Avery Dennison 64 Series User manual

03/10 Rev. 5.04-04 SERVICE MANUAL Service Mechanics
64-xx – 64-xx Dispenser
Service Mechanics
General Notes................................................3
Safety Instructions......................................3
Special key combinations...........................4
Serial numbers...........................................4
Factory settings..........................................5
Service data ...............................................5
Housing..........................................................6
Important instructions.................................6
Overview of housing parts..........................6
Front hood..................................................6
Rear hood ..................................................7
Left front housing........................................8
Right front housing.....................................9
Right lower housing....................................9
Cutter cover................................................9
Plug cover ..................................................9
Material unwinder.........................................10
Servicing the unwinder.............................10
Adjusting the unwinders brake torque......11
Tension arm .............................................12
Bearing bushes ........................................12
Ribbon transport unit....................................13
Important notes ........................................13
Ribbon unwinding mandrel (type 1)..........15
Ribbon unwinding mandrel (type 2)..........17
Ribbon unwinding mandrel (type 3)..........20
Ribbon rewinding mandrel (type 1) ..........22
Ribbon rewinding mandrel (type 2) ..........23
Ribbon rewinding mandrel (type 3) ..........25
Setting the ribbon zero line ......................27
Setting the braking torque........................27
Ribbon core brake....................................30
Ribbon guide............................................30
Ribbon transport roller..............................31
Ribbon end sensor...................................32
Removing the complete print module ..........33
Construction of the print module ..............33
Disassembly of the print module..............33
Feed unit.......................................................35
Construction of the feed unit.....................35
Feed rollers...............................................35
Contact roller unit......................................37
Material guide ...........................................38
Material end sensor ..................................39
Punch sensor............................................40
Printhead......................................................41
General information about the printhead ..41
Overview printhead settings......................42
Replacing the printhead............................43
Printhead adjustment....................................44
Setting the head aperture .........................44
Adjusting the printhead position................46
Adjusting the print head contact pressure.47
Adjusting the printhead voltage.................48
Print head lift mechanic................................49
Print head sensor......................................49
Print head motor .......................................50
Contact pressure lever..............................50
Connections and electrics ............................51
Important instructions................................51
Power Supply............................................52
Motor / Sensor Cable harness..................54
Cable harness D-Sub connector...............55
Cover switch .............................................58
Overview of the sensors...............................59
Boards (Gen. 2)............................................60
Important information about boards..........60
CPU board................................................60
Motor driver board.....................................62
Operating panel ........................................63
Boards (Gen. 3)............................................64
Operation panel ........................................64
CPU board................................................65
Motor output stage boards........................67
I/O board...................................................69
Centronics board.......................................70
USI board..................................................71
Locking clips for flat strap plugs................72

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Assembling accessories ..............................73
Antistatic kit..............................................73
Remote operator panel.............................77
Dustfilter for 64-08 up to serial number
075580 .....................................................80
Dustfilter for 64-xx with serial number
075580 or higher.......................................81
Index.............................................................83

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General Notes
Safety Instructions
WARNING!
The printer operates using mains voltage! Touching electrically live parts
can cause exposure to hazardous electrical currents and may lead to
burns.
Only authorised service technicians are permitted to disassemble the
housing.
Before disassembling housing components, turn off the unit and
unplug the power cable.
If the unit needs to be powered up for repairs or testing after the housing
has been disassembled, respect the following:
Never touch electrically live parts. This also applies to low voltage
parts.
The power supply can become hot. Let the power supply cool down
before touching it.
After the printer was switched off, wait at least 1 minute before
touching any electric contacts at the power supply.
Never open the housing of the power supply! Faulty power supplies
should always be replaced, not repaired.
After switching off the printer, wait at least 1 minute before touching
any electric contacts at the power supply.
Ensure that the electrical system is in perfect condition:
– Check the electrical system on a regular basis.
– Fasten loose connections.
– Replace damaged cables immediately.
Only operate the unit once the housing has been reassembled
properly.
After assembling, check the printer according to the regulations
relevant in your country.
CAUTION! Always make sure the electronic circuitry is protected from
electrostatic discharge:
Wear ESD protective gear.
Before opening the unit, make sure it is placed on an earthed surface.

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Special key combinations
Some printer functions are ought to be only accessible to the authorized
service technician. Those functions can therefore not be selected easily. To
activate them, the printer has to be restarted, while simultaneously a certain
key combination is pressed for some seconds.
Key
combination Function Description see…
Cut+Prog H8 forced start Topic section "Firmware",
paragraph "Loading the Firmware
(using Boot Loader).
Feed+Prog Access to special
service parameters Topic section "Info-printouts and
parameters", parameter
"SERVICE FUNCTIONS/ Head
exchange".
Cut+Online+
Feed+Prog H8 forced start and
access to special
service parameters
Tab. 1 Special key combination for use by authorized service technicians.
Serial numbers
Some assemblies were subject to one or more constructive changes and
can therefore be ordered in several versions. The spare parts catalog notes
in those cases the serial number or the production month/year of the
machine, which is required to be compatible with the respective assembly.
The serial number can be found on the rating plate of the machine as
illustrated below [1].
xxxxxxyymm
yy = Year, mm = Month
xxxxxx = sequential number
[1] Rating plate at an ALX 926. The machine was built in 07/2004 and has the serial
number 052773.

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Factory settings
All parameters are preset ex works to values specific to each device type.
These factory settings can be restored at all times with the parameter
SPECIAL FUNCTION > Factory settings.
Default values Precondition: The parameter SPECIAL FUNCTION > Default values is set to
"standard". Is the parameter set to "User defined", those values will be
recovered, which had been set at the time, "User defined" was selected.
More detailed information about factory settings can be found in the subject
section "Info Printouts and Parameters", parameter SPECIAL FUNCTION >
Factory settings.
Service data
The status printout "Service Status" lists the printers most important service
data. Some of the counters on it, e.g. the covered distance of the printhead,
are increased automatically, others, e.g. the number of exchanged
printheads, must be increased manually by the service technician. This
happens by calling the appropriate parameter (Tab. 2).
For information on the status printout see topic section "Info-printouts and
parameters", paragraph "PRINT INFO/ Service status".
Find the service parameters in topic section "Info-printouts and
parameters", paragraph "SERVICE FUNCTION".
Menu Parameter Call in order to
Service Increase the counter "Service
operations"
Head exchange Increase the counter "Head number"
Roller exchange Increase the counter "Roller number"
Cutter exchange Increase the counter "Cutter number"
SERVICE
FUNCTION
Serv. data reset Reset all counters to their initial value
Tab. 2 Those parameters increase the corresponding counters on the info-printout
"Service Status".

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Housing
Important instructions
The housing may only be opened by
authorised trained personnel!
Before opening the housing, switch off
the device and pull out the mains plug! If
this is not done, there is a danger of
accidents being caused by dangerous
contact voltage.
Overview of housing parts
The housing consists of the following
individual parts:
– Front hood (1)
– Rear hood (2)
– Left front housing (3)
– Right front housing (4)
– Right lower housing (5)
– Cutter cover (6)
– Plug cover (7)
Front hood
Disassembling
After being opened the front hood (1)
can be removed by unscrewing four
(Phillips) screws (8).
The right front housing (4) remains
affixed to the front hood.
Assembly
Tighten the screws with 200 Ncm.
Tool
– Phillips screwdriver
1
2
3 4
5
6
7
1
8 8 8 8
4

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Rear hood
Disassembling
The rear hood (2) can be removed by
unscrewing the 6 Phillips screws (1).
Prise off the rear hood somewhat to the
side in order to lift the metal tab (3) out
of its recess and at the same time
remove it with an upward movement.
Assembly
Tighten the screws with 160 Ncm.
Tool
– Phillips screwdriver
1 1 1
2
1 1 1
3

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Left front housing
Disassembling/assembly
1. Unscrew the Phillips screws (1).
2. Carefully remove the front housing (2) to
the side.
3. Pull off the flat ribbon cable plug (3) at
the rear of the operating panel. Press
the operating panel from behind out of
the housing.
4. Unscrew the cutter connection (4).
Tools
– Phillips screwdriver
– Socket wrench size 4.5
3
4
1
1
2

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Right front housing
Disassembling/assembly
The right front housing (1) is fixed to the
front hood with six Phillips screws (2)
and can be removed.
Tool
Phillips screwdriver
Right lower housing
Disassembling/assembly
The right lower housing (3) is fixed to
the base pan by two Allan key screws
(4) and can be removed.
Tool
Allan key size 2.5
Cutter cover
Disassembling/assembly
The cutter cover (5) is fixed to the print
module by two Allan key screws (6) and
can be removed.
Tool
Allan key size 3
Plug cover
Disassembling/assembly
The plug cover is mounted on the cutter
connection and can be removed.
6
2
2
2
2
2
2 1
5
4
4
3
6

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Material unwinder
The material unwinder comprises the
unwinder (1) and the tension arm (2). The
tension arm is for counteracting jolting
movements of the material which can be
caused by sudden acceleration or braking.
The unwinder itself is braked and can be
adjusted to different core diameters.
Servicing the unwinder
Tool
– Screwdriver
Disassembling/assembly
1. Remove the retaining ring (3).
2. Pull off the entire unwinding core (4).
During assembly:
Check for easy movement and inspect
the braking system (if necessary grease
the unwinding axle).
4
3
1
2

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Adjusting the unwinders brake torque
Tools •Spring balance 5 N (1) (article no. 93665-01)
•Reel with wound-up textile ribbon (Ø 76 mm or 3") (2)
Fig. 1 Left side: Aid for adjusting the brake torque: Reel with textile ribbon (2) and spring
balance (1). Right side: Measuring the pulling force.
Adjusting 1. Attach the reel to the unwind mandrel.
2. Hang the spring balance to to the sleeve of the textile ribbon.
3. Hook the spring balance into the foil loop and pull on it until the foil mandrel
turns slowly and steady. Read off the traction (see Fig. 1 right side).
While pulling at the rewinding mandrel, it is essential to keep the foil feed
roller blocked!
The pulling force may vary within the indicated tolerances (see Tab. 3).
Printer Admissible
pulling force Article no. brake sponge No. of sponges each unwinder
64-04
64-05
64-06 0.6 – 1.5 N A0938 1
64-08 0.9 – 1.9 N A1607 2
Tab. 3 The pulling force must match the dedicated range.
4. Compare the measured pulling force to the values given in Tab. 3.
5. If the measured value exceeds the admissible range, the unwinder has to
be disassembled and the included brake sponge to be exchanged.
It may be necessary to insert additional brake sponges to reach the
required pulling force.
See chapter Material unwinder on page 10.
2
1

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Tension arm
Design changes
Serial no.
Date Changed item
0663910
06/2006 Simple tension arm spring
(type 1) was replaced by
spring with rope drive and
pulley (type 2).
Rectangular self-adhesive
stoppers were replaced by
cylindrical screw-in stoppers.
Disassembling/assembly
Type 1:
1. Unmount the spring (1) from the
nose(2).
Type 2:
1. Unmount the wire hook (3).
2. Draw the tension arm (5) off the axle (6).
Lightly grease the axle to allow the firmly
sitting tension arm to be moved more
easily.
During assembly:
Check the free movement of the tension
arm.
The tension arm must move between
the two strokes (4).
Tool
– Phillips screwdriver
Bearing bushes
Disassembling/assembly
First remove the clamping ring and then
the three bearing bushes (7). 5
6
7
1 2
3
4
4

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Ribbon transport unit
Important notes
Components
The ribbon transport unit (part of the print
module) consists of:
– Ribbon unwinding mandrel (1a) with
brake mechanism (1b)
– Ribbon rewinding mandrel (2a) with
drive (2b)
– Ribbon deflection axle (3)
– Ribbon transport roller (4)
Design changes
Serial #
Date Change Retrofitting
054300
10/2004 Brake at ribbon unwinding mandrel:
Loop-spring brake (type 1) replaced by
brake with two compression springs
(type 2)
057118
03/2005 Drive at ribbon unwinding mandrel:
Round belt (type 1) replaced by toothed
belt (type 2)
Parts kit for upgrading from type 1 to
type 2: A6043
075257
02/2008 Brake at ribbon unwinding mandrel:
design modification of the ribbon brake
(type 3).
Drive at ribbon unwinding mandrel:
design modification of the friction clutch
(type 3).
Parts kits for upgrading from type 2 to
type 3:
Unwinder:
Up to serial number 0542990410: A9199
From serial number 0543000410: A9180
Rewinder:
From serial number 0543000410: A9179
For printers up to this serial number,
retrofitting is not possible.
Upgrading the un-/rewinder from type 2 to type 3 is recommended.
2a4 1a
3
1b 2b

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Lubricating plastic parts
All plastic parts pictured below must be
greased at the inner diameter (arrow)
before assembling it. All other surfaces
must be absolutely free of grease.

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Ribbon unwinding mandrel
(type 1)
Tools
– 2.5 and 2 mm allen keys
– Size 7 and 8 socket wrenches
– Plastic hammer
– Philips screwdriver, medium size
Preparation for dismantling
1. Remove front and rear hood.
2. Unscrew the contact spring (5).
3. Remove the ribbon end sensor (6).
How? - See paragraph Ribbon end
sensor on page 32.
4. Remove the securing nut (7).
Continued on the next page.
6
5
7

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Disassembling
1. Turn out the threaded rod. To do this,
turn the red hexagon head (on the side
of the print head ) in an anti-clockwise
direction. Hold the cap (1) while doing
this.
2. Detach the cap (1), spacing ring, contact
spring (2), oscillator disc (3) and brake
disc (4).
3. Unattach the brake spring (5), detach
the round belt disc (below it).
4. Unscrew the two grub screws (6) of the
start disc (7). Remove the buffer disc.
5. Remove the shims.
6. Pull the ribbon mandrel out of its bearing
to the print head side.
Pay attention to the shims on the ribbon
mandrel axle (print head side).
Assembly
1. Insert the ribbon mandrel, put on the
shim(s) and buffer disc.
2. Affix the buffer disc with both grub
screws.
3. Put on the round belt disc. Lay the brake
spring around the disc and hang it in.
4. Put on the brake disc, oscillator disc and
contact spring one after the other.
5. Push the threaded rod through.
6. Place the spacing ring on the end of the
threaded rod.
7. Screw the threaded rod into the cap until
the contact spring is compressed by a
few millimetres.
Turn the cap when putting it on until it
can be easily moved along the ribbon
mandrel axle.
Continued on the next page.
1
2
7
6
5 4
3

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8. Tighten the fastening nut until the
threaded rod protrudes about one
millimetre out of the nut.
9. Assemble the ribbon photoelectric
switch and contact spring.
Ribbon unwinding mandrel
(type 2)
Tools
– 2.5 and 2 mm allen keys
– Size 7 and 8 socket wrenches
– Plastic hammer
Preparation for disassembling
1. Remove front and rear hood.
2. Remove cap (1).
2. Unscrew the contact spring (2).
3. Remove the ribbon end sensor (3).
How? - See paragraph Ribbon end
sensor on page 32.
4. Measure and note how deep the nut (5,
circled) and cap are screwed on to the
threaded rod.
5. Remove the securing nut (4).
Continued on the next page.
2
3
4
1
5

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Disassembly
1. Turn the threaded rod by the hexagonal
head out of the cap (1) and pull it out of
the ribbon mandrel.
2. Remove cap (1), spacer ring, spring (2)
shim rings, timing disc (3) and brake
disc (4).
3. Remove the lock washer (7) from the
brake lever. Unmount the brake rod (8)
from the brake lever. Remove the brake
lever (5).
4. Loosen both set screws (9) at the stop
disc (6). Remove the stop disc.
5. Remove the shim rings.
6. Push the ribbon mandrel through to the
opposite site.
If necessary, force the ribbon mandrel
out by tapping it lightly with the plastic
hammer.
1
2
3
4
5
6
7 8
9
6

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Assembly
To assemble the device, follow the steps in
the reverse order. Make sure to do the
following:
Mount the stop disc (6) with the larger
chamfer pointing outwards.
Lightly grease the bearing surface of the
brake lever (5) before assembly (with
universal grease). Make sure that no
grease gets between the discs! Mount
the brake lever with the bulge side (fig.
right, arrow) facing outward.
Mount the brake disc (4) with the sharp
edge pointing outwards.
Screw the cap and nut onto the
threaded rod till they reach the depth
noted earlier.
After the assembly: set the braking
torque.
See section Setting the braking torque
on page 27.
5
4
6

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Ribbon unwinding mandrel
(type 3)
Tools
– 2.5 and 2 mm allen keys
– Size 7 and 8 socket wrenches
– Plastic hammer
Preparation for disassembling
1. Remove front and rear hood.
2. Remove cap (1).
2. Unscrew the contact spring (2).
3. Remove the ribbon end sensor (3).
How? - See paragraph Ribbon end
sensor on page 32.
4. Measure and note how deep the nut (5,
circled) and cap are screwed on to the
threaded rod.
5. Remove the securing nut (4).
Continued overleaf.
1
2
3
4
5