Read these instructions thoroughly before attempting to install this option.

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1 Rewind Option Kit Installation Instructions This kit includes the parts and documentation necessary to install the Media Rewind option into the following printers: 0XiIIIPlus, 0 dpi 0XiIIIPlus, 00 dpi 0XiIIIPlus, 600 dpi Read these instructions thoroughly before attempting to install this option. Prepare for Installation Parts List Before proceeding, verify that your kit contains the items for your printer listed below. Printed on 007 ZIH Corp. All product names and numbers are Zebra chlorine-free trademarks, and Zebra and the Zebra logo are registered recycled paper. trademarks of ZIH Corp. All rights reserved. 55L-00

2 Rewind Option Kit Prepare for Installation Table Kit Parts List Item Qty Part Number Description Ref G55M 0XiIIIPlus Rewind Option kit, 0 and 00 dpi G55-6 0XiIIIPlus Rewind Option kit, 600 dpi HW Screw, (sold in quantities of 5) HW09 Flat Washer, (sold in quantities of 5) 9688 Flange Bearing G0M Platen Roller, 0 and 00 dpi G06M Platen Roller (600 dpi) 5 G55M Rewind Spindle Assembly J-Hook 7 7 Platen Support Bracket 8 HW09-00 Screw, (sold in quantities of 50) 9 HW80 Crescent Ring, 0.5 (sold in quantities of 00) 0 G8M Rewind Plate G0M Bearing Housing Assembly 6M RTU/MTU Pulley Assembly 758M RTU/MTU Pulley Assembly (600 dpi) HW8 E-Ring, (sold in quantities of 5) 589- Rewind Drive Belt (0 and 00 dpi) 589- Rewind Drive Belt (600 dpi) 5 HW80 Flat Washer, (sold in quantities of 5) 6 HW05 Wave Washer, (sold in quantities of 5) 7 09M Rewind Platen Pulley (0 and 00 dpi) G795M Rewind Platen Pulley (600 dpi) 8 G6609-M Take-Label Sensors Assembly 9 HW Screw (sold in quantities of 00) Idler Pulley N/A Spacer (Part of platen roller kits) 007 Idler Shaft N/A Spacer (Part of 6M) 0 Hex Key (Allen wrench), Long 7/6 in. N/A = Not available as a separate part (listed for identification purposes only). Bold = Part available for purchase. Italic = Part not available for purchase, listed and shown for reference only. 55L-00 A 0XIIIIPlus Installation Instruction /0/007

3 Rewind Option Kit Prepare for Installation Figure Kit Contents /0/007 0XIIIIPlus Installation Instruction 55L-00 A

4 Rewind Option Kit Prepare for Installation Manuals Required 0XiIIIPlus-Series User Guide 0XiIIIPlus Maintenance Manual Tools Required Tools You need these tools to complete this procedure: Phillips Screwdriver Set SAE Nutdriver Set SAE Hex Key (Allen wrench) Set Utility Knife Metric/Inch Ruler Polyester Strip, Zebra Part number 0776 Metric/Inch Spring Scale, Zebra Part number 0 Utility Pliers 55L-00 A 0XIIIIPlus Installation Instruction /0/007

5 Rewind Option Kit Remove the Electronics Cover 5 Remove the Electronics Cover 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.. See Figure. Remove the electronics cover by removing the two mounting screws securing it and then lifting up from the rear corner. Figure Remove the Electronics Cover Lift up at rear corner. Electronics cover Electronics cover mounting screws () Channel Lip of cover /0/007 0XIIIIPlus Installation Instruction 55L-00 A

6 6 Rewind Option Kit Remove AC/DC Power Supply Remove AC/DC Power Supply. See Figure. Disconnect all wires and cables attached to the AC/DC power supply. Note Note the position and orientation of all wires and cables to ensure proper connection. Figure Remove the Cables PCMCIA Option Board Main Logic Board AC/DC Power Supply 5 Main logic board (MLB) cutter option connector, P Upper take-label sensor MLB connector, P Lower take-label sensor MLB connector, P Beaded cable tie 5 Cutter power connector, J5. Remove the beaded cable tie. 55L-00 A 0XIIIIPlus Installation Instruction /0/007

7 Rewind Option Kit Remove AC/DC Power Supply 7. See Figure. Remove the two screws securing the insulating shield and the remove the shield.. Remove the mounting screw and two nuts securing the power supply assembly. Figure Remove and Install Power Supply Do not remove the heat-conduction pad. 5 AC/DC power supply AC/DC power supply mounting screw AC/DC power supply mounting nuts () Shield mounting screws () 5 AC/DC power supply shield 5. Remove the power supply assembly. /0/007 0XIIIIPlus Installation Instruction 55L-00 A

8 8 Rewind Option Kit Install the Rewind Option Kit Install the Rewind Option Kit See Figure on page and Table on page for item numbers. Install the Idler Pulley. See Figure 5. Remove the plastic plug in the lower access hole near the bottom of the side plate. Figure 5 Remove the Plastic Plug Lower access hole cover. Place a flat washer onto mounting screw. Place the mounting screw and washer through the lower access hole and idler pulley mounting hole in the main frame. On the electronics side, install the idler shaft onto the mounting screw.. Position the idler shaft in the middle of the mounting hole and tighten. Apply a small amount of grease to the idler shaft, ensuring no grease is on other components.. Slide the idler pulley, flat side facing out, onto the idler shaft. 55L-00 A 0XIIIIPlus Installation Instruction /0/007

9 Rewind Option Kit Install the Rewind Option Kit 9 Install the Media Rewind Spindle. Remove and discard the cover plate and screws of the media rewind spindle mounting hole in the lower center portion of the main frame.. Install the bearing housing assembly using three screws and three flat washers. Do not tighten the screws at this time.. Install the shaft of the media rewind spindle through the bearing housing assembly.. Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off. Place the wave washer, flat washer, and pulley, counter-sunk side facing out, onto the media rewind spindle shaft, then the spacer, and secure with the E-ring. Install the Lower Platen Roller. Install the platen support bracket to the side plate using two washers and two screws. Do not tighten the screws at this time.. Remove the plastic plug from the rewind platen mounting hole near the bottom of the main frame.. From the electronics side install a flange bearing, flange facing out, into the rewind platen mounting hole.. From the media side, insert the long end of the platen roller shaft into the flange bearing. 5. Insert the remaining flange bearing into the platen support bracket, flange facing out. 6. Caution Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and mounting buttons. These are under tension and could fly off. Slide the short end of the platen roller shaft through the bearing and the install the E-ring to secure it. 7. Tighten the mounting screws securing the platen support bracket. The bracket may need adjustment later. 8. From the electronics side, slide the spacer and the platen roller pulley onto the rewind platen shaft. 9. Align the two pulley set screws with the flat surfaces of the rewind platen shaft and tighten. The pulley should be positioned with approximately 5 mm (0.0 in.) between the E-ring and the platen support bracket on the media side. /0/007 0XIIIIPlus Installation Instruction 55L-00 A

10 0 Rewind Option Kit Install the Rewind Option Kit Install and Adjust the Rewind Drive Belt. See Figure 6. Loosen, but do not remove, the screws that secure the ribbon take-up spindle assembly. Access the screws through the holes in the ribbon take-up pulley. Figure 6 Ribbon Take-Up Pulley More Tension Less Tension INCHES Take-up pulley mounting screw access holes () Ribbon take-up pulley Main drive belt Stepper motor pulley. Slide the ribbon take-up assembly toward the front of the printer, relieving the belt tension, and remove the main drive belt from the stepper motor pulley.. Use a utility knife to carefully cut away and remove the clear plastic spacer on the stepper motor pulley. 55L-00 A 0XIIIIPlus Installation Instruction /0/007

11 Rewind Option Kit Install the Rewind Option Kit. See Figure 7. Ensuring both plastic washers on the stepper motor pulley are positioned to the outside, route the media rewind belt around the inner most stepper motor pulley, media rewind pulley, rewind platen pulley, and idler pulley. Figure 7 Install Rewind Drive Belt 5 6 Rewind drive belt Stepper motor pulley Idler pulley Rewind platen pulley 5 Rewind spindle mounting screw access holes () 6 Rewind spindle pulley 5. Slide the media rewind assembly toward the rear of the printer until the belt tension is tight or adjustment margin is used up. Tighten the rewind spindle assembly screws. Access is through the holes in the rewind pulley. 6. Grasp the idler pulley and shaft assembly while loosening the mounting screw. Slide the assembly toward the rear of the printer until the belt tension is tight, and then retighten the mounting screw. 7. Hook a spring scale at the midpoint of the lower section of the belt and pull up. The belt should deflect 6.5 mm (0.5 in.) with a tension of 000 grams (.5 in. lbs). If this condition does not exist, readjust the belt tension by changing the position of the idler pulley. 8. When adjustment is completed, reinstall the plastic plug in the lower access hole in the print mechanism side plate. 9. See Figure 6 on page 0. Reinstall the main drive belt over the stepper motor pulley, platen pulley, and ribbon take-up pulley. Ensure that one of the stepper motor pulley spacers is placed on each side of this drive belt. 0. Slide the ribbon take-up assembly toward the rear until the belt tension is tight. Tighten the ribbon take-up spindle mounting screws using the access holes in the ribbon take-up pulley. /0/007 0XIIIIPlus Installation Instruction 55L-00 A

12 Rewind Option Kit Install the Rewind Option Kit. Hook a spring scale at the midpoint of the belt section between the stepper motor pulley and the ribbon take-up spindle pulley and pull down to the left. The belt deflection should be 6.5 mm (0.50 in.) with a tension of 000 grams (.5 in. lbs). If this condition does not exist, readjust the belt tension by changing the position of the ribbon take-up assembly. Install Take-Label Sensor Important Do not install the take-label sensors on cutter units. The take-label sensors are required in the peel-off mode of operation.. See Figure 8. Remove the upper and lower take-label cover plates by removing the screws and pushing cover plate out of the mounting holes. Figure 8 Install the Take-Label Sensors 5 Cover plate mounting screws () Upper take-label mounting hole Lower take-label mounting hole Upper take-label sensor 5 Lower take-label sensor. See Figure on page. Feed the upper sensor cable through the upper mounting hole.. Position the sensor with the window facing down, and secure with screw.. Feed the lower sensor cable through the lower mounting hole. 5. Position the sensor with the window facing up, and secure with screw. 6. See Figure on page 6. Route the cables through the cable clamps and toward the main logic board (MLB) ensuring the wires do not come in contact with any moving parts. 55L-00 A 0XIIIIPlus Installation Instruction /0/007

13 Rewind Option Kit Reinstall the Electronics Cover 7. Connect the upper sensor connector to P on the MLB. 8. Connect the lower sensor connector to P on the MLB. Note When in Peel-Off Mode, if the two sensors are not aligned, the take-label LED illuminates and the will be no operation. Reinstall the Electronics Cover. See Figure 9. Reinstall the electronics cover by aligning the cover so that it slips over the main frame.. Reinstall the mounting screws to secure the electronics cover. Figure 9 Install the Electronics Cover PREVIOUS NEXT SETUP EXIT POWER TAKE LABEL ERROR C HEC K RIBBON PAPER OUT PAUSE PAUSE FEED DATA CANCEL C ALIBRATE. Reconnect the AC power cord and data cable.. Electronics cover Main frame Mounting screws () 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. /0/007 0XIIIIPlus Installation Instruction 55L-00 A

14 Rewind Option Kit Configure the Printer Configure the Printer See the User Guide to configure the printer to the Rewind Mode. Rewind Mode rewinds a printed roll of continuous media or a printed roll with liner and labels. To use this option to dispense individual labels and rewind the media backing only, see the User Guide to set the printer to the Peel-Off Mode. The rewind option kit usually requires some adjustments to prevent printing problems such as ribbon wrinkle, non-centered labels, and tearing media. Print a number of test labels to check for problems. Use the following procedures to correct any problems. Adjust the Tracking If the media walks from side to side or tears or wrinkles against the backing plate of the media rewind spindle, it may be necessary to adjust the position of the rewind plate assembly (mounted on the front of the printer) or the rewind spindle assembly.. See Figure 0. Remove the rewind plate assembly, and loosen the nuts securing the hook plate to the rewind plate. a. Move the outer end of the hook plate up, to force media to wind closer to the backing plate. or b. Move the outer end down, to force media away from the backing plate. Figure 0 Install, Remove and Adjust Rewind Plate 5 6 Slots Rewind plate Top lip Hook plate 5 Adjustment slot 6 Adjustment nuts () 55L-00 A 0XIIIIPlus Installation Instruction /0/007

15 Rewind Option Kit Configure the Printer 5. Reinstall the rewind plate and print a number of test labels. If problems persist, readjust the hook plate.. If the media cannot be made to track correctly after making this adjustment, check the distance from the backing plate to the main frame. The factory set dimension is mm (0.550 in.) ±0.5 mm (0.00 in.). Figure Adjust Rewind Spindle Position 5 Hex key, 7/6 in. Setscrews (), located inside spindle Rewind spindle Collar, located inside the spindle 5 Tracking plate. Loosen the two set screws in the collar located inside the rewind spindle assembly near the backing plate. The set screws are accessible through a single hole in the rewind spindle assembly. Reposition the backing plate as required and retighten the set screws in the collar. 5. Perform the rewind plate assembly adjustment in step and step until the desired results are achieved. /0/007 0XIIIIPlus Installation Instruction 55L-00 A

16 6 Rewind Option Kit Configure the Printer Adjust Tension Media that is rewound too tightly can cause mis-registration of labels, tearing, or poor print quality due to smudging. Media rewound too loosely can jam up the printer before completing a roll or make it impossible to separate labels from liner in Peel-Off Mode. See Figure to adjust the tension.. Loosen the set screw in the adjusting nut at the end of the rewind spindle assembly. Figure Adjust the Spindle Tension 5 Spring gauge Polyester strip Adjusting nut Setscrews () 5 Reinforced hole. Insert a hex key through the access hole at the rear of the rewind spindle assembly into one of the set screws in the collar to prevent the rewind spindle shaft from turning while adjusting the tension.. Position the adjusting nut with fingers or pliers as required. in for more tension out for less tension 55L-00 A 0XIIIIPlus Installation Instruction /0/007

17 Rewind Option Kit Configure the Printer 7. Measure the spindle tension using a spring scale gauge. Place a media core on the spindle and attach a 5 mm ( in.) wide by 7.6 m (0 in.) long strip of polyester film to the core with adhesive tape. Wind the film in the direction shown in Figure. 5. Insert the spring scale tip through the reinforced hole in the end of the strip and pull slowly and evenly, in. (5 mm) per second, in the direction shown. Make this measurement several times to ensure an accurate reading. This tension should be approximately grams (.. in. lb.). 6. Readjust tension as required and recheck the tension setting. Retighten the adjusting nut set screw. 7. Recheck the tension after running a full roll of labels. Note Depending on your application, it may be necessary to deviate slightly from the recommended tension setting shown above. Adjust the Lower Roller The lower roller alignment has much the same effect on media tracking as the rewind plate alignment does in Rewind Mode.. See Figure. Loosen the mounting screws securing the platen support bracket to the side plate. Figure Adjust Platen Support Bracket Mounting screws () Platen support bracket Bearing () Lower platen roller /0/007 0XIIIIPlus Installation Instruction 55L-00 A

18 8 Rewind Option Kit Configure the Printer. Adjust the bracket as required and tighten the mounting screws. Moving the bracket toward the rear of the printer forces the media to wind closer to the large backing plate on the rewind spindle. Moving the bracket toward the front of the machine moves the media away from the backing plate.. Perform this adjustment until the required results are achieved. Adjust Tension For liner and label combinations that are particularly difficult, it may be necessary to increase the rewind tension in Peel-Off Mode. Follow the same procedure used for the Rewind Mode. 55L-00 A 0XIIIIPlus Installation Instruction /0/007

160S Rewind Option Kit Installation Instructions

160S Rewind Option Kit Installation Instructions Installation Instructions GENERAL This kit includes the parts and documentation necessary to install the Media Rewind Option into the Zebra 160S printer. Read these instructions thoroughly before attempting