Avery SNAP 656 User Manual

Users Manual

Model 656 / 636

AVERY DENNISON

Manual Edition 8.1

01 January, 2012

Manual Part Number 511398

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ii •••• Users Manual Model 656/636

Contents

Scope 1

Introduction................................................................................................................................ 1

Safety Issues / Warnings 1

Caution.......................................................................................................................................1

Warranty Information 2

Customer Responsibility 4

Location of Printer ..................................................................................................................... 4

AC Power Line .......................................................................................................................... 5

Unpacking.................................................................................................................................. 5

Inventory of Components........................................................................................................... 6

Printer Setup 7

Installing the Stacker.................................................................................................................. 7

Fuse Configuration..................................................................................................................... 8

P.C. Board Identification ........................................................................................................... 9

TCB Dip Switch Settings........................................................................................................... 9

Installing the Power Cord ..........................................................................................................9

Installing the PC Interface Cable ............................................................................................. 10

Installing the PC Software ....................................................................................................... 10

Product Description 11

Printer Description................................................................................................................... 11

Personal Computer Specifications ........................................................................................... 12

Printer Specification ................................................................................................................ 12

Printer Operation 14

Loading Ink.............................................................................................................................. 14

Loading Stock .......................................................................................................................... 15

Butt Splicing Stock .................................................................................................................. 16

Web Guide Adjustment............................................................................................................ 17

Print Head Operation ............................................................................................................... 17

Control Panel Operation 19

Control Buttons........................................................................................................................ 19

Indicator Lights........................................................................................................................ 20

LCD Display............................................................................................................................ 21

Users Manual Model 656/636 •••• iiiB

Front Panel Menu Map ............................................................................................................22

Front Panel Power Up / Home Screens ....................................................................................23

Front Panel Mode Descriptions................................................................................................ 25

Adjustments / Maintenance 34

Print Head Handling ................................................................................................................ 34

Print Head Cleaning .................................................................................................................35

Print Head Replacement........................................................................................................... 36

Print Head Adjustment............................................................................................................. 38

Stock Feed Roller Adjustment .................................................................................................39

Knife Square Adjustment......................................................................................................... 39

Stacker Adjustments.................................................................................................................40

Sensor Identification / Adjustment / Calibration......................................................................40

Print Registration Sensor .........................................................................................................42

Sensor Calibration:...................................................................................................................43

Lubrication Procedure.............................................................................................................. 44

Printer Set Up Sequence ..........................................................................................................45

Electrical Trouble Shooting 46

Power Up / Sign On / Communications ...................................................................................46

Stock / Ink Advance.................................................................................................................48

Print..........................................................................................................................................49

Cut / Stack................................................................................................................................51

Mechanical Trouble Shooting 52

Stock ........................................................................................................................................ 52

Ink ............................................................................................................................................ 54

Print..........................................................................................................................................55

Electrical Drawings 56

Printer Wiring ..........................................................................................................................56

Electrical System Schematic .................................................................................................... 58

Motherboard Power Connectors ..............................................................................................59

Appendix A 60

Error Messages ........................................................................................................................60

Appendix B 61

Software Upgrade Chip Placement Positions...........................................................................61

Front Panel Diagnostic Descriptions........................................................................................ 63

Appendix C 64

Ink and Stock Transfer Types ..................................................................................................64

Appendix D 67

Knife MFG Guideline .............................................................................................................. 67

Appendix E 70

iv •••• Users Manual Model 656/636

Printhead Life Extension.......................................................................................................... 70

Printhead Fail Modes ............................................................................................................... 71

Printhead Cleaning Procedure.................................................................................................. 72

Printhead Installation and Removal Procedures....................................................................... 73

Static Checks for 636/656 Printers .......................................................................................... 74

Print Quality Adjustment ......................................................................................................... 76

Appendix F 77

Platen Rollers for 6x6 and 676 Printers ................................................................................... 77

Assembly Drawings 83

Unwind Assembly Drawing ..................................................................................................... 84

Unwind Parts List .................................................................................................................... 85

Contrast Sensor Drawing ......................................................................................................... 86

Contrast Sensor Parts List ........................................................................................................ 87

Web Guide / Light Bar Assembly Drawing ............................................................................. 88

Web Guide / Light Bar Parts List............................................................................................. 89

Drive Assembly Drawing......................................................................................................... 90

Drive Parts List ........................................................................................................................ 91

Printhead Assembly Drawing................................................................................................... 92

Printhead Parts List .................................................................................................................. 93

Ink Unwind / Rewind Assembly .............................................................................................. 94

Ink Unwind / Rewind Parts List............................................................................................... 95

Feed & Ink Drive Assembly .................................................................................................... 96

Feed & Ink Drive Parts List ..................................................................................................... 97

Timing Belt Threading Diagram.............................................................................................. 98

Timing Belt Parts List.............................................................................................................. 99

Knife Assembly Drawing....................................................................................................... 100

Knife Parts List ...................................................................................................................... 101

Stacker Assembly Drawing (Part 1)....................................................................................... 102

Stacker Parts List (Part 1) ...................................................................................................... 103

Stacker Assembly Drawing (Part 2)....................................................................................... 104

Stacker Parts List (Part 2) ...................................................................................................... 105

Cooling Fan Assembly Drawing............................................................................................106

Cooling Fan Parts List ........................................................................................................... 107

Optional 4.25” Pickup Assembly...........................................................................................108

Optional 4.25” Pickup Parts List ........................................................................................... 109

Optional 4.25” Stacker Assembly .......................................................................................... 110

Optional 4.25” Stacker Parts List........................................................................................... 111

Rewind Assembly Drawing....................................................................................................112

Contrast Sensor Webguide Option Drawing .......................................................................... 114

Contrast Sensor Webguide Option Parts List......................................................................... 115

Cover Assembly Drawing...................................................................................................... 116

Cover Parts List ..................................................................................................................... 117

Users Manual Model 656/636 •••• vB

Scope

Introduction

This user manual was arranged for the person who is going to operate the printer.
The information is arranged in the order that is needed to install and then operate the
printer. It starts with general information, then to unpacking the carton, setup,
installing the ink and stock, printer operation, control panel operation, and finally
care and maintenance of the printer.

We at AVERY DENNISON hope that you will come to appreciate the efforts and
quality that have gone into producing your AVERY DENNISON 656 / 636 Printer
and wish to remind you that you are our number one priority. We welcome any
constructive comments or criticisms so that we may continue to offer you the best
printer in the industry for years to come.

Safety Issues / Warnings

Caution

This printer has some pinch points. All of these areas have been well guarded and it
is recommended that the safety features of this printer are never altered or defeated.

Warning: This is a class A product. In a domestic
environment this product may cause radio
interference in which case the user may be required
to take adequate measures.

Users Manual Model 656/636 Scope •••• 1B

Warranty Information

Warranty Policy

Avery Dennison Retail Information Systems, In-Plant Printing Solutions provides the following warranty policy.

Scope

Warranties against defects from workmanship for equipment and parts manufactured and sold from Sayre,
PA. Includes time and material except as otherwise noted below.

Time

− New equipment and parts: 6 months

− Refurbished equipment and parts: 90 days

− Warranty period starts when equipment ships from selling location.

General Conditions

Avery Dennison extends warranty coverage under the following conditions.

− Equipment and parts will perform within published specifications. Promised or implied statements by any

Avery Dennison employee or representative will not be deemed to vary the terms of the warranty.

− Equipment and parts must be installed and operated according to recommended procedures and

operating conditions.

− Consumable elements are not covered. Consumable elements are those that show normal wear from

typical equipment usage including, without limitation, printheads, knives, rollers in contact with the web,
and sonic units. Avery Dennison reserves the right to determine which elements are defined as
“consumable.”

− No customer maintenance may be performed except as directed by qualified Avery Dennison personnel.

− Equipment and parts damaged by negligence or abuse are not covered.

− Avery Dennison US reserves the right in its sole discretion to incorporate any modifications or

improvements in the machine system and machine specifications which it considers necessary but does
not assume any obligation to make said changes in equipment previously sold.

Equipment Purchased In US and Shipped In US

− Avery Dennison US covers warranty for equipment and parts installed and operated in the Americas

(United States, Canada, Mexico, Central America, Caribbean Region, and South America excluding
Brazil).

− Outside the US, the local Avery Dennison office is responsible for equipment and parts warranty.

Customers must ensure coverage during machine purchase.

2B •••• Warranty Information Users Manual Model 656/636

− Equipment purchased and exported to regions outside local Avery Dennison office coverage are not

covered by warranty. The purchasing agent must acquire a service contract from the Avery Dennison
office where the equipment or parts are operated to ensure machine coverage. For example, if an agent
purchases a printer in the US, exports to Brazil, and then needs warranty coverage, Avery Dennison Brazil
has no obligation to provide warranty coverage. The agent must purchase services from Avery Dennison
Brazil.

THE WARRANTIES PROVIDED HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ANY IMPLIED
WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY
OF QUALITY OR PERFORMANCE, WHETHER EXPRESS OR IMPLIED. EXCEPT THE WARRANTY OF
TITLE, IN NO EVENT SHALL AVERY DENNISON BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, EVEN IF AVERY DENNISON HAS BEEN ADVISED OF THE POSSIBILITY
OF SUCH DAMAGES.

Service

When ordering machines and supplies in the U.S.A., reference all correspondence to the address below.

AVERY DENNISON Corporation

One Wilcox Street

Sayre, PA 18840

Call: 1-800-967-2927 or [phone]

Fax: [phone]

For spare parts, requests for service or technical support, contact

AVERY DENNISON Corporation

One Wilcox Street

Sayre, PA 18840

Call: 1-800-967-2927 or [phone]

Fax: [phone]

For parts and service in other countries, please contact your local AVERY DENNISON supplier.

Users Manual Model 656/636 Warranty Information •••• 3B

Customer Responsibility

Location of Printer

The printer weighs approximately 57 Lbs (~26Kg) and requires a table of sufficient
quality and strength to handle this load while the printer is operating. AVERY
DENNISON recommends an industrial type work table having the approximate
dimensions of 96" wide to 30" deep to 32" high. (See Figure 1).

Figure 1 - Recommended Workstation Layout.

The location of the AVERY DENNISON 656 / 636 printer should be based on
human factors. The printer should be located in an area that maintains optimum flow
of your product while providing for the operator’s comfort. AVERY DENNISON
has taken significant steps to ensure that the operator controls and operations are
easily accessible. This goal can only be met, however, if the printer is also located
with human factors in mind. These include the height of the printer, the space around
the printer, and the accessibility to the printer.

The AVERY DENNISON 656 / 636 printer is a high-resolution thermal printer.
While AVERY DENNISON has designed the printer to be reasonably quiet, it is
recommended to locate the printer in an area where printing and cutting repetitious
noise is acceptable.

The unit should always be operated with the cover closed to minimize the amount of
dust and dirt in the printer.

4B •••• Customer Responsibility Users Manual Model 656/636

AC Power Line

Unpacking

AVERY DENNISON requires that the electrical service be 10 Amps @ 115VAC or
10 Amps @ 230VAC. This will allow the computer and any additional support or
service equipment to be plugged into the same service.

Any electrical service that is supplying a AVERY DENNISON printer or peripheral
equipment connected to a AVERY DENNISON printer should follow standard
electrical code practices including proper grounding and neutral requirements.

The AVERY DENNISON printer was designed to operate in an industrial setting for
extended periods of time; however, the printer is controlled by a microprocessor that
is very sensitive to brownouts or power spikes. For this reason as well as the
minimum recommended current supply, AVERY DENNISON recommends that a
separate “clean” service be installed or reserved for the exclusive use of the AVERY
DENNISON printer and it’s peripherals.

The AVERY DENNISON printer is shipped in a large cardboard box that may be
difficult to move by hand.

DO NOT REMOVE THE PRINTER FROM THE BOX OR UNPACK IN THE
SHIPPING / RECEIVING DEPARTMENT.

NOTE: Unpacking in the shipping/receiving department is not recommended for the

following reasons. First: The cardboard carton in which your AVERY DENNISON
printer was shipped allows the printer to be moved with a forklift, forkcart or hand
cart. Because of the weight of the printer, it is easier and safer to use one of these
devices to move the printer to its intended installation location. Second: Leaving the
printer in the carton while it is being moved within your facility will help to protect
the printer during any movements to this location. Once the printer has reached its
intended location you should begin the unpacking process.

Open the printer from the top of the box (See Figure 2). Do not cut deep into the
carton, as there are items located just under the top. Remove the items located on the
top insert. Remove the top insert. Lift the printer onto the table with the two banding
straps. Remove the two straps and the plastic from the printer. Inspect the printer for
shipping damage. If damage is discovered, contact AVERY DENNISON for further
instructions - in the U.S.A. at [phone]. In other countries please contact your
local AVERY DENNISON supplier. Once you are satisfied that there was no
obvious shipping damage to the printer, the printer can now be lifted to its intended
location.

Users Manual Model 656/636 Customer Responsibility •••• 5B

In some cases, a double box has been used to ship your printer.

Figure 2 Shipping Carton.

Save the shipping materials to relocate the printer or return to factory for service.

Inventory of Components

The following list shows the additional parts (pieces) that should be included in your
AVERY DENNISON 656 / 636 shipping container. If anything is missing, notify
AVERY DENNISON immediately - in the U.S.A. at [phone]. In other
countries please contact your local AVERY DENNISON supplier.

- AVERY DENNISON 656 / 636 "User's Manual”

- Tool kit

- A quick-disconnect power cord

- Stacker assembly

- Optional software ordered to drive the printer.

- A serial communications cable / converter.

NOTE: Some of the above parts may be inside of the envelope that contains the tool
kit.

AVERY DENNISON 656 / 636 TOOL KIT (#351390)

241149 Anti-Static Gloves (2)
921309 Hex Key Set
921364 3/16" Long Ball Driver
181301 2.5mm Ball Driver
351156 Chip Removal Tool
511398 656 / 636 Users Manual
241132 Anti Static Wrist Strap
921338 T-T Printer Cleaning Kit

6B •••• Customer Responsibility Users Manual Model 656/636

Printer Setup

Installing the Stacker

Remove the stacker from the separate packaging. Remove the packaging from
around the stacker and save with the rest of the printer packing supplies.

Swing open the top cover to the printer. Locate the large knob and two round pins on
the right hand side of the printer. Loosen the knob enough to allow the stacker to
slide between the printer housing and the knob. The stacker will rest on the two pins.
Slide the stacker to the back until it contacts the up-right frame. Tighten the knob.
Adjusting the stacker is covered later.

Install the stacker up-right rails. Remove one of the thumbscrews. Insert the
thumbscrew through the mating hole in the up-right rail assembly. Thread the
thumbscrew into the mounting block. Repeat the above procedure for the other
thumbscrew.

There is a cable with a connector leading from the back of the stacker that plugs into
a socket on the TCB (Refer to the P.C. Board Identification section in this manual).
The socket and plug are polarized. Rotate the plug until the polarized keyway and
socket align and push the stacker connector into the socket.

Users Manual Model 656/636 Printer Setup •••• 7B

Location of 115V Text

Location of 230V Text

A

B C

Fuse Configuration

The main fuse(s) on the AVERY DENNISON 656 / 636 are located inside the AC
power entry receptacle. The entry has a fuse drawer that holds the fuse(s) and selects
the appropriate line voltage. If the voltage in the window DOES NOT match the AC
line voltage intended to be supplied to the printer, DO NOT plug the power cord in.
Reconfigure as follows:

1) Using a flat blade screwdriver, open the AC entry by lifting the tab just above the
voltage indicator window.

2) Remove the red fuse drawer.

3) Remove all fuses and the fuse jumper if it is present.

4) Insert into the fuse drawer the correct number and style of fuses and fuse jumper
for your application.

Configuration Number One: Line voltage within the range of

(See Figure 3A) 90 - 132VAC @ 50 - 60Hz

1) Install one 921167 - 10.0A 250V Fast Acting 1/4 x 1 1/4"

2) Install one Fuse Jumper

Configuration Number Two: Line voltage within the range of

(See Figure 3B) 180 - 265VAC @ 50 - 60Hz

1) Install two 921168 10.0A 250V Fast Acting 5 x 20MM

NOTE: The fuse jumper must be removed to install both 5 x 20mm fuses.

Figure - 3A Figure - 3B

Fuse Jum per

One 1/4 x 1 1/4" Fuse Far Side

The fuses must be between points A
and B as shown not B and C.

5 x 20 m m fuse

FRONT FRONT

Location of 115V Text

Location of 230V Text

Two 5 x 20MM Fuses One Each

8B •••• Printer Setup Users Manual Model 656/636

4) Reinsert the fuse drawer into the AC entry with the desired voltage up.

5) Close the AC entry and verify the correct voltage is now visible.

P.C. Board Identification

Mother Bd. (371170) - Horizontal on bottom of printer

Front Panel Bd. (511108) - User interface system

Thermal Control Bd. (371105TT) - AT Slot 2

Head Driver Bd. (341106TT) - AT Slot 1

TCB Dip Switch Settings

DIP SWITCH # DEFINITION 636 656

8 DOWNSTACKER /

LOKPRINT

7 UNUSED OFF OFF
6 UNUSED OFF OFF
5 STACKER JAM ENABLE ON

4 MACHINE TYPE OFF OFF
3 MACHINE TYPE ON OFF
2 UNUSED OFF OFF
1 DPI 240 OFF

DOWNSTACKER ON

LOKPRINT® OFF

DISABLE OFF

300 ON

DOWNSTACKER ON

LOKPRINT® N/A

ENABLE ON

DISABLE OFF

240 OFF
300 ON

Installing the Power Cord

A power cord is shipped with each printer. The cord for 115-volt printers will use
the standard three-prong plug used in the U.S.A. A 230-volt printer and some other
115-volt configurations will have the plug end of the cable removed. It is the
customer’s responsibility to have the plug and alteration work done by a certified
electrician. AVERY DENNISON supplies printers to many countries with many
variations. Therefore we leave this to the customer to make the proper selection for
their country.

Users Manual Model 656/636 Printer Setup •••• 9B

Installing the PC Interface Cable

The 656 / 636 requires a 9-pin RS232 cable. This cable is provided with the printer.
If the cable was not found it can be ordered from AVERY DENNISON (Part no.

351124).

The male end of the cable should be connected to the 9-pin D-shell female connector
that is located on the right side of the printer at the TCB (refer to the P.C. Board
Identification section in this manual). The female end of the cable is made to fit a 9­pin male RS232 connector on the back of a PC. In case a 9 pin serial port is not
available a 9 to 25-pin converter is also shipped with all printers.

Installing the PC Software

The software to drive the AVERY DENNISON family of printers is covered in
separate documentation. The "Formatter / PcMate Plus" software to create formats
on site for the AVERY DENNISON 656 / 636 printer is a Windows application. The
original "Selfform" will not create formats for the 656 / 636. The new "Formatter /
PcMate Plus" package is capable of creating formats for all AVERY DENNISON
control printers.

The original DOS version of "PcMate" has been updated to drive the 656 / 636
printer. PcMate DOS version 3.05 or higher is needed.

The printer is also capable of operating directly from a mainframe when using the
RS232 interface and AVERY DENNISON's PCL command language.

10B •••• Printer Setup Users Manual Model 656/636

Product Description

Printer Description

The AVERY DENNISON model 656 / 636 thermal printer (See Figure 4) is an
electronic printer that can print on Fabric Tapes, Card Stock, Heat Seal, and Pressure
Sensitive rolled stocks. The printer interfaces to a computer or a main frame system
thus allowing electronic data input or even custom design of labels with AVERY
DENNISON’S “Formatter / PcMate Plus" program. This printer can generate a
complete label printed on one side.

• Design your own labels on a PC

• Computer interface = IBM Compatible

• Mainframe direct interface

• RS232 9 Pin D shell female Serial interface connector

Figure 4 - AVERY DENNISON Model 656 / 636 Label
Printer

Users Manual Model 656/636 Product Description •••• 11B

Personal Computer Specifications

This specification describes the hardware and application software requirements for
the Personal Computer that is used to download to the AVERY DENNISON 636 /
656 Printer.

The AVERY DENNISON 636 / 656 Printer uses a Windows version of “PcMate
Plus / Formatter”. This application will create the tag or label formats (layouts) then
fill and transfer data to the printer through the serial port of the computer.

“PcMate Plus / Formatter ” Requires the following;

• IBM® PC or compatible

• Microsoft Windows® 98 2nd edition or higher

(Including Win 2000, ME, NT, and XP)

• 64 Megabytes RAM

• 1 Gigabyte Hard Drive

• Pentium or Pentium Type processor - 400 MHz or higher

• 3-1/2" floppy drive and CD Rom

DISK DRIVES: You will need a hard disk with at least 100 megabytes of free disk
space to store the PcMate Plus program. Additional space will be required to store
formats, batches, etc.

Refer to your specific software package for proper installation procedures.

Printer Specification

Print
method:

Label Size

Print Area Max: up to 5" (127mm) web x up to 13.875" (352.4 mm) feed

Resolution

Fonts

Logos

Care
Symbols

Justification Left, Right, and Center - field selectable

Narrow web thermal transfer or thermal direct one sided printer

Speed - up to 7 IPS (177.8mm/second)

Max: up to 5.125" (130.2mm) web x up to 7" (177.8 mm) feed cut and stacked

- Up to 14.0" (355.6mm) feed w/ rewind
Min: 1" (25.4mm) web x 1" (25.4mm) feed

Min: None

240 DPI x 240 DPI
300 DPI x 300 DPI

Two scalable fonts resident: condensed, standard, and bold typefaces, upper and lower case
4pt up to 96pt (300 DPI), 6pt up to 96pt (240 DPI)

all rotations 0°, 90°, 180°, 270°

No restriction on number or size per tag (up to maximum image area)
All rotations 0°, 90°, 180°, 270°

Full Ginetex Care Symbol set and full NAFTA / ASTM Care Symbol Set
Fully Scaleable

All rotations 0°, 90°, 180°, 270°

12B •••• Product Description Users Manual Model 656/636

Stock Support for blank or pre-printed fabrics, blank or pre-printed card stock and die cut blank or pre-

printed pressure sensitive

Interface AVERY DENNISON PCL via RS232 serial port - 9 pin D-shell

Control
Panel

Dimensions

Weight 57 Lbs. ( 26Kg.)

Electrical 90-132 / 180-265 VAC 50-60Hz 10Amp Switch selectable

Temperature

Humidity 5% to 90% non-condensing

Other
Features

Ink Ribbon AVERY DENNISON standard thermal colors and widths

Options

Push-button printer function with 2 Line x 24 Character International LCD Backlit Display

16.0" (406.4 mm) high x 27" (685.8 mm) wide
including stacker x 18.5" (469.9mm) deep

41°F (5°C) to 104°F (40°C)

- Downloading of information while printer is operating

- Sequenced Fields

- Time/Date Stamping

- Life Counts

- Operator adjustable: strobe, cut position, print position, baud rate, and buffer size

- Error Detection of: stock out, ink out, print head open, full stacker, stacker jam, and print head
over-temperature

- Display: labels left to print in a batch, batch ID, total life inches, total life cuts

- Self Diagnostics

- Missed sense mark detection and correction

- Slot, Notches, Hole or Reflective registration detection

- SV-100 Barcode Verifier System

- Rewind Unit

- Reflective Sensor (Back of web)

- PcMate

- Formatter / PcMate Plus

- Spare Parts Kit

- International Hardware Kit

- Optional 4.25” Stacker

- Optional Downstacker

Optional 4.25” Stacker Specifications

• 4.25” Web x 1 ¾” Feed

• Will work on 636, 656 & 676

• Old machines may require the knife strut to be replaced with one that has a

mount hole – Part number 355018.

• Fabric and heat seal only - not for pressure sensitive or tags.

• Stack height dependent on material size and weight. (May not reach full stacker

height)

• Jam sensor will require relocating the LED to the center position for the 676 and

back set of holes for the 636 & 656.

• If changing from standard stacker to 4.25” stacker - the knife guard must be

changed to match the stacker being used.

Users Manual Model 656/636 Product Description •••• 13B

Printer Operation

Loading Ink

Figure 5 - Ink Threading Path

The ink ribbon comes packaged in a plastic bag. For best results, leave the ink
ribbon wrapped in this bag until you are ready to use it in the printer. Use the
procedure and diagram above for loading the ink.

1) Unwrap the ink ribbon and put it on the ink-ribbon unwind arbor (See Figure 5) by
pressing it on to the arbor when the three slots are lined up.

2) Make sure the ink ribbon comes off the roll in the direction shown above and is
threaded as illustrated.

NOTE: A new ink ribbon has a leader that makes it easier to use when threading the

ribbon through the print area.

3) Put an empty ink-ribbon take-up core on the ink rewind arbor. The ink take-up
core must be at least as wide as the ink supply. The adhesive on the supply roll of
ink can be used to fasten the leader to the rewind core.

4) Advance the ink until ink starts to wrap around the take-up core.

5) You should rotate the ink arbors to keep excess slack ink from between the print
head and the ink cores.

NOTE: Make sure that the ink-ribbon take-up core and the ink-ribbon supply roll

are against the ink backer plate so that the ink ribbon tracks straight
through the print station.

14B •••• Printer Operation Users Manual Model 656/636

Loading Stock

FIGURE 6 – Tag Stock Threading

FIGURE 6A – Fabric Threading

LOADING STOCK FOR THE FIRST TIME

1) Adjust the unwind width wider than the roll of stock to be loaded. Set the stock
roll on the unwind between the guides with the stock unwinding from the top
clockwise. Adjust the unwind width down to the stock size without clamping the
core.

2) Adjust the web guides on the decurler bar to a width wider than the stock.

3) Remove the tape or pull the glued end of the stock loose from the supply roll of
stock. Pull off about 2 feet (.5 m) of stock to thread it through the printer.

NOTE: If the end of the material was glued down, cut off all material that has glue

on any surface.

Users Manual Model 656/636 Printer Operation •••• 15B

4) Open the hinged cover to the printer.

5) Open the print head by pushing the release lever and allowing the head to swing
up.

6) Open the feed roller by rotating the feed pressure knob fully counter clockwise.

7) After looping the leading edge of the stock over the two decurler bars, slide it
through the funnel containing the registration sensor and light bar. Keep the stock
in the center, as the printer is center justified.

8) As the stock exits the sensor area, continue to slide the stock through the print
station.

9) Once the stock passes though the feed rollers, slide it through the auxiliary feed
then through the knife and into the stacker.

10) Check that the stock is center and tracking straight through the printer. Adjust as
needed.

11) Close the feed roller and the print head.

12) Rewind any loose stock back onto the supply roll.

13) Adjust the web guides on the decurler down to the edges of the stock without
deforming the stock.

Butt Splicing Stock

NOTE: DO NOT RUN BUTT SPLICES THROUGH THE PRINT STATION

The AVERY DENNISON 656 / 636 has been designed so that supplies can be
changed / replenished quickly. Removing the stock trailer remaining in the printer
and re-threading the stock altogether can be quicker than butt splicing can. If
however you have determined a butt splice is necessary, you can tape together the
leader of the new stock roll & the trailer of the depleted stock still in the printer.

When the stock is depleted and the printer stops with a stock out error message, load
a new supply roll onto the printer unwind following the procedure previously
outlined. Make sure you have determined how the new roll should go on the unwind
to prevent any twisting in the stock. Tape the two ends together and remove all slack
by rotating the supply roll counterclockwise. Open the printhead and feed roller and
manually advance the splice beyond the print station.

NOTE: Whenever stock of a different type or width is put on the printer, a sample

WITH THE PRINTHEAD CLOSED.

run should be performed. If the print quality / registration is acceptable,
you can immediately begin your production run. If the print quality /
registration needs to be optimized, (Refer to the Printer Setup procedures
and perform the procedure needed to make the necessary improvement).

16B •••• Printer Operation Users Manual Model 656/636

Web Guide Adjustment

The AVERY DENNISON 656 / 636 printer has been designed with only three web
guides in the printer that need to be changed as the width of the rolls change from
format to format. None of these adjustments requires any tools.

The first guide is on the unwind itself. A knob located on the front of the unwind
adjusts the width of the guides on the unwind while maintaining center justification.
To increase the width turn the knob counter clockwise to decrease the width, turn the
knob clockwise. Adjust the unwind width wider than the roll of stock to be loaded.
Set the stock roll on the unwind between the guides with the stock unwinding from
the top clockwise. Adjust the unwind width down to the stock size without clamping
the core.

The second sets of guides are located on the decurler just to the left of the stock
registration funnel. Once a stock is loaded and tracking straight through the printer
adjust this set of web guides down to the edges of the stock without deforming the
stock. Loosen the plastic thumbscrew and slide the collar into the new position then
retighten the thumbscrew. Fine adjustments of the stocks web position can be made
by simply moving the collar as a set in or out. If the guides are too tight, the stock
will have rolled up edges.

The only other web guide adjustment is the stacker up-right rails (refer to the Stacker
Adjustments section in this manual). To fine turn the location of the up-rights, loosen
the knob behind each upright rail and slide the rail in or out as needed. The up-right
rails should be located approx. 1/16" (1.5mm) to the back or front of the label or tag
as it enters the stacker.

Print Head Operation

The print head module is to be opened and closed for threading the stock and ink.
The head must also be opened to clean the head and for print head replacement.
Later in the manual, under Print Head Cleaning, and Print Head Replacement,
cleaning and replacement will be covered.

The print head has an interlock switch that prevents the printer from running with the
head in the open position. If the head is open the display will read - HEAD OPEN.

WARNING: DO NOT TOUCH THE PRINT HEAD WITHOUT WEARING THE

To open the print head for threading supplies, press the lower portion of the latch
(see figure 7). The head mount plate will hinge from the back to swing open.

ANTI-STATIC GLOVES AND THE STATIC WRIST STRAP.

Users Manual Model 656/636 Printer Operation •••• 17B

Figure 7 - Print Head Operation

To close the head mount plate, move the head down while depressing the latch.
When the mount plate swings past the top of the latch release.

18B •••• Printer Operation Users Manual Model 656/636

Control Panel Operation

Control Buttons

Start

- Starts the printer.

- ON LINE light must be GREEN.

(Batches downloaded to be printed)

Feed

- FEED and START must both be used.

- Feed will stop when the buttons are released.

- Labels between the head and knife will be cut and stacked as finished
labels.

- Stock moves through in one continuous strip.

- Stock moves through without printing.

- Ink will not advance; ink save on the 656 will automatically be activated.

- The print head must be closed.

Users Manual Model 656/636 Control Panel Operation •••• 19B

Indicator Lights

Test

- TEST and START must both be used.

- Test will stop when the buttons are released.

- Labels between the head and knife will be cut and stacked as finished
labels.

- Stock moves through in one continuous strip.

- Stock moves through with test pattern printing.

- The ink will advance with the stock.

- The print head must be closed.

Stop

- The stop button will stop the printer at the end of the current label being
printed.

The AVERY DENNISON 656 / 636 has three Indicator lights. These lights are used
along with the LCD display to tell the operator the current status of the printer.

On Line

OFF

- Has not been powered on.

- Is in its power - up sequence.

- Failed the system test.

After Power Up Sequence:

- Printer is running.

20B •••• Control Panel Operation Users Manual Model 656/636

ORANGE

- System is operational.

- Ready for batches to be downloaded.

GREEN

- Batches to print, ready to start.

Sensor

GREEN = "C" SENSOR

- Printer is stopped, - light is on, - sensor is setting over a stock sensor
mark hole.

- Flashing light while the printer is running, - the sensor is in-line with the
registration HOLES.

ORANGE = REFLECTIVE SENSOR

- Flashing light while the printer is running, - the sensor is in-line with the
registration PRINTED MARKS.

Error

ORANGE

- System inter-lock triggered, display for error.

LCD Display

The LCD display is a 2 line, 24 character, with back lighting feature for easy
readability. The first line of the display in most cases will be a prompt or question.
The second line is the response.

Users Manual Model 656/636 Control Panel Operation •••• 21B

Front Panel Menu Map

Ready For Batches

Only available

with VL70

Verifier



Print / Cut

Positions



Print Checkout

Format



Print Position



Change Cut

Position



Dot Shift



Test Head Lift



Print Head Setup



Change Strobe



Change Head

Category



Calibrating

Hole / Slot In

Hole / Slot Not In

Top Refl Over

Top Refl Not Over

Bot Refl Over

Bot Refl Not Over

Stacker Blocked

Stacker Not

Sensors



Sensor



Sensor



Mark



Mark



Mark



Mark





Blocked



Life Counts /

Label Counter

Total Labels

Total Inches Of

Controller Version

Imager Version

Versions





Produced



Stock







Feature Setup

Cutter Is Enabled

Emulation Mode:

Default Transfer

Baud Rate:

Change Date and

Inksave Is Enabled

Print Speed

High Capacity

Flagging Mode







Type



Language:



Protocol:





Time







Stacker





Verifier Setup

Print Verifier

Print Verifier

Clean Scan

Verifier Is Enabled



History



Setup



Memory



22B •••• Control Panel Operation Users Manual Model 656/636

Front Panel Power Up / Home Screens

POWER UP (DIAGNOSTICS TESTS)

D I A G N O S T I C T E S T 1

This screen is displayed while the Front Panel is initializing and waiting for the
Thermal Control Board (TCB) response. While this screen is displayed the code will
check the functionality of the LED's and the display. Each state of the LED's will be
checked - (orange, green, amber and off). The LCD is checked by writing a character
to the display, checking for communications and then reading the character back and
comparing with the code. If an error occurs, the code will halt the diagnostic test and
blink the ERROR LED.

The keypad is also checked during DIAGNOSTIC TEST 1. Each key is tested to see
if it is stuck on. If a fault condition is detected, the test is halted and the screen will
display the first error key found with the following display:

( B U T T O N N A M E ) K E Y S T U C K

The (BUTTON NAME) will be one of the push button names on the front panel ­START, FEED, TEST, STOP, EXIT, MODE, <YES, NO>, OR ENTER.

When the code has finished the above tests, the code will attempt to communicate
with the Thermal Control Board (TCB).

D I A G N O S T I C T E S T # # #

T C B V E R S I O N 0 0 . 0 0

This screen will be updated with diagnostic numbers as the TCB and AT go through
different stages of PowerPC initialization.

The diagnostic test screen will also be displayed when the Diagnostic tests that are
runable from the front panel are being executed.

Once the diagnostic tests are complete, the Front Panel should display the HOME
screen.

HOME SCREEN

R E A D Y F O R B A T C H E S

6 X 6 / 3 0 0

OR

B A T C H I D

P C L 0 0 1 1 0

Q U A N T I T Y

Users Manual Model 656/636 Control Panel Operation •••• 23B

T P A T T E R N

When the printer is powered up and all initializations are complete, if there aren’t any
Batches to print, the "HOME" screen will be "READY FOR BATCHES" and the
model and print head density.

When there are Batches to be printed, the "HOME" screen will be the

"BATCH ID QTY" screen. The Batch ID / Batch Qty screen displays the currently
cutting batch ID and labels remaining to be cut.

When the Batch Id/Qty screen is the home screen and the user presses the EXIT
button the Model and DPI are displayed briefly before the Batch Id/Qty screen is
displayed.

If the printer is performing a FEED or a TEST pattern, the screen will show
"FEEDING" or "PRINTING TEST PATTERN" respectively on line two, the top line
will be blank

F E E D I N G

P R I N T I N G T E S

Pressing the MODE/Down Arrow key will take the user to the various mode screens
listed below (refer to the Front Panel Mode Descriptions section in this manual).

Pressing the EXIT/Up Arrow key at any time will take the user back to the "HOME"
screen.

PRINTER ADJUSTMENTS

P R E S S E N T E R F O R

P R I N T / C U T P O S I T I O N S

PRINTHEAD ADJUSTMENTS

P R E S S E N T E R F O R

P R I N T H E A D S E T U P

CALIBRATE SENSORS

P R E S S E N T E R F O R

C A L I B R A T I N G S E N S O R S

LIFE COUNTS/VERSIONS

P R E S S E N T E R F O R

L I F E C O U N T S / V E R S I O N S

24B •••• Control Panel Operation Users Manual Model 656/636

SETUP SCREEN

P R E S S E N T E R F O R

F E A T U R E S E T U P

VERIFIER SETUP SCREEN

P R E S S E N T E R F O R

V E R I F I E R S E T U P

Front Panel Mode Descriptions

There are six (6) main mode levels that are selected and modified using the following
function keys:

Use the MODE ↓ key to move through the main mode screens shown below:

PRESS ENTER FOR

PRINT / CUT POSITIONS

PRESS ENTER FOR

PRINT HEAD SETUP

PRESS ENTER FOR

CALIBRATING SENSORS

PRESS ENTER FOR

LIFE COUNTS / VERSIONS

PRESS ENTER FOR

FEATURES SETUP

PRESS ENTER FOR

VERIFIER SETUP

Use the EXIT ↑ to move to the HOME screens.

Users Manual Model 656/636 Control Panel Operation •••• 25B

PRINT/CUT POSITIONS

P R E S S E N T E R F O R

P R I N T / C U T P O S I T I O N

This screen follows the "BATCH ID / BATCH QTY" screen if there are batches to
be printed; otherwise it follows the "READY FOR BATCHES / MODEL DPI" home
screen.

Pressing ENTER will take the user to the "PRINT / CUT POSITIONS" screens.
Pressing the MODE / Down Arrow key will take the user to the "PRINTHEAD
SETUP" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.

P R E S S E N T E R T O

P R I N T C H E C K O U T F O R M A T

This screen is the first screen under "PRINT / CUT POSITIONS". Pressing ENTER
will cause the printer to print the checkout format. The printer will setup to do the
checkout format and start printing. The front panel will remain on this screen so the
user can use the MODE/Down Arrow key to get to the printer adjustments. When the
EXIT/Up Arrow key is pressed the printer stops printing the checkout format and
goes back to what it was doing before the checkout was requested.

Pressing the MODE/Down Arrow key will take the user to the "PRINT POSITION”
screen. Pressing the EXIT/Up Arrow key will take the user back to the "HOME"
screen.

P R I N T P O S I T I O N

V A L U E : ± X X N E W V A L U E : ± Y Y

This screen follows the "PRINT CHECKOUT FORMAT" screen. This screen
allows the print position to be adjusted in the feed direction.

The <YES / NO> buttons are used to change the new print value. The value is
displayed in a positive/negative format. The value ranges for XX and YY can be
from a -9 to a +9. Pressing ENTER will change the CURRENT PRINT value to the
NEW PRINT value. A more positive number will move the print to the right while a
more negative number will move the print to the left.

Pressing the MODE/Down Arrow key will take the user to the "CHANGE CUT
POSITION" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.

C H A N G E C U T P O S I T I O N

V A L U E : ± X X N E W V A L U E : ± Y Y

This screen follows the "PRINT POSITION" screen. This screen allows the cut
position to be adjusted. The <YES / NO> buttons are used to change the new cut
value. The value is displayed in a positive/negative format. The value ranges for XX
and YY can be from a -9 to a +9. Pressing ENTER will change the CURRENT CUT
value to the NEW CUT value. A more positive number will move the cut to the right
while a more negative number will move the cut to the left.

Pressing the MODE/Down Arrow key will take the user to the "DOT SHIFT" screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.

26B •••• Control Panel Operation Users Manual Model 656/636

D O T S H I F T

V A L U E : ± X X N E W V A L U E : ± Y Y

This screen follows the "CHANGE CUT POSITION" screen. This screen allows the
print position to be adjusted in the WEB direction. The <YES / NO> buttons are
used to change the new shift value. The value is displayed in a positive/negative
format. The value ranges for XX and YY can be from a -16 to a +16 dots. Pressing
ENTER will change the CURRENT DOT SHIFT value to the NEW DOT SHIFT
value. A more positive number will move the print to the front while a more negative
number will move the print to the back.

Pressing the MODE/Down Arrow key will take the user back to the "PRINT CHECK
OUT FORMAT" screen. Pressing the EXIT/Up Arrow key will take the user back to
the "HOME" screen.

PRINTHEAD SETUP

P R E S S E N T E R F O R

P R I N T H E A D S E T U P

This screen follows the "PRINT/CUT POSITIONS" screen.

Pressing ENTER will take the user to the "PRINTHEAD SETUP" screens. Pressing
the MODE / Down Arrow key will take the user to the "CALIBRATING SENSORS"
screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME"
screen.

C H A N G E S T R O B E

V A L U E : ± X X N E W V A L U E : ± Y Y

This screen is the first screen under "PRINTHEAD SETUP" screen. This screen
allows the user to adjust the strobe. The <YES / NO> buttons are used to change the
new value. The value is displayed in a positive/negative format. The value ranges for
X and Y can be from a -7 to a +7. Pressing ENTER will change the CURRENT
STROBE value to the NEW STROBE value. A more positive number will make the
print darker while a more negative number will make the print lighter.

Pressing the MODE/Down Arrow key will take the user to the "CHANGE HEAD
CATEGORY" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

H E A D C A T E G O R Y

V A L U E : ± X X N E W V A L U E : ± Y Y

This screen follows the "CHANGE STROBE" screen. The screen allows the user to
enter the head category. The <YES / NO> buttons are used to change the new head
category value. The value ranges from 1 to 8. Pressing ENTER will change the
CURRENT HEAD category value to the NEW HEAD value. See the section
“PRINTHEAD REPLACEMENT” for instructions for setting the head category.

Pressing the MODE / Down Arrow key will take the user back to the "CHANGE
STROBE" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

Users Manual Model 656/636 Control Panel Operation •••• 27B

CALIBRATE SENSORS

P R E S S E N T E R T O

C A L I B R A T E S E N S O R S

This screen follows the "PRINT HEAD SETUP" screen.

Pressing ENTER will take the user to the "CALIBRATE SENSORS" screens.
Pressing the MODE / Down Arrow key will take the user to the "LIFE COUNTS /
VERSIONS" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

H O L E / S L O T I N S E N S O R

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This is the first screen under "CALIBRATE SENSORS". Place the stock hole/slot
sense mark under the sensor. Slowly move the stock under sensor until the NEW
VALUE reading is its smallest value then press ‘Enter’.

Pressing the MODE/Down Arrow key will take the user to the "HOLE / SLOT NOT
IN SENSOR" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

H O L E / S L O T N O T I N S E N S O R

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This screen follows the "HOLE / SLOT IN SENSOR" screen. Place the stock under
the sensor so that it blocks the sensor and when NEW VALUE is at its largest value
press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "TOP REFL OVER
MARK" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

T O P R E F L O V E R M A R K

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This screen follows the "HOLE/SLOT NOT IN SENSOR" screen. Place the stock
under the sensor so that the reflective mark is under the sensor and when NEW
VALUE is at is largest value press ‘Enter’.

Pressing the MODE/Down Arrow key will take the user to the "TOP REFL NOT
OVER MARK" screen. Pressing the EXIT/Up Arrow key will take the user back to
the "HOME" screen.

T O P R E F L N O T O V E R M A R K

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This screen follows the "TOP REFL OVER MARK" screen. Place the stock under
the sensor so that the stock is under the sensor but the reflective mark is not under the
sensor and when NEW VALUE is at is smallest value press ‘Enter’.

Pressing the MODE/Down Arrow key will take the user to the "BOT REFL OVER
MARK" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.

28B •••• Control Panel Operation Users Manual Model 656/636

B O T R E F L O V E R M A R K

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This screen follows the "TOP REFL NOT OVER MARK" screen. Place the stock
over the sensor so that the reflective mark is over the sensor and when NEW VALUE
is at is largest value press ‘Enter’.

Pressing the MODE/Down Arrow key will take the user to the "BOT REFL NOT
OVER MARK" screen. Pressing the EXIT/Up Arrow key will take the user back to
the "HOME" screen.

B O T R E F L N O T O V E R M A R K

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This screen follows the "BOT REFL OVER MARK" screen. Place the stock over
the sensor so that the stock is over the sensor but the reflective mark is not over the
sensor and when NEW VALUE is at is smallest value press ‘Enter’.

Pressing the MODE/Down Arrow key will take the user to the "STACKER
BLOCKED" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.

S T A C K E R B L O C K E D

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This screen follows the "BOT REFL NOT OVER MARK" screen. Place the stock in
the stacker jam sensor so that the stock is within the sensor site path and when NEW
VALUE is at is highest value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "STACKER NOT
BLOCKED" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

S T A C K E R N O T B L O C K E D

V A L U E : 0 0 0 N E W V A L U E : 0 0 0

This screen follows the "STACKER BLOCKED" screen. Remove any stock from
the stacker jam sensor so that no stock is within the sensor site path and when NEW
VALUE is at is lowest value press ‘Enter’.

Pressing the MODE/Down Arrow key will take the user back to the "HOLE / SLOT
IN SENSOR" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

LIFE COUNTS/VERSIONS

P R E S S E N T E R F O R

L I F E C O U N T S / V E R S I O N S

This screen follows the "CALIBRATE SENSORS" screen. Pressing ENTER will
take the user to the "LIFE COUNTS / VERSIONS" screens.

Pressing the MODE / Down Arrow key will take the user to the "FEATURE SETUP"
screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME"
screen.

Users Manual Model 656/636 Control Panel Operation •••• 29B

L A B E L C O U N T E R : 0 0 0 0 0 0

P R E S S E N T E R T O R E S E T

This screen is the first screen under "LIFE COUNTS / VERSIONS". This screen
shows total labels produced since the last counter reset. Pressing the ENTER key
will reset the counter to zero.

Pressing the MODE / Down Arrow key will take the user to the "TOTAL LABELS
PRODUCED" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

T O T A L L A B E L S P R O D U C E D

0 0 0 0 0 0 0 0 0 0

This screen follows the "LABEL COUNTER" screen. This screen displays the total
labels produced since the printer was built. This counter is NOT resettable by the
user.

Pressing the MODE / Down Arrow key will take the user to the "TOTAL INCHES
OF STOCK" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

T O T A L I N C H E S O F S T O C K

0 0 0 0 0 0 0 0 0 0

This screen follows the "TOTAL LABELS PRODUCED" screen. This screen
displays the total inches since the printer was built. This value is NOT resettable by
the user.

Pressing the MODE/Down Arrow key will take the user to the "CONTROLLER
VERSION" screen. Pressing the EXIT / Up Arrow key will take the user back to the
HOME screen.

C O N T R O L L E R V E R S I O N

2 . 1 6

This screen follows the "TOTAL INCHES OF STOCK" screen. This screen shows
the operating system version for the controller (TCB).

Pressing the MODE / Down Arrow key will take the user to the "IMAGER
VERSION" screen. Pressing the EXIT / Up Arrow key will take the user back to the
HOME screen.

I M A G E R V E R S I O N

2 . 1 6

This screen follows the "CONTROLLER VERSION" screen. This screen shows
operating system version for the imager (AT).

Pressing the MODE/Down Arrow key will take the user back to the "LABEL
COUNTER" screen.

Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.

30B •••• Control Panel Operation Users Manual Model 656/636

FEATURE SETUP SCREEN

P R E S S E N T E R F O R

F E A T U R E S E T U P

This screen follows the "LIFE COUNT / VERSIONS".

Pressing ENTER will take the user to the "FEATURE SETUP" screens. Pressing the
MODE/Down Arrow key will take the user to the "VERIFIER SETUP" screen.

C U T T E R I S E N A B L E D

P R E S S E N T E R T O D I S A B L E

C U T T E R I S D I S A B L E D

P R E S S E N T E R T O E N A B L E

E M U L A T I O N M O D E : N O N E

N E W E M U L A T I O N M O D E : 6 3 0

Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.

OR

This screen is the first screen of the "FEATURE SETUP". This screen allows the
cutter to be enabled or disabled. Pressing ENTER will toggle from ENABLED to
DISABLED and vice versa. Pressing the MODE/Down Arrow key will take the user
to the "EMULATION MODE" screen. Pressing the EXIT/Up Arrow key will take
the user back to the "HOME" screen.

This screen follows the "CUTTER ENABLE/DISABLE" screen. This screen allows
the EMULATION MODE to be changed. Use the <YES and NO> keys to move
between NONE, 630, and 650 modes. Pressing ENTER will update the emulation
mode with the selection after new emulation mode. Pressing the MODE/Down
Arrow key will take the user to the "DEFAULT TRANSFER TYPE" screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.

D E F A U L T T R A N S F E R T Y P E

V A L U E : X X X N E W V A L U E : Y Y Y

This screen follows the "EMULATION MODE" screen IF emulation mode is
something other than none. This screen allows the DEFAULT TRANSFER TYPE to
be changed. This transfer type is used when the printer is in 630 or 650 emulation
mode. The 630 and 650 do not send valid 6X6 transfer types in their PCL code.
This default is used for those formats. Use the <YES and NO> keys to change the
number value at the cursor position. Pressing ENTER will update the current value
with the new value (i.e. 053 for type 53). After ENTER is pressed on the last digit
the TRANSFER TYPE on the top line will be updated. Pressing the MODE/Down
Arrow key will take the user to the "LANGUAGE" screen. Pressing the EXIT/Up
Arrow key will take the user back to the "HOME" screen.

L A N G U A G E : X X X X X X

N E W L A N G U A G E : Y Y Y Y Y Y

This screen follows the "DEFAULT TRANSFER TYPE" screen. This screen allows
the front panel display language to be changed. Use the <YES and NO> keys to
move between the supported languages on the printer. Any number of front panel
languages can be stored on the Flash Disk Module (dependent on available space). If
no additional languages other than the default are available on the printer XXXXXX
and YYYYYY will be the same value. Pressing ENTER will update the display

Users Manual Model 656/636 Control Panel Operation •••• 31B

language with the selection. Pressing the MODE / Down Arrow key will take the
user to the "PROTOCOL" screen. Pressing the EXIT / Up Arrow key will take the
user back to the "HOME" screen.

Warning: Mis-matched communication protocols may result in the inability to

communicate with the printer and / or loss of data.

P R O T O C O L : X X X X X X

N E W P R O T O C O L : Y Y Y Y Y Y

This screen follows the "LANGUAGE" screen. This screen allows the
communications protocol to be changed between the supported types. Use the <YES
and NO> keys to move between the supported protocols – RTS/CTS is considered
hardware handshaking and XON/XOFF is considered to be software. Pressing
ENTER will update the communications protocol with the selection. Pressing the
MODE/Down Arrow key will take the user to the "BAUD RATE" screen. Pressing
the EXIT/Up Arrow key will take the user back to the "HOME" screen.

B A U D R A T E : X X X X X X

N E W B A U D R A T E : Y Y Y Y Y Y

This screen follows the "PROTOCOL" screen. This screen allows the serial
communications speed to be changed. Use the <YES and NO> keys to move
between the supported speeds – typical is 9600 dependent on serial communication
cable length. Pressing ENTER will update the communications speed with the
selection. Pressing the MODE/Down Arrow key will take the user to the "CHANGE
DATE AND TIME" screen. Pressing the EXIT/Up Arrow key will take the user
back to the "HOME" screen.

C H A N G E D A T E A N D T I M E

0 3 / 1 4 / 0 0 1 2 : 0 5 P M

This screen follows the “BAUD RATE” screen. This screen allows the system date
and time to be changed. When this screen appears, the first digit of the month will be
blinking. (The date is shown in US format, MM/DD/YY.) Pressing the <YES and
NO> keys will change the digit up and down respectively. Pressing ENTER will
move to the next digit. Only the digits and the A or P in AM or PM can be changed.
When all changes are complete, pressing the MODE/Down Arrow key will take the
user to the “INKSAVE ENABLE/DISABLE” screen, and pressing the EXIT/Up
Arrow key will take the user back to the “HOME” screen. If an illegal date or time is
entered, this screen will be re-displayed with the original date or time. A valid date
and time must be entered before the user can go on.

I N K S A V E I S E N A B L E D

P R E S S E N T E R T O D I S A B L E

OR

I N K S A V E I S D I S A B L E D

P R E S S E N T E R T O E N A B L E

This screen allows ink save to be enabled or disabled. Ink save is an option that is
available on certain models. It must be enabled in the format to operate. If ink save
is enabled in the format, it can be disabled using this screen. Pressing ENTER will
toggle from ENABLED to DISABLED and vice versa. Pressing the MODE/Down
Arrow key will take the user to the "CUTTER ENABLE/DISABLE" screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.

32B •••• Control Panel Operation Users Manual Model 656/636

VERIFIER SETUP

P R E S S E N T E R F O R

V E R I F I E R S E T U P

This screen follows the "FEATURE SETUP" screen.

Pressing ENTER will take the user to the "VERIFIER SETUP" screens. Pressing the
MODE/Down Arrow key will take the user back to the "PRINT/CUT POSITIONS"
screen. Pressing the EXIT/Up Arrow key will take the user back to the "HOME"
screen.

Note: This screen for SV-70 Verifier only

P R E S S E N T E R T O

P R I N T V E R I F I E R H I S T O R Y

This screen is the first screen under "VERIFIER SETUP". Pressing ENTER will
cause the printer to print a verifier history report containing bar code information for
all the problem scans since the scan memory was last cleared.

Pressing the MODE/Down Arrow key will take the user to the "PRINT VERIFIER
SETUP" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.

Note: This screen for SV-70 Verifier only

P R E S S E N T E R T O

P R I N T V E R I F I E R S E T U P

This screen follows the "PRINT VERIFIER HISTORY" screen. Pressing ENTER
will cause the printer to print a report containing the present verifier setup.

Pressing the MODE/Down Arrow key will take the user to the "CLEAR SCAN
HISTORY" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.

Note: This screen for SV-70 Verifier only

P R E S S E N T E R T O

C L E A R S C A N M E M O R Y

This screen follows the "PRINT VERIFIER SETUP" screen. Pressing ENTER will
clear the verifier scan memory.

Pressing the MODE/Down Arrow key will take the user to the "VERIFIER
ENABLE" screen. Pressing the EXIT/Up Arrow key will take the user back to the

V E R I F I E R I S E N A B L E D

P R E S S E N T E R T O D I S A B L E

V E R I F I E R I S D I S A B L E

P R E S S E N T E R T O E N A B L E

"HOME" screen.

OR

This screen follows the "CLEAR SCAN HISTORY" screen. This screen allows the
verification process to be enabled or disabled. Pressing ENTER will toggle from
ENABLED to DISABLED and vice versa.

Pressing the MODE/Down Arrow key will take the user back to the "PRINT
VERIFIER HISTORY" screen. Pressing the EXIT/Up Arrow key will take the user
back to the "HOME" screen.

Users Manual Model 656/636 Control Panel Operation •••• 33B

Adjustments / Maintenance

Print Head Handling

Warning

Print heads can be damaged easily, and are subject to premature failure if not cleaned
on a regular basis. Please follow the procedures carefully to help ensure print head
life and print quality.

Thermal print heads are very sensitive and must be handled with care to help ensure
longer print head life. Because print heads may be damaged through a number of
ways, AVERY DENNISON has developed the following procedures;

Handling

Static discharge is very detrimental to thermal print heads. To avoid contacting print
heads with a static charge, follow these simple procedures:

- All print heads should be kept in original anti-static bags until they are
installed in the printer.

- The 656 / 636 printer is supplied with an anti-static wrist strap. Locate the
strap - it must be worn at all times when handling the print heads.

- Do not touch any terminals extending from the print head or the print line.

- Anti-static gloves are provided with your printer upon installation and
extras may be ordered from AVERY DENNISON. These gloves must
be worn at all times when handling the print head. If an anti-static glove
is not available, make absolutely certain to thoroughly wash and dry your
hands before handling the print head. Oils from your hands can
contaminate the print line and quickly destroy the printing elements.

34B •••• Adjustments / Maintenance Users Manual Model 656/636

Print Head Cleaning

CAUTION: TURN OFF THE POWER TO THE PRINTER BEFORE
STARTING ANY CLEANING.

NEVER REMOVE THE HEAD FROM THE PRINTER EXCEPT FOR
REPLACEMENT.

Supplies:

- Always use clean supplies when cleaning the head.

- NEVER use anything abrasive to the head.

- NEVER use anything metallic on or near the printhead.

- Alcohol and a foam swab are the recommended items to use when cleaning the
printhead.

The Anti-static wrist strap (which must contact the skin and be
tight) and anti-static gloves must be worn at all times when
handling a print head to avoid damaging the print head.

RECOMMEND AVERY DENNISON "MASTER CLEANING KIT" # 921338

Procedure:

-The print head should be cleaned every two to four hours of continuous usage. A
good cleaning of the print head after eight to twelve hours of continuous usage
should be done. This cleaning must be done with the print head in the printer.

- Apply a liberal amount of alcohol to a foam swab.

- Rub the swab across the print line of the printhead to remove the build-up.

- The platen roller and feed rollers should also be cleaned with alcohol to remove ink
and card dust build-up.

Users Manual Model 656/636 Adjustments / Maintenance •••• 35B

Print Head Replacement

NEVER REMOVE THE PRINT HEAD FROM THE PRINTER EXCEPT FOR

REPLACEMENT.

TURN OFF THE POWER TO THE PRINTER BEFORE STARTING ANY

ELECTRONIC COMPONENT REPLACEMENT.

NOTE: The Anti-static wrist strap (which must contact the skin and be tight) and

anti-static gloves must be worn at all times when handling a print head to avoid
damaging the print head.

1) Review the Printhead Handling Procedure Sheet packaged with each print head to
determine if any procedures have changed before beginning this procedure.

2) Remove the ink from the printer for easy access to the print head.

3) Remove the outer screw holding the static brush / guard and rotate the brush /
guard up to expose the print head cable connector on the print head.

4) Unplug the print head cable from the print head. Unplug the cable by gently
pulling it straight out of the connector.

5) Back the print head pressure screw off counterclockwise as far as possible.

6) Place your hand (with static gloves on) underneath the print line of the print head
and push up to release the locator pins on the heat sink, while moving the print
head to the right of the printer. This will remove the print head assembly from the
mount plate. You may need to "help" the print head out by pushing on the heat
sink with your left hand.

7) Remove the two print head mount screws located on the top of the print head
assembly with a 2.5mm ball driver.

8) Remove the old printhead from the heat sink.

9) Place the new print head into the heat sink. Check to see that the new printhead
sits square in the heat sink and that there is no endplay. If there is endplay, or the
head does not seat properly, the heat sink guide will need adjustment.

10) Replace the two print head lock screws. Be sure that the head is resting flat on
the heat sink before tightening these screws.

11) Replace the print head assembly in the printer, making sure that the pin at the
back of the heat sink goes into the hole in the mount plate. Make sure that the
guide pins insert into both the front and back grooves.

12) Reconnect the print head cable, making sure that the connector is seated tightly.
Swing the static brush / guard back into position and reinstall its mount screw.

NOTE: If the cable is not connected correctly, the print head will be damaged when

the printer is powered on. Check to see that the cable is tight by observing
from underneath the print head. The print head cable connector should be
inside of the black connector located on the print head.

13) Replace the ink and double-check your work. Power the printer on and make

sure that no adverse effects are noted.

14) Set the head category. Press the MODE key twice to get to the ENTER

PRINTHEAD SETUP prompt. Press the ENTER key, the press the MODE key
until the HEAD CATEGORY prompt appears. Use the <YES and NO> keys to
select the head category. The head category is based on the mean resistance of
the print head being used. The printhead will have a value for the average

36B •••• Adjustments / Maintenance Users Manual Model 656/636

printhead resistance, for example “Rav = 1438Ω”, printed on a label on the
printhead. Look up the value in the following table and enter the appropriate
head category. Press the ENTER key to enter the value. The printer must be
turned off and back on for the change to take effect.

HEAD

CATEGORY

AVERAGE

RESISTANCE

(Rav)

1 1320-1365

2 1366-1410

3 1411-1455

4 1456-1500

5 1501-1545

6 1546-1590

7 1591-1635

8 1636-1680

As a final test of the print head installation, run a test pattern to check the print

quality. You should observe an even grid of rectangles. If you do not see such a
grid, you may wish to reference the topic of print head tangent adjustment.

Users Manual Model 656/636 Adjustments / Maintenance •••• 37B

Print Head Adjustment

Clean Platen Roller

You may determine if the print head has been adjusted properly by performing a test
pattern as documented under Control Buttons in this manual. A properly adjusted
print head will produce an even grid of rectangles when the test pattern is performed.

Before making any judgments as to the quality of the print head, it is absolutely
necessary to ensure that the platen roller and the printhead is clean of all
debris. Clean the platen roller located immediately beneath the print head with a

clean cloth and a small amount of alcohol. Be careful not to damage the platen roller
while cleaning. If the roller is worn, replace the roller.

Print Head Tangent Point

Proper print head tangent is perhaps the most important adjustment to make. A print
head, which is not properly adjusted, will result in poor print quality, poor heat
dissipation and possible ink wrinkling problems. When the printer was
manufactured, the print head was adjusted to the proper tangent point on the platen
roller, however, with print head replacements the tangent point for the new print head
may change. It is necessary to understand how to properly adjust the print head.

The print head tangent adjustment must be done with the head pressure set light.
Turn the pressure screw counterclockwise. Run a test pattern to determine the
minimum adjustment required.

If the entire test pattern is broken up, the printhead is probably not adjusted to the
proper tangent point. To adjust the tangent point loosen the two print head mount
screws one half turn with a 2.5mm ball driver provided in your spare parts kit. Do
not remove the print head from the printer. Once the screws have been loosened, use
the adjustment thumbscrew to move the head right or left. Since the adjustment is
very precise, do not turn the thumbscrew more than 1/4 of a turn before running
another test pattern to determine if you are adjusting the print head in the proper
direction. Tighten the two mount screws (Do not over tighten). Run a test pattern
again to determine if further adjustment is required.

Print Head Pressure Setting

The print head pressure setting is very important. Keep the lightest setting possible.
This will improve print head life while maintaining quality print.

The printer has been factory set. Further adjustment of the pressure adjusting screw
should be minimal.

If readjustment is required, proceed as follows: Power on the printer. Remove the
ink and stock from the printer. With the print head open, turn the pressure screw
counterclockwise until it does not contact the printhead mount plate; it should slide
freely back and forth. Close the print head. Slide the pressure screw until it sits
directly over the center of the stock. Turn the pressure screw clockwise until it
makes contact with the head mount plate plus 1/2 turn to add pressure. As the stock
width changes adjust the pressure screw position accordingly.

Download the proper format for the stock that is loaded. Press start. The print
quality should be acceptable if the pressure screw is properly positioned.

Once the print quality is acceptable, start to back off the screw until the print begins
to fade. Once the print is starting to fade, increase the pressure by 4 clicks.

38B •••• Adjustments / Maintenance Users Manual Model 656/636

Minimum pressure should be used when running narrow stocks; wide stocks require
slightly greater pressure. Additional print quality will be obtained by adjustments of
the Tangent point (refer to Print Head Adjustment Tangent in this manual).

If you are unable to correctly adjust the screw for good print, call for service.

Squaring the Print Head

If the test pattern, printed on a wide web (4" (100mm) plus), is lighter on one edge
than the other, it is possible that the printhead is out of square. This can be detected
by looking at the front edge of the print head in reference to the print head holder.
To remedy this problem, power off the printer and remove the print head as outlined
in the Print Head Replacement section in this manual. The print head adjustment
plate has been manufactured so when properly adjusted the head will be square. The
print head holder has a locator plate that must slide up snug against the printhead
mount plate. Install the head and it should be square to the web.

Stock Feed Roller Adjustment

General

The rubber pressure roller is supported by an eccentric shaft mounted in bearings
located in vertical slots in the front and rear mounting plates of the drive module.
This roller is mounted in an extension spring controlled arm so no pressure
adjustment is required.

Knife Square Adjustment

The knife has an adjustment to square the cut to the stock. To make the adjustment,
loosen the two cap screws, one on top of the knife and one below the knife, using the
3/16” ball driver in the tool kit. Move the knife in the direction desired to square the
cut and retighten.

Users Manual Model 656/636 Adjustments / Maintenance •••• 39B

Stacker Adjustments

The stacker has four adjustments that can be made without a tool to accommodate
different types and widths of stock.

Stock Length Adjustment

Loosen the two thumb screws at the base of the stacker uprights and slide the
uprights to a position that allows the cut tag or label to hang over the last belt roller
approximately 1/4" (6mm). Retighten.

Stock Width Adjustment

Loosen the two thumbscrews behind the stacker uprights and adjust the stacker
uprights to the desired stock width position. Retighten.

Stacker Angle Adjustment

Loosen the lever located on the side of the stacker assemble nearest the operator and
adjust the angle of the stacker with a few cut labels in the stacker so that there is a
slight gap under the last label as it hangs over the last belt drive roller. Retighten.

Stacker Full Adjustment

The sensor on the inboard stack upright is used to stop the printer when the stack is
full. A thumbscrew adjustment is provided to set the stack height.

Warning, some stock materials cannot be stacked to the full height of the
stacker because of excessive weight.

Sensor Identification / Adjustment / Calibration

Sensor Identification:

Stock Out

A micro switch located on the back of the stock unwind will detect and stop the
printer when the stock core is lifted because the stock is consumed.

Hole / Slot Index Registration

The stock hole / slot registration is via an optical sensor used in conjunction with an
LED light bar located in the stock funnel which allows the printer to register to pre­punched or preprinted stock.

Reflective Index Registration

The same optical sensor used for stock hole / slot registration, allows the printer to
register to preprinted stock by detecting a black mark when the LED light bar is
turned off via the format.

40B •••• Adjustments / Maintenance Users Manual Model 656/636

Ink Out

An optical sensor located near the ink unwind arbor allows the printer to monitor the
availability of ink.

Roller Drop (656)

An optical sensor on back of the printer upright allows the printer to control and
register the platen roller position to perform ink save.

Feed Open

A micro switch on the back of the feed module will detect the position of the feed
module pressure knob and only allow the printer to operate with the feed pressure
knob closed.

Jam

An optical sensor located in the stacker will detect each cut label as it leaves the
cutter. If a cut fails to occur or a label remains in the sensor sight path, the machine
will stop.

Full Stacker

A micro switch on the stacker rail allows the printer to detect a full load of labels in
the stacker. The stack full condition will stop the machine when the stacker is full.

Sensor Adjustment

All the micro switches and optical sensors in your 6X6 printer were calibrated at the
time your printer was manufactured, however from time to time it may become
necessary to readjust / recalibrate due to the large variety of stocks and inks that can
be run on the machine.

Stock Out

With a full roll of stock loaded on the stock unwind with the unwind web guides
properly adjusted you should heard the switch click as you raise and lower the roll.
If not the switch bale is adjusted by carefully bending it as needed.

Users Manual Model 656/636 Adjustments / Maintenance •••• 41B

Print Registration Sensor

Web Position Adjustment

If you are running sense mark media with a hole or slot for registration the
registration sensor web position must be adjusted for the sense mark media being run:

1) Open the feed roller and print head.

2) Move the stock by hand in the feed direction until the registration hold or slot

desired is in the slot on the sensor funnel over the red LED light bar.

3) Close the feed and the print head.

4) Slide the sensor block assembly using the sensor handle while looking at the

sensor LED on the front panel. When the LED turns on with the registration
sensor over the media in the vicinity of the hole / slot, and stays on, the sensor is
over the registration hole or slot.

If your machine stops, for no apparent reason, while it is in the middle of printing a
batch, you may be missing sense marks (three consecutive tickets in a row in which a
sense mark was not found). Check for the following:

- The front panel will display an error message indicating that there has been a
missed sensor.

1) Check that the web guides have been positioned properly - both on the unwind

and decurler.

2) Compare the actual feed length of the sense mark stock being run with the feed

length set in the format.

3) Repeat the sensor alignment procedure.

Rotation Alignment

The optical sensor for the light from the LED bar for stock registration is mounted on
a square shaft directly above the web plate assembly, just prior to the print station.
Although this bar is factory adjusted prior to shipment, it may become necessary to
readjust the bar to assure proper light reception. If after following the previous
procedure the missed sense mark error continues to occur proceed as follows.

1) Remove the stock from the machine.

2) Slide sensor block to its furthest rear travel (away from the operator).

3) Remove the back cover of the machine.

4) While holding the screw that secures the square bar to the machine upright, rotate
the square bar to align the sensor to the slot over the light bar. Retighten the
screw as needed.

NOTE: In order to determine the optimum alignment us the front panel display (refer

to the Sensor Calibration and Front Panel Mode Description sections in this
manual)

5) Slowly slide the receiver block to its furthest forward position (towards the
operator) while confirming that the sensor alignment is maintained throughout its
travel. The change in the front panel should be last than 50.

42B •••• Adjustments / Maintenance Users Manual Model 656/636

Feed Open

If the feed open switch is in need of adjustment, first check and adjust as needed the
feed pressure, as it will affect the switch adjustment. With the machine rear cover
removed while opening and closing the feed pressure knob you should hear the
switch clicking. If not, the switch bale is adjusted by carefully bending it as needed.

Sensor Calibration:

Optical Sensor Electrical Calibration:

Re calibration times are indicated in the troubleshooting section.

The following guidelines indicate the proper procedure used to calibrate these
sensors.

Note: Clean all optical sensors with clean compressed air or canned air prior to

Supplies:

- Always use clean supplies when cleaning the sensor and light bar.

- NEVER use anything abrasive on the sensor and light bar.

adjustment, as dust and debris will adversely affect their performance.

- NEVER use an alcohol-based solution when cleaning the sensor or light bar.

- Dry air or a cotton swab are the AVERY DENNISON recommended items to use
when cleaning the sensor and light bar.

There are three basic steps to calibrating each optical sensor.

1) Select the sensor to be calibrated in the Calibrate Sensors mode on the front panel.

2) Place media or ink as the case maybe in the appropriate sensor and press the
“enter” button on the front panel.

3) In the case of stock registration sensing reposition the media so that a hole / slot or
black reflective mark is in the sight path of the appropriate registration sensor and
press the “enter” button on the front panel. In the case of stacker jam sensor
reposition the media so the media is not in the sight path of the jam sensor and
press the “enter” button on the front panel.

Users Manual Model 656/636 Adjustments / Maintenance •••• 43B

Lubrication Procedure

General

The 636 / 656 series printers are factory equipped with either composition bearings
not requiring lubrication or pre-lubricated bronze bearings. The one exception is the
rub cams on either end of the rotary knife. Periodic cleaning of the printer and
removal of dust will greatly enhance the length of the time the printer will function.

Cam - Lubrication Procedure

1) Clean dust and residue from cams (using alcohol or other suitable solvent) daily,
or approximately every 100K cuts. Use any good quality general-purpose grease
(not oil). Apply with cotton swab or other non-metallic device.

2) If lubrication is omitted, knife will squeak and draw attention to required
lubrication.

Composition (Iglide) Bearings

1) If field replacement of an assembly fitted with an Iglide bearing is performed, a
single drop of spindle oil should be applied to assist in bearing break-in.

2) If, after long use, an Iglide bearing starts to "squeak", disassemble the component
containing the bearing and lightly abrade the shaft surface. Clean the bearing
(dust or old oil) with alcohol, re-lubricate with 1 drop of light oil and reassemble.

No other printer lubrication should be required in normal use.

44B •••• Adjustments / Maintenance Users Manual Model 656/636

Printer Set Up Sequence

1) Power off the printer, remove the stock and ink and thoroughly clean the printer
from the unwind to the stacker using alcohol and a clean soft cloth. The print head
should be cleaned as per the Print Head Cleaning section in this manual.

- NEVER use an alcohol-based solution when cleaning the sensors or light bar.

2) Load a full roll of an average width stock and ink on the printer.

3) Power on the printer. After passing the diagnostics tests the front panel will
display READY FOR BATCHES.

4) Arrow down to the Print / Cut Position mode and press enter.

At the Print Checkout Format screen press enter.

5) Press start. After several labels have been print and cut stop the printer and
evaluate the last label out.

6) Adjust as needed the print head position and then pressure for optimum print
quality (refer to the Print Head Adjustment section in this manual).

7) Confirm the centerline is actual in the center of the media. If it is not, first check
and adjust as needed the unwind core guides, then adjust the decurler collars. If
the print quality is inadequate refer back to step number six.

8) Using two consecutive labels back to back, check the squareness of the cut.
Adjust the knife module as needed (refer to the Knife Square Adjustment section in
this manual).

9) Using the front panel, adjust the label leading edge cut to be 1.0" +- .032" from
the cut line printed on the label. The printer is now ready for production formats at
which time you should need only to fine-tune the print, cut, and strobe via the front
panel for individual formats.

NOTE: If the printer is used to print on multiple media types, the print head may

need to be adjusted for optimum print quality on each media as they are ran.

Users Manual Model 656/636 Adjustments / Maintenance •••• 45B

Electrical Trouble Shooting

Power Up / Sign On / Communications

Problem Probable Cause Corrective Action

Printer fails to power up. 1) Incorrect power amplitude. 1) Confirm that the AC entry is configured for the

line voltage intended to be applied to the printer.
Failure to do so can damage the printer's internal
power supply (refer to the Fuse Configuration
section in this manual).

2) Lack of power to printer. 1) Check that both ends of the power cord are
plugged in securely.

2) Confirm that the outlet the printer is plugged
into has power.

3) Missing or blown fuse(s) 1) Check that the fuse(s) located inside the AC
entry are present and intact. Replace as needed
(refer to the Fuse Configuration section in this
manual).

4) Unconnected cable / connector

inside printer.

5) Thermal Control Board

unplugged from the Mother Board

Front panel displays no text

or nothing at all.

1) Front panel cable unplugged. 1) Power off and remove the power cord from the

1) Power off and remove the power cord from the
AC entry. Remove the back cover and inspect
the cables and connectors to and from the power
supplies (refer to the Electrical System
Schematic in this manual).

1) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat the
Thermal Control Board.

AC entry. Remove the back cover and inspect
the cable and connectors to and from the front
panel (refer to the Electrical System Schematic
section in this manual).

46B •••• Electrical Trouble Shooting Users Manual Model 656/636

Problem Probable Cause Corrective Action

Front panel does not

complete diagnostics test

2.

Printer does not receive

batches.

2) Printer not powered on or has not

3) Data sent to wrong printer. 1) In PcMate change to the printer the data is

4) Configuration incorrect in

5) Faulty Thermal Control Board. 1) Replace Thermal Control Board.

6) Jumpers not configured correctly. 1) Contact AVERY DENNISON Service.

1) One or more PC board(s)
unplugged from the Mother
Board.

1) Serial communications cable
loose or unconnected.

completed diagnostics tests.

PcMate.

1) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat the
offending board.

1) Check and secure both ends of the serial cable
with the thumbscrews.

1) Power printer on and wait until front panel
displays "Ready for batches". Re-download
data.

intended to be sent.

1) Reconfigure PcMate for AVERY DENNISON
PCL printer as per your PcMate manual.

Users Manual Model 656/636 Electrical Trouble Shooting •••• 47B

Stock / Ink Advance

Problem Probable Cause Corrective Action

Stock does not advance

when the start button is
depressed.

2) An interlock condition exists. 1) Determine the number and type of interlock(s)

3) Feed motor unplugged or faulty. 1) Check feed motor cable and/or replace feed

4) Thermal Control Board

5) Feed roller not closed. 1) Close feed rollers and press start twice (once to

6) Feed rollers bound. 1) With power off check that all rollers turn freely.

7) Stock bound. 1) With the print head and feed open check that the

Ink does not advance when

the start button is
depressed.

1) No batches to be printed. 1) Download batch (if batch downloaded uses the
same format as a previously downloaded batch
the printer with start automatically).

by reading the front panel display. As each is
corrected the number of errors will decrease
(Example "Error 901 Stock Out" reload stock).

motor.

1) Check Thermal Control Board / AT board

unplugged or faulty.

1) No batches to be printed. 1) Download batch (if batch downloaded uses the

connection and or replace Thermal Control
Board.

clear the feed open error, and once to start
printer).

stock will pull through the printer with little to
no resistance.

same format as a previously downloaded batch
the printer with start automatically).

2) An interlock condition exists. 1) Determine the number and type of interlock(s)
by reading the front panel display. As each is
corrected the number of errors will decrease
(Example "Error 901 Stock Out" reload stock).

3) Ink motor unplugged or faulty. 1) Check ink motor cable and or replace ink motor.

4) Thermal Control Board

unplugged or faulty.

5) Ink roller bound. 1) With power off check that all rollers and arbors

6) Ink bound. 1) With the print head open check that the ink will

1) Check Thermal Control Board / AT board
connection and or replace Thermal Control
Board.

turn freely.

pull through the printer with little to no
resistance.

48B •••• Electrical Trouble Shooting Users Manual Model 656/636

Print

Problem Probable Cause Corrective Action

Printer advances stock but

does not print.

2) Miss adjusted print head tangent

3) Miss adjusted print head pressure. 1) Set print head pressure (refer to Print Head

4) Print head cable unconnected or

5) Print head faulty. 1) Replace print head.

6) Head Driver Board unplugged or

Printer stops after ever

third label.

2) Stock registration sensor

Print registration is off in

the feed direction.

1) Stock registration sensor miss
aligned.

position.

faulty.

faulty.

1) Stock registration sensor miss
aligned.

uncalibrated.

1) Printer print position is incorrect. 1) Enter the Print / Cut Positions Mode on the front

1) Adjust sensor position so that the sensor light on
the front panel flashes as a sense mark hole
passes under the sensor.

1) Set print head tangent position (refer to Print
Head Adjustment section in this manual).

Adjustment section in this manual).

1) Power off the printer and reinsert the offending
connector or replace cable.

1) Check Head Driver Board / AT board
connection and or replace Head Driver Board.

1) Adjust sensor position so that the sensor light on
the front panel flashes as a sense mark hole
passes under the sensor.

1) Calibrate the sensor (refer to the Sensor
Calibration section in this manual).

panel and readjust the Print Position setting as
needed.

2) Field(s) position incorrect in the
format.

3) Bound platen roller. 1) Check that the platen roller turns freely on its

Print registration is off in

the web direction.

2) Web guides incorrectly adjusted. 1) Check and adjust as needed (refer to Web Guide

3) Unwind incorrectly adjusted. 1) Check and adjust as needed (refer to Web Guide

4) Incorrect DIP switch settings on

1) Printer incorrectly threaded. 1) Check and rethread the stock as needed (refer to

the Thermal Control Board.

1) Using Formatter / PcMate Plus – check and
readjust the field(s) position(s) as needed.

shaft. If it does not, replace it.

Loading Stock section in this manual).

Adjustment in this manual).

Adjustment in this manual).

1) Check and reset DIP switches as needed (refer
to TCB Dip Switch Settings section in this
manual.

Users Manual Model 656/636 Electrical Trouble Shooting •••• 49B

Problem Probable Cause Corrective Action

Print contrast is too light or

dark.

2) Printer strobe setting is incorrect. 1) Enter the Print Head Setup Mode on the front

3) Miss adjusted print head position. 1) Set print head position (refer to Print Head

4) Miss adjusted print head pressure. 1) Set print head pressure (refer to Print Head

Voids in print image in the

feed direction.

2) Print head dirty. 1) Power off the printer clean the print head and

3) Faulty print head. 1) After cleaning head and running the test pattern

4) Miss adjusted print head position. 1) Set print head position (refer to Print Head

5) Miss adjusted print head pressure. 1) Set print head pressure (refer to Print Head

1) Incorrect strobe setting selected
in the format.

1) Ink miss aligned with format. 1) Adjust ink position on the arbors to achieve full

1) Using Formatter / PcMate Plus - check and
adjust the strobe setting according to the stock
and ink being used.

panel and readjust the Strobe setting as needed.

Adjustment section in this manual).

Adjustment section in this manual).

ink coverage over all fields on the format.

platen (refer to Print Head Cleaning section in
this manual).

to confirm that a void still exists, replace the
print head.

Adjustment section in this manual).

Adjustment section in this manual).

6) Worn platen roller. 1) Replace platen roller.

Printer continually stops

with an erroneous
interlock condition.

2) Sensor position miss adjusted. 1) Determine which sensor and relocate

3) Ink sensor type (light / dark)

1) Sensor uncalibrated. 1) Determine which sensor and re-calibrate as
needed (refer to Sensor Calibration section in
this manual).

accordingly.

1) Either change the ink or the ink type in the
incorrect in the format for the ink
type being used.

format.

50B •••• Electrical Trouble Shooting Users Manual Model 656/636

Cut / Stack

Problem Probable Cause Corrective Action

Printer fails to cut labels

(the rotary knife does
not rotate).

2) Knife cable unconnected. 1) Power off and remove the power cord from the

3) Knife jammed causing auto

4) Faulty knife motor. 1) Replace the knife motor.

5) Faulty knife motor drive circuit

The stacker fails to run. 1) The stacker cable is unconnected. 1) Power off and insert the stacker cable in the

2) Faulty stacker motor. 1) Replace the stacker motor.

3) Stacker jammed causing auto

1) The cut is disabled in the Feature
Setup mode.

resetting fuse to trip on the
Thermal Control Board.

on the Thermal Control Board.

resetting fuse to trip on the
Thermal Control Board.

1) Enter the Feature Setup Mode on the front panel
and Enable the knife.

AC entry. Remove the back cover and inspect
the cable and connector to the knife module
(refer to the Electrical System Schematic
section in this manual).

1) Remove cause of jam at the knife.

1) Replace the Thermal Control Board.

stacker socket on the Thermal Control Board.

1) Remove cause of jam at the stacker.

4) Faulty stacker motor drive circuit
on the Thermal Control Board.

1) Replace the Thermal Control Board.

Users Manual Model 656/636 Electrical Trouble Shooting •••• 51B

Mechanical Trouble Shooting

Stock

Problem Probable Cause Corrective Action

Stock will not roll or jumps 1) Incorrect adjustment of unwind

web guides

2) Adjust unwind knob until back plate and front

3) Adjust turn-bar collars to same position as

Printer fails to stop at end

of roll.

Stock does not pull

smoothly through
printhead module.

2) Stock is slipping in drive or drive

1) Stock roll is too tight in guides. 1) Adjust unwind knob until back plate and front

1) Turn bar collars too tight. 1) Adjust turn-bar collars to same position as

pressure is uneven.

1) Be sure stock roll is as flat as possible and does
not extend over core.

post touch roll. Do not over-tighten. Roll must
rotate smoothly.

unwind back plate and front post.

post touch roll. Do not over-tighten. Roll must
rotate smoothly.

unwind back plate and front post.

1) Be sure cam lift knob is closed. Be sure springs
are not improperly installed on bottom pins. Be
sure cam lift surfaces are not holding lift arms up
when knob is in the run position. Re-adjust
unwind and collars to relieve possible stock
“pinch”.

52B •••• Mechanical Trouble Shooting Users Manual Model 656/636

Problem Probable Cause Corrective Action

Cracks or craze marks

appear on face of
finished labels.

Stock jams in bridge blade

rollers or knife area.

2) Knife not cutting full width of

3) Stacker not operating or nip

Will not stack. 1) Stacker not operating. 1) See step 3 above.

2) Stacker position on printer too far

3) Incorrect rail position or stacker

1) Incorrect adjustment of decurler. 1) Move decurler turn-bar toward unwind end of
printer until cracks no longer appear.

1) Drive mounted blade roller ass’y

missing or rollers set too high.

stock.

rollers not turning.

forward so labels go under rear
stacker rail.

bed angle.

1) Mount missing ass’y. Adjust roller position by
loosen screws in slots in lower bridge blade
mount and raising blade until .015-.020” of
roller extends above plate.

1) Loosen knife shear adjustment screws and move
outer end of knife until full cut is accomplished.

1) Check stacker connection to access port. Be
sure nip roller is free to rotate and moves easily
in the bearing slots.

1) Loosen stacker mounting knob and move
stacker toward rear of printer - tighten.

1) Using a cut label, position stacker rails so that
approximately 3/8" (9.5mm) overhangs the
second grooved roller. Loosen quick-turn
handle on stacker clamp and raise or lower
stacker bed until opening between 1st label
overhang and belt surface will allow entry of
next label.

Knife will not cut or partial

cut

2) Partial cut 1) Loosen shear adjustment screws and move outer

1) Incorrect pre-load on clutch pawl. 1) With back cover removed and power off ­operate solenoid by hand. When lever is moved,
clutch pawl should move counter-clockwise
about 1/32" (0.79mm) with the "Pacman" in
home position. If not - loosen "Pacman" set
screws and readjust "Pacman" to stop with
spring in detent.

end of knife until full cut is obtained.

Users Manual Model 656/636 Mechanical Trouble Shooting •••• 53B

Ink

Problem Probable Cause Corrective Action

Ink wrinkles or will not pull

smoothly.

2) Unwind roller and ink take-up

3) Ink buildup on turn bar(s). 1) Clean with alcohol.

4) Incorrect ink width. 1) Use an ink width no wider than stock being

Ink rolls loosely on take-up

roller.

2) Take-up core binding on locator

3) Excessive back tension. 1) Adjust knurled knob clockwise as far as

1) Incorrect adjustment of unwind
roller brake resistance.

roller misaligned.

1) Take-up roller not turning. 1) Be sure belt is on rear drive sprocket. Be sure

plate.

1) Adjust knurled knob clockwise as far as
possible without breaking ink or stalling ink
motor. Do not bottom adjustment knob.
Replacement of fiber brake disc may be
required if printer has high hours.

1) Align rear edge of ink with rear of print area
(allow approximately 1/8" (3mm) overlap).
Loosen thumb cap screw on ink roll locator
plate and adjust until it touches rear of ink roll
on unwind arbor. Slide rewind core toward
rear of printer until it just contacts plate.

printed. This is especially critical when using a
narrow web with cut down rollers.

magnetic drive (rear of center frame) can turn
freely. No adjustment for tension is available
or required.

1) Move core .015" - .030" (.38mm - .76mm) away
from plate.

possible without breaking ink or stalling ink
motor. Do not bottom adjustment knob.
Replacement of fiber brake disc may be
required if printer has high hours.

4) Take-up roller too full. 1) Remove used ink roll. It is designed to hold
only 1 full roll.

54B •••• Mechanical Trouble Shooting Users Manual Model 656/636

Print

Problem Probable Cause Corrective Action

Poor print - uneven or no

print (mechanical).
Also see electrical
trouble shooting.

2) Broken ink. 1) Replace ink and readjust (See INK

3) Ink not rewinding. 1) Readjust (See INK trouble shooting).

1) Incorrect printhead pressure
adjustment.

1) Remove stock and ink. Close printhead.
Release pressure (knurled knob). Readjust
pressure by turning knob clockwise until it just
contacts printhead plate. Reinstall stock and
ink. Turn adjuster clockwise approximately 1/8
turn (5 clicks of knob). As printer operates,
increase pressure (2-3 clicks at a time) until
best print is obtained. Slide knob in or out in
slot to obtain even print across the face of the
label. Narrow webs will require less pressure
on adjuster. If print is still poor, loosen (2) M3
cap screws visible on outer edges of printhead
carrier. Adjust tangent point to optimum print
by rotating M3 knurled wheel in top center of
printhead plate. Lock in place with 2 outer M3
cap screws.

troubleshooting).

Users Manual Model 656/636 Mechanical Trouble Shooting •••• 55B

Electrical Drawings

Printer Wiring

56B •••• Electrical Drawings Users Manual Model 656/636

KNIFE

MOTOR

STACKER

J9

FEED

MOTOR

BROWN

J2

BROWN

J3

INK

MOTOR

ORANGEJ8GRAYJ7ORANGE

J10

GRAY

J7

ROLLER

DROP

MOTOR

RED

ORANGE

J12

J11

THERMAL CONTROL

BOARD, 371105TT

HEAD DRIVER

BOARD, 341106TT

PRINT HEAD

SYSTEM HARNESS

FRONT PANEL

OPEN

J13

BROWN

J2

BROWN

J1

BROWN

J5

NC

J1

24V
POWER
SUPPLY

511116

VERIFIER

SERIAL

J6

Users Manual Model 656/636 Electrical Drawings •••• 57B

Electrical System Schematic

NOTES:

1. ALL AC WIRE 18AWG 600V INTERNATIONAL
COLOR CODE:
LINE BROWN
NEUTRAL LT. BLUE
EARTH GROUND GREEN W/ YELLOW STRIPE

2. DC OUTPUT OF POWER SUPPLY:
+5V RED
+12V YELLOW
+24V GRAY
RETURN BLACK

3. FLASH DISK REPLACED PCMCIA BOARD, REMOVE IF FLASH
DISK IS INSTALLED.

58B •••• Electrical Drawings Users Manual Model 656/636

Motherboard Power Connectors

The power supply connector on any PC / XT or PC / AT compatible motherboard is made up of dual six-pin male connectors.
Two female connectors from the power supply plug directly onto these male connectors. The following diagrams illustrate
the proper method of attaching the connectors.

Ensure that all of the black wires are located next to each other in the center of the two connectors (as shown in the diagram
below), and that the clamps on the backside of the connectors ate secured along the PCB header. All pins should be covered.

Warning: Connecting the power supply incorrectly may cause irreversible (unwarranted) damage! Ensure that the power is
turned off before connecting the power supply. Make certain that the 115 / 230VAC fuse drawer is in the correct position.

Users Manual Model 656/636 Electrical Drawings •••• 59B

Appendix A

Error Messages

On the Machine's detection of errors/error, the displays will show the first error encountered and allow the
displaying of any other errors with the <YES / NO> keys, which will "Scroll" through additional errors if any.

XX is the total number of errors at the time of error detection.

ERROR SCREENS:
The screen advances to next error with each depression of the "NO>" key
The screen retreats to prior error with each depression of the "<YES" key
The screen reverts back to the first error when the “EXIT” key is pressed.

X X E R R O R ( S )

S T O C K O U T 9 0 1

Error Message Error

HEAD 1 OVER TEMP 404
HEAD 2 OVER TEMP 405
HEAD 3 OVER TEMP 406
STOCK OUT 901
CHECK STACKER 902
INK OUT STATION 1 904
INK OUT STATION 2 905
INK OUT STATION 3 906
MISSED SENSE MARK 908
FEED OPEN 910
VERIFIER HALT 1 912
VERIFIER HALT 2 913
IMAGER ERROR 919
HEAD OPEN STATION 1 920
HEAD OPEN STATION 2 921
HEAD OPEN STATION 3 922

60B •••• Appendix A Users Manual Model 656/636

Appendix B

Software Upgrade Chip Placement Positions

Head Driver Board P/N 341106TT

15
30

R2

D4 5

D3 3

D4 8

D3 6

D2 4

D1 2

D2 9

D4 1

D3

D1 5

D3 7

D2 5

PN .3 4 11 06 R EV 0
PA X AR S N.

R14

U2

C9

J P 2

P IN 1

J2

J1

1
16

C1

R4

D46

D34

D21

D9

D32

D44

D7

D19

D4

D13

D38 D16

D11D35

D47 D23

D22

D10

D8

D39

D2

D1

R5

U 1 7

D27 D20

D26 D14

A58

C2

R56

R55

R54

R42

R41

R53

R52

R51

R50

C4

U1 7

J6

A45

R49

C6

U1 3

C8

C5

R43

U1 1

K1

R33

R47

R46

R35

R34

R48

R45

R44

U1 2

C7

A1

R36

C23

U1 0

+

C1 5

J7

R3 8

R39

R37

R20

R32

R30

R28

R26

U3

R40R31

R29

R27

R25

C13C12

U1 5

J5

Q1

R23

R24

C3

R9

R8R6

R7

R1

4321

R1 7

U6

U5

R1 0

R1 8R1 6 R 1 5

R1 1

C1 4

C10

C11

U9

R2 2

R2 1R1 9

R3

R63

D40

D28

D17

R62

R1 3R1 2

D5D42

U4

C1 6

R61

D31

D18

D30

U 1

U8U7

U1

J4

R60 R59

D6 D43

C2 0

C1 9

C18

C17

R64

J3

C2 2

R57

U 1 4

U1 6

A1

J P 1

U14

C2 1

JP 1

HEAD DRIVER BOARD, Upgradeable software I.C.'s include U1, U14, U17.

PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow.

(Use chip removal tool P/N. 351156 for square I.C removal)

JUMPER SETTING

JP1 On = 240DPI

Off = 300 DPI

JP2 1 to 2

Users Manual Model 656/636 Appendix B •••• 61B

U 36

U 23

U 21

U 4

U 3

U 18

U 19

U 20

U 22

Thermal Control Board P/N 371105TT

THERMAL CONTROL BOARD, Upgradeable software I.C.'s include U3, U4, U18 - U23, U36.
PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow.
DIP CHIPS align notch on chip with the notch on the socket (U3 & U4 chips are four pins smaller than U3 & U4 sockets, position chips towards top of socket so
that the unused socket pins are at the bottom closest to the notch.

(Use chip removal tool p/n. 351156 for square I.C.'s)

62B •••• Appendix B Users Manual Model 656/636

Front Panel Board P/N 511108

(Use chip removal tool p/n. 351156 for square I.C.'s)

FRONT PANEL BOARD, Upgradeable software I.C.'s include U1.
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.

Front Panel Diagnostic Descriptions

Diagnostic

Numbers

Descriptions

1 Front panel initialization
2 TCB Opsys initialization
5 Attempting Serial Host Initialization
6 Initializing Verifier
7 Executing Protected Mode Imaging Code
8 Checking Flash Disk Module

9 Attempting to read in scalable fonts.
10 Initializing Font Scaler
11 Attempting to load code pages
12 Attempting to read in logos
13 Attempting to read in care symbols
14 Waiting for Machine Definition from TCB
15 Attempting to create test pattern
16 Attempting to create strobe tables
17 Attempting to read in formats
18 Protected Mode Imaging Code initialization complete
19 Serial Communications Activated

0 Power up complete

Note: There must be a PCMCIA card installed in the slot if the PCMCIA option board is installed. If the

PCMCIA card is not present – the front panel will stop at Diagnostic 2.

Users Manual Model 656/636 Appendix B •••• 63B

Appendix C

Ink and Stock Transfer Types

Transfer Type values associated with the XT commands.

Value Transfer Type

51 Heat Seal & SD-1111 Ink
52 Topcoated card stock & TT-3111 Ink
53 Topcoated card stock & TT-1111 Ink
54 Topcoated card stock & HR-3111 Ink
55 Topcoated card stock & HR-1111 Ink
56 Topcoated Card Stock & TW-1111 Ink
57 Topcoated card stock & TW-1151 Ink
58 Pressure Sensitive & TT-3111 Ink
59 Pressure Sensitive Thermal Receptive & TT-1111 Ink
60 Pressure Sensitive Thermal Receptive & TW-1111 Ink
61 Pressure Sensitive & TW-1151 Ink
62 Pressure Sensitive & HR-3111 Ink
63 Uncoated Tag Stock & TT-3111 Ink
64 Uncoated Tag Stock & TT-1111 Ink
65 Uncoated Tag Stock & HR-3111 Ink
66 Uncoated Tag Stock & HR-1111 Ink
67 Uncoated Tag Stock & TW-1111 Ink
68 Uncoated Tag Stock & TW-1151 Ink
69 Fabric 2800 & TT-1111 Ink
70 Fabric 2800 & HR-3111 Ink
71 Fabric 2800 & TT-3111 Ink
72 Fabric 2800 & HC-3111 Ink
73 Fabric 2800 & HR-1111 Ink
74 Fabric 2795 & TT-1111 Ink
75 Fabric 2795 & HR-3111 Ink
76 Fabric 2795 & TT-3111 Ink
77 Fabric 2795 & HC-3111 Ink
78 Fabric 2795 & HR-1111 Ink
79 Coated Tag Stock & HR-4111 Ink

64B •••• Appendix C Users Manual Model 656/636

Value Transfer Type

80 Pressure Sensitive & HR-4111 Ink
81 Uncoated Tag Stock & HR-4111 Ink
82 Fabric 2800 & HR-4111 Ink
83 Fabric 2795 & HR-4111 Ink
84 New Pressure Sensitive (no xfer) & TT-3111 Ink
85 New Pressure Sensitive (no xfer) & TT-1111 Ink
86 New Pressure Sensitive (no xfer) & TW-1111 Ink
87 New Pressure Sensitive (no xfer) & TW-1151 Ink
88 New Pressure Sensitive (no xfer) & HR-1111 Ink
89 New Pressure Sensitive (no xfer) & HR-3111 Ink
90 New Pressure Sensitive (no xfer) & HR-4111 Ink
91 Coated Tag Stock & GP-1111 Ink
92 Uncoated Tag Stock & GP-1111 Ink
93 New Pressure Sensitive (no xfer) & GP-1111 Ink
94 2800 Fabric & GP-1111 Ink
95 2795 Fabric & GP-1111 Ink
96 2795 Fabric & CT-1111 Ink
97 4800 Fabric & CT-1111 Ink
98 4800 Fabric & CT-1114 Ink (Blue)

99 4800 Fabric & GP-1111 Ink
100 2395NWT Fabric & CL-1111 Ink (UK)
101 2395NWT Fabric & XC-3111 Ink (UK)
102 2395NWT Fabric & HR-1111 Ink (UK)
103 2495NWT Fabric & CL-1111 Ink (UK)
104 2495NWT Fabric & XC-3111 Ink (UK)
105 2495NWT Fabric & HR-1111 Ink (UK)
106 4000NWT Fabric & CL-1111 Ink (UK)
107 4000NWT Fabric & XC-3111 Ink (UK)
108 4000NWT Fabric & HR-1111 Ink (UK)
109 4002NWT Fabric & CL-1111 Ink (UK)
110 4002NWT Fabric & XC-3111 Ink (UK)
111 4002NWT Fabric & HR-1111 Ink (UK)
112 G.S. Satin & XC-3111 Ink (UK)
113 2012T Fabric & XC-3111 Ink (UK)
114 1021T Fabric & XC-3111 Ink (UK)
115 2800 Fabric & CT-1111 Ink
116 591SST Fabric & CT-1111 Ink

Users Manual Model 656/636 Appendix C •••• 65B

Value Transfer Type

117 591SST/601SST Fabrics & CT-1114 Ink
118 601SST Fabric & CT-1111 Ink
119 591SST/601SST Fabrics & CT-1115 Ink
120 591SST/601SST Fabrics & CT-1117 Ink
121 591SST Fabric & CT-1112 Ink
122 601SST Fabric & CT-1112 Ink
155 4900NWT / 4900HSA & HS1111 Ink
156 1800FRA & TW1111 Ink
157 1800FRA & GP1111 Ink
158 2085NWT / 2495NWT / 2360NWT & HS1111 Ink
159 2360NWT / 2800NWT & XC3111 Ink
160 2895NWT / 2800NWT & HS1111 Ink
161 2895NWT & XC3111 Ink
162 2895NWT & HC3111 Ink
163 1800MWA & GP1111 Ink
164 1800MWA & TW1111 Ink
165 604LKP / 601LKP & DS7501 / 7502 / 7504 Inks
166 604LKP / 601 LKP & DS7503 Ink
167 4800NBC Fabric & HS1011 Ink
168 2012T Fabric & HS1111/1112 Ink
169 4360NBT Fabric & SD1011 Ink
170 4041THS Fabric & HS1111 Ink
171 4700TWT Fabric & PL1111 Ink
172 4800TST Fabric & CT1111 Ink
173 4800TST Fabric & CT1112 Ink
174 4800TST Fabric & CT1114 Ink
175 4800TST Fabric & CT1115 Ink
176 4800TST Fabric & CT5137 Ink
177 4800TST Fabric & HS1111 Ink
178 770SWT Fabric & CT1112 Ink
179 770SWT Fabric & CT1114 Ink
180 770SWT Fabric & CT1115 Ink
181 770SWT Fabric & CT5137 Ink
182 772SWT Fabric & CT1112 Ink
183 772SWT Fabric & CT1114 Ink
184 772SWT Fabric & CT1115 Ink
185 772SWT Fabric & CT5137 Ink

66B •••• Appendix C Users Manual Model 656/636

Appendix D

+.000

Knife MFG Guideline

Solenoid Trigger Setting

-.020

1. After the clutch and actuator is mounted to the knife, attach the solenoid assembly to the inside

support using two 6-32 x 3/8 cap screws, flat washers, and lock washers. Make sure the plunger
moves freely and does not bind. Motor and faceplate must be mounted also.

2. Check the gap between the actuator and the top of the pin on the clutch as shown in drawing.

The plunger should be pushed in to make the measurement.

Other hints if there is still a problem:

• If the gap is greater then .047”, an old solenoid bracket is being used. Replace (P/N 357003) or

slot the bracket.

• If plunger binds, the solenoid is not parallel with the base of the bracket that mounts to the knife

support, and/or the actuator slot is bottoming out on the roll pins that are on the plunger. Make
adjustment or replace the bracket.

Users Manual Model 656/636 Appendix D •••• 67B

• Torsion Spring should be at an angle of 60±2°. Lay the spring over the drawing below to see if

the spring is made properly.

• Plunger pins should be centered on shaft. If either pin is loose DO NOT use the plunger. The

pins should be checked before installing.

• (Rev 3) Replace both roll pins on all reworked assemblies.

• (Rev 4) Effective 3/3/97 a large nylon washer will be added between the coil pin and the c-clip

on the plunger. To install, the c-clip has to be removed, then put the large washer on the
plunger and push it down against the coil pin. While holding it in that location, re-install the c­clip. Now the Small nylon washer and spring can be put on the plunger and inserted into the
solenoid.

- 989513

• There should be a .010-.020 gap (for roller clutch only) between the two clutch pieces.

68B •••• Appendix D Users Manual Model 656/636

• (Test on the solenoid test box.) The knife must cut both fabric and card stock. The solenoid

should operate on both the high and low settings.

• Excessive motor drag must be minimal at start/stop and while running. Replace or repair

problem component. On old knife assemblies, there are bronze bushings in outer support. They
may be causing a bind. Ream bushing and retest. (Do not ream if it is a roller bearing.)

• (Rev 1) Pre-load setting adjustment. While motor is running, not while cutting, loosen set

screws on “pac-man” and rotate the rotary blade clockwise, mark the stopping position on the
“pac-man”, rotate counterclockwise, mark the “pac-man”, then rotate the blade to the middle of
the two marks and tighten the set screws.

• (Rev 2) All new knife assemblies have a blue clutch. The clutch outer race bushing has an I.D.

of .500 and the 2 extension springs are .012 dia wire.

• (Rev 2) The 2 extension springs on all rebuilt clutches must have the .009 dia. wire springs

replaced with .012 wire springs.

• (Rev 5) Replace Knife Actuator 357020, if it is worn or if there is a “bulge” at the 90-degree

bend.

• (Rev 6) Changed feeler gauge tolerance from .047 MIN

Users Manual Model 656/636 Appendix D •••• 69B

Appendix E

Printhead Life Extension

Matching stock and ink widths

If your customer is running multiple media and multiple widths on their AVERY DENNISON machine, Great!
They are taking advantage of one the most compelling features of our printers: multimedia capability. Our
printers can also reduce the width of the ink to only that area being printed. However, we run into printhead
problems when customer combine both these features.

The edge of the narrower stock not covered by the ink will gouge the printhead and cause dots to be
out.

Here, the customer will have much
shorter printhead life because of the
edge of the narrower, uncovered
stock.

Printhead

WRONG!

The solution is to make sure that
the narrower stocks have at
least 1/8” of ink coverage over
the edge. The widest stock
does not need full ink coverage.

RIGHT!

This edge which is

not covered by ink

will erode the

printhead.

Must have 1/8" inch

overlap to protect the

printhead from the

stock edges

Will have missing dots from

the eroded printhead when

this prints out.

Printhead

Overlap unneccessary because

this is the widest stock being

printed

70B •••• Appendix E Users Manual Model 656/636

Printhead Fail Modes

Symptoms, Causes, Solutions

Symptom #1:

sometimes in the print area, and sometimes not. If in a barcode, the verifier will halt the printer.

Cause: Paper dust or dirt on the printhead
causing the ink to print without printhead firing.
The dot is NOT failed on. The printhead is
DIRTY.

If not addressed immediately: the line will go
from black or gray to white and the dot will fail.
The printhead will be damaged.

Solution: Immediately stop the printer and clean the printhead in the machine.

If problem continues: Remove the printhead and clean with hard pressure.

A dot is leaving a line in the print direction. The dot appears to be dragging or failed on,

Lines of

print from

a dragging

dot

Specialty

Style: Fall
Color: Rose

23456 78901

Brand

$5.95

Specialty

Brand

Style: Fall

Color: Rose

23456 78901

$5.95

Specialty

Brand

Style: Fall
Color: Rose

23456 78901

$5.95

Specialty

Brand

Style: Fall

Color: Rose

23456 78901

$5.95

Specialty

Brand

Style: Fall
Color: Rose

23456 78901

$5.95

Symptom #2:

Edges of barcode and text do not appear

crisp and sharp.

23456 78901

Cause: Strobe is too high. Printhead is dirty.

Solution: Reduce front panel strobe one increment at a time until

fuzzy printing goes away.

If problem continues: Clean the printhead as described below.

Fuzzy edges

Symptom #3:

appears missing. The verifier will halt the machine if the missing dot is in a barcode.

While printing along fine early in the printheads life (< 300,000 inches), a dot suddenly

Cause: Most likely, the printhead failed from static.

Solution: Replace the printhead.

If problem continues: Check that the machine has all the static upgrades. Double check the connections

and wires.

Users Manual Model 656/636 Appendix E •••• 71B

Printhead Cleaning Procedure

Printhead performance and life are influenced by proper handling and cleaning.

• Dirt on the printhead that causes problems is often too small to see.

• Exercise care in handling printheads, as they are very susceptible to static. Use the wrist grounding strap

and anti-static gloves when handling.

• It is OK to scrub the printhead HARD to clean it. Use rubbing alcohol and the “loop side” or “wool side” of

Velcro, followed by drying with rough, brown paper towels.

• If the printhead doesn’t work, take it out and clean it again.

• For maximum printhead life, clean the printhead after every roll change of ink or every 20,000 inches.

In Machine Cleaning Procedure

1. Stop the machine after the last batch has printed to avoid
loosing data.

2. Turn the machine off.

3. Open the printhead carriage assembly.

4. Soak a small amount of rubbing alcohol on a cotton swab and
apply to the printhead.

5. Scrub the printhead several times with hard force using the
“wool side” of Velcro.

6. Dry the printhead with a dry, brown paper towel.

7. Shut the printhead carriage assembly and resume printing.

8. If a problem continues, remove the printhead and clean it.

Dirt along the

print line.

Printhead cleaning when removed from the printer

1. Remove the printhead.

2. Place the printhead upside down on the edge of a clean
table with the connector pug over the edge of the table.

3. Soak a small amount of rubbing alcohol on a cotton swab
and apply to the print line.

4. Scrub the printhead several times using HARD pressure
with the “loop side” of Velcro.

5. Dry with a dry, brown paper towel.

6. Replace the printhead.

Heavy finger

pressure here

Thumb here to

hold against

the table

Scrub here,

hard pressure

Table edge

72B •••• Appendix E Users Manual Model 656/636

Printhead Installation and Removal Procedures

Printhead removal procedure

1. Attach the grounding strap to your wrist and the printer.

2. Turn the machine off.

3. Leaving the printhead shut, completely loosen the two tangent

locking screws but leave them loose in the holes.

4. Slowly open the printhead carriage assembly. Maneuver the

printhead down and to the right, pulling the wire pack out from
the shield.

5. Disconnect the wire pack and carefully remove the printhead.

Printhead installation procedure

1. Position the printhead loosely under the printhead

carriage assembly.

2. Connect the wire pack.

3. Position the printhead in the printhead carriage

assembly so that the alignment pegs match up
and the printhead fits snugly.

4. Shut the printhead while maintaining snug fit on

the printhead.

5. Tighten the tangent set screws.

Shield

Printhead Carriage Assembly

Printhead
alignment

pegs

Wire pack

Open Printhead Carriage

Tangent locking

screw locations

Users Manual Model 656/636 Appendix E •••• 73B

Static Checks for 636/656 Printers

1. Stacker: With an ohmmeter, check continuity between the main stacker
roller, which has the belts on it, and the chassis ground. Chassis ground
can be any screw near the serial cable. Check that these two important
enhancements are functioning:

WRONG!

a) Check the grounding clip is installed

and making physical contact with the
main stacker roller. Sometimes, the
clip is installed but moved off the
roller.

Grounding

clip

b) Check the stacker mounting knob has

Washer

Stacker knob removed

a large washer installed. Make sure
to tighten the knob all the way.

2. Ink arbors: With an ohmmeter, check for
continuity on the two ink arbors and three
ink turn rollers. Place one lead of the
ohmmeter on the arbor and the other on the
chassis ground screw.

3. Printhead static protections. Check for proper installation.

a) Static brushes. Make sure the brushes are

installed and just barely touching the stock
and ink. Too much dragging and they wear;
too little contact and they don’t dissipate the
static.

b) Static shield. Make sure the static shield is

installed and the screws are tight.

RIGHT!

Machine side of the

stacker

Ink arbors

Ink turn rollers

Static

brushes

Shield

74B •••• Appendix E Users Manual Model 656/636

Steps for initial set up on a AVERY DENNISON 636
or 656

1. Software: In Formatter, open the format. From the Format menu, select Attributes. Select the “Ink Setup”

tab. Check that the combination of stock and ink types matches what is running on the machine.

2. Pressure: Open the printhead such that it hangs at an angle.

Loosen the printhead pressure knob enough to that it just
sticks and does not slide from gravity. Position the knob in the
center of the ink. Close the printhead, tighten 3/4 of a turn.

3. Tangent: Set the tangent so that the locking screw is centered

when looking down on the printhead.

4. Strobe: Using the arrow keys, select “Setup” on the front

panel. Using the arrow keys again, select “Strobe”. If not 0,
return the strobe setting to zero using the arrow keys, and
then the “Enter” key.

Printhead Carriage Assembly

5. Ink tension: Back the tension on the ink unwind and take up to minimal. Turn the tension knobs left or

counter-clockwise.

6. Stock widths: The width of the ribbon must be greater than the supply width. Since some supplies are

more abrasive to printheads than others, using a ribbon wider than your supply helps protect the
printhead. Failure to do this may void your warranty. Replacement printheads are expensive.

Pressure

adjustment knob

Tangent locking

screw locations

Tangent

adjustment knob

7. Cleaning: Clean the printhead with an approved printhead cleaning method. Use rubbing alcohol on a lint

free cloth or the “Hook side” of Velcro. Always turn off the machine and wear the wrist grounding strap.

Never touch the printhead with a metal object like a knife or screwdriver.

Users Manual Model 656/636 Appendix E •••• 75B

Print Quality Adjustment

!. Tangent - Move the tangent adjust knob left or right to improve print quality. In general, the best print will

be slightly to the left of center.

Specialty

Brand

Style: Fall
Color: Rose

23456 78901

Printhead

Stock

Platten

roller

Ink

Printhead

Stock

Platten

roller

Ink

Tangent too far left

Tangent properly adjusted

Specialty

Brand

Style: Fall
Color: Rose

23456 78901

$5.95

Printhead

Ink

Stock

Platten

roller

Tangent too far right

Specialty

Brand

2. Pressure - Adjust printhead pressure to get desired print definition. If the pressure seems like it is getting
too tight, readjust tangent. Don’t tighten the printhead to maximum or damage to the printhead could
occur.

3. Strobe - Adjust strobe for print darkness and bar code scanability. Adjust one increment at a time.

4. Ink - Use ink unwind and take-up tensions adjustments to eliminate any ink wrinkles or skid marks.

76B •••• Appendix E Users Manual Model 656/636

Appendix F

Platen Rollers for 6x6 and 676 Printers

There are several types of platen rollers made for the 6x6 and the 676 series of
controlled printers. The material printed will determine the color (hardness) of the
roller as well as width of the cut down part of the platen. The green rollers are harder
and used for fabric applications. The red rollers are softer and are used for tag
applications. The rollers are determined by tapes / tags and is not dependant on the
ink selection. The width of the fabric will determine the width of the cut down part
of the green platen roller. The ink should not extend beyond the edge of the cut
down part of the platen. The 1 3/8” roller can be used for fabric from the minimum
1” to 1 1/8” wide. The 3” cut down platen roller can be used from 1 1/8” to 2 ½” in
width. Fabric from 2 ½” wide up to the full 5” width of the printer should use the
regular full size platen rollers.

The following pages will show the platen rollers used in the 6x6 and 676 controlled
printers. They are approximately full size. Just compare the roller you are using to
one of the pictures and using the following chart – select the replacement part
number. The first 6x6 machines had beige colored covers and the web path was back
justified. The later model of 6x6 has gray colored covers and has a web path that is
centered on the platen rollers in the same way as the 676.

Machine Part Number

636/656 Beige Covers

Back Justified Web Path 355096 Standard Full Width Tag Stock - Red – w / Ink Save (656)

355029 Standard Full Width Green - Fabric – wo / Ink Save
355083 Standard Full Width Green - Fabric – w / Ink Save (656)
355044 3” Cut Down Green - Fabric – wo / Ink Save
355082 3” Cut Down Green - Fabric – w / Ink Save (656)

636/656 Gray Covers

Center Justified Web Path 355096 Standard Full Width Tag Stock - Red – w / Ink Save (656)

355029 Standard Full Width Green - Fabric – wo / Ink Save
355083 Standard Full Width Green - Fabric – w / Ink Save (656)
375030 1 3/8” Cut Down Green - Fabric – wo / Ink Save
375031K 1 3/8” Cut Down Green - Fabric – Ink Save (656)
375026 3” Cut Down Green - Fabric – wo / Ink Save
375025K 3” Cut Down Green - Fabric – w / Ink Save (656)

676

Center Justified Web Path 355096 Standard Full Width Tag Stock - Red – w / Ink Save

355029 Standard Full Width Green - Fabric – wo / Ink Save
355083 Standard Full Width Green - Fabric – w / Ink Save
375030 1 3/8” Cut Down Green - Fabric – wo / Ink Save
375031K 1 3/8” Cut Down Green - Fabric – w / Ink Save
375026 3” Cut Down Green - Fabric – wo / Ink Save
375025K 3” Cut Down Green - Fabric – w / Ink Save

355009 Standard Full Width Tag Stock - Red – wo / Ink Save

355009 Standard Full Width Tag Stock - Red – wo / Ink Save

355009 Standard Full Width Tag Stock - Red – wo / Ink Save

Platen Roller Description and Use

Users Manual Model 656/636 Appendix F •••• 77B

Standard Platen Roller

Non Ink Save

636 / 656 All

676

Part Number 355009 – Red
Part Number 355029 - Green

_____________________________________________________________________________________________

Standard Platen Roller

Ink Save

656 All

676

Part Number 355096 – Red
Part Number 355083 – Green

78B •••• Appendix F Users Manual Model 656/636

Back Justified Platen Roller

3” Cut Down

Non Ink Save

636 / 656 w/ Beige Covers

Part Number 355044 - Green

_____________________________________________________________________________________________

Back Justified Platen Roller

3” Cut Down

w / Ink Save

656 w/ Beige Covers

Part Number 355082 - Green

Users Manual Model 656/636 Appendix F •••• 79B

Center Justified Platen Roller

1 3/8” C ut D own

Non Ink Save

636 / 656 w/ Gray Covers

676

Part Number 375030 - Green

_____________________________________________________________________________________________

Center Justified Platen Roller

1 3/8” Cut Down

w / Ink Save

656 w/ Gray Covers

676

Part Number 375031K - Green

80B •••• Appendix F Users Manual Model 656/636

Center Justified Platen Roller

3” Cut Down

Non Ink Save

636 / 656 w/ Gray Covers

676

Part Number 375026 - Green

_____________________________________________________________________________________________

Center Justified Platen Roller

3” Cut Down

Ink Save

656 w/ Gray Covers

676

Part Number 375025K - Green

Users Manual Model 656/636 Appendix F •••• 81B

Assembly Drawings

Users Manual Model 656/636 Assembly Drawings •••• 83B

Unwind Assembly Drawing

84B •••• Assembly Drawings Users Manual Model 656/636

Unwind Parts List

Item Part # Description Qty

1 373012 Web guide, Rear 1
2 373009 Lead screw, Tape unwind 1
3 373011 Adjuster, Outer web guide 1
4 373010 Rod, Web guide, Outer 1
5 353002 Bracket, Unwind 1
6 105023 Impression Adjust, Knob/SS Kit 1
7 373014 Bracket, Sensor mount 1
8 373013 Bracket, Stock out 1

9 191120 Micro switch 1
10 989973 4-40 x ½ Cap screw 2
11 990069 8-32 Hex nut 1
12 990000 2-56 x ¼ Cap screw 2
13 990065 8-32 x 3/8 Button head screw 1
14 371142 Stock out switch harness (*NS) 1
15 990513 Small wire tie (*NS) 1

Users Manual Model 656/636 Assembly Drawings •••• 85B

Contrast Sensor Drawing

86B •••• Assembly Drawings Users Manual Model 656/636

Contrast Sensor Parts List

Item Part # Description Qty

1 990111 10-32 x 3/4 Flat head screw 3 15 990374 Collar, 1/2" 2
2 514016 Bracket, Sensor ass'y 1 16 514020 Sensor, Mount block 1
3 514017 Shaft, Ink turn bar 1 17 194020 Web turn shaft 4
4 514019 Bracket, Sensor mount 1 18 281140 Scanner, Contrast 1
5 990056 8-32 x 1/2 Flat head screw 4 19 990484 1/4-20 x 1/2 Nylon screw 2
6 514018 Bracket, Sensor guide 1 20 424044 Bracket, Sensor hold down 1
7 376086 Roller, Ass'y 1 21 989534 4mm x 6mm Pan hd Phil screw 2
8 990133 1/4-20 x 3/4 Flat head screw 5 22 990038 Hex nut, 6-32 2

9 990268 Dowel pin, 3/16 x 1/2 2 23 990050 8-32 x 1/4 Cap screw 2
10 511206 Frame, 636/656B Upright 1 24 990019 6-32 x 1/4 Button head screw 2
11 990121 1/4-20 x 5/8 Cap screw 3 25 376057 Bracket, Static brush 1
12 511112 Cable, Contrast sensor 1 26 355039 Static brush 1
13 990083 10-32 x 3/4 Cap screw 1
14 990313 Thumb screw knob, #10 1 514098 Can be ordered as an assembly

Item Part # Description Qty

Users Manual Model 656/636 Assembly Drawings •••• 87B

Web Guide / Sensor Assembly Drawing

18

15

16

17

11

11

5

1

11

15

27

28

29

31

23

7

20

39

30

21

19

26

25

24

22

6

13

14

7

12

11

32

2

33

34

8

34

33

3

6

35

36

37

38

7

4

88B •••• Assembly Drawings Users Manual Model 656/636

10

11

9

11

10

Web Guide / Sensor Assembly Parts List

Item Part # Description Qty

BRACKET WEB/SENSOR GUIDE

1 514102

2 554017 SHAFT, DECURLER ROLLER 1

3 514090 TAPE ROLL IDLER, MOLDED 1

4 990328 E-RING, 1/2 1

5 990166 1/4-20 X 5/8 BHCS 1

6 374059 SHAFT, SENSOR GUIDE 4

7 999100 BUSHING FL, 3/16 X 5/16 X 1/8 6

8 374060 SHAFT, WEB GUIDE ADJUST 1

9 374061 WEB GUIDE HOLDER 1

10 105023K IMPRESSION ADJ. KNOB 2
11 990091 10-32 X 1/2 BHCS 8
12 374055 BRACKET, FRONT PLATE 1
13 554058 SHAFT, THREADED ROD UPPER 1
14 554059 SHAFT, THREADED LOWER 1
15 554064A GEAR, SENSOR ADJ. ALT 2
16 374058 GEAR, IDLER, 36T 1
17 990262 SNAP RING, 1/4 1
18 990007 4-40 X 1/8 KNURLED CUP POINT 4
19 374049 BRACKET, MOUNT LED 1
20 532015 CLAMP, SENSOR 1

MOUNT ASSY 1

Item Part # Description Qty

21 991279 4-40 X 1/8 BHCS 2
22 551169 SENSOR, LED WIRED 1
23 374050 BRACKET, SENSOR MOUNT 1

TOP & BOTTOM REFLECTIVE SENSOR

24 371128
25 990448 WASHER, .125 X .313 X .031 1
26 990424 4-40 X 3/8 SHCS 1
27 516001 BRACKET, STATIC BRUSH, INK 1
28 990119 1/4-20 X 3/8 SHCS 1
29 989978 #8 STAR WASHER 2
30 990066 8-32 X 1/4 BHCS 2
31 990069 8-32 HEX NUT 2
32 554004 BRACKET, WEB GUIDE MOUNT 1
33 374051 BRACKET, WEB GUIDE 2
34 990090 10/32 X 3/8 BHCS 4
35 554006 BRACKET, WEB GUIDE MOUNT FRONT 1
36 554005 ADAPTER, WEB GUIDE 1
37 990016 6-32 X 3/8 SHCS 1
38 990312 THUMB SCREW KNOB, #6 1
39 355039 STATIC BRUSH 1

HARNESS 1

Users Manual Model 656/636 Assembly Drawings •••• 89B

Drive Assembly Drawing

A

90B •••• Assembly Drawings Users Manual Model 656/636

Drive Parts List

Item Part # Description Qty Item Part # Description Qty

1 514012 Feed knob / SS 1

2 990120 ¼-20 x ½” Cap screw 5

3 514093 Front drive support Ass’y 1

4 991085 Extension spring 2

5 514003 Pin, Spring anchor 2

6 514009K Spring lever, Front 1

7 990325 3/16” “E” Ring 2

8 514001 Shaft, Idler roller 1

9 514011 Bridge plate, Web 1
10 990090 10-32 x 3/8” Button head screw 4
11 354004 Bridge blade, Lower 1
12 355018 Support, Knife/Drive/Print 1
13 354014 Driven roller, Molded 1
14 354094 Roller, Drive Ass’y 1
15 354017 Shaft, Idler gear 1
16 354008A Gear, Idler 1

KEY: Index Numbers 1A are components of assembly A.

All items above are included in the B assembly

17 354009A Gear, Driven 1
18 514090 Tape roll idler, Molded 1
19 514094 Lift cam Ass’y 1
20 514010K Spring lever, Rear 1
21 514092 Rear drive support, Ass’y 1
22 990023 6-32 x ½” Flat head screw 1

23 990416 ¼-20 x ½” Flat head screw 1
24A 374026 Plate support 2
25A 354022 Spring, Eccentric lift 2
26A 999070 3/16 x 5/16 x 5/16” Fl. Bushing 2
27A 374025 Pre-feed plate 1
28A 990003 4-40 x ¼” Flat head screw 4
29A 354013 Idler roller, Molded 1

A 374094 Roller, Drive Ass’y 1
B 514091 Feed assembly, Spring loaded 1

Users Manual Model 656/636 Assembly Drawings •••• 91B

Printhead Assembly Drawing

92B •••• Assembly Drawings Users Manual Model 656/636

Printhead Parts List

Item Part # Description Qty Item Part # Description Qty

1 515002 Shaft, Eccentric 1
2 355096 Platen roller (See Appendix F) 1
3 357011 Static brush 1
4 990066 8-32 x 1/4 Button head screw 4
5 355038 Knob clip 1
6 990047 8-32 x 1/8 Cap screw 1
7 355094 Assembly, Adjuster, Print head 1
8 355032 Plate, Print head mount 1

9 990120 1/4-20 x 1/2 Cap screw 5
10 990250 Dowel pin, 3/16 x 2 1
11 355031 Holder, Print head 1
12 355035 Pressure, Adjuster 1
13 355042 Plate, Locator print head 1
14 989976 Washer, #6 Star 2
15 990016 6-32 x 3/8 Cap screw 2

16 999041 Iglide, 1/4 x 5/16 x 1/4 Flange 1
17 355034 Shaft, Adjustment 1
18 355040 Block, Head adjust 1

19 355033 Adjustment, Plate, Print head 1
20 990028 6-32 x 3/8 Flat head screw 1
21 355092 Ass’y, Print head, Inner support 1
22 355018 Support, Knife / Drive / Print 1
23 355093 Ass’y, Print head, Outer Support 1
24 356020 Roller, Molded (Ink) 1
25 355041 Static shield 1
26 355039 Static brush 1
27 355037 Pin, Pivot 2
28 990037 Washer, #6 SAE 2
29 990015 6-32 x 1/4 Cap screw 2
30 999051 Bushing, 3/16 x 5/16 x 5/16 Oilite 1
31 355008 Spring, Torsion print head 1
32 515087 Head lift motor assembly 1
33 351101

351102
34 990492 Dowel pin, 3mm x 8mm 2
35 990444 3m x 14mm Cap screw 2

Print head, 6X6, 240 DPI
Print head, 6X6, 300 DPI

1
1

Users Manual Model 656/636 Assembly Drawings •••• 93B

Ink Unwind / Rewind Assembly

94B •••• Assembly Drawings Users Manual Model 656/636