92-2534-01 Rev.

Cutter Option
Installation Instructions

Overview
This document describes the contents and installation of the A-Class Mark II Cutter option. After verifying the kits contents and the tools needed, follow the steps to install and use the option. A maintenance procedure and a parts list are also included, so keep this documentation for future reference.

Only qualified service technicians should install this option. For safety and to avoid equipment damage, always turn Off power and unplug the power cord before starting CAUTION this installation and when performing service.

Contents of the Cutter Kit

This kit contains the following items:
1 2 3 4 5 6 7 8 9

Mounting Bracket Cutter CCA Lock Washer (2) Jack Screw (2) Control Cable Interface Cable Screw (2), Flat Head M4 X 6 Cutter Assembly Flat Washer (5) Screw (4), M4 X 20 Screw, M4 X 10 Warning Label

2 1 5 3 4 6 11 WARNING 12

9 8 7 10

10 11 12

Tools Required
To install this option, you will need a 3mm hex wrench, a 3/16-inch open-end wrench, a standard screwdriver and a Philips screwdriver.

Wear a wrist strap and follow standard ESD prevention measures during this procedure. CAUTION

Step 1: Preparing the Printer

A) Turn Off the Power Switch, unplug the power cord from the AC Receptacle, disconnect all interface cables and, if necessary for total access, remove the printer from the applicator system.
Power Switch AC Receptacle

Access Cover

B) Raise the Access Cover and the Head Lift Lever. Remove any media from the printer then lower the Head Lift Lever.
Head Lift Lever

Access Cover

C) If the Warning Label covers the Cable Receiver in the Access Cover, remove the Warning Label. (For the Cable Receivers location, see the illustration in Step 2, part C.)
Warning Label

D) Remove the following items from the Card Cage:

Card Cage

Remove the two Card Cage Cover Screws then remove the Card Cage Cover; Remove the two Main Logic CCA Screws then remove the Main Logic CCA; and, Remove the two Applicator Interface CCA Screws then remove the Applicator Interface CCA.
Card Cage Cover Main Logic CCA Main Logic CCA Screws (2 places) Applicator Interface CCA Applicator Interface CCA Screws (2 places) Card Cage Cover Screws (2 places)

E) Remove the two Service Panel Screws then remove the Service Panel, and remove the seven Rear Cover Screws then remove the Rear Cover.
Service Panel Service Panel Screws (2 places) Rear Cover Rear Cover Screws (7 places)

Step 2: Installing the Option

The following illustrations have the Rear Bracket removed for clarity. It is not nessacry to remove the Rear Bracket from your printer.

A) Starting from the back of the printer, insert the Interface Cable (Item 6) through the Centerplate Aperture.
Centerplate Aperture

Interface Cable

J17 Backplane CCA

B) Connect the Control Cable (Item 5) to J17 on the Backplane CCA.

Control Cable

Access Cover

Centerplate Aperture

Cable Receiver

C) Snap the Interface Cable Connector securely into the Cable Receiver in the Access Cover.

Interface Cable Connector

D) Route the Interface Cable across the top and then down the side of the Drive Motor, as shown.
Interface Cable Cable Bundle

Drive Motor

E) Route the Control Cable down the Cable Bundle and secure it using the twist ties.

Control Cable

Mounting Bracket

F) Place the Cutter CCA (Item 2) into the Mounting Bracket (Item 1) then install the Lock Washers (Item 3) and Jack Screws (Item 4), as shown. Securely tighten the Jack Screws.

Jack Screws Lock Washers

Cutter CCA

Rear Bracket

G) Secure the assembled Mounting Bracket to the Rear Bracket using the Mounting Screws (Item 7).
Mounting Screws Mounting Bracket (assembled)

Rear Bracket

H) Connect and secure the Interface Cable to J2 on the Cutter CCA, and connect the Control Cable to J1.
Interface Cable

J2 J1 Control Cable Cutter CCA

I)

Replace the Card Cage items: Replace the Main Logic CCA then secure it using the two Main Logic CCA Screws; Replace the Applicator Interface CCA then secure it using the two Applicator Interface CCA Screws; and, Replace the Card Cage Cover then secure it using the two Card Cage Cover Screws.

Main Logic CCA Main Logic CCA Screws (2 places)

Card Cage

Card Cage Cover Card Cage Cover Screws (2 places)

Applicator Interface CCA

Applicator Interface CCA Screws (2 places)

J) Align the Tabs on the Rear Cover to the Slots in the Centerplate then slide on the Rear Cover. Secure the Rear Cover using the seven Rear Cover Screws (3 hex and 4 Philips screws).

Centerplate

Service Panel Screws (2 places)

K) Replace the Service Panel and secure it using the two Service Panel Screws.

Service Panel Rear Cover Screws (7 places)

Slots

Tabs Rear Cover

L) Align the Cutter Assembly (Item 8) to the holes in the Centerplate and install the four Washers (Item 9) and Long Mounting Screws (Item 10). Also install the Washer (Item 9) and Short Mounting Screw (Item 11). However, do not tighten these screws leave them loose enough to allow the Cutter Assembly to be positioned.
Cutter Assembly Washer Short Mounting Screw

Centerplate

Long Mounting Screw (4 places)

Washer (4 places)

M) Tighten the Vertical Mounting Screw. Position the Cutter Assembly so that media will pass through the middle of the Cutter Throat then tighten the top two Long Mounting Screws. Next, loosen the Vertical Mounting Screw one-half turn then press down on the Lower Mounting Block and tighten the bottom two Long Mounting Screws. Retighten the Vertical Mounting Screw. Then, tighten the Short Mounting Screw and the Thumbscrew.
Cutter Throat Lower Mounting Block Short Mounting Screw Thumbscrew Cutter Assembly Long Mounting Screw (4 places) Vertical Mounting Screw

N) Connect the Cutter Cable to the Cutter Port, and then affix the Warning Label (Item 12) to the Cutter Assembly, as shown.
Cutter Port Warning Label Cutter Cable

O) If removed from the applicator system, reinstall the printer. Reconnect all interface cabling.

Cutter Assembly

Step 3: Using the Option

During operation, cut labels will be dispensed after printing. Be sure to use media that is rated for use with the Cutter (see Cutting Requirements, near the end of this document). Begin using the option as follows:

A) Load Media (see the Operators Manual for loading details). Then, route the Media out the Cutter Opening.

B) Plug the power cord into the AC Receptacle and turn On the Power Switch.
Cutter Throat

Media

C) Ensure that READY is displayed on the front panel then press the FEED Key, and proceed according to your observations: If a cut label is dispensed, this completes the installation; or, If the label feeds forward without being cut, proceed to Step 4: Configuring the Printer.

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Step 4: Configuring the Printer

While the Cutter option is a plug and play device, this step may be necessary if the printers default configuration has been changed. Follow the steps below (or consult the Operators Manual, if necessary) to configure the printer:
A) Press the MENU Key on the printers front panel. B) Using the Key, scroll to PRINTER OPTIONS then press the ENTER Key. C) Using the Key, scroll to CUTTER then press the ENTER Key. D) E) F) Using the Key, scroll to AUTO then press the ENTER Key. Press the ESC Key then, at the SAVE CHANGES? prompt, select YES. Turn the Power Switch Off and On to reset the printer and complete the configuration.

Note: The operation of the Cutter can also be controlled by host software commands, so ensure that your labeling program is properly configured for use, and for cutting labels to the desired size. To test the Cutters operation, see Testing the Cutter (near the end of this document).

Maintaining the Cutter

To ensure trouble free operation, the Cutter should be cleaned after printing each roll of labels. Additionally, if the cutting action becomes sluggish, immediate cleaning is recommended. Clean the Cutter as follows: Cutter Blades are SHARP: Keep body parts away from the cutting surfaces. Never use metal objects on the cutting surfaces. Take proper precautions when using isopropyl CAUTION alcohol, a flammable liquid.

1) Turn Off the Power Switch and unplug the power cord from the AC Receptacle. Raise the Access Cover then remove the media from the printer.

Access Cover

Cutter Cable Thumbscrew

2) Unplug the Cutter Cable. Remove the Thumbscrew and the Vertical Mounting Screw, and then remove the Cutter Assembly from the Mount.
Cutter Assembly

Vertical Mounting Screw

Mount

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Cover Screws

3) Remove the two Cover Screws from the Cutter Assembly and then remove the Cover.
Cutter Cover

Cutter Assembly

4) Using compressed air, remove any debris trapped inside the mechanism. Using a Cotton Swab dampened with alcohol, wipe the Fixed Blade clean, and then slightly raise the Sled and wipe the Moveable Blade clean.
Moveable Blade Fixed Blade Sled Cotton Swab

Note: For cleaning heavy deposits from the blades, WD-40 (or another non-damaging adhesive remover) can be substituted for isopropyl alcohol provided this substitute is carefully and sparingly applied using a cotton swab. Never spray WD-40 (or a similar substance) directly onto the assembly; severe damage can result.

5) While the Sled is raised, check the Pad Wick for sufficient lubrication if dry, replace the Pad Wick.
Pad Wick

6) Allow both blades to dry. Replace the Cutter Cover, and then secure it to the Cutter Assembly using the two Cover Screws.

7) Place the Cutter Assembly onto the Mount. Then, replace the Vertical Mounting Screw and the Thumbscrew; tighten both to secure the Cutter Assembly to the printer.

8) Reconnect the Cutter Cable.

9) Reload Media and close the Access Cover to complete the procedure.

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Testing the Cutter

The printer features a diagnostics menu that allows the function of the Cutter option to be verified. During testing, results will be displayed in a running counter following each cutter-cycling attempt made by the printer. Follow the steps below (or consult the Operators Manual, if necessary) to perform a functional test of the Cutter:
A) Press the MENU Key on the printers front panel. B) Using the Key, scroll to DIAGNOSTICS then press the ENTER Key. C) Using the Key, scroll to OPTIONS TESTING then press the ENTER Key. D) E) F) Using the Key, scroll to TEST CUTTER then press the ENTER Key. Using the Key or the Key, select the number of test cycles (1, 10, or 100 times) that you want to perform. Press the ENTER Key to begin the test.

Note: At any time during the testing phase, press the CANCEL Key to terminate testing and return to operating mode.

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Cutting Requirements
Table 1, below, lists the media requirements for use in the cutter mechanism. For a complete listing of media requirements, see the Operators Manual.
Minimum Inches 1.0 Millimeters 25 Inches 4.0 Maximum Millimeters 102

Description Media Width Media Weight Maximum

160 g/m2 (see note below) Table 1

The values in the following tables are only provided as a guide and should not be used as specifications since variances within the same basis weight can occur due to the characteristics of the stock. In addition, similar weight stocks can vary between manufacturers.

Note: The cutter may able to cut heavier media than indicated, but it is recommended that cutting performance be verified by testing the cutter with the intended stock. Table 2 shows the approximate media thickness in mils (thousands of an inch) relative to the metric weight for that media. Table 3 shows the different basis weights for the differing media types, which are equivalent in weight when compared to the metric weight.

Metric Weight to Thickness in Mils Metric Weight (g/m2) 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Copy Paper (mils) 2.7 3.2 3.7 4.3 4.8 5.3 5.9 6.4 6.9 7.5 8.0 8.5 9.1 9.6 Business Ticket Card Stock Stock (mils) (mils) 2.8 3.4 3.9 4.5 5.0 5.6 6.2 6.7 7.3 7.9 8.4 9.0 9.5 10.1 2.1 2.5 2.9 3.3 3.7 4.2 4.6 5.0 5.4 5.8 6.2 6.6 7.1 7.5 Table 2 Label w/ Linerless Liner label stock Stock (mils) (mils) 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 5.2 5.7 6.1 6.5 6.9 7.3 1.8 2.2 2.6 2.9 3.3 3.7 4.0 4.4 4.8 5.1 5.5 5.9 6.2 6.6

Metric Weight to Equivalent Weight in Lbs Metric Weight (g/m2) 60.0 66.6 74.0 88.8 103.6 118.4 131.7 135.5 148.0 150.5 161.8 165.6 175.8 199.4 Basis Weight (Copy Paper) 16.0 18.0 20.0 24.0 28.0 31.0 35.0 36.0 39.0 40.0 43.0 44.0 47.0 53.0 Table 3 Basis Weight (Card Stock) 22.0 24.0 28.0 33.0 39.0 44.0 48.0 50.0 54.0 56.0 60.0 61.0 65.0 74.0 Basis Weight (Tag stock) 37.0 41.0 45.0 55.0 64.0 73.0 82.0 83.0 91.0 93.0 100.0 102.0 108.0 122.0

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