Head Fault Error on Avery Printers [Error 5006]

June 19, 2008 by

Some Avery-Dennison printers have a print head that is automatically raised and lowered for printing by use of a stepper motor and sensor combination.  This type of arrangement can be found on printers such as the 64-xx series and on the AP7.t machine.


Occasionally the raising or lowering of the head may not occur as it is supposed to, resulting in a ‘head fault error’ (error 5006).  Should this error occur, and if it cannot be cleared, it is likely due to one of the following problems.


  1. Print head is not fully secured on the thermal print bar.  Check to make sure that the head assembly is firmly positioned on the print bar.
  2. Problem with connection between peripheral device board and the print head (either a bad or loose cable, or malfunction on the board)
  3. Failure of the head stepper motor
  4. Broken or cracked sensor disk on the head stepper motor (requires replacement of the whole motor)
  5. Faulty head sensor


Persistent 5006 errors should be referred to a qualified service technician.


Ribbon Errors on Avery Printers [Error 5008]

May 2, 2008 by

Many thermal bar code printers are capable of functioning in one of two modes: printing with a ribbon (thermal transfer) or printing using a special chemically treated paper (direct thermal).  Mistakes in setting up these different modes of printing can result in errors.  On the newer Avery printers, including the 64-xx series, AP4.4, AP5.4, and AP7.t, problems involving the print mode appear as error 5008.


The 5008 error is basically the detection of a ‘no ribbon’ condition.  In other words, the printer does not detect the presence of a ribbon in the machine.  Resolving the problem depends initially on which print mode you intend to use for your application.  Here briefly are some things to look for.


If the printer is being used in direct thermal mode, the printer of course is using no ribbon, so this error is actually extremely rare.  The usual cause for this error is attempting to run the printer in direct mode with the ‘ribbon save’ device activated.  ‘Ribbon save’ is a function that is available on the 64-xx printers as well as the AP7.t that causes the print head to lift up when it is not printing, and stops the ribbon motor.  To resolve this ‘no ribbon’ problem, follow these steps:


1)      Press the ONLINE button to acknowledge the error,

2)      Locate the Ribbon Autoecon function under System Parameters, and make sure that it is set for ‘thermal printing’ (that is, direct mode, which switches off the ribbon end function),

3)      Return the printer to normal Online mode. Printing should resume normally.


If the printer is being run in thermal transfer mode, this error is often the result of a problem with the ribbon tension.  As a rule, this simply means that at the start-up of a print job, the ribbon is not sufficiently taut.  Solving this problem is simple: Press the FEED button to acknowledge the error.  The LCD display will read ‘OFFLINE     x JOBS’.  Adjust the ribbon and make sure that it is taut.  Press the ONLINE key to resume printing.


In other cases, error 5008 is simply a warning that the printer has run out of ribbon.  In this case, press the CUT key and then the FEED key.  The LCD display will read ‘OFFLINE     x JOBS’.  Install a new ribbon in the printer, and then press the ONLINE key to resume printing.


One further note: Print drivers for the Avery-Dennison models being discussed here do not have a special setting for print mode.  In other words, it is not necessary to select either thermal transfer or direct thermal in order for the printer to function correctly.

Paper Errors on Avery-Dennison Printers: Errors 5001 and 5002

April 23, 2008 by

One of the most basic elements of printing on labels or tags is making sure that the material is properly loaded in the machine. As a rule, this is a simple matter. However, from time to time problems occur that result in error messages from the printer. On the newer Avery-Dennison printers, such as the 64-xx series, the AP4.4, AP5.4, and AP7.t printers, two different sorts of errors are possible: 1) No Gap Found [5001] or 2) Material End Error [5002]. Fortunately, in most cases, these problems are easy to resolve. Here are some things to look for if these problems occur.


This message simply indicates that the printer has been unable to locate the label gap or notch that separates one label or tag from another. Once the error occurs, it should be acknowledged by pressing the ONLINE key.

Before continuing to print, check for possible problems:

  1. Is the correct type of material loaded in the machine?
  2. Is the correct sensor type selected?

[Driver and software settings should be checked.]

  1. Is the paper sensor situated so that it can detect the gap or notch?
  2. Is the material jammed up at the platen roller?
  3. Is there dirt on the paper sensor?

As a rule it is typically one of these issues or a combination of them that causes the ‘No Gap Found’ error. So usually a careful check of the above issues will resolve the problem.


This error indicates that the printer in unable to detect the presence of any sort of material in the paper sensor.

In general, there are two sorts of things that cause this issue:

  1. Material may have run out. At the end of a roll of labels or tags, the Material End indicator will be displayed.
  2. Improper tracking of the label or tag stock may result in the material moving out of the paper sensor altogether, thus triggering the error message.

Resolving this problem is usually easy. First, acknowledge the error by pressing the ONLINE key on the printer. The LCD display will then read, ‘OFFLINE x JOBS’.

Next, re-insert your media and make sure that it is passing through the paper sensor. Also check the media guides behind the print block to ensure that label tracking is maintained from the media holder forward to the print head. Once everything is properly positioned, press the ONLINE button to resume printing.

Factory Default Settings on Avery-Dennison Printers

April 16, 2008 by

Sometimes one of the easiest ways to solve a printer problem is to restore the machine to its original factory settings. On the newer Avery-Dennison printers, such as the AP4.4, AP5.4, AP7.t, and 64-xx series, this reset is accomplished by following a few simple steps. The procedure for resetting the printer is provided here, along with some cautions that you should consider before you actually go ahead and do the reset.


  1. With the printer in ONLINE mode, press the ON/OFFLINE key. The LCD display will read ‘OFFLINE’.
  2. Press the ESC key. The printer will now be in System mode, which provides access to all of the printer’s parameter menus. The first menu that you will see reads, ‘PRINT INFO’.
  3. Press the CUT key until you arrive at ‘SPECIAL FUNCTION’.
  4. Press the ONLINE key to enter the submenu.
  5. Press the CUT key until you come to ‘FACTORY SETTINGS’.
  6. Hit the ONLINE key once. The printer will display a prompt indicating whether you want to go ahead with the factory reset. Press the ONLINE key to continue.
  7. The printer will automatically re-initialize and return to ONLINE mode.


After running this procedure, the print head resistance value will need to be reset. The value that you need to use is provided for you on the print head itself. For example, on the underside of the AP5.4 print head, you will see something like the following: ‘R=1204’. This number indicates the print head resistance value in ohms.

In addition, resetting the factory defaults erases any special settings that may be required for particular print applications. Any such special functions will need to be turned back on manually.

How to connect the Generic / Text Only driver to the LPT1: port on your computer

April 11, 2008 by



Go to Printers and Faxes and select Add a printer you will get the following screen


Press Next select Local printer attached to this computer and make sure that the Automatically detect Plug and Play printer is unchecked then click Next


You will ge the screen below.  Make sure that you are using the LPT1: port, as shown and click Next



Select Generic in the left hand column and Generic / Text Only in the right column and press Next


You may change the name if you wish because it does not affect the function of the driver.  It will be required if you already have this driver installed on your PC.  You do not need to make it you Default printer, but may if you wish.  Press Next when you are done.


I do not share the printer, but you may if you wish.  Press Next.



Select No as shown below and click Next


Press Finish and the printer will install


You may now select the printer driver you have installed.

Threshold calibration on a Toshiba TEC B-472/B-572/SX-4T/SX-5T

April 11, 2008 by

When the printer is ONLINE, press PAUSE

The printer should display PAUSE

Release the PAUSE button and then press and hold the PAUSE button.

One of two things should happen depending on firmware version.

1. The printer should start issuing labels – you should continue to hold the pause PAUSE key until at least three labels are issues

2. OR the display will show TRANSMISSIVE. Then do as in number one.

When the labels are done, press RESTART to put the printer back ONLINE.


You may put the labels back in the machine if you wish, but it is not necessary.

PAPERJAM on a Toshiba TEC B-472/B-572/SX-4T/SX-5T

April 11, 2008 by

On a Toshiba TEC thermal printer, PAPERJAM XX simply means that the printer did not see top of form (TOF) where it was expecting to see TOF. The XX portion is how many labels/tags are remaining in the print job.


In most cases, PAPERJAM is caused when the user presses the FEED key without sending a print job to the printer first.


Without sending a print job to the printer, the printer assumes a 4”x3”, die cut, plain white label with ribbon and no options turned on.


If PAPERJAM persists when a print job has been sent, determine the following:

· Are the labels preprinted? (not a plain white label)

o To resolve this problem, use the preprint sensor(set in the software) and do a Threshold Calibration.

· Were the labels measured to make sure that the label size is what is expected.

· Measure the gap to ensure that the expected gap is programmed.

· Is the paper sensor on the label and will it see a gap/notch/TOF?

· Is something stuck in the gap sensor

· Does the ribbon go through the gap sensor? (it should not)