Paxar 656, 636 User Manual

Users Manual

Model 656 / 636

PAXAR Systems Group

Manual Edition 3.0

18 February 2002

Manual Part Number 351398

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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 3

Location of Printer.....................................................................................................................3

AC Power Line ..........................................................................................................................4

Unpacking.................................................................................................................................. 4

Inventory of Components ..........................................................................................................5

Printer Setup 6

Installing the Stacker .................................................................................................................6

Fuse Configuration .................................................................................................................... 7

P.C. Board Installation............................................................................................................... 7

TCB Dip Switch S2 Settings .....................................................................................................8

Installing the Power Cord .......................................................................................................... 8

Installing the PC Interface Cable...............................................................................................9

Installing the PC Software......................................................................................................... 9

Product Description 10

Printer Description................................................................................................................... 10

Personal Computer Specifications........................................................................................... 11

Unit Specification .................................................................................................................... 11

Printer Operation 13

Installing Ink Ribbon ............................................................................................................... 13

Loading Stock.......................................................................................................................... 14

Butt Splice ...............................................................................................................................15

Web Guide Adjustment ........................................................................................................... 15

Print Head Open / Close .......................................................................................................... 16

Control Panel Operation 17

Printer Controls........................................................................................................................17

Indicator Lights........................................................................................................................19

Front Panel Menu Functions.................................................................................................... 20

Users Manual Model 656/636 • iii

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

Display Modes .........................................................................................................................23

Maintenance / Adjustments 29

Print Head Handling ................................................................................................................29

Print Head Cleaning................................................................................................................. 30

Print Head Replacement ..........................................................................................................31

Print Head Adjustment.............................................................................................................32

Registration Sensor Adjustment ..............................................................................................33

Stock out Adjustment...............................................................................................................37

Knife Square Adjustment.........................................................................................................37

Stacker Adjustments ................................................................................................................38

Stock Feed Adjustment............................................................................................................38

Mechanical Adjustment Of Feed Roller Pressure (Blue Roller)..............................................39

Mechanical Adjustment of Stock Sense - Mark Light Receiver.............................................. 39

Electrical Connections 41

Machine Wiring ....................................................................................................................... 41

Relay Assembly .......................................................................................................................42

Electrical System Schematic.................................................................................................... 43

Motherboard Power Connectors ..............................................................................................44

Electrical Trouble Shooting 45

Power Up / Sign On / Communications...................................................................................45

Stock / Ink Advance.................................................................................................................47

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

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

Electrical Trouble Shooting / Machine Set Up Sequence........................................................ 52

Mechanical Trouble Shooting 53

Stock ........................................................................................................................................53

Ink............................................................................................................................................55

Print .........................................................................................................................................56

Knife ........................................................................................................................................57

Mechanical Trouble Shooting Sequence .................................................................................59

Lubrication Procedure .............................................................................................................59

Appendix A 60

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

Appendix B 61

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

Appendix C 64

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

Appendix D 67

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

iv • Users Manual Model 656/636

Assembly Drawings 71

Unwind Assembly Drawing ....................................................................................................72

Unwind Parts List ....................................................................................................................73

Web Guide / Light Bar Assembly Drawing.............................................................................74

Web Guide / Light Bar Parts List ............................................................................................ 75

Drive Assembly Drawing ........................................................................................................ 76

Drive Parts List........................................................................................................................ 77

Printhead Assembly Drawing .................................................................................................. 78

Printhead Parts List.................................................................................................................. 79

Ink Unwind / Rewind Assembly..............................................................................................80

Ink Unwind / Rewind Parts List ..............................................................................................81

Ink Rewind Arbor Assembly................................................................................................... 82

Ink Rewind Arbor Parts List.................................................................................................... 83

Feed & Ink Drive Assembly.................................................................................................... 84

Feed & Ink Drive Parts List.....................................................................................................85

Timing Belt Threading Diagram..............................................................................................86

Timing Belt Parts List.............................................................................................................. 87

Ink Turn Roller Assembly ....................................................................................................... 88

Ink Turn Roller Parts List........................................................................................................ 89

Knife Assembly Drawing ........................................................................................................ 90

Knife Parts List........................................................................................................................ 91

Stacker Assembly Drawing .....................................................................................................92

Stacker Parts List ..................................................................................................................... 93

Rewind Assembly Drawing..................................................................................................... 94

Rewind Parts List..................................................................................................................... 95

Stock Out Sensor Assembly Drawing .....................................................................................96

Stock Out Sensor Parts List .....................................................................................................97

Optional Stackers 98

4.25” Stacker Specifications....................................................................................................99

Optional 4.25” Pick-up Assembly .........................................................................................100

Optional 4.25” Pick-up Parts List.......................................................................................... 101

Optional 4.25” Stacker Assembly.......................................................................................... 102

Optional 4.25” Stacker Parts List ..........................................................................................103

Optional Down Stacker Assembly Drawing (Part 1)............................................................. 104

Optional Down Stacker Parts List (Part 1) ............................................................................105

Optional Down Stacker Assembly Drawing (Part 2)............................................................. 106

Optional Down Stacker Parts List (Part 2) ............................................................................107

Optional Down Stacker Assembly Drawing (Part 3)............................................................. 108

Optional Down Stacker Parts List (Part 3) ...........................................................................109

Users Manual Model 656/636 • v

Scope

Introduction

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

We at PAXAR hope that you will come to appreciate the efforts and quality which
have gone into producing your PAXAR 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 machine has some pinch points. All of these areas have been well guarded and
it is recommended that the safety features of this machine are never altered or
defeated.

Users Manual Model 656/636 Scope • 1

Warranty Information

Limited Warranty

PAXAR Systems Group, Division of PAXAR Corporation, extends the following
warranties to the original purchaser of a PAXAR 656 / 636 which has been installed
and operated using recommended procedures and operating conditions.

Parts

Parts found defective in material or workmanship will be replaced at no charge for a
period of six months following the machine's shipment date. Parts damaged by
negligence, abuse, or normal wear are not covered. PAXAR 656 / 636 parts classed
as normal wear items include print heads, feed and platen rollers, and knife blades.

Service

Service to replace defective parts as defined above, shall be provided at no charge
for a period of six months following the shipment date.

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

PAXAR Corporation

One Wilcox Street

Sayre, Pa. 18840

Call: 1-800-96PAXAR or [phone]

Fax: [phone]

For spare parts, requests for service or technical support

Paxar Service Group

170 Monarch Lane

Miamisburg, OH 45342

Call: [phone]

Fax: [phone] for Warranty Parts

Fax: [phone] or [phone] for Customer Parts Orders

For parts and service in other countries please contact your local PAXAR supplier.

PAXAR Apparel Identification Systems Group reserves the right to incorporate any
modifications or improvements in the machine system and machine specifications
which it considers necessary and does not assume any obligation to make said
changes in equipment previously sold.

2 • Warranty Information Users Manual Model 656/636

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. PAXAR
recommends an industrial type work table having the approximate dimensions of 96"
wide to 30" deep to 32" high. Refer to Figure 1a.

Figure 1a Recommended workstation layout.

The location of the PAXAR 656 / 636 printer should be based on human factors.
The printer should be located in an area which maintains optimum flow of your
product while providing for the operator’s comfort. PAXAR 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 PAXAR 656 / 636 printer is a high resolution thermal printer. While PAXAR
has designed the printer to be reasonably quiet, it is recommended to location 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 machine.

Users Manual Model 656/636 Customer Responsibility • 3

AC Power Line

Unpacking

PAXAR requires that the electric service be 10 Amps @ 110VAC or 10 Amps @
220VAC. This will allow the computer and any additional support or service
equipment to be plugged into the same service.

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

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

The PAXAR printer is shipped in a large cardboard box which may be difficult to
move by hand.

DO NOT REMOVE THE PRINTER FROM THE CRATE 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 PAXAR 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 new 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 1b). 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
machine for shipping damage. If obvious damage is discovered, contact PAXAR for
further instructions - in the U.S.A. at 570-888-9116. In other countries please
contact your local PAXAR 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.

4 • Customer Responsibility Users Manual Model 656/636

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

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

Inventory of Components

The following list shows the additional parts (pieces) which should be included in
your PAXAR 656 / 636 shipping container. If anything is missing, notify PAXAR
immediately - in the U.S.A. at 570-888-9116. In other countries please contact your
local PAXAR supplier.

Figure 1b Shipping Carton.

- PAXAR 656 / 636 "User's Manual"

- Tool kit

- A quick-disconnect power cord

- Optional IC card for custom Logos or additional fonts that were special ordered.
(in the back of the manual)

- Stacker assembly

- Optional software ordered to drive the printer.

- A serial communications cable

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

PAXAR 656 / 636 TOOL KIT (#351390)

241149 Anti-Static Gloves (2)

921309 Hex Key Set

921316 3/16" Long Ball Driver

181301 2.5mm Ball Driver

301156 Chip Removal Tool

351398 656 / 636 Users Manual

Users Manual Model 656/636 Customer Responsibility • 5

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 thumb screws. Insert the thumb
screw through the mating hole in the up-right rail assembly. Thread the thumb
screw into the mounting block. Repeat the above procedure for the other thumb
screw.

There is a harness and connector leading from the back of the stacker that plugs into
the center connector on the last PC board. The connector and plug are polarized.
Rotate the plug until the polarized plug and connector align and push them together.

6 • Printer Setup Users Manual Model 656/636

Fuse Configuration

The main fuse(s) on the Paxar 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 number in the window DOES NOT match the AC
line intended to be supplied to the printer, DO NOT plug the power cord in. Re
configure as follows:

1) Using a flat blade screw driver, 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 between the range of

Configuration Number Two: Line voltage between the range of 180 -

90 - 132VAC @ 50 - 60Hz

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

2) Install one Fuse Jumper

See Figure FUSE1

265VAC @ 50 - 60Hz

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

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

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 Installation

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

See Figure FUSE2

Install P.C. Boards as follows:

Users Manual Model 656/636 Printer Setup • 7

Memory Card Option Board (350016) - Slot 5 (from back)

Diskless Rom Bd. (281164) - Slot 4

Thermal Control Bd. (351105) - Slot 2

Head Control Bd. (351106) - Slot 1

TCB Dip Switch S2 Settings

TCB DIP SWITCH S2 SETTINGS

1 DPI OFF = 240 ON = 300

2 DPI (Undefined) OFF = Default ON =

3 MACHINE TYPE OFF = 656 ON = 636

4 MACHINE TYPE (Undefined) OFF = Default ON =

5 JAM SENSOR OFF = not installed ON = installed

6 UNDEFINED OFF = Default ON =

7 UNDEFINED OFF = Default ON =

8 UNDEFINED OFF = Default ON =

Installing the Power Cord

A power cord is shipped with each printer. The cord for 110 volt printers, will use
the standard three prong plug used in the U.S.A. A 220 volt printer and other 110
volt configurations must have the receptacle end of the connector removed and the
proper plug installed. It is the customers responsibility to have the plug and
alteration work done by a certified electrician. Paxar supplies printers to many
countries with many variations. Therefore we leave this to the customer to make the
proper selection for their country.

8 • Printer Setup Users Manual Model 656/636

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 order from PAXAR (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. The female end of the cable is made to
fit a 9-pin male RS232 connector on the back of the PC.

Installing the PC Software

The software to drive the Paxar family of printers is covered in separate
documentation. The "Formatter" software to create formats by the customer for the
Paxar 656 / 636 printer is a Windows application. The original software "Selfform"
will not create formats for the 656 / 636. The new "Formatter" package is capable of
making formats for all Paxar control printers.

The original DOS version of "PCMate" has been updated to drive the 656 / 636
printer. PCMate DOS version 3.05 or later needs to be used.

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

Users Manual Model 656/636 Printer Setup • 9

Product Description

Printer Description

The PAXAR MODEL 656 / 636 THERMAL PRINTER (Figure 2) is an electronic
printer that can print on Fabric Tapes, Card Stock, Heat Seal Stock and Pressure
Sensitive roll stocks. This printer interfaces to a computer or a main frame system
that allows the customer to print computer input or even design a label with
PAXAR’S PCMate Plus's "FORMATTER" 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 2 PAXAR MODEL 656 / 636 LABEL PRINTER

10 • Product Description Users Manual Model 656/636

Personal Computer Specifications

This specification describes the hardware and application software requirements for
the Personal Computer that is connected to the PAXAR 656 / 636 Printer.

The PAXAR 656 / 636 Printer uses a DOS Version of PCMate or a Windows
version of “PcMate Plus / Formatter ”. These applications 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® 95 or higher (Including Win 2000, ME, and NT)

- 16 Megabytes RAM (minimum) - 32 Megabytes recommended

- 50 Megabytes (minimum) free disk space

- Pentium or Pentium Type processor - 200 Mhz or higher

- 3-1/2" floppy drive

Refer to your specific software package for proper installation procedures.

Unit 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

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

Interface

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 standard domestic
300 DPI x 300 DPI standard internationally

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 International Set
.200" (5.1mm) x .200" (5.1mm) (240 DPI) (4 care symbols per 1" (25.4mm))
.156" (3.9mm) x .187" (4.8mm) (300 DPI) (5 care symbols per 1" (25.4mm))

All rotations 0°, 90°, 180°, 270°

pre-printed pressure sensitive

PAXAR PCL via RS232 serial port - 9 pin D-shell
Verifier serial port - 8 pin MicroDin

Users Manual Model 656/636 Product Description • 11

Control

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

Panel

Dimensions

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

Weight 57 Lbs. ( 26Kg.)

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

Temperature

41°F (5°C) to 104°F (40°C)

Humidity 5% to 90% non-condensing

Other
Features

- Downloading of information while machine 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, guard open, full stacker, 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

Ink Ribbon PAXAR standard thermal colors and widths

Options

- VL70 Barcode Verifier System

- Rewind Unit (110V or 220V)

- Reflective Sensor (Back of Web Only)

- PCMate

- SELFFORM

- Spare Parts Kit

- International Hardware Kit

12 • Product Description Users Manual Model 656/636

Printer Operation

Installing Ink Ribbon

NOTE: WHEN THIS MACHINE IS TURNED ON FOR THE FIRST TIME,
A PAXAR FIELD ENGINEER MUST BE PRESENT.

Figure 2

(Threading path)

The ink ribbon comes pre-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 below for loading the ink.

1) Unwrap the ink ribbon and put it on the ink-ribbon supply arbor (Figure 2) 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 below and is
threaded as illustrated (see Figure 2).

NOTE: A new ink ribbon has a leader which 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-ribbon take-up arbor. The ink
take-up core must be at least as wide as the ink supply. The tape on the supply
roll of ink will be used to fasten the leader to the core.

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

5) Lower the take-up arbor into place. You will have to rotate the ink arbor as the
swing arm is returned to the drive roller to keep excess slack ink from between
the print head and the take up roller.

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

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

Users Manual Model 656/636 Printer Operation • 13

Loading Stock

Ink Take-up

Stock out

Decurler

FIGURE 3 STOCK THREADING

LOADING STOCK FOR THE FIRST TIME

1) Slide the outboard stock guide to a position wider than the roll of stock to be
loaded. Set the stock roll core over the outboard guide and slide the roll to the
back guide. Move the outboard stock guide in until it contacts the stock roll.

2) 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 material was glued to the core, cut off all material that has glue on

any surface.

3) Open the print head by pressing the release lever.

4) Open the web guide just before the print head platen roller to a width wider than
the stock to be used.

5) With the cover in the up position, slide the leading edge of the stock through the
lower guide that also contains the sensor system. Keep the stock to the back of
the printer as the unit is a back justified printer.

6) As the stock exits the sensor area, continue to slide the stock through the
print station. At this point you may need to direct the edge of the stock
below the ink drive roller.

7) With the feed roller open, slide the stock through the two feed rollers, aux. feed
and through the knife into the stacker approximately 1/2 to 3/4 of an inch.

8) Check that the stock is still to the back of the printer.

9) Adjust the front web guide, just in back of the platen roller, until it just misses the
front guide. This is to allow for the slight tolerance variation in the stock.

10) Close the feed roller and the print head station.

11) Rewind any loose stock onto the supply roll.

14 • Printer Operation Users Manual Model 656/636

Butt Splice

NOTE: DO NOT RUN BUTT SPLICES THROUGH THE PRINT STATION

The PAXAR 656 / 636 has been designed with the operators need to change supplies
quickly in mind. Re threading the stock is quicker than butt splicing. If you have
determined a butt splice is necessary, tape the free end of the new stock roll & the
free end still in the printer together. Make sure you have determined how the new
roll will go on the printer to prevent any twist in the stock.

Following the procedure previously outlined, load new supply roll onto the printer.
Remove all slack by rotating the supply roll counterclockwise. Advance splice
beyond the print station. This can best be accomplished by using the stock feed
function switch combination (see push button description in Control Panel section).

NOTE: Whenever stock of a different type or width is put on the printer, a sample
run should be performed. If the print quality is acceptable, you can immediately
begin your production run. If the print quality needs to be optimized, refer to the
Setup Procedures and perform the procedure needed to make the necessary
improvement.

Web Guide Adjustment

The Paxar 656 / 636 printer has been designed with the operators needs in mind.
Therefore there are only two web guides in the printer that may need to be changed
as the width of the rolls change for formats. Neither of these adjustments require a
tool. Guide adjustments have already been covered in the stock loading procedure.

The first guide is on the roll support bar. The front guide must be slid to the back of
the printer to hold the supply roll against the back guide plate. Place your thumb
against the round stub close to the support bar. Push the guide until it firmly
contacts the front of the supply roll. This will hold the supply against the back
guide. This completes the adjustment for this guide.

The second guide is located just to the left of the print head and platen roller. This
guide must be set close to the front edge of the card stock but must not pinch the
edges. If the guide is too tight, the card stock will have rolled up edges. To move
this guide place your finger to the inside or the guide opposite the guide pressure
screw and pull to widen the opening. To close down the opening, place your thumb
against the side of the pressure screw to slid the guide in.

NOTE: THE BACK EDGE OF THE WEB GUIDES HAVE BEEN FACTORY
SET. CHECK THAT THE FORMAT HAS BEEN MADE CORRECTLY BEFORE
MAKING FURTHER ADJUSTMENTS.

There are two independent adjustments and one fixed back guide. The one fixed
back guide is opposite the platen roller guide. This has been located to control the
edge of the stock to the first dot on the print head. This location is critical to Paxar's
Formatter software. Do not adjust this guide with out consulting a Paxar service
engineer.

The adjustable back guide is located on the back of the stock support bar. This
guide is moved by loosening the button head screw located to left of the support bar.
Loosen the screw and slide the forward or back as needed. The ideal location is to
measure from the front of the plate 31/32" (24.6mm) back to the housing.

Users Manual Model 656/636 Printer Operation • 15

The only other adjustment for the back of the web is the back stacker up-right rail.
To move the location of the up-right loosen the knob under the stacker and slide the
unit in or out as needed. The up-right rail should be located approx. 1/16" (1.5mm)
to the back of the label or tag as it enters the stacker.

Print Head Open / Close

The print head module is to be opened and closed for threading the stock and ink.
The unit must also be opened to clean the head and for print head replacement.
Later in the manual, under separate heading, 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 GUARD
OPEN. Both the top cover and head use the same command.

WARNING: DO NOT TOUCH THE PRINT HEAD WITHOUT WEARING THE
ANTI-STATIC GLOVES AND THE STATIC WRIST STRAP.

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

Figure Print Head Open / Closed

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

16 • Printer Operation Users Manual Model 656/636

Control Panel Operation

Printer Controls

Start

Feed

Test

- Starts the printer

- ON LINE light must be GREEN

(Batches downloaded to be printed)

- 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 continuos strip

- Stock moves through without printing

- Ink will not advance, ink save on the 656 / 636 will automatically be
activated.

- The print head must latched in the down position.

- TEST and START must both be used

Users Manual Model 656/636 Control Panel Operation • 17

Stop

- 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 continuos strip

- Stock moves through with test pattern printing

- The ink will advance with the stock.

- The print head must be latched in the down position.

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

18 • Control Panel Operation Users Manual Model 656/636

Indicator Lights

The Paxar 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 it's power - up sequence.

- Failed the system test

After Power Up Sequence:

ORANGE

GREEN

Sensor

GREEN = "C" SENSOR

Error

- Printer is running.

- System is operational

- Ready for batches to be downloaded

- batches to print, ready to start

- Printer is stopped, - light is on, - sensor is setting over a web sensor
mark

- 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

ORANGE

- System inter-lock triggered, display for error.

Users Manual Model 656/636 Control Panel Operation • 19

Front Panel Menu Functions

Ready For Batches

Î

Print Reports

ÐÐÐ Ð

Î

Setup

Î

Life Counts

Î

Protected Features

Last Verifier Scan Print Position Label Counter Set Date / Time

ÐÐÐ Ð

Verifier History Cut Position Total Labels Change Password

ÐÐÐ Ð

Verifier Setup Cutter Enable /

Total Inches Change Language

Disable

ÐÐ Ð

Clear Verifier Scan

Adjust Strobe Verifier Enable /

Memory

Ð

Change Emulation

Mode

Disable

Ð

Change Ink

Transfer Type

Ð

Checkout Format

20 • Control Panel Operation Users Manual Model 656/636

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.

Diagnostic Tests

During power up the following tests and screens will be displayed.

ENGLISH ONLY VXX.XX

DIAGNOSTIC TEST 1

This screen is displayed during the Control Panel test.

This screen will be displayed while the Front Panel is initializing and waiting for the
TCB response. The top line will display the FRONT PANEL code version and the
machine language (ENGLISH,GERMAN,SPANISH ETC). For example if German
were the second language installed the screen would look as follows:

GERMAN / ENGLISH VXX.XX

DIAGNOSTIC TEST 1

The code will check the functionality of the LED's and the display. Each state of
the LED's will be checked - (red, green, amber and off). The code will check the
LCD display 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:

(BUTTON NAME) KEY STUCK

DIAGNOSTIC TEST 1

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 Control Board (TCB). If all tests are complete and no errors detected, then
the system will go to DIAGNOSTIC TEST 2 and display the TCB code version.

CONTROLLER VXX . XX

DIAGNOSTIC TEST 2

This screen should be displayed once the TCB has requested signon from the Front
Panel and the system is waiting for the AT to complete its initialization.

Users Manual Model 656/636 Control Panel Operation • 21

HOME SCREEN

READY FOR BATCHES

IMAGER VXX . XX

OR

BATCH ID QTY

PCL001 000000010

When the printer is powered up and all initializations are complete, and if there are
no Batches to print, the HOME screen will be “READY FOR BATCHES" and the
A.T. code version number (IMAGER VXX.XX) will be displayed.

When at the "READY FOR BATCHES" screen, and the HOST is mapping, the
screen will display :

BUILDING IMAGE

IMAGER VXX . XX

When at the "READY FOR BATCHES" screen and there are no batches and the
"ENTER" key is held down the screen will display the last batch printed (if any).

LAST BATCH WAS XXXXXXX

IMAGER VXX . XX

When there are Batches to be printed the HOME screen will be "BATCH ID QTY"
screen, the Batch ID / Batch Qty screen will display the currently cutting batch ID
and labels left to cut.

If the printer is performing a FEED or a TEST pattern this screen will show
"FEEDING" or "PRINTING TEST PATTERN" respectively on line two.

PAXAR 656/240

IMAGER VXX . XX

This is the MACHINE ID screen. This screen shows the machine model - (656 or

636) and the print head type - (240DPI or 300 DPI). This screen will momentarily
appear whenever the EXIT / Up arrow is pressed, and there are batches to be printed.

After this momentary display, the "HOME" screen is again displayed.

Pressing the MODE / Down Arrow key will take the user to the next screen.

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

22 • Control Panel Operation Users Manual Model 656/636

Display Modes

There are four (4) main mode levels which 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 REPORTS

PRESS ENTER FOR

SETUP

PRESS ENTER FOR

LIFE COUNTS

PRESS ENTER FOR

PROTECTED FEATURES

Use the EXIT ↑ to move to the HOME screens.

Print Report Mode

Use the Mode ↓ key to move to the following screen.

PRESS ENTER FOR

PRINT REPORTS

Use the Enter ↵ key to enter this mode.

PRESS ENTER TO

PRINT LAST VERIFIER SCAN

This is the first screen under Reporting features. This screen will appear if
a verifier is connected to the printer. This screen allows the user to print the
last scan report.

Prints the failure cause for the last bad barcode scan.

Users Manual Model 656/636 Control Panel Operation • 23

PRESS ENTER TO

PRINT VERIFIER HISTORY

This screen follows the PRINT LAST VERIFIER SCAN screen if a verifier
is connected to the printer. This screen allows the user to print history
report of the scanner reads.

Prints a report of the history of barcode scan quality.

PRESS ENTER TO

PRINT VERIFIER SETUP

This screen follows the PRINT VERIFIER HISTORY REPORT screen if a
verifier is connected to the printer. This screen allows the user to print a
verifier report containing verifier setup information.

Prints a report of all verifier current settings.

ENTER TO CLEAR

VERIFIER SCAN MEMORY

This screen follows the BARCODE VERIFIER ON screen if there is a
verifier connected to the printer. This screen allows the user to clear the
scan history memory in the verifier.

Pressing ENTER clears the verifier scan history.

Pressing the MODE ↓ key will take the user to the Strobe adjust screen.

Pressing the EXIT ↑ key will take the user back to the HOME screen.

Setup Mode

Use the Mode ↓ key to move to the following screen.

PRESS ENTER FOR

SETUP

Use the Enter ↵ key to enter this mode.

CHANGE PRINT

PRINT: 0 NEW PRINT: + 2

For 300 and 240 dpi machines = .016" increments.

Use the <YES key to decrease the number and the > NO key to increase
the number.

Adjustment from - 9 to + 10. Zero is the middle of the range

Use the Enter ↵ key to save the new value

24 • Control Panel Operation Users Manual Model 656/636

Use the Mode ↓ key to move to the following screen.

CHANGE THE CUT

CUT: 0 NEW CUT: -2

Each increment for 300 dpi machine = .026"

Each increment for 240 dpi machine = .025"

Use the <YES key to decrease the number and the > NO key to increase
the number.

Adjustment from - 9 to + 10. Zero is the middle of the range

Use the Enter ↵ key to save the new value

CUTTER IS DISABLED

PRESS ENTER TO ENABLE

This screen allows the operator to turn the cutter ON or OFF.

Press the Enter ↵ key, this will toggle between the enable / disable mode.

The screen will display the cutter status on the first line.

The knife motor will continue to run. If the printer is used in the rewind
mode only, the knife motor plug may be disconnected.

CHANGE STROBE

STROBE: 0 NEW STROBE: +2

0 = Recommended center position, adjustable to ± 7 settings.

Use the <YES key to decrease the number and the > NO key to increase
the number.

Use the Enter ↵ key to save the value and move to the next number.

Recommend cleaning the head, adjusting head tangent and setting head
pressure before changing this strobe setting.

EMULATION MODE:630

NEW EMULATION MODE:650

This screen follows the STROBE ADJUST screen. This screen allows the
selection of an emulation mode. The 656 / 636 is capable of emulating
other PAXAR printers. When in this mode, the 656 / 636 will produce PCL
tags as close as possible to the tags produced by the printer being emulated.
Formats designed for the 656 / 636 can not be printed on the older printers,
but formats designed for the older printers emulated by the 656 / 636 can be
printed on the 656 / 636 printer.

Compatibility Notes:

• If the dpi of the 656 / 636 printer does not match the emulating printers

dpi, then certain field types such as barcodes, logos, care symbols will
not be the exact size of the fields printed on the older printer.

Users Manual Model 656/636 Control Panel Operation • 25

• The 650 printer is center justified, meaning the web is centered under

the printhead. The 656 / 636 is a back justified printer, meaning the
web is to the back of the printer. This will not cause a discrepancy
unless the web of the stock does not match the web defined in the
format.

• The verifier will be setup to a specific setting when a verifier is

present. The verifier can be disabled from the front panel.

The <YES / >NO buttons are used to change the emulation.

Pressing ENTER will change the current emulator mode to the new
emulator mode.

Pressing the MODE/Down Arrow key will take the user to the next screen.

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

TRANSFER TYPE:052

NEW TRANSFER TYPE:000

This screen follows the EMULATION MODE screen. This screen allows
the selection of a ink and stock TRANSFER TYPE. See appendix C for
details of ink and stock combinations.

The <YES / >NO buttons are used to increment or decrement each digit.
Pressing ENTER will advance to the next digit. After changing the last
digit, pressing ENTER will change the current transfer type to the new
transfer type. Enter all three digits - including the leading zero.

Pressing the MODE/Down Arrow key will take the user to the next screen.

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

PRESS ENTER TO

PRINT CHECKOUT FORMAT

This screen follows the TRANSFER TYPE screen. This screen allows the
printing of a checkout format.

Pressing ENTER will print the checkout format.

Pressing the MODE/Down Arrow key will take the user to the next screen.

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

Life Counters Mode

Use the Mode ↓ key to move to the following screen.

PRESS ENTER FOR

LIFE COUNTS

26 • Control Panel Operation Users Manual Model 656/636

Use the Enter ↵ key to enter this mode.

Use the Mode ↓ key to move to the following screens.

LABEL COUNTER:0000000000

ENTER TO RESET

Used to count labels for a work period (example, a shift )

Enter will reset the count to "0".

TOTAL LABELS PRODUCED

0000000000

Non resettable counter.

TOTAL STOCK INCHES

0000000000

Non resettable counter.

Use the EXIT ↑ to move to the HOME screens.

Protected Mode

Use the Mode ↓ key to move to the following screen.

PRESS ENTER FOR

PROTECTED FEATURES

Use the Enter ↵ key to enter this mode.

ENTER PASSWRD (4 DIGITS)

PASSWORD 0

The Protected Feature screen will appear as shown.

Use the <YES key to decrease the number and the > NO key to increase the
number.

Use the Enter ↵ key to save the value and move to the next number.

The password is (4) numbers.

If an incorrect password is entered, the screen will display

INVALID, PRESS ENTER

PASSWORD XXXX

Users Manual Model 656/636 Control Panel Operation • 27

If password is correct, the Mode ↓ key will go to the next screen.

CHANGE DATE/TIME

01/04/95 08:55 AM

Use the < YES / >NO buttons to increment through numbers.

All 10 digits can be changed and also the A will toggle between A and P.
The date is always in the MONTH / DAY / YEAR format and the time is
always in the 12 hr AM / PM format.

Use enter to move to the next digit or to the AM / PM field.

Use the Mode ↓ key to save new time and date and move to the next
screen.

CHANGE PASSWORD (4 DIGITS)

NEW WORD 0

Use the < YES / >NO buttons to increment through numbers.

Use enter to move to the next digit.

Final enter saves new password.

PRESS ENTER

FOR 2ND LANGUAGE

Use Enter ↵ to toggle between ENGLISH and 2ND LANGUAGE.

Note: Pressing the TEST button and the MODE button at the same time
will toggle the second language from any screen.

OR

If no second language available the screen will display as follows:

NO 2ND LANGUAGE

AVAILABLE

Use the Mode ↓ key to move to the following screen.

VERIFIER IS ENABLED

PRESS ENTER TO DISABLE

Use Enter ↵ to toggle between ENABLED and DISABLE for the verifier.

Use the EXIT ↑ to move to the HOME screens.

28 • Control Panel Operation Users Manual Model 656/636

Maintenance / Adjustments

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, Paxar 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
placed in the machine.

- 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 machine upon installation and
extras may be ordered from Paxar. 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.

Users Manual Model 656/636 Maintenance / Adjustments • 29

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 cotton swab are the recommended items to use when cleaning the
printhead.

RECOMMEND PAXAR "MASTER CLEANING KIT" # 921338

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.

Procedure:

-The Printhead 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 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.

30 • Maintenance / Adjustments Users Manual Model 656/636

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 machine for easy print head removal.

3) Unplug the ribbon cable that runs to the print head. Unplug the cable by firmly,
but gently pulling it out.

4) Back the print head pressure screws off counterclockwise as far as possible.

5) 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 pulling the print
head to the right of the machine. 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.

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

7) Remove the old printhead carefully from the heat sink.

8) 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 end play. If there is end play, or
the head does not seat properly, the heat sink guide will need adjustment.

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

10) 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.

11) Reconnect the print head cable, making sure that the connector is seated tightly.

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

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

12) Replace the ink and double check your work. Power the machine on and make
sure that no adverse effects are noted. 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
chevrons. 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 Maintenance / Adjustments • 31

Print Head Adjustment

Tangent

Proper print head tangent is perhaps the most important adjustment to make. A
printhead which is not properly adjusted will result in poor print quality, poor heat
dissipation and possible ink wrinkling problems. When the machine 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 printhead.

Clean Platen Roller

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

making any judgments as to the quality of the printhead, 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 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 pressure adjusting screw
should be minimal.

If readjustment is required, proceed as follows: Power on the printer. Remove the
ink and card 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 web. Turn the pressure screw clockwise until it makes
contact with the head mount plate plus 1/2 turn to add pressure. As the web width
changes adjust the pressure screw 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 fail. Once the print is starting to fail, increase the pressure by 4 clicks. Minimum
pressure should be used when running narrow webs, wide webs require slightly
greater pressure. Additional print quality will be obtained by adjustments of the
Tangent point, (see Print Head Tangent Point)

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

32 • Maintenance / Adjustments Users Manual Model 656/636

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 printhead holder.
To remedy this problem, power off the machine and remove the print head as
outlined in the print head installation information. The printhead adjustment plate
has been manufactured so when properly adjusted the head will be square. The
printhead holder has a locator plate that must be slide up snug against the printhead
mount plate. Install the head and it should be square to the web.

Print Head Tangent Point

The print head pressure adjustment must be done with the head pressure set light.
Turn the pressure screw counterclockwise. Run a test pattern to determine the
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 lock
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 thumb screw to move the
head forward and backwards. Since the adjustment is very precise, do not turn the
thumb screw 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 further
adjustment required.

Once you have restored a smooth even test pattern, re-tighten the two print head
mount screws (Do not over tighten) and run one last test pattern.

Registration Sensor Adjustment

Adjusting Print Sensor Position

If you are running sense mark material with a hole or slot for registration:

- Open the feed roller and print head.

- Move the stock by hand in the feed direction until the registration desired is in the

slot window for the pickup sensor.

- Close both the feed and print head.

- Slide the top sensor assembly using the sensor handle while looking at the

registration index sensor. When the light turns on, and stays on, the sensor is over
the registration hole.

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

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

Users Manual Model 656/636 Maintenance / Adjustments • 33

- Check that the front web guides have been positioned properly - both on the
supply roll and in front of the print roller.

- Check that the feed roller pressure has been set equally across the roller.

- Check to see that the print head pressure has been set properly.

- Repeat the sensor alignment procedure.

Cleaning Print Sensor

When print registration, in reference to sense mark, becomes inconsistent or erratic
the Sensor and Light Bar may need to be cleaned.

Supplies:

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

- Never use anything abrasive to the sensor and light bar.

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

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

Sensor Trim Pots

Your 656 / 636 printer is equipped with several sensors used to detect the status of
the printer and its supplies. While these sensors are calibrated at the time your
printer is manufactured, there may be times when re-calibration is required. Re
calibration times are indicated in the troubleshooting section.

The following guidelines indicate the proper procedure used to calibrate the sensors.
A voltmeter is highly recommended for this procedure, however the Bank of Lights
will provide an estimation of sensor performance until peak performance can be
achieved with a voltmeter.

Suggestion: clean all optical sensors prior to adjustment as dust and debris will
adversely effect their performance.

34 • Maintenance / Adjustments Users Manual Model 656/636

DIP Switch

p

12345678

J9 J1

R48 R50 R51 R49 R47 R54R52

11 12 13 18 16 8 10

14 17

4

Bank of

Lights

1. Top Ink Sensor

2. Bottom Ink Sensor

3. Registration Sensor

4. Opt. Reflective Sensor

5. RESERVED

6. Full Stack Sensor

7. Headlift Sensor

10. +5VDC ok

21

22

8. RESERVED

9. 24V enable

+5VDC

GND

3

9

NOTICE:

Thermal Controller Board as viewed from back of

All test point voltage measurements including sensor adjustments should be made on the DC scale
with the black lead of the meter connected to the ground test point 22. Care should be taken to
ensure that meter leads do not short against unintentional test points throughout the measurement
procedures.

rinter

Hole / Slot Index Registration Sensor

Sensor Blocked Sensor Not Blocked

Test Point:

Adjustment Pot

#3 Light Status:

Desired Voltage:

The Hole / Slot Registration Sensor in conjunction with the light bar allows the printer to register to
preprinted media. The low level is the more crucial of the two adjustments. Note that the same pot is
used for both adjustments and a compromise value must be achieved. Begin by removing the stock
from the sensor path. Measure the low voltage throughout the mechanical travel of the sensor by
sliding it inboard and outboard. The voltage at all points should not vary more than 0.75VDC. If it
does the sensor slide bar and or the light bar must be mechanically aligned (see Hole / Slot Index
Registration Sensor Mechanical Adjustment below). Once this is achieved find the web location
where the low voltage is the highest and adjust the pot until the reading is 0.75VDC or less. Now
block the sensor path with the media you intend to run. The high level should be greater than 3.5VDC
at all points of the sensor’s travel.

TP13 TP13

R51 R51

On Off

> 3.50 VDC < 0.75 VDC

Hole / Slot Index Registration Sensor Mechanical Adjustment:

There are two areas that can be adjusted to correct the voltage readings. The upper sensor square bar
may be loosened from the back of the printer and rotated. The second adjustment is to loosen the light
bar mount screws and move the bar in the web direction. When the light bar screws are retightened be
careful not to over tighten and brake the light bar PC board.

Users Manual Model 656/636 Maintenance / Adjustments • 35

Reflective Index Registration Sensor

Sensor on Plain Stock;

Not on Mark

Test Point:
Adjustment Pot
#4 Light Status:

Desired Voltage:

The Optional Reflective Registration Sensor, if installed, allows the printer to
register to preprinted media by detecting a black mark. Begin by placing the stock
so that the black mark is not in the sensor's sight path and adjust the pot until the
high value is achieved. Then place the stock so that the black mark is directly in
front of the sensor's sight path and adjust until the low level is met. The low level is
the more crucial of the two adjustments.

NOTE: The same pot is used for both adjustments and a compromise value must be
achieved.

TP8 TP8
R47 R47

On Off

> 3.50 VDC < 0.75 VDC

Sensor Directly on

Mark

Film Out Sensor / Top Ink Sensor

Sensor Blocked Sensor Not Blocked

Test Point:
Adjustment Pot
#1 Light Status:

Desired Voltage:

TP12 TP12

R50 R50

On Off

> 3.50 VDC < 0.75 VDC

The Film Out Sensor allows the printer to monitor the availability of ink. Begin by
blocking the sensor with the ink intended for use and adjust the pot until the high
value is achieved. Then remove the ink from the sensor and adjust until the low
level is met. The low level is the more crucial of the two adjustments.

NOTE: The same pot is used for both adjustments and a compromise value must be
achieved.

Bottom Ink Sensor

Sensor Blocked Sensor Not Blocked

Test Point:
Adjustment Pot
#2 Light Status:

Desired Voltage:

The Bottom Ink Sensor is not available at this time and is reserved for future
expansion.

TP16 TP16

R49 R49

On Off

> 3.50 VDC < 0.75 VDC

36 • Maintenance / Adjustments Users Manual Model 656/636

Headlift Sensor

Sensor Blocked Sensor Not Blocked

Test Point:

Adjustment Pot

#7 Light Status:

Desired Voltage:

The Headlift Sensor allows the printer to register the platen roller on 656 printers.
Begin by rotating the platen roller until the flag is blocking the sensor. The platen
roller has been slotted to accept a regular screwdriver on the front of the machine to
assist in this operation. Adjust the pot until the high value is achieved. Then rotate
the platen roller until the flag is no longer blocking the sensor. Adjust the pot until
the low level is met. The low level is the more crucial of the two adjustments.

NOTE: The same pot is used for both adjustments and a compromise value must be
achieved.

TP18 TP18

R52 R52

On Off

> 3.50 VDC < 0.75 VDC

Full Stacker Sensor - Jam Sensor

Sensor Blocked Sensor Not Blocked

Test Point:

Adjustment Pot

#6 Light Status:

Desired Voltage:

The Full Stacker Sensor allows the printer to detect a full load of labels in the
stacker. The stack full condition will be detected by a switch and will stop the
machine when the stacker is full. The Jam Sensor feature will detect each cut label
as it leaves the cutter. If a cut fails to occur, the machine will stop. To adjust the
jam sensor, block the sensor and adjust the pot until the high value is achieved.
Remove the block from the sensor and adjust the pot until the low level is met. The
low level is the more crucial of the two adjustments.

TP11 TP11

R48 R48

On Off

> 3.50 VDC < 0.75 VDC

NOTE: The same pot is used for both adjustments and a compromise value must be

achieved.

Stock out Adjustment

The stock out sensor has been set at the factory, however for some stocks it may be
necessary to adjust the sensor to detect stock out. With a full roll of stock loaded in
the machine, run the printer and observe how far behind the stock (to the left of the
stock) the stock out wire rod is located. This should be between 1/4 and 1/2 inch (6
to 12mm) behind the running stock. If not, loosen the set screw and rotate the wire
to the acceptable distance and re tighten.

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 re tighten.

Users Manual Model 656/636 Maintenance / Adjustments • 37

Stacker Adjustments

The stacker has four adjustments which can be made without a tool to accommodate
different types of stocks.

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). Re tighten.

Stock Width Adjustment

Loosen the two thumb screws behind the stacker uprights and adjust the stacker
upright nearest to the operator to the desired stock width position. Re tighten.

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. Re tighten.

Stacker Full Adjustment

The sensor on the inboard stack up right is used to stop the printer when the stack is
full. A thumb screw adjustment is provided to set the stack height. Warning, some

stock materials can not be stacked to the full height of the stacker because of
excessive weight.

Stock Feed Adjustment

When changing stock type, the stock feed should be readjusted. This is important to
reduce any slip for too light an adjustment and reduce excessive roller wear for too
tight an adjustment. To adjust, loosen the two top set screws using the 5/64 Allen
key in the kit. With the new stock in the drive roller, fully close the stock feed lever
(rotate fully counter-clockwise). Tighten both set screws until there is slight pressure
on the stock. Run the one inch pull format and adjust the set screws an equal amount
based on the results. If the one inch label measures less than one inch, tighten
(clockwise) each screw slightly and repeat the measurement. It the one inch label
exceeds one inch, loosen (counter-clockwise) the tension on both set screws equally.
As a final check for stock feed balance between in board and outboard, the inboard
edge of the stock should be 31/32" (24.6mm) from the main vertical support plate of
the printer. To move the stock inboard, away from the operator, loosen the inboard
set screw slightly. This can be done while running the unit. To move the stock
outboard, toward the operator, loosen the outboard set screw slightly.

38 • Maintenance / Adjustments Users Manual Model 656/636

Mechanical Adjustment Of Feed Roller Pressure (Blue
Roller)

General

The blue 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. These bearings are supported by compression springs and controlled by set
screws located in the top of the bearing mounts.

Adjustment Procedure:

1) Release eccentric control lever and remove stock.

2) Using a piece of the same stock being run as a "feeler" gauge, adjust set-screws
until "feeler" gauge just slides between rollers evenly across width of rollers with
pressure eccentric lever closed.

3) Release pressure and rethread. Further equally adjust set-screws (2) clockwise
1/2 - 3/4 of a turn. Close pressure lever.

4) Operate machine. Minor adjustments can now be made to the set-screws to cause
stock to run 31/32" (24.6mm) from upright frame.

Mechanical Adjustment of Stock Sense - Mark Light
Receiver

General

The receiver for light from the LED emissions bar for stock registration is mounted
on a square shaft directly above the web guide plate assembly, just prior to the print
module. Although this bar is factory adjusted prior to shipment, it may be necessary
to readjust the bar to assure proper light reception.

Adjustment Procedure:

1) Remove machine rear cover.

2) Slide receiver block to the rear of the square bar.

3) Thread pre punched stock through web guide and adjust outer guide to lightly

touch outer edge of stock.

4) Move stock until pre punched hole is visible in slot above LED bar.

5) Slide receiver block out until it is located approximately over the hole. (accurate

adjustment forward and back can be accomplished when printer is electrically
activated.)

Users Manual Model 656/636 Maintenance / Adjustments • 39

Electrical Connections

Machine Wiring

Orange

Orange

Orange

Red

Brown

Brown

Orange

Gray

THERMAL CONTROL BOARD

HEAD DRIVER BOARD

Gray

Orange

Red

Orange

Brown

REAR VIEW OF 656

Users Manual Model 656/636 Electrical Connections • 41

Black

Power

Relay Assembly

Part #

351136

42 • Electrical Connections Users Manual Model 656/636

Electrical System Schematic

Users Manual Model 656/636 Electrical Connections • 43

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 illustrates
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 back
side 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.

44 • Electrical Connections Users Manual Model 656/636

Electrical Trouble Shooting

Power Up / Sign On / Communications

Problem Probable Cause Corrective Action

Machine fails to power up with no

light present in the AC power
switch.

Machine fails to power up with light

present in the AC power switch.

1) Incorrect power amplitude. 1) Confirm that the AC entry is
configured for the line voltage
intended to be applied to the
machine. Failure to do so can
damage the machine's internal
power supply. Refer to the "Fuse
Configuration".

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

2A) Confirm that the outlet the

machine is plugged into has power.

3) Missing or blown fuse(s) 3) Check that the fuse(s) located
inside the AC entry are present and
intact. Replace as needed. Refer to
the "Fuse Configuration".

1) Unconnected cable / connector

inside machine.

2) Thermal Control Board unplugged

from the Mother Board

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 supply. Refer to the
"Electrical System Schematic".

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

Front panel displays no text or

nothing at all.

Users Manual Model 656/636 Electrical Trouble Shooting • 45

1) Front panel cable unplugged. 1) Power off and remove the power
cord from the AC entry. Remove
the back cover and inspect the
cable and connectors to and from
the front panel. Refer to the
"Electrical System Schematic".

Problem Probable Cause Corrective Action

Front panel does not complete

diagnostics test 2.

Machine does not receive batches. 1) Serial communications cable loose

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

2) Relay unplugged or faulty. 2) Power off and remove the power

3) PCMCIA cartridge not inserted
correctly in optional PCMCIA
slot.

or unconnected.

2) Machine not powered on or has
not completed diagnostics tests.

3) Data sent to wrong printer. 3) In PCMate change to the printer

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

cord from the AC entry. Remove
the back cover and inspect the
cables and connectors to and from
the relay. Refer to the "Electrical
System Schematic" and "Relay
Assembly".

3) Insert a PCMCIA cartridge with
the arrow up and towards the front
of the machine so that the ejector
button pops out.

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

2) Power machine on and wait until
machine displays "Ready for
batches". Re download data.

the data is intended to be sent.

4) Configuration incorrect in
PCMate.

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

6) Jumpers not configured correctly. 6) Contact Paxar Service.

4) Re configure PCMate for Paxar
PCL printer as per your PCMate
manual.

46 • Electrical Trouble Shooting Users Manual Model 656/636

Stock / Ink Advance

Problem Probable Cause Corrective Action

Stock 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 machine with start
automatically).

2) An interlock condition exists. 2) 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 910 Stock Out"
reload stock).

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

4) Thermal Control Board unplugged

or faulty.

5) Feed roller not gripping stock. 5) Adjust the feed pressure. Refer to

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

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

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

"Mechanical Adjustment Of Feed
Roller Pressure".

rollers turn freely.

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

Users Manual Model 656/636 Electrical Trouble Shooting • 47

Problem Probable Cause Corrective Action

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 machine with start
automatically).

2) An interlock condition exists. 2) 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 910 Stock Out"
reload stock).

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

4) Thermal Control Board unplugged

or faulty.

5) Ink roller bound. 5) With power off check that all

6) Ink bound. 6) With the print head open check

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

rollers and arbors turn freely.

that the ink will pull through the
printer with little to no resistance.

48 • Electrical Trouble Shooting Users Manual Model 656/636

Print

Problem Probable Cause Corrective Action

Machine advances stock but does not

print.

Machine stops after ever third label. 1) Stock registration sensor miss

1) Stock registration sensor miss
aligned.

2) Miss adjusted print head position. 2) Set print head position. Refer to

3) Miss adjusted print head pressure. 3) Set print head pressure. Refer to

4) Print head cable unconnected or
faulty.

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

6) Head Driver Board unplugged or
faulty.

aligned.

2) Stock registration sensor
uncalibrated.

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

"Print Head Tangent Point".

"Print Head Pressure Setting".

4) Power off the machine and
reinsert the offending connector
or replace cable.

6) 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 slot or hole
passes under the sensor.

2) Using TP13 and R51 on the
Thermal Control Board re
calibrate the sensor. Refer to
"Sensor Trim Pots".

Print registration is off in the feed

direction.

Users Manual Model 656/636 Electrical Trouble Shooting • 49

1) Feed pressure setting is off. 1) Set feed pressure. Refer to
"Mechanical Adjustment Of Feed
Roller Pressure".

2) Print position is incorrect. 2) Enter the setup menu and readjust
the print setting as needed.

3) Field(s) position incorrect in the

format.

4) Bound platen roller. 4) Check that the platen roller turns

3) Using formatter check and
readjust the field(s) position(s) as
needed.

freely on it's shaft. If it does not
replace it.

Problem Probable Cause Corrective Action

Print registration is off in the web

direction.

Print contrast is too light or dark. 1) Incorrect strobe setting selected in

Voids in print image in the feed

direction.

1) Machine incorrectly threaded. 1) Check and rethread the media as

2) Web guides incorrectly adjusted. 2) Check and adjust as needed. Refer

3) Unwind incorrectly adjusted. 3) Check and adjust as needed. Refer

4) Incorrect DIP switch settings on
the Thermal Control Board.

the format.

2) Incorrect strobe setting in the
machine setup.

3) Miss adjusted print head position. 3) Set print head position. Refer to

4) Miss adjusted print head pressure. 4) Set print head pressure. Refer to

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

needed. Refer to "Loading
Stock".

to "Web Guide Adjustment".

to "Web Guide Adjustment".

4) Check and reset DIP switches as
needed. Refer to "TCB Dip
Switch S2 Settings".

1) Using Formatter check and adjust
the strobe setting according to the
media and ink being used.

2) Enter the setup menu and readjust
the strobe as needed.

"Print Head Tangent Point".

"Print Head Pressure Setting".

to achieve full ink coverage over
all fields on the format.

Machine continually stops with an

erroneous interlock condition.

2) Print head dirty. 2) Power off the machine clean the
print head and platen. Refer to
"Print Head Cleaning".

3) Faulty print head. 3) After cleaning head and running
the test pattern to confirm that a
void still exists, replace the print
head.

4) Miss adjusted print head position. 4) Set print head position. Refer to
"Print Head Tangent Point".

5) Miss adjusted print head pressure. 5) Set print head pressure. Refer to
"Print Head Pressure Setting".

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

1) Sensor uncalibrated. 1) Determine which sensor and re­calibrate as needed. Refer to
"Sensor Trim Pots".

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

3) Ink sensor type (light / dark)

incorrect in the format for the ink
type being used.

3) Either change the ink or the ink
type in the format.

50 • Electrical Trouble Shooting Users Manual Model 656/636

Cut / Stack

Problem Probable Cause Corrective Action

Machine fails to cut labels (the rotary

knife does not rotate).

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

1) The cut is disabled in the setup
menu.

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

3) Knife jammed causing auto
resetting fuse to trip on the
Thermal Control Board.

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

5) Faulty knife motor drive circuit on
the Thermal Control Board.

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

3) Stacker jammed causing auto
resetting fuse to trip on the
Thermal Control Board.

1) Enable the knife in the setup menu
via the front panel..

cord from the AC entry. Remove
the back cover and inspect the
cable and connector to the knife
module. Refer to the "Electrical
System Schematic".

3) Remove cause of jam at the knife.

5) Replace the Thermal Control
Board.

cable in the stacker port on the
Thermal Control Board.

3) Remove cause of jam at the
stacker.

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

3) Replace the Thermal Control
Board.

Users Manual Model 656/636 Electrical Trouble Shooting • 51

Electrical Trouble Shooting / Machine Set Up Sequence

If the printer is mechanically operable, proceed as follows:

1) Power off the printer, remove the media and ink and thoroughly clean it 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 instructions section in the manual.

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

3) Power on the printer. After passing diagnostics test one and two the front panel
will display READY FOR BATCHES.

4) Arrow down to the setup mode and press enter. Set the print, cut, and strobe to 0.

5) From the host PC download a batch of 1000 labels using the 6X6 setup format 92.

6) Adjust as needed the print head position and then pressure for optimum print
quality. Refer to the Print Head Adjustment section in the manual. If the machine
will not pull stock for this step refer to step number seven.

7) Adjust the feed pressure to pull 11.0" +- .032" of media. Refer to the Stock Feed
Adjustment section in the manual. After the machine is pulling the correct amount
of media, measure the distance between the top of the media and the tracking line.
This distance must be .5" +- .032" through out the label. If it is not, first check and
adjust as needed the unwind core guide, and the web guide, then if needed adjust
the feed pressure from side to side until it is. Re-verify that the label is 11.0" in
length. 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 referring to the Knife Square Adjustment section in
the manual.

9) Using the front panel adjust the physical cut to be 1.0" +- .032" from the cut line
on the label. The machine is now ready for production formats at which time the
operator should need only to adjust the print, cut, and strobe via the front panel.

NOTE: If the machine 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.

52 • Electrical Trouble Shooting Users Manual Model 656/636

Mechanical Trouble Shooting

Stock

Problem Probable Cause Corrective Action

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

web guides

Machine fails to stop at end of roll. 1) Incorrect adjustment of stock-out

switch trigger arm.

Stock does not pull smoothly through

printhead module.

1) Web guide in sensor plate
incorrectly adjusted.

2) Stock is slipping in drive or drive
pressure is uneven.

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

2) Adjust rear web guide to 31/32"
(24.6mm) from case surface to
guide surface touching roll.

3) Adjust outer web guide to touch
stock roll but not pinch the roll.

1) Adjust stock-out switch arm to
approximately 3/4" (19mm) from
back side of stock when threaded
through machine.

1) Adjust moveable web guide to
touch outer edge of stock with rear
edge touching rear web guide. Do
not pinch.

2) Remove stock from drive rollers.
Using a piece of stock the same
thickness as the stock being run as
a "feeler" gauge, adjust set screws
in drive endplates clockwise until
"feeler" gauge barely slides
between rollers with pressure lever
closed. Rotate set screws
clockwise an additional 1/2 - 3/4
turn. Rethread and operate. Minor
adjustment can now be made to
cause stock to run 31/32"
(24.6mm) from upright frame.

Users Manual Model 656/636 Mechanical Trouble Shooting • 53

Problem Probable Cause Corrective Action

Cracks or craze marks appear on face

of finished labels.

Stock jams in bridge blade rollers or

knife area.

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

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

NOTE: Stock-out switch rod may

have to be readjusted after moving
decurler.

1) Knife mounted bridge blade too

close to stationary bridge blade.

2) Knife not cutting full width of

stock.

3) Stacker not operating or nip rollers

not turning.

2) Stacker position on machine too

far forward so labels go under rear
stacker rail.

1) Loosen screws in upper knife
securing bridge blade roller
assembly and slide up (holes in
blade are slotted) until rollers just
contact stock. Tighten screws.

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

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

2) Loosen stacker mounting knob
and move stacker toward rear of
machine - tighten.

3) Incorrect rail position or stacker
bed angle.

Knife will not cut or partial cut 1) Incorrect pre-load on clutch pawl. 1) With back cover removed and

2) Partial cut 2) Loosen shear adjustment screws

3) 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.

power off - operate solenoid by
hand. When lever is moved, clutch
pawl should move counter­clockwise about 1/32" (0.79mm)
with the "pac-man" in home
position. If not - loosen "pac-man"
set screws and readjust "pac-man"
to stop with spring in detent.

and move outer end of knife until
full cut is obtained.

54 • Mechanical Trouble Shooting Users Manual Model 656/636

Ink

Problem Probable Cause Corrective Action

Ink wrinkles or will not pull

smoothly.

Ink rolls loosely on take-up roller. 1) Take-up roller not turning. 1) Check that roller swing arm (rear

1) Incorrect adjustment of unwind
roller brake resistance.

2) Unwind roller and ink take-up
roller misaligned.

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

4) Incorrect ink width. 4) Use an ink width no wider than

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.

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

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

of printer) is not binding and
Roundthane™ belt is not broken
or slips excessively.

2) Take-up core binding on locator
plate.

3) Take-up core not contacting ink
drive roller.

4) Take-up roller too full. 4) Remove used ink roll. It is

Users Manual Model 656/636 Mechanical Trouble Shooting • 55

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

3) Assure that take-up roll is not
binding on locator plate and
swing arm moves freely.

designed to hold only 1 full roll.

Print

Problem Probable Cause Corrective Action

Poor print - uneven or no print

(mechanical). Also see electrical
trouble shooting.

1) Incorrect printhead pressure
adjustment.

2) Broken ink. 2) Replace ink and readjust (see INK

3) Ink not rewinding. 3) Readjust (see INK trouble

1) Remove stock and ink. Close
printhead. Release pressure (2
knurled knobs). Readjust
pressure by turning knob(s)
clockwise until they just contact
printhead plate. Reinstall stock
and ink. Turn adjusters
clockwise approximately 1/8 turn
(5 clicks of knob). As machine
operates, increase pressure (2-3
clicks at a time) until best print is
obtained. Narrow webs will
require less pressure on front
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
screw in top center of printhead
plate. Lock in place with 2 outer
M3 cap screws.

trouble shooting).

shooting).

56 • Mechanical Trouble Shooting Users Manual Model 656/636

Knife

Problem Probable Cause Corrective Action

Double Cuts, extra knife cycle 1) Solenoid sticking in 1) Check proper assembly of washers.

Clean plunger with alcohol and
completely dry.

2) Worn Trip Arm on Clutch
actuator.

3) Worn Stop roll pin on clutch 3) Replace Clutch if not solved above.

Skips cut, double length label 1) Solenoid did not pull in 1) Check gap on the trip arm to clutch body

2) Trip arm sticking on clutch roll
pin.

3) Low voltage to solenoid 3) Check power supply voltage for 12 and

4) Weak solenoid driver 4) Substitute TCB. Change back if not

5) Bad Solenoid 5) Unusual, but replace Solenoid and

Noisy Rattle when not cutting but

motor turning

1) Packman not visibly homing 1) Adjust Packman to center the home

2) Replace Actuator

must be about .040 inches. If too large,
solenoid has less force. Check
assembly of spring and washers. Use
latest engineering assembly procedure.
Clean Solenoid.

2) Check for burr on trip arm catching on
clutch stop roll pin. File off burr on
clutch roll pin and/or replace trip arm.

24 volts

solved.

adjust.

location of the packman to the quiet
location. If the knife still does not
home, clean knife cams and lubricate.

If still does not home, replace blades. If

still does not home, replace clutch.

2) Packman homing ok but noisy. 2) Adjust Packman to center the home
location of the packman to the quiet
location .

3) Dirty Clutch 3) Clean clutch and one drop of light oil.

4) Packman slipping 4) Order improved set screws with multiple
points that bite better to shaft.

5) Bad Motor Gear Box 5) Replace Knife Motor

Users Manual Model 656/636 Mechanical Trouble Shooting • 57

Problem Probable Cause Corrective Action

Knife stops during cut in stock 1) Check life of blades 1) If warn and dull, may stall in stock. If

life is greater than 2 million, replace
blades.

2) Clean cams and lubricate 2) Make sure oiler is on knife. Instruct
Operator to oil weekly. Make sure oil
is available.

3) Clutch worn out and can’t stay

engaged

Slight Long and Short Tags 1) Sticking Solenoid 1) Check gap on the trip arm to clutch body

2) Sticking Trip Arm to Clutch Roll

Pin

3) Clutch has trouble picking up 3) Clean clutch and replace if not solved

Stock popping in front of knife 1) Slow knife rotation 1) Worn out blades create too much load

2) Clutch has trouble engaging and

stock runs into blades

Knife does not cycle 1) Solenoid not engaging 1) Trip knife solenoid by hand to see if

3) Replace Clutch

must be about .040 inches. If too large,
solenoid has less force. Check
assembly of spring and washers. Use
latest engineering assembly procedure.
Clean Solenoid.

2) Check for burr on trip arm catching on
clutch stop roll pin. File off burr on
clutch roll pin and/or replace trip arm.

for motor and knife slows down too
much during cut. Replace Blades.

2) Clean clutch and replace if not solved.

knife cycles. If cycles and cuts, check
cable to solenoid, check solenoid
adjustments and assembly, check gap
and replace solenoid if necessary.

2) Knife Motor Broken 2) Replace Knife Motor, good for 10
million labels by spec

3) Clutch total failure 3) Unlikely, but change if necessary

4) Solenoid Drive circuit failure 4) Replace Cable or TCB

5) Knife motor not cycling 5) Replace Cable or TCB

Continuous Knife cycling 1) Solenoid stuck in 1) Clean and adjust solenoid.

2) Circuit stuck on 2) Unplug solenoid wires from knife
module connector and should stop
cutting. If it does stop cutting, replace
TCB.

3) Very bad trip arm to stop pin on

clutch

58 • Mechanical Trouble Shooting Users Manual Model 656/636

3) Unusual, but file roll pin and replace trip
arm.

Mechanical Trouble Shooting Sequence

If the printer is electrically operable, proceed as follows:

1) Open printhead and drive pressure roller and remove stock.

2) Adjust unwind inner web guide to 31/32" (24.6mm) per instructions (See

Printer Operation - Web Guide Adjustment).

3) Take a short (2-3") (50-75mm) piece of stock you wish to run and adjust the drive
module pressure per instructions (See

Feed Adjustments).

4) Rethread machine, close drive module pressure handle. Close print module.
Release pressure on printhead adjustment knobs. Operate printer and fine tune
drive module pressure until web tracks at 31/32" (24.6mm) from back edge to
center frame.

5) Open drive pressure module, remove stock and ink and readjust print module
pressure per instructions (See

Adjustments).

6) Reinstall stock and ink, operate and make any further adjustments (sense-mark,
stock-out arm, stacker etc) per trouble shooting section of manual.

Maintenance / Adjustments - Print Head

Maintenance / Adjustments - Stock

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.

Users Manual Model 656/636 Mechanical Trouble Shooting • 59

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 "<" and ">" keys, which "Scroll" through additional errors if any.

ERROR SCREENS:
The screen advances to next error with each depression of the ">" key
The screen retreats to prior error with each depression of the "<" key

ERROR MESSAGE ERROR NUMBER

"1/10 ERRORS" 901
"STOCKOUT"

"1/10 ERRORS" 904
"INK OUT"

"1/10 ERRORS" 910
"HEAD OR FEED OPEN"

"1/10 ERRORS" 701
"MISSED SENSE MARK"

"1/10 ERRORS" 903
"DOOR OPEN"

"1/10 ERRORS" 902
"STACK FULL"

"1/10 ERRORS" 404
"HEAD OVTEMP

"1/10 ERRORS" 912
"VERIFIER HALT"

"1/10 ERRORS 911
"SYS ERRORS"

"1/10 ERRORS" 913
"DOWN LOAD ERR"

60 • Appendix A Users Manual Model 656/636

Appendix B

Software Upgrade Chip Placement Positions

Thermal Control Board P/N 351105

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

THERMAL CONTROL BOARD, Upgradeable software I.C.'s include U16 and U53.
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.

Users Manual Model 656/636 Appendix B • 61

Diskless Rom Board P/N 281164

DISKLESS ROM BOARD, Upgradeable software I.C.'s include U12, U16, and U20.
Position new I.C.'s in same orientation as pictured above.
SWITCH POSITIONS, SW1: 1 and 6 = OFF

SW2: 1 thru 4 = ON

, 2 thru 5 = ON,

Head Driver Board P/N 351106

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

HEAD DRIVER BOARD, Upgradeable software I.C.'s include U1, U2, U8, and U18.

62 • Appendix B Users Manual Model 656/636

Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.

Front Panel Board P/N 351108

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

FRONT PANEL BOARD, Upgradeable software for FPNL x.x
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.

Users Manual Model 656/636 Appendix B • 63

Appendix C

Ink and Stock Transfer Types

Value Transfer Type

051 Heat Seal & SD-1111 Ink

052 Topcoated card stock & TT-3111 Ink

053 Topcoated card stock & TT-1111 Ink

054 Topcoated card stock & HR-3111 Ink

055 Topcoated card stock & HR-1111 Ink

056 Topcoated Card Stock & TW-1111 Ink

057 Topcoated card stock & TW-1151 Ink

058 Pressure Sensitive & TT-3111 Ink

059 Pressure Sensitive Thermal Receptive & TT-1111 Ink

060 Pressure Sensitive Thermal Receptive & TW-1111 Ink

061 Pressure Sensitive & TW-1151 Ink

062 Pressure Sensitive & HR-3111 Ink

063 Uncoated Tag Stock & TT-3111 Ink

064 Uncoated Tag Stock & TT-1111 Ink

065 Uncoated Tag Stock & HR-3111 Ink

066 Uncoated Tag Stock & HR-1111 Ink

067 Uncoated Tag Stock & TW-1111 Ink

068 Uncoated Tag Stock & TW-1151 Ink

069 Fabric 2800 & TT-1111 Ink

070 Fabric 2800 & HR-3111 Ink

071 Fabric 2800 & TT-3111 Ink

072 Fabric 2800 & HC-3111 Ink

073 Fabric 2800 & HR-1111 Ink

64 • Appendix C Users Manual Model 656/636

Value Transfer Type

074 Fabric 2795 & TT-1111 Ink

075 Fabric 2795 & HR-3111 Ink

076 Fabric 2795 & TT-3111 Ink

077 Fabric 2795 & HC-3111 Ink

078 Fabric 2795 & HR-1111 Ink

078 Fabric 2395 & CL-1111 Ink

078 Fabric 2495 & CL-1111 Ink

078 Fabric 4000 & CL-1111 Ink

079 Coated Tag Stock & HR-4111 Ink

080 Pressure Sensitive & HR-4111 Ink

081 Uncoated Tag Stock & HR-4111 Ink

082 Fabric 2800 & HR-4111 Ink

083 Fabric 2795 & HR-4111 Ink

084 New Pressure Sensitive (no xfer) & TT-3111 Ink

085 New Pressure Sensitive (no xfer) & TT-1111 Ink

086 New Pressure Sensitive (no xfer) & TW-1111 Ink

087 New Pressure Sensitive (no xfer) & TW-1151 Ink

088 New Pressure Sensitive (no xfer) & HR-1111 Ink

089 New Pressure Sensitive (no xfer) & HR-3111 Ink

090 New Pressure Sensitive (no xfer) & HR-4111 Ink

091 Coated Tag Stock & GP-1111 Ink

092 Uncoated Tag Stock & GP-1111 Ink

093 New Pressure Sensitive (no xfer) & GP-1111 Ink

094 2800 Fabric & GP-1111 Ink

095 2795 Fabric & GP-1111 Ink

096 2795 Fabric & CT-1111 Ink

097 4800 Fabric & CT-1111 Ink

116 591SST Fabric & CT-1111 Ink

Users Manual Model 656/636 Appendix C • 65

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

66 • Appendix C Users Manual Model 656/636

Appendix D

Knife MFG Guideline

Solenoid Trigger Setting

+.000

-.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 • 67

• 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.

68 • Appendix D Users Manual Model 656/636

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

• (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 • 69

Assembly Drawings

Users Manual Model 656/636 Assembly Drawings • 71

Unwind Assembly Drawing

72 • Assembly Drawings Users Manual Model 656/636

Unwind Parts List

Item Part # Description Qty

1 353001

353005

2 353002 Bracket, Unwind 1
3 353003 Guide, Unwind Front 1
4 990089 10:32 x 1/4 Button Head 1
5 990170 5/16:18 x 3/4 Cap Screw 1
6 990277 5/16” Bellville Washer 1
7 990439 .340 x .740 Nylon Washer 1

Guide, Unwind Rear
Optional Unwind backer plate (not
shown)

1
1

Users Manual Model 656/636 Assembly Drawings • 73

Web Guide / Light Bar Assembly Drawing

74 • Assembly Drawings Users Manual Model 656/636

Web Guide / Light Bar Parts List

Item Part # Description Qty

1 188008 T-Nut 1
2 351120 Light Bar Harnessed 1
3 354006 Bracket, Web Guide Sensor 1
4 354003 Web Guide Outer 1
5 354001 Plate, Web Guide Mount 1
6 928012 Spring 1
7 990066 8:32 x 1/4 Button Head 2
8 990091 10:32 x 1/2 Button Head 1
9 990438 1:72 x .188 Cap Screw 2

Users Manual Model 656/636 Assembly Drawings • 75

Drive Assembly Drawing

76 • Assembly Drawings Users Manual Model 656/636

Drive Parts List

Item Part # Description Qty

1 196052 Idler Pulley Bushing 1
2 244024 Feed Knob/SS 1
3 354002 Bridge Plate, Web 1
4 354004 Bridge Blade, Lower 1
5 354008A Gear, Idler 1
6 354009A Gear, Driven 1
7 354014 Driven Roller, Molded 1
8 354017 Shaft, Idler Gear 1

9 354021 Eccentric Shaft 1
10 354092 Support, Rear Drive Assembly 1
11 354093 Support, Front Drive Assembly 1
12 354094 Roller, Drive Assembly 1
13 354095 Roller, Tape Assembly 1
14 355018 Support, Knife/Drive/Print 1
15 990023 6-32 x ½” Flat Head Screw 1
16 990090 10-32 x 3/8” Button Head Screw 4
17 990120 ¼-20 x ½” Cap Screw 5
18 990416 ¼-20 x ½” Flat Head Screw 1

Users Manual Model 656/636 Assembly Drawings • 77

Printhead Assembly Drawing

78 • Assembly Drawings Users Manual Model 656/636

Printhead Parts List

Item Part # Description Qty Item Part # Description Qty

1 355004 Shaft, Eccentric (PRT) 1 21 990015 6-32UNC-2A X .25 Cap Screw 2
2 355083 Roller, Molded Printhead 1 22 990028 6-32UNC-2A X .38 Fl Hd Screw 1
3 355008 Spring, Torsion Printhead 1 23 990037 #6 Washer 2
4 355018 Support, Drive/Knife/Print 1 24 990047 8-32UNC-2A X .125 Cap Screw 1
5 355032 Plate, Printhead Mount 1 25 990066 8-32UNC-2A X .25 Btn Hd Screw 4
6 355033 Adjustment Plate, Printhead 1 26 990492 3M X 8M Dowel Pin 1
7 355031 Holder, Printhead 1 27 999041 1/4 X 5/16 X 1/4 Fl Iglide 1
8 355034 Shaft, Adjustment 1 28 990250 3/16 X 2.00 Dowel 1

9 355035 Pressure Adjuster 1 29 989976 #6 Star Washer 2
10 355037 Pin, Pivot 1 30 990016 6-32UNC-2A X .38 Cap Screw 2
11 355038 Knob Clip 1 31 999051 3/16 X 5/16 X 5/16 Bushing 1
12 355039 Static Brush 1 32 990444 3M X14 Cap Screw 2
13 355040 Block, Head Adjust 1 33 990120 1/4-20UNC-2A X .50 Cap Screw 5
14 355041 Shield, Static 1 34 355097 Ink Motor Assembly 1
15 355042 Plate, Locator Printhead 1 35 351102 Printhead 300DPI 1
16 355094 Adjuster, Printhead Assy 1 351101 Printhead 240 DPI
17 357011 Static Brush 1
18 355092 Support, Inner Printhead Assy 1
19 355093 Support, Outer Printhead Assy 1
20 356020 Roller, Molded Ink 1

Users Manual Model 656/636 Assembly Drawings • 79

Ink Unwind / Rewind Assembly

80 • Assembly Drawings Users Manual Model 656/636

Ink Unwind / Rewind Parts List

Item Part # Description Qty Item Part # Description Qty

1 356010 Shaft Lock 2 17 990251 1/8 x 1/2" Dowel Pin 1
2 990042 8-32 x 3/13" Set Screw 2 18 990133 1/4-20 x 3/4" Flat Head Screw 1
3 990490 Spring 2 19 990122 1/4-20 x 3/4" Cap Screw 1
4 999009 5/16" Thrust Bearing 2 20 376016 Bearing Housing 1
5 356053 Unwind Shaft 1 21 999002 Bearing 2
6 376087 Arbor Assembly 1 22 376023 Bearing Spacer 1
7 376003 Ink Arbor Guide 2 23 376025 Bearing Spacer 1
8 516113 Ink Guide 1 24 991018 Internal Snap Ring 1

9 376088 Arbor Unwind Assembly 1 25 376024 Bearing Spacer 1
10 990083 10-32 x 3/4" Cap Screw 1 26 990019 6-32 x 1/4" Button Head Screw 4
11 990313 #10 Thumb Cap 1 27 376022 Sprocket Altered 1
12 376026 Unwind Fiber Spacer 1 28 376014 Adapter Ink Sprocket 1
13 356016 Shaft, Foil Bracket 1 29 990102 #10 SAE Washer 1
14 376048 Disc Brake 1 30 990091 10-32 x 1/2" Button Head Screw 1
15 376017 Hub Rewind 1 31 990058 8-32 x 1/4" Set Screw 1
16 376029 Shaft, Rewind 1

Users Manual Model 656/636 Assembly Drawings • 81

Ink Rewind Arbor Assembly

Field Retrofit Kit

82 • Assembly Drawings Users Manual Model 656/636

Ink Rewind Arbor Parts List

Item Part # Description Qty

1 356010 Lock Spring Pressure 1
2 --------- No Longer Used -­3 991036 Compression Spring 1
4 999009 5/16 Thrust Bearing 1
5 376087 Arbor Assembly 1
6 376048 Unwind Fiber Spacer 1
7 356191 Fixed Rewind Shaft Assembly 1
8 356192 Front Bearing Housing Assembly 1

9 991038 ¾” Serrated Bellville Washer 1
10 356193 Rear Bearing Housing Assembly 1
11 991037 .047” Steel Shim 1
12 356108 42T Timing Belt Pulley 1
13 990134 ¼-20 x ¼ Button Head 1
14 990434 ¼” External Tooth Washer 1

Users Manual Model 656/636 Assembly Drawings • 83

Feed & Ink Drive Assembly

84 • Assembly Drawings Users Manual Model 656/636

Feed & Ink Drive Parts List

Item Part # Description Qty

15 990111 10-32 x ¾” Flat Head Screw 6
16 356106 Offset Plate 2
17 990451 1 9/16 Stand-Off 3
18 351141 Ink Motor 1
19 245026 Feed Motor 1
20 990081 10-32 x ½” Cap Screw 12
21 194023 1 3/8 Stand-Off 3
22 284025 14 Tooth Pulley 2

N/A 356109 Ink Timing Belt (85 Tooth) 1
N/A 356110 300dpi Feed Timing Belt (60

N/A 356026 240dpi Feed Timing Belt (57

1

Tooth)

1

Tooth)

Users Manual Model 656/636 Assembly Drawings • 85

Timing Belt Threading Diagram

86 • Assembly Drawings Users Manual Model 656/636

Timing Belt Parts List

Item Part

Number

23A 356109 1 85T Timing Belt Double Sided

23B 356111 1 65T Timing Belt Double Sided

23C 356195 1 20T Idler Pulley w/ Bronze Bushing

24A 356110 1 60T Timing Belt (300dpi)
24B 356026 1 57T Timing Belt (240dpi)

Qty Description

(First 100 units only)

(101 +)

(First 100 units only)

Not Shown

Users Manual Model 656/636 Assembly Drawings • 87

Ink Turn Roller Assembly

88 • Assembly Drawings Users Manual Model 656/636

Ink Turn Roller Parts List

Item Part

Number

25 376086 1 Turn Bar Assembly
26 990416 1 ¼-20 x ¼” Flat Head
27 356105 1 Turn Bar Bracket
28 990121 1 ¼-20 x 5/8” Cap Screw
29 354090 1 636/656 Feed Assembly

Qty Description

(Only inner support bracket shown)

Users Manual Model 656/636 Assembly Drawings • 89

Knife Assembly Drawing

90 • Assembly Drawings Users Manual Model 656/636

Knife Parts List

Item Part

Number

1 197003 1 #10 Washer 21 357019K 1 Clutch, Square Drive
2 197308 1 Adjuster, Knife 22 357018 1 Knife Guard
3 197311 1 Cam, Knife Homing 23 357091 1 Bracket, Inner Knife Assembly
4 197312 1 Spring, Cam 24 357092 1 Bracket, Outer Knife Assembly
5 197313 1 Plate, Spring Cam 25 357093 1 Knife, Stationary
6 357020 1 Actuator, Knife 26 357094 1 Knife Rotary
7 197317 1 Compression Spring 27 990016 2 6:32 x 3/8 Cap Screw
8 351123 1 Knife Solenoid Harness 28 990082 4 10:32 x 5/8 Cap Screw

9 517099 1 Knife Motor Assembly 29 990120 5 1/4:20 x 1/2 Cap Screw
10 354005 1 Upper Bridge Blade 30 990123 2 1/4:20 x 1 Cap Screw
11 354013 1 Molded Idler Roller 31 990102 2 #10 SAE Washer
12 355018 1 Support, Knife/Drive/Print 32 990261 1 3/16 Snap Ring
13 357003 1 Mount, Solenoid 33 990449 3 M3 x 6 Cap Screw
14 357021K 1 Adapter, Knife Motor 34 999055 1 8:32 x3/8 Flat Head
15 357005 1 Clutch Adapter w/ 8:32 x 1/4 SS 35 999099 2 3/16 x 5/16 x 1/4 Flanged Bushing
16 357006 1 Spring, Torsion Front (Natural

17 357007 1 Spring, Torsion Rear (Red Finish) 37 990065 1 8:32 x 3/8 Button Head
18 357011 1 Static Brush 38 990066 4 8:32 x 1/4 Button Head
19 357013 1 Mount, Cam Stop 39 990019 1 6:32 x 1/4 Button Head
20 357016 1 Standoff, Solenoid Arm 40 990122 1 1/4:20 x 3/4 Flat Head

Qty Description Item Part

Number

36 989978 1 #8 Star Washer

Finish)

41 999097 1 Flanged Bushing (Inc. w/

Qty Description

357021k)

Users Manual Model 656/636 Assembly Drawings • 91

Stacker Assembly Drawing

92 • Assembly Drawings Users Manual Model 656/636

Stacker Parts List

Item Part

Number

1 144034 1 Feed Lock Knob 23 358092 1 Roller, Stacker Assembly
2 184002 1 Thumb Screw Lock 24 358094 1 Roller, Stacker Support Assembly
3 188008 1 Stacker T-Nut 25 989979 1 10:32 x 1 Set Screw
4 358023 1 Knob Assembly 26 990006 2 4:40 x 1/4 Cap Screw
5 247035 1 Drive Pulley 27 990037 2 #6 SAE Washer
6 351160 1 Full Stacker Switch Harness 28 990042 4 8:32 x 3/16 Set Screw
7 351161 1 Stacker Motor Harnessed 29 990079 1 10:32 x 1/4 Cap Screw
8 358001 1 Stacker Support 30 990080 2 10:32 x 3/8 Cap Screw

9 358091 1 Stacker Base Assembly 31 990085 2 10:32 x 1-1/4 Cap Screw
10 358004 1 Stacker Lock 32 990090 1 10:32 x 3/8 Button Head
11 358006 1 Rail, Rear Stacker 33 990313 3 #10 Thumb Screw
12 358007 1 Rail, Front Stacker 34 990369 2 1/8” Collar
13 358008 2 Roller, Idler 35 990446 2 .188 x .500 x 8:32 Shoulder Screw
14 358010 1 Shaft, Roller 36 990450 2 .375 Round Spacer
15 358011 4 Pivot, Idler Roller 37 990641 2 6:32 Wing Nut
16 358012 1 Plate, Stacker Locator (not shown) 38 999044 2 .313 x .437 x .375 Flanged

17 358013 1 Trip Rod 39 999100 4 3/16 x 5/16 x 1/8 Flanged Bearing
18 358015 2 Roller Support 40 990102 2 #10 SAE Washer
19 358016 1 Shaft, Roller 41 351125 1 Stacker Harness
20 358017 1 Spring, Trip Rod 42 990533 1 Tie Down
21 358018 1 1/5P 40T Timing Belt 43 990513 1 Wire Tie
22 358021

3580191515

Qty Description Item Part

Number

O’Ring (long) “X” = 3.1875
O’Ring (short) “X” = 2.1875

44 358005 2 Pressure Roller

45 358020 1 Label Side Support

Qty Description

Bushing

Users Manual Model 656/636 Assembly Drawings • 93

Rewind Assembly Drawing

94 • Assembly Drawings Users Manual Model 656/636