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 to install this option. Adding the Rewind Option to a printer requires the installation of several parts and assemblies and should be performed by a qualified Service Technician. The Service Technician must follow all of the step-by-step procedures provided in these instructions. REFERENCE MATERIALS 31450L S-SeriesUser sguide 38452L S-Series Maintenance Manual, Vol. 1 TOOLS REQUIRED Number 1 and number 2 Phillips screwdrivers American Standard Allen wrench set, American Standard nut driver set Utility knife, pliers, Metric/inch ruler Commercial Metric/English spring scale (0-2.25 Kg/0-5 lbs.) Polyester strip, 2 x 30 inches (5 cm x 76 cm), pn 01776 Media core, pn 01777 Anti-static protection system KIT PARTS See Parts List on page 2. 38455L Rev. 2 7/29/02 Page 1 of 10
KIT NO. 38455 PARTS LIST This kit includes the parts listed in Table 1 below. Before beginning the installation process, ensure all listed parts are enclosed.! QTY PART NUMBER DESCRIPTION 1 11301 Wrench, long, Allen, 7/64 inch 1 38366 Option Assembly, Media Rewind (All the parts listed below are part of the Media Rewind Option Assembly.) 1 01660 Grease, 1.4 oz. can 2 02252 E-ring 2 07435 Screw, Allen, 6-32 1 22004-1 Spacer (on rewind platen shaft) 1 30114 Washer, flat 1 30115 Washer, wave 1 30118 E-ring 1 30207 Shaft, idler pulley 1 30247 Washer, flat 1 30265 Pulley, idler 2 30392-004 Screw, Allen, 6-32 x 0.25 1 30392-006 Screw, Allen, 6-32 x 0.37 3 30393-006 Screw, Allen, 8-32 x 0.37 1 31336M Pulley Assembly, RTU/MTU 1 40019 Plate, roller adjust (also called platen support bracket) 6 40193 Washer, flat 1 45189-2 Belt, media rewind, 0.080 pitch x 255 teeth 1 46155M Spindle assembly, media rewind 1 46383 Plate assembly, rewind, std. 1 46278M Platen shaft, rewind (also called peel roller) 1 46609M Sensor assembly kit, take-label 1 46611 Upper sensor (transmitter) (black and blue leads) 1 46612 Lower sensor (detector) (black and green leads) 1 48018 Pulley assembly, rewind platen 2 49688 Ball bearing, flanged, sld. 1 38455L Installation instructions, media rewind option 1 47456L Installation instructions, platen roller kit 1 31336L Installation instructions, RTU/MTU pulley Page 2 of 10 38455L Rev. 2 7/29/02
PRINTER DISASSEMBLY CAUTION: The printer electronics are susceptible to static discharge. It is recommended the technician wear an anti-static wrist strap and attach it to the printer chassis. 1. Turn the printer OFF (0) and remove the power cord. 2. Open the side cover and remove media and ribbon. Close the side cover. 3. Properly connect yourself to an anti-static protection system. 4. Remove the left side panel of the printer by removing the Phillips screws that hold it on. REWIND OPTION INSTALLATION PROCEDURES Mechanical Parts Installation In the following procedures, reference to Figure 1 is required. Figure 1 illustrates the parts and assemblies that are contained in this option kit. It is generally a good practice to locate the parts you will be assembling and reference their position on the assembly drawing. NOTE: To avoid accidental damage, keep the printhead in the closed position. Figure 1. Rewind Option Assembly 38455L Rev. 2 7/29/02 Page 3 of 10
1. With the media access door open, locate and remove the plastic plug from the print mechanism side plate lower access hole. Retain the plastic plug for reassembly later. 2. Slide a flat washer, pn 40193, onto the Allen screw, pn 30392-006. Use the 7/64 inch Allen wrench, provided with this kit, to insert the screw and washer through the lower access hole and into the idler pulley mounting slot in the printer main frame. On the electronics side of the main frame, attach the idler pulley shaft, pn 30207, to the screw. 3. Position the idler pulley shaft in the middle of the mounting slot and tighten the mounting screw. Apply a very small amount of grease, pn 01660, to the idler pulley shaft. Be very careful to keep excess grease away from other components. 4. Slide the idler pulley, pn 30265, flat side out, onto the idler pulley shaft. 5. In the lower portion of the printer main frame, locate and remove the plastic plug from the media rewind spindle mounting hole. Discard this plastic plug. 6. Slide the bearing housing assembly off of the media rewind spindle assembly, pn 46155. 7. Install the bearing housing assembly on the printer main frame using three of the Allen screws, pn 30393-006, and three flat washers, pn 40193. Do not tighten the screws at this time. 8. Insert the shaft of the media rewind spindle assembly, pn 46155M, through the bearing housing assembly. 9. Place wave washer, pn 30115, flat washer, pn 30114, and RTU/MTU pulley, pn 31336, over the media rewind spindle shaft. Note: The countersunk side of pulley must face out. Secure the E-ring, pn 30118, into the groove in the spindle shaft. 10. Attach the roller adjust plate, pn 40019, to the print mechanism side plate with two washers, pn 40193, and two Allen screws, pn 30392-004. Do not tighten the screws at this time. 11. Install two E-rings, pn 02252, in the grooves on the ends of the rewind platen shaft, pn 46278M. 12. Remove the plastic plug from the rewind platen mounting hole near the bottom of the main frame. Discard this plastic plug. 13. Place the flanged ball bearing, pn 49688, wide end first, over the longer end of the rewindplatenshaft. 14. Insert the longer end of the rewind platen shaft and the bearing into the main frame mounting hole. 15. Place flat washer, pn 30247, and spacer, pn 22004-1, onto the right end of the rewind platen shaft. 16. Place the remaining flanged ball bearing, pn 49688, wide end first, over the right end of the rewind platen shaft and insert it into the mounting hole in the roller adjust plate. 17.Usea7/64inchAllenwrenchandtighten the mounting screws that secure the roller adjust plate to the side plate. The plate may need adjustment later. 18. Slide the rewind platen pulley, pn 48018, onto the rewind platen shaft, pn 46278M. Page 4 of 10 38455L Rev. 2 7/29/02
19. Align the two pulley set screws with the flat surfaces of the rewind platen shaft. Tighten them with a 1/16 inch Allen wrench. A clearance of approximately 6 mm (0.24 inch) should be available between the inside edge of the pulley and the main frame. Drive Belt Installation and Adjustment Refer to Figure 2 during the adjustment procedure that follows. If necessary, refer to the S-Series Maintenance Manual for further details of this procedure. 1. Use a 9/64 inch Allen wrench to loosen, but do not remove, the three Allen screws that hold the ribbon take-up spindle assembly at the top of the printer main frame. Access the Allen screws through the three holes in the ribbon take-up pulley. 2. Slide the ribbon take-up spindle assembly toward the front of the printer to relieve the belt tension. Remove the main drive belt from the stepper motor pulley. 3. Use a utility knife to carefully cut away and remove the clear plastic spacer on the stepper motor pulley. 4. Route the media rewind belt, pn 45189-2, around the stepper motor pulley, the media rewind pulley assembly, the rewind platen pulley, and the idler pulley. NOTE: At this point, both plastic washers on the stepper motor pulley must be positioned to the outside of the rewind belt. 5. Slide the media rewind assembly toward the rear of the printer until rewind belt tension is tight or adjustment margin is used up. Tighten the three Allen screws with a 9/64 inch Allen wrench. Access the Allen screws through the three holes in the media rewind pulley. 6. Grasp the idler pulley and shaft assembly while loosening the Allen screw with the long 7/64 inch Allen wrench. Slide the assembly toward the rear of the printer, until belt tension is tight, then tighten the Allen screw. 7. Hook a commercial spring scale at the midpoint of the lower section of the belt and pull up. Use a ruler to measure belt deflection. The belt should deflect 0.250 inches (6.35 mm) with a tension of 2000 grams (4.5 lbs). If the tension is not correct, readjust belt tension by changing the idler pulley position. 8. Once you complete the adjustment, reinstall the plastic plug in the print mechanism side plate access hole. 9. Replace the main drive belt over the stepper motor pulley, platen pulley, and ribbon take-up pulley. NOTE: Make sure one of the stepper motor pulley spacers is placed on each side of this drive belt. 10. Slide the ribbon take-up assembly toward the rear of unit until the belt tension is tight. Tighten the three Allen screws with a 9/64 inch Allen wrench using the three access holes in the ribbon take-up pulley. 11. Hook a commercial 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. Use a ruler to measure belt deflection. The belt deflection should be 0.250 inches (6.35 mm) with a tension of 2000 grams (4.5 lbs). If this tension is not correct, readjust belt tension by changing the position of the ribbon take-up assembly. 38455L Rev. 2 7/29/02 Page 5 of 10
Figure 2. Drive Belt Tension Adjustments Page 6 of 10 38455L Rev. 2 7/29/02
Take-Label Sensor Installation (Required for Peel-Off Operation ONLY) 1. Remove the plastic plugs from the upper and lower take-label sensor mounting holes by pushing them out from the inside of the electronics cabinet. Discard the plastic plugs. 2. Insert the upper take-label sensor assembly, pn 46611 (black and blue electrical leads), part of take label sensor assembly, pn 46609M, connector and cable through the upper take-label sensor hole in the printer main frame. 3. Position the sensor with the window facing directly down and use one screw, pn 07435, to fasten the sensor in place. 4. Route the wires alongside those of the adjacent head open sensor and through the cable clamp near the ribbon take-up pulley and attach the cable connector to J12 on the main logic board. NOTE: Make sure the wires do not come in contact with any moving parts. 5. Insert the lower take-label sensor assembly, pn 46612 (black and green electrical leads), part of take label sensor assembly, pn 46609M, connector and cable through the lower take-label sensor hole in the printer main frame. 6. Position the sensor with the window facing directly up and use one screw, pn 07435, to fasten the sensor in place. 7. Plug the cable connector into the mating connector on the LED display board. NOTE: Keep the cable away from any moving parts. Printer Reassembly 1. Replace the left side panel. Secure it with the Phillips screws. 2. Reconnect the AC power cord. 3. Printer reassembly is now complete. OPERATION Rewind Mode Refer to the printer s User s Guide for procedures for installing the rewind plate, pn 46383, and instructions to set the machine for rewind mode. Rewind mode rewinds a printed roll of continuous media or a printed roll with backing and labels. Peel-Off Mode To use this option to dispense individual labels and rewind the media backing only, refer to the User s Guide to set the machine for peel-off mode. The rewind plate is not used in the peel-off mode. 38455L Rev. 2 7/29/02 Page 7 of 10
Adjustments The rewind option kit usually requires adjustments to prevent printing problems such as ribbon wrinkle, non-centered labels, and tearing of the media. Print a number of test labels to check for problems. Use the following procedures to correct any problems. Rewind Mode Adjustments Tracking Adjustment If the media walks from side to side, or if it tears or wrinkles against the backing plate on the media rewind spindle, it may be necessary to adjust the position of the rewind plate assembly mounted on the front of the printer. Refer to Figure 3. Figure 3. Rewind Plate Assembly 1. Remove the rewind plate assembly from the front of the printer and loosen the 5/16 inch hex nuts that attach the hook plate to the rewind plate. 2. To force the media to wind closer to the large backing plate on the rewind spindle, move the outer end of the hook plate upward. or Move the outer end downward to force the media away from the backing plate. Page 8 of 10 38455L Rev. 2 7/29/02
3. Reinstall the rewind plate on the front of the printer and print a number of test labels. If problems persist, adjust the hook plate position again. Tension Adjustment 1. If media is rewound too tightly, label misregistration, label tearing, or poor print quality can occur. Media rewound too loosely can cause printer jamming or make it impossible to separate labels from backing in peel-off mode. Refer to Figure 4 to adjust the tension. Figure 4. Rewind Spindle Assembly Tension Adjustment 2. A commercial spring scale should be used to set the spindle tension. Use adhesive tape to attach a 2 inch wide by 30 inch long strip of polyester tape, pn 01776, to the media core, pn 01777, on the spindle in the direction shown in Figure 4. 3. Insert the spring scale tip through the reinforced hole in the end of the strip and pull slowly and evenly, 2 inch (51mm) per second, in the direction shown. Make this measurement several times to insure an accurate reading. This tension should be approximately 1400-1600 grams (3.14-3.60 lbs). 4. If required, readjust the tension as described below. 5. Use a 3/32 inch Allen wrench to loosen the set screw in the adjusting nut at the end of the rewind spindle shaft. 38455L Rev. 2 7/29/02 Page 9 of 10
6. Position the adjusting nut with fingers or pliers as required; inward (clockwise) for more tension, outward (counterclockwise) for less tension. If the spindle shaft turns with the adjustment nut, insert a 1/16 inch Allen wrench through the access hole at the rear of the spindle and into one of the slots in the plastic clutch. Hold the shaft in place with the Allen wrench while turning the adjustment nut. 7. Tighten the set screw in the adjustment nut prior to measuring the tension. 8. If proper tension is not achieved, loosen the set screw and reposition the adjusting nut. 9. When proper tension is obtained, tighten the set screw into the adjusting nut. 10. Recheck the tension after running a full roll of labels. NOTE: Depending on the width of the media and the thickness of the backing material, it may be necessary to deviate slightly from the recommended tension setting shown above. Peel-Off Mode Adjustments Lower Roller Adjustment The lower roller alignment has much the same effect on media tracking in peel-off mode as the rewind plate alignment does in rewind mode. Refer to Figure 1. 1. Use a 7/64 inch Allen wrench to loosen the two Allen screws, pn 30392-004, which attach the roller adjust plate, pn 40019, to the side plate. 2. Moving the plate toward the rear of the printer forces the media to wind closer to the large backing plate on the rewind spindle. Moving the plate toward the front of the machine moves the media away from the backing plate. Adjust as required and tighten the Allen screws. 3. Perform this adjustment until required results are achieved. Tension Adjustment For backing/label combinations that are particularly difficult, it may be necessary to increase rewind tension in the peel-off mode. Follow the same procedure that you would use for the rewind mode. Page 10 of 10 38455L Rev. 2 7/29/02