liner rewind upgrade - zebra technologies · caution • wear protective eye wear when installing...

Liner Rewind Upgrade

Installation Instructions

This kit includes the parts and documentation necessary to install the liner rewind option kit into the 105SL™ printer.

Read these instructions thoroughly before attempting to install this kit.

Caution • A qualified service technician must perform this installation.

© 2008 ZIH Corp. All product names and numbers are Zebra trademarks, and Zebra and the Zebra logo are registered

trademarks of ZIH Corp. All rights reserved.

Printed on chlorine-free recycled paper. 33180L-001

Liner Rewind UpgradePrepare for Installation

2

Prepare for Installation

Parts List

Table 1 • Kit Parts List

Item Qty Part Number DescriptionRef 1 G33180 Liner Rewind Option Kit1 3 HW30393-006 Screw, 8-32 x 0.37 (sold in quantities of 25)2 6 HW40193 Washer, 0.406 x 0.172 x 0.048 (sold in quantities of 25)3 2 49688 Flanged Bearing (Part of 30211M)4 1 G32011M Rewind Platen Roller Maintenance Kit5 1 45055 Liner Rewind Spindle maintenance Kit6 1 40490-2 Rewind Hook7 1 32347 Rewind Platen Roller Adjust Plate8 5 HW30392-004 Screw, 6-32 x 0.25 (sold in quantities of 50)9 1 HW33810 C-ring (sold in quantities of 100)10 1 30334-7 Bearing Housing Assembly (Part of 45055)11 1 31336M 300 dpi RTU/MTU Pulley Maintenance Kit12 1 HW33811 E-ring, 0.500 x 0.042 (sold in quantities of 25)13 1 45189-2 Rewind Drive Belt14 1 HW33804 Flat Washer, 0.76 x 0.51 x 0.03 (sold in quantities of 25)15 1 HW30115 Washer, 0.740 x 0.520 x 0.080 (sold in quantities of 25)16 1 48018 Rewind Platen Pulley17 1 G46609-4M Lower Take Label Sensor Assembly (Black/Red Wires)

Upper Take Label Sensor Assembly (Green/Yellow Wires)

18 6 HW32334 Screw, 6-32 x 0.37 (sold in quantities of 100)19 1 30265 Idler Pulley20 1 22004-1 Rewind platen pulley Spacer21 1 30207 Idler Shaft22 1 46909 Rewind Spindle Pulley Spacer 0.750 x 0.520 x 0.323 1 11301 Long Hex Key (Allen Wrench) 7/64″N/S 1 01660 Grease (Lubriplate GR-132)

Bold = Part available for purchase.Italic = Part not available for purchase, listed and shown for reference only.

33180L-001 A 105SL Installation Instruction 02/19/2008

3Liner Rewind UpgradePrepare for Installation

Figure 1 • Kit Contents

Reference Materials• 105SL Maintenance Manual

• 105SL User Guide

Tools Required

3

1

2

4

72

39 810 5

6

1817 11

14

1519

12 22

13

16 202

8

23

21

Tools • You need these tools to complete this procedure:

Phillips Screwdriver Set

Standard Hex Key (Allen wrench) Set

Spring Tension Gauge 2200g

Metric/inch Ruler

Antistatic Wriststrap and Mat

Needle Nose PliersLong Needle Nose Pliers

Safety Goggles

02/19/2008 105SL Installation Instruction 33180L-001 A

Liner Rewind UpgradeDifferences in Printer Configurations

4

Differences in Printer ConfigurationsThe printer identification label on the rear of the unit identifies the configuration of the printer. The format of the Configuration Number is as follows:

10500-1XXX-XXXX

These instructions cover the two major configurations of the 105SL. The significant differences between configurations are denoted by the first digit of the second group of numbers. If that digit is a zero (0) or one (1), the 105SL has separate AC and DC power supplies. If that digit is a two (2) or three (3), the 105SL has an integrated AC/DC power supply. The main logic board is different in the two configurations.

Remove the Electronics Cover

1.

Note • Retain all parts removed during disassembly, unless otherwise directed.

Caution • A qualified service technician must perform this installation.

Caution • Turn off (O) the printer and disconnect it from the power source before performing the following procedure.

Turn off (O) the printer and disconnect the AC power cord and all data cables.


5Liner Rewind UpgradeRemove the Electronics Cover

2. See Figure 2. Remove the electronics cover by removing the two mounting screws securing it and then lifting up from the rear corner.

Figure 2 • Remove the Electronics Cover

3.

4. Which configuration of 105SL are you working on?

1 Electronics cover2 Electronics cover mounting screws (2)3 Channel4 Lip of cover

Lift up at rear corner.

2

4

1

3

Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead.

Open the media door and remove the media and ribbon.

If you have configuration… Then…

10500-0XXX-XXXX and 10500-1XXX-XXXX Continue with Remove the DC Power Supply.

10500-2XXX-XXXX and 10500-3XXX-XXXX Go to Remove the AC/DC Power Supply on page 7.


Liner Rewind UpgradeRemove the DC Power Supply

6

Remove the DC Power Supply

1.

2. See Figure 3. Inside the electronics cabinet, remove the two nuts and one mounting screw that secure the DC power supply assembly in position.

Figure 3 • DC Power Supply Removal/Installation

3. Remove the DC power supply assembly from the printer.

4. Go to Install the Liner Rewind on page 8.

Note • You can leave all wires and cables attached to the DC power supply board. With wires still attached, move the assembly aside to gain access to the area of the printer you need to install the kit parts.

Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

1 DC power supply assembly2 Heat conduction pad3 Mounting nuts (2)4 Mounting screw

Note • The black heat conduction pad MUST NOT be discarded.

POWER

TAKELABEL

ERROR

CHECK RIBBO

N

FEED

PAPEROUT

PAUSE

DATA

PREVIOUS

NEXT/SAVE

SETUP/EXIT

14

3 2


7Liner Rewind UpgradeRemove the AC/DC Power Supply

Remove the AC/DC Power Supply

1.

2. See Figure 4. Remove and retain the two screws securing the insulation shield to the standoffs on the power supply. Carefully unwrap the top of the shield and remove it from the power supply.

Figure 4 • AC/DC Power Supply Removal and Installation

3. Remove and retain the two nuts and one mounting screw that secure the AC/DC power supply assembly in position.

Note • You can leave all wires and cables attached to the AC/DC power supply board. With wires still attached, move the assembly aside to gain access to the area of the printer you need to install the kit parts.

1isCaution • 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.

Caution • Observe proper electrostatic safety precautions when handling static-sensitive components such as circuit boards and printheads.

Connect yourself to an antistatic device.

1 AC/DC power supply assembly2 Mounting screw3 Mounting nuts (2)4 Insulation shield5 Insulation shield mounting screws (2)6 Heat conduction pad, do not remove.

1

2

43

5

6


Liner Rewind UpgradeInstall the Liner Rewind

8

4. Remove the power supply assembly from the printer.

Install the Liner Rewind1. See Figure 5. Remove and retain the plastic plug in the lower access hole near the bottom

of the print mechanism side plate.

Figure 5 • Rewind Assembly Installation

Note • The black heat conduction pad MUST NOT be discarded.

1 2

3

45 3 6

78

9

Rewind Platen Mounting Hole

Lower Access Hole

Rewind Spindle Mounting Hole

1311 1214

15

16

210

17

18

10

2192120

22

23

Upper Take-Label Sensor Mounting Hole

Lower Take-Label Sensor Mounting Hole

Stepper Motor Pulley


9Liner Rewind UpgradeInstall the Liner Rewind

2. Place a flat washer onto one of the screws. Using the hex key 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 to the mounting screw.

3. Position the idler shaft in the middle of the mounting slot and tighten the mounting screw.

4. With a toothpick or small screwdriver, apply a very small amount of grease to the idler shaft.

5. Orient the idler pulley as shown, and slide it onto the idler shaft.

6. Remove and discard the plastic plug from the rewind spindle mounting hole.

7. Slide the bearing housing assembly off the shaft of the liner rewind spindle assembly.

8. Install the bearing housing assembly on the printer main frame using three screws and three flat washers. Do not tighten the screws at this time.

9. Insert the shaft of the rewind spindle through the bearing housing assembly.

10. Place the wave washer, flat washer, and pulley over the shaft of the rewind spindle.

1 Mounting screws (3)2 Mounting washers (6)3 Flanged bearing (2)4 Rewind platen roller5 Roller adjust plate6 C-ring7 Bearing housing assembly8 Rewind spindle9 Hook10 Mounting screws (2)11 E-ring12 Rewind pulley spacer13 Rewind pulley14 Flat washer15 Spring washer16 Mounting screws (2)17 Upper take-label sensor (green/yellow wires)18 Lower take-label sensor (black/red wires)19 Rewind platen roller spacer20 Idler shaft21 Rewind platen pulley22 Idler pulley23 Rewind drive belt

Note • Avoid getting grease anywhere except on the idler shaft.



10

11.

12. Attach the rewind platen roller adjust plate to the side plate with two flat washers and two screws. Do not tighten the screws at this time.

13. Remove and discard the plastic plug from the rewind platen roller mounting hole.

14. Insert the long end of the rewind platen roller through the rewind platen roller mounting hole.

15. Place one flange bearing over the left end of the platen roller, flange facing out. Press the bearing into the mounting hole of the main frame.

16. Place the opposite end of the platen roller through the rewind platen roller adjust plate.

17. Place the remaining flange bearing over the right end of the rewind platen roller with the flange facing out and the press the bearing into the mounting hole in the rewind platen adjust plate. Secure it with the C-ring.

18. Tighten the mounting screws that secure there wind platen roller adjust plate to the side plate. It may need adjustment later.

19. Slide rewind platen pulley spacer onto the platen roller.

20. Slide rewind platen pulley onto the rewind platen roller and align the two set screws with the flat surfaces of the rewind platen roller.

21. Leave approximately a 0.5 mm (0.020 in.) gap between the C-ring and platen support bracket. Tighten the two pulley set screws.

22. Remove the plugs from the upper and lower take-label sensor mounting holes.

Caution • Wear protective eye wear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off.

Slide the rewind pulley spacer onto the shaft of the rewind spindle and then press the E-ring into the groove in the shaft of the rewind spindle.

Note • Use part # 31336M for 300 dpi printers or part # 48018M for 203 dpi printers.

Note • The upper take-label sensor has green/yellow wires.



23. See Figure 6. Insert the upper take label sensor connector and cable through the upper hole in the main frame.

Figure 6 • Sensor Installation

24. Position the sensor with the window facing down. Secure the sensor to the main frame with one screw.

25. Insert the lower take label sensor connector and cable through the lower hole in the main frame.

26. Position the sensor with the window facing up. Secure the sensor to the main frame with one screw.

1 Upper take-label sensor (green/yellow wires)2 Lower take-label sensor (black/red wires)3 Mounting screws (2)

Note • The lower take-label sensor has black/red wires.

1

2

3



12

27. See Figure 7. Route the sensor wires through the cable clamps and bring them to the main logic board. Ensure that the wires do not come in contact with any moving parts.

Figure 7 • Sensor Connector Location

1 Lower take-label sensor, J152 Upper take-label sensor, J163 Upper take-label sensor, P24 Lower take-label sensor, P1

S2

J7

J6 J5

J1

J1

J3

J4

J2

J8J9

J10

J10

J11

J11

J12J13J14J15

J16J17J18J19J20

J21

P6

P25

P27

P8

P2P1

P3

P32P31P19

P5

P10

1

2

3

4

Printer Configuration 10500-0XXX0XXXX and 10500-1XXX-XXXX

Printer Configuration 10500-2XXX0XXXX and 10500-3XXX-XXXX



28. Which configuration of 105SL are you working on?


10500-0XXX-XXXX and 10500-1XXX-XXXX

Connect the upper take label sensor connector to J16 on the main logic PCB and the lower take label sensor connector to J15.


Connect the upper take label sensor connector to P2 on the main logic PCB and the lower take label sensor connector to P1.

Note • 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.



14

29. See Figure 8. Rotate the ribbon take-up pulley until the three holes in the pulley align with the three mounting screws that secure the ribbon take-up spindle assembly to the printer.

Figure 8 • Remove and Install the Main Drive Belt

30. Align the holes in the ribbon take-up pulley with the three spindle assembly mounting screws and then loosen, but do not remove, the three mounting screws.

31. Slide the ribbon take-up spindle assembly to the right to relieve the tension on the main drive belt.

32. Remove the main drive belt by sliding it off the ribbon take-up pulley.

1 Ribbon take-up pulley2 Platen pulley3 Stepper motor pulley4 Main drive belt5 Ribbon pulley adjustment access holes (3)

4

5

2

3

1


15Liner Rewind UpgradeInstall the Rewind Drive Belt

Install the Rewind Drive Belt1. See Figure 9. Route the rewind drive belt around the inside stepper motor pulley, rewind

spindle pulley, rewind platen roller pulley and the idler pulley.

Figure 9 • Initial Rewind Drive Belt Tensioning

2. Slide the rewind assembly toward the rear of the printer until the belt tension is tight. Extend the wrench through the access holes in the liner take-up pulley assembly, and tighten the three screws.

1 Stepper motor pulley2 Spring tension gauge3 Idler pulley4 Rewind platen pulley5 Ruler6 Rewind spindle pulley7 Rewind spindle access holes8 Rewind drive belt

Note • The rewind assembly may reach the limit of travel before the belt is tight.

INCHES

12

3

2200

2000

1800

1600

1400

81

2

3

4

5

6

7


Liner Rewind UpgradeInstall the Rewind Drive Belt

16

3. Grasp the idler pulley and shaft assembly. Loosen the screw securing the idler pulley, and slide the assembly toward the rear of the printer until belt tension is tight. Tighten the screw to secure the idler pulley.

4. Hook a spring scale at the midpoint of the lower section of the belt and pull up. The belt should deflect 6 mm (0.25 in.) with a tension of 2000 grams (4.5 lbs.). Readjust the belt tension by changing the position of the idler pulley.

5. When adjustment is completed, reinstall the plastic plug in the lower access hole in the print mechanism side plate.

6. See Figure 10. Reintall the main drive belt around the stepper motor pulley, the platen pulley, and the ribbon take-up pulley.

Figure 10 • Adjust the Main Drive Belt

1 Ribbon take-up spindle pulley2 Platen roller pulley3 Ruler4 Stepper motor pulley5 Spring tension gauge6 Ribbon take-up mounting screw access holes (3)

22002000180016001400

INCHES1

2

3

1

61

2

3

4

5


17Liner Rewind UpgradeInstall the Rewind Drive Belt

7. Hook a 2200-gram spring tension gauge to the belt and carefully slide the ribbon take-up spindle assembly to the left to increase belt tension.

8. When a scale reading of 2000 grams ±250 grams (4.5 lbs. ±0.5 lbs.) creates a deflection of 6 mm (0.25 in.), tighten the three mounting screws.

9. Which configuration 105SL are you working on?



a. See Figure 3 on page 6. Reinstall the DC power supply assembly.

b. Continue with Reinstall the Electronics Cover.


a. See Figure 4 on page 7. Reinstall the AC/DC power supply assembly.

b. Continue with Reinstall the Electronics Cover.


Liner Rewind UpgradeReinstall the Electronics Cover

18

Reinstall the Electronics Cover1. See Figure 11. Reinstall the electronics cover by aligning the cover so that it slips over the

main frame.

2. Reinstall the mounting screws to secure the electronics cover.

Figure 11 • Install the Electronics Cover

3.

4. Reconnect the AC power cord and data cables.

5. Turn on (I) printer.

6. Perform a PAUSE key self-test and observe the tracking of the liner.

7. Does the liner track properly?

1 Electronics cover2 Main frame3 Mounting screws (2)

PAUSE

CALIBRATE

DATA

CANCEL

FEED

PAUSE

TAKE LABEL

PAPEROUT

CHECK RIBBO

N

ERROR

PREVIOUS

POWER

NEXTEXITSETUP

1

3

2

Caution • When you are loading media or ribbon, remove all jewelry that could come into contact with the printhead or other printer parts.

Reinstall the media and ribbon.

If… Then…

No Continue with Adjust the Rewind Platen Adjust Plate.Yes Go to Reconfigure the Printer for Peel Operation on page 20


19Liner Rewind UpgradeAdjust the Rewind Platen Adjust Plate

8. If the liner does not track properly, proceed to Adjust the Rewind Platen Adjust Plate.

Adjust the Rewind Platen Adjust PlateIf the liner is tracking off to one side, perform the following procedure to position the platen support bracket.

1. Refer to Figure 12. Loosen, but do not remove, the two screws holding the platen support bracket to the side bracket.

Figure 12 • Platen Support Bracket Adjustment

2. Adjust the bracket position as required and tighten the screws.

3. Tighten the two screws. Check label liner tracking again.

4. Repeat the procedure until the required results are achieved.

1 Side plate2 Mounting screws (2)3 Rewind platen roller adjust plate4 Rewind platen roller

Note • Moving the bracket toward the front of the machine moves the label liner material toward the main frame. Moving the bracket toward the rear of the machine moves the label liner away from the main frame.

1

2

34


Liner Rewind UpgradeReconfigure the Printer for Peel Operation

20

Reconfigure the Printer for Peel Operation1. Enter the configuration mode by pressing Setup/Exit.

2. Press Next/Save until you get to Print Mode.

3. Press (+) or (–) key until you select PEEL-OFF.

4. Pressing Setup/Exit leave the configuration mode. Press the (+) or (–) key to select Permanent. Press Next/Save to accept and make permanent.


liner rewind upgrade - zebra technologies · caution • wear protective eye wear when installing...

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