Xi ™- Series

XiIII™-
Maintenance Manual
 Xi ™- Series
XiIII™-
Maintenance Manual

48152L Rev. 1 07/00

48152L Rev. 1 07/00
 TABLE OF CONTENTS

TABLE OF CONTENTS

LIST OF TABLES ....................................................................... viii

LIST OF FIGURES ......................................................................... x

SECTION 1 SYSTEM DESCRIPTION

DESCRIPTION.........................................................................................................................1-1
SCOPE ......................................................................................................................................1-1
RELATED MANUALS............................................................................................................1-1
PRINTER SPECIFICATIONS .................................................................................................1-2
Options ..................................................................................................................................1-2
ZEBRA PROGRAMMING LANGUAGE II (ZPL II)............................................................1-2
BAR CODES ............................................................................................................................1-3
STANDARD PRINTER FONTS .............................................................................................1-4
MEDIA CONSIDERATIONS..................................................................................................1-8
RIBBON CONSIDERATIONS................................................................................................1-9
PRINTER CONSIDERATIONS ..............................................................................................1-9
GENERAL SPECIFICATIONS .............................................................................................1-10
ELECTRICAL REQUIREMENTS ........................................................................................1-10
ENVIRONMENTAL OPERATING RANGES .....................................................................1-10
COMMUNICATION SPECIFICATIONS.............................................................................1-11
Serial Data Communication Interface Overview.................................................................1-11
Communication Buffer ........................................................................................................1-12
Standard Serial Communication Connector ........................................................................1-12
Serial Communication Signal Levels ..................................................................................1-13
Communication Code..........................................................................................................1-14
Parallel Data Communications Interface Overview ............................................................1-14
Parallel Port Connector........................................................................................................1-14
Optional Interface Boards....................................................................................................1-15

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SECTION 2 OPERATIONS OVERVIEW

OPERATOR CONTROLS .......................................................................................................2-1
Front Panel Display ...............................................................................................................2-1
Front Panel Keys ...................................................................................................................2-2
Front Panel Lights .................................................................................................................2-3
LOADING MEDIA ..................................................................................................................2-4
Tear-Off Mode.......................................................................................................................2-4
Peel-Off Mode .......................................................................................................................2-5
Rewind Mode (for Printers Without the Cutter Option) .......................................................2-6
Cutter Mode...........................................................................................................................2-8
Rewind Mode (for Printers With the Cutter Option).............................................................2-9
Fanfold Media Loading .......................................................................................................2-10
Removing the Label Backing Material................................................................................2-12
Ribbon Loading ...................................................................................................................2-13
Ribbon Removal..................................................................................................................2-15
POSITIONING THE MEDIA SENSORS..............................................................................2-16
Transmissive Sensor............................................................................................................2-16
BLACK MARK SENSOR......................................................................................................2-17

SECTION 3 TROUBLESHOOTING
POWER-ON SELF TEST.........................................................................................................3-1
PRINTER SELF TESTS...........................................................................................................3-3
Introduction ...........................................................................................................................3-3
CANCEL Key Self Test ........................................................................................................3-3
PAUSE Key Self Test ...........................................................................................................3-4
FEED Key Self Test ..............................................................................................................3-4
FEED Key and PAUSE Key Self Test ..................................................................................3-5
PAUSE Key and CANCEL Key Self Test ............................................................................3-5
FEED Key and CANCEL Key Self Test...............................................................................3-6
Communications Diagnostics Test ........................................................................................3-6
EXTENDED PRINTER DIAGNOSTICS................................................................................3-7
PAUSE Key Loopback Test ..................................................................................................3-7
FEED Key Loopback Test.....................................................................................................3-8

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BASIC TROUBLESHOOTING.............................................................................................3-11
FACTORY ASSISTANCE.....................................................................................................3-16
Returning Equipment...........................................................................................................3-16

SECTION 4 MAINTENANCE
MAINTENANCE CONCEPTS................................................................................................4-1
Tools Required for Corrective Maintenance: ........................................................................4-1
Test Equipment Required ......................................................................................................4-1
PREVENTIVE MAINTENANCE............................................................................................4-2
Cleaning the Zebra Xi III Printer...........................................................................................4-2
Cleaning The Printhead .........................................................................................................4-3
Printhead Cleaning Procedure ...............................................................................................4-4
Cleaning the Upper Media Guide (Snap Plate): 140XiIII, 170XiIII, & 220XiIII. .................4-5
Cleaning the Upper Media Guide (Snap Plate): 90/96XiIII ..................................................4-6
CORRECTIVE MAINTENANCE ...........................................................................................4-7
Configuration.........................................................................................................................4-7
Entering the Setup Mode .......................................................................................................4-7
CALIBRATION .......................................................................................................................4-8
Media and Ribbon Sensor Sensitivity Calibration ................................................................4-8
Sensor Sensitivity ................................................................................................................4-11
Sensing Typical Thermal Transfer Non-Continuous Die Cut Labels. ................................4-11
Sensing Continuous Media..................................................................................................4-13
STANDARD KST PRINTHEAD REPLACEMENT ............................................................4-14
PRINTHEAD ADJUSTMENTS ............................................................................................4-17
Print Quality Adjustments ...................................................................................................4-17
Wear Plate Position Adjustment..........................................................................................4-19
Printhead Position Adjustment ............................................................................................4-20
Printhead Pressure Adjustment............................................................................................4-21
Strip Plate Adjustment.........................................................................................................4-22
Darkness Adjustment...........................................................................................................4-22
Media Tear-Off Position Adjustment..................................................................................4-23
TRANSMISSIVE MEDIA SENSOR POSITION ADJUSTMENT ......................................4-24
Reflective Media Sensor Adjustment ..................................................................................4-26

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LCD Viewing Adjustment...................................................................................................4-26

Take Label Sensor Alignment .............................................................................................4-26
MEDIA TRACKING ADJUSTMENTS ................................................................................4-27
Rewind Mode ......................................................................................................................4-27
Peel-Off Mode .....................................................................................................................4-28
Spindle Adjustment and Maintenance.................................................................................4-29
Tension Measurement Procedure ........................................................................................4-29
Spindle Tension Adjustment ...............................................................................................4-30
REMOVING THE MAIN LOGIC BOARD ..........................................................................4-32
Installing the Main Logic Board..........................................................................................4-32
REMOVING THE DC POWER SUPPLY ASSEMBLY ......................................................4-36
INSTALLING THE DC POWER SUPPLY ASSEMBLY ....................................................4-36
REMOVING THE AC POWER SUPPLY ASSEMBLY ......................................................4-37
INSTALLING THE AC POWER SUPPLY ASSEMBLY ....................................................4-37
MAIN DRIVE BELT - REMOVAL, REPLACEMENT & ADJUSTMENT ........................4-40
90/96XiIII, 140XiIII and 170XiIII........................................................................................4-40
220XiIII................................................................................................................................4-41
REWIND DRIVE BELT - REMOVAL, REPLACEMENT & ADJUSTMENT...................4-42
AC POWER FUSE REPLACEMENT ...................................................................................4-44
PLATEN ROLLER INSTALLATION...................................................................................4-46
Platen Roller Replacement ..................................................................................................4-46
Peel Option Lower Platen Roller Replacement...................................................................4-49
OPTION INSTALLATION....................................................................................................4-53
Font ROM Installation.........................................................................................................4-53
Memory Card and Font Card Installation............................................................................4-54
SIMM Installation ...............................................................................................................4-55
Optional Supply Spindle Installation...................................................................................4-56
Optional Bifold Door Installation........................................................................................4-60
Optional Counter Board Installation ...................................................................................4-61
Rewind Option.....................................................................................................................4-63
Optional Interface Boards....................................................................................................4-73
External PrintServer II Installation......................................................................................4-77
Coax Communications Interface Boards.............................................................................4-82

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APPLICATOR INTERFACE PORT/REAL TIME CLOCK.................................................4-86

Real Time Clock Commands...............................................................................................4-88
Cutter Option Kit.................................................................................................................4-96
Cutter Option Installation Procedures .................................................................................4-98
LCD Display ...........................................................................................................................4-99
Cutter Mechanical Assembly Installation .........................................................................4-101
Cutter Circuit Board and Optical Sensor Installation........................................................4-102

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

DESCRIPTION........................................................................................................................ 5–1

SECTION 6 MISCELANEOUS INFORMATION AND APPENDICES

ASCII CODE CHART..............................................................................................................6-2
SETTING BURN TEMPERATURE FOR IN SPEC BAR CODES........................................6-3
Printing Conditions................................................................................................................6-3

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LIST OF TABLES
Table 1-1 Font Matrices for 8 dot/mm (203 DPI) XiIII Printheads ............................................1-4
Table 1-2 Font Matrices for 12 dot/mm (300 DPI) XiIII Printheads ..........................................1-5
Table 1-3 Font Matrices for 24 dot/mm (600 DPI) 96 XiIII Printheads .....................................1-6
Table 1-4 Media Considerations .................................................................................................1-8
Table 2-1 Front Panel Keys.........................................................................................................2-2
Table 2-2 Front Panel Lights.......................................................................................................2-3
Table 3-1 Format Sequence.........................................................................................................3-6
Table 4-1 Recommended Preventive Maintenance Schedule......................................................4-2
Table 4-2 S1 Switch Position.....................................................................................................4-34
Table 4-3 DC Power Connections .............................................................................................4-51
Table 4-4 DC Power Connector Identification ..........................................................................4-57
Table 4-5 Kit Numbers ..............................................................................................................4-65
Table 4-6 Media Rewind Option Kit Parts List .........................................................................4-66
Table 4-7 Dip Switch Settings ...................................................................................................4-80
Table 4-8 Dip Switch Settings Coax Interface...........................................................................4-84
Table 4-9 Date & Time Command Characters ..........................................................................4-89
Table 4-10 Cutter Option Kit Parts List ...................................................................................4-96
Table 4-11 DC Power connectors.............................................................................................4-99
Table 5-1 90XiIII, 96XiIII, 140XiIII and 170XiIII Final Assembly Mechanical........................ 5–4
Table 5-2 Final Assembly All Printers (Electrical).................................................................... 5–6
Table 5-3 220XiIII Final Assembly Mechanical View 1 ........................................................... 5–8
Table 5-4 90/96XiIII, 140XiIII, 170XiIII Print Mechanism Assembly View 1........................ 5–10
Table 5-5 90/96XiIII, 140XiIII, 170XiIII Print Mechanism Assembly View 2........................ 5–12
Table 5-6 All Series Print Mechanism Assembly View 3 ....................................................... 5–14
Table 5-7 220XiIII Print Mechanism View 1........................................................................... 5–16
Table 5-8 220XiIII Printer Mechanism View 2........................................................................ 5–18
Table 5-9 90XiIII Printhead Support Assembly....................................................................... 5–20
Table 5-10 96XiIII Printhead Support Assembly..................................................................... 5–22
Table 5-11 140XiIII Printhead Support Bracket ...................................................................... 5–24
Table 5-12 170XiIII Printhead Support Assembly................................................................... 5–26
Table 5-13 220XiIII Printhead Support Assembly................................................................... 5–28
Table 5-14 Media Supply Hanger ............................................................................................ 5–30

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Table 5-15 Optional Media Supply Spindle............................................................................. 5–32

Table 5-16 Compliant Roller Assembly................................................................................... 5–34
Table 5-17 Ribbon Supply Spindle Assembly ......................................................................... 5–36
Table 5-18 Ribbon Take-Up Spindle Assembly ...................................................................... 5–38
Table 5-19 Media Rewind Assembly....................................................................................... 5–40
Table 5-20 Cutter Assembly .................................................................................................... 5–42

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LIST OF FIGURES
Figure 1-1 Default Fonts Examples ............................................................................................1-7
Figure 1-2 Interface Connections..............................................................................................1-11
Figure 1-3 RS-232 Signaling.....................................................................................................1-13
Figure 1-4 RS-422/RS-485 Signaling .......................................................................................1-13
Figure 2-1 Front Panel.................................................................................................................2-1
Figure 2-2 Roll Media Loading Tear-Off Mode .........................................................................2-4
Figure 2-3 Peel-Off Mode Loading.............................................................................................2-5
Figure 2-4 Rewind Mode w/o Cutter Option Loading................................................................2-7
Figure 2-5 Cutter Mode Loading ................................................................................................2-8
Figure 2-6 Rewind Mode w/Cutter Loading ...............................................................................2-9
Figure 2-7 Fan Fold Media Loading .........................................................................................2-11
Figure 2-8 Ribbon Installation ..................................................................................................2-14
Figure 2-9 Ribbon Removal......................................................................................................2-15
Figure 2-10 Upper Media Sensor Location...............................................................................2-16
Figure 2-11 Lower Media Sensor Location ..............................................................................2-17
Figure 3-1 CANCEL Key Test Sample Label ............................................................................3-3
Figure 3-2 PAUSE Key Test Sample Label................................................................................3-4
Figure 3-3 FEED Key Self Test Sample Label ...........................................................................3-5
Figure 3-4 Communications Diagnostics Self Test.....................................................................3-6
Figure 3-5 PAUSE Key Loopback Test Sample Label...............................................................3-7
Figure 3-6 Format 1 (4) Test Sample Label................................................................................3-8
Figure 3-7 Format 2 (5) Test Sample Label................................................................................3-8
Figure 3-8 Format 3 (6) Test Sample Label................................................................................3-9
Figure 3-9 Format 7 (11) Test Sample Label..............................................................................3-9
Figure 3-10 Format 8 (12) Test Sample Label............................................................................3-9
Figure 3-11 Format 9 (13) Test Sample Label..........................................................................3-10
Figure 3-12 Format 10 (14) Test Sample Label........................................................................3-10
Figure 4-1 Cleaning a Typical Printhead ....................................................................................4-4
Figure 4-2 Removal and Installation of Snap Plate for 140/170/220XiIII ..................................4-5
Figure 4-3 Removal and Installation of Snap Plate for 90/96XiIII .............................................4-6
Figure 4-4 Typical Media Sensor Profile..................................................................................4-12
Figure 4-5 Printhead Replacement............................................................................................4-16

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Figure 4-6 Printhead Adjustment Illustration............................................................................4-19

Figure 4-7 Printhead Pressure Adjustment................................................................................4-21
Figure 4-8 Tear-Off Position Adjustment .................................................................................4-23
Figure 4-9 Upper Media Sensor Position Adjustment ..............................................................4-25
Figure 4-10 Lower Media Sensor Position Adjustment ............................................................4-25
Figure 4-11 Take Label (Label Available) Sensor Location .....................................................4-26
Figure 4-12 Rewind Plate Assembly .........................................................................................4-27
Figure 4-13 Rewind Spindle Positioning...................................................................................4-28
Figure 4-14 Peel-Off Lower Roller Alignment..........................................................................4-29
Figure 4-15 Spindle Tension Adjustments ................................................................................4-31
Figure 4-16 Circuit Board Location and Interconnection..........................................................4-33
Figure 4-17 Main Logic Board and DC Power Supply Board...................................................4-35
Figure 4-18 AC Power Supply Board ........................................................................................4-38
Figure 4-19 90/96/140/170 XiIII Main Drive Belt.....................................................................4-40
Figure 4-20 220XiIII Main Belt .................................................................................................4-41
Figure 4-21 Rewind Drive Belt..................................................................................................4-43
Figure 4-22 AC Power Fuse Replacement.................................................................................4-44
Figure 4-23 International Safety Organizations.........................................................................4-45
Figure 4-24 Platen Roller Assembly..........................................................................................4-46
Figure 4-25 Left Side, Side Frame View of Main Drive Belt....................................................4-47
Figure 4-26 Print Mechanism ....................................................................................................4-48
Figure 4-27 DC Power PCB Location and Interconnections for XiIII Printers .........................4-51
Figure 4-28 Left Side, Side Frame View of Rewind Drive Belt................................................4-52
Figure 4-29 Print Mechanism View With Lower Platen Roller (Peel Option Only).................4-52
Figure 4-30 Font ROM Installation ...........................................................................................4-53
Figure 4-31 Memory and Font Card Installation .......................................................................4-54
Figure 4-32 SIMM Installation ..................................................................................................4-55
Figure 4-33 Main Logic Board ..................................................................................................4-56
Figure 4-34 Rear View...............................................................................................................4-57
Figure 4-35 Mounting Bracket Removal ...................................................................................4-58
Figure 4-36 Removal and Installation........................................................................................4-58
Figure 4-37 Spindle tension adjustment ....................................................................................4-59
Figure 4-38 Old Door Removal .................................................................................................4-60

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Figure 4-39 New Bifold Door Installation.................................................................................4-60

Figure 4-40 Side View of Printer...............................................................................................4-61
Figure 4-41 DC Power Supply...................................................................................................4-63
Figure 4-42 Rewind Assembly Installation ...............................................................................4-64
Figure 4-43 Label Available Sensor Location ...........................................................................4-69
Figure 4-44 Position Adjustment of Rewind Spindle Assembly ...............................................4-71
Figure 4-45 Tension Adjustment of Rewind Spindle Assembly ...............................................4-72
Figure 4-46 Internal PrintServer II.............................................................................................4-73
Figure 4-47 Configuration Label Internal PrintServer II ...........................................................4-74
Figure 4-48 Rear View...............................................................................................................4-75
Figure 4-49 Interface Board Location........................................................................................4-76
Figure 4-50 External PrintServer II ...........................................................................................4-77
Figure 4-51 Twinax Installation.................................................................................................4-78
Figure 4-52 Coax Communications Interface Board Installation ..............................................4-82
Figure 4-53 Applicator/Real Time Clock Installation ...............................................................4-87
Figure 4-54 Printed Result of the Example ZPL II Script .........................................................4-95
Figure 4-55 Part Identification Cutter Option............................................................................4-97
Figure 4-56 DC Power PCB location and interconnections for XiIII printers ...........................4-99
Figure 4-57 Cover Plate Locations ..........................................................................................4-100
Figure 4-58 Mechanical Side Assembly ..................................................................................4-100
Figure 4-59 Cutter Mechanical Assembly Positioning ............................................................4-103
Figure 4-60 Linkage and circuit board installation..................................................................4-103
Figure 4-61 Cutter Option Circuit Board.................................................................................4-104
Figure 4-62 Cutter Motor Leads ..............................................................................................4-104
Figure 5-1 Final Assembly 90/96XiIII, 140XiIII and 170XiIII Mechanical............................... 5–5
Figure 5-2 Final Assembly All Printers Electrical ..................................................................... 5–7
Figure 5-3 220XiIII Final Assembly Mechanical....................................................................... 5–9
Figure 5-4 90/96XiIII, 140XiIII and 170XiIII Print Mechanism Assembly View 1 ................ 5–11
Figure 5-5 90/96XiIII, 140XiIII and 170XiIII Print Mechanism Assembly View 2 ............... 5–13
Figure 5-6 All Series XiIII Print Mechanism Assembly View 3.............................................. 5–15
Figure 5-7 220XiIII Print Mechanism View 1 ......................................................................... 5–17
Figure 5-8 220XiIII Print Mechanism View 2 ......................................................................... 5–19
Figure 5-9 90XiIII Print Head Support Assembly.................................................................... 5–21

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Figure 5-10 96XiIII Print Head Support Assembly.................................................................. 5–23

Figure 5-11 140XiIII Print Head Support Assembly................................................................ 5–25
Figure 5-12 170XiIII Print head Support Bracket .................................................................... 5–27
Figure 5-13 220XiIII Print Head Support Assembly................................................................ 5–29
Figure 5-14 Media Supply Hanger........................................................................................... 5–31
Figure 5-15 Optional Media Supply Spindle ........................................................................... 5–33
Figure 5-16 Compliant Roller Assembly ................................................................................. 5–35
Figure 5-17 Ribbon Supply Spindle Assembly........................................................................ 5–37
Figure 5-18 Ribbon Take-Up Spindle Assembly..................................................................... 5–39
Figure 5-19 Media Rewind Assembly ..................................................................................... 5–41
Figure 5-20 Cutter Assembly ................................................................................................... 5–43
Figure 5-21 Cutter Option Assembly View 2 .......................................................................... 5–44
Figure 6-1 Bar Code Examples ...................................................................................................6-4

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Notes

xiv XiIII Maintenance Manual 48152L Rev. 1 07/00

SYSTEM DESCRIPTION SECTION 1

SECTION 1 SYSTEM DESC RIPTION

DESCRIPTION
The Zebra XiIII™-Series thermal transfer demand printers are versatile label and ticket printers
designed to print high quality bar codes, various sizes and styles of alphanumeric characters, and
graphics in either the thermal transfer or direct thermal mode. The XiIII-Series printers have the
flexibility to meet a variety of applications. The Zebra Programming Language II (ZPL II®) allows
the programmer to format the printed material. ZPL II is transparent to protocol converters and
allows the XiIII-Series printers to be easily integrated with most systems and host mainframes.

SCOPE
This manual contains the information necessary for the proper maintenance of the Zebra 90XiIII™,
96XiIII™, 140XiIII™, 170XiIII™, and 220XiIII™ printers. Information presented applies to all
XiIII-Series models, unless otherwise indicated.

Section 1 System Description provides an overview of the contents of this maintenance manual.
Also contains overall description and specifications of the XiIII Series printers.

Section 2 Operation Overview details the printer operator controls, power and data cable hook-up,
loading supplies in all modes, setting up software, calibration and configuration.

Section 3 Troubleshooting presents the diagnostic tests that are built into the XiIII-Series printers.
Examples of the labels that print for most of these diagnostic tests are illustrated and contains
troubleshooting tables showing symptom, diagnosis and action columns to assist the repair
technician in quickly locating and repairing a printer fault. Example labels illustrate several
common misalignment conditions and the best methods of adjustment.

Section 4 Maintenance discusses the recommended cleaning procedures for the printer and the
printhead. Recommended cleaning agents and a preventive maintenance schedule are specified.
Provides disassembly, replacement and reassemble instructions for the XiIII printers. Required tools
and test equipment is specified. Adjustment procedures are provided along with the required
tensions, torque and tolerances. Instructions on AC power fuse replacement are also contained in
this section.

Section 5 Maintenance and Assembly Drawings provides the assembly drawing and parts lists.

Section 6 Miscellaneous Information and Appendices contains reference material that will assist
the technician when installing and maintaining the printer.

RELATED MANUALS
A further description of the XiIII printer models may be found in the XiIII-Series User Guide (PN
48025L). More information on ZPL II programming language can be found in the ZPL II
Programming Guide Volume 1: Command Reference (PN 45541L), ZPL II Programming Guide
Volume 2: (PN 45542L) and the ZebraNet® Networking: Print Server II™ Operations Guide
(PN 45537L).

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SECTION 1 SYSTEM DESCRIPTION

This section of the manual is intended to supplement the printer’s User's Guide by providing
additional information to aid the service technician in troubleshooting and maintaining the printer.

PRINTER SPECIFICATIONS
Options
• Cutter • IBM twinax interface
• Rewind • IBM coax interface
• Bar-One® Windows™-based WYSIWYG • ZebraNet PrintServer II, including Ethernet
on-screen label design and print application interface (10Base-T), WebView graphical
software setup and printer control, and Alert
unsolicited error notification
• Cutter tray • RS-485 interface
• Cutter-rewind • Downloadable Fonts
• Media supply spindle (1.6”/40 mm core) • Font cards
• Media supply spindle (3”/76 mm core) • DRAM memory expandable to 12 MB
• Double-hinged media door with clear panel • Memory cards
• Applicator interface • Printer drivers for Windows operating
systems
• Real time clock • Advanced counter

ZEBRA PROGRAMMING LANGUAGE II (ZPL II)

• Downloadable graphics, scalable and bitmap • Controlled via mainframe, mini- computer,
fonts, and label formats PC, portable data terminal
• Object copying between memory areas • Programmable quantity with print, pause,
(RAM, memory card, and internal FLASH) and cut control
• Code Page 850 character set • Communicates in printable ASCII characters
• Adjustable print cache • Error-checking protocol
• Data compression • Slew command
• Automatic virtual input buffer management • Serialized fields
• Automatic memory allocation • In-spec OCR-A and OCR-B
• Format inversion • UPC/EAN
• Mirror image printing • User-programmable password
• Four-position field rotation (0º, 90º, 180º, • Status message to host upon request
and 270º)

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SYSTEM DESCRIPTION SECTION 1

BAR CODES
• Bar code ratios - 2:1, 7:3, 5:2, & 3:1 • ISBT-128
• Codabar (supports ratios of 2:1 up to 3:1) • LOGMARS
• CODABLOCK • MaxiCode
• Code 11 • Micro PDF
• Code 39 (supports ratios of 2:1 up to 3:1) • MSI
• Code 49 (2-dimensional bar code) • PDF-417 (2-dimensional bar code)
• Code 93 • Plessey
• Code 128 (with subsets A, B, and C and • POSTNET
UCC case C codes)
• Data Matrix • QR-Code
• EAN-8, EAN-13, EAN extensions • Standard 2 of 5
• Industrial 2 of 5 • UPC-A, UPC-E, UPC extensions
• Interleaved 2 of 5 (supports ratios of 2:1 up • Check digit calculation where applicable
to 3:1, Modulus 10 Check Digit)

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SECTION 1 SYSTEM DESCRIPTION

STANDARD PRINTER FONTS

Fonts A, B, C,D,E,F,G,H, and GS are expandable up to 10 times, height and width independently.
However, fonts E and H (OCR-A and OCR-B) are not considered “in-spec" when expanded.
The scalable smooth font 0 (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 available memory.
IBM Code Page 850 international character sets are available in the fonts A, B, C, D, E, F, G, and 0
through software control.

Font Matrix Type* Character Size

Inches Millimeters

Char/inch

Char/inch
character
Height

Height

Height
Width

Width

Width
Inter-

Gap

A 9 5 1 U-L-D 0.044 0.029 33.90 1.13 0.75 1.33

B 11 7 2 U 0.054 0.044 22.60 1.38 1.13 0.89
C,D 18 10 2 U-L-D 0.088 0.059 16.95 2.25 1.50 0.67
E 28 15 5 OCR-B 0.138 0.098 10.17 3.50 2.50 0.40
F 26 13 3 U-L-D 0.128 0.079 12.71 3.25 2.00 0.50
G 60 40 8 U-L-D 0.295 0.236 4.24 7.50 6.00 0.17
H 21 13 6 OCR-A 0.103 0.093 10.71 2.63 2.38 0.42
GS 24 24 0 SYMBOL 0.118 0.118 8.48 3.00 3.00 0.33
P 20 18 N/A U-L-D .098 .089 N/A 2.49 2.26 N/A
Q 28 24 N/A U-L-D .138 .118 N/A 3.51 2.99 N/A
R 35 31 N/A U-L-D .172 .153 N/A 4.37 3.89 N/A
S 40 35 N/A U-L-D .197 .172 N/A 5.00 4.37 N/A
T 48 42 N/A U-L-D .236 .207 N/A 5.99 5.26 N/A
U 59 53 N/A U-L-D .290 .261 N/A 7.37 6.63 N/A
V 80 71 N/A U-L-D .394 .349 N/A 10.0 8.86 N/A
0 Default: 15 x 12 U-L-D Scalable
*U = Uppercase, L = Lowercase, D = Descenders

Table 1-1 Font Matrices for 8 dot/mm (203 DPI) XiIII Printheads

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SYSTEM DESCRIPTION SECTION 1

Font Matrix Type* Character Size

Inches Millimeters

Char/inch

Char/inch
character
Height

Height

Height
Width

Width

Width
Inter-

Gap
A 9 5 1 U-L-D .030 0.020 50.00 0.76 0.51 1.97
B 11 7 2 U .037 0.030 33.33 0.93 0.76 1.31
C,D 18 10 2 U-L-D .060 0.040 25.00 1.53 1.02 0.98
E 41 20 6 OCR-B .137 0.087 11.54 3.47 2.20 0.45
F 26 13 3 U-L-D .087 0.053 18.75 2.20 1.36 0.74
G 60 40 8 U-L-D .200 0.160 6.25 5.08 4.07 0.25
H 30 19 9 OCR-A .100 0.093 10.71 2.54 2.37 0.42
GS 24 24 0 SYMBOL .080 0.080 12.50 2.03 2.03 0.49
P 20 18 N/A U-L-D .098 .089 N/A 2.49 2.26 N/A
Q 28 24 N/A U-L-D .138 .118 N/A 3.51 2.99 N/A
R 35 31 N/A U-L-D .172 .153 N/A 4.37 3.89 N/A
S 40 35 N/A U-L-D .197 .172 N/A 5.00 4.37 N/A
T 48 42 N/A U-L-D .236 .207 N/A 5.99 5.26 N/A
U 59 53 N/A U-L-D .290 .261 N/A 7.37 6.63 N/A
V 80 71 N/A U-L-D .394 .349 N/A 10.0 8.86 N/A
0 Default: 15 x 12 U-L-D Scalable
*U = Uppercase, L = Lowercase, D = Descenders

Table 1-2 Font Matrices for 12 dot/mm (300 DPI) XiIII Printheads

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SECTION 1 SYSTEM DESCRIPTION

Font Matrix Type* Character Size

Inches Millimeters

Char/inch

Char/mm
character
Height

Height

Height
Width

Width

Width
Inter-

Gap
A 9 5 1 U-L-D .015 0.010 100.00 0.38 0.25 4.00
B 11 7 2 U .018 0.015 66.66 0.46 0.38 2.60
C,D 18 10 2 U-L-D .030 0.020 50.00 0.77 0.51 2.00
E 82 40 6 OCR-B .137 0.087 11.54 3.47 2.20 0.45
F 26 13 3 U-L-D .043 0.027 37.50 1.10 0.68 1.50
G 60 40 8 U-L-D .100 0.080 12.50 2.54 2.04 0.50
H 60 38 9 OCR-A .100 0.093 10.71 2.54 2.37 0.42
GS 24 24 0 SYMBOL .040 .040 25.00 1.02 1.02 1.00
P 20 18 N/A U-L-D .098 .089 N/A 2.49 2.26 N/A
Q 28 24 N/A U-L-D .138 .118 N/A 3.51 2.99 N/A
R 35 31 N/A U-L-D .172 .153 N/A 4.37 3.89 N/A
S 40 35 N/A U-L-D .197 .172 N/A 5.00 4.37 N/A
T 48 42 N/A U-L-D .236 .207 N/A 5.99 5.26 N/A
U 59 53 N/A U-L-D .290 .261 N/A 7.37 6.63 N/A
V 80 71 N/A U-L-D .394 .349 N/A 10.0 8.86 N/A
0 Default: 15 x 12 U-L-D Scalable (smooth) font
*U = Uppercase, L = Lowercase, D = Descenders

Table 1-3 Font Matrices for 24 dot/mm (600 DPI) 96 XiIII Printheads

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SYSTEM DESCRIPTION SECTION 1

FONT E -- (OCR-B) ABCDwxyz 12345

FONT H -- (OCR-A) UPPER CASE ONLY

FONT U--

FONT V--

Figure 1-1 Default Fonts Examples

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SECTION 1 SYSTEM DESCRIPTION

MEDIA CONSIDERATIONS

Media Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII

Tear-off 0.7" (18 mm) 0.7" (18 mm) 0.7" (18 mm) 0.7" (18 mm)
Peel-off 0.5" (13 mm) 0.5" (13 mm) 0.5" (13 mm) 0.5" (13 mm)
Minimum label length
Cutter 1.5" (38 mm) 1.5" (38 mm) 1.5" (38 mm) 1.5" (38 mm)
Rewind 0.25" (6 mm) 0.25" (6 mm) 0.25" (6 mm) 0.25" (6 mm)
Total media width Minimum 0.79" (20 mm) 1.57” (40 mm) 2.00” (51 mm) 4.25” (108 mm)
(Includes + liner, if any) Maximum 3.54" (90 mm) 5.51” (140 mm) 7.1” (180 mm) 8.80” (224 mm)
Total thickness Minimum 0.003” (0.076 mm) 0.003” (0.076 mm) 0.003” (0.076 mm) 0.003” (0.076 mm)
(includes liner, if any) Maximum 0.012” (0.305 mm) 0.012” (0.305 mm) 0.012” (0.305 mm) 0.012” (0.305 mm)
Cutter maximum full-width
.014" (.35 mm) 009" (.23 mm) .007" (.18 mm) .005" (.14 mm)
media thickness
Roll media core inside diameter 3” (76 mm) 3” (76 mm) 3” (76 mm) 3” (76 mm)
Maximum roll diameter 8.0” (203 mm) 8.0” (203 mm) 8.0” (203 mm) 8.0” (203 mm)
Minimum 0.079” (2 mm) 0.079” (2 mm) 0.079” (2 mm)
Preferred 0.118” (3 mm) 0.118” (3 mm) 0.118” (3 mm)
Inter-label gap
Maximum inter-label gap =
Maximum
2 x (label length for which you have calibrated the printer) + 1”
Maximum internal fanfold media 8.0” x 3.54” x 4.5” 8.0” x 5.51” x 4.5” 8.0” x 7.1” x 4.5” 8.0” x 8.8” x 4.5”
pack size (label + liner) L x W x H (203x90x114 mm (203x140x114 mm) (203x180x114 mm) (203x224x114 mm)
0.12" x .25" 0.12" x .25" 0.12" x .25" 0.12" x .25"
Ticket/tag sensing notch L x W
(3 mm) x (6 mm) (3 mm) x (6 mm) (3 mm) x (6 mm) (3 mm) x (6 mm)
Ticket/tag sensing hole diameter 0.125" (3 mm) 0.125" (3 mm) 0.125" (3 mm) 0.125" (3 mm)
Effective leading edge Vertical 0.060” (±1.5 mm) ±0.070” (±1.8 mm) 0.060” (±1.5 mm) ±0.050” (±1.3 mm)
registration accuracy* Horizontal 0.060” (±1.5 mm) ±0.070” (±1.8 mm) 0.060” (±1.5 mm) 0.060” (±1.5 mm)
Mark length
(measuring Minimum 0.12” (3 mm) 0.12” (3 mm) 0.12” (3 mm) 0.12” (3 mm)
parallel to
label/tag Maximum 0.43” (11 mm) 0.43” (11 mm) 0.43” (11 mm) 0.43” (11 mm)
edge)
Mark width
Additional (measuring Minimum 0.43” (11 mm) 0.43” (11 mm) 0.43” (11 mm) 0.43” (11 mm)
specs. for perpendicula
black r to label/tag Maximum Full media width Full media width Full media width Full media width
mark edge
sensing Mark location Marks must be located within .040" (1 mm) of the inside media edge.
> 1.0 ODU > 1.0 ODU > 1.0 ODU > 1.0 ODU
Mark density
(Optical Density Unit) (Optical Density Unit) (Optical Density Unit) (Optical Density Unit)
Maximum density of the
back of the media on
0.5 ODU 0.5 ODU 0.5 ODU 0.5 ODU
which the black mark is
printed

* Media registration and minimum label length are affected by media type and width, ribbon type,
print speed, and printer mode of operation. Performance improves as these factors are optimized.
Zebra recommends always qualifying any application with thorough testing.

Table 1-4 Media Considerations

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 SYSTEM DESCRIPTION SECTION 1

RIBBON CONSIDERATIONS

Ribbon Specifications 90/96XiIII 140XiIII 170XiIII 220XiIII

Ribbon width (To protect the
print head from wear, Zebra Maximum 3.4" 87 mm 5.10“ 130 mm 7" 170 mm 8.60" 220 mm
recommends using ribbon at least
as wide as the media you are Minimum 0.79" 20mm 1.57" 40 mm 2.0" 51 mm 4.33" 110 mm
using.)
2:1 media to ribbon roll
984' 300 m 984' 300 m 984' 300 m 984' 300 m
Standard ratio
lengths 3:1 media to ribbon roll
1476' 450 m 1476' 450 m 1476' 450 m 1476' 450 m
ratio
Inner diameter of core 1.0" 25.4 mm 1.0" 25.4 mm 1.0" 25.4 mm 1.0" 25.4 mm
Roll size Outside diameter of full
3.2" 81.3 mm 3.2" 81.3 mm 3.2" 81.3 mm 3.2" 81.3 mm
ribbon roll

PRINTER CONSIDERATIONS

Printing Specifications 90XiIII 96XiIII 140XiIII 170XiIII 220XiIII

300 dots per inch 600 dots/inch 203 dots per inch 300 dots per inch 203 dots per inch
Resolution
12 dots/mm 23.5 dots/mm 8 dots/mm 12 dots/mm 8 dots/mm
0.0033" x 0.0039 0.0016”x0.0016” 0.0049" x 0.0049 0.0033" x 0.0039" 0.0049" x 0.0049"
Dot size (square)
0.085 x 0.100 mm .042 x.042 mm 0.125 x 0.125 mm 0.085 x 0.100 mm 0.125 x 0.125 mm
0.12" ± .035" 0.12" ± .035" 0.10" ± .035" 0.10" ± .035" 0.10" ± .035"
First dot location
(3 mm ±.89mm) (3 mm ±.89mm) (2.5 mm ±.89mm) (2.5 mm ±.89mm) (2.5 mm ±.89mm)

Max print width 3.4" (86 mm) 3.2” (81 mm) 5.04 (128 mm) 6.6" (168 mm) 8.5" (216 mm)

Non- Standard memory 39" (991 mm) 20" (508 mm) 39" (991 mm) 39" (991 mm) 39" (991 mm)
continuous
printing 12 Mbyte memory 39" (991 mm) 39" (991 mm) 39" (991 mm) 39" (991 mm) 39" (991 mm)
Print
length
(max) Standard memory 80” (2032 mm) 20" (508 mm) 121” (3073 mm) 41” (1041 mm) 71” (1803 mm)
Continuous
printing 12 Mbyte
100” (2540 mm) 52” (1321 mm) 150” (3810 mm) 100” (2540 mm) 150” (3810 mm)
additional memory
Ladder (rotated)
3.9 mil to 39 mil 1.6 mil to 16 mil 4.9 mil to 49 mil 3.9 mil to 39 mil 4.9 mil to 49 mil
Bar code modulus orientation
(“X”) dimension Picket fence
3.33 mil to 33mil 1.6 mil to 16 mil 4.9 mil to 49 mil 3.33 mil to 33mil 4.9 mil to 49 mil
(non-rotated)
Thin film printhead with Element Energy
Yes Yes Yes Yes Yes
Equalizer (E3)

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SECTION 1 SYSTEM DESCRIPTION

GENERAL SPECIFICATIONS

Physical
90/96XiIII 140XiIII 170XiIII 220XiIII
Characteristics
Height 15.5" 393.7 mm 15.5" 393.7 mm 15.5" 393.7 mm 15.5" 393.7 mm
Width 9.15" 232.4 mm 11.15" 283.2 mm 13.15" 334.4 mm 15.65" 397.5 mm
Depth 19.5" 495.3 mm 19.5" 495.3 mm 19.5" 495.3 mm 19.5" 495.3 mm
Weight (without options) 50 lb 22.7 kg 55 lb 25 kg 67 lb 30.5 kg 72 lb 32.7 kg

ELECTRICAL REQUIREMENTS
• Autoselect 90-264 VAC; 48-62 Hz
• 5 Amps for entire AC voltage range
• 25 Watts standby power consumption
• 200/300/350/450 Watts maximum power consumption for 90 XiIII, 96XiIII, 140XiIII, 170XiIII,
220XiIII respectively. (printing 100% black at 6 ips)
• UL 1950 Listed - Certified to CAN/CSA-C22.2 No. 950-M89 and IEC 950
• Complies with CISPR22B and with FCC and Canadian DOC class “A” rules
• Carries the CE mark of compliance

ENVIRONMENTAL OPERATING RANGES

Temperature Operating
Thermal Transfer: +41oF to +104oF (+5oC to +40oC)
Direct Thermal: +32oF to +104oF (0oC to +40oC)
Storage -40oF to +140oF (-40oC to +60oC)
Non-condensing relative Operating 20% to 85%
humidity Storage 5% to 85%

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SYSTEM DESCRIPTION SECTION 1

COMMUNICATION SPECIFICATIONS
Serial Data Communication Interface Overview
The Zebra XiIII has a single data terminal equipment (DTE) port that supports RS-232, RS-422 and
RS-485 serial data communications. Baud rate, parity, data length, stop bits, and XON/XOFF or
DTR control protocols are front panel selectable. Refer to Figure 1-2. A 25-pin DB25S connector at
the rear of the printer provides the data and control leads necessary to communicate through all three
signaling methods. The method used is specific to the application of the printer.
For all RS-232 data and control input and output signals, the Zebra XiIII follows both the Electronic
Industries Association’s (EIA) RS-232 and the Consultative Committee for International Telegraph
and Telephone (CCITT) V.24 specifications.

RS-232 Connector (DTE)

Rear Panel DB-25S
J3
1 Frame Ground

2 TXD (Transmit Data Output)

3 RXD (Receive Data Input)

4 RTS (Request To Send Output)

6 DSR (Data Set Ready Input)

+5 V 7 Signal Ground
F1
1 Amp 9 +5 VDC Source

20 DTR (Data Terminal Ready Output)

Parallel
Interface
Connector
RS-422/RS-485 Connector
Rear Panel DB-25S
+5 V J3
F1
9 +5 VDC Source
1 Amp
14 Output B (-)
DB-25 Serial 19 Output A (+)
+5 V
Interface 10k
Connector 13 Input B (-)
20k
16 Input A (+)
10k 100
11 Signal Ground Ref.

1 Frame Ground

AC Power
On/Off SwitcH

AC Power
Cable Connection

Figure 1-2 Interface Connections

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SECTION 1 SYSTEM DESCRIPTION

Communication Buffer
The XiIII-Series printer has a communication buffer that stores the incoming data until that
information can be acted upon (imaged). Communication handshaking (DTR/DSR control signals
or XON/XOFF control codes) is used to control when the host can send data to the printer.
The size of the buffer is 5000 characters. As data is received by the XiIII-Series printer, the
processor monitors the number of characters in the buffer. If the buffer is filled beyond 4744
characters, the XiIII will turn the DTR control lead to the OFF condition (negative voltage) or
transmit an XOFF (DC-3) control character to the host. When the buffer empties below 4250
characters, the XiIII will turn DTR to the ON condition (positive voltage) or transmit an XON
(DC-1) control character to the host.
Standard Serial Communication Connector
The DTE port is a DB25S connector located at the rear of the XiIII-Series printer. It provides
connection to a host via RS-232, RS-422 or RS-485 signaling. Refer to Figure 1-2 for wiring
diagrams.
The pin outs and signal descriptions for the DTE port are as follows:
Pin 1—FG (Frame ground) for cable shield.
Pin 2—TXD (RS-232 Transmit Data): Output from printer
Pin 3—RXD (RS-232 Receive Data): Input to printer
Pin 4—RTS (RS-232 Request to Send): Output from printer
Pin 6—DSR (RS-232 Data Set Ready): Input to printer
Pin 7—SG (Signal ground) for RS-232
Pin 9—+5VDC source (1 Amp maximum)
Pin 11—SGR (Signal ground reference) RS-422/RS-485
Pin 13—Data input B(-) RS-422/RS-485
Pin 14—Data output B(-) RS-422/RS-485
Pin 16—Data input A(+) RS-422/RS-485
Pin 19—Data output A(+) RS-422/RS-485
Pin 20—DTR (RS-232 Data Terminal Ready):
NOTE: Pins 5, 8, 10, 12, 15, 17-18 and 21-25 are not used and are not terminated.

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 SYSTEM DESCRIPTION SECTION 1

Serial Communication Signal Levels

Refer to Figure 1-3. RS-232 data signals are defined as either Mark or Space, while control signals
are ON (Active-Positive Voltage) or OFF (Inactive-Negative Voltage). Although the permitted
voltage levels can range from ±3VDC to ±25VDC, the levels for the XiIII-Series printer are as
follows:

RS-232 Transmit and Receive Data

Mark or OFF = -7 to -10 VDC

Space or ON = +7 to +10 VDC

Start Parity
Bit Data Bits Bit
+Space

0 Vdc
1 2 3 4 5 6 7
(idle)
- Mark
(idle)
Logic 1 Stop
Logic 0 Bit
Figure 1-3 RS-232 Signaling

Refer to Figure 1-4. RS-422 and RS-485 data signals are also either Mark or Space. The voltage
levels are +5 VDC and 0 VDC when monitored from a specified reference point. The levels for the
XiIII-Series printer, when referenced to signal ground are:

RS-422 and RS-485 Transmit and Receive Data

Mark Output/Input A = +5V and Output/Input B = 0V

Space Output/Input A = 0V and Output/Input B = +5V

Logic 0
Stop
Logic 1 Bit
Mark (Idle) (Idle)
(+5 VDC)
1 2 3 4 5 6 7

(0 VDC)
Space
Start Data Bits Parity
Bit Bit

Figure 1-4 RS-422/RS-485 Signaling

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SECTION 1 SYSTEM DESCRIPTION

Communication Code
The XiIII-Series printer sends and receives ASCII (American Standard Code for Information
Interchange) characters in one of two formats, Serial Data or Parallel Data.

NOTE: When using the serial data format, the baud rate, number of data and stop bits per
character, and parity are selectable. Parity only applies to data transmitted by the XiIII-
Series printer. For received data, the parity bit is ignored.

Parallel Data Communications Interface Overview

A standard 36-pin parallel connector is available at the rear of the printer for connection to the data
source. Under normal circumstances, data sent from the printer to the host in response to a “Printer
Status Request” command is sent through the RS-232 serial port. However, if the host has a
properly configured IEEE-1284 parallel port that is recognized by the printer, status information will
be returned through the parallel port. Port selection for status information is determined each time
the printer is turned on.
Parallel Port Connector
The following table shows the pin configuration and function of a standard PC-to-Printer
Centronics® Parallel cable.

36-pin Connector Description

1 nStrobe/HostClk
2-9 Data Bits 1-8
10 nACK/PtrClk
11 Busy/PtrBusy
12 PError/ACKDataReq
13 Select/Xflag
14 nAutoFd/HostBusy
15 Not Used
16 & 17 Ground
18 +5V @ 1A
19-30 Ground
31 ninit
32 nFault/NDataAvail
33 & 34 Not Used
35 +5V through a 4.7 KW Resistor
36 NSelectIn/1284 active

NOTE: Optional Ethernet Networking Communications via ZebraNet PrintServer II. Refer to
the ZebraNet Networking: PrintServer II Operating Guide (45537L) when using this
communications option.

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SYSTEM DESCRIPTION SECTION 1

Optional Interface Boards

For information about the IBM® plug-compatible Twinax Interface, the IBM® plug-compatible
Coax Interface, the RS-485 network interface, refer to the instructions that accompany the interface
option kits.
DATA Status Indicator: ON indicates that data processing or printing is taking place, but no data is
being received. OFF indicates that no data is being received or processed. FLASHING indicates
that data is being received. (Flashing slows down when the printer is unable to accept any more data
due to the data input buffer being full. Flashing returns to normal rate when the data input buffer is
no longer full and data is again being received.)

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SECTION 1 SYSTEM DESCRIPTION

Notes

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OPERATION OVERVIEW SECTION 2

SECTION 2 OPERATIONS O VERVIEW

OPERATOR CONTROLS
This section discusses the functions of the various controls and indicators on the printer. The
operator should become familiar with each of these functions.

Front Panel Display

The Front Panel Display communicates operational and programming modes and parameters.

Figure 2-1 Front Panel

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SECTION 2 OPERATION OVERVIEW

Front Panel Keys

Refer To Figure 2-1.

Key Function
Starts and stops the printing process.
• If the printer is not printing: no printing can occur.
• If the printer is printing: printing stops once the current label is complete.
Press to remove error messages from the display.

NOTE: Pause mode can also be activated via ZPL II (~PP, ^PP).
Forces the printer to feed one blank label each time the key is pressed.
• Printer not printing: one blank label immediately feeds.
• Printing: one blank label feeds after the current batch of labels is complete.

NOTE: Equivalent to the Slew to Home Position (~PH, ^PH) ZPL II instruction.
When in the pause mode, this key will cancel print jobs.
• Print job in queue: press once for each print job to be deleted.
• Press and hold for several seconds to cancel all print jobs in the printer’s
memory. The DATA light will turn off.
When in Pause mode, this key will calibrate the printer for:
• Media length.
• Media type (continuous or non-continuous).
• Print mode (direct thermal or thermal transfer).
• Sensor values.
NOTE: The keys below are used only when configuring the printer. Specific uses of these keys
are explained in the Configuration section of the User's Guide (P/N 48025L).

• Scrolls back to the previous parameter.

• Press and hold to quickly go backward through parameter sets.

• Scrolls forward to the next parameter. (Saves any changes you’ve made in the
configuration and calibration sequence.)
• Press and hold to quickly advance through parameter sets.

Enters and exits the configuration mode.

These keys change the parameter values. They are used in different ways depending
on the parameter displayed. Common uses are: to increase/decrease a value, answer
“yes” or “no,” indicate “on” or “off,” scroll through several choices, input the
password, or set up the printer for a firmware download.

Table 2-1 Front Panel Keys

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OPERATION OVERVIEW SECTION 2

Front Panel Lights

Refer To Figure 2-1

NOTE: If two operating conditions occur simultaneously (for example, one that causes a light to
be on constantly and one that causes the same light to flash), the light will flash.

Light Status Indication

Power Off The printer is off or power is not applied.
On The printer is on.
Take Label Off Normal operation.
(Peel-off mode only.) The label is available. Printing is paused until the
Flashing label is removed.
Error Off Normal operation — no printer errors.

Flashing A printer error exists. Check the display screen for more information.

Off Normal operation — ribbon (if used) is properly loaded.

Check Ribbon
Printing is paused, the front panel displays a warning message, and the
PAUSE light is on.
On
• If the printer is in direct thermal mode: Ribbon is loaded.
• If the printer is in thermal transfer mode: No ribbon is loaded.
Paper Out Off Normal operation — media is properly loaded.
No media is under the media sensor. Printing is paused, the display
On
shows an error message, and the PAUSE light is on.
Pause Off Normal operation.
The printer has stopped all printing operations. Either the PAUSE key
was pressed, a pause command was included in the label format, the on-
On
line verifier detected an error, or a printer error was detected. Refer to
the display screen for more information.
Data Off Normal operation. No data being received or processed.
On Data processing or printing is taking place. No data is being received.
The printer is receiving data from or sending status information to the
Flashing host computer. Flashing slows when the printer cannot accept more
data, but returns to normal once data is again being received.

Table 2-2 Front Panel Lights

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SECTION 2 OPERATION OVERVIEW

LOADING MEDIA
NOTE: A calibration must be performed when media and ribbon (if used) are first installed in the
printer, or when a different type of media or ribbon is being used.

Tear-Off Mode
Refer to Figure 2-2.

1. Open the printhead.

2. Slide the media guide and media supply guide as far from the printer frame as possible. Flip
down the media supply guide.
3. Load media as shown.
4. Flip up the media supply guide. Slide in the media guide and media supply guide so they just
touch, but not restrict, the edge of the roll.
5. Close the printhead.

Printhead Lever Media

Supply
Open Guide

Media

Closed Media
Guide

Figure 2-2 Roll Media Loading Tear-Off Mode

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OPERATION OVERVIEW SECTION 2

Peel-Off Mode
NOTE: Rewind option required.
Refer to Figure 2-3.

1. Remove the rewind plate from the front of the printer (if installed). Store it on the two mounting
screws on the inside of the front panel.
2. Open the printhead.
3. Slide the media guide and media supply guide as far from the printer frame as possible. Flip
down the media supply guide.
4. Load media as shown.

Media
Open Supply
Guide
Label Media

Closed Media
Guide

Tear-Off/
Peel-Off
Bar

Label
Backing Rewind
Spindle
Rewind
Plate

Hook Guide
Plate

Figure 2-3 Peel-Off Mode Loading

5. When loading media, allow approximately 36” (914 mm) of media to extend past the tear-
off/peel-off bar. Remove all labels from this portion to create a leader.
6. Remove the hook from the rewind spindle. If you are using a core, slide it onto the rewind
spindle until it is flush against the guide plate.
7. Wind the label backing around either the 3” (76 mm) core or the rewind spindle and reinstall the
hook.

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SECTION 2 OPERATION OVERVIEW

8. Flip up the media supply guide. Slide in the media guide and media supply guide so they just
touch, but not restrict, the edge of the roll.
Before closing the printhead, make sure:
• The media is positioned against the inside guides.
• The media is taut and parallel with itself and the pathway when wound onto the rewind
spindle/core.
9. Close the printhead.
To discard the label backing from the rewind spindle, refer to “Removing the Label Backing
Material” on page 2-12.

Rewind Mode (for Printers Without the Cutter Option)

NOTE: Rewind option required.
Refer to Figure 2-4.

1. Remove the rewind plate from its storage location in front of the print mechanism inside the
media compartment.
2. Invert the rewind plate so that the lip on the attached hook plate points down.
3. Insert the hook plate lip approximately ½" (13 mm) into the lower opening in the side plate.
4. Align the upper end of the rewind plate with the corresponding opening in the side plate. Slide
in the rewind plate so that it stops against the printer’s main frame.
5. Open the printhead.
6. Slide the media guide and media supply guide as far from the printer frame as possible. Flip
down the media supply guide.
7. Load media as shown.
8. When loading media, allow approximately 36” (914 mm) of media to extend past the printhead.
Remove all labels from this portion to create a leader.
9. Remove the hook from the rewind spindle. If you are using a core, slide it onto the rewind
spindle until it is flush against the guide plate.
10. Wind the label backing around either the 3” (76 mm) core or the rewind spindle and reinstall the
hook.
11. Flip up the media supply guide. Slide in the media guide and media supply guide so they just
touch, but not restrict, the edge of the roll.
Before closing the printhead, make sure:
• The media is positioned against the inside guides.
• The media is taut and parallel with itself and the pathway when wound onto the rewind
spindle/core.
12. Close the printhead.

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OPERATION OVERVIEW SECTION 2

Media
Open Supply
Guide
Media

Closed Media
Guide

Side
Plate

Rewind
Spindle

Rewind
Plate Guide
Hook Plate

Figure 2-4 Rewind Mode w/o Cutter Option Loading

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SECTION 2 OPERATION OVERVIEW

Cutter Mode
NOTE: Cutter option required.
Refer to Figure 2-5.

1. Open the printhead.

2. Slide the media guide and media supply guide as far from the printer frame as possible. Flip
down the media supply guide.
3. Load media as shown.
4. Flip up the media supply guide. Slide in the media guide and media supply guide so they just
touch, but not restrict, the edge of the roll.
5. Close the printhead.
6. The printer will automatically feed out and cut one label when the printer is turned on.

Printhead Lever Media

Open Supply
Guide
Media

Closed Media
Guide

Cutter

Figure 2-5 Cutter Mode Loading

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Rewind Mode (for Printers With the Cutter Option)

NOTE: Cutter and rewind options required.
Refer to Figure 2-6.

1. Remove the rewind plate from its storage location in front of the print mechanism inside the
media compartment.
2. Invert the rewind plate so that the lip on the attached hook plate points down.
3. Insert the hook plate lip approximately ½" (13 mm) into the lower opening in the side plate.
Slide in the rewind plate so that it stops against the printer’s main frame.
4. Insert the two small tabs on the rewind plate into the corresponding slots in the cutter support
bracket. (The rewind plate should spring into the proper position.)
5. Open the printhead.
6. Slide the media guide and media supply guide as far from the printer frame as possible. Flip
down the media supply guide.
7. Load media as shown.

Media
Open Supply
Guide
Media

Closed Media
Guide

Side
Cutter Plate

Rewind
Spindle

Rewind Guide
Plate Hook Plate

Figure 2-6 Rewind Mode w/Cutter Loading

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SECTION 2 OPERATION OVERVIEW

8. When loading media, allow approximately 36” (914 mm) of media to extend past the printhead.
Remove all labels from this portion to create a leader.
9. Remove the hook from the rewind spindle. If you are using a core, slide it onto the rewind
spindle until it is flush against the guide plate.
10. Wind the label backing around either the 3” (76 mm) core or the rewind spindle and reinstall the
hook.
11. Flip up the media supply guide. Slide in the media guide and media supply guide so they just
touch, but not restrict, the edge of the roll.
Before closing the printhead, make sure:
• The media is positioned against the inside guides.
• The media is taut and parallel with itself and the pathway when wound onto the rewind
spindle/core.
12. Close the printhead.

Fanfold Media Loading

Refer to Figure 2-7.

Fanfold media feeds through either the bottom or rear access slot from outside the printer.
1. Open the printhead.
2. Slide the media guide as far from the printer frame as possible.
3. Load media as shown. If in cutter mode, route media through the cutter.
4. Slide in the media guide so it just touches, but not restricts, the edge of the roll.
5. Close the printhead.

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Bottom Supply
Printhead Lever

Open

Closed
Media
Guide

Media

Rear Supply
Printhead Lever

Open

Closed
Media
Guide

Media

Figure 2-7 Fan Fold Media Loading

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Removing the Label Backing Material

Since the rewind spindle holds the backing from a standard-size media roll, we recommend that you
perform this procedure whenever you change the media.
To remove the backing material from the rewind spindle, follow these steps (you don’t need to turn
off the printer for this procedure).
1. Unwind approximately 36” (914 mm) of backing from the rewind spindle. Cut it off at the
spindle.
2. Pull out the hook. Slide the backing material off of the rewind spindle and discard.
3. Wind the media around the rewind spindle once or twice and reinstall the hook. Continue
winding to remove any slack in the media.

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Ribbon Loading
To load ribbon, refer to Figure 2-8 and follow the procedure below.
NOTE: Use ribbon that is at least as wide as the media. The smooth backing of the ribbon
protects the printhead from wear and premature failure due to excessive abrasion. (For
the direct thermal print mode, ribbon is not used and should not be loaded in the printer.)

1. Align the segments of the ribbon supply spindle.

2. Place the ribbon roll on the ribbon supply spindle.

NOTE: Make sure that the core is pushed up against the stop on the ribbon supply spindle and
that the ribbon is aligned squarely with its core. If this is not done, the ribbon may not
cover the printhead entirely on the inside, exposing print elements to potentially
damaging contact with the media.
3. Open the printhead.
4. (Optional) To make ribbon loading and unloading easier, make a leader for your ribbon roll if it
doesn’t already have one.
Ribbon
5. Tear off a strip of media (labels and backing) Label
about 6-12” (152-305 mm) long from the roll.
Peel off a label from this strip. Apply half of Strip of Media Backing
this label to the end of the strip and the other 6-12 Inches Long
half to the end of the ribbon. This acts as a
ribbon leader.
6. Thread the ribbon (with leader, if used) as
shown without creasing or wrinkling it.
7. Before wrapping the ribbon around the
ribbon take-up spindle, ensure that the arrow
on the knob aligns with the indented notch
(see Figure 2-9 inset).
8. Place the ribbon (with leader, if used) around the ribbon take-up spindle and wind
counterclockwise for several turns.
9. Close the printhead.

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Ribbon Ribbon
Printhead Take-Up Supply
Lever Spindle Spindle
Open

Closed

90XiIII/96XiIII/140Xi III

Ribbon Ribbon
Printhead Take-Up Supply
Lever Spindle Spindle
Open

Closed

170XiIII/220XiIII

Figure 2-8 Ribbon Installation

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OPERATION OVERVIEW SECTION 2

Ribbon Removal
1. Break the ribbon as close to the ribbon take-up spindle as possible.
2. Refer to Figure 2-9. While holding the ribbon take-up spindle, turn the knob (1) clockwise until
it stops. This will cause the ribbon release bars to pivot down (2), easing the spindle’s grip on
the wound ribbon.
3. Slide the ribbon off the ribbon take-up spindle. Once the spent ribbon has been removed, ensure
that the arrow on the knob aligns with the indented notch in the ribbon take-up spindle (see
Figure 2-9).
4. Remove the empty core from the ribbon supply spindle.
5. Follow the ribbon loading procedure on page 2-13 to load the new ribbon.

Figure 2-9 Ribbon Removal

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POSITIONING THE MEDIA SENSORS

Transmissive Sensor
The web or gap sensor, better known as the “transmissive sensor,” detects the gap or hole/notch
between labels.
The transmissive sensor actually consists of two sections: a light source (the lower media sensor)
and a light sensor (the upper media sensor). The media passes between the two.
The upper media sensor must be positioned:
• Directly over the hole or notch, or
• Anywhere along the width of the media if there is a gap between labels.
NOTE: If you are using continuous media, position the upper media sensor over the media so
that the printer can detect an out-of-paper condition.

Upper Media Sensor

Adjustment

Figure 2-10 Upper Media Sensor Location

Adjusting the Upper Media Sensor

Refer to Figure 2-10. (For clarity, not all printer parts are shown.)
1. Remove the ribbon (if it is installed).
2. Locate the upper media sensor. The upper media sensor “eye” is directly below the adjustment
screw head.

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OPERATION OVERVIEW SECTION 2

3. Slightly loosen the upper media sensor adjustment screw (Phillips head).
4. Using the tip of the screwdriver, slide the upper sensor along the slot to the desired position.
5. Secure the upper media sensor adjustment screw.

Adjusting the Lower Media Sensor

Position the lower media sensor (refer to Figure 2-11) by sliding it in its slot until it is positioned
under the upper media sensor.

Figure 2-11 Lower Media Sensor Location

BLACK MARK SENSOR

The black mark sensor is in a fixed position and enabled via the front panel (details in “Configuring
the Printer” in the User's Guide).

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Notes

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TROUBLESHOOTING SECTION 3

SECTION 3 TROUBLESHOO TING

Test routines are built into the Zebra XiIII-Series printers to aid the technician in diagnosing faults.
Some of these tests are enabled by pressing a front panel key while turning the printer power switch
ON.
POWER-ON SELF TEST
A Power-On Self Test (POST) is performed each time the printer is turned ON. This test checks for
proper initialization of various electronic circuits and establishes starting parameters as those stored
in the printer’s memory. During this test sequence, the front panel LEDs will turn ON and OFF to
ensure proper operation.
At the end of this self test, only the POWER LED will remain lit. If other LEDs are also lit, refer to
Basic Troubleshooting, page 3-11.
If the printer is set up for non-continuous media, one or more labels will feed out, up to a maximum
length of one label plus three additional inches of media.
To initiate the Power-On Self Test, turn the printer ON using the power switch located at the rear of
the printer. The front panel power-on indicator will light. The other front panel LEDs and the
Liquid Crystal Display (LCD) monitor the progress and indicate the results of the self test. The
normal self test sequence is shown on the following page.

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The normal self test sequence is as follows:

1. All lights turn on simultaneously and then turn off in sequence

through the following steps.

2. SRAM Test SRAM functionality test performed.

3. Option ROM Test Option ROM functionality test performed. The words “Not
Installed” will be added to the display if optional ROM is not used.

4. Printhead Test Printhead is checked for proper operation.

5. Processor Test Processor functionality test performed. The word “Failed” will be
added to the display if the test fails.

6. E-Cubed Test E-cubed functionality test performed. The word “Failed” will be
added to the display if the test fails.

7. EEPROM Test EEPROM/PROM functionality test performed. The word “Failed”

will be added to the display if the test fails.

8. Memory Card Test Optional PCMCIA Memory Card functionality test performed. The
word “Failed” will be added to the display if the test fails.

9. Depending on how the ∧MF (Media Feed) instruction is set, the

Printer will feed to the first web or label length, calibrate ribbon
and media sensors, or set label length and feed one or more labels.
Checking flash memory.
Checking Flash

10. Printer Ready Printer is ready for operation. Refer to “Configuration" to set
x.x MB VXX.X.X specific parameters. Designate prompt language with the ∧KL
command or from the menu.

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PRINTER SELF TESTS

Introduction
These self tests produce sample labels and provide specific information that help determine the
operating conditions for the printer.
Each self test is enabled by holding in a specific front panel key while turning the power switch ON.
Keep the key pressed until the front panel LEDs turn ON.

When the Power-On Self Test is completed, the selected printer self test will automatically start.

NOTE: When performing self tests, all data interface cables should be disconnected from the
printer.

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 print
starting at the top of the label.

When canceling a self test prior to its actual completion, always turn the printer power OFF and then
back ON to reset the printer.

CANCEL Key Self

Test
This self test will print a single
label which contains a listing of
the current configuration
parameters stored in
configuration (EEPROM)
memory. See Figure 3-1. To
perform this self test, press the
CANCEL key while turning the
power switch ON
The configuration may be
changed either temporarily (for
specific label formats or ribbon
and label stock) or permanently
(by saving the new parameters
in EEPROM memory). Saving
new parameters occurs
whenever a printer
configuration procedure is
performed. Refer to the user’s
guide for further details on the
printer configuration procedure.

Figure 3-1 CANCEL Key Test Sample Label

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SECTION 3 TROUBLESHOOTING

PAUSE Key Self Test

1. The initial self test prints 15 labels (see Figure 3-2) at a speed of 1" per second for the 96XiIII
and 2.4” per second for all others; then automatically PAUSES the printer. Each time the
PAUSE key is pressed, additional 15 labels will print.
2. While the printer is PAUSED, press the CANCEL key once to alter the self test. Now each time
the PAUSE key is pressed, the printer will print the self test labels at 4" per second for the 96
XiIII, 6” per second for all others. Fifteen (15) additional labels will be printed each time the
PAUSE button is pressed.
3. While the printer is PAUSED, press the CANCEL key a second time to change the self test print
speed back to of 1" per second for the 96XiIII and 2.4” per second for all others. However, each
time the PAUSE key is pressed, the printer prints 50 labels.
4. While the printer is PAUSED, press the CANCEL key a third time to change the self test print
speed to 6” per second (4" for 96XiIII). Each time the PAUSE key is pressed, the printer prints
50 labels.
5. While the printer is PAUSED, press the CANCEL key a fourth time to change the self test print
speed to the printer’s fastest speed. Each time the PAUSE key is pressed, the printer prints 15
labels.

Figure 3-2 PAUSE Key Test Sample Label

FEED Key Self Test

NOTE: 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.
The FEED key self test label will print out at various positive and negative darkness settings relative
to the darkness value shown on the configuration label. See the label example in Figure 3-3. Inspect
these labels and determine which one has the best darkness setting for the application. This value
can be entered into the printer by configuring the “Setting Darkness” parameter found in the
configuration section of the user’s guide.
The value printed on the selected test label is added to (plus) or subtracted from (minus) the
“Darkness” value specified on the configuration label.
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TROUBLESHOOTING SECTION 3

The resulting numeric value (0 to 30) that is best for that specific media/ribbon combination should
be entered as the “Darkness” parameter.

Figure 3-3 FEED Key Self Test Sample Label

FEED Key and PAUSE Key Self Test

To temporarily reset the printer configuration to the factory default values, press these two keys at
the same time, while turning the power ON. The factory default values will be active until power is
turned OFF. If factory default values are “saved” during configuration, a media calibration
procedure must be performed and some parameters must be reconfigured. Refer to the printer
user’s guide for more details.

PAUSE Key and CANCEL Key Self Test

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 back
feeds 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. See Figure
3-5 for a sample label.

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SECTION 3 TROUBLESHOOTING

FEED Key and CANCEL Key Self Test

This self test is normally performed during the manufacturing process or after a major overhaul of
the mechanical assemblies. This test prints seven pre-programmed label formats at speeds of 6” and
2” per second. The printer will automatically PAUSE after each format. The sequence of label
formats is shown in Table 3-1. Refer to Figures 3-4 through 3-10 for sample labels.

FORMAT PRINTING TEST FUNCTION

1 20 at 6 ips* Left Ribbon Wrinkle Test
2 20 at 6 ips* Right Ribbon Wrinkle Test
3 20 at 6 ips* Bar Code Wrinkle Test (Code-39)
4 20 at 2 ips** Left Ribbon Wrinkle Test
5 20 at 2 ips** Right Ribbon Wrinkle Test
6 20 at 2 ips** Bar Code Wrinkle Test (Code-39)
7 20 at 6 ips* Useable Area Test
8 20 at 6 ips* Head Temperature Test
9 20 at 6 ips* Upper Smear Test
10 20 at 6 ips* Lower Smear Test
11 20 at 2 ips** Useable Area Test
12 20 at 2 ips** Head Temperature Test
13 20 at 2 ips** Upper Smear Test
14 20 at 2 ips** Lower Smear Test
* 96XiIII operates at 4 ips
** 96XiIII operates at 1 ips
Table 3-1 Format Sequence

Communications Diagnostics Test

This test is controlled by configuring the “Setting Communications Mode” parameter found in the
configuration section of the printers user’s guide. Refer to Figure 3-4 for a sample label resulting
from this test.
NOTE: This label will be inverted when printed.

Figure 3-4 Communications Diagnostics Self Test

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TROUBLESHOOTING SECTION 3

EXTENDED PRINTER DIAGNOSTICS

Additional diagnostic tests are available for printhead assembly adjustments. These diagnostic tests
are only accessible when the data interface cable is disconnected from the printer and a loopback
connector is attached in its place.
The serial loopback connector is a 25 pin “D” Type (DB25P – Male) with the following pins tied
together.
• Pins 2 and 3
• Pins 6 and 20
• Pins 13 and 14
• Pins 16 and 19
The parallel loopback connector is a standard 36-pin parallel connector mounted to a small printed
circuit board. This connector is available from Zebra Technologies as part # 44680M.
For each of these diagnostic tests, the printer will “transmit” the test label format out of the data
interface connector to the loopback connector. The loopback connector passes the test label format
to the printer as "received data" and the test label is printed.

PAUSE Key Loopback Test

This test demonstrates the media movement capabilities of the printer and provides a test label to
view while making print quality adjustments.
With the loopback connector in place, press the PAUSE key while turning the power switch ON.
After the Power-On Self Test, the printer will print 500 head test labels. Each label will back feed
prior to printing and feed to the rest position after printing.
A serialized number will print on each label for label comparison purposes if required. See label
example in Figure 3-5. The PAUSE key can be used to stop and restart the printing operation.

Figure 3-5 PAUSE Key Loopback Test Sample Label

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SECTION 3 TROUBLESHOOTING

FEED Key Loopback Test

With the loopback connector in place, press the FEED key while turning the power switch ON.
After the Power-On Self Test, the printer will begin printing the same series of label formats as
shown in Table 3-1 for FEED key/CANCEL key test. The printer will pause at the end of each
printed format. Press the PAUSE key to begin printing the next format. Sample labels are shown in
Figures 3-6 through 3-12.
The PAUSE key can be used to stop and restart the printing operation. When the printer is paused,
the CANCEL key can be used to move to the next label format.

Figure 3-6 Format 1 (4) Test Sample Label

Figure 3-7 Format 2 (5) Test Sample Label

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TROUBLESHOOTING SECTION 3

Figure 3-8 Format 3 (6) Test Sample Label

Figure 3-9 Format 7 (11) Test Sample Label

Figure 3-10 Format 8 (12) Test Sample Label

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SECTION 3 TROUBLESHOOTING

Figure 3-11 Format 9 (13) Test Sample Label

Figure 3-12 Format 10 (14) Test Sample Label

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TROUBLESHOOTING SECTION 3

BASIC TROUBLESHOOTING
Consult the Troubleshooting Table that follows and compare the printer output to the sample labels
provided on the following pages to improve the quality of your labels.

SYMPTOM DIAGNOSIS ACTION

All LEDs light, but Main logic board or flash Download new flash or replace the main
nothing displays on faulty. logic board.
LCD and printer will not
operate.
All LEDs flash on and No significant amount of Replace the main logic board.
off. DRAM tested good.
Take Label LED Printer misconfigured for If peel-off is desired, check take label
flashing. Peel-Off Mode. sensor.
Printer locks up while Main logic board failure. Replace main logic board.
running Power-On Self
Test.
EEPROM checksum is Replace the main logic board.
EEPROM CHECKSUM incorrect.
INVALID

No media loaded or Load media correctly.

ERROR CONDITION incorrectly loaded.
PAPER OUT
Misadjusted media sensor. Check media sensor position and
sensitivity.
Printer stops and Maximum label length set Verify maximum label length setting is
ERROR LED flashes. shorter than label length. correct.
Printer set for non- Install proper media or reset printer for
continuous media, but current media type.
continuous media is loaded.
For thermal transfer: 1. Load ribbon correctly.
ERROR CONDITION
RIBBON OUT ribbon not loaded or
incorrectly loaded. 2. Insure snap plate is properly installed.
or
Printer stops and Ribbon sensor not sensing 3. Perform media and ribbon sensor
ERROR LED flashes. ribbon that is correctly calibration.
loaded.
For Direct Thermal: Remove ribbon.
WARNING Ribbon loaded Verify snap plate is properly installed.
RIBBON IN
unnecessarily.

Printhead is not fully closed. Close printhead completely.

ERROR CONDITION Head open sensor not Check head open sensor and flag for
HEAD OPEN detecting position flag, or proper operation.
flag not in the proper
Printer stops and position.
ERROR LED flashes.

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SECTION 3 TROUBLESHOOTING

SYMPTOM DIAGNOSIS ACTION

Printhead element is Printer resumes printing when the
WARNING overheated. printhead element cools to a normal
HEAD OVERTEMP operating temperature.

Printer stops and

ERROR LED flashes.

Printhead element is not hot Environment too cold for proper printing.
WARNING enough to print properly. Relocate printer to warmer area.
HEAD UNDERTEMP

Printer stops and

ERROR LED flashes.

Print head element is going To override this message, (1) place ^JT in
ERROR CONDITION bad. your format and then (2) ~JO to turn off
HEAD ELEMENT BAD the HEAD TEST.

Experiencing print Clean printhead and test for proper

quality problems. printing. Replace print head if necessary.
The cutter blade is Turn the power OFF. Remove the media,
ERROR CONDITION in the media path. reload the media and turn power ON. If
CUTTER JAMMED
the error condition still exists, check cutter
sensors and control board. Replace if
necessary.

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TROUBLESHOOTING SECTION 3

SYMPTOM DIAGNOSIS ACTION

Printer stops and Not enough memory to You may do any of the following:
PAUSE LED lights. perform the function
LCD displays: indicated in the second line A. STORING ERRORS - With PAUSE
of the display. ON, use the ~HM ZPL II command to
(It is possible that the display the amount of memory available.
printer is configured for Then redesign the graphic/format to fit in
ERROR CONDITION
CUTTER JAMMED continuous label stock with the available memory or remove items
the maximum label length from memory to create more space.
set too long.) Or
Functions: Press PAUSE to skip that step in the
process and continue to the next step.
1. Creating a bitmap -
bitmap size is larger than B. With PAUSE ON, press CANCEL and
the label length/width the printer skips that label formatting
specified. process and continues to the next label
2. Storing a bitmap - not format.
enough memory available to
store the bitmap created. C. Turn power OFF to clear printer
3. Building a format - label memory and start all over again.
is too complex.
4. Storing a format - format
size is too large to fit in
available memory.
5. Storing a graphic -
graphic image is too large to
fit in the available memory.
6. Storing a font - not
enough memory to store the
font.

Poor Print Quality. Darkness set too low. Reconfigure darkness setting.
Incorrect media and Ribbon. Replace media and ribbon.
Printhead just replaced. Insure printhead is installed properly with
no wires or debris caught underneath.
Print head Adjustments Perform required adjustments.
incorrect.
Print head Resistance not Reconfigure printhead resistance.
configured to proper value.

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SECTION 3 TROUBLESHOOTING

SYMPTOM DIAGNOSIS ACTION

Truncated print, no Maximum label length Set the correct label length.
print, or feed button parameter set less than the
operates incorrectly actual label length.
while using non- Printer, that is in rewind or Load media correctly for rewind or
continuous media. peel-off mode, was powered peel-off mode.
on without media or
backing around the rewind
spindle.
Long tracks of missing Wrinkled ribbon. See wrinkled ribbon in this table.
print on several labels.
Print element damaged. Replace printhead.
Fine gray lines on blank Wrinkled ribbon. See Wrinkled Ribbon in this Table.
labels at angles.
Wrinkled ribbon. Ribbon fed through machine Load ribbon correctly.
incorrectly.
Incorrect burn temperature. Set the burn temperature to the lowest
setting possible for good print quality.
Incorrect printhead pressure Set the pressure to the minimum needed.
or balance. Refer to the printhead balance adjustment
and printhead pressure adjustment
procedures.
Media not feeding properly; Make sure the media is snug by adjusting
it is walking from side to the media guide.
side.
Strip plate needs adjusting. Perform adjustments.
Ribbon supply spindle Perform adjustments.
tension needs adjusting.
Print head needs realigning Perform adjustments.
with platen roller.
Ribbon take-up spindle Perform adjustments.
tension needs adjusting.
Three point mount for Perform adjustments.
ribbon supply spindle needs
adjusting.
Ribbon supply core Perform adjustments.
slipping; spindle blades
need adjusting.
Light printing or no Print head needs balancing. Adjust balance. See printhead balance
printing on the left or adjustment procedures.
right side of the label.

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SYMPTOM DIAGNOSIS ACTION

Mis-registration/skips Improper sensor type selected. Perform media sensor adjustments.
labels. Misadjusted media sensors. Perform spindle adjustments.
Improper spindle tensions. Correct ZPL format.
Improper ZPL format. Calibrate Printer.
Mis-registration and Media was pulled when motor Open and close the print head, so it
misprint of 1 to 3 labels. was not moving. calibrates to find the label length.
Printer, that is in rewind or Load media correctly for rewind or peel-
peel off mode, was powered off mode.
ON without media or backing
around rewind spindle.
Misadjusted media sensor. Place media sensor in proper position.
Vertical drift in top-of- A plus or minus 1mm vertical Use top position setting to reposition the
form registration. drift is allowable due to the top-of-form.
tolerances of the mechanical
Calibrate if excessive.
parts and printer modes.

Label jam in rear area of Upper media plate (snap Clean upper media plate (snap plate).
the printhead. plate) needs cleaning.
Print label feeds out and Printer set for cutter mode Set correct print mode.
then backfeeds with no cutter installed.
immediately resting
under the printhead.
Changes in parameter Parameters are set incorrectly. Cycle the power. Reload factory
settings did not take defaults. Then, set parameters and save
effect. permanently.
If problem continues, there Replace the main logic board.
may be a problem on the main
logic board.
Missing LCD characters LCD may need replacing. Run the Power-On Self Test and check
or parts of characters. that LCD display is showing all
characters.
ZPL was sent to printer, Communications parameters Print a communications diagnostic label.
but not recognized. are incorrect. Check for format or overrun errors.
Buffer light remains ON Reset communication parameters.
or flashes. Prefix and delimiter Set the characters in the printer to match
characters set in printer do not ZPL format.
match the ones used in ZPL. If problem continues, check the ZPL
format for changed ^CC, ^CT, and ^CD.
Zebra protocol is on. Set protocol = none.

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FACTORY ASSISTANCE
Should any problem be encountered which cannot be corrected with the aid of this manual,
immediately contact your distributor or the Zebra Technical Support department to minimize
downtime and/or assist in returning the equipment.

Returning Equipment
Should it become necessary to ship your XiIII-Series printer, carefully pack it in a suitable container
to avoid damage during transit. A note describing the failure must be enclosed with the unit.
Whenever possible, the original shipping container should be used. If the original shipping
container is not available, a replacement can be ordered by contacting the Technical Support
department. If other containers are used, a procedure similar to the original factory packaging
should be followed.
Remove all media and ribbon from the printer. Enclose the unit in a protective, dust-proof bag and
insure that the unit floats in an outer carton of shock absorbing material.
A Return Materials Authorization (RMA) number is required for all equipment being returned.
Contact Zebra Technologies Corporation’s Technical Support department to obtain an RMA
number. Equipment returned for service without prior authorization may be refused.

CAUTION:
BEFORE PACKING THE PRINTER, REMOVE ANY RIBBON AND PAPER
ROLLS FROM THE MEDIA COMPARTMENT. DO NOT PACKAGE THE
PRINTER IN A RIGID CONTAINER WITHOUT UTILIZING SHOCK
MOUNTS OR SHOCK-ABSORBING PACKING MATERIAL. A RIGID
CONTAINER WILL ALLOW SHOCK ON THE OUTSIDE TO BE
TRANSMITTED TO THE UNIT AND MAY CAUSE DAMAGE.

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MAINTENANCE SECTION 4

SECTION 4 MAINTENANCE

MAINTENANCE CONCEPTS
Maintenance for the Zebra XiIII-Series thermal transfer demand printer can be divided into two basic
categories:
• This section of the manual contains preventive maintenance procedures and operator care
instructions. These procedures may be performed by the operator as well as the service
technician and should be performed on a regular basis. Preventive maintenance consists of a
visual inspection and general cleaning of the interior and exterior of the printer. Preventive
maintenance also includes cleaning the printhead and the associated media and ribbon paths.
• Corrective maintenance provides the service technician with detailed steps for resolving faults by
adjustment or the replacement of components or modules.
Tools Required for Corrective Maintenance:
• Screwdriver, regular 1/4" flat-blade extended • Set of inch allen wrenches (1/16", 3/32",
reach (10" shaft) (magnetic) 5/64", 7/64", 9/64")
• Screwdriver, Phillips Head no. 1 • Hex head driver, 3/32"
• Screwdriver, Phillips Head no. 1, extended • Hex head driver, 7/64"
reach (10" shaft) (magnetic) • Spring scale, 0 – 2250 g (part # HT344)
• Screwdriver, Phillips Head no. 2 • Hex head driver, 7/64" extended reach (10"
• Nut driver, 1/4" shaft) (part # HT368)
• Nut driver, 5/16" • Wire cutters
• Long-nose pliers • Hex head driver, 7/64" extended reach (15"
shaft) (part # 46482)
• Set of inch combination (open end/box end) • Spindle torque adjustment kit (part # 01773)
wrenches (must include a 7/16")

Test Equipment Required

• Multi-meter and test leads
• Anti-static mat and anti-static wrist strap (for removing PC board)

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SECTION 4 MAINTENANCE

PREVENTIVE MAINTENANCE
Cleaning the Zebra Xi III Printer

AREA METHOD INTERVAL

Printhead Solvent
Platen roller Solvent After every roll of media (or
500 feet of fanfold media)
Transmissive when printing in direct thermal
Air blow
Media Sensor mode and after every roll of
ribbon when printing in the
Reflective (black mark) sensor Air blow thermal transfer mode.
Media path Solvent
Tear-off/peel-off bar Solvent As needed.
Snap plate Solvent As needed.
Label available
Air blow Monthly
sensor
Ribbon Sensor Air blow After every roll.
Ribbon feeding Visual inspection After every roll.

Visual inspection 6 months

Belts or
(Look for belt wear) after every 500 rolls.
Media supply Formal preventive maintenance is not required.
spindle
The spindle torque should be tested every year, or 500 rolls of
Media take-up
media, for the media take-up and optional media supply spindles
spindle
or every 200 rolls of ribbon for the ribbon supply and ribbon take-
Ribbon supply up spindles.
spindle

The spindle torque need not be readjusted unless the printer is

Ribbon take-up
malfunctioning.
spindle

Clean stationary cutter blade with solvent when it becomes

gummed up with adhesive and cut debris.
Cutter
After cleaning, apply a small amount of grease to the moving
cutter parts.

Table 4-1 Recommended Preventive Maintenance Schedule

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MAINTENANCE SECTION 4

WARNING:
UNLESS INDICATED OTHERWISE, TURN PRINTER POWER OFF
BEFORE PERFORMING MAINTENANCE PROCEDURES.

CAUTION:
USE ONLY THE CLEANING AGENTS DESCRIBED IN THE FOLLOWING
PROCEDURES. ZEBRA TECHNOLOGIES WILL NOT BE RESPONSIBLE
FOR ANY OTHER FLUIDS BEING USED ON THIS PRINTER.

EXTERIOR: The exterior surfaces of the XiIII-Series printer may be cleaned as required by using a
lint-free cloth. DO NOT use solvents or harsh cleaning agents. If the unit is excessively dirty, a
mild detergent solution or desktop cleaner may be used sparingly.
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 SUPPLIES: When cleaning supplies are required, reorder the preventive maintenance
kit (part # 01429).

WARNING:
THE USE OF CERTAIN LUBRICANTS SUCH AS PENETRATING OIL AND
SILICONE OIL WILL DAMAGE THE PRINTER’S SPINDLES AND
INHIBIT PROPER OPERATION. DO NOT LUBRICATE ANY PARTS IN
THIS PRINTER UNLESS CALLED FOR IN THE INSTALLATION AND
ADJUSTMENT PROCEDURES.

Cleaning The Printhead

Inconsistent print quality such as voids in the bar codes or graphics may indicate a dirty printhead.
For optimum performance, the printhead should be cleaned regularly. Zebra Technologies
Corporation recommends performing the cleaning procedure when installing a new roll of ribbon,
when installing a new roll of direct thermal media or after having printed 500 feet of continuous or
fanfold media.
It is not necessary to turn the printer power OFF prior to cleaning. If power is turned OFF, all label
formats, images and parameter settings stored in the printer’s formatting RAM memory will be lost.
Permanent parameter settings stored in EEPROM will be retained. When power is turned back ON,
it may be necessary to reload some items into the printer’s memory.

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SECTION 4 MAINTENANCE

Printhead Cleaning Procedure

1. Open the printhead by moving the printhead lever to the open position.
2. Remove the media and ribbon (if present).
3. Refer to Figure 4-1. Use a cleaning swab and wipe the print elements from end to end. (The
print elements are the grayish/black strip just behind the chrome strip on the underside of the
printhead.) Allow a few seconds for the solvent to evaporate.
4. Rotate the platen roller and clean thoroughly with a solvent and an applicator.
5. Brush or vacuum any accumulated paper lint and dust away from the rollers and the media and
ribbon sensors.
6. Reload ribbon and/or media, close and latch the printhead, restore power (if necessary) and run
the PAUSE Key Self Test to check print quality.

Printhead
Lever
Printhead

Black
Mark
Sensor

Ribbon
Sensor

Label
Available Platen Peel-off/tear-off
Sensors Roller Bar

Figure 4-1 Cleaning a Typical Printhead

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MAINTENANCE SECTION 4

Cleaning the Upper Media Guide (Snap Plate): 140XiIII, 170XiIII, &
220XiIII.
Clean the snap plate to remove label adhesive or a label that has adhered to the underside of the snap
plate.
1. Insert a small-blade screwdriver or similar tool into the loop on the left side of the snap plate.
Lift the snap plate. See Figure 4-2.
CAUTION: Use care to not bend, twist, or otherwise deform the loops!
2. Repeat step one on the right side of the snap plate.
3. Remove the snap plate from the printer.
4. Clean the snap plate with cleaning solvent and a soft cloth.
5. To reinstall the snap plate, insert the two tabs on the bottom of the snap plate into the two slots of
the media pathway. See Figure 4-2.
6. Slide the snap plate toward you.
7. Press down on the loops to lock the snap plate into place.

Loop

Loop
Upper Media Guide
(Snap Plate)

Loop Slot

Tab

Loop
Slot
Tab

Figure 4-2 Removal and Installation of Snap Plate for 140/170/220XiIII

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SECTION 4 MAINTENANCE

Cleaning the Upper Media Guide (Snap Plate): 90/96XiIII

Clean the snap plate to remove label adhesive or a label that has adhered to the underside of the snap
plate.
1. Lift the front edge of the snap plate.
CAUTION: Use care to not bend or twist.
2. Remove the snap plate from the printer. See Figure 4-3.
3. Clean the snap plate with cleaning solvent and a soft cloth.
4. To reinstall the snap plate, insert the two L-shaped tabs on the bottom of the snap plate into slots
of the media pathway.
5. Slide the snap plate to the rear of the slots.
6. Press down on the snap plate to lock it into position.

Snap
plate

Removal

Slot

L-shaped tab

Slot
L-shaped tab

Installation
Figure 4-3 Removal and Installation of Snap Plate for 90/96XiIII

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MAINTENANCE SECTION 4

CORRECTIVE MAINTENANCE
A preventive maintenance kit (# 01429) containing six cleaning swabs soaked in solvent (alcohol) is
available from Zebra Technologies Corporation.

WARNING:
UNLESS INDICATED OTHERWISE, TURN PRINTER POWER OFF
BEFORE PERFORMING MAINTENANCE PROCEDURES.

Configuration
After you have installed the media and ribbon and the POST (Power-On Self Test) is complete, the
front panel display shows “PRINTER READY.” You may now set printer parameters for your
application using the front panel display and the five keys directly below it.
Refer to the Zebra XiIII-Series printer user’s guide for further details on configuring the printer for
your application.
If it becomes necessary to restore the initial printer defaults, see the “FEED Key and PAUSE Key
Self Test” in the troubleshooting section (Section 3) of this manual.
Entering the Setup Mode
To enter the programming mode, press the SETUP/EXIT key. Press either the NEXT/SAVE key or
PREVIOUS key to scroll to the parameter you wish to set. Throughout this process, press the
NEXT/SAVE key to continue to the next parameter, or press the PREVIOUS key to go back to the
previous parameter in the sequence.
Changing Password-Protected Parameters
Certain parameters are password-protected by factory default.

CAUTION:
DO NOT CHANGE PASSWORD-PROTECTED PARAMETERS UNLESS
YOU’RE SURE YOU KNOW WHAT YOU’RE DOING! IF THEY ARE
SET INCORRECTLY, THESE PARAMETERS COULD CAUSE THE
PRINTER TO FUNCTION IN AN UNPREDICTABLE WAY.

The first attempt to change one of these parameters (pressing one of the BLACK OVAL keys) will
require you to enter a four-digit password. This is done via the “ENTER PASSWORD” display.
The left black oval key changes the selected digit position. The right BLACK OVAL key increases
the selected digit value. After entering the password, press the NEXT/SAVE key. The parameter
you are trying to change will be displayed. If the password was entered correctly, you can now
change the value.
The default password value is 1234. The password can be changed using the ^KP (Define
Password) ZPL II instruction.

NOTE: Once the password has been correctly entered, it need not be entered again unless you
leave and re-enter the programming mode using the SETUP/EXIT key.

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SECTION 4 MAINTENANCE

NOTE: You can disable the password protection feature so that it no longer prompts you for a
password by setting the password to ØØØØ via the ^KPØ ZPL/ZPL II command. To re-
enable the password-protection feature, send the ZPL/ZPL II command ^KPx, where “x”
can be any number, 1-4 digits in length, except Ø.

Leaving the Setup Mode

You can leave the setup mode at any time by pressing the SETUP/EXIT key. The SAVE
CHANGES display will appear. There are five choices, described below. Press the left or right
black oval key to display the sequence of choices. When your choice is displayed on the LCD, press
the NEXT/SAVE key to save settings.
PERMANENT: saves the current settings. Values are stored in the printer even when power is
turned OFF.
TEMPORARY: saves the current settings until changed again or until power is turned OFF.
CANCEL: cancels all setting changes made since entering the programming mode except the
darkness and tear-off settings (if they were changed).
LOAD DEFAULTS: loads factory default settings. Refer to the user’s guide for default values.
NOTE: If you load factory default settings, you will have to perform a media and ribbon sensor
calibration.
LOAD LAST SAVE: reloads the settings made during the last permanent save.
CALIBRATION
Two types of calibrations can be performed by the printer:
1) Standard Calibration: Pressing the CALIBRATE key causes the printer to feed media and
ribbon and set the values it detects. This includes media, media backing material (the spaces
between labels), media out, and ribbon in/out status (which determines the print mode—thermal
direct or thermal transfer). This form of calibration also occurs as part of the “Sensor Profile”
and “Media and Ribbon Calibration” procedures described on next page.
2) Media and Ribbon Sensor Sensitivity Calibration (using non-continuous media): Performing
the “Media and Ribbon Calibration” procedure, on the next page, first resets the sensitivity of the
sensors to better detect the media and ribbon you are using. With the sensors at their new
sensitivity levels, the printer then performs the standard calibration described above. Changing
the type of ribbon and/or media may require this calibration process to reset the sensitivity of the
media and ribbon sensors. Indications that the sensitivity may need to be reset would be a
“CHECK RIBBON” light ON with the ribbon properly installed or non-continuous media being
treated as continuous media.
Media and Ribbon Sensor Sensitivity Calibration

NOTE: Before you begin this procedure, make sure that the “Maximum Length” is set to a value
equal to or greater than the length of the labels you are using. If the maximum length is
set to a lower value, the calibration process will assume that continuous media is in the
printer.

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MAINTENANCE SECTION 4

Sensor Profile
1. Press the SETUP/EXIT key to enter the programming mode.
2. Press the NEXT/SAVE key multiple times until the printer’s LCD displays:

SENSOR PROFILE
3. Press the RIGHT OVAL key to initiate the standard calibration procedure and print a media
sensor profile. (See Figure 4-4 for a media and ribbon sensor profile sample printout.)
The media sensor profile may be used to troubleshoot registration problems that may be caused
when the media sensor detects preprinted areas on the media or experiences difficulty in determining
web location. If the media and/or ribbon sensors sensitivity needs to be adjusted, press the
NEXT/SAVE key to access the media and ribbon calibrate procedure below.
Media and Ribbon Calibration
NOTE: The following procedure is used to adjust the sensitivity of the media and ribbon sensors.
It must be followed exactly as presented. All steps must be performed even if only one of
the sensors requires adjustment.
1. Press the NEXT/SAVE key to skip this procedure.
or
Press the RIGHT OVAL key to start the calibration procedure. The front panel LCD should
show:

LOAD BACKING
CANCEL CONTINUE
2. Press the LEFT OVAL key to cancel the operation, or open the printhead and remove as many
labels as needed to load a section of blank backing material under the media sensor. (If you are
unsure of the media sensor location, refer to Figure 4-9 and 4-10.)

3. Press the right oval key to continue. The front panel LCD should show:

REMOVE RIBBON
CANCEL
4. Press the left oval key to cancel the operation.

or
Remove the ribbon (sliding it as far to the right as possible will have the same effect as removing
it), and close the Printhead.
5. Press the right oval key to continue. The front panel LCD should show:

CALIBRATING
PLEASE WAIT

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SECTION 4 MAINTENANCE

6. The printer automatically adjusts the base settings as determined by the media and ribbon sensors
due to the specific media and ribbon combination you are using. On the sensor profile: this
corresponds to moving the graph up or down to optimize the readings for your application.
When this part of the calibration process is completed, the front panel LCD should show:

RELOAD ALL
CONTINUE

7. Open the printhead and pull the media forward until a label is positioned under the media sensor.
8. Move the ribbon back to its proper position.
9. Close the printhead.
10. Press the right oval key to continue. The printer performs the second part of the calibration
process and the front panel LCD should show:

MEDIA AND RIBBON

CALIBRATE

This part of the calibration is equivalent to pressing the CALIBRATE key on the printer’s front
panel. The media sensor determines a new value based on the presence of media and backing and
determines the label length. The ribbon sensor determines a new value based on the presence of
ribbon and puts the printer in either thermal direct or thermal transfer mode.
Once media stops feeding, the calibration process is complete!
11. To see the new settings, press PREVIOUS and print a sensor profile.
12. Press the SETUP/EXIT key to leave the programming mode. When asked to SAVE CHANGES,
select “Permanent”.

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Sensor Sensitivity
The detailed information that follows amplifies the “Media and Ribbon Sensor Calibration”
description just performed.
• The procedure prompts the user to load just the liner (backing material) in the media sensor
path and removes the ribbon from the ribbon sensor area.
• This step prepares the printer to automatically adjust the gain of the media amplifier to
produce a 3 Volt output while sensing just the liner.
• This step also prepares the printer to adjust the gain of the ribbon amplifier to produce a 2
volt output while no ribbon is in the path.
Sensing Typical Thermal Transfer Non-Continuous Die Cut Labels.
Once the user has loaded backing and removed the ribbon, continuing the process adjusts the gain of
the sensor amplifiers. The results of this process are subsequently indicated on the printer
configuration label as:
Media LED.....Duty cycle applied to the media amplifier to achieve the 3 volt output while
viewing backing material only.
Ribbon LED ...Duty cycle applied to the ribbon amplifier to achieve the 2 volt output while
viewing only the reflector (ribbon out condition).
Reinstalling the ribbon and media and continuing the process (media is feeding) automatically
adjusts the remaining values needed to function properly. These values are determined as follows:
The Max Label Length setting is read and the printer begins feeding labels to determine the web
sensor value. This value is indicated on the printer configuration label as:
Web Sensor... the voltage level distinguishing “backing only” from “label plus backing”,
specified as a percentage of 5 volts.
Media Sensor...the “Paper Out” value equal to a certain percentage of 5 volts. This is
programmed to be at 75% (5 volts x 75% = 3.75 volts).
The Ribbon Sensor value is calculated. This value is indicated on the printer configuration label as:
Ribbon Sensor ... determined by taking 75% of the minimum “ribbon in” calculation. This is
displayed as a percentage of 5 volts.
The Label Length is now measured by feeding one label. This value is indicated on the Printer
Configuration Label as:
Label Length....the distance (in dot rows) between the rising edge of consecutive peaks (as it
crosses the web value) minus 2 millimeters.

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Media Sensor Profile

The media sensor profile is a graphical representation of the calculated sensor values. The
limitations associated with successfully printing the profile are that the label stock must be wide
enough and long enough to allow the whole display to be viewed. An incorrect label length may
inadvertently allow the peaks to print in the interlabel gap.
The following profile represents these sensor values for a typical 1-1/2” 6A label stock with 5319
ribbon used in a 140XiIII.
50..............................................Web Sensor
75..............................................Media Sensor
64..............................................Ribbon Sensor
19..............................................Media LED
24..............................................Ribbon LED
304............................................Label Length

Figure 4-4 Typical Media Sensor Profile

NOTE: A Paper Out condition will occur during normal printing functions, if the sensed level is
above 75% (3.75 volts) for 1/2” of media movement. However, if the sensed value is
above 75%, after recovering from an error condition (i.e. Head Open, Paper Out, Ribbon
Out), the printer will indicate PAPER OUT immediately. Thus, there is no attempt to
feed a label any distance until the sensed value is below the media sensor value.

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MAINTENANCE SECTION 4

Sensing Continuous Media

Continuous media does not present a web to the media sensors. When monitored, the web sensor
value will be less than the media sensor value. The printer then automatically reconfigures the
media type to “Continuous”.
Sensing Tag Stock with a Notch
The media sensors can be calibrated using no backing, however this may allow one label length to
feed during a paper out condition as if a label were missing from the liner. This may occur if the
adjusted level of the media LED allows a no backing condition to achieve 3 volts. A better method
of calibration is to use a strip of standard label liner to adjust the sensor sensitivity. The only
drawback to this method is that a “Paper Out” condition will result if the hole or notch is present at
the media sensor (web value exceeds the media sensor value) after an error condition. See the
previous “NOTE” regarding a paper out condition.
Direct Thermal Printing
During the ribbon LED adjustment, if there is no ribbon in the printer, no difference in the “Ribbon
In” and “Ribbon Out” values are detected. During direct thermal printing, the printer continues to
monitor the ribbon sensor input and will generate a “Ribbon In” error and stop printing if the ribbon
sensor value increases during the printing process.

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SECTION 4 MAINTENANCE

STANDARD KST PRINTHEAD REPLACEMENT

Refer to Figure 4-5 while performing the following procedure.

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. THE TECHNICIAN MUST WEAR AN ANTI-STATIC WRIST
STRAP CONNECTED TO THE PRINTER CHASSIS WHEN REMOVING
AND REPLACING THE PRINTHEAD.

1. Turn the printer OFF and remove the power cord.

2. Open the printhead assembly and remove the media and ribbon; then close the printhead
assembly.
3. Properly connect yourself to an anti-static protection system.
4. Locate the spring-loaded mounting screw on top of the printhead assembly.
5. Loosen the mounting screw until it disengages from the printhead.

CAUTION:
USE CARE TO MINIMIZE ANY PHYSICAL DAMAGE TO THE
PRINTHEAD DURING THE REMAINDER OF THIS PROCEDURE.

6. Slowly open the printhead assembly. The printhead will be resting on the platen while the rest of
the assembly pivots back out of the way.
7. Spread apart the holding tabs on the sides of the printhead data connector to release the data
cables.
8. Grasp the outside edges of the printhead power cable connector and press down on the power
cable locking tab.
9. While maintaining pressure on the locking tab, disconnect the printhead power cable and remove
the printhead through the front of the printer.
10. Prior to installing the new printhead, note the resistance value located on the right side of the
new printhead label. See Figure 4-5.
11. Connect the printhead power cable to the appropriate connector.
12. Spread apart the holding tab on the top of the data connector (two data connectors on the
220XiIII) and press the appropriate printhead data cable into each connector. The holding tabs
must “snap” into place around the cable connectors.
13. Carefully position the alignment slots in the new printhead over the alignment posts on the
underside of the mounting bracket.

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MAINTENANCE SECTION 4

14. Once the printhead is seated properly, carefully tighten the mounting screw to a value of 5-6
inch/pounds. (Make sure the screw is properly aligned before tightening.)
15. Refer to Figure 4-1. Use a cleaning swab to thoroughly clean the print element (gray area) of the
new printhead.
16. Reinstall media and ribbon.
17. Connect the AC power cord and turn the printer power ON.
18. After the POST, enter the configuration mode, enter the new printhead resistance value, then
permanently save the configuration.
19. Turn the printer OFF, then perform the PAUSE Key Self Test and check print quality.
20. The printer should be ready for operation. If problems arise, refer to the troubleshooting section.

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SECTION 4 MAINTENANCE

Do Not Loosen
These Screws !!
Printhead
Mechanism
Assembly
Printhead
Mounting
Screw

Printhead
Alignment
Posts

Printhead
Data
Connector
Power Cable
Locking Tab

Printhead
Printhead Power
Alignment Connector
Slots
140Xi III And 170XiIII Resistance
Printhead Label

Resistance
Label
Printhead
Alignment
Slots
220XiIII Printhead
Resistance
Label
Printhead
Alignment
Slots
90/96XiIII Printhead

Figure 4-5 Printhead Replacement

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MAINTENANCE SECTION 4

PRINTHEAD ADJUSTMENTS
Print Quality Adjustments
Five interrelated adjustments lead to optimum print quality with increased printhead life:
• Printhead Parallelism
• Wear Plate (Balance) Position
• Printhead Position
• Printhead Pressure
• Strip Plate Positioning
To achieve optimum results with print quality adjustments, install full width media and ribbon.
NOTE: Verify the media and ribbon are properly matched and darkness/print speed
configurations are correct for the application before performing any mechanical
adjustments.

Prior to Performing Printhead Adjustments

1. Position the toggle(s) as follows:

(90/96XiIII) position the toggle in the center of the upper

print mechanism.

(140XiIII, 170XiIII and 220XiIII) reference the printhead

mounting screw as the center of two halves of the print
mechanism, and position each toggle at the center of each
half.
30mm 2. Compress the toggle spring by turning the lower knurled
nut clockwise until the distance from the top of the toggle
foot to the bottom of the lower knurled nut equals 30mm.
3. Perform the PAUSE Key Self Test by pressing the PAUSE
key while turning the printer power ON.

NOTE: The order in which the adjustments are performed depends on the print quality of the
labels printed during the PAUSE Test.

The first two printhead adjustments (Parallelism and Wear Plate) must be completed prior to
attempting to locate the optimum print position. As with the other adjustments, parallelism and wear
plate adjustments are interrelated. Adjusting one may have an effect on the position of the other.
Excessive toggle pressure will lead to an increased printhead wear and decreased printhead
life.
Increased printhead life is possible by combining minimum toggle pressure and optimum printhead
position over the platen roller

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SECTION 4 MAINTENANCE

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.
Printhead Parallelism Test
1. Prior to starting this test, insure the installed media is “squared” with the tear-off Bar.
2. When the printer begins printing PAUSE Key Self Test labels, refer to the user's guide and adjust
the darkness for a clear presentation of all lines on the test label.
3. The uppermost line on the test label should be parallel to the top edge of the label, within a
tolerance of 0.020”.
4. If the print lines are not parallel with the top of the label, proceed to the printhead parallelism
adjustment. If parallelism is within tolerance, proceed to the wear plate position adjustment.
Printhead Parallelism Adjustment
Refer to Figure 4-6 during this procedure.
1. Using a 7/64" allen wrench or 7/64" hex driver, loosen the four allen screws at the top rear of the
print mechanism.
2. Adjust the parallel location of the uppermost lines by turning one of the two flat head screws
located at the back of the print mechanism.
NOTE: Only small adjustments should be required.
3. To move the printhead forward, turn the adjustment screw clockwise as viewed from the rear of
the printer.
4. To move the printhead backward, turn the adjustment screw counter-clockwise as viewed from
the rear of the printer.
5. Adjust each side as necessary to align the uppermost line of the test label parallel with the top
edge of the label.
6. To check the results of your adjustments, run additional PAUSE Key Self Test labels and check
for proper parallelism.
7. Tighten the four top Allen screws and run more PAUSE Key Self Test labels to verify proper
positioning.

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MAINTENANCE SECTION 4

Toggle Knurled Note: Loosen 4 Hex Cap Screws

Adjusting Nut Before Adjusting Head

Wear Plate
Adjustment
Screws

Parallelism
Adjustment
Screws

Strip Note: The Ribbon Take-up Spindle

Plate Is Not Shown In This Illustration

Figure 4-6 Printhead Adjustment Illustration

Wear Plate Position Adjustment

This adjustment is performed in conjunction with the printhead parallelism, printhead position and
printhead pressure adjustments.
Adjusting the wear plate position produces even pressure across the full width of the printhead and
platen roller.
Refer to Figure 4-6 for the location of the adjustment screws used in the following procedure.
1. Using a # 1 phillips head screwdriver, loosen the 2 screws on the front of the strip plate.
2. Activate the PAUSE Key Self Test by pressing the PAUSE key while turning the printer power
ON.
3. After printing a few labels, PAUSE the printer and reduce the DARKNESS value until the test
labels are a charcoal gray color.
4. Print additional PAUSE Key Self Test labels and observe the print quality.
5. If lighter or no printing is observed on one side of the label as compared with the other, continue
with this adjustment. (This assumes the toggle pressure has been properly balanced.)
6. Using a 7/64 allen wrench, slightly loosen the 2 allen screws mounted on the wear plate.
7. Continue to print PAUSE test labels while adjusting the wear plate eccentric for even printing.

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SECTION 4 MAINTENANCE

8. Adjust the wear plate eccentric by turning it by hand or with a 7/16 open end wrench or with a
pair of utility pliers.
9. Adjust the wear plate eccentric clockwise to increase pressure on the main frame side of the label
or adjust it counter-clockwise to increase pressure on the outboard side of the printer.
10. When even print quality is achieved, hold the wear plate in position and tighten the 2 wear plate
screws.
11. Continue to print PAUSE test labels and verify parallelism is correct.
12. If parallelism is out of tolerance, perform the printhead parallelism adjustment.
13. If no other adjustment is required, align the strip plate and tighten the 2 phillips head screws.
Printhead Position Adjustment
This adjustment is performed in conjunction with the printhead parallelism, wear plate position, and
printhead pressure adjustments.
Adjusting the printhead position aligns the head for optimum print quality.
Refer to Figure 4-6 for location of adjustment screws used in the following procedure.
1. The thermal elements of the printhead should be aligned just behind the crest of the platen roller.
2. Print test labels using the PAUSE Key Self Test.
3. Set the darkness to achieve as close to optimum print quality as possible.
4. Using a 7/64" allen wrench, loosen the four allen screws at the top rear of the print mechanism.

CAUTION:
IN STEP 5, TO PREVENT PRINTHEAD DAMAGE, LOOSEN THE FOUR
TOP SCREWS BEFORE TURNING THE TWO REAR ADJUSTMENT
SCREWS.

5. Adjust the printhead position for optimum print quality by equally turning the two screws located
at the back of the print mechanism. Adjustments are made in very small increments.
Turn both screws one-eighth turn clockwise and observe the changes in print quality. Turn both
screws 1/8 turn counter-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.)
6. Enter the configuration mode and decrease the darkness until the PAUSE test labels are a
charcoal gray color.
7. Carefully look at the PAUSE test labels for streaks, flowering, and other print quality problems.
8. If required, adjust the hex-head screws and observe if print quality problems are corrected.
9. Enter the configuration mode and increase the darkness until the PAUSE test labels are printed at
optimum resolution and contrast.
10. Since printhead parallelism, wear plate position and printhead positions are interrelated, carefully
look at the test labels for changes in these settings and adjust if necessary.

4-20 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

Printhead Pressure Adjustment

Printhead pressure is the fourth of the four interrelated adjustments. Using lower printhead pressure
and darkness settings can extend printhead life. If printing is too light on one side, or if thick media
is used, printhead pressure may require adjustment.
Refer to Figure 4-7 for the location of the pressure toggles. The 90/96XiIII printers use only one
toggle that should be positioned over the center of the media width. The 140XiIII, 170XiIII, and
220XiIII printers have two toggles. These toggles are typically positioned at the 1/4 and 3/4
positions across the width of the media. If the media is sufficiently narrow that both toggles will not
fit within its edges, the inside toggle should be centered above the media and the outside toggle
should be reduced to a minimum.
1. Print PAUSE Key Self Test labels to check print quality.
2. To increase printhead pressure, loosen the upper knurled nut on the toggle and adjust the lower
toggle adjusting nut downwards.
3. To decrease printhead pressure, loosen the upper knurled nut and adjust the lower toggle
adjusting nut upwards.
4. Adjust printhead pressure for optimum print quality.
5. To lock the toggle pressure, tighten the upper knurled nut against the lower toggle adjusting nut.
6. Though different media and ribbon combinations may require different toggle settings, a
suggested initial distance between the top of the toggle foot to the bottom of the lower knurled
nut equals 30mm. See page 4-17.
7. Enter the configuration mode and set the darkness to the optimum level for the installed media.

Toggle
Adjusting
Nuts

Strip Plate
Positioning Screw

Figure 4-7 Printhead Pressure Adjustment

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-21

SECTION 4 MAINTENANCE

Strip Plate Adjustment

The strip plate adjustment 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. Refer to Figure 4-7.
1. Print PAUSE Key Self Test labels.
2. Press the PAUSE key and, after the printer pauses, observe the ribbon for possible problems such
as wrinkling.
3. Loosen the two phillips head screws holding the strip plate to the front of the printhead
assembly.
4. While running the PAUSE Key Self Test, lower the strip plate so that the ribbon is flat, smooth
and tracks properly when fed to the ribbon take-up spindle.
5. Tighten the strip plate phillips head screws and print a minimum of 25 labels while checking for
ribbon wrinkle, tracking and media/ribbon separation problems. (If ribbon problems persist,
check the torque settings of the ribbon supply spindle and adjust tension if required.)
Darkness Adjustment
Due to differences in types of media/ribbon and wear on thermal printhead elements, it may be
necessary to adjust the darkness setting (burn temperature) of the XiIII printhead to achieve proper
printing. This adjustment is accomplished by using the LCD display and the membrane keys.
NOTE: Turning the printer OFF is not required for the new setting to take effect.
To adjust the darkness, follow the procedure below:

CAUTION:
SET THE DARKNESS TO THE LOWEST SETTING POSSIBLE FOR THE
DESIRED PRINT QUALITY. DARKNESS SET TOO HIGH FOR A GIVEN
RIBBON MAY CAUSE INK SMEARING, RIBBON WRINKLE AND/OR
BURNING THROUGH OF THE RIBBON, AS WELL AS REDUCED
PRINTHEAD LIFE.

1. Begin printing a batch of labels. Refer to Section 3 and use the PAUSE key and CANCEL key
self test label or, preferably, one of your own formats.
2. (Refer to the printer configuration discussion in the User Guide.) Using the front panel display
and the membrane keys, adjust the darkness setting to obtain the desired print quality.
Decreasing the value in the display causes a lighter (less black) image. Increasing the value
causes a darker (blacker) image.

4-22 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

Media Tear-Off Position Adjustment

Refer to Figure 4-8. This adjustment sets the rest position of the media over the tear bar after
printing. To achieve the desired tear-off position, refer to the user's guide. Power need not be turned
OFF to set this parameter.

Nominal factory set tear line

location will usually be 00

Label Motion

Figure 4-8 Tear-Off Position Adjustment

This illustration shows higher values move the label further out from the printer (moves the tear line
closer to the leading edge of the next label). While lower values move the label into the printer
(moves the tear line closer to the edge of the printed label).

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-23

SECTION 4 MAINTENANCE

TRANSMISSIVE MEDIA SENSOR POSITION ADJUSTMENT

The transmissive media sensor senses either the “web” between labels or a hole or notch in the print
media to determine the length of the label or ticket.
The factory-set position should be sufficient for any width label when using media with a web, so
little or no repositioning should be required. If it does become necessary to reposition the
transmissive media sensor, refer to Figures 4-9 and 4-10 and perform the upper media sensor
adjustment followed by the lower media sensor adjustment.
To adjust the upper media sensor for the inside half of the media width, follow these steps:
1. Remove the ribbon and locate the upper media sensor.
2. (90XiIII/96XiIII/140XiIII/170XiIII) carefully loosen the phillips head screw located at the top of
the sensor.
(220XiIII) DO NOT loosen the phillips head screw.
3. Slide the upper sensor along the slot to the desired position.

NOTE: When using label stock that has a web between labels, position the upper media sensor
anywhere along the web, except where the rounded corners of the label are detected.
When using tag stock, position the upper sensor directly over the hole or notch.
4. Tighten the phillips head screw.

To adjust the upper media sensor for the outside half of the media width, follow these steps:
1. Remove the ribbon and locate the upper sensor.
2. Remove the phillips head screw. This releases the upper sensor and the sensor wire cover.
3. Lift the upper media sensor assembly and move the sensor and the wire cover to the outside half
of the mounting bracket. Carefully pull the wires through the tie wrap. You may need to set
aside the sensor wire cover if the adjustment is far to the outside.
4. Replace and tighten the phillips head screw.

To adjust the lower media sensor, follow these steps:

1. Locate the lower media sensor assembly (a spring clip holding a circuit board) under the rear
idler roller.
2. Position the sensor by sliding it in its slot, so that the two brass colored infrared emitters are
centered under the upper sensor.
3. Gently pull wires out as required. (Wires should have a little slack.)

NOTE: If the sensor is being moved inward and a large loop of wire results, remove the cover
from the electronics side of the printer and gently pull the wires through. It is important
that the wires be properly clamped so that they do not rub any drive belts.

4-24 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

Upper
Media Sensor
Adjustment

220XiIII Printer Only

Figure 4-9 Upper Media Sensor Position Adjustment

Lower
Media Sensor

Figure 4-10 Lower Media Sensor Position Adjustment

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-25

SECTION 4 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 XiIII-Series printers, the position of the
reflective media sensor is fixed against the mainframe and has no adjustment. Refer to the printer
user's guide to configure the printer for operation with either the reflective media sensor or the
transmissive media sensor previously discussed.
LCD Viewing Adjustment
The brightness of the liquid crystal display (LCD) may be adjusted for optimal viewing. Refer to the
LCD ADJUST configuration parameter in the printer's user's guide.
Take Label Sensor Alignment
The take label (label available) sensor activates only when the Zebra XiIII is set to peel-off mode.
This mode requires the media rewind spindle option. The media sensor pair is NOT installed on
Zebra XiIII printers without this option.
Refer to Figure 4-11 for the location of the take label sensor components. When the beam is broken,
the XiIII-Series printer will be inhibited from printing or feeding (in peel-off mode only). It may,
however, accept additional label formats if the buffer is not full. There is no sensitivity adjustment
for the take label sensor. If you encounter problems, make certain the XiIII printer is set to peel-off
mode and the sensors are aligned. Sensors are aligned at the factory or when the media rewind
spindle option is installed. No adjustments are required after installation.

Label
Available
Sensors

Figure 4-11 Take Label (Label Available) Sensor Location

4-26 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

MEDIA TRACKING ADJUSTMENTS

Rewind Mode
If the media walks from side to side, tears, or wrinkles against the media rewind tracking plate, it
will be necessary to adjust the rewind plate assembly. Refer to Figures 4-12 and 4-13.
1. Remove the rewind plate assembly and loosen the 5/16 hex nuts, which attach the hook plate to
the rewind plate. Moving the outer end of the hook plate up will force the media towards the
rewind tracking plate while moving this end down will move the media away from the tracking
plate. (The opposite effect will occur if the same adjustments are performed on the inner end of
the hook plate.)
2. Reinstall the rewind plate assembly and print a number of test labels. If problems persist,
readjust the hook plate.
3. If the media cannot be made to track correctly with this adjustment, check the distance from the
outside of the tracking plate to the main frame. This dimension is set at the factory and should
be 0.547 (13.9 mm) to 0.567 (14.4 mm). If the distance needs to be reset, refer to Figure 4-13
and proceed to step 4 below.
4. Use a 1/16 hex allen wrench to loosen the two set screws in the collar located inside the rewind
spindle assembly. The screws are accessible through a single hole in the spindle assembly, as
shown in Figure 4-13. Reposition the spindle assembly closer to or farther from the main frame
as required, and retighten the two collar set screws.
5. Perform steps 1 and 2 until required results are achieved.

Hook Plate

Rewind Plate

Hex Nuts

Figure 4-12 Rewind Plate Assembly

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-27

SECTION 4 MAINTENANCE

1/16 Inch
Hex Allen Wrench
Tracking
Plate

Collar

Figure 4-13 Rewind Spindle Positioning

Peel-Off Mode
In peel-off mode, the lower roller alignment has the same affect on media tracking as the rewind
plate alignment does in rewind mode. Refer to Figure 4-14 and perform the following procedure.
1. Use a 7/64” hex allen wrench to loosen the two allen head screws which attach the platen support
bracket to the side plate.
2. Moving the bracket toward the front of the machine moves the label backing material away from
the rewind tracking plate. Moving the bracket toward the rear of the machine moves the label
backing toward the tracking plate. Adjust bracket position as required and tighten the allen head
screws.
3. Repeat steps 1 and 2 until required results are achieved.

4-28 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

7/64" Hex
Allen
Screws
Lower
Roller
Platen
Support
Bracket

Figure 4-14 Peel-Off Lower Roller Alignment

Spindle Adjustment and Maintenance

There are four spindles that 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.

WARNING

DO NOT DISASSEMBLE SPINDLE!!!

Tension Measurement Procedure

The procedure for measuring spindle tension is similar for all four spindles. Refer to the Spindle
Tension Adjustment Diagram in Figure 4-15 for any specific requirements.
1. Use adhesive tape to attach a 2 wide strip of polyester film (part # 01776) to the spindle shaft (or
core where required) as illustrated in Figure 4-15. Wind the polyester film around the spindle (or
core) about 5 times in the direction indicated.
2. Measure tension by slowly pulling the film with a spring scale. Pull ONLY in the direction
shown. The pull rate should typically be 2” per second.
3. Compare the spring scale reading with the force values provided in Figure 4-15. Perform the
spindle adjustment only if the reading is out of spec.
4. If adjustment is made, recheck the tension after running a full roll of labels.
48152L Rev. 1 07/00 XiIII Maintenance Manual 4-29
SECTION 4 MAINTENANCE

Spindle Tension Adjustment

Refer to the spindle tension adjustment diagram in Figure 4-15 and adjust the spindle tension as
follows:
1. Loosen the set screw(s) if present in the adjustment nut at the end of the spindle.
2. Turn the adjustment nut clockwise to increase the tension or counter-clockwise to decrease the
tension. Tighten the set screws if present.
NOTE: If the shaft of the ribbon take-up, media take-up or optional media supply spindle turns
when attempting to turn the adjustment nut. Refer to Figure 4-13 and insert an allen
wrench through the access hole on the inner end of the spindle and into the set screw in
the shaft collar. DO NOT TURN THE ALLEN WRENCH. Simply hold the shaft in
place with the allen wrench while turning the adjustment nut.
3. Measure the spindle tension as performed above. Compare the tension reading on the spring
scale with the appropriate force value provided in Figure 4-15. Repeat the adjustment procedure
until the correct tension is obtained.
Spindle Maintenance
• Tension should be checked periodically.
• Spindles should be kept clean of dust, dirt etc.

WARNING
DO NOT APPLY LUBRICATION TO ANY OF THE SPINDLES IN THE
XiIII-SERIES PRINTERS.

4-30 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

Align All Three Sections

Before Installing Ribbon Core.

Ribbon Supply F1
Spindle Assy
90/96XiIII 140XiIII 170XiIII 220XiIII
Spindle (force) (grams) (grams) (grams) (grams)
Ribbon Supply (f1) 450 ±50 450 ±50 500 ±50 600 ±50
Ribbon Takeup (f2) 450 ±50 450 ±50 550 ±50 630 ±50
Media Supply (f3) 300 ±50 300 ±50 300 ±50 300 ±50 Attach Polyester
Media Rewind (f4) 1450 ±100 1450 ±100 1650 ±100 1830 ±100
Film Strip To
Ribbon Core
With Tape

F3

Media Supply
Spindle Assy

Media
Core

Push Buttons In

Ribbon Takeup
Spindle Assy

F4

Loosen The Set Screws On The

Adjusting Nut. Turn The Nut
Media Rewind In/out To Increase/decrease
Spindle Assy The Force. After Adjustment,
Secure The Nut To The Shaft
With The Set Screws.

Media
Core

Figure 4-15 Spindle Tension Adjustments

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-31

SECTION 4 MAINTENANCE

REMOVING THE MAIN LOGIC BOARD

The XiIII-Series main logic board may require removal. When replacement is necessary or when
installing various options in the field follow the procedure below to remove the XiIII-Series main
logic board.

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS HIGHLY RECOMMENDED
THE TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP
CONNECTED TO THE PRINTER CHASSIS.

1. Be sure the printer is OFF and the AC power cord and signal interface cables are disconnected.
2. Remove the left side panel of the printer by removing the phillips head screws which hold it on.
3. Remove any font card or memory card from the card slot located at the rear of the printer, by
pressing the card release button.
4. If an optional interface board is installed in the printer, remove it.
5. Refer to Figure 4-16, disconnect all ribbon cable and small wire connectors from the main logic
board (note their positions).
6. Refer to Figure 4-17. At the rear of the printer, remove the screws holding the serial and parallel
interface connectors to the back of the printer.
7. Remove the main logic board by squeezing the tips of the plastic stand-off at the top and bottom
right hand corners of the board.
8. Flash memory is installed on main logic board. Latest software can be downloaded from Zebra
Technologies website.
Installing the Main Logic Board
Follow the procedure below to install the XiIII-Series main logic board.
1. Refer to Figure 4-16 and Table 4-2 and place rotary switch S1 in the proper position for the
printer under repair (rotary switch S2 must remain in the zero (0) position).
2. Refer to Figure 4-17. Position the cables out of the way while placing the main logic board onto
the plastic stand-off at the top and bottom right hand corners of the board.
3. At the rear of the printer, install the 4 phillips head screws which hold the serial and parallel
interface connectors to the back of the printer.
4. Refer to Figure 4-16. Carefully reconnect all the ribbon cables and small wire connections to the
proper connectors on the main logic board.

4-32 XiIII Maintenance Manual 48152L Rev. 1 07/00

 Rotary
Switches S1
S2

Cutter
MAIN LOGIC PCB J7

48152L Rev. 1 07/00

Option
J8
MAINTENANCE

DC Power PCB
J9

Lcd Display J10

Lower J11
Media Sensor
J12
J13
Upper J14
J15
Media Sensor J16
J17
J18
Lower J19
J20
Label Available
Sensor
Upper J21
Label Available
Sensor

XiIII Maintenance Manual

J11
Ribbon Sensor J1 J10 J9
J8 J7
Head Open
Sensor J6 J5
J4
Black Mark AC POWER
Sensor PCB J1

Figure 4-16 Circuit Board Location and Interconnection

T0 J10 On
J3 J2 DC POWER PCB
DC Power PCB

Printhead Printhead Additional Stepper

Data Power Printhead Power Motor
(all XiIII Printers) For 220XiIII Printers LCD Display
Cutter Option

4-33
SECTION 4
SECTION 4 MAINTENANCE

5. Refer to Figures 4-17. If required, install the optional interface board through the rear of the
printer. (Insure the data cable is properly connected between the main logic board and the
interface board.)
6. Reinstall font card or memory card into the card slot located at the rear of the printer.
7. Reconnect the AC power cord and the communication cable.
8. Turn the printer ON and configure the printer parameters. Be sure to enter the printhead
resistance value indicated on the label attached to the printhead.
9. Reinstall the left side panel.
NOTE: During the programming process, you must perform a complete printer calibration.
Pressing the front panel CALIBRATE key will not provide the full calibration process
required when a main logic board is first installed.

Switch Function Switch Function

Position Position
0 Diagnostics 8 140XiIII KST (8 dots/mm 8”/sec max)
1 170PAX Left Hand (12dots/mm) 9 140XiIII KST (8 dots/mm 8”/sec max)
2 170PAX Right Hand (12dots/mm) A 140XiIII KST (8 dots/mm 12”/sec max)
3 170PAX Left Hand (8dots/mm) B 140XiIII KST (8 dots/mm 12”/sec max)
4 170PAX Right Hand (8dots/mm) C Undefined
5 96XiIII Printhead Toshiba D Undefined
6 90XiIII Printhead (12 dots/mm) E 220XiIII Printhead (8 dots/mm)
7 Undefined F 170XiIII Printhead (12 dots/mm)

Table 4-2 S1 Switch Position

4-34 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

DC Power Supply Assembly

Heat Conductor Pad

Switches
Rotary

Main Logic
Interface
Optional

Board

PCB
Optional
Memory

ROMs
Font
Card

(2)

Figure 4-17 Main Logic Board and DC Power Supply Board

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-35

SECTION 4 MAINTENANCE

REMOVING THE DC POWER SUPPLY ASSEMBLY

The XiIII-Series DC power supply assembly may require removal when replacement is necessary or
when installing various options in the field. Follow the procedure below to remove the XiIII-Series
DC power supply assembly.

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS HIGHLY RECOMMENDED
THE TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP
CONNECTED TO THE PRINTER CHASSIS.

1. Be sure the printer is OFF and the AC power cord and signal interface cable are disconnected.
2. Remove the left side panel of the printer by removing the phillips head screws that hold it on.
3. Refer to Figure 4-16. Unplug all ribbon cable and small wire connectors from the DC power
supply board (note their positions).
4. Refer to Figure 4-17. Remove the mounting screw and two hex nuts holding the DC power
supply assembly against the printer chassis.
5. Remove the DC power supply assembly from the printer. (The black heat conduction pad need
not be removed.)
6. Perform the installation procedure below, being very careful with all cables.
INSTALLING THE DC POWER SUPPLY ASSEMBLY
Follow the procedure below to install the XiIII-Series DC power supply assembly.
1. Refer to Figure 4-17. Position the cables out of the way while placing the DC power supply
assembly into the printer. (Insure the heat conduction pad is in position.)
2. Refer to Figure 4-17. Install the mounting screw and two hex nuts that hold the DC power
supply assembly against the printer chassis.
3. Refer to Figure 4-16. Carefully connect all the Ribbon Cables and Small Wire Cables to the
proper connectors on the DC Power Supply Board.
4. Reconnect the AC power cord and the signal interface cable.
5. Hold in the PAUSE key while turning the AC power ON. Observe the printer Power-On Self
Test and examine the test labels which print for proper print quality. (If necessary, refer to the
user's guide to configure the darkness setting.)
6. Reinstall the left side panel.

4-36 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

REMOVING THE AC POWER SUPPLY ASSEMBLY

The XiIII-Series AC power supply assembly may require removal. When replacement is necessary
or when installing various options in the field follow the procedure below to remove the XiIII-Series
AC power supply assembly.

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS HIGHLY RECOMMENDED
THE TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP
CONNECTED TO THE PRINTER CHASSIS.

1. Be sure the printer is OFF and the AC power cord and signal interface cables are disconnected.
2. Remove the left side panel of the printer by removing the phillips head screws that hold it on.
3. Refer to Figure 4-16. Unplug all ribbon cable and small wire connectors from the main logic
board and AC power supply board (note their positions).
4. Remove the hex nut holding the ground lead from the power entry module to the printer chassis.
5. Refer to Figure 4-18. Remove the 2 screws at the top and center right hand corners of the metal
mounting plate directly behind the main logic board.
6. At the rear of the printer, remove the 3 phillips head screws holding the rear panel to the back of
the printer.
7. Slide the main logic board and rear panel assembly out and away from the printer.
8. Remove the AC power supply assembly by removing the 5 hex nuts and 2 spacers which hold
the assembly against the mounting posts. (The black heat conduction pad need not be removed.)
9. Perform the AC power supply assembly installation procedure below, being very careful with all
cables.
INSTALLING THE AC POWER SUPPLY ASSEMBLY
Follow the procedure below to install the XiIII-Series DC power supply assembly.
1. Refer to Figure 4-18. Position the cables out of the way while placing the AC power supply
assembly into the printer. (Insure the heat conduction pad is in position.)
2. Refer to Figure 4-18. Install the 5 hex nuts and 2 spacers that hold the AC power supply
assembly against the printer chassis. (Insure the plastic spacers are installed on the two left
posts.)
3. Slide the main logic board and rear panel assembly into the printer.
4. Refer to Figure 4-18. Install the 2 screws at the top and center right hand corners of the metal
mounting plate directly behind the main logic board.
5. At the rear of the printer, install the 3 phillips head screws which hold the rear panel to the back
of the printer.
6. Use the hex nut to install the ground lead from the power entry module to the printer chassis.
See Figure 4-18.

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-37

SECTION 4 MAINTENANCE

Conduction
Heat

Pad
Main Logic Board
and Rear Panel

Power Entry
Module
Power Supply
Assembly
AC

Figure 4-18 AC Power Supply Board

4-38 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

7. Refer to Figure 4-16. Install all ribbon cable and small wire connectors onto the main logic
board and AC power supply board.
8. Reconnect the AC power cord and the signal interface cable.
9. Hold in the PAUSE key while turning the AC power ON. Observe the printer Power-On Self
Test and examine the test labels which print for proper print quality.
10. Reinstall the left side panel.
11. The printer is now ready for operation.

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-39

SECTION 4 MAINTENANCE

MAIN DRIVE BELT - REMOVAL, REPLACEMENT & ADJUSTMENT

90/96XiIII, 140XiIII and 170XiIII
For 220XiIII, refer to page 4-41.
1. Turn the printer OFF and remove the AC power cord.
2. Remove the left side panel of the printer by removing the phillips head screws that hold it on.
3. Refer to Figure 4-19 and rotate the ribbon take-up pulley until the 3 holes in the pulley are
aligned with the 3 mounting screws which hold the ribbon take-up spindle assembly to the
printer frame.
4. Use a 9/64 allen wrench to reach through the holes in the ribbon take-up pulley and loosen the 3
spindle assembly mounting screws.
5. Slide the ribbon take-up spindle assembly to the right to relieve the tension on the main drive
belt.
6. Remove the old main drive belt and install the new one.
7. Hook a 2200 gram spring scale to the belt as shown in Figure 4-19, 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 1/4
inch, tighten the 3 mounting screws to a torque of 20 inch-pounds.
9. Replace the left side panel and reapply AC power.

Access To
Mounting
Screws

3
2
1 S
C HE
22

IN
0
20

0
00
18
00
16
0
14

0
00

Spring
Scale

Figure 4-19 90/96/140/170 XiIII Main Drive Belt

4-40 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

220XiIII
For 90/96XiIII, 140XiIII and 170XiIII, refer to page 4-40.
1. Turn the printer OFF and remove the AC power cord.
2. Remove the left side panel of the printer by removing the phillips head screws that hold it on.
3. Refer to Figure 4-20 and note the position of the idler gear used to adjust the tension of the main
drive belt.
4. In the media compartment, locate the idler gear mounting screw. Use a 7/64 allen wrench to
loosen the idler gear mounting screw.
5. Refer to Figure 4-20 and slide the idler gear assembly toward the rear of the printer to relieve the
tension on the main drive belt.
6. Remove the old main drive belt and install the new one.
7. Hook a 2200 gram spring scale to the belt as shown in Figure 4-20, and carefully slide the idler
gear assembly toward the front of the printer to increase belt tension.
8. When a scale reading of 2000 grams ± 200 grams (4.5 lbs. ± 0.5 lbs.) creates a deflection of 1/4
inch, tighten the idler gear mounting screw.
9. Replace the left side panel and reapply AC power.

Idler 3
Gear
2
1 S
HE
22
0

IN C
20

0
0
18

0
16

00
14

00
00

Spring
Scale

Figure 4-20 220XiIII Main Belt

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-41

SECTION 4 MAINTENANCE

REWIND DRIVE BELT - REMOVAL, REPLACEMENT & ADJUSTMENT

1. Turn the printer OFF and remove the AC power cord.
2. Refer to Figure 4-17 and remove the DC power supply from the printer.
3. Refer to Figure 4-21 and note the position of the idler gear used to adjust the tension of the
rewind drive belt.

4. On the media side of the printer locate the

lower access hole in the side frame and
remove the plug. Use a 7/64 allen wrench
with a 10" minimum shaft length
(90/96/140/170XiIII) or a 12" minimum shaft
length (220XiIII) to reach through the hole
and loosen the idler gear mounting screw.

Lower Access
Hole

5. Slide the idler gear assembly toward the front of the printer to relieve the tension on the rewind
drive belt.
6. Remove the old rewind drive belt and install the new one.
7. Hook a 2200 gram spring scale to the belt as shown in Figure 4-21, and carefully slide the idler
gear assembly to the left to increase belt tension.
8. When a scale reading of 2000 grams ± 250 grams (4.5 lbs. ± .5 lbs.) creates a deflection of 1/4,
tighten the idler gear mounting screw to a torque of 20 inch-pounds.
9. Refer to Figure 4-17 and perform the DC power supply installation procedure.

4-42 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

1400

1600
1800

2000

2200

Idler
Gear

INCHES
2
31

Figure 4-21 Rewind Drive Belt

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-43

SECTION 4 MAINTENANCE

AC POWER FUSE REPLACEMENT

The XiIII-Series printer uses a metric-style fuse (5 x 20 mm IEC) rated at F5A, 250V. The AC
power entry module comes with two approved fuses in the fuse holder: one is “In-Circuit” and the
second is provided as a “spare” (refer to Figure 4-22). The end caps of the fuse must bear the
certification mark of a known international safety organization (refer to Figure 4-23). To replace a
faulty fuse, use the following procedure.

WARNING
TURN THE PRINTER'S AC POWER SWITCH OFF AND DISCONNECT
THE PRINTER'S AC POWER CABLE BEFORE REPLACING ANY FUSES.

1. Refer to Figure 4-22. Using a small blade screwdriver or similar tool, remove the fuse holder
that is part of the AC power entry module at the rear of the printer.
2. Remove the faulty fuse and install a new fuse in the “In-Circuit” position. If you use the spare
fuse, be sure to order a new replacement fuse. Fuses can be ordered from your Zebra distributor.
3. Snap the fuse holder back into the AC power entry module.
4. Reconnect the power cable and turn printer ON.
NOTE: If AC power is not restored, an internal component failure may have occurred. The
printer will require servicing.

Fuse
Holder AC Power
Entry
Module
Small Blade
Screwdriver

In-Circuit
Fuse

Fuse
Holder
Spare
Fuse

Figure 4-22 AC Power Fuse Replacement

4-44 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

+
R

Figure 4-23 International Safety Organizations

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-45

SECTION 4 MAINTENANCE

PLATEN ROLLER INSTALLATION

Small Spacer for Lower Platen Roller Replacement-

Peel Option Only (Except on 220XiIII)
Large Spacer for Platen Roller Replacement for all Models
(Also Used on 220XiIII Lower Platen Roller Replacement)

Platen Roller
C-Clip

Bearings (2)
Washer

Figure 4-24 Platen Roller Assembly

Platen Roller Replacement

1. Turn the printer off and remove the power cord and the printer communications cable (if
connected).
2. Open the printhead assembly and remove any media and ribbon.
3. Remove the left side panel of the printer by removing the phillips head screws holding it in
place.
4. Carefully slide the main drive belt off of the ribbon take-up Pulley (see Figure 4-25).
5. Using the 2 mm allen wrench loosen, but do not remove, the two set screws in the platen pulley
assembly (see Figure 4-25).
6. Pull the platen pulley off of the platen roller shaft.
7. Using a piece of a label (or masking tape), mark the peel/tear-off bar so that you can identify the
top and right side of the bar for reinstallation (see Figure 4-26).
8. Using the 7/64” allen wrench, remove the peel/tear-off bar mounting screw near the platen roller
shaft (see Figure 4-26).
9. Remove the peel/tear-off bar.
10. Remove the C-clip off the platen roller as shown in Figure 4-26.
11. Slide the platen roller as far to the left as possible and remove the right bearing.
12. Slide the platen roller to the right and remove the roller.
13. Remove the left bearing.
NOTE: Do not re-use the old bearings.

4-46 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

14. Note the orientation of the new bearings in Figure 4-24. Install the new right bearing with the
flange of the bearing on the outside of the right side of the print mechanism (see Figure 4-26).
15. Orient the replacement platen roller so that the short end of the shaft with the groove is on the
right side (when facing the front of the printer).
16. Insert the right end of the shaft into the bearing installed in step 14.
17. Slide the washer included in the kit on the right end of the platen roller shaft as shown in Figure
4-24.
18. Install the C-clip on the right end of the platen roller shaft as shown in Figure 4-26.

Inside Peel/Tear-Off Bar

Mounting Screw

Ribbon Take-Up
Pulley

Main Drive Belt

Platen Pulley Assy

Figure 4-25 Left Side, Side Frame View of Main Drive Belt

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-47

SECTION 4 MAINTENANCE

Platen Roller Pulley

Large Spacer (All Models)

Bearing

Platen Roller
C-Clip

Peel/Tear-Off Bar
Mark with Label/Tape
Top & Right Side Peel/Tear-Off Bar
Mounting Screw Bearing
Washer
Figure 4-26 Print Mechanism

23. Install the left bearing from the left side of the printer, with the flange on the outside (left side) of
the side frame.
24. Reinstall the peel/tear-off bar first by reorienting the bar based on the marking put on it in step 7.
25. Install both of the peel/tear-off bar mounting screws finger tight.
26. Insure that there is a gap between the platen roller and the peel/tear-off bar approximately the
thickness of a business card.
27. Tighten both peel/tear-off bar mounting screws.
28. Slide the large spacer on the left side of the platen roller shaft.
29. Slide the platen roller pulley on the left side of the platen roller shaft. Leave approximately a
.020 gap between C-clip and washer on the right hand side of the platen roller shaft.
30. Tighten the two set screws on the platen roller pulley. Both set screws should be against the flat
portions of the shaft.
31. Reinstall the main drive belt.

4-48 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

32. Reload media and ribbon.

33. Connect the power cord and perform a PAUSE Key Self Test to test print quality and observe the
tracking of the main drive belt.
34. Replace the left side panel.
35. Replace the communications cable.

Peel Option Lower Platen Roller Replacement

1. Turn the printer off and remove the power cord and the printer communications cable (if
connected).
2. Open the printhead assembly and remove any media and ribbon.
3. Remove the left side panel of the printer by removing the phillips head screws holding it in
place.
4. Note and remove all ribbon cable connectors and small wire connectors from the DC power
supply assembly (see Figure 4-27).
5. Remove the mounting screw and two hex nuts holding the DC power supply assembly against
the chassis (see Figure 4-27).
6. Remove the DC power supply assembly.
7. Carefully slide the rewind drive belt off the media take-up pulley (see Figure 4-28).
8. Using the 2mm allen wrench loosen, but do not remove, the two set screws in the peel-off pulley
assembly (see Figure 4-28).
9. Pull the peel-off pulley assembly off the lower platen roller shaft.
10. Using a 7/64” allen wrench, remove the two screws holding the roller adjust plate in place on the
print mechanism (see Figure 4-29).
11. Remove the roller adjust plate and lower platen roller.
12. Remove the old bearing from the printer side frame.
13. Remove the C-clip from the end of the old platen roller.
14. Slide the roller adjust plate off of the old platen roller shaft and remove the bearing.
NOTE: Do not re-use the old bearings.
15. Install a new bearing on the roller adjust plate with the flange of the bearing on the outside (right
side) of the plate.
16. Orient the replacement platen roller so that the short end of the shaft with the groove is on the
right side (when facing the front of the printer).
17. Slide the bearing and roller adjust plate on to the right end of the replacement platen roller shaft.
NOTE: For lower platen roller replacement (peel option only), the washer in the replacement kit
is not used and should be discarded.
18. Slide the C-clip on the groove on the right end of the platen roller shaft.

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-49

SECTION 4 MAINTENANCE

19. Install the new left bearing from the left side of the printer, with the flange on the outside (left
side) of the side frame.
NOTE: For lower platen roller replacement (peel option only), the small spacer is used for all
models except the 220XiIII.
20. Slide the small spacer (large spacer for the 220XiIII) on the left side of the platen roller shaft.
21. Slide the media take-up pulley on the left side of the platen roller shaft. Leave approximately a
.020 gap between C-clip and bearing on the right hand side of the platen roller shaft.
22. Tighten the two set screws on the media take-up pulley. Both set screws should be against the
flat portions of the shaft.
23. Reinstall the rewind drive belt. If necessary, adjust the belt tension per the instructions found on
page 4-42.
24. Reinstall the DC power supply assembly into the printer. Install the mounting screw and two
hex nuts holding the DC power supply assembly against the chassis (see Figure 4-27).
25. Reconnect all ribbon cable connectors and small wire connectors to the DC power supply
assembly. (See Figure 4-27.)
26. Reload media and ribbon in the peel mode.
27. Connect the power cord.
28. Perform a PAUSE Key Self Test and observe the tracking of the rewind drive belt, the tracking
of the label backing material and to test print quality.
If the label backing material is tracking off to one side perform steps 29 through 31.
29. Using a 7/64” allen wrench, loosen the two screws holding the roller adjust plate on the print
mechanism (see Figure 4-29).
30. Move the roller adjust plate in the appropriate direction to compensate for the tracking and
tighten the allen head screws.
• Moving the roller adjust plate toward the front of the printer moves the label backing
material away from the roller adjust plate.
• Moving the roller adjust plate toward the rear of the printer moves the label backing material
towards the roller adjust plate.
31. Repeat steps 29 and 30 until the required results are achieved.
32. Replace the left side panel.
33. Replace the communications cable.

4-50 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

J7

J8

J9
Main Logic J10
PCB
J11

J12
J13
J14
J15
J16
J17J18
J19
J23
J20

J21

J1 J11 J10 J9
J8 J7
J6 J5
J4
AC Power PCB
J3 J1

J2 DC Power PCB

Hex Nut Mounting Screw Hex Nut

Figure 4-27 DC Power PCB Location and Interconnections for XiIII Printers

DC Power Connectors
NOTE: J5-J10 have the same outputs.
J1 J1 AC Power PCB J7 Cutter Option
J2 Additional Printhead Power for 220XiIII Printers J8 N/A
J3 Printhead Power for all XiIII Printers J9 LCD Display
J4 Stepper Motor J10 J20 Main Logic PCB Power
J5 N/A J11 J11 Main Logic PCB Data
J6 N/A

Table 4-3 DC Power Connections

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-51

SECTION 4 MAINTENANCE

Rewind Drive Belt

Media Take-Up
Pulley

Idler
Gear

Peel-Off Pulley Assembly

Figure 4-28 Left Side, Side Frame View of Rewind Drive Belt

Small Spacer For All

Models Except 220XiIII.
Large Spacer For 220XiIII
Only.

7/64” Allen
Bearing Head Screws
Rewind Platen
Pulley
Washers

Platen Roller

Roller Adjust Plate C-Clip

Bearing

Figure 4-29 Print Mechanism View With Lower Platen Roller (Peel Option Only)

4-52 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

OPTION INSTALLATION
Font ROM Installation

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS HIGHLY RECOMMENDED
THE TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP
CONNECTED TO THE PRINTER CHASSIS.

Font ROM installation optional scalable and bit-mapped fonts are available in ROMs.
To install the font ROMs, refer to Figure 4-30 below.
1. Turn the AC power switch OFF and disconnect the power cord.
2. Remove the left side panel of the printer by removing the phillips head screws.
3. If there is a option board installed remove the option card shield. Push the card eject button to
remove option board.
4. If there are program ROM's in the sockets you will have remove them.
5. Insert the tines of the extraction tool firmly into the slots in the chip socket. Be sure the tines
catch under the ROM chip as you gently squeeze. The chip will rise out of the socket.
6. Insert the new ROM with the notched corner positioned to the top, as seen in Figure 4-30.
Slowly seat the chip in place being sure it is straight in the socket.
11
U

Font
ROM U1
0

Gently
Squeeze

Figure 4-30 Font ROM Installation

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-53

SECTION 4 MAINTENANCE

Memory Card and Font Card Installation

To replace the memory card or font card, read the instructions included in the option kit. The
general installation procedure is as follows:

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS HIGHLY RECOMMENDED
THE TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP
CONNECTED TO THE PRINTER CHASSIS.

1. Turn the AC power OFF before installing the card.

2. Refer to Figure 4-31 and remove the option card shield from the rear of the printer.
3. Insert the memory or font card, with the notch UP, into the card slot as shown. (Insert far
enough to cause the eject button to pop out.)
4. Reinstall the option card shield over the option card and card slot.
5. Press and hold the FEED key while turning the printer power switch ON.
6. Verify the presence of additional memory or optional fonts by checking the information on the
configuration label printed during the power on sequence.
7. The printer is now ready to operate with the additional memory or font option.

Card Eject
Button

Memory/font
Option Card Notch
Option Card
Shield

Figure 4-31 Memory and Font Card Installation

4-54 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE SECTION 4

SIMM Installation
To replace the SIMM, read the instructions included in the option kit. The general installation
procedure is as follows:

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS HIGHLY RECOMMENDED
THE TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP
CONNECTED TO THE PRINTER CHASSIS.

1. Be sure the printer is OFF and the AC power cord is disconnected.

2. Remove the left side panel of the printer by removing the phillips head screws that hold it on.
3. Refer to Figure 4-32 and locate the SIMM socket on the main logic board.
4. Install the SIMM into the socket as illustrated in Figure 4-32. Make sure the SIMM is locked
securely into position.
5. Reconnect the AC power cord.
6. Reinstall left side panel.
7. Press and hold the FEED Key while turning the printer power switch ON.
8. Verify the presence of additional memory or optional fonts by checking the information on the
configuration label printed during the power on sequence.
9. The printer is now ready to operate with the additional memory option.

2
1
Insert
Simm On
Angle

Side View

Figure 4-32 SIMM Installation

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-55

SECTION 4 MAINTENANCE

Optional Supply Spindle Installation

1. Be sure the printer is OFF and the AC power cord and printer cable is disconnected.
2. Remove the left side panel of the printer by removing the phillips head screws that hold it on.

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS HIGHLY RECOMMENDED
THE TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP
CONNECTED TO THE PRINTER CHASSIS.

3. Remove any font card or memory card from the card slot located at the rear of the printer, by
removing the option card shield and pressing the card release button. See Figure 4-31.
4. If an optional interface board is installed in the printer, refer to the removal instructions in the
maintenance manual for that board before continuing with this procedure.
5. Refer to Figure 4-33. Unplug all ribbon cable connectors and small wire connectors from the
main logic board, (note their positions).

J7

J8

J9
Main Logic J10
Board
J11

J12
J13
J14
J15
J16
J17
J18
J19
J23
J20

J21

J11
J1 J10 J9
J8 J7
J6 J5
J4
AC Power PCB
J3 J1

J2 DC Power PCB

Figure 4-33 Main Logic Board

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MAINTENANCE SECTION 4

DC Power Connectors
NOTE: J5-J10 have the same outputs.
J1 J1 AC Power PCB J7 Cutter Option
J2 Additional Printhead Power for 220XiIII Printers J8 N/A
J3 Printhead Power for all XiIII Printers J9 LCD Display
J4 Stepper Motor J10 J20 Main Logic PCB Power
J5 N/A J11 J11 Main Logic PCB Data
J6 N/A

Table 4-4 DC Power Connector Identification

Allen Head
Screw

Parallel
Phillips Head
Interface
Connector Screws

DB-25 Serial
Interface 3/16
Connector Studs

AC Power
On/off Switch

AC Power
Cable Connection

Figure 4-34 Rear View

6. Refer to Figure 4-34. At the rear of the printer, remove the screws holding the serial and parallel
interface connectors to the back of the printer.
7. Remove the main logic board by squeezing the tips of the plastic standoff at the top and bottom
right hand corners of the board.
8. Remove the main logic board mounting plate. See Figure 4-35.

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SECTION 4 MAINTENANCE
Main Logic Board
Mounting Plate

Phillips
Screws

Main Logic
Board

Figure 4-35 Mounting Bracket Removal

9. Use a 5/32" allen wrench to remove the media hanger mounting screw and washer. Refer to
Figure 4-36.
10. Remove the media hanger by lifting it straight up then out from the printer frame.

Allen Screw Allen Screw

Washer

Support

Figure 4-36 Removal and Installation

11. Install the media supply spindle with support between the shaft and the printer frame. Refer to
Figure 4-36.
12. Install the screw and washer onto the end of the spindle shaft.
13. Use a 3/16" allen wrench tighten the mounting screw.
14. Re-install main logic board mounting plate. Refer to Figure 4-35.
15. Re-install the main logic board. Refer to Figure 4-35.

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MAINTENANCE SECTION 4

16. Reconnect all cables and small wire connector removed previously. See Table 4-4
17. Re-install any optional memory/font boards and option card shield. See Figure 4-31
18. Re-install any optional interface boards.
19. Reconnect cabling to interface boards.
20. To adjust spindle tension, refer to Figure 4-37.
21. Use adhesive tape to attach a 2 wide strip of polyester film (part # 01776) to the spindle shaft (or
core where required) as illustrated. Wind the polyester film around the spindle (or core) about 5
times in the direction indicated
22. Measure tension by slowly pulling the film with a spring scale. Pull ONLY in the direction
shown. The pull rate should typically be 2” per second.
23. The spring tension reading should 300 grams ±50.
If not make adjustments using the tension adjustment nut.
• Clockwise increases tension.
• Counter clockwise decreases tension.
24. If adjustment is made, recheck the tension after running a full roll of labels.

Tension Adjustment
Nut

Media Supply
Spindle Assy

Media
Core

Figure 4-37 Spindle tension adjustment

25. Re-install side panel.

26. Refer to user guide for installation of media and ribbon.

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-59

SECTION 4 MAINTENANCE

Optional Bifold Door Installation

1. Raise the existing Media Access Socket Head

Door. Cap Screw

2. Remove the five (5) 6-32 7/64”

socket head cap screws (Be sure to
have a good hold on the door when
removing the last screws) and set
screws aside (see Figure 4-38).
3. Remove old door

Figure 4-38 Old Door Removal

Socket Head
Cap Screw
4. Install new door using the five (5)
6-32 7/64” socket head cap screws
removed in step 2 (see Figure 4-39).
5. Installation is complete.

Figure 4-39 New Bifold Door Installation

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MAINTENANCE SECTION 4

Optional Counter Board Installation

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS RECOMMENDED THAT THE
TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP CONNECTED TO
THE PRINTER CHASSIS.

Refer to Figure 4-40 when completing this procedure.

1. Be sure the printer is OFF and the AC power cord and printer cable is disconnected.
2. Remove the left side panel of the printer by removing the phillips head screws.

Figure 4-40 Side View of Printer

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SECTION 4 MAINTENANCE

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS RECOMMENDED THAT THE
TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP CONNECTED TO
THE PRINTER CHASSIS.

3. Locate the two mounting holes in the main logic board mounting plate.
4. Install the two plastic standoffs in these holes.
5. Align the counter board, with the cable connector on top, with the standoffs. Attach the counter
board to the standoffs using the two plastic screws supplied.
6. Attach the cable as seen in Figure 4-40 to the counter board.
7. Connect the other end of the ribbon cable to either J7 or J8 on the main logic board.
8. Route the power connector and wires through the cable tie seen in Figure 4-40. Connect the
open end of the power connector to either of the open plugs, J5 through J10 on the DC power
supply.
9. Install the side panel removed in step 2.

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MAINTENANCE SECTION 4

Rewind Option
The printer must be partially disassembled in order to install the various parts provided in this kit.
Follow the procedures listed below.
1. Turn printer power OFF at the rear of the printer and disconnect the AC power cord.
2. Remove all media and ribbon from the printer.
3. Access the electronics cabinet by removing the screws in the left side panel.
4. Disconnect all wires and cables attached to the DC power supply board.
5. Inside the electronics cabinet, remove the mounting screw and two nuts which hold the
DC power supply assembly in position. See Figure 4-41.

DC Power Supply Assembly

Heat Conductor Pad

Figure 4-41 DC Power Supply

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SECTION 4 MAINTENANCE

6. Remove the DC power supply assembly from the printer chassis.

7. Open the media access door, locate and remove the plastic plug in the lower access hole near the
bottom of the print mechanism side plate (see Figure 4-42). Save the plug.

2
1

Rewind Spindle
3 Mounting Hole

5
11

6
10
Lower Access Hole
4
7 9
Rewind Platen
Mounting Hole 8
3 2
Note: Spacer Must Be
Positioned between the
Rewind Drive Belt and
the Main Drive Belt 18
Stepper Motor 19
Main Drive
Pulley
Belt 16
12 15

Spacer
19
20 13
23
14
17

22
21

2
Lower Access Hole
8

18

Figure 4-42 Rewind Assembly Installation

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MAINTENANCE SECTION 4

Parts List
Table 4-6 lists the parts found in the Media Rewind Option Kits. The last four columns indicate
which parts are used in the particular kit for the different printers. Use Table 4-6, Figure 4-42 to do
an inventory of the parts before installing the kit. The parts received are dependent on the kit
ordered for a particular printer. Labels on the parts packaged in the kits may not show the "M"
reorder designation shown on some of the part numbers in Table 4-5.

NOTE: Only the parts listed in Table 4-5 (with part numbers) are available as service items.
Parts for the assemblies and some of the assemblies are not available (N/A) as service
items.

Platen Roller Maintenance Kit (contains items 3, 4, 9 & 21

22101M
above) 220XiIII
Platen Roller Maintenance Kit (contains items 3, 4, 9 & 21
Platen Roller 40038M
above) 140XiIII
Replacement
Kit Part Platen Roller Maintenance Kit (contains items 3, 4, 9 & 21
46278M
Numbers above) 170XiIII
Platen Roller Maintenance Kit (contains items 3, 4, 9 & 21
47601M
above) 90XiIII

Table 4-5 Kit Numbers

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SECTION 4 MAINTENANCE

PART 22455 46355 47355 48355

" ITEM QTY DESCRIPTION
NUMBER 220XiIII 170XiIII 90XiIII 140XiIII
30393- Screw, 8-32 X X X X
1 3
006
2 6 40193 Washer, Flat X X X X
N/A Flange Bearing (Part of Platen Roller X X X X
3 2
Kits)
N/A Platen Roller (Part of 22101M) X
N/A Platen Roller (Part of 46278M) X
4 1
N/A Platen Roller (Part of 47601M) X
N/A Platen Roller (Part of 40038M) X
22155M Rewind Spindle Assy (220XiIII) X
46249M Rewind Spindle Assy (170XiIII) X
5 1
47155M Rewind Spindle Assy (90XiIII) X
48155M Rewind Spindle Assy (140XiIII) X
47062-4 J-Hook (220XiIII) X
47062-3 J-Hook (90XiIII) X
6 1
47062-2 J-Hook (140XiIII) X
47062-1 J-Hook (170XiIII) X
7 1 40019 Platen Support Bracket X X X X
30392- Screw, 6-32 X X X X
8 3
004
9 1 02252 E-Ring X X X X
22383M Rewind Plate (220XiIII) X
46383M Rewind Plate (170XiIII) X
10 1
47383M Rewind Plate (90XiIII) X
48383M Rewind Plate (140XiIII) X
22334M Bearing Housing Assy (220XiIII) X
11 1
30334M Bearing Housing Assy (all but 220XiIII) X X X
12 1 31336M RTU/MTU Pulley Assy X X X X
13 1 30118 E-Ring X X X X
14 1 45189-2 Drive Belt, Rewind X X X X
15 1 30114 Washer, Flat X X X X
16 1 30115 Washer, Wave X X X X
17 1 30914M Pulley, Rewind Platen X X X X
18 1 46609-4M Take Label Sensors Assy X X X X
19 2 07435 Screw 6-32 X X X X
22265 Idler Pulley (220XiIII) X
20 1
30265 Idler Pulley (all but 220XiIII) X X X
21 1 N/A Spacer (Part of Platen Roller Kits) X X X X
22207 Idler Shaft (220XiIII) X
22 1
30207 Idler Shaft (all but 220XiIII) X X X
23 1 N/A Spacer (Part of 31336M) X X X X
N/S 1 11301 Hex Allen Wrench, Long 7/64" X X X X
N/A – Not Available As Separate Service Item
N/S – Not Shown

Table 4-6 Media Rewind Option Kit Parts List

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Installation
1. Place a flat washer (Figure 4-42, #2) onto one of the socket head cap screws (Figure 4-42, #8).
Use the 7/64" allen wrench provided with this kit to 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 (Figure 4-42, #22) to the
mounting screw.
2. Position the idler shaft in the middle of the mounting slot and tighten the mounting screw. Apply
a very small amount of grease (provided in kit) to the idler shaft with a toothpick or small
screwdriver. Be very careful to keep excess grease away from other components.
3. Slide the idler pulley (Figure 4-42, #20), flat side out, onto the idler shaft.
4. In the lower center portion of the main frame, remove the cover plate from the rewind spindle
mounting hole (see Figure 4-42). The cover plate and mounting screws are not reused.
5. Slide the bearing housing assembly (Figure 4-42, #11) out of the media rewind spindle assembly
(Figure 4-42, #5).
6. Install the bearing housing assembly on the printer main frame using three of the socket head cap
screws (Figure 4-42, #1) and three flat washers (Figure 4-42, #2). Do not tighten the screws at
this time.
7. Insert the shaft of the rewind spindle (Figure 4-42, #5) through the bearing housing assembly.
8. Place the wavy washer (Figure 4-42, #16), flat washer (Figure 4-42, #15), and pulley
(Figure 4-42, #12) over the rewind spindle shaft.
9. Slide the spacer (Figure 4-42, #23) on the rewind spindle shaft. Press the "E" ring
(Figure 4-42, #13) into the groove in the rewind spindle shaft.
10. Attach the platen support bracket (Figure 4-42, #7) to the side plate with two (2) flat washers
(Figure 4-42, #2) and two (2) socket head cap screws (Figure 4-42, #8). Do not tighten the
screws at this time.
11. Remove the plastic plug from the rewind platen mounting hole near the bottom of the main
frame (see Figure 4-42).
12. Insert the long end of the rewind platen shaft (Figure 4-42, #4) through the rewind platen
mounting hole.
13. Place the flange bearing (Figure 4-42, #3) over the left end of the rewind platen shaft. Press the
bearing into the mounting hole with the flange on the outside (left side) of the main frame.
14. Place the opposite end of the rewind platen shaft through the platen support bracket (Figure
4-42, #7).
15. Place the remaining flange bearing (Figure 4-42, #3) over the right end of the rewind platen shaft
with the flange of the bearing on the outside (right side) of the platen support bracket. Press it
into the mounting hole in the platen support bracket and secure with the E-Ring (Figure
4-42, #9).
16. Use a 7/64" hex allen wrench and tighten the mounting screws that secure the platen support
bracket to the side plate. The bracket may need adjustment later.
17. Slide the spacer (Figure 4-42, #21) onto the rewind platen shaft.

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SECTION 4 MAINTENANCE

18. Slide the rewind platen pulley (Figure 4-42, #17) onto the rewind platen shaft and align the two
pulley set screws with the flat surfaces of the rewind platen shaft.
19. Leave approximately a .020 gap between the E-Ring (Figure 4-42, #9) and platen support bracket
(Figure 4-42, #7) and tighten the two pulley set screws with a 1/16" hex allen wrench.
20. Position the rewind plate as shown in Figure 4-43 with the attached hook plate pointing down.
21. Insert the hook plate a short distance (1/2") into the lower opening in the side plate.
22. Align the upper end of the media rewind plate with the corresponding opening in the side plate
and slide the rewind plate in so that it stops against the printer's main frame (see Figure 4-43).
Drive Belt Tension Adjustment
1. Use a 9/64" hex allen wrench to loosen, but do not remove, the three socket head cap screws that
hold the ribbon take-up spindle assembly at the top of the printer main frame. Access the cap
screws through the three holes in the ribbon take-up pulley.
2. Slide the ribbon take-up assembly towards the front of the printer, relieving the belt tension, and
remove the main drive belt from the stepper motor pulley.
3. Route the rewind drive belt (Figure 4-42, #14) around the stepper motor pulley, media take-up
pulley assembly (Figure 4-42, #12), the rewind platen pulley (Figure 4-42, #17) and the idler
pulley (Figure 4-42, #20). The spacer on the stepper motor pulley must be positioned between
the rewind drive belt and the main drive belt.
4. Slide the rewind assembly (Figure 4-42, #5) towards the rear of the printer until the belt
(Figure 4-42, #14) tension is tight or adjustment margin is used up. Tighten the (3) socket head
cap screws with a 9/64" hex allen wrench, using the (3) access holes in the media take-up pulley
assembly (Figure 4-42, #12).
5. Grasp the idler pulley and shaft assembly (Figure 4-42, #20), while loosening the socket head
cap screw (Figure 4-42, #8) with the long 7/64" hex allen wrench. Slide the assembly towards
the rear of the printer, until belt tension is tight, then tighten the socket head cap screw.
6. Hook a spring scale at the midpoint of the lower section of the belt and pull up. The belt should
deflect .250 inches with a tension of 2000 grams (4.5 lbs.). Readjust the belt tension by
changing the position of the idler pulley.
7. When adjustment is completed, reinstall the plastic plug in the lower access hole
(see Figure 4-42) in the print mechanism side plate.
8. Replace the main drive belt over the stepper motor pulley, platen pulley, and ribbon take-up
pulley. Make sure the spacer on the stepper motor pulley is positioned to the outside of the
rewind belt.
9. Slide the ribbon take-up assembly towards the rear of unit until the belt tension is tight. Tighten
the (3) socket head cap screws with a 9/64" hex allen wrench using the (3) access holes in the
ribbon take-up pulley.
10. 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 .250
inches with a tension of 2000 grams (4.5 lbs.). Readjust the belt tension by changing the position
of the ribbon take-up assembly.

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Label Available Sensor Installation

(Do Not Install on Cutter Units)
The Take-Label Sensors are only required in the Peel-Off Mode of operation.
1. Remove the upper and lower take-label sensor cover plates by removing the two socket head cap
screws with a 7/64" hex allen wrench.
2. Refer to Figure 4-43 for label sensor location. Insert the upper take-label sensor assembly
(Figure 4-42, #18, black/blue wires) connector and cable through the upper take-label sensor
hole in the main frame.
3. Position the sensor with the window facing directly down and use one (Figure 4-42, #19) screw
to fasten the sensor in place.
4. Refer to Figure 4-43 for label sensor location. Insert the lower take-label sensor assembly
(Figure 4-42, #18, black/green wires) connector and cable through the lower take-label sensor
hole in the main frame.
5. Position the sensor with the window facing directly up and use one (Figure 4-42, #19) screw to
fasten the sensor in place.
6. Route the wires through the cable clamps and toward the main logic board (see Figure 4-33).
Make sure that the wires do not come in contact with any moving parts.
7. Connect the upper label available sensor connector to J16 on the main logic board and the lower
label available sensor connector to J15 (see Figure 4-33).

NOTE: When in the "PEEL OFF" mode, if the two sensors are not aligned with each other, the
take label LED will come on and the printer will not operate.

Hook Plate

Rewind Plate

Hex Nuts

Figure 4-43 Label Available Sensor Location

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SECTION 4 MAINTENANCE

Printer Reassemble
1. Install the DC power supply assembly and mounting hardware.
2. Replace the left side panel and mounting screws.
3. Reconnect the AC power cord.
4. Printer reassemble is now complete.
Adjustments
The Rewind Option Kit usually requires some 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
1. If the media walks from side to side or 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 or the rewind spindle assembly. Refer to Figures 4-43 and 4-44.
2. Remove the rewind plate assembly from the front of the printer and loosen the 5/16" Hex nuts
(see Figure 4-43) which attach the hook plate to the rewind plate.
Move the outer end of the hook plate (see Figure 4-43) up, to force the media to wind closer to
the large backing plate (see Figure 4-44) on the rewind spindle, once the printer is placed back in
operation.

or
Move the outer end down to force the media away from the backing plate.
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.
4. If the media cannot be made to track correctly after making this adjustment, check the distance
from the backing plate to the main frame. This dimension is set at the factory and should be
.550" (14 mm) ± .020" (.5 mm). If the distance needs to be reset, refer to Figure 4-44 and
perform steps 5 and 6.
5. Use a 1/16" hex allen wrench to 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, as shown in Figure 4-44. Reposition the backing plate as required
and retighten the set screws in the collar.
6. Perform the rewind plate assembly adjustment in steps 1 and 2 until the desired results are
achieved.

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1/16“ Hex
Allen Wrench

Backing Plate

J-Hook

Figure 4-44 Position Adjustment of Rewind Spindle Assembly

Tension Adjustment
If the backing material is wound too tight on the spindle, it can cause mis-registration of labels,
tearing, or poor print quality due to smudging. Backing material rewound too loose could jam up the
printer before completing a roll, or make it impossible to separate the labels from the backing. Refer
to Figure 4-45 to adjust the tension.
1. A spring scale gauge should be used to set the spindle tension. Use adhesive tape to attach a 2"
wide by 30" long strip of polyester film to the spindle in the direction shown in Figure 4-45.
2. Insert the spring scale tip through the reinforced hole in the end of the strip and pull slowly and
evenly (2" per second) in the direction shown. Make this measurement several times to insure an
accurate reading. This tension should be approximately 1200-1400 grams.
3. If required, readjust the tension as described below and re-check the tension setting.
4. Use a 1/16" hex allen wrench to loosen the two set screws in the tension adjusting nut at the end
of the rewind spindle assembly (see Figure 4-45).
5. To keep the spindle from rotating while turning the adjusting nut, insert the 1/16" hex allen
wrench through the access hole at the rear of the rewind spindle into one of the set screws in the
collar.
6. Refer to Figure 4-45. Turn the adjusting nut with fingers or pliers clockwise for more tension, or
counter-clockwise for less tension.
7. Tighten one of the adjusting nut set screws and retest (step 2).

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SECTION 4 MAINTENANCE

8. If proper tension is not achieved, loosen the set screws and readjust the adjusting nut as needed.
9. When proper tension is obtained, tighten both set screws 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.

Spring Scale

Polyester Strip

Adjusting Nut

Figure 4-45 Tension Adjustment of Rewind Spindle Assembly

Peel-Off Mode Adjustments

Lower Roller Adjustment
If the media walks from side to side, it may be necessary to adjust the position of the lower roller.
Refer to Figure 4-42.
1. Use a 7/64" hex allen wrench to loosen the (2) socket head cap screws (Figure 4-42, #8) which
attach the platen support bracket (Figure 4-42, #7) to the side plate.
2. Moving the bracket toward the rear of the printer will force the media to wind closer to the main
frame. Moving the bracket toward the front of the machine will move the media away from the
Main Frame. Adjust as required and tighten the socket head cap 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 tension adjustment procedures on the previous
page used for the REWIND MODE ADJUSTMENTS.

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MAINTENANCE SECTION 4

Optional Interface Boards

Ribbon Cable
Connector

Test
Button
Status
Indicator
Ethernet
Connector

Figure 4-46 Internal PrintServer II

Test Button – This generates a detailed configuration label.

Status Indicator – A bi-colored indicator displays the state of the PrintServer II.
Ethernet Connection – Connection for a 10BaseT cable. Connecting the PrintServer II will not
interrupt network operation.
Ribbon Connector – The internal PrintServer II is powered by the printer; no additional power
source is required.

NOTE: To print a configuration label from your Zebra printer, a 4” wide by 6” long label is
recommended. If the label is smaller, some information may print outside the label
edges. If you are printing on a 90XiII or 90XiIII-Series printer, some of the heading
information on the right side of the label will not print. Refer to Figure 4-47 for any
missing data.

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SECTION 4 MAINTENANCE

Figure 4-47 Configuration Label Internal PrintServer II

Internal PrintServer II Installation

This section provides the information necessary to install the internal PrintServer II in the Zebra ,
XiIII-Series printers. Read this section completely before performing the installation procedure.
NOTE: The parallel port on the back of the printer is not operational when the internal
PrintServer II is installed. The hardware of the PrintServer II mounting bracket covers
the parallel port (refer to Figure 4-49).
This installation should be performed by a qualified service technician. The service technician must
follow the step-by-step procedure provided in these instructions.
After you have finished installing the PrintServer II hardware; refer to the appropriate section of this
guide for information on establishing a connection for your network type.

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS RECOMMENDED THAT THE
TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP CONNECTED TO
THE PRINTER CHASSIS.

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MAINTENANCE SECTION 4

1. Turn the printer power off and disconnect the AC power cord.
2. Refer to Figure 4-48 or 4-49. At the rear of the printer, remove the two screws and the blank
cover plate or an existing optional interface board positioned next to the main RS-232 and
parallel interface connectors.

Parallel
Interface
Connector
DB-25 Serial Remove Screws
Interface and Plate
Connector

AC Power
On/Off Switch
AC Power
Cable Connection

Figure 4-48 Rear View

3. Remove the left side panel.

4. Insert the ribbon cable and PrintServer II device through the mounting slot.
5. Fold the cable and the ferrite bead back over the mounting bracket (Figure 4-49), and connect the
ribbon cable connector into the keyed Interface Data Cable Connector (J4) on the main logic
board. Make sure the connector is properly seated and that pin 1 of the Interface Data Cable
Connector is connected to pin 1 of J4.

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SECTION 4 MAINTENANCE

Ferrite
Bead

Data Cable
Connector
Ribbon Cable

Ribbon Cable

Ferrite
Bead

Figure 4-49 Interface Board Location

6. Fasten the PrintServer II interface board in place with the cover plate screws removed in step 2.
7. Check all small cable connectors along the back of the main logic board for firm connections.
Reinstall the left side-panel.
8. This kit includes a label printed with the Ethernet MAC hardware address for the PrintServer II.
Remove the backing from the label and affix it to the back of the printer.
9. Reconnect the AC power cord and turn the printer power on.
10. Consult your System Administrator before configuring the PrintServer II for your network!

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MAINTENANCE SECTION 4

External PrintServer II Installation

Hardware Description

Figure 4-50 External PrintServer II

Test Button – This generates a detailed configuration label.

Status Indicator – A bi-colored indicator displays the state of the PrintServer II.
Ethernet Connection – Connection for a 10BaseT cable. Connecting the PrintServer II will not
interrupt network operation.
Parallel Connector – The external PrintServer II is powered by the printer; no additional power
source is required.
External PrintServer II Installation
The external ZebraNet PrintServer II is installed using the following steps:
1. Turn the printer power off. Attach the PrintServer II device directly into the parallel port on the
printer. Secure the PrintServer II to the printer with the wire locks.
2. Insert an active 10BaseT cable into the Ethernet connector on the back of the PrintServer II
device.
3. Turn the printer power on. The status indicator will blink orange during the POST (Power-On
Self Test) phase and change to green when stabilized.
4. Press the test button located on the back of the PrintServer II. This will print out a configuration
label.
NOTE: To print a configuration label from your Zebra printer, a 4” wide by 6” long label is
recommended. If the label is smaller, some information may print outside the label
edges. If you are printing on a 90XiIII or 90XiIII-Series printer, some of the heading
information on the right side of the label will not print. Refer to Figure 4-47 for any
missing data.

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SECTION 4 MAINTENANCE

Twinax Communications Interface Boards

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS RECOMMENDED THAT THE
TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP CONNECTED TO
THE PRINTER CHASSIS.

Installation Instructions
1. Turn the power OFF and disconnect the AC power cord.
2. Refer to Figure 4-51. At the rear of the printer, remove the two screws and the blank cover plate
or existing interface board positioned next to the main RS-232 and parallel interface connectors.
(Save the screws.)
3. To access the electronics area remove the left side panel by removing the fastening screws.

Interface
Board

Data Interface
Cable Data
Connector Cable

Figure 4-51 Twinax Installation

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4. Refer to Figure 4-51. Plug the 40 pin interface data cable into the keyed interface data cable
connector (J4) on the main logic board.
5. Insert the twinax Interface Board partially into the mounting slot then attach the other end of the
interface data cable into the data cable connector at the rear of the twinax interface board.
(Make sure pin 1 of J4 is connected through the cable to pin 1 of the interface data cable
connector.)
6. Dress the ribbon cable behind the twinax interface board as you slide the board completely into
the printer.
7. Fasten the twinax interface board in place with the screws removed in step 2; then reinstall the
side cover.
8. Connect the 9-pin twinax adapter cable connector to the mating connector on the interface board.
9. Connect the twinax cable from the host computer to the mating connector on the adapter cable.
10. Set the DIP switches in the proper positions for the application; see Table 4-7 then reconnect the
power cord and turn the AC power on.
11. Insure the printer configuration is set to:

Parameter Setting
Host Port Twinax/Coax

12. Send a sample label format from the host computer to the printer to test for proper operation.

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SECTION 4 MAINTENANCE

Dip Switch Setting

Print complete
Switch #1 Description
Left An “Operation Complete” status message is sent to the host after a label format is
completely printed. The host can then send the next label format to be printed.
Right Enables the “Early Print Complete” function. The host can send additional print jobs
to the Zebra printer without waiting for the actual completion of the current print job.
The printing status sent to the host reflects the label formats received, not the ones
completed.
EBCDIC Buffer Print
Switch #2 Description
Left Normal operation (received EBCDIC data is translated to ASCII Data).
Right Received EBCDIC data prints as large characters that are readable hex equivalents.
Printer Emulation Selections
Switch #3 Switch #4 IBM Printer Configured
Left Left 5256 Model 3
Left Right 5225 Model 4
Right Left 5224 Model 2
Right Right 4212 Model 2
Default Language Selections
Switch #5 Switch #6 Switch #7 Switch #8 Language Selected
Left Left Left Left 0 -Multinational
Left Left Left Right 1 - USA/Canada (Factory setting)
Left Left Right Left 2 - Austria/Germany
Left Left Right Right 3 - Belgium
Left Right Left Left 4 - Brazil
Left Right Left Right 5 - Canada (French)
Left Right Right Left 6 - Denmark/Norway
Left Right Right Right 7 - Finland/Sweden
Right Left Left Left 8 - France
Right Left Left Right 9 - Italy
Right Left Right Left A - Japan
Right Left Right Right B -Japan (English)
Right Right Left Left C - Portugal
Right Right Left Right D - Spain
Right Right Right Left E - Spanish Speaking
Right Right Right Right F - United Kingdom
NOTE: The language character sets 1 - US/Canada and B - Japan (English) are the same. The
character sets for D - Spain and E - Spanish Speaking are the same.

Table 4-7 Dip Switch Settings

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Dip Switch Setting (cont'd)

Cable Address Switch Settings
Switch #9 Switch #10 Switch #11 Address Selected
Left Left Left 0 – (Factory Setting)
Left Left Right 1
Left Right Left 2
Left Right Right 3
Right Left Left 4
Right Left Right 5
Right Right Left 6
Right Right Right 7 – (Use in Diagnostic Mode Only)
Star Panel Overdrive
Switch #12 Description
Left Normal Operation

Table 4-7 Dip Switch Settings (cont'd)

After setting the DIP switches, turn the printer power OFF and back ON. With the exception of DIP
switch #2, the printer monitors the positions of the DIP Switches only during the Power-On Self
Test.
The EBCDIC Buffer Print function is enabled whenever DIP Switch #2 is placed in the “Right”
position.

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SECTION 4 MAINTENANCE

Coax Communications Interface Boards

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS RECOMMENDED THAT THE
TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP CONNECTED TO
THE PRINTER CHASSIS.

Installation Instructions
1. Turn the power Off and disconnect the AC power cord.
2. Refer to Figure 4-52. At the rear of the printer, remove the two screws and the blank cover plate
or existing interface board positioned next to the main RS-232 and parallel interface connectors.
(Save the screws.)
3. To access the electronics area, remove the left side panel by removing the fastening screws.

Interface
Board

Data Interface
Cable Data
Connector Cable

Figure 4-52 Coax Communications Interface Board Installation

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MAINTENANCE SECTION 4

4. Refer to Figure 4-52. Plug the 40 pin interface data cable into the keyed interface data cable
connector (J4) on the main logic board.
5. Insert the coax interface board partially into the mounting slot then attach the other end of the
interface data cable into the data cable connector at the rear of the coax interface board.
(Make sure pin 1 of J4 is connected through the cable to pin 1 of the interface data cable
connector.)
6. Dress the ribbon cable behind the coax interface board as you slide the board completely into the
printer.
7. Fasten the coax interface board in place with the screws removed in step 2; then reinstall the side
cover.
8. Connect the 9-pin coax adapter cable connector to the mating connector on the interface board.
9. Connect the coax cable from the host computer to the mating connector on the adapter cable.
10. Set the DIP switches in the proper positions for the application, refer to Table 4-8, then reconnect
the power cord and turn the AC power on.
11. Insure the printer configuration is set to:

Parameter Setting
Host Port Twinax/Coax

12. Send a sample label format from the host computer to the printer to test for proper operation.

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SECTION 4 MAINTENANCE

Dip Switch Setting

Test Mode
Switch #1 Description
Left Normal label printing operation.
Right When printer power is applied, the coax interface performs a self-test. A self test label
printout lists the coax interface software revision, the selected language, results of the
RAM/ROM tests and a sample code 39 bar code.
EBCDIC Buffer Print
Switch #2 Description
Left Normal operation (received EBCDIC data is translated to ASCII Data).
Right Received EBCDIC data prints as large characters which are readable hex equivalents.
Use only for troubleshooting with the printer in the “Diagnostics” mode.
Default Language Selections
Switch #3 Switch #4 Switch #5 Switch #6 Language Selected
Left Left Left Left 0 -Multinational
Left Left Left Right 1 - USA/Canada (Factory setting)
Left Left Right Left 2 - Austria/Germany
Left Left Right Right 3 - Belgium
Left Right Left Left 4 - Brazil
Left Right Left Right 5 - Canada (French)
Left Right Right Left 6 - Denmark/Norway
Left Right Right Right 7 - Finland/Sweden
Right Left Left Left 8 - France
Right Left Left Right 9 - Italy
Right Left Right Left A - Japan
Right Left Right Right B -Japan (English)
Right Right Left Left C - Portugal
Right Right Left Right D - Spain
Right Right Right Left E - Spanish Speaking
Right Right Right Right F - United Kingdom
NOTE: The language character sets 1 - US/Canada and B - Japan (English) are the same. The
character sets for D - Spain and E - Spanish Speaking are the same.
Intervention Required Message
Switch #7 Description
Left Inhibits the sending of the "Intervention Required" (IR) status message.
Right When a printer error condition is monitored by the coax interface for a period of at
least 10 minutes, an "Intervention Required" (IR) status message is sent to the host.

Table 4-8 Dip Switch Settings Coax Interface

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Dip Switch Setting (cont'd)

Early Print Complete
Switch #8 Description
Left An "Operation Complete" status message is sent to the host after a label format is
completely printed. The host can then send the next label format to be printed.
Right Enables the "Early Print Complete" function. The host can send additional print jobs
to the printer without waiting for the actual completion of the current print job. The
printing status sent to the host reflects the label formats received, not the ones
completed.
Buffer Size Selection
Switch #9 Switch #10 Description
Left Left 3564 Byte buffer
Left Left 3440 Byte buffer
Left Right 1920 Byte buffer
Left Right 960 Byte buffer

Switch #11 Not Active

Switch 12 Not Active

Table 4-8 Dip Switch Settings Coax Interface (cont'd)

After setting the DIP switches, turn the printer power OFF and back ON. With the exception of DIP
switch #2, the printer monitors the positions of the DIP Switches only during the Power-On Self
Test.
The EBCDIC Buffer Print function is enabled whenever DIP Switch #2 is placed in the “Right”
position.

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SECTION 4 MAINTENANCE

APPLICATOR INTERFACE PORT/REAL TIME CLOCK

CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS RECOMMENDED THAT THE
TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP CONNECTED TO
THE PRINTER CHASSIS.

1. Turn the printer power Off and disconnect the AC power cord.
2. Remove the left side panel by loosening the mounting screws.
3. Refer to Figure 4-53 and remove the two screws and the blank cover plate (or the interface board
and cables) installed next to the PCMCIA memory card slot. (Save the screws.)
NOTE: There are two interface data cables that need to be attached from the RTC/applicator
circuit board to the main logic board if the applicator interface and the RTC are to work
at the same time. J1 on RTC board connects the RTC and J4 connects the applicator
interface.
4. Attach the DC power cable to J5 on the RTC/Applicator circuit board then connect one or both
interface data cables to J1 and J4 as needed.
5. Refer to Figure 4-53, insert the RTC/Applicator circuit board and cables partially into the
mounting slot. Then connect the other end of the interface data cables to one of the open serial
data connectors on the main logic board and the DC power cable to one of the open connectors
on the DC power supply board.
6. Slide the RTC/applicator circuit board completely into the mounting slot, and fasten it in place
with the two screws removed in step 3.
7. Reinstall the left side panel.
8. Attach the AC power cord then turn the printer power on.
9. Configure the real time clock parameters according to info on next page; then send a sample
label format from the host computer to the printer to test for proper operation.

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J1 - Real Time Clock

Connector

J1 Connect To One
Of The Open Serial
Hex Head Cap Connectors On
Screws (2) The Main Logic Board
J4

RTC/Applicator J5 J4 - Applicator
Interface Board Connector

J5 - Power
Connector

Connect To One
Of The Open Power
Connectors On The
PCB Access DC Power Supply Board
Panel

Figure 4-53 Applicator/Real Time Clock Installation

Real Time Clock Parameters

The following parameters are added to the Front Panel Configuration prompts only when the Real
Time Clock hardware is installed in the XiIII-Series printer.
Idle Display
Selects the printer's Idle Display format and the method of displaying the time/date
information. This parameter also affects the Configuration Label printout and the SET
DATE and SET TIME formats.
Selections:
FW VERSION MM/DD/YY 24HR MM/DD/YY 12HR
DD/MM/YY 24HR DD/MM/YY 12HR

If FW VERSION is selected, the format on the Configuration Label and on the SET DATE

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SET TIME
Allows entry of the RTC time in the format selected by the IDLE DISPLAY parameter.
Use the Left Oval Key to select the position to be adjusted. Then use the Right Oval Key to
select the correct value for that position.

SET DATE
Allows entry of the RTC date in the format selected by the IDLE DISPLAY parameter.
Use the Left Oval Key to select the position to be adjusted. Then use the Right Oval Key to
select the correct value for that position.

Real Time Clock Commands

General Information on the use of real time clock (RTC)
NOTE: The ZPL II commands for the RTC are only applicable if the option is installed in the
printer.
The Field Clock (^FC) command is used to specify the clock-indicator character for the primary,
secondary, and tertiary clocks. This command must be included within each label field command
string whenever the date or time clock values are required within the field. No date or time clock
information can be printed in a label field unless this command is included.
A clock indicator can be any printable character except the ZPL II Format Prefix, Control Prefix, or
Delimiter characters. The default value for the primary clock-indicator is the percent sign (%). The
secondary and tertiary clock indicators have no defaults and must be specified in order for that clock
to be used.
The ZPL II Field Data (^FD) command has been expanded to recognize the clock indicators and
associated command characters, and to replace them during the printing process with the
corresponding time or date parameter. For example, if the primary clock indicator is the percent sign
(%), then during printing, the character sequence %H in the ^FD statement would be replaced by
the 2-digit current hour.
NOTE: If the Real Time Clock hardware is not installed, or the ^FC command has not preceded
the ^FD statement, no replacement would occur. In this case, the characters “%H”
would print as text on the label.
The name of the day of the week, the name of the month, and the AM or PM designation can also be
inserted in place of a specific clock indicator/command character sequence. See Table 4-9 for the list
of command characters and their functions.
The Set Offset (^SO) command permits the printing of specific times and dates relative to the
primary clock. The secondary (or tertiary) clock is enabled when secondary (or tertiary) offsets are
entered using this command. The secondary (or tertiary) clock time and date are determined by
adding the offsets to the current clock reading.

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One ^SO command is required to set the secondary offset and an additional ^SO command is
required for a tertiary offset. The offsets remain until changed or until the printer is either powered
down or reset.
NOTE: Only dates from January 1, 1998 to December 31, 2097 are supported. Setting the offsets
to values that result in dates outside this range is not encouraged or guaranteed.
The Set Mode/Language (^SL) command is used to select the language in which to print the names
of the days of the week, and the names of the months. This command also sets the printing mode,
which can be ‘S’ for START TIME or ‘T’ for TIME NOW. In START TIME mode, the time printed
on the label is the time that is read from the Real Time Clock when the label formatting begins
(when the ^XA command is received by the printer). In TIME NOW mode, the time printed on the
label is the time that is read from the Real Time Clock when the label is placed in the queue to be
printed.

%a is replaced by the abbreviated weekday name

%A is replaced by the weekday name
%b is replaced by the abbreviated month name
%B is replaced by the month name
%d is replaced by the day of the month number, 01 to 31
%H is replaced by the hour of the day (military), 00 to 23
%I is replaced by the hour of the day (civilian), 01 to 12
%j is replaced by the day of the year, 001 to 366
%m is replaced by the month number, 01 to 12
%M is replaced by the minute, 00 to 59
%p is replaced by the AM or PM designation
%S is replaced by the seconds, 00 to 59
%U is replaced by the week# of the year, 00 to 53, Sunday is 1st day
%W is replaced by the week# of the year, 00 to 53, Monday is 1st day
%w is replaced by the day # of the week, 00 (Sunday) to 06 (Saturday)
%y is replaced by the last 2 digits of the year, 00 to 99
%Y is replaced by the full 4 digit year number
– where % is the specified clock indicator character

Table 4-9 Date & Time Command Characters

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Time and Date Precision (in Time Now Mode)

The time and date placed in a label field is determined at the time the label bitmap is created by the
printer. If a batch of labels is formatted, the date and time will be the same for all labels in the batch.
If the printer is PAUSED during the printing process and remains
in that state for a period of time, when printing resumes, the time and date will still be the same as
when the batch was first started.
If more precise time and date stamps are required on the labels, the ^CO (Cache On) ZPL II
command can be used to limit the memory available for label bitmaps and thus reduce the number of
labels containing the same time and date stamp. To determine the value for the “b” parameter of the
^CO command, perform the steps that follow:
NOTE: Please cycle the printer power off and on to clear the memory before performing the steps
below.
1) Print a Memory Usage Label (^XA^WD*:*.*^XZ) and note the following value:
Available RAM (in BYTES) (A) __________
2) Print a Configuration Label and note these values:
Printer “Print Width” (in DOTS) (NOT the Label Width)
(B) __________
Label Length (in DOTS) (C) __________
3) Determine the desired maximum number of queued labels with the same Time and Date
value. (D) __________
NOTE: Increasing the number of queued labels will improve throughput performance, but Real
Time Clock values will be less accurate. Two is usually an appropriate compromise.
4) Substitute the values for B through D from the previous page into the following formula:
The “label queue” memory required (in BYTES)
(B x C x D) / 8 = (E) __________
5) Substitute the values for A and E into the following formula:
The “^CO command” memory required (in KBYTES)
( (A – E) / 1024) – 5 = (F) __________

NOTE: If the value of (F) is less than zero, then no ^CO command is needed. If the value of (F)
is greater than zero, use the integer portion in the ^CO command.

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EXAMPLE
Available RAM (A) = 714748 BYTES
Print Width (B) = 832 DOTS
Label Length (C) = 1000 DOTS
Max Labels Queued (D) = 2
The “label queue” memory required
(B x C x D) / 8 (E) = 208000 BYTES
The “^CO command” memory required (F) = 489.87 KBYTES
( (714748 – 208000) / 1024) – 5

Therefore, the correct ^CO command string to add to the label format would be:

^XA^COY,489^XZ

This command string will cause 489 KBYTES to be set aside as Font Memory and make it
unavailable as label format memory. The memory remaining will only allow two labels to be
formatted at one time, and the time and date will be more precise for those two labels.

^KD Date/Time Format

The ^KD (Date/Time Format) instruction is used to select the format in which the Real Time
Clock’s date and time information is printed on a configuration label.
The format for the ^KD instruction is:

^KDa
Where
^KD = Date/Time Format
a = Value indicating desired date/time format
0 = Normal version number string (Default)
1 = MM/DD/YY w/24 hour clock
2 = MM/DD/YY w/12 hour clock
3 = DD/MM/YY w/24 hour clock
4 = DD/MM/YY w/12 hour clock
NOTE: If the Real Time Clock hardware is not present, the display mode will be set to “Version
Number”.
NOTE: If the display mode is set to "Version Number" and the Real Time Clock hardware is
present, the date/ time format shown on the configuration label when setting the
date/time will be in the format: MM/DD/YY with a 24 hour clock.

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^FC FIELD CLOCK

The ^FC (Field Clock) instruction is used to set the clock-indicators (delimiters) and the clock
mode, for use with the Real Time Clock hardware. This command must be included within each
label field command string each time the Real Time Clock values are required within the field.
The format for the ^FC instruction is:

^FCa,b,c
FCa,b,c
Where
^FC = Field Clock
a = Primary clock indicator character
Default = %
b = Secondary clock indicator character
No Default – cannot be the same as “a” above
c = Tertiary clock indicator character
No Default – cannot be the same as “a” or “b” above
NOTE: If no Real Time Clock hardware is present, this command is ignored.

^SL SET MODE/LANGUAGE

The ^SL (Set Mode/Language) instruction is used to specify the language in which Real Time Clock
information is printed and to specify the mode of operation for the Real Time Clock.
NOTE: The ^SL command must be placed in front of the first time field ^FO command.
The format for the ^SL instruction is:

^SLa,b
Where
^SL = Set Mode/Language
a = Mode
S = START TIME mode (Default)
T = TIME NOW mode
b = Language Number
(Default = The language selected via the ^KL instruction)
1 = English 4 = German 7 = Portuguese 10 = Spanish 2
2 = Spanish 5 = Italian 8 = Swedish 11 = Dutch
3 = French 6 = Norwegian 9 = Danish 12 = Finnish

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^SO SET OFFSET

The ^SO (Set Offset) instruction is used to set the secondary offset and the tertiary offset from the
primary Real Time Clock.
The format for the ^SO instruction is:

^SOa,b,c,d,e,f,g
Where
^SO = Set Offset
a = Clock (No Default)
2 = Secondary Clock
3 = Tertiary Clock
b = Months Offset (Default = 0) (Range –32,000 to +32,000)
c = Days Offset (Default = 0) (Range –32,000 to +32,000)
d = Years Offset (Default = 0) (Range –32,000 to +32,000)
e = Hours Offset (Default = 0) (Range –32,000 to +32,000)
f = Minutes Offset (Default = 0) (Range –32,000 to +32,000)
g = Seconds Offset (Default = 0) (Range –32,000 to +32,000)

^ST SET DATE/TIME

The ^ST (Set Date/Time) instruction is used to set the date and time of the Real Time Clock.
The format for the ^ST instruction is:

^STa,b,c,d,e,f,g
Where
^ST = Set Date/Time
a = Month (Default = Current Month) Valid Range = 01 to 12
b = Day (Default = Current Day) Valid Range = 01 to 31
c = Year (Default = Current Year) Valid Range = 1998 to 2097
d = Hour (Default = Current Hour) Valid Range = 00 to 23
e = Minute (Default = Current Minute) Valid Range = 00 to 59
f = Second (Default = Current Second) Valid Range = 00 to 59
g = Format
A = AM
P = PM
M= 24 Hour (Military) (Default)

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Sample ZPL
The ZPL II scripts shown below establish the initial settings for the date and time clock and must be
sent to a printer to provide proper date and time parameters for the ZPL II script on the following
page.
Setting the date and time for the Real Time Clock only needs to be done once. An on-board battery
maintains the date and time when the printer is reset and when the printer power is turned OFF.
To set the date and time to April 23, 1999 at 2:30 PM the following command string should be sent
to the printer:
^XA
^ST04,23,1999,02,30,0,P^FS
^XZ
To initialize the Real Time Clock and set up two offset values (offset #2 set to 3 months and 1 hour
in the future, offset #3 set to 1 year in the past), the following command sequence should be sent to
the printer:
^XA
^SL
^SO2,3,0,0,1,0,0^FS
^SO3,0,0,-1,0,0,0^FS
^XZ
The following script references the initial settings (from above) to provide the output shown in
Figure 4-54. It also illustrates the various methods of printing the date and time initialized on the
previous page within separate fields on continuous media. For the below example, the ^FC
command delimiters are:

% Primary clock indicator

{ Secondary clock indicator
# Tertiary clock indicator

^XA
^LL175
^FO10,025^AD^FC%,{,#^FD1: Mil: %H:%M:%S Civ: %I:%M:%S %p^FS
^FO10,050^AD^FC%,{,#^FD2: Mil: {H:{M:{S Civ: {I:{M:{S {p^FS
^FO10,075^AD^FC%,{,#^FD3: Mil: #H:#M:#S Civ: #I:#M:#S #p^FS
^FO10,100^AD^FC%,{,#^FD1: On %A, %B %d, %Y (%a, %m/%d/%y, %d %b %Y).^FS
^FO10,125^AD^FC%,{,#^FD2: On {A, {B {d, {Y ( {a, {m/{d/{y, {d {b {Y).^FS
^FO10,150^AD^FC%,{,#^FD3: On #A, #B #d, #Y (#a, #m/#d/#y, #d #b #Y).^FS
^XZ
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1: Mil: 14:30:00 Civ: 02:30:00 PM

2: Mil: 15:30:00 Civ: 03:30:00 PM
3: Mil: 14:30:00 Civ: 02:30:00 PM
1: On Friday, April 23, 1999 (Fri, 04/23/99, 23 Apr 1999).
2: On Friday, July 23, 1999 (Fri, 07/23/99, 23 Jul 1999).
3: On Thursday, April 23, 1998 (Thur, 04/23/98, 23 Apr 1998).

Figure 4-54 Printed Result of the Example ZPL II Script

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Cutter Option Kit

Adding the Cutter Option to this 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.
Cutter Option Kit Parts List

Part 90/96 140 170 220

✔ Item # Qty Description
Number XiIII XiIII XiIII XiIII
1 1 49730M Cutter Option Circuit Board X X X X
2 1 49604-010 Cutter Power Cable X X X X
3 1 49600-012 Cutter Data Cable X X X X
4 1 30313 Sensor Clamp X X X X
5 1 46618M Cutter Optical Sensor Assembly X X X X
6 1 30374M Cutter Motor Assembly X X X X
1 22459 Cutter Catch Tray Kit 220 XiIII X
1 46459 Cutter Catch Tray Kit 170 XiIII X
7
1 47459 Cutter Catch Tray Kit 90 XiIII X
1 48459 Cutter Catch Tray Kit 140 XiIII X
8 1 30449 Hex Allen Key, 5/64” X X X X
9 1 44632 Ferrite Core X X X X
10 1 46224 Grommet X X X X
11 1 N/A Drive Link Assembly X X X X
12 1 N/A Cutter Mechanical Assembly X X X X
13 2 30394-005 Screws (Motor Mounting) X X X X
14 6 30392-004 Screw 6-32 X X X X
15 4 30391-003 Screw 4-40 X X X X
16 1 02133 E-Ring X X X X
17 1 01822 Nut X X X X
18 1 01155 #4 Lock Washer X X X X
N/A = Not Available as a separate part (listed for identification purposes only)
NOTE: Only the parts listed above (with part numbers) are available as service items. Parts
for the assemblies and some of the assemblies are not available as service items.
NOTE: Cutter option not available on 96XiIII.

Table 4-10 Cutter Option Kit Parts List

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11
4

1 3

12

8
9 10

The lock washer, nut, E-ring and screws are not shown here (see Table 4-10)

Figure 4-55 Part Identification Cutter Option

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CAUTION:
THE PRINTER ELECTRONICS ARE SUSCEPTIBLE TO STATIC
DISCHARGE. BEFORE PROCEEDING, IT IS RECOMMENDED THAT THE
TECHNICIAN WEAR AN ANTI-STATIC WRIST STRAP CONNECTED TO
THE PRINTER CHASSIS.

Printer Disassembly
The printer must be partially disassembled in order to install the parts in this kit.
1. Turn the printer off and remove the power cord and the printer communications cable (if
connected).
2. Remove the left side panel of the printer by removing the phillips head screws holding it in
place.
3. Note and remove all ribbon cable connectors and small wire connectors from the DC power
supply assembly (see Figure 4-56).
4. Remove the mounting screw and two hex nuts holding the DC power supply assembly against
the chassis (see Figure 4-56).
5. Remove the DC power supply assembly.
Cutter Option Installation Procedures
Cutter Motor Installation
NOTE: The cover plates and cover plate mounting screws are not reused.
1. Open the media access door. Using a 7/64” allen wrench, remove the cutter assembly cover
plate (see Figure 4-57).
2. Using a 9/64” allen wrench, remove the cutter motor cover plate (see Figure 4-57).
3. Position the cutter motor near the mounting hole on the mechanical side of the printer (see Figure
4-58).
4. Pass the cutter motor leads through the slit in the rubber grommet (Figure 4-58, #10). Insert the
grommet into the slot located in the lower right area of the motor mounting hole and slide it into
the small hole. The electrical connector must be positioned on the electronics side of the printer.
To prevent the leads from coming out, rotate the grommet so the cut is facing away from the
motor.
5. Position the cutter motor against the printer frame so that the screw holes in the motor line up
with the holes in the frame, with the motor shaft toward the front of the printer.
6. Attach the motor to the printer frame using the two (2) motor mounting screws (Figure 4-58,
#13).

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J7
J8

J9
J10
J11

J12
J13
J14
J15
J16
J17
J18
J19
J23
J20

J21

J11 J10 J9
J1
J8 J7
J6 J5
J4
AC Power PCB
J3 J1

J2 DC Power PCB

Hex Nut Mounting Screw Hex Nut

Figure 4-56 DC Power PCB location and interconnections for XiIII printers

DC Power Connectors
NOTE: J5-J10 have the same outputs.
J1 J1 AC Power PCB J7 Cutter Option
J2 Additional Printhead Power for 220XiIII Printers J8 N/A
J3 Printhead Power for all XiIII Printers J9 LCD Display
J4 Stepper Motor J10 J20 Main Logic PCB
J5 N/A J11 J11 Main Logic PCB Data
J6 N/A

Table 4-11 DC Power connectors

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SECTION 4 MAINTENANCE

Cutter Assembly
Cover Plate

Cover Plate
Screws

Cutter Motor
Cover Plate

Figure 4-57 Cover Plate Locations

Toggle
Handle

14

13
Upper Drive Arm

12
Upper Cutter
Bracket

6
10
Lower Cutter
Bracket

14

Figure 4-58 Mechanical Side Assembly

(See Table 4-10 for part identification)

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Cutter Mechanical Assembly Installation

1. Locate the pre-assembled cutter mechanism and refer to Figure 4-58. The upper cutter bracket at
the right rear corner of the cutter is placed in a horizontal position for shipping. Loosen the
mounting screw using a 7mm (9/32") wrench. Rotate the bracket to a vertical position as in
Figure 4-58 and snug up the screw. Do not tighten.
2. Under the left end of the Cutter, use a 7/64" hex wrench to loosen the two 6-32 screws which
attach the lower cutter bracket to the cutter support bracket (see Figure 4-58).
3. Locate and orient the cutter mechanism as shown in Figure 4-58. Carefully work the mechanism
into position partially in the main frame opening in front of the printhead. Position the upper
cutter bracket so the threaded holes are inside the side plate and aligned with the two holes in the
side plate near the toggle handle. Loosely attach the upper bracket to the side plate with two of
the 6-32 screws (Figure 4-58, #14).
4. Now align the slots in the lower cutter bracket with the threaded holes in the main frame and
loosely attach the bracket with two more of the 6-32 screws (Figure 4-58, #14).
5. Refer to Figure 4-59. Open the printhead and observe the position of the tear-off bar (in front of
the platen roller) and the rear cutter blade. Position the cutter mechanism so that the rear cutter
blade is parallel with the outer edge of the tear-off bar across the entire width of the media path.
The Cutter Mechanism should be positioned as far forward as possible while maintaining
parallelism with the tear-off bar. This should prevent interference of the rear cutter blade with
the tear-off bar. Tighten all mounting screws.
NOTE: While tightening the upper cutter bracket mounting screw, be careful to not change the
position of the media guide. if the media guide moves out of position, set it’s height so
that the lower edge is flush with the rear opening in the cutter mechanism.
The lower cutter blade is held in position by two springs. If these springs touch the tear
bar or other printer parts, the lower cutter blade will not float properly and will cause
excessive wear and premature failure of the cutter blades.
6. Check the clearance between the back of the cutter mechanism and the tear bar by inserting a
screwdriver from the front of the cutter mechanism and press the top of the lower cutter blade
toward the printer. The blade should move a minimum of .030 inches. If necessary, loosen the
four phillips head screws on the bottom of the cutter module and reposition the cutter mechanism
away from the tear-off bar.
Drive Link Assembly Installation
1. Remove the screw from the mounting post on the drive link assembly (Figure 4-60, #11). Secure
the assembly with the screw, from the media side of the frame through the mounting hole into
the drive link assembly.
2. The upper drive arm is pre-assembled to the cutter module (see Figure 4-58). Place the long
drive link of the drive link assembly (Figure 4-60, #11) over the connecting post on the upper
drive arm and secure it with the E-ring (Figure 4-60, # 16).
3. Attach the lower drive arm of the drive link assembly (Figure 4-60, #11) to the cutter motor
shaft. Loosen the screws to insure the lower drive arm rotates freely on the motor shaft.
4. Apply a small amount of grease to the slot in the drive link assembly (Figure 4-60, #11) where
the bearing will ride. Remove any excess grease to avoid damaging the optical sensor.

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Cutter Circuit Board and Optical Sensor Installation

1. Attach the power cable (Figure 4-60, #2) to J2 on the cutter circuit board (see Figure 4-61).
2. Attach the data cable (Figure 4-60, #3) to Jl on the cutter circuit board (see Figure 4-61).
3. Locate the four (4) standoffs on the printer frame where the cutter board will be mounted.
4. Route the cutter motor leads between the two right hand standoffs and out under the bottom of
the circuit board.
5. Position the cutter circuit board over all four standoffs.
6. Place the lock washer (Figure 4-60, #18) onto screw (Figure 4-60, #15) and install through the
lower right hand circuit board mounting hole. Do not tighten at this time.
7. Install the three remaining mounting screws (Figure 4-60, #15) and tighten all four screws.
8. Wind the motor leads around the ferrite core as shown in Figure 4-62.
9. Pass the cutter board power cable along the bottom of the printer frame toward the main logic
board.
10. Plug the motor leads into the cutter motor connector J4 on the cutter circuit board (see
Figure 4-61) with the black lead to the left. To minimize interference between components,
wedge the top of the ferrite core under the cutter board relay.
11. Install the cutter optical sensor assembly (Figure 4-60, #5) on the sensor mounting post. The
Sensor part of the assembly should be mounted towards the printer frame.
12. Place the sensor clamp (Figure 4-60, #4) over the sensor and start the nut (Figure 4-60, #17) on
the Post. Do not tighten the nut at this time.
13. Route the sensor leads under the clamp and towards the rear of the printer, and lightly tighten the
nut to hold the wires in position. Be careful not to pinch the wires.
14. Plug the cutter sensor leads into the cutter Opto connector J3 on the cutter circuit board
(see Figure 4-61).
15. Check the installation and insure that no wiring will touch any moving parts.

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Rotary Cutter Blade

Upper Cutter Bracket
Mounting Screw
.100“
Media Guide (2.5 mm)
Insure the Top of the Tear-Off
Bar is Positioned Above or
Level With the Top of the Rear Cutter
Rear Cutter Blade Tear-Off Blade
Bar
Clearance of .030“ Minimum
Between Rear Cutter Blade
and Tear-off Bar

Relative Position of the Rotary Cutter Blade When the Drive Link Assembly
is Stopped by the Optical Sensor, When the Power is on in the Cutter Mode

Figure 4-59 Cutter Mechanical Assembly Positioning

2
3
15

18
1

16
Long Drive
Link
Lower Drive
Arm
17
4

Grease

5
Sensor Mounting
Post

Figure 4-60 Linkage and circuit board installation

(See Table 4-10 for part identification)

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SECTION 4 MAINTENANCE

J1 to Main
Logic Board

J3 to Cutter J4 to Cutter
Opto Senser Motor

Figure 4-61 Cutter Option Circuit Board

Ferrite Core

Cutter Motor
Leads
Red

Black

Figure 4-62 Cutter Motor Leads

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MAINTENANCE SECTION 4

Lower Drive Arm Mechanical Alignment

NOTE: To perform the lower drive arm mechanical alignment, some cables must be connected
between the AC power supply, the DC power supply and the cutter board, but access to
the cutter board is still required. In order to do this, the DC power supply assembly must
not be installed inside the printer. Instead, the DC power supply assembly must be
carefully positioned so that the cables are connected and will still allow access to the
cutter board. Connect only the cables listed below.
1. Connect the power cable from Jl on the AC power supply board to J1 on the DC power supply
board (see Figure 4-56).
2. Connect the power cable from J2 on the cutter board to any available J5-J10 connector (normally
J7) on the DC power supply board (see Figure 4-56).
3. Connect the data ribbon cable from J1 on the cutter board to any available J7-J10 connector
(normally J10) on the main logic board (see Figure 4-56).
NOTE: Do not connect any other cables or connectors at this time.
4. Attach the AC power cord and turn the printer on. If the cutter motor starts, wait for it to stop.
NOTE: The cutter motor must be rotated until the two flat surfaces of the cutter motor shaft are
aligned with the set screws in the lower drive arm, while the lower drive arm is in a
vertical position (sensor flag down).
5. Attach a test clip at one end of a jumper cable to the lead on the right end of capacitor C1
(+5 VDC SOURCE) on the cutter board (see Figure 4-61).
6. Briefly, touch the test clip at the other end of the jumper cable to test point TP1 on the cutter
board to "jog" the cutter motor to the desired position.
7. Position the lower drive arm so the sensor flag is centered between the front and back portions of
the optical sensor, then tighten the two set screws.
8. The set screws must be extremely tight to insure proper operation of the cutter mechanism.
Tighten the set screws with the 5/64" allen key (Figure 4-55, #8) included with this kit. As a
reference, when the set screws are tight, the allen key should deflect approximately 0.6" (1.5 cm)
past the point of tightness. The tightness specification is 20 in. lb. (2.3 N/M).
9. Activate the cutter motor, and make certain the sensor flag travels through the slot in the optical
sensor without touching it.
10. Turn the printer power switch off.
DC Power Supply Board Reinstallation
1. Install the DC power supply and tighten the mounting screw and two hex-head nuts. Insure all
wires are positioned away from any moving mechanical parts and are not pinched or cut.
2. Carefully connect the remaining cables/connectors to the DC power supply board and verify
proper placement and orientation (see Figure 4-56).
3. Reconnect the AC power cord.

48152L Rev. 1 07/00 XiIII Maintenance Manual 4-105

SECTION 4 MAINTENANCE

4. Turn the printer power switch on and use the front panel LCD and control keys to configure the
unit for cutter mode. Save as "PERMANENT" and then turn the printer power switch off. Refer
to the printer user's guide for this procedure.
5. To test the cutter for proper operation, load media and ribbon, hold in the PAUSE key while
turning the AC power on and run labels through the printer. If either of the following two
conditions are not met, proceed to the upper drive arm alignment:
a. Media fed through the printer without hitting either of the cutter blades.
b. The cutter cut through the label material completely.
6. Complete this installation procedure by reinstalling the left side panel.

Upper Drive Arm Alignment

NOTE: The upper drive arm is part of the cutter mechanical assembly and has been aligned at
the factory. If for some reason the position is altered, the following procedure may be
used to realign the upper drive arm. The printer must be programmed to operate in the
cutter mode prior to performing the following procedure. If it is not already programmed
for cutter mode, refer to the printer user's guide for assistance.
1. Remove the printer's left side panel, if attached.
2. Loosen the allen head cap screw that clamps the upper drive arm to the rotary cutter blade shaft.
The drive arm may be snug on the shaft.
3. Apply power to the printer. The lower drive arm of the drive link assembly should rotate once
and stop when the sensor fag activates the optical sensor.
4. Refer to Figure 4-59. After the drive link assembly stops, hold the upper drive arm in position
and adjust the rotary cutter blade so that the gap between the cutting edge on the left end and the
cutting edge of the rear cutter blade is approximately a .100" (2.5mm).
NOTE: If the gap between the cutting edges is too large, the cutter may not cut properly across
the entire media width. If the gap is too small, the media may catch on the rotary cutter
blade edge and cause a jam.
5. Position the upper drive arm out from the cutter frame so its flat surface is flush with the end of
the rotary cutter blade shaft.
NOTE: Overtightening the screw can damage the drive arm and can strip out the threads.
6. 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.
7. Test the cutter alignment by feeding maximum width label stock through the printer and insuring
that complete cutting of the label occurs. If necessary, repeat steps 4, 5, and 6 to achieve
complete cutting of the labels.
8. With a felt tip pen, draw a line across the outer face of the upper drive arm and the end of the
cutter blade shaft. Should cutter operation problems ever occur, this "witness mark" would show
at a glance if the alignment of the clamp and the cutter blade shaft has changed.

4-106 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

SECTION 5 MAINTENANC E AND ASSEMBLY

DRAWINGS

Description

Use the mechanical assembly drawings when troubleshooting or replacing components and use the
associated parts list when ordering replacement parts. Item parts that do not have associated part
numbers are not available and need to be ordered using the next highest assembly number.

Top: 90XiXiIII™
Xi and 96XiXiIII™
Xi
Bottom: 140Xi
XiIII™,
Xi 170Xi
XiIII™
Xi and 220Xi
XiIII™
Xi

48152L Rev. 1 07/00 XiIII Maintenance Manual 5–1

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Table of Contents
List of Figures
Figure 5-1 Final Assembly 90/96XiIII, 140XiIII and 170XiIII Mechanical..................................... 5–5
Figure 5-2 Final Assembly All Printers Electrical ........................................................................... 5–7
Figure 5-3 220XiIII Final Assembly Mechanical............................................................................. 5–9
Figure 5-4 90/96XiIII, 140XiIII and 170XiIII Print Mechanism Assembly View 1 ...................... 5–11
Figure 5-5 90/96XiIII, 140XiIII and 170XiIII Print Mechanism Assembly View 2 ..................... 5–13
Figure 5-6 All Series XiIII Print Mechanism Assembly View 3.................................................... 5–15
Figure 5-7 220XiIII Print Mechanism View 1 ............................................................................... 5–17
Figure 5-8 220XiIII Print Mechanism View 2 ............................................................................... 5–19
Figure 5-9 90XiIII Print Head Support Assembly.......................................................................... 5–21
Figure 5-10 96XiIII Print Head Support Assembly........................................................................ 5–23
Figure 5-11 140XiIII Print Head Support Assembly...................................................................... 5–25
Figure 5-12 170XiIII Print head Support Bracket .......................................................................... 5–27
Figure 5-13 220XiIII Print Head Support Assembly...................................................................... 5–29
Figure 5-14 Media Supply Hanger................................................................................................. 5–31
Figure 5-15 Optional Media Supply Spindle ................................................................................. 5–33
Figure 5-16 Compliant Roller Assembly ....................................................................................... 5–35
Figure 5-17 Ribbon Supply Spindle Assembly.............................................................................. 5–37
Figure 5-18 Ribbon Take-Up Spindle Assembly........................................................................... 5–39
Figure 5-19 Media Rewind Assembly ........................................................................................... 5–41
Figure 5-20 Cutter Assembly ......................................................................................................... 5–43
Figure 5-21 Cutter Option Assembly View 2 ................................................................................ 5–44

5–2 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

List of Tables
Table 5-1 90XiIII, 96XiIII, 140XiIII and 170XiIII Final Assembly Mechanical.............................. 5–4
Table 5-2 Final Assembly All Printers (Electrical).......................................................................... 5–6
Table 5-3 220XiIII Final Assembly Mechanical View 1 ................................................................. 5–8
Table 5-4 90/96XiIII, 140XiIII, 170XiIII Print Mechanism Assembly View 1.............................. 5–10
Table 5-5 90/96XiIII, 140XiIII, 170XiIII Print Mechanism Assembly View 2.............................. 5–12
Table 5-6 All Series Print Mechanism Assembly View 3 ............................................................. 5–14
Table 5-7 220XiIII Print Mechanism View 1................................................................................. 5–16
Table 5-8 220XiIII Printer Mechanism View 2.............................................................................. 5–18
Table 5-9 90XiIII Printhead Support Assembly............................................................................. 5–20
Table 5-10 96XiIII Printhead Support Assembly........................................................................... 5–22
Table 5-11 140XiIII Printhead Support Bracket ............................................................................ 5–24
Table 5-12 170XiIII Printhead Support Assembly......................................................................... 5–26
Table 5-13 220XiIII Printhead Support Assembly......................................................................... 5–28
Table 5-14 Media Supply Hanger .................................................................................................. 5–30
Table 5-15 Optional Media Supply Spindle................................................................................... 5–32
Table 5-16 Compliant Roller Assembly......................................................................................... 5–34
Table 5-17 Ribbon Supply Spindle Assembly ............................................................................... 5–36
Table 5-18 Ribbon Take-Up Spindle Assembly ............................................................................ 5–38
Table 5-19 Media Rewind Assembly............................................................................................. 5–40
Table 5-20 Cutter Assembly........................................................................................................... 5–42

48152L Rev. 1 07/00 XiIII Maintenance Manual 5–3

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 90XiIII, 96XiIII, 140XiIII, 170XiIII

Item Part Number Description Qty
1 46937 Media Door with Window 1
1 47936 Media Door without Window 1
1 47077M Kit, Media Door Bi-fold with Window 1
2 48272 Label, Media Load 1
3 *30392-004 Screw, 6-32 x .25, Phillips head 5
4 01861 Label, Supplies 1
5 46396-006 Screw, 6-32 x .37, Phillips head 1
6 30407-008 Screw, 6-32 x .5, 3/64 Allen 4
7 44114 Screw, M4.2 x 8 Hilo 12
8 44356 Washer, .198, .75 .085 3
9 46142 Name Plate, 170XiIII 1
9 47142 Name Plate, 90XiIII 1
9 48142 Name Plate, 140XiIII 1
9 47146 Name Plate, 96XiIII 1
10 48267 Spacer, 90/96XiIII and 170XiIII 2
11 22021 Switch, Panel Membrane 1
12 22492M Kit, Maintenance, Switch Panel ( Complete) 1
13 46037-1 Cover, Front; 170XiIII 1
13 47037-1 Cover, Front; 90/96XiIII 1
13 48037-1 Cover, Front; 140XiIII 1
14 46755M LCD, Back Light 1
15 *30392-003 Screw, 6-32 x .19 3
16 01130 Nut, 6-32 3
17 07257 Washer 3
18 46491-1 Panel, Lower Media Trim, 170XiIII 1
18 46491-2 Panel, Lower Media Trim, 140XiIII 1
18 46491-3 Panel, Lower Media Trim, 90/96XiIII 1
19 46836 Spacer 2
20 30256-B Nut, Thumb, 6-32 x .50 Brass 2
21 38342 Bracket, Front Cover, 170XiIII 1
21 47342 Bracket, Front Cover, 90/96XiIII 1
21 48342 Bracket, Front Cover, 140XiIII 1

Table 5-1 90XiIII, 96XiIII, 140XiIII and 170XiIII Final Assembly Mechanical

*Also Available in Hardware Kit 48205M

5–4 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

3
4

7
5

3
3
6
8

10
14
15 3
13 16
12

11 17
17
16
17
3
7

16

18
20
21
19

Figure 5-1 Final Assembly 90/96XiIII, 140XiIII and 170XiIII Mechanical

48152L Rev1 07/00 XiIII Maintenance Manual 5-5
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: All Printers

Item Part Number Description Qty
1 47004M Kit, Maintenance Main Logic Board 1
2 01130 Nut, 6-32 Hex Washer Head 2
3 01117 Clamp, Cable .312 Nylon 5
4 06222 Clamp, Cable .50 1
Kit, Maintenance RTU/MTU Pulley
5 31336M 1
(90XiIII, 140XiIII, 170XiIII, 220XiIII)
5 47358M Kit, Maintenance RTU/MTU Pulley 600dpi (96XiIII) 1
Belt, Conductive .080P 235T (90XiIII, 140XiIII, 170XiIII,
6 45189-5 1
220XiIII)
6 45189-12 Belt, Conductive .080P 245T (96XiIII) (600dpi) 1
7 Q06020 Tie-wrap, .09W x 3.62L 1
Assembly Platen Pulley Maintenance (90XiIII, 140XiIII,
8 40355M 1
170XiIII, 220XiIII)
8 47356M Kit Maintenance Platen Pulley 600dpi (96XiIII) 1
9 38226M Kit Maintenance Reflect Media Sensor 1
10 46199M Kit, Stepper Motor w/Pulley (90XiIII, 170XiIII) (300 dpi) 1
10 46198M Kit, Stepper Motor w/Pulley (140XiIII, 220XiIII) (203 dpi) 1
10 46196M Kit, Stepper Motor w/Pulley (96XiIII) 1
Belt, Conductive .080P 255T (90XiIII, 140XiIII, 170XiIII,
11 45189-2 1
220XiIII)
11 45189-13 Belt, Conductive .080P 265T (96XiIII) 1
Kit, Maintenance Pulley Ribbon Take-up/Media Take-up
12 31336M 1
(90XiIII, 140XiIII, 170XiIII)
12 47358M Kit Maintenance Pulley, RTU/MTU (96XiIII) 1
13 46392-006 Screw, 6-32 x 0.37 Truss Head Phillips 1
14 49604-010 PA Cable Power Distribution 1
15 49600-010 PA Cable SP Comm 1
Assembly Pulley, Peel-Off Maintenance (90XiIII, 140XiIII,
16 30914M 1
170XiIII, 220XiIII)
16 47915M Kit Maintenance Peel-Off Pulley (96XiIII) 1
17 49790M Kit Maintenance Power Supply DC RT 1
18 46777 PA Cable Power AC 1
19 04393 Tie-wrap Beaded 1
20 49780M Kit Maintenance PCB Power Supply AC 1
21 30208 Washer Flt .500 x .191 x .030 2
22 01152 Washer Flt .375 x .156 x .065 1

Table 5-2 Final Assembly All Printers (Electrical)

*Also Available in Hardware Kit 48205M

5–6 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

Idler Pulley
220XiIII Only 6

J7 3

J8
2 5
1 Stepper Motor Stepper Motor
J9
7 Pulley Pulley
W/o Rewind With Rewind
J10
3
8
J11
9
J12
J13 4 3 Typical
J14
J15 Cable Clamp
J16 InstallatioN
J17
J18
J19 10
J23
J20
2
11
22
J21 13
12 16
J11 J9
J1 14 J10
15 J8 J7 Ground
Tail
J6 J5
19 J4

20 J1
18 17
J3 J2 2
21
A A

From Cutter
Main Frame
Motor

Section A-A

Figure 5-2 Final Assembly All Printers Electrical

48152L Rev1 07/00 XiIII Maintenance Manual 5-7

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 220XiIII

Item Part Number Description Qty
1 46937 Media Door with Window 1
1 47936 Media Door without Window 1
1 47077M Kit, Media Door Bi-fold with Window 1
2 *30392-004 Screw, 6-32 x .25, CP SO H BO 18
3 01861 Label, Supplies w/Logo 1
4 46396-006 Screw, 6-32 x .37, Tr Ph S Bz 2
5 30407-008 Screw, 6-32 x .5, 3/64 Allen 4
6 44114 Screw, M4.2 x 8 HiLo Hex 3
7 07257 Washer, .438 x .188 x .036 9
8 22142 Name Plate, 220XiIII 1
9 22021 Switch, Panel Membrane 1
10 22492M Kit, Maintenance, Switch Panel 1
11 22037-1 Cover, PCB 1
12 46755M Kit, Maintenance LCD Back Light 1
13 01130 Nut, 6-32 Hex Washer Head 4
14 22491 Panel, Lower Media Trim 1
15 46836 Spacer 2
16 *30256-B Nut, Thumb, 6-32 x .50 Brass 2
17 22342 Bracket, Front Cover 1

Table 5-3 220XiIII Final Assembly Mechanical View 1

*Also Available in Hardware Kit 48205M

5–8 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

2
3

2 4
2

5
7

2
12 2
11 13
10
6
9
7
4

17
13

14
16

15

Figure 5-3 220XiIII Final Assembly Mechanical

48152L Rev1 07/00 XiIII Maintenance Manual 5-9
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 90XiIII, 96XiIII, 140XiIII, 170XiIII Printer Model: 90XiIII, 96XiIII, 140XiIII, 170XiIII
Item Part Number Description Qty Item Part Number Description Qty
1 *30392-004 Screw, 6-32 x .25 13 29 46278M Kit, Maintenance Platen .780 x 6.73 (170 XiIII) 1
2 REF Tri Mount Shoulder 1 29 47601M Kit, Maintenance Platen .788 x 3.588 (90 XiIII 96 XiIII) 1
3 46352M Kit, Maintenance Flag 1 29 40038M Kit, Maintenance Platen .78 x 5.213 (140 XiIII) 1
4 01130 Nut, 6-32 Hex Washer Head 1 30 02252 Ring, Crescent, .250 Yel 2
5 30353M Assembly, Head up Switch 1 31 30825 Plate, Upper Media Guide (Snap Plate) (90 XiIII 96 XiIII) 1
6 30266 Stop, Head Lift Spring 1 31 48043-1 Plate, Upper Media Guide (Snap Plate) (170 XiIII) 1
7 40462 Cover, Media Take-up Sensor 2 31 48043-2 Plate, Upper Media Guide (Snap Plate) (140 XiIII) 1
8 *06268 Washer, Lock #6 3 32 Q10019 Ring, E Ext .250 1
9 *30392-006 Screw, 6-32 x .37 2 33 38202M Kit, Bar Pivot (170 XiIII) 1
10 48023 Bearing, Rulon .313 x .190 x .375 1 33 47202M Kit, Bar Pivot (90 XiIII 96 XiIII) 1
11 47009-1 Roller .37 .312 x 4.437 (90XiIII, 96XiIII) 1 33 48202M Kit, Bar Pivot (140 XiIII) 1
11 47009-3 Roller .37 .312 x 6.437 (140XiIII) 1 34 35099M Assembly, Toggle Move Maintenance 1 or 2
11 47009-8 Roller .37 .312 x 8.437 (170 XiIII) 1 35 46302-4M Kit, Maintenance Media Sensor (170 XiIII) 1
12 30007-1 Shaft, Roller .187 x 4.5 (90XiIII, 96XiIII) 1 35 47302-4M Kit, Maintenance Media Sensor (90 XiIII 96 XiIII) 1
12 30007-3 Shaft, Roller .187 x 5.60 (140XiIII) 1 35 48302-4M Kit, Maintenance Media Sensor (140 XiIII) 1
12 30007-8 Shaft, Roller (170XiIII) 1 36 48411 Screw, Thumb 2
13 44001 Screw, Self-Tap M3.5 x 11mm w/5mm Hex Head 11 37 46691-1M Kit, Maintenance Assembly, Dancer Arm w/Springs (90 XiIII 96 1
14 40355M Assembly, Platen Pulley Maintenance 1 XiIII)
15 38226 Kit, Maintenance Reflective Media Sensor 1 37 46691-2M Kit, Maintenance Assembly, Dancer Arm w/Springs (140 XiIII) 1
16 *30256-B Nut, Thumb 1 37 46691-3M Kit, Maintenance Assembly, Dancer Arm w/Springs (170 XiIII) 1
17 30305RM Assy, Guide Media (90 XiIII, 96 XiIII) 1 38 *07229 Washer, Curved. .49 x .33 x .0075 1
17 40305RM Assy, Guide Media (140XiIII) 1 39 *30423-003 Screw, Set 8-32 x .187 1
17 46305M Assy, Guide Media (170XiIII) 1 40 38202M Kit, Bar Pivot (170 XiIII) 1
18 30033 Guide,Adjustable Media 1 40 47202M Kit, Bar Pivot (90 XiIII 96 XiIII) 1
19 46267 Plug, Hole .5 Diameter x .125 thick 12 40 48202M Kit, Bar Pivot (140 XiIII) 1
20 46091 Grommet, for a 1.25 x .625 cutout 1 41 40248 Plate, Shaft Wear 1
21 30023 Plate, Cover Cutter 1 42 40154 Pin, Eccentric 1
22 46224 Grommet, Rubber, .312 x .34 x .109 1 43 30956 Washer, Flat .207 x .146 x .030 2
23 46199M Kit, Maintenance Motor Stepper (90XiIII, 170XiIII) (300 dpi) 1 44 *30392-008 Screw, 6-32 x .50 1
23 46198M Kit, Maintenance Motor Stepper (140XiIII, 220XiIII) (203 dpi) 1 45 30826 Plug, Hole 2
23 46196M Kit, Maintenance Motor Stepper (96XiIII) (600 dpi) 1 46 30236 Screw, 4-40 x .25 1
24 *30393-006 Screw, 8-32 x .37 4 47 30494 Washer .32 x .119 x .062 1
25 REF Flange, Ball Bearing, .5 x .250 x .125 2 48 40031 Cover, Sensor Wire 1
26 30105 Bearing, Nylon, .312 x .251 x .078 1 49 46302-4M Kit, Maintenance Media Sensor (Includes Upper and Lower 1
27 46105 Bearing, Nylon, .312 x .251 x .140 1 Sensor)
28 46808 Bar, Peel/Tear-Off (170 XiIII) 1 50 30827 Bracket, PCB Media Sensor 1
28 47808 Bar, Peel/Tear-Off (90 XiIII, 96 XiIII) 1
28 48808 Bar, Peel/Tear-Off (140 XiIII) 1

*Also Available in Hardware Kit 48205M

Table 5-4 Printer Model: 90XiIII, 96XiIII, 140XiIII, 170XiIII Print Mechanism Assembly

5-10 XiIII Maintenance Manual 48152L Rev1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

46
47

17
48
1 49
3 4 18
2 35
16 1 Upper Media Sensor
1 Sub Assembly
33 36
15 50
34
6
7
19 20
1 21 32

Lower Media Sensor

10 13 Sub Assembly
7
11 1 31
140/170 90/96 37
12

14

38
27 39

22 26 40

25 41
30 42
43
8 8 44
9
1 29

13 45 1
23
24

Figure 5-4 90/96XiIII, 140XiIII and 170XiIII Print Mechanism Assembly View 1
48152L Rev1 07/00 XiIII Maintenance Manual 5-11
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 90XiIII, 96XiIII, 140XiIII, 170XiIII

Item Part Number Description Qty
1 *30118 E-Ring Ext .500 x .042 1
2 31336M Kit, Maintenance RTU/MTU (90XiIII, 140XiIII and 170XiIII) 1
2 47358M Kit Maintenance Pulley, RTU/MTU (96XiIII) 1
3 *30114 Washer, Flt, .76 x .51 x .03 1
4 *30115 Washer, Wave, .740 x .520 x .080 1
5 06250 E-Ring EXT .312 Yel 1
6 40027 Spring, Torsion 1
7 *30106 Ring, Crescent, External, .312 1
8 *30393-006 Screw, 8-32 x .37 6
9 *40193 Washer, Flt, .406 x .172 x .048 3
10 REF Screw, ¼-20 x .75 Cap 1
11 30466 Washer, .26 x .63 x .06 1
12 REF Support, Media Supply 1
13 46253M Kit, Media Supply Three (3) Inch (170XiIII) (Optional) 1
13 46044M Kit, 40mm, Media Supply (170XiIII) (Optional) 1
13 47253M Kit, Media Supply Three (3) Inch (90/96XiIII) (Optional) 1
13 47044M Kit, 40mm, Media Supply (90/96XiIII) (Optional) 1
13 48253M Kit, Maintenance Spindle Supply Three (3) Inch (140XiIII) (Optional) 1
13 48044M Kit, 40mm Media Supply, (140XiIII) (Optional) 1
14 *30239 Washer, Crescent, .415 x 323 x .062 1
15 46151M Kit, Maintenance Spindle Ribbon Supply (170XiIII) 1
15 47151M Kit, Maintenance Spindle Ribbon Supply (90/96XiIII) 1
15 48151M Kit, Maintenance Spindle Ribbon Supply (140XiIII) 1
16 46350 Kit, Upgrade Enhanced Ribbon Take-Up (170XiIII) 1
16 47250 Kit, Upgrade Enhanced Ribbon Take-Up (90/96XiIII) 1
16 48250 Kit, Upgrade Enhanced Ribbon Take-Up (140XiIII) 1
17 46813-7M Kit, Maintenance Compliant Roller (170XiIII only) 1
18 01130 Nut, 6-32 Hex Washer Head 1

Table 5-5 90/96XiIII, 140XiIII, 170XiIII Print Mechanism Assembly View 2

*Also Available in Hardware Kit 48205M

5–12 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

Part of 17

12

13
18

10
11 Optional Media
Supply Spindle

1 2
3
See Media Supply Hanger
4
8 Assembly
9
8
See Specific Printer
Printhead Support
14 Assembly Drawing
5
6 7

15

16
17

Figure 5-5 90/96XiIII, 140XiIII and 170XiIII Print Mechanism Assembly View 2
48152L Rev1 07/00 XiIII Maintenance Manual 5-13
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: All Series

Item Part Number Description Qty
1 47004M Kit, Maintenance Main Logic Board 1
2 *30391-003 Screw, 4-40 x .19 4
3 49036-1 Cover, PCB Option 1
4 49605-009 Cable, Power Switch 1
5 49669 Switch, Power 1
6 30406-006 Screw, 4-40 x .375 2
7 49673 Power Entry w/Fuse and Ground. Wire 1
8 49699-01 Cable (Brown) 1
9 49699-06 Cable (Blue) 1
10 46392-006 Screw, Truss Head Phillips, 6-32 x .37 7
11 *01159 Washer, Lock #6 1
12 01130 Nut, 6-32 Hex Washer Head 3
13 22416 Standoff, 4-40 Hex 2
14 *01155 Washer, Lock #6 2
15 07696 Screw, 4-40 x .31 2
16 30236 Screw, 4-40 x .25 1
17 49013 Cover, Memory Card, (PCMCIA) 1
18 46102-1 Panel, Rear 1
19 47020M Kit, Maintenance Counter Board 1
20 49313 Spacer, Top, (AC Power Supply) 2
21 01822 Nut, 4040 5
22 49780M Kit, Maintenance PCB Power Supply AC 1
23 49285 Pad, Insulation (AC Power Supply) 1
24 30253 Plate, Options Cover 1
25 46254 Plate, Cover, Cutter 1
26 30405-006 Screw. ¼-20 x .38 1
27 30466 Washer .26 x .63 x .06 1
28 *30393-006 Screw, 8-32 x .37 5
28 30393-010 Screw, 8-32 x .62 (220XiIII) 3
29 30407-004 Screw, 6-32 x .25 2
30 49790M Kit, Maintenance Power Supply DC 1
31 46015 Bumper 4
32 08754 Eye, .183 x .157 x .187 4
33 *07435 Screw, Lock Hex, 6-32 x .37 4
34 49286 Pad, Insulation DC Power Supply 1

Table 5-6 All Series Print Mechanism Assembly View 3

*Also Available in Hardware Kit 48205M

5–14 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

17
3
2
16
18

19
1 26
15 27

10
AA
4 BB
13
BB
AA
28
12 14 BB
BB CC AA
CC 11
CC
CC 5 15 AA
10
6 7 29
8 Brown
9 Blue

28
20
AA, BB, & CC Indicate
Mounting Hardware
Positions. 12

23
32
21 30
31
22

24 32
33 33
25

34
Figure 5-6 All Series XiIII Print Mechanism Assembly View 3
48152L Rev1 07/00 XiIII Maintenance Manual 5-15
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 220XiIII Printer Model: 220XiIII

Item Part Number Description Qty Item Part Number Description Qty
1 46091 Grommet (for 1.25 x .625 cutout) 2 30 REF Flange, Ball Bearing .5 x .250 x .125 2
2 *30392-004 Screw, 6-32 x .25 13 31 30105 Bearing, Nylon .312 x .251 x .078 1
3 REF Tri Mount Shoulder 1 32 46105 Bearing, Nylon .312 x .251 x .140 1
4 46352M Kit, Maintenance Flag 1 33 02252 Ring, Crescent .250 1
5 01130 Nut, 6-32 Hex Washer Head 1 34 22101M Kit, Maintenance Platen .780 x 8.73 1
6 30353M Assembly, Head up Switch Maintenance 1 35 22222M Kit, Maintenance Bar Pivot 2
7 46896 Bushing 2 36 22222M Kit, Maintenance Bar Pivot 1
8 46128 Washer, Flat, Nylon .505 x .192 x .015 2 37 Q10019 Ring, E Ext .250 1
9 48023 Bearing, .313 x .190 x .375 2 38 48043-4 Plate, Upper Media Guide (Snap Plate) 1
10 30009-10 Roller, .37 x .312 1 39 22302M Kit, Maintenance Media Sensor 1
11 30007-9 Shaft, Roller 1 40 48411 Screw, Thumb 2
12 *30392-008 Screw, 6-32 x .50 2 41 30827 Bracket, Media Sensor PCB 1
13 *30392-006 Screw, 6-32 x .25 2 42 46302-4M Kit, Maintenance Media Sensor (Includes Upper Sensor) 1
14 *06268 Washer, Lock #6 3 43 22391M Assembly, Dancer Arm w/Springs 1
15 40462 Cover, Take Label Sensor 2 44 *07229 Washer, Curved .49 x .33 x .0075 1
16 44001 Screw, Self-Tap 3.5 x 11 mm with 5mm Hex Head 11 45 *30423-003 Screw, Set 8-32 x .187 1
17 40355M Assembly, Platen Pulley Maintenance 1 46 22222M Kit, Maintenance Bar Pivot 1
18 38226 Kit, Maintenance Reflective Media Sensor 1 47 40248 Plate, Shaft Wear 1
19 40462 Nut, Expansion 8/10 1 48 40154 Pin, Eccentric 1
20 *30256-B Nut, Thumb 6-32 x .50 Brass 2 49 30956 Washer, Flat .207 x .146 x .030 2
21 22305M Kit, Maintenance Guide Media 1 50 30826 Plug, Hole 2
22 30033 Guide, Adjustable Media 1 51 30236 Screw, 4-40 x .25 1
23 22304M Kit, Maintenance Damper Cover 1 52 30494 Washer .32 x .119 x .062 1
24 *30402-006 Screw, 6-32 x .37 1 53 40031 Cover, Sensor Wire 1
25 46267 Plug, Hole .5 Diameter x .125 Thick 3 54 46302-4M Kit, Maintenance Media Sensor (Includes Lower Sensor) 1
26 46224 Grommet, Rubber .312 x .34 x .109 2 55 44931 Ring, E .218 Shaft 1
27 31493M Kit, Maintenance Motor, DC Stepper 1 56 44288 Washer, .50 x .25 x .031 2
28 *30393-006 Screw, 8-32 x .37 1
29 22808 Bar, Peel/Tear-off 1

*Also Available in Hardware Kit 48205M

Table 5-7 220XiIII Print Mechanism View 1

5-16 XiIII Maintenance Manual 48152L Rev1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

Ref.22039 Cover

49
1 56 50
55
21

51
6 2 53
18 52
3 4 5
22 39
19
2 Upper Media Sensor
20 2
2 Sub Assembly
23
36
7
15 40
14 24
13
12 1 35
37
8 10
9 11 16 25 Lower Media Sensor
16
4 Sub Assembly
16
2 38
41
17

42
32 43
31 44
26
34
30 33 2 45 46
47
15 14
14 12
2
29 2
27 28 17 48

Figure 5-7 220XiIII Print Mechanism View 1

48152L Rev1 07/00 XiIII Maintenance Manual 5-17
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 220XiIII

Item Part Number Description Qty
1 *30118 E-Ring .500 x .042 1
2 31336M Kit, Maintenance RTU/MTU Pulley 1
3 *30114 Washer, Flat .76 x .51 x .03 1
4 *30115 Washer, Wave .740 x .520 x .080 1
5 06250 E-Ring .312 Yel 1
6 40027 Spring, Torsion 1
7 *30106 Ring, Crescent, External .312 1
8 30265 Pulley, Idler 1
9 22207 Shaft, Idler Pulley 1
10 *30393-006 Screw, 8-32 x .37 5
11 *40193 Washer, Flat .406 x .172 x .048 4
12 30466 Washer, .26 x .63 x .06 1
13 *30392-004 Screw, 6-32 x .25 1
14 Ref Support, Media Supply 1
15 22253M Kit, Maintenance Spindle, Media Supply 1
16 *30239 Washer, Crescent .415 x .323 x .062 1
17 22151M Kit, Maintenance Spindle, Ribbon supply 1
18 22250 Kit Upgrade Enhanced Ribbon Take-up 1
19 22213-7M Kit, Maintenance Compliant Roller 1
20 30392-014 Screw, 6-32 x .87 3

Table 5-8 220XiIII Printer Mechanism View 2

*Also Available in Hardware Kit 48205M

5–18 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

Part of 19
14

15
20

12 Optional Media
Supply Spindle

1 2
3 See Media Supply Hanger
4
10 Assembly
11

16
See Specific Printer
5 9 Support Assembly Drawing
6 8
7

11 13
17

18
19

Figure 5-8 220XiIII Print Mechanism View 2

48152L Rev1 07/00 XiIII Maintenance Manual 5-19
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model 90XiIII

Item Part Number Description Qty
1 *30392-004 Screw, 6-32 x .25 10
2 30781 Cable, Ground Printhead 1
3 *01159 Washer, Flat .250 x .125 x .028 4
4 48182 Rivet Snap .138 x .08 Plastic 2
5 30314R Adhesive 1
6 30007-5 Shaft, Roller .187 x 4.105 1
7 46882-003 Screw, 4-40 x 3/16 2
8 47017 Plate, Ribbon Strip 1
9 48099-2 Roller .332 x .212 x 4.050 1
10 22016 Screw, M3 x .5 Low Profile 1
11 47212 Plate, Pressure 1
12 46899-3 Brush, Static 1
13 47103 Bracket, Head Mounting 1
14 *06268 Washer, #6 Lock 4
15 30013 Plate, Washer 1
16 *30402-006 Screw, 6-32 x .37 1
17 30494 Washer, .320 x .119 x .062 1
18 Q06020 Tie-wrap .09 W x 3.62 L 1
19 *01153 Washer, Flat .250 x .125 x .028 1
20 *30391-003 Screw, 4-40 x .19 1
21 47641 Cable, Printhead Data 1
22 46665M Kit, Maintenance, Sensor Ribbon 1
23 47000M Kit, Maintenance Printhead 1
24 47640 Cable, Printhead Power 1
25 47014 Plate, Guard 1
26 *40193 Washer, Flat .406 x .172 x .048 2
27 *40194 Washer, Curved .344 x .172 x .006 2
28 *46481-1 Screw, Adjustment M3.5 2

Table 5-9 90XiIII Printhead Support Assembly

*Also Available in Hardware Kit 48205M

5–20 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

1
1
2

3
4 3
Detail Front Surface Of Pressure Plate
Scale 2=1 47212 Should Be Flush To Below
Ends Of Mtg Brkt 47103

Wrap Ground Strap

As Shown
12
5 1
(Adhesive
This Side Only)
6
11

15
13
7 10
9 14

5-6
8

5-6
18
Note: 16
1. Position Ribbon Sensor (46665) Tab Not 17 6-8
To Be Flush With Top Edge Of Pivot Bar
(48162). Gap .010 Min./.030 Max. Below Top Edge
2. Remove Tab As Shown From Printhead 20 19
Data Connector. Remaining Printhead Data Connector
Tab Must Snap Over Connector
3. Screw Tightening Torques Unless 21
Otherwise Specified To Be 10-12 In. Lbs. 22 28
Other Values Appear In Boxes In (See Note 2) (See 27
In. Lbs. ( X-Y ) Note 1) 26

25
24

23 1

Figure 5-9 90XiIII Print Head Support Assembly

48152L Rev1 07/00 XiIII Maintenance Manual 5-21
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model 96XiIII

Item Part Number Description Qty
1 *30392-004 Screw, 6-32 x .25 10
2 30781 Cable, Ground Printhead 1
3 *01159 Washer, Flat .250 x .125 x .028 4
4 48182 Rivet Snap .138 x .08 Plastic 1
5 30314R Adhesive 1
6 30007-5 Shaft, Roller 1
7 46882-003 Screw, 4-40 x .19 2
8 47017 Plate, Ribbon Strip 1
9 48099-2 Roller .332 x .212 x 4.050 1
10 22016 Screw, M3 x .5 Low Profile 1
11 47212 Plate, Pressure 1
12 47099 Brush, Static 1
13 47203 Bracket, Head Mounting 1
14 *06268 Washer, #6 Lock 4
15 30013 Plate, Washer 1
16 *30402-006 Screw, 6-32 x .37 1
17 30494 Washer, .320 x .119 x .062 1
18 Q06020 Tie-wrap .09 W x 3.63 L 1
19 *01153 Washer, Flat .250 x .125 x .028 1
20 *30391-003 Screw, 4-40 x .19 1
21 46803M Kit, Maintenance Printhead Cable (600dpi) 1
22 46665M Kit, Maintenance Sensor Ribbon 1
23 47500M Kit, Maintenance Printhead (600dpi) 1
24 47640 Cable Printhead Power 1
25 47014 Plate, Guard 1
26 *40193 Washer, Flat .406 x .172 x .048 2
27 *40194 Washer, Curved .312 x .144 x .016 2
28 *46481-1 Screw, Adjustment 6-32 2

Table 5-10 96XiIII Printhead Support Assembly

*Also Available in Hardware Kit 48205M

5–22 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

1
1
2

3
4 3
Detail Front Surface Of Pressure Plate
Scale 2=1 47212 Should Be Flush To Below
Ends Of Mtg Brkt 47103

Wrap Ground Strap

As Shown
12
5 1
(Adhesive
This Side Only)
6
11

15
13
7 10
9 14

5-6
8

5-6
18
Note:
16
1. Position Ribbon Sensor (46665) Tab Not 17
To Be Flush With Top Edge Of Pivot Bar 6-8
(48162). Gap .010 Min./.030 Max. Below Top Edge
2. Remove Tab As Shown From Printhead 20 19
Data Connector. Remaining Printhead Data Connector
Tab Must Snap Over Connector
3. Screw Tightening Torques Unless
21 29
Otherwise Specified To Be 10-12 In. Lbs. 22
Other Values Appear In Boxes In (See Note 2) (See
In. Lbs. ( X-Y )
28
Note 1) 27

26
25
24

23 1

Figure 5-10 96XiIII Print Head Support Assembly

48152L Rev1 07/00 XiIII Maintenance Manual 5-23

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model 140XiIII

Item Part Number Description Qty
1 *30392-004 Screw, 6-32 x .25 10
2 30781 Cable, Ground Printhead 1
3 *01159 Washer, Flat .250 x .125 x .028 4
4 48182 Rivet Snap .138 x .08 Plastic 2
5 30314R Adhesive 1
6 30007-4 Shaft, Roller 1
7 46882-003 Screw, 4-40 x .19 2
8 48017 Plate, Ribbon Strip 1
9 48099-5 Roller 1
10 22016 Screw, Printhead Mounting 1
11 48212 Plate, Pressure 1
12 31899 Brush, Static 1
13 48003 Bracket, Head Mounting 1
14 *06268 Washer, #6 Lock 4
15 40013 Plate, Washer 1
16 *30402-006 Screw, 6-32 x .37 1
17 30494 Washer, .320 x .119 x .062 1
18 Q06020 Tie-wrap .09 W x 3.63 L 1
19 *01153 Washer, Flat .250 x .125 x .028 1
20 *30391-003 Screw, 4-40 x .19 1
21 46682 Cable, Printhead Data 1
22 46665M Kit, Maintenance Sensor Ribbon 1
23 48000M Kit, Maintenance Printhead 1
24 49640-021 Cable, Printhead Power 1
25 48014 Plate, Guard 1
26 48162 Bar, Head Pivot 1
27 *40193 Washer, Flat .406 x .172 x .048 2
28 *40194 Washer, Curved .312 x .144 x .016 2
29 *46481-1 Screw, Adjustment 6-32 2

Table 5-11 140XiIII Printhead Support Bracket

*Also Available in Hardware Kit 48205M

5–24 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

1
1
2

3
4 3
Detail Front Surface Of Pressure Plate
Scale 2=1 47212 Should Be Flush To Below
Ends Of Mtg Brkt 47103

Wrap Ground Strap

As Shown
12
5 1
(Adhesive
This Side Only)
6
11

15
13
7 10
9 14

5-6
8

5-6
Note:
18
16
1. Position Ribbon Sensor (46665) Tab Not 17
To Be Flush With Top Edge Of Pivot Bar 6-8
(48162). Gap .010 Min./.030 Max. Below Top Edge
2. Remove Tab As Shown From Printhead 20 19
Data Connector. Remaining Printhead Data Connector
Tab Must Snap Over Connector
3. Screw Tightening Torques Unless
21 29
Otherwise Specified To Be 10-12 In. Lbs. 22
Other Values Appear In Boxes In (See Note 2) (See
In. Lbs. ( X-Y )
28
Note 1) 27

26
25
24

23 1

Figure 5-11 140XiIII Print Head Support Assembly

48152L Rev1 07/00 XiIII Maintenance Manual 5-25
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model 170XiIII

Item Part Number Description Qty
1 *30392-004 Screw, 6-32 x .25 10
2 30781 Cable, Ground Printhead 1
3 *01159 Washer, Flat .250 x .125 x .028 4
4 48182 Rivet Snap .138 x .08 Plastic 2
5 30314R Adhesive 1
6 30007-7 Shaft, Roller 1
7 46882-003 Screw, 4-40 x .19 2
8 46017 Plate, Ribbon Strip 1
9 48099-8 Roller 1
10 22016 Screw, Printhead Mounting
11 46170 Plate, Pressure
12 46173 Brush, Static
13 46169 Bracket, Head Mounting 1
14 *06268 Washer, #6 Lock 1
15 46013 Plate, Washer 1
16 *30402-006 Screw, 6-32 x .37 1
17 30494 Washer, .320 x .119 x .062 1
18 Q06020 Tie-wrap .09 W x 3.63 L 1
19 *01153 Washer, Flat .250 x .125 x .028 1
20 *30391-003 Screw, 4-40 x .19 1
21 46682 Cable, Printhead Data 1
22 46665M Kit, Maintenance Sensor Ribbon 1
23 46500M Kit, Maintenance Printhead 1
24 49640-023 Cable, Printhead Power 1
25 46174 Plate, Guard 1
26 46002-1 Bar, Head Pivot 1
27 *40193 Washer, Flat .406 x .172 x .048 1
28 *40194 Washer, Curved .312 x .144 x .016 1
29 *46481-1 Screw, Adjustment 6-32 1

Table 5-12 170XiIII Printhead Support Assembly

*Also Available in Hardware Kit 48205M

5–26 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

1
1
2

3
4 3
Detail Front Surface Of Pressure Plate
Scale 2=1 47212 Should Be Flush To Below
Ends Of Mtg Brkt 47103

Wrap Ground Strap

As Shown
12
5 1
(Adhesive
This Side Only)
6
11

15
13
7 10
9 14

5-6
8

5-6
18
Note:
16
1. Position Ribbon Sensor (46665) Tab Not 17
To Be Flush With Top Edge Of Pivot Bar 6-8
(48162). Gap .010 Min./.030 Max. Below Top Edge
2. Remove Tab As Shown From Printhead 20 19
Data Connector. Remaining Printhead Data Connector
Tab Must Snap Over Connector
4. Screw Tightening Torques Unless
21 29
Otherwise Specified To Be 10-12 In. Lbs. 22
Other Values Appear In Boxes In (See Note 2) (See
In. Lbs. ( X-Y )
28
Note 1) 27

26
25
24

23 1

Figure 5-12 170XiIII Print Head Support Assembly

48152L Rev1 07/00 XiIII Maintenance Manual 5-27

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model 220XiIII

Item Part Number Description Qty
1 Ref Pad, Pressure 1
2 *30392-004 Screw, 6-32 x .25 10
3 30781 Cable, Ground Printhead 1
4 *01159 Washer, Flat .250 x .125 x .028 4
5 48182 Rivet Snap .138 x .08 Plastic 2
6 30314R Adhesive 1
7 30007-8 Shaft, Roller 1
8 46882-003 Screw, 4-40 x .19 2
9 22017 Plate, Ribbon Strip 1
10 30009-9 Roller 1
11 22016 Screw, Printhead Mounting 1
12 22180 Plate, Pressure 1
13 22191 Brush, Static 1
14 22003 Bracket, Head Mounting 1
15 *06268 Washer, #6 Lock 7
16 22013 Plate, Washer 1
17 *30402-006 Screw, 6-32 x .37 1
18 30494 Washer, .320 x .119 x .062 1
19 Q06020 Tie-wrap .09 W x 3.63 L 1
20 *01153 Washer, Flat .250 x .125 x .028 1
21 *30391-003 Screw, 4-40 x .19 1
22 22640-020 Cable, Printhead Data 1
23 22602 Cable, Printhead Data 1
24 46665M Kit, Maintenance Sensor Ribbon
25 22640-025 Cable, Printhead Power 1
26 22000M Kit, Maintenance Printhead 1
27 22174 Plate, Guard 1
28 22002 Bar, Head Pivot 1
29 *40193 Washer, Flat .406 x .172 x .048 2
30 *40194 Washer, Curved .312 x .144 x .016 2
31 *46481-1 Screw, Adjustment 6-32 2

Table 5-13 220XiIII Printhead Support Assembly

*Also Available in Hardware Kit 48205M

5–28 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

Detail Front Surface Of Pressure Plate

2
2 Scale 2=1 22180 Should Be Flush To Below
3 Ends Of Mtg Brkt 22003-p
1

4
5 4 Wrap Ground Strap
As Shown

13
6 2
(Adhesive
This Side Only)
7
12

16
14
8 11 15
10
5-6
9

5-6
19
17
Note: 18 6-8
1. Position Ribbon Sensor (46665) Tab Not
To Be Flush With Top Edge Of Pivot Bar
(48162). Gap .010 Min./.030 Max. Below Top Edge 21 20
2. Remove Tab As Shown From Printhead 1/2-3/4
Data Connector. Remaining Printhead Data Connector
22
Tab Must Snap Over Connector 31
24
4. Screw Tightening Torques Unless (See
Otherwise Specified To Be 10-12 In. Lbs. Note 1) 30
29
Other Values Appear In Boxes In
In. Lbs. ( X-Y ) 23
28

27
(See Note 2)
25
26 2

Figure 5-13 220XiIII Print Head Support Assembly

48152L Rev1 07/00 XiIII Maintenance Manual 5-29

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: All XiIII Series Printers

Item Part Number Description Qty
1 REF Block, Bearing 2
2 REF Guide, Outer Edge 1
3 22152M Kit, Maintenance Link and Pad 1
4 47153M Kit, Maintenance Media Hanger (90/96XiIII) 1
4 48153-4M Kit, Maintenance Media Hanger (140 XiIII) 1
4 46153M Kit, Maintenance Media Hanger (170 XiIII) 1
4 22153M Kit, Maintenance Media Hanger (220 XiIII) 1

Table 5-14 Media Supply Hanger

*Also Available in Hardware Kit 48205M

5–30 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

2
Complete Hanger Assemblies
90/96XiIII 47153M
140XiIII 48153-4M

Part of 170XiIII 46153M

#3 220XiIII 22153M

Figure 5-14 Media Supply Hanger

48152L Rev. 1 07/00 XiIII Maintenance Manual 5–31

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 90XiIII, 96XiIII, 140XiIII, 170XiIII

NOTE: Optional 40mm Media Supply Spindle not Available for 220XiIII.
Item Part Number Description Qty
1 N/A Screw, 6-32 x .125 6
2 REF Blade, 3” Core Media Supply (90/96XiIII) 3
2 REF Blade, 40mm Core Media Supply (90/96XiIII) 3
2 REF Blade, 3” Core Media Supply (140XiIII) 3
2 REF Blade, 40mm Core Media Supply (140XiIII) 3
2 REF Blade, 3” Core Media Supply (170XiIII) 3
2 REF Blade, 40mm Core Media Supply (170XiIII) 3
2 REF Blade, 3” Core Media Supply (220XiIII) 3
3 46068 Spring, Compression 1
4 N/A Nut, Locking 5/8 x 18 1
5 47253M Kit Media Supply Spindle 3” Spindle Complete (90/96XiIII) 1
5 47044M Kit, 40mm Spindle Complete (90/96XiIII) 1
5 48253M Kit Media Supply Spindle 3” Spindle Complete (140XiIII) 1
5 48044M Kit, 40mm Spindle Complete (140XiIII) 1
5 46253M Kit Media Supply Spindle 3” Spindle Complete (170XiIII) 1
5 46044M Kit, 40mm Spindle Complete (170XiIII) 1
5 22253M Kit Media Supply Spindle 3” Spindle Complete (220XiIII) 1

Table 5-15 Optional Media Supply Spindle

*Also Available in Hardware Kit 48205M

5–32 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

Figure 5-15 Optional Media Supply Spindle

48152L Rev. 1 07/00 XiIII Maintenance Manual 5–33

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: 170XiIII and 220XiIII

Item Part Number Description Qty
1 01130 Nut, 6-32 Hex Washer Head (170XiIII) 3
2 30392-014 Screw, 6-32 x .87 (220XiIII) 3
3 *30392-004 Screw, 6-32 x .25 2
4 46127 Washer, .312 x .153 x .030 2
5 22213-7M Kit, Maintenance Compliant Roller Assembly (220XiIII) 1
5 46813-7M Kit, Maintenance Compliant Roller Assembly (170XiIII) 1

Table 5-16 Compliant Roller Assembly

*Also Available in Hardware Kit 48205M

5–34 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

4
5

Figure 5-16 Compliant Roller Assembly

48152L Rev. 1 07/00 XiIII Maintenance Manual 5–35

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: All XiIII Series Printers

Item Part Number Description Qty
1 47151M Kit, Maintenance Spindle Ribbon Supply (90/96XiIII) 1
2 48151M Kit, Maintenance Spindle Ribbon Supply (140XiIII) 1
3 46151M Kit, Maintenance Spindle Ribbon Supply (170XiIII)
4 22151M Kit, Maintenance Spindle Ribbon Supply (220XiIII) 1
5 30070-2 Blade, Ribbon Supply, Inner 1
6 30401-002 Screw, 4-40 x .12 8 Max
7 30070-1 Blade, Ribbon Supply, Outer 1
8 40070-2 Blade, Ribbon Supply, Inner 1
9 40070-1 Blade, Ribbon Supply, Outer 3 Max
10 46211 Spring, Compression. .53 x .660 x .62 1
11 38042 Spring, Torsion, .739 x .805 1
12 47171 Housing, Ribbon Spindle Spring 1
13 46397-375 Nut, Locking Thin Hex 1

Table 5-17 Ribbon Supply Spindle Assembly

*Also Available in Hardware Kit 48205M

5–36 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

4
8
6

3
8
6

2 8
Long
6 End

10

11
1 5
6
7

12

13

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.

Figure 5-17 Ribbon Supply Spindle Assembly

48152L Rev1 07/00 XiIII Maintenance Manual 5-37

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: All XiIII Series Printers

Item Part Number Description Qty
1 47250 Kit, Upgrade Enhanced RTU (90/96XiIII) 1
1 48250 Kit, Upgrade Enhanced RTU (140XiIII) 1
1 46350 Kit, Upgrade Enhanced RTU (170XiIII) 1
1 22250 Kit, Upgrade Enhanced RTU (220XiIII) 1
2 47251M Kit, Assy. Spindle/Clutch (90/96XiIII) 1
2 48251M Kit, Assy. Spindle/Clutch (140XiIII) 1
2 46351M Kit, Assy. Spindle/Clutch (170XiIII) 1
2 22251M Kit, Assy. Spindle/Clutch (220XiIII) 1
3 47276 Spring, Compression 1
4 47251-2M Kit, Maintenance End Cap/Release Bar (90/96XiIII) 1
4 48251-2M Kit, Maintenance End Cap/Release Bar (140XiIII) 1
4 46351-2M Kit,Maintenance End Cap/Release Bar (170XiIII) 1
4 22251-2M Kit, Maintenance End Cap/Release Bar (220XiIII) 1

Table 5-18 Ribbon Take-Up Spindle Assembly

*Also Available in Hardware Kit 48205M

5–38 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

2
3
5
4

Figure 5-18 Ribbon Take-Up Spindle Assembly

48152L Rev. 1 07/00 XiIII Maintenance Manual 5–39

SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: All XiIII Series Printers

Item Part Number Description Qty
1 47383M Assy., Maintenance Plate, Rewind (90/96XiIII) 1
1 48383M Assy., Maintenance Plate, Rewind (140XiIII) 1
1 46383M Assy., Maintenance Plate, Rewind (170XiIII) 1
1 22383M Kit, Maintenance Plate, Rewind (220XiIII) 1
2 30914M Assembly, Peel-Off Pulley (90XiIII, 140XiIII,170XiIII, 220XiIII) 1
2 47915M Kit, Maintenance Peel-Off Pulley (96XiIII) 1
3 30265 Pulley, Idler (90/96XiIII,140XiIII,170XiIII) 1
3 22265 Pulley, Idler (220XiIII) 1
4 30207 Shaft, Idler Pulley (90/96XiIII,140XiIII,170XiIII) 1
4 22207 Shaft, Idler Pulley (220XiIII) 1
5 45189-5 Belt, Drive Rewind .080P 235T (90XiIII, 140XiIII,170XiIII, 1
220XiIII)
5 45189-12 Belt, Drive Rewind .080P 245T (96XiIII) 1
6 *30118 E-Ring, External .500 x .042 1
7 31336M Kit, Maintenance MTU/RTU Pulley (90XiIII, 140XiIII,170XiIII, 1
220XiIII)
7 47358M Kit, Maintenance Pulley MTU (96XiIII) 1
8 *30114 Washer, Flat .76 x .51 x .03 1
9 *30115 Washer, Wave .740 x .520 x .080 1
10 *30393-006 Screw, 8-32 x .31 3
11 *07435 Screw 6-32 x .37 2
12 *40193 Washer, Flat .406 x .172 x .048 1
13 46609-4M Kit, Maintenance Take-Label Sensor (Includes Lower Sensor) 1
14 47155M Kit, Maintenance Spindle Media Rewind (90/96XiIII) 1
14 48155M Kit, Maintenance Spindle Media Rewind (140XiIII) 1
14 46249M Kit, Maintenance Spindle Media Rewind (170XiIII) 1
14 22155M Kit, Maintenance Spindle Media Rewind (220XiIII) 1
15 *40193 Washer, Flat .406 x .172 x .048 3
16 *30392-004 Screw, 6-32 x .25 2
17 02252 Ring, Crescent .25 2
18 40019 Plate, Roller Adjustment 1
19 *30247 Washer, Flat .42 x .262 x .0740 1
20 30261 Washer, Flat .442 x .255 x .020 2
21 47601M Kit, Maintenance Platen .78 x 3.588 (90/96XiIII) 1
21 40038M Kit, Maintenance Platen .78 x 5.213 (140XiIII) 1
21 46278M Kit, Maintenance Platen .78 x 6.73 (170XiIII) 1
21 22101M Kit, Maintenance Platen .78 x 8.73 (220XiIII) 1
22 46609-4M Kit, Maintenance Take-Label Sensor (Includes Upper Sensor) 1
23 30104 Bearing, Ball .50 x .25 x .125 2

Table 5-19 Media Rewind Assembly

*Also Available in Hardware Kit 48205M

5–40 XiIII Maintenance Manual 48152L Rev. 1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

Note: Spacers Must Be

Positioned On Both Sides
Of Belt

Stepper Motor Pulley (Ref.)

12
11
7 9
8

13
6 Grn/Yellow

3 5

10

2 4

11
1
14

15
16
17
18
Rewind Version 15
22 16
Blk/Red 21
23
20
19

Figure 5-19 Media Rewind Assembly

48152L Rev1 07/00 XiIII Maintenance Manual 5-41
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Printer Model: All XiIII Series Printers Printer Model: All XiIII Series Printers
Item Part Number Description Qty Item Part Number Description Qty
1 02133 E-Ring, .188 Black 4 26 *30391-003 Screw, 4-40 x .19 4
2 30199 Bearing .375 x .189 x .125 3 27 49604-010 Cable, Power Distribution 1
3 30214 Link, Main 1 28 49600-012 Cable, SP Comm 1
4 Q10019 E-Ring, .250 Black 1 29 49730M Kit, Maintenance PCB Cutter Control 1
5 30210 Washer, Flt .564 x .384 x .060 2 30 46280M Kit, Maintenance Arm Drive Upper 1
6 30217-1 Pin, Link .187 Dia. 1 31 30816 Bracket, Cutter Lower 1
7 30208 Washer, Flt .500 x .191 x .030 2 32 *40193 Washer, Flt .406 x .172 x .048 2
8 30215 Link, Slotted 1 33 *30392-004 Screw 6-32 x .25 4
9 30198 Bearing .500 x .252 x .250 1 34 10421 Screw M4 x .7 x 5 4
10 30133 Bearing, Ball .375 x .187 x .125 1 35 30819 Bracket, Cutter Support (90/96XiIII) 1
11 30313 Clamp, Wire Cutter Opto 1 35 40819 Bracket, Cutter Support (140XiIII) 1
12 *01822 Nut, 4-40 5 35 46819 Bracket, Cutter Support (170XiIII) 1
13 30380M Kit, Maintenance Lower Drive Arm 1 35 22819 Bracket, Cutter Support (220XiIII) 1
14 30219 Flag, Sensor 1 36 30196-100 Module, Cutter (90/96XiIII) 1
15 *01155 Washer, Lock #4 1 36 30196-150 Module, Cutter (140XiIII) 1
16 30236 Screw 4-40 x .25 3 36 30196-200 Module, Cutter (170XiIII) 1
17 30216 Post, Pivot 1 36 30196-251 Module, Cutter (220XiIII) 1
18 46618 Cutter Sensor 1 37 30320 Brush, 4.50 x .50 Carbon (90/96XiIII) 1
19 30394-005 Screw, 10-32 x .312 2 37 40320 Brush, 6.50 x .50 Carbon (140XiIII) 1
20 30382RM Assy., Cutter/Rewind Plate Maintenance (90/96XiIII) 1 37 46320 Brush, 8.50 x .50 Carbon (170XiIII) 1
20 40382RM Assy., Rewind Plate Maintenance (140XiIII) 1 37 22320 Brush, 10.47 x .50 Carbon (220XiIII) 1
20 46382M Assy., Maintenance Cutter/Rewind Plate (170XiIII) 1 38 30181 Guide, Upper Cutter (90/96XiIII) 1
20 22382M Assy., Maintenance Cutter/Rewind Plate (220XiIII) 1 38 40181 Guide, Upper Cutter (140XiIII) 1
21 30405-006 Screw, ¼-20 x .38 (90/96XiIII, 140XiIII, 170XiIII) 1 38 46181 Guide, Upper Cutter (170XiIII) 1
21 30405-008 Screw, ¼-20 x .50 (220XiIII) 1 38 22193 Guide, Upper Cutter (220XiIII) 1
22 *44632 Ferrite Ring 1.1 x .75 1 39 46807 Bracket, Upper Cutter 1
23 46224 Grommet, Rubber 1 40 Q10011 Screw, M4 x .7 2
24 08449 Tiewrap .187 W x 11.5 L 1
25 30374M Assembly, Cutter Motor Maintenance 1

*Also Available in Hardware Kit 48205M

Table 5-20 Cutter Assembly

5-42 XiIII Maintenance Manual 48152L Rev1 07/00

MAINTENANCE AND ASSEMBLY DRAWINGS SECTION 5

2 27 28
26
1
3 7
8
9
10
13
1 14
15
16 39 34
2 17
4 29
5 30
6 40
12 7
2
1
11 38

19 12

20 18
36 37
See Note 1 21 16
22 24
(See Detail A) 25
23 31 35
32 34

33

Note
1. If Rewind Option Is Installed On Cutter 23
Machine, Be Sure To Order Cutter/rewind (Ref)
Plate (order By Model's Part No.)

2. Position Brush So That Approximately 1/2" Wrap Wires Thru Toroid

1/8" Of The Brush's Bristles Rub Against Each (Ref) Center 5 Times (will Wrap
Moving Label And The Brush's Bristles Are 4 Times Around Outside)
Parallel To The Label Edge. Detail A

Figure 5-20 Cutter Assembly View 1

48152L Rev1 07/00 XiIII Maintenance Manual 5-43
SECTION 5 MAINTENANCE AND ASSEMBLY DRAWINGS

Rotary Cutter Blade

Upper Cutter Bracket

Mounting Screw

Insure the Top of the Tear

.100"
off Bar is Positioned Above
Media Guide (2.5 Mm)
or Level With the Top of
the Rear Cutter Blade
Tear-off
Bar
Rear Cutter
Clearance of .030" Blade
minimum between
rear cutter blade 10421 screws (4) control
and tear-off bar position of cutter module
Relative position of the rotary cutter & squareness to media
blade when the drive link assembly is
stopped by the optical sensor, when
the power is on in the cutter mode

Set screws to engage flats

on motor shaft when lower
arm is in vertical position

Motor
Rotation
Direction Motor
Shaft

01660
Grease Black flag to be
All Around Cable holder centered in optical
(30313) to be assy
securely over
cables

Front View Side View

Figure 5-21 Cutter Option Assembly View 2

5–44 XiIII Maintenance Manual 48152L Rev. 1 07/00

MISCELLANEOUS INFORMATION & APPENDICES SECTION 6

SECTION 6 MISCELANEOU S INFORMATION AND

APPENDICES

Insert Installation Instructions the rear of this section.

48152L Rev. 1 07/00 XiIII Maintenance Manual 6-1

SECTION 6 MISCELLANEOUS INFORMATION & APPENDICES

ASCII CODE CHART

American Standard Code for Information Interchange

HEX CHAR HEX CHAR HEX CHAR HEX CHAR

00 NUL 20 space 40 @ 60 ‘
01 SOH 21 ! 41 A 61 a
02 STX 22 “ 42 B 62 b
03 ETX 23 # 43 C 63 c
04 EOT 24 $ 44 D 64 d
05 ENQ 25 % 45 E 65 e
06 ACK 26 & 46 F 66 f
07 BEL 27 ‘ 47 G 67 g
08 BS 28 ( 48 H 68 h
09 HT 29 ) 49 I 69 i
0A LF 2A * 4A J 6A j
0B VT 2B + 4B K 6B k
0C FF 2C , 4C L 6C l
0D CR 2D - 4D M 6D m
0E SO 2E . 4E N 6E n
0F SI 2F / 4F O 6F o
10 DLE 30 0 50 P 70 p
11 DC1 31 1 51 Q 71 q
12 DC2 32 2 52 R 72 r
13 DC3 33 3 53 S 73 s
14 DC4 34 4 54 T 74 t
15 NAK 35 5 55 U 75 u
16 SYN 36 6 56 V 76 v
17 ETB 37 7 57 W 77 w
18 CAN 38 8 58 X 78 x
19 EM 39 9 59 Y 79 y
1A SUB 3A : 5A Z 7A z
1B ESC 3B ; 5B [ 7B {
1C FS 3C < 5C \ 7C |
1D GS 3D = 5D ] 7D }
1E RS 3E > 5E ^ 7E ~
1F US 3F ? 5F __ 7F DEL

NOTE: Shaded codes NOT recommended for use as a Command Prefix, Format
Prefix or Delimeter Character

6-2 XiIII Maintenance Manual 48152L Rev. 1 07/00

MISCELLANEOUS INFORMATION & APPENDICES SECTION 6

SETTING BURN TEMPERATURE FOR IN SPEC BAR CODES

Not all direct thermal and thermal transfer materials have the same burn temperature requirements.
The best way to check for the proper burn temperature is to use a bar code verifier that actually
measures bars/spaces and will calculate the PCS ratio. Without the assistance of a verifier, your eyes
and/or the scanner to be used in the system, are the best bet for picking the optimum burn setting.
What follows is a simple yet effective method for adjusting the burn temperature to print IN SPEC
bar codes.

1. Load media (and ribbon if required) according to the appropriate media loading and ribbon
loading instructions found in the printer’s User Guide. Insure the print method is appropriately
characterized for either direct thermal or thermal transfer.
2. To print a label for evaluation, use the following procedure:
• With power OFF, depress and hold the FEED key.
• Turn the printer power ON, then release the FEED key.
• The printer will perform the Power-On Self Test (POST), calculate label length, and then
begin printing test labels.
3. Print a label, then depress the PAUSE key. The label will contain two bar codes as well as other
printer information. Normal bar codes are printed in a horizontal format as they feed out of the
printer. Rotated bar codes are printed in a vertical format.
4. Compare the test label printed, to the bar codes in Figure 6-1. If the test label appears under
burned or over burned, refer to section 4.1 and increase or decrease the BURN TEMP setting
accordingly.
5. Resume printing by pressing the PAUSE key again. Print a few labels at the new setting and
verify that proper IN SPEC Bar Codes are being printed. Repeat steps 3, 4 and 5 until satisfied.
6. To terminate the printing of the test labels, depress the PAUSE key, then depress the CANCEL
key.

Printing Conditions
Over-burned – Over-burned labels are obvious. The normal bar code bars increase in size, and the
openings in small alphanumeric characters may fill in with ink. It may be readable but not IN SPEC.
Rotated bar code bars and spaces will run together.
Slightly Over-burned - Slightly over-burned labels are not as obvious. The normal bar code will be
IN SPEC. Small character alphanumerics will be bold and could be slightly filled in. The rotated
bar code spaces are small when compared to the IN SPEC Code, possibly making the code
unreadable.
Slightly Under-burned - Slightly under-burned labels are, in some cases, preferred to slightly over-
burned for IN SPEC bar codes. Both normal and rotated bar codes will be IN SPEC, but small
alphanumeric characters may not be complete.
Under-burned – Under-burned labels are very obvious. Both normal and rotated bar codes have
incomplete bars and spaces. Small alphanumeric characters are unreadable.

48152L Rev. 1 07/00 XiIII Maintenance Manual 6-3

SECTION 6 MISCELLANEOUS INFORMATION & APPENDICES

In Spec - The IN SPEC bar code can only be confirmed by a verifier, but it should exhibit some very
visible characteristics. The normal bar code will have complete, even bars and clear, distinct spaces.
The rotated bar code will also have complete bars and clear distinct spaces. Although it may not
look as good as a slightly over-burned bar code, it will be IN SPEC. In both normal and rotated
styles, small alphanumeric characters will look complete.

Figure 6-1 Bar Code Examples

6-4 XiIII Maintenance Manual 48152L Rev. 1 07/00