lock, #4 Screw, 6-32, .37 Cover Plate with Opening (Serial) Nut, Thumb, 6-32, .50 Pad, PVC, 4.0 x .37, .062 Screw, 4-40, .25 Screw, 4-40, .
S -Series Maintenance Manual: Volume 1 38102 (SERIAL) 38103 (PARALLEL) 38532M (SERIAL) 38692M (PARALLEL) C 31038 C C 31517 A A A A P P A A A B T 46325-3 (7) REMOVE MASKING DISC 105 Se Parts Lists S B S A A T 30916 M L K K 31040 A A 31532M C 31646M 01152 K 30391-006 J 30407-008 H S 30269 (2) 01155 N T S 01912 P T 30240 01159 S R A A T G A T 30256 F A E 01130 D 07435 C 01448 B 30391-004 A 30392-004 CODE PART NUMBER SCREW LIST E E E E E 380
105 Se Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105Se Final Assembly (Page 2 of 2) PART NUMBER 30257M 30307 30336-1M 30336-2M 30355M 30357M 30392-004 30914M 31528 31532M 40355M 40357M 45189-2 45189-5 Page 8-4 DESCRIPTION Pulley, Peel-Off Platen (6 Dots/mm) Flag, Head Open Pulley, Ribbon Take-Up Pulley, Media Take-Up Pulley, Main Platen (6 Dots/mm) Pulley, Stepper Motor (6 Dots/mm and 12 Dots/mm) Screw, 6-32, .
S -Series Maintenance Manual: Volume 1 105 Se Parts Lists M M M M M M M M 31532M 105Se Final Assembly (page 2 of 2) Page 8-5
105 Se Parts Lists PART NUMBER 01130 01159 02252 06250 06319 07229 07321 30033 30104 30105 30106 30114 30115 30118 30239 30256-B 30260 30307 30336-1M 30353M 30355M 30357M 30392-004 30392-008 30393-006 30466 35020 35025 35082 35136 35137 35302RM 35909 38226M 38099M 38825-2 PRINTER MODEL: 105Se Print Mechanism Assembly DESCRIPTION Nut, 6-32 Washer, External Lock, #6 Ring, Crescent, .250 Ring, “E” External, .312 Screw, 10-32, .37 Washer, Curved, .49 x .33 x .0075 Screw, 6-32, .
S -Series Maintenance Manual: Volume 1 105 Se Parts Lists 30336-1M 45189-5 30118 30393-006 (3) 30353M 01130 30307 30392-004 12/6 DOT 30355M 8DOT 40355M 30392-004 (2) 30114 Q10057 01159 40051M 30115 30393-006 (3) 35082 40490-2 30392-004 01159 45025 06250 40027 30106 40050M 35136 (2) 30466 35020 35137 38226M 12/6 DOT 30357 8 DOT 40357 30392-004 (3) 45053M 46105 35025 (6 PLCS) 01130 40305RM (ASSY) 30033 30256-B 30392-004 (2) 30239 35302RM 30104 02252 40001 40444 02252 06319 (3) 4
105 Se Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105Se Printhead Support Assembly PART NUMBER 01153 01159 01882 10401 30301-003 30392-004 30402-006 30494 30531 30781 31007 31521 31899 40014 40193 40194 44000M 44200M 44800M 45003 45013 Page 8-8 DESCRIPTION Washer, Flat, .250 x .125 x .028 Washer, Lock, #6 Screw, 4-40, .19 Screw, M3 x .5 x 4 Screw, 4-40, .19 Screw, 6-32, .25 Screw, 6-32, .37 Washer, .320 x .119 x .
S -Series Maintenance Manual: Volume 1 105 Se Parts Lists 30392-004 (8) 30392-004 (4) 31899 30781 01159 10401 (3) 48023 (2) 45003 (6 & 8 DOT) 45013 (12 DOT) 46481-1 (2) 40194 (2) 40193 (2) 31007 01153 30301-003 30402-006 (2) 01882 (2) 30494 30531 SEE NOTE 1 PRINTHEAD PIVOT BAR 40014 NOTE: 1. POSITION SENSOR (30531) TAB FLUSH WITH TOP EDGE OF BAR (40002).
105 Se Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105Se Peel-Off Option Assembly PART NUMBER 02252 07435 30104 30114 30115 30118 30257M 30265 30336-2M 30392-004 30393-006 30914M 40001 40490-2 45189-2 46609M 47062-2 Page 8-10 DESCRIPTION QUANTITY Ring, Crescent, .250 Screw, 6-32, .37 Flange, Ball Bearing, .5 x .250 x .125 Washer, Flat, .76 x .51 x .03 Washer, Save, .740 x .520 x .08 Ring, “E”, External, .500 x .
S -Series Maintenance Manual: Volume 1 STEPPER MOTOR PULLEY (REF.) 105 Se Parts Lists P/O 46609M (BLK/BLU LEADS) 45189-5 MAIN DRIVE BELT (REF.
105 Se Parts Lists S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105Se Media Rewind Option Assembly PART NUMBER 02252 07435 30104 30114 30115 30118 30257M 30265 30336-2M 30392-004 30393-006 30914M 40001 40055RM 40383RM 45189-2 46609M Page 8-12 DESCRIPTION Ring, Crescent, .250 Screw, 6-32, .37 Flange, Ball Bearing, .5 x .250 x .125 Washer, Flat, .76 x .51 x .03 Washer, Save, .740 x .520 x .08 Ring, “E”, External, .500 x .
S -Series Maintenance Manual: Volume 1 STEPPER MOTOR PULLEY (REF.) 105 Se Parts Lists P/O 46609M (BLK/BLU LEADS) 45189-5 MAIN DRIVE BELT (REF.
105 Se Parts Lists PART NUMBER 01155 01822 02133 06224 08449 10421 10427 30133 30196-150 30198 30199 30208 30210 30214 30215 30216 30217-1 30219 30236 30313 30380M 30391-003 30392-004 30394-005 30405-006 30816 31024 31181 31374M 31730M 31807 S -Series Maintenance Manual: Volume 1 PRINTER MODEL: 105Se PRINTER MODEL: 105Se Cutter Option Assembly Cutter Option Assembly DESCRIPTION Washer, Lock #4 Nut, 4-40 E-Ring, .188, Black Grommet, Rubber Tiewrap Screw, M4 x .7 x 5 Screw, M4, .7 Bearing, Ball .
S -Series Maintenance Manual: Volume 1 SET SCREWS TO ENGAGE FLATS ON MOTOR SHAFT WHEN LOWER ARM IS IN VERTICAL POSITION MOTOR ROTATION DIRECTION .100" (2.5 mm) MEDIA GUIDE INSURE THE TOP OF THE TEAR TEAR-OFF OFF BAR IS POSITIONED ABOVE BAR OR LEVEL WITH THE TOP OF THE REAR CUTTER BLADE CLEARANCE OF .
105 Se Parts Lists R Page 8-16 S -Series Maintenance Manual: Volume 1
