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Paxar 545 User Manual

Paxar model 545 printer users manual
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Users Manual
Model 545
PAXAR Systems Group
Manual Edition 5.1
15 February 2002
Manual Part Number 341398

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Summary of Contents for Paxar 545

  • Page 1 Users Manual Model 545 PAXAR Systems Group Manual Edition 5.1 15 February 2002 Manual Part Number 341398...
  • Page 2 This page intentionally blank...

  • Page 3: Table Of Contents

    Installing the Stacker ... 18 Cable Installation ... 20 Installing the Applications Software ... 21 Printer Operation / Adjustments Installing and Removing Ink Cartridges... 22 Adjusting the Unwind... 24 Loading Fabric for the First Time ... 24 Users Manual Model 545™ • i...
  • Page 4 Power Up / Sign On / Communications...67 Fabric Advance...69 Print ...70 Cut / Stack...71 Mechanical Trouble Shooting Fabric ...72 Ink...73 Print ...73 Sensor Locations...74 Non-volatile Memory Reset...75 Electrical Drawings Printer Wiring ...76 Electrical System Schematic...77 Motherboard Power Connectors ...78 ii • Users Manual Model 545™...
  • Page 5 Stacker Assembly Drawing – Part 1 ... 114 Stacker Parts List – Part 1... 115 Stacker Assembly Drawing – Part 2 ... 116 Stacker Parts List – Part 2... 117 Rewind Assembly Drawing... 118 Rewind Parts List... 119 Users Manual Model 545™ • iii...

  • Page 6: Scope

    We at PAXAR hope that you will come to appreciate the efforts and quality, which have gone into producing your PAXAR 545 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.

  • Page 7: Warranty Information

    Warranty Information Limited Warranty PAXAR Systems Group, Division of PAXAR Corporation, extends the following warranties to the original purchaser of a PAXAR 545 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 printer's shipment date.

  • Page 8: Location / Power Requirements

    30" deep to 32" high. Recommended Workstation Layout. The location of the PAXAR 545 printer should be based on human factors. The printer should be located in an area that maintains optimum flow of your product while providing for the operator’s comfort. PAXAR has taken significant steps to ensure that the operator controls and operations are easily accessible.

  • Page 9: Ac Power Line

    AC Power Line PAXAR requires that the electric service be 10 Amps @ 115VAC or 10 Amps @ 230VAC. This will allow the computer and any additional support or service equipment to be plugged into the same service. Any electrical service 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.

  • Page 10: Unpacking / Inventory

    Unpacking / Inventory Unpacking The PAXAR printer is shipped in 2 large cardboard boxes, of which one may be difficult to move by hand. DO NOT REMOVE THE PRINTER FROM THE BOX OR UNPACK IN THE SHIPPING / RECEIVING DEPARTMENT.

  • Page 11: Inventory Of Components

    - Stacker assembly - One or two print modules as ordered. - PCMCIA Card containing special Swiss fonts for the 545 printer, also used to store Logos or additional fonts that were special ordered. (located in the back of the manual) - Any optional software ordered.

  • Page 12: Product Description

    Product Description Printer Description The PAXAR model 545 ink jet printer is an electronic printer that can print on fabric rolled tape. The printer interfaces to a computer or a main frame system thus allowing electronic data input or even custom design of labels with PAXAR’S “Formatter / PcMate Plus"...

  • Page 13: Printer Specification

    Stock Support for blank and pre-printed fabrics – Roll size up to 12” (305mm) diameter Interface PAXAR PCL via RS-232 serial port – 9 pin D-shell Control Push-button printer function with 2 Line x 24 Character International LCD Backlite Display...

  • Page 14: Personal Computer Specifications

    Personal Computer that is used to download to the PAXAR 545 Printer. The PAXAR 545 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.

  • Page 15: Printer Assembly

    Printer Assembly Fuse Configuration The main fuse(s) on the Paxar 545 are located inside the AC entry. The entry has a fuse drawer that holds the fuse(s) and selects the appropriate line voltage. If the voltage in the window DOES NOT match the AC line amplitude intended to be supplied to the printer, DO NOT plug the power cord in.

  • Page 16: Installing The Power Cord

    6) Close the AC entry and verify the correct voltage is now visible. Installing the Power Cord A power cord is shipped with each printer. The cord for 115-volt printers will use the standard three-prong plug used in the U.S.A. A 230-volt printer and some other 115-volt configurations will have the plug end of the cable removed.

  • Page 17: P.c. Board Identification

    5 STACKER JAM SENSOR 6 UNDEFINED 7 UNDEFINED 8 LOKPRINT / DOWN STACKER Users Manual Model 545™ A – Mother Bd. (371170) B – Head Driver Bd. (341106) C – Memory Card Bd. (350016) D – Thermal Control Bd. (371105IJ) - AT Slot 2 E –...

  • Page 18: Inserting A Pcmcia Card

    If using a single IC card, the card must be inserted into the slot closest to the rear of the printer. NOTE: The printer loads the data from the PCMCIA card at power up, after 16 • Printer Assembly inserting a PCMCIA - power cycle the machine.

  • Page 19: Print Module Insertion And Removal

    Swing open the top cover to the printer. In order to install or remove the print modules the ink cartridges MUST be out of the machine. To install the print module push the module release lever (A) to the right and with your other hand align the module between the mount rails.

  • Page 20: Print Module Handling

    Swing open the top cover to the printer. Make sure that the stacker bed is in the most upright position by loosening the locking knob and rotating the bed up and then re tightening the locking knob.
  • Page 21 Remove the spring-loaded screw and washer from the top of the inner stacker rail. Place the threaded stud into the slot of the outer rail and reattach the washer, spring and nut. Printer Assembly • 19 Users Manual Model 545™...

  • Page 22: Cable Installation

    PC Interface Cable The 545 requires a 9-pin RS-232 cable which is provided with the printer. If the cable was not found it can be ordered from PAXAR - (Part no. 351124).

  • Page 23: Installing The Applications Software

    Paxar 545 printer is a Windows application. The original "Selfform" will not support the 545. The new "PcMate Plus / Formatter " package is capable of creating formats for all Paxar control printers. Version 3.16.3 or higher is needed.

  • Page 24: Printer Operation / Adjustments

    AS THE PRINT MODULE NEEDLES ARE UNPROTECTED WHILE THE PRINT MODULES ARE IN THE PRINTER. module in the left position prints the bottom of the label if the 545 is printing one over one. into the slot below the print module. The end with the two round holes goes into the slot with the label up.
  • Page 25 3) Remove the ink cartridges by pulling them straight out from their current position. Printer Operation / Adjustments • 23 Users Manual Model 545™...

  • Page 26: Adjusting The Unwind

    Adjusting the Unwind Before loading fabric for the first time and anytime the fabric width changes - the unwind position must be adjusted - as the 545 is a center justified machine. Loading Fabric for the First Time • •...

  • Page 27: Threading Diagram

    • Users Manual Model 545™ Open the hinged cover to the printer and thread the fabric through the splice / fabric out sensor (B drawing two), the active unwind, the barrel rollers, the head guards (A drawing two), the feed module, the knife, and then the stacker as shown.
  • Page 28 This will result in a loop in the fabric under the active unwind sensor of about .250” as shown below. .250 26 • Printer Operation / Adjustments Users Manual Model 545™...

  • Page 29: Web Guide Adjustment

    Web Guide Adjustment The Paxar 545 printer has been designed with crowned rollers to maintain center tracking. The only web guides in the printer are located on the active unwind block. These web guides are adjustable without the use of tools. The only other web width adjustment is the stacker up-right rails (refer to the Stacker Label Width Adjustment).
  • Page 30 You will need to lift the pre-feed rollers between the feed and knife in order to push the fabric through the knife. After the fabric is pulled through the knife, continue feeding through to the stacker belts. Users Manual Model 545™...

  • Page 31: Stacker Position Adjustment

    • Users Manual Model 545™ Once the web has been centered in the printer or it has stabilized from running, confirm that equal numbers of belts exist on either side of the fabric, and that the spacing to the nearest belt is the same on each side. This is achieved by loosening the stacker mount screw and moving the stacker forward or back accordingly.

  • Page 32: Stacker Label Length Adjustment

    Turn the lock knob counter-clockwise to allow the stack end of the stacker to rotate. Once the stack is so that the stacker rails are approximately 5° to 30° off horizontal, tighten the lock knob by turning it clock-wise. Users Manual Model 545™...

  • Page 33: Stacker Full Level Adjustment

    • • • Users Manual Model 545™ To change the height at which the machine will stop, first loosen the plastic thumbscrew located on the stacker upright and slide it up or down. Once the desired stop level is reached retighten the thumbscrew.

  • Page 34: Replenishing Fabric At End Of Roll

    / registration needs to be optimized, refer to the Printer Setup procedure and make the necessary adjustments. The PAXAR 545 machine and the fabric it prints on have been designed so that factory splices can be detected. When a splice is detected, the machine will stop with a “STOPPED FOR SPLICE “...

  • Page 35: Print Head Operation

    Care should be taken not to obstruct the path of the print head swing arms as it may disrupt their travel and adversely effect print quality. Parked Position Users Manual Model 545™ Print Position Printer Operation / Adjustments • 33...

  • Page 36: Printer Setup

    Printer Setup From time to time it may be necessary or desirable to reset the printer to a known state of print / cut. The following procedure can be used to make the necessary changes. Only adjust the adjustments that are needed in the order that follows;...
  • Page 37 9) On the front panel adjust the PRINT OFFSET STATION 2 to produce one 10) On the front panel the CUT POSITION should be set to 0, as this is a non-sense Users Manual Model 545™ straight continuous feed print line on the back of the label.

  • Page 38: Sensor Calibration

    Refer to the Front Panel Mode Descriptions under the Control Panel Operation section. 36 • Printer Operation / Adjustments print line to be directly over station 1’s web print line. Users Manual Model 545™...

  • Page 39: Control Panel Operation

    Control Panel Operation Control Buttons Start Feed Test Users Manual Model 545™ - Starts the printer. - ON LINE light must be GREEN. (Batches downloaded to be printed) - If “Stopped For Splice” error condition exists: Fabric will be advanced until the splice is beyond the print stations.

  • Page 40: Indicator Lights

    Stop Indicator Lights The Paxar 545 has three Indicator lights. These lights are used along with the LC display to tell the operator the current status of the printer. On Line Sensor 38 • Control Panel Operation - Fabric moves through with test pattern printing.

  • Page 41: Lcd Display

    The second line is the response. Users Manual Model 545™ mark hole. - Flashing light while the printer is running, - the sensor is in-line with the registration HOLES. ORANGE = REFLECTIVE SENSOR - Flashing light while the printer is running, - the sensor is in-line with the registration PRINTED MARKS.

  • Page 42: Front Panel Menu Map

    Over Mark Stacker Blocked Stacker Not Blocked Stock Out Blocked Stock Out Not Blocked ↑ ↵ Users Manual Model 545™ Life Counts / Feature Setup Verifier Setup Versions → → Cutter Enabled Print Verifier (Re settable) / Disabled Total Labels...

  • Page 43: Front Panel Power Up / Home Screens

    The diagnostic test screen will also be displayed when the Diagnostic tests that are run able from the front panel are being executed. Once the diagnostic tests are complete, the Front Panel should display the HOME screen. Users Manual Model 545™ T E S T N A M E ) K E Y...

  • Page 44: Home Screen

    Model Number is displayed briefly before the Batch Id/Qty screen is displayed again. If the printer is performing a FEED or a TEST pattern, the screen will show "FEEDING" or "PRINTING TEST PATTERN" respectively on line two, the top...

  • Page 45: Printer Adjustments

    F E A T U R E VERIFIER SETUP SCREEN P R E S S V E R I F I E R Users Manual Model 545™ E N T E R F O R P O S I T I O N S...

  • Page 46: Front Panel Mode Descriptions

    PRESS ENTER FOR CALIBRATING SENSORS PRESS ENTER FOR LIFE COUNTS / VERSIONS PRESS ENTER FOR FEATURES SETUP PRESS ENTER FOR VERIFIER SETUP Use the EXIT ↑ to move back to the HOME screens. 44 • Control Panel Operation Users Manual Model 545™...
  • Page 47 This screen is the first screen under "PRINT / CUT POSITIONS". Pressing ENTER will cause the printer to print the checkout format. The printer will setup to do the checkout format and start printing. The front panel will remain on this screen so the user can use the MODE / Down Arrow key to get to the printer adjustments.
  • Page 48 N E W V A L U E : ± Y Y O F F S E T S T A T I O N N E W V A L U E : ± Y Y Users Manual Model 545™...
  • Page 49 Pressing the MODE / Down Arrow key will take the user to the "CLEANING STATION 2" screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen. Users Manual Model 545™ C U T P O S I T I O N...
  • Page 50 C L E A N I N G F O R S T A T I O N A C T I V A T I O N H E A D S P R E S S E N T E R Users Manual Model 545™...
  • Page 51 Pressing the MODE / Down Arrow key will take the user to the "BOT REFL OVER MARK" screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen. Users Manual Model 545™ E N T E R S E N S O R S...
  • Page 52 N E W V A L U E : 0 0 0 O U T B L O C K E D N E W V A L U E : 0 0 0 M A R K Users Manual Model 545™...
  • Page 53 0 0 0 0 0 0 0 0 0 0 This screen follows the "TOTAL LABELS PRODUCED" screen. This screen displays the total inches since the printer was built. This value is NOT resettable by the user. Pressing the MODE / Down Arrow key will take the user to the "CONTROLLER VERSION"...
  • Page 54 D I S A B L E D E N T E R E N A B L E M O D E : N O N E M O D E : N O N E Users Manual Model 545™...
  • Page 55 Any number of front panel languages can be stored on the optional PCMCIA card (dependent on available space). If no additional languages other than the default are available on the printer XXXXXX and YYYYYY will be the same value. Pressing ENTER will update the display language with the selection.
  • Page 56 P R I N T This screen is the first screen under "VERIFIER SETUP". Pressing ENTER will cause the printer to print a verifier history report containing bar code information for all the problem scans since the scan memory was last cleared.

  • Page 57: Maintenance

    Please follow the procedures carefully to help ensure print module life and print quality. Because print modules may be damaged through a number of ways, Paxar has developed the following recommendations; Handling Electro Static Discharge is very detrimental to print heads and PCBs. To avoid damaging the components of a print module follow these simple procedures: Users Manual Model 545™...

  • Page 58: Print Module Replacement / Height Adjustment

    DUE TO THE TOLERANCES IN THE PRINT MODULES AND OF THE 1) Remove the ink cartridge from the printer in order to remove the print module. 2) Remove the print module by holding the release lever to the right and lifting the 3) Insert a replacement print module in the reverse order.

  • Page 59: Print Head Swing Arm Stop Adjustment

    Rotating the screw counter clockwise will decrease the overlap or increase the gap. Rotating it clockwise will decrease the gap or increase the overlap. Once adjusted properly - the image should appear square with no gap or overlap in the center. Users Manual Model 545™ Maintenance • 57...

  • Page 60: Automated Print Head Cleaning

    Level 3 - is used when few nozzles will not print. Level 4 - is used when level three will not clear all nozzles, and for new print modules, to purge the heads of analog / air and fill them with ink. Users Manual Model 545™...

  • Page 61: Manual Manifold Seal Cleaning

    Positioning Swing Arms for Seal Cleaning Users Manual Model 545™ care not to contact the print head nozzle plates while the print heads are in the print position. Use nothing other than foam tips with minimal pressure while cleaning the manifold seals.
  • Page 62 Use a wiping action across the seals to avoid pushing any debris down into the manifold seal holes. • When done cleaning, press the “NO (→)” button to swing the (active) print station(s) to the home / park position. Users Manual Model 545™...

  • Page 63: General Machine Cleaning

    If not, the switch bale is adjusted by carefully bending it as needed. Users Manual Model 545™ The knife has an adjustment to square the cut to the fabric. To make the adjustment, loosen the two cap screws, one on top of the knife and one below the knife, using the 3/16”...

  • Page 64: Lubrication Procedure

    Lubrication Procedure General The 545™ series printers are factory equipped with pre-lubricated bronze bearings that do not require lubrication. 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.

  • Page 65: Changing Stacker Belts

    Changing Stacker Belts 8-32 CAP SCREWS FIGURE 1 1. Remove stacker rail assembly by removing full stacker connector and (2) 8-32 cap Users Manual Model 545™ screws from stacker mounting plate. (See figure 1) FULL STACKER CONNECTOR Maintenance • 63...
  • Page 66 6-32 SET SCREWS 8-32 SCREW (SEE ITEM 5) DRIVE BELT COVER FIGURE 3 3. Remove the drive belt cover. 4. Loosen 6-32 set screws in ends of main drive roller. (See figure 3) 64 • Maintenance Users Manual Model 545™...
  • Page 67 6. Remove the thumbscrew on the front side of the stacker rail base and let the 7. Pull the drive away from the frame enough to allow the roller / belts to be lifted Users Manual Model 545™ remove the pin. (See figure 3) square nut on the underside fall out.
  • Page 68 SMALL DUAL DRIVE BELTS (SEE ITEM 8) FIGURE 5 8. Remove small dual drive belts from one side of front roller to allow assembly of new belts. 9. To re-assemble, reverse procedure above. 66 • Maintenance Users Manual Model 545™...

  • Page 69: Electrical Trouble Shooting

    Mother Board Front panel displays no text 1) Front panel cable unplugged. or nothing at all. Users Manual Model 545™ Probable Cause 1) Confirm that the AC entry is configured for the line voltage intended to be applied to the printer.

  • Page 70: Corrective Action

    "Ready for batches". Re-download data. 1) In PcMate change to the printer that the data is intended to be sent. 1) Reconfigure PcMate for Paxar PCL printer as per your PcMate manual. printer and re-download. 1) Replace Thermal Control Board.

  • Page 71: Fabric Advance

    7) Thermal Control Board unplugged or faulty. 8) Finishing Interface Board unplugged or faulty. Users Manual Model 545™ Probable Cause 1) Download batch (if batch downloaded uses the same format as a previously downloaded batch the printer with start automatically).

  • Page 72: Print

    1) Check and adjust as needed. 1) Enter the Print / Cut Positions Mode on the front panel and readjust Station 2 Dot Shift setting as needed. 1) Check and reset DIP switches as needed. Corrective Action Users Manual Model 545™...

  • Page 73: Cut / Stack

    Thermal Control Board. 3) Faulty stacker motor. 4) Faulty stacker motor drive circuit on the Thermal Control Board. Users Manual Model 545™ Probable Cause 1) Enter the Print Head Cleaning Mode and clean the print module. 1) Adjust the swing arm stop position as needed to prevent any gap or overlap in the center of the image.

  • Page 74: Mechanical Trouble Shooting

    If not - loosen "pac- man" set screws and readjust "pac-man" to stop with spring in detent. 1) Loosen shear adjustment screws and move outer end of knife until full cut is obtained. Corrective Action Users Manual Model 545™...

  • Page 75: Ink

    Problem Print Problem Users Manual Model 545™ Probable Cause Probable Cause Corrective Action Corrective Action Mechanical Trouble Shooting • 73...

  • Page 76: Sensor Locations

    E – Ink Cartridge Status – Detects if an ink cartridge is inserted into the machine F – Feed Open Sensor – Detects if the feed lever is open. 74 • Mechanical Trouble Shooting present. amount of slack in the active unwind. and also gives information about the ink cartridge Users Manual Model 545™...

  • Page 77: Non-Volatile Memory Reset

    3) Power on the machine, wait at least 30 seconds, then turn power off. 4) Change switch number 2 back to its original position. 5) Power on the machine and reset the front panel adjustments as needed. Users Manual Model 545™ Mechanical Trouble Shooting • 75...

  • Page 78: Electrical Drawings

    Electrical Drawings Printer Wiring 76 • Electrical Drawings Users Manual Model 545™...

  • Page 79: Electrical System Schematic

    NEUTRAL LT. BLUE EARTH GROUND GREEN W/YELLOW STRIP 2. DC OUTPUTS OF POWER SUPPLY: +12V YELLOW +24V GRAY RETURN BLACK Users Manual Model 545™ HARNESSED 24V POWER SUPPLY 341116 CONN 6 115V STRAP +24V 115V STRAP RETURN +12V 5V/12V POWER SUPPLY...

  • Page 80: Motherboard Power Connectors

    Warning: Connecting the power supply incorrectly may cause irreversible 78 • Electrical Drawings (unwarranted) damage! Ensure that the power is turned off before connecting the power supply. Make certain that the 115 / 230VAC fuse drawer is in the correct position. Users Manual Model 545™...

  • Page 81: Appendix A

    E R R O R ( S ) V E R I F I E R Users Manual Model 545™ The screen advances to next error with each depression of the "NO>" key The screen retreats to prior error with each depression of the "<YES” key The screen reverts back to the first error when the “EXIT”...

  • Page 82: Appendix B

    C 1 5 Head Driver Board P/N 341106 (Use chip removal tool P/N. 351156 for square I.C removal) JUMPER SETTING 2 to 3 Users Manual Model 545™ R 1 9 R 2 1 R 2 2 C 2 2 R 1 0...
  • Page 83 PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow. DIP CHIPS align notch on chip with the notch on the socket (U3 & U4 chips are four pins smaller than U3 & U4 sockets, position chips towards top of socket so Users Manual Model 545™ R 4 0...

  • Page 84: Front Panel Diagnostic Descriptions

    Waiting for Machine Definition from TCB Attempting to create test pattern Attempting to create strobe tables Attempting to read in formats Protected Mode Imaging Code initialization complete Serial Communications Activated Power up complete 82 • Appendix B Users Manual Model 545™...

  • Page 85: Appendix C

    Caution: Expired ink may damage print heads. Check the expiration date on the Users Manual Model 545™ cartridge label. Do not use expired ink. Contact your Paxar representative for instructions on returning expired cartridges. Appendix C • 83...

  • Page 86: Appendix D

    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 545™...

  • Page 87: Appendix E

    FLASHPOINT: >120 ° C FLAMMABLE LIMITS: LEL: Not Known RECOMMENDED EXTINGUISHING MEDIA: RECOMMENDED SPECIAL FIRE FIGHTING PROCEDURES: None required UNUSUAL FIRE AND EXPLOSION HAZARD: Users Manual Model 545™ DATE PREPARED: September 28, 1998 PAXAR CORPORATION, Systems Group PAXAR CORPORATION 1595 Cedar Line Drive Rock Hill, SC 29730 C.A.S#...
  • Page 88 Wash eyes immediately with large amounts of water until no evidence of material remains (at least 15 minutes). Get medical attention immediately. Remove contaminated clothing and wash affected area with mild soap and large amounts of water. If irritation or rash develops, get medical attention. Users Manual Model 545™...
  • Page 89 The information contained herein is furnished without warranty of any kind. It is compiled with the best information available to Paxar at the time of its preparation. Users should consider these data only as a supplement to other information gathered...

  • Page 91: Assembly Drawings

    Assembly Drawings Assembly Drawings • 89 Users Manual Model 545™...

  • Page 92: Frame Assembly Cover Drawing

    Frame Assembly Cover Drawing 90 • Assembly Drawings Users Manual Model 545™...

  • Page 93: Frame Cover Parts List

    Frame Cover Parts List Item Users Manual Model 545™ Part # Description 341203 560 Base Pan 341206 Frame, Upright 341202 Back Cover 341204 Hinged Cover 341201 Front Cover 341216 Mounting Block, Triangle 990053 8-32 x ¾ Cap Screw 341210 Feet, 1 ½” Dia. Rubber 991079 8-32 ½...

  • Page 94: Frame Assembly Drawing

    Frame Assembly Drawing 92 • Assembly Drawings Users Manual Model 545™...

  • Page 95: Frame Parts List

    Frame Parts List Item Users Manual Model 545™ Part # Description 341206 Frame, Upright 341128 Assembly, Print Module Cable 345046 Chase Way, Trailing 345108 Actuator, Shroud Lock 341203 #10 Lock Washer 990082 10-32 x 5/8 Cap Screw 345037 Knob, Chase...

  • Page 96: Sub - Frame Assembly Drawing

    Sub - Frame Assembly Drawing 94 • Assembly Drawings Users Manual Model 545™...

  • Page 97: Sub - Frame Parts List

    990016 6-32 x 3/5 Cap Screw 343039 Shaft, D-G Spindle 343048 Bearing, Ball Spindle * Items Marked with an Asterisk Make up ABC Spindle Assembly - Part # 344091P. Users Manual Model 545™ Item Part # 343038 Spindle .65 343110 Bracket, “F” Post 343058 Roller, Convex 343055 Spacer, .65 Spindle...

  • Page 98: Power Unwind Assembly Drawing

    Power Unwind Assembly Drawing 96 • Assembly Drawings Users Manual Model 545™...

  • Page 99: Power Unwind Parts List

    343116 Guide, Web Inside 990273 #10 Bellville Washer 343115 Bracket, Outer Web Guide 343141 6-32 x 3/8 Sem Screw 343126 Knob, Web Guide Users Manual Model 545™ Item Part # 989966 Washer, 4 Star 990001 4-40 x 5/8 Cap Screw 990122 ¼-20 x ¾...

  • Page 100: Unwind Support Assembly Drawing

    Unwind Support Assembly Drawing 98 • Assembly Drawings Users Manual Model 545™...

  • Page 101: Unwind Support Parts List

    990105 10-32 x ¼” Set Screw 990056 8-32 x ½” Flat Head Screw 990066 8-32 x ¼” Button Head Screw NOTE: # are components of assembly A. Users Manual Model 545™ Item Part # 343207 Bracket, Indicator 343224 Label, Indicator 991138 6-32 x 5/8”...

  • Page 102: Unwind Nip Roller Assembly Drawing

    Unwind Nip Roller Assembly Drawing 100 • Assembly Drawings Users Manual Model 545™...

  • Page 103: Unwind Nip Roller Parts List

    Unwind Nip Roller Parts List Users Manual Model 545™ Item Part # Description 343192 Post, Snubber 343134 Arm, Unwind Nip 343131 Cradle, Unwind Nip 343130 Anchor, Nip Spring 990051 8-32 x 3/8 Cap Screw 343195 Assembly, Roller, Nip 343133 Shaft, Nip Roller 990325 “E”-Ring 3/16...

  • Page 104: Unwind Snubber Assembly Drawing

    Unwind Snubber Assembly Drawing 102 • Assembly Drawings Users Manual Model 545™...

  • Page 105: Unwind Snubber Parts List

    Unwind Snubber Parts List Item Users Manual Model 545™ Part # Description 343128 Carrier, Snubber 343162 Bracket, Snubber Comb 343192 Post, Snubber 343143 Stud, Snubber Spring 343144 Spring, Extension, Snubber 343145 Anchor, Snubber Spring 343139 Roll Pin .156 x 1.25 990329 “E”-Ring 7/32...

  • Page 106: Print Module Assembly Drawing

    Print Module Assembly Drawing 104 • Assembly Drawings Users Manual Model 545™...

  • Page 107: Print Module Parts List

    The same module is used in both the right and the left print stations. The part number for the complete assembly is 345090. Users Manual Model 545™ Assembly Drawings • 105...

  • Page 108: Cartridge Support Deck Assembly Drawing

    Cartridge Support Deck Assembly Drawing 106 • Assembly Drawings Users Manual Model 545™...

  • Page 109: Cartridge Support Deck Parts List

    989974 8-32 x 5/8” Cap Screw 346212 Bracket, Ground Clip 346204 Bracket, Ink Support 346201 Ink Support 990240 3/32 x ½” Roll Pin Users Manual Model 545™ Item Part # 346206 Lever, Actuator 990225 3/16 x 1/8” Shoulder Screw 346205 Lever, Actuation Bar 345105 3/32 x .312”...

  • Page 110: Feed Assembly Drawing

    Feed Assembly Drawing 108 • Assembly Drawings Users Manual Model 545™...

  • Page 111: Feed Parts List

    Feed Parts List Item Users Manual Model 545™ Part # Description 341206 Frame, Upright 351141 Ink Motor 344056K Drive Gear, 24T 990081 10-32 x ½ Cap Screw 990728 #10 Lock Washer 990017 6-32 x ½ Cap Screw 990037 #6 Washer SAE 991073 Standoff, 1 ¾, 10-32 THD...

  • Page 112: Feed Roller Assembly

    Feed Roller Assembly 110 • Assembly Drawings Users Manual Model 545™...

  • Page 113: Feed Roller Parts List

    514012 Knob, Feed Cam Lift 990120 ¼-20 x ½ Cap Screw 344090 Assembly, Roller Drive 354017 Shaft, Idler Gear 990325 Snap ring, 3/16 “E”-Ring Users Manual Model 545™ Item Part # 354008A Gear, Idler 990023 6-32 x ½ F.H.S. 990416 ½-20 x ½ F.H.S.

  • Page 114: Knife Assembly Drawing

    Knife Assembly Drawing 112 • Assembly Drawings Users Manual Model 545™...

  • Page 115: Knife Parts List

    357005 Clutch Adapter w/ 8:32 x 1/4 SS 990122 ¼-20 x ¾ Flat Head Screw 357007 Spring, Torsion Rear (Red Finish) 357011 Static Brush 357013 Mount, Cam Stop Users Manual Model 545™ Item Part # 357016 Standoff, Solenoid Arm 357019K Clutch, Square Drive 990019 6-32 x ¼...

  • Page 116: Stacker Assembly Drawing - Part 1

    Stacker Assembly Drawing – Part 1 114 • Assembly Drawings Users Manual Model 545™...

  • Page 117: Stacker Parts List - Part 1

    Static Brush 990167 ¼ Washer 990126 ¼-20 x 1-3/4 Cap Screw 348006 Bracket, “T” Nut Retainer *NS= Not shown Users Manual Model 545™ Item Part # 990019 6-32 x ¼ Button Head Screw 378216 Sensor Mount, Lower 991029 Knob, 3 Prong, 10-32 Stud...

  • Page 118: Stacker Assembly Drawing - Part 2

    Stacker Assembly Drawing – Part 2 116 • Assembly Drawings Users Manual Model 545™...

  • Page 119: Stacker Parts List - Part 2

    358017 Spring, Trip Rod 990028 6-32 x 3/8 Socket Flat Head Scr. 990029 6-32 x ¼ Socket Flat head Scr. 188008 “T” Nut #10 Machined Square *NS= Not shown Users Manual Model 545™ Item Part # 348021 Roller, Idler 348093 Assembly, Drive Roller...

  • Page 120: Rewind Assembly Drawing

    Rewind Assembly Drawing 118 • Assembly Drawings Users Manual Model 545™...

  • Page 121: Rewind Parts List

    990465 comp. spring 112031 Timing belt 67t 1/5p 112036 EAR motor insulation 999121 1/2 x 3/4 x 1/2 bushing *NS= Not shown Users Manual Model 545™ Item Part # 112037 support, shaft bearing 990090 10:32 x 3/8 btn hd screw...

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