Memjet MACH 5 Service Manual
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Memjet MACH 5 Service Manual

Digital color printer
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MACH 5, AS-950C, HJ950C
DIGITAL COLOR PRINTER

SERVICE GUIDE

Rev 6-23-14

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Summary of Contents for Memjet MACH 5

  • Page 1: Service Guide

    MACH 5, AS-950C, HJ950C DIGITAL COLOR PRINTER SERVICE GUIDE Rev 6-23-14...

  • Page 2: Safety Precautions

    SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE RENA MACH 5 PRINTER. BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: ...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents SECTION 1 – Before You Begin Recommended Troubleshooting Supplies Common Service Tools Needed: Minimum Computer System Requirements Print Engine Reference Note: If you Have Setup-Operations Questions: SECTION 3 – Troubleshooting Print Quality Issues: Examples of Print Quality Issues (including possible causes and solutions) Scuff Marks and Smudging Issues: Fuzzy/Distorted Print The Ink Tank(s)
  • Page 4 TABLE OF CONTENTS Section 6 – Disassembly/Assembly Procedures Preparing the Printer for Service Installation and Service Videos (where to find) Basic Disassembly Service Disassembly Procedures Left-hand (Operator) Side Covers Right-hand (Non-Operator) Side Cover Replacing Motor Drive Belt or Motor Replacing the Clutch Replacing the Feeder Encoder and/or Encoder Sensor Replacing Feed Rollers Replacing Delivery Rollers...
  • Page 5 TABLE OF CONTENTS Inspecting the Wiper Roller Cleaning/Replacing Service Station Items Removing the Service Station Cleaning the Service Station Wiper Roller Removal and Cleaning or Replacement Wiper Motor Assembly Removal and Cleaning Printing Platen and Capping Station Removal and Cleaning Cleaning the Service Station Tray Suggestion for High Volume Users: Installing the Service Station...
  • Page 6 TABLE OF CONTENTS NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________...

  • Page 7: Section 1 - Before You Begin

    SECTION 1 BEFORE YOU BEGIN SECTION 1 – Before You Begin The following troubleshooting guides are provided to assist you in solving any problems that might occur with the Digital Color Printer. We have tried to make them as complete as possible, but this section will always be evolving.

  • Page 8: Minimum Computer System Requirements

    SECTION 1 BEFORE YOU BEGIN Minimum Computer System Requirements • Windows XP, Windows Vista, Windows 7. Supports 32 and 64 bit systems. • You must have administrative privileges on the system. • Pentium II, 2 GHz minimum (Pentium Dual Core, 2.5 GHz or better, is optimal) •...

  • Page 9: Section 3 - Troubleshooting

    SECTION 3 TROUBLESHOOTING SECTION 3 – Troubleshooting The following troubleshooting guides are provided to assist you in solving any problems that might occur with the Digital Color Printer. We have tried to make them as complete as possible, but this section will always be evolving.

  • Page 10: Examples Of Print Quality Issues (Including Possible Causes And Solutions)

    Examples of Print Quality Issues (including possible causes and solutions) The Memjet printhead cartridge contains 70,400 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for some nozzles to become contaminated or clogged.
  • Page 11 SECTION 3 TROUBLESHOOTING Clogged Nozzles: Clogged/damaged/dead/ nozzles will normally show as thin, crisp, vertical lines of missing color. Multiple adjacent nozzles, with same issue, will show as wider, crisp, vertical lines of missing color. Clogged nozzles are normally due to Printhead nozzle dehydration or partial contamination. Damaged nozzles are normally due to improper cleaning or debris on wiper roller causing damage to head.
  • Page 12 SECTION 3 TROUBLESHOOTING Color Mixing Issues: Color mixing will show as muddy, mottled or distorted (grainy) colors. Color mixing occurs when the ink from one color channel crosses over into another color channel. Since the inkjet nozzle rows are located very close to one another (ten rows of 7,040 nozzles, located within a 0.8 mm space), it is easy for partials or fibers to create bridges across color channels.

  • Page 13: Scuff Marks And Smudging Issues

    SECTION 3 TROUBLESHOOTING Scuff Marks and Smudging Issues: Scuff Marks occur when the media makes contact with an area of the printhead that has ink on it. Smudging occurs when the wet image, on the media, makes contact with something (most commonly the printhead) before it is dry.
  • Page 14 SECTION 3 TROUBLESHOOTING Smudging: Here is an example of “smudging” that occurred when an area of this page, with a wet image, made contact with the printhead. Note: There are also scuff marks in this example. As mentioned previously; smudging will increase the chance for scuff marks;...

  • Page 15: Fuzzy/Distorted Print

    SECTION 3 TROUBLESHOOTING Fuzzy/Distorted Print Fuzzy/distorted print can occur for a number of reasons; listed/shown below. Problem: Poor original image quality (less than 300 dpi). Solution: Use high quality images. Problem: Choosing to print image in low resolution from software application. Solution: Set image to highest resolution possible from software application.

  • Page 16: The Ink Tank(S)

    SECTION 3 TROUBLESHOOTING The Ink Tank(s) CONDITION PROBLEM SOLUTION Installed New Ink Tank and One or more of the “septum Try removing and re- shortly after the related Ink needles” didn’t fully puncture the installing the Tank. See septum seal on the new Ink Tank. “Installing The Ink Tanks”.

  • Page 17: The Printhead Cartridge

    TROUBLESHOOTING The Printhead Cartridge The Memjet printhead cartridge contains over 70,000 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for some nozzles to become contaminated or clogged.
  • Page 18 SECTION 3 TROUBLESHOOTING The Printhead Cartridge (continued) CONDITION PROBLEM SOLUTION Wet the Printhead nozzles System will not prime the Printhead nozzles dry (air pulled through nozzles; not allowing using distilled water and a printhead after installing system to create vacuum) wet, lint-free cloth.

  • Page 19: The Printer

    SECTION 3 TROUBLESHOOTING The Printer Troubleshooting Tip: If you recently replaced the Main Board and you are experiencing problems; please see “Replacing the Main PC Board (MPCA)” and “MPCA (Main Printed Circuit Assembly) Connections”; to verify your connections. Also check for damaged wires and loose connections. NOTE: The printer will not print if any of the five ink tanks are empty or missing.

  • Page 20: Power (Power-Up) Problems

    If Power Supply is providing power (24VDC) to Main PCB, replace Main PCB. Wrong model Check “set_model” in Toolbox, Service Menus, selection in Toolbox Commands Help menu. M1 = MACH 5. M2 = MACH 8. Valid for FW 20140408 or higher...

  • Page 21: Service Station Problems

    SECTION 3 TROUBLESHOOTING Service Station Problems CONDITION PROBLEM SOLUTION Service Station was not installed Eject Service Station. Cycle print Service Station Drive properly. engine off/on. If drive motor turns Motor stalls. without stalling then motor is OK. Before re-installing Service Make sure SS is installed squarely.

  • Page 22: Interface Communication Problems

    SECTION 3 TROUBLESHOOTING Interface Communication Problems CONDITION PROBLEM SOLUTION Wrong USB port selected in “M Verify that you are selecting the M Series Driver does not respond to printer being Series Driver”. appropriate USB port in the connected via USB. driver Ports Tab.

  • Page 23: Feeding Problems

    SECTION 3 TROUBLESHOOTING Feeding Problems CONDITION PROBLEM SOLUTION Intermittent feeding Media Support Wedge not used. The Media Support Wedge adds a slope to the stack and helps feeding. Side Guides set too tight to media. Readjust Side Guides. Dirty Feed Rollers. Clean the Feed Roller with distilled water and a cloth.
  • Page 24 SECTION 3 TROUBLESHOOTING Feeding Problems (continued) CONDITION PROBLEM SOLUTION Right edge of media Media is hitting the limits inside Make sure Adjustable Media Side Guide being damaged as it the print engine. is at least 1/8” away from side frame. If stock is over 9.5”...

  • Page 25: Error's And Warnings

    SECTION 3 TROUBLESHOOTING Error’s and Warnings Alert Window Messages Messages sent from the driver and displayed on PC screen in a small popup window. MESSAGE SOLUTION Cleaning in Progress Wait until the message disappears. The printer will start printing your job once the cleaning process has completed.

  • Page 26: Toolbox System Status Messages

    SECTION 3 TROUBLESHOOTING Toolbox System Status Messages Displayed, in red, in the M Series Toolbox utility. SYSTEM STATUS PROBLEM SOLUTION Out of Paper Load media into printer and press the PAPERPATH_FEED_TIME Media is not reaching PAPER/RESUME button. the print engine. If media is present;...
  • Page 27 SECTION 3 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. SYSTEM STATUS PROBLEM SOLUTION X = Color. Ink Tank replacement will be necessary X_INK_LOW soon. Reorder Ink One or more Ink Tanks Example: CYAN_ INK_LOW are low on ink.
  • Page 28 SECTION 3 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. SYSTEM STATUS PROBLEM SOLUTION The printer’s electronics If just powered on, wait a few minutes; TILT_ERROR have detected that the error may clear by itself. Once Tilt EXCESSIVE_TILT_ERROR print engine is too far level reading changes to “black”...
  • Page 29 SECTION 3 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. SYSTEM STATUS PROBLEM SOLUTION Problem communicating Eject Printhead and inspect/clean [Crit 63 03-phead offline with Printhead or Pen contacts (printhead and pen board). cancelpage restart] Board.
  • Page 30 SECTION 3 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. SYSTEM STATUS PROBLEM SOLUTION If just powered on, wait a minute; error PRINTHEAD_UNPRIMED Printhead priming may clear by itself. process has failed. If priming fails; replace missing/empty Ink Tanks or Tanks that are reading less than 30%.

  • Page 31: Ink Accumulating In The Wrong Areas Of The Printer

    SECTION 3 TROUBLESHOOTING Ink Accumulating in the Wrong Areas of the Printer Ink deposited into the Service Station during purging, cleaning, capping travels from the service station into a trough below the service station, where it is channeled down into the Waste Ink Tray. If ink is accumulating in areas that are not normal waste ink paths please check the following possibilities.

  • Page 32: Jams In The Printer

    SECTION 3 TROUBLESHOOTING Jams in the Printer When the printer detects a media feed problem, it will stop automatically. Depending on where the media stops; the message “PAPERPATH_PAPERJAM” or “PAPERPATH_FEED_TIMEOUT” will be displayed in the Toolbox. Once the jam has been removed from the system and the print engine is closed; press the PAPER/RESUME button on the control panel or press the Clear Error button in the Toolbox to continue printing.

  • Page 33: How To Zero The Tilt Sensor

    SECTION 3 TROUBLESHOOTING Misfeeds Misfeeds can be corrected by readjusting the Sheet Separators to the media or replacing them. See “Replacing the Sheet Separators”. How to Zero the Tilt Sensor CAUTION! Prior to using this option, verify that your printer is on a sturdy, level surface. This is of utmost importance, since being out of level can cause the printer to perform poorly.

  • Page 34: Section 4 - Toolbox Service Features

    SECTION 4 TOOLBOX SERVICE FEATURES SECTION 4 – Toolbox Service Features Using / Opening the Printer Toolbox Once the Printer Driver is installed you have access to the Toolbox. The Toolbox lets you check printer status, monitor ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your computer.

  • Page 35: Firmware Download Feature

    SECTION 4 TOOLBOX SERVICE FEATURES Firmware Download Feature [E] Firmware Download – Get the latest version of firmware for your Printer. How to download new firmware: 1. When you are notified that new firmware is available for your Printer, download the *.fbf file and save it to your desktop.

  • Page 36: Network Configuration Menu

    SECTION 4 TOOLBOX SERVICE FEATURES Network Configuration Menu 1. The “Network Configuration” page opens. Use Network Settings to enter the correct settings for your network. 2. Connect Ethernet cable to Network Port on Rear Panel of Printer. Service Menus For authorized service personnel only. Provides access to more advanced Printer Control and Maintenance menus.

  • Page 37: Printer Maintenance Configuration Screen

    SECTION 4 TOOLBOX SERVICE FEATURES Printer Maintenance Configuration Screen: Allows technician to enable or disable certain maintenance functions. “Zero Tilt Sensor” can reset the Tilt Warning in the Printer Status column. You can also “Print Sample Page,” “Print Configuration,” “Print Diagnostics,” “Print Demo Page,” “Print Ink Channels”...

  • Page 38: Printer Control Configuration Screen

    SECTION 4 TOOLBOX SERVICE FEATURES Printer Control Configuration Screen: Allows technician to make fine adjustments as to how a job is fed into and through the Printer and how it will print. You can also return the Printer to the default settings by pressing the “Reset to Factory Settings” button. NOTE: After changing the settings on this page and pressing Submit, you must properly power-down the Print Engine, before they will be saved.

  • Page 39: Scan Sensors Screen

    SECTION 4 TOOLBOX SERVICE FEATURES Scan Sensors Screen: Scan Sensors (Check/Pole Sensor Conditions): Provide status and history log on sensors located throughout the Printer. (See chart below) SENSOR DESCRIPTION Entry Sensor Interrupted (media present) = 0-60 (Paper Path Entry) Uninterrupted (no media) = 255 Blackmark Sensor NOTE: Not applicable for this model.

  • Page 40: Commands Help Screen

    SECTION 4 TOOLBOX SERVICE FEATURES Commands Help Screen: Printer Commands Help Screen: Provides a list and descriptions of available EWS service commands. CAUTION! To help avoid issues that may be caused by using these commands improperly; commands should not be used unless you are following the instruction of a Tier 2 Support Agent or are following a written procedure from this manual.

  • Page 41: Section 5 - Measurements And Adjustments

    SECTION 5 MEASUREMENTS & ADJUSTMENTS SECTION 5 – Measurements and Adjustments CAUTION ALWAYS WEAR A WRIST STRAP THAT IS GROUNDED WHEN TOUCHING ELECTRONIC DEVICES. Drive Belt Tension Adjustment REQUIREMENT: To ensure the Drive Belt has the proper tension, use the 42-101-33T Belt Tension Tool to properly adjust Motor Belt Drive tension without guesswork.

  • Page 42: Power Supply

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Power Supply The Power supply converts the incoming AC voltage into 24 VDC. The DC output provides power to the electronics for the entire printer. Power Supply Measurements: Input: 100 – 240 VAC (This is an auto-switching power supply) Output: 24 VDC (+ or –...

  • Page 43: Media Sensors

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Media Sensors Feed Sensor The feed sensor detects the media as it feeds between the sheet separation area and the print engine. This is a retro-reflective sensor. The sensor is located below the deck of the printer (see image below). The sensor looks up at a reflector, which is attached to the underside of the plate on the center pressure rollers.
  • Page 44 SECTION 5 MEASUREMENTS & ADJUSTMENTS Troubleshooting Tips: 1) If the sensor signal (Senor LEDs or voltage at I/O Board) is NOT switching check the following: Check the sensor connection to the I/O board. Check to be sure the sensor and reflector are clean. Check the angle of the reflector (could be bent).

  • Page 45: Print Engine Sensors

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Print Engine Sensors There are two media sensors within the feed path of the print engine that are used to monitor paper entering and exiting the print engine area. There is also a Margin sensor in the paper feed path, but this sensor is not active (not used). Entry Sensor Receiver Mark Sensor...

  • Page 46: Feeder Encoder Sensor And Encoder Wheel

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Feeder Encoder Sensor and Encoder Wheel The Feeder Encoder is responsible for matching the speed of the feed section with the speed of the print engine. If a problem develops with this sensor (example: encoder wheel gets dirty), then you will normally see issues with the transition of media from the feed section to the print engine.

  • Page 47: Dust Exhaust Fans

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Dust Exhaust Fans In conjunction with the Antistatic Brush Assembly the fans and air plenums are used to remove dust and debris from media. This is done to reduce the amount of dust and debris that enters the print- engine area.

  • Page 48: Clutch (Feed Roller Drive)

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Clutch (Feed Roller Drive) The clutch is used to engage/disengage drive to the feed rollers. When the Feeder Motor is driving and the clutch is engaged; the feed rollers are driven to deliver media into the print engine. Measurement: To check the clutch for proper operation: Measure from TP3, to the bottom pin on J7 (Clutch In), on...

  • Page 49: Feed Roller Drive Pulley Test

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Feed Roller Drive Pulley Test: With the clutch removed; rotate the Feed Roller Drive Pulley (sprocket) counter-clockwise. The center section (clutch drive spline) should also drive counter-clockwise with the rotation of the Pulley. If the center section does not drive with the counter-clockwise rotation of the Pulley;...

  • Page 50: Dual Pinch Valve Connection

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Dual Pinch Valve Connection If you should receive the [System Status: Fatal 71 02-? offline cancelpage] [System Status: MECH_FAIL_PERMANENT] message, in the Toolbox utility window; along with the message “Reason: ids valve failed three times” “Reason: Ink valve failed”;...
  • Page 51 SECTION 5 MEASUREMENTS & ADJUSTMENTS 3. Look through the open side of the Printer. The Dual Pinch Valve connector (white) is located just behind the metal duct, for the lower dust exhaust fan. Note: The factory has started to hot- glue this connection;...

  • Page 52: Interface (I/O) Board Test Points

    SECTION 5 MEASUREMENTS & ADJUSTMENTS Interface (I/O) Board Test Points This board is located on the non-operator side of the printer. NOTES: There are two versions of the Interface (I/O) Board (42-500-30 and 42-500-30 Rev B). The Rev B board has additional FAN connections. The measurement information shown below is valid for both.

  • Page 53: Section 6 - Disassembly/Assembly Procedures

    SECTION 6 DISASSEMBLY AND ASSEMBLY Section 6 – Disassembly/Assembly Procedures Preparing the Printer for Service NOTE: We suggest the use of protective gloves during this process. For System you Can Deprime. If possible; please follow the procedure, as outlined below, before performing service tasks. Please complete the following to prepare the printer for service.

  • Page 54: Installation And Service Videos (Where To Find)

    SECTION 5 DISASSEMBLY AND ASSEMBLY Installation and Service Videos (where to find) Installation and Service Videos are also available for this product. Neopost/Hasler Technicians: Please see the Knowledgebase for Installation and Service Videos. Rena Systems Technicians: Please see the Rena Dealer Net area for Installation and Service Videos. Basic Disassembly Turn off Power Disconnect Power Cord...

  • Page 55: Left-Hand (Operator) Side Covers

    SECTION 6 DISASSEMBLY AND ASSEMBLY Left-hand (Operator) Side Covers 1. Remove (2) screws at the top and bottom of the Left- hand Rear Side Cover. Remove the Cover. 2. Remove (2) screws at the top and bottom of the Left- hand Front Side Cover.

  • Page 56: Right-Hand (Non-Operator) Side Cover

    SECTION 5 DISASSEMBLY AND ASSEMBLY Right-hand (Non-Operator) Side Cover 1. Remove the (2) screws at the top of the Cover. Then remove the (3) screws from the bottom of the Cover. Major Components under Right-Hand (Non-Operator) Side Cover 1. Interface PC Board 2.

  • Page 57: Replacing Motor Drive Belt Or Motor

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing Motor Drive Belt or Motor 1. Remove Right-hand Side Cover. NOTE: To remove the motor, remove the five screws holding the right-hand side cover. 2. [1] Loosen the (2) motor mounting screws to relieve tension on the Motor Drive Belt. [2] Then remove the (2) screws ] and the Encoder Sensor.

  • Page 58: Replacing The Feeder Encoder And/Or Encoder Sensor

    SECTION 5 DISASSEMBLY AND ASSEMBLY 3. Push the Clutch toward the pulley to get access to the mounting pin. Remove the retaining pin. 4. Remove the Clutch from the Feed Roller Shaft. 5. Reassemble in reverse order. Replacing the Feeder Encoder and/or Encoder Sensor 1.

  • Page 59: Replacing Feed Rollers

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing Feed Rollers 1. Unplug the Printer from power. 2. Follow the instructions above and remove the Right- hand Side Cover, Drive Belt and Clutch before beginning the replacement of the Feed and Forwarding Rollers. 3.
  • Page 60 SECTION 5 DISASSEMBLY AND ASSEMBLY 8. Lift the Center Plate Assembly from the machine and set aside. 9. Remove the screw holding the Clutch Support Bracket and remove the bracket. 10. Remove the Rear Feed Roller Drive Pulley. NOTE: The spring and washer keep tension on the clutch so that the pin holding the clutch remains in place.
  • Page 61 SECTION 6 DISASSEMBLY AND ASSEMBLY 11. Remove the washer and spring from the Feed Roller Shaft. NOTE: The spring and washer keep tension on the clutch so that the pin holding the clutch remains in place. Reassemble these parts as shown. 12.

  • Page 62: Replacing Delivery Rollers

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Delivery Rollers The Delivery Rollers are part of the Front Center Assembly on the feed end of the Print Engine. 1. Remove the Left hand Rear Side Cover. Remove (2) screws at the top and bottom of the Rear Left- hand Side Cover.
  • Page 63 SECTION 6 DISASSEMBLY AND ASSEMBLY 4. Remove Top Cover. Remove “cover pivot screw” on right-hand side (non-operators side). Remove Top Cover and set aside. Tip: To save time; you can skip this step. Top cover will be released once you remove the operator side-frame (step 8). 5.
  • Page 64 SECTION 5 DISASSEMBLY AND ASSEMBLY Remove Ink Tank Door. Carefully unhook the (2) springs (one on each side), then remove the mounting screw from the left-hand side (Control Panel Side). Remove Door and set aside. Tip: To save time; you can skip this step. Ink Tank Door will be released once you remove the operator side-frame (step 8).
  • Page 65 SECTION 6 DISASSEMBLY AND ASSEMBLY 10. Remove Side Fan (2 screws). [A] Remove Media Bracket Stud #1 (1 screw) and the small screw holding the Assembly on left-hand side. [B] Take the Front Center Plate by sliding it off the alignment studs on the Print Engine.

  • Page 66: Replacing Interface (I/O) Board

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Interface (I/O) Board 1. Remove the Right hand Side Cover. 2. Carefully unplug all connections from the I/O Board. NOTE: The connector locations on Rev B boards are different than shown here. Wires are labeled for easy reconnection.

  • Page 67: Replacing The Main Pc Board (Mpca)

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing the Main PC Board (MPCA) Valid for Z3 and higher Print Engines. WARNING THE FOLLOWING PROCEDURE SHOULD ONLY BE DONE BY A QUALIFIED, TRAINED SERVICE REPRESENTATIVE. Before you Begin: • Verify that you have ordered and received the proper version board for the Print Engine that is installed, in your printer.
  • Page 68 SECTION 5 DISASSEMBLY AND ASSEMBLY Procedure: 1. Turn off the Printer CAUTION WHENEVER POWERING DOWN UNIT, ALWAYS: 1. PRESS THE POWER BUTTON ON THE CONTROL PANEL. 2. WAIT FOR THE PRINTER TO STOP PROCESSING. 3. THEN PRESS THE MAIN POWER SWITCH ON THE REAR PANEL. 2.
  • Page 69 SECTION 6 DISASSEMBLY AND ASSEMBLY 7. Remove the Main PCB Cover Using a T10 Torx driver remove the screws that secure the cover. There will be 4 or 5 screws, depending on print-engine version. Tip: The top section of this cover wraps around the back- side of the enclosure.
  • Page 70 SECTION 5 DISASSEMBLY AND ASSEMBLY 11. Install the New Main PCB to the frame using the T10 screws. 12. Carefully reconnect all connections to the New Main PCB, in the following order. Please follow this process, step by step, to be sure each connection is installed into the appropriate socket.
  • Page 71 SECTION 6 DISASSEMBLY AND ASSEMBLY a. J1002 Cable J1002 Socket Location (Connection)
  • Page 72 SECTION 5 DISASSEMBLY AND ASSEMBLY b. J1000 Cable J1000 Socket Location (Connection)
  • Page 73 SECTION 6 DISASSEMBLY AND ASSEMBLY c. J551 Cable J551 Socket Location (Connection)
  • Page 74 SECTION 5 DISASSEMBLY AND ASSEMBLY d. J703 Cable J703 Socket Location (Connection)
  • Page 75 SECTION 6 DISASSEMBLY AND ASSEMBLY e. P2002 Cable P2002 Socket Location (Connection)
  • Page 76 SECTION 5 DISASSEMBLY AND ASSEMBLY f. P2004 Cable P2004 Socket Location (Connection)
  • Page 77 SECTION 6 DISASSEMBLY AND ASSEMBLY g. P2006 Cable P2006 Socket Location (Connection)
  • Page 78 SECTION 5 DISASSEMBLY AND ASSEMBLY h. J35 Cable J35 Socket Location (Connection)
  • Page 79 SECTION 6 DISASSEMBLY AND ASSEMBLY i. P1 Cable P1 Socket Location (Connection)
  • Page 80 SECTION 5 DISASSEMBLY AND ASSEMBLY j. P2005 Cable P2005 Socket Location (Connection)
  • Page 81 SECTION 6 DISASSEMBLY AND ASSEMBLY k. P2003 Cable P2003 Socket Location (Connection)
  • Page 82 SECTION 5 DISASSEMBLY AND ASSEMBLY l. J20 Cable J20 Socket Location (Connection)
  • Page 83 SECTION 6 DISASSEMBLY AND ASSEMBLY m. J2001 Cable J2001 Socket Location (Connection)
  • Page 84 SECTION 5 DISASSEMBLY AND ASSEMBLY n. J250 Data Cable J250 Data Cable Socket Location (Connection) o. J260 Data Cable J260 Data Cable Socket Location (Connection)
  • Page 85 SECTION 6 DISASSEMBLY AND ASSEMBLY 13. Verify that All Cables Are Installed NOTE: There will be 10 open sockets after all cables have been installed. Open Sockets: J550, J554, J553, J750, J706, J504, J353, J400, J37, P900.
  • Page 86 SECTION 5 DISASSEMBLY AND ASSEMBLY 14. Reinstall the Main PCB Cover with 4 or 5 screws removed in Step 7. Do NOT over-tighten the screws. Be careful not to pinch any wires. Tip: Triple check that all connections have been properly made before installing the Main PCB Cover.

  • Page 87: Mpca (Main Printed Circuit Assembly) Connections

    SECTION 6 DISASSEMBLY AND ASSEMBLY MPCA (Main Printed Circuit Assembly) Connections NOTE: Valid for Z3 and higher Print Engines. This info is NOT valid for Z2i Print Engines The following chart shows where the connections to the MPCA come from and a brief description of what they are used for (what they do).

  • Page 88: Removing The Print Engine

    SECTION 5 DISASSEMBLY AND ASSEMBLY Removing the Print Engine Note: There is a “service video” available for this procedure. 1. Open the Top Cover. Open the Toolbox, press the Release Printhead button. Printer will "deprime" pumping all the ink back to the ink tanks, then the Printhead Cover will open. Remove the Printhead Cartridge and carefully put it back in the original packaging.
  • Page 89 SECTION 6 DISASSEMBLY AND ASSEMBLY Remove Ink Tank Door. Carefully unhook the (2) springs (one each side), then remove the mounting screw from the left-hand side (Control Panel Side). Remove Door and set aside. Tip: To save time; you can skip this step. Ink Tank Door will be released once you remove the operator side-frame (step 12).
  • Page 90 SECTION 5 DISASSEMBLY AND ASSEMBLY Unplug Network, USB and Main Power connectors from Print Engine Circuit Board. Disconnect the wires attached to the Power, Paper and Cancel Buttons at connectors. NOTE: Wires are labeled to simplify reconnection. 10. Remove Antistatic Brush Assembly [A] from mounting studs.
  • Page 91 SECTION 6 DISASSEMBLY AND ASSEMBLY 11. Disconnect the following wires from the Interface Printed Circuit Board located on the right hand side of the Printer Frame.: [A] Clutch Out (J8), [B] S4 (J9) [C] Motor In (J2). NOTE: Connector location [C] on Rev B boards is different than shown here.
  • Page 92 SECTION 5 DISASSEMBLY AND ASSEMBLY 13. Slide the printer off the side of the work table so you can reach underneath to access and remove the four Allen screws; securing the Print Engine to the Base Plate. NOTE: The image above shows a printer on its side to help identify screw locations only. This is NOT the suggested way to access and remove these screws.

  • Page 93: Print Engine Basic Disassembly

    SECTION 6 DISASSEMBLY AND ASSEMBLY Print Engine Basic Disassembly The Print Engine must be removed from the Printer for these procedures. See "Removing the Print Engine" in previous pages. It is also assumed that the ink tanks, printhead and service station are removed. Removing the Print Engine Base Provides access to parts located underneath the Print Engine.

  • Page 94: Replacing Peristaltic Pump Assembly

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Peristaltic Pump Assembly Remove old Pump Assembly: [A] Remove (4) screws that hold bracket to chassis. [B] Cut cable tie holding wiring harness to Assembly. [C] Unplug connector from pump motor circuit board. [D] Cut as shown or remove hoses from barbs.

  • Page 95: Cleaning Dual Pinch Valve Sensors

    SECTION 6 DISASSEMBLY AND ASSEMBLY Cleaning Dual Pinch Valve Sensors If “Valve: Unknown” appears for other than a few seconds in the “Valve:” line of the Printer Toolbox, it may indicate that the DPV Sensors are blocked (dusty/dirty). The Print Engine must be removed and turned on its side for this procedure.

  • Page 96: Replacing Dual Pinch Valve Sensor Pc Board

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Dual Pinch Valve Sensor PC Board The Dual Pinch Valve Sensor PC Board Replacement Kit (42-900-85) includes a new Sensor Printed Circuit Board, three (3) metal Inserts and a Pinch Valve Wrench. Remove the Dual Pinch Valve Assembly. [A] Remove (4) screws that hold Bracket to Chassis.
  • Page 97 SECTION 6 DISASSEMBLY AND ASSEMBLY 2. Detach the Motor Assembly. Remove the three (3) screws [A] holding the Pinch Valve Motor Assembly on the Pinch Valve Body. Remove the Motor Assembly. 3. Remove the single screw, shown, and then remove the Dual Pinch Valve Sensor PC Board from the Valve body.
  • Page 98 SECTION 5 DISASSEMBLY AND ASSEMBLY 6. Attach the Motor Assembly. Install all three (3) screws [A] and then tighten them to secure the Pinch Valve Motor Assembly to the Pinch Valve Body. 7. Remove the Pinch Valve Wrench. 8. Reinstall the Pinch Valve Assembly in reverse order.

  • Page 99: Replacing Dpca Board

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing DPCA Board [A] Remove (2) screws on the outside of the chassis that attach the Circuit Board Bracket to chassis. [B] Carefully move the DPCA Assembly out to unplug the wire harness connectors. NOTE: Make sure you know which connectors go with which socket.

  • Page 100: Replacing Buffer Boxes (3 Per Machine)

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Buffer Boxes (3 per machine) [A] Each Buffer Box is held in place by (2) screws accessed through the ink tank station. Using a long Phillips screwdriver, remove the screws and pull up on the Box to remove it from the chassis.

  • Page 101: Removing The Pen Driver Printed Circuit Assembly (Pca)

    SECTION 6 DISASSEMBLY AND ASSEMBLY Removing the Pen Driver Printed Circuit Assembly (PCA) Location: Upper Clamshell next to the Printhead Cartridge Bay. [A] Remove the Pen Driver PCA Cover (lightly glued in place). [B] Disconnect the (2) Ethernet data cables, then unplug the power connector and Main PCA harness connectors.

  • Page 102: Replacing The Ink Tank Latches

    SECTION 5 DISASSEMBLY AND ASSEMBLY Internal: [A] Remove the Pen Driver Printed Circuit Board Cover. [B] Remove (2) screws from bottom of Pen Driver Printed Circuit Board Bay. [C] Locate and carefully release the (2) black locking tabs holding the Starwheel Assembly to the metal bracket.
  • Page 103 SECTION 6 DISASSEMBLY AND ASSEMBLY 3. Once the Latch pops up, click “Shutdown” to shut down the Printer. 4. Lift the Latch manually to access the (2) Latch Springs. 5. Remove the Printhead Cartridge by tilting it toward the ink lines, then carefully lifting it out of the Printhead Compartment.
  • Page 104 SECTION 5 DISASSEMBLY AND ASSEMBLY regulations. Intall the new Printhead Latch: 1. Align the right tab of the Latch with the right hinge and gently press into place. Repeat for the left side. 2. [A] Use needle-nose pliers to install the right Spring into the plastic tab in the base of the housing.

  • Page 105: Replacing The Printhead Lever Latch Solenoid

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing the Printhead Lever Latch Solenoid Follow the steps below to replace the Lever Latch Solenoid: Remove the Printhead Latch Solenoid 1. Go to the Printer Toolbox User Interface screen and click “System Deprime”. 2. Click “Release Printhead” to release the Printhead Latch.
  • Page 106 SECTION 5 DISASSEMBLY AND ASSEMBLY 7. Remove the two (2) screws securing the Solenoid to the Base Assembly. 8. Cut two cable ties [A]. Unplug the Solenoid connector [B] from the wiring harness. 9. Carefully lift the Base Assembly just enough to remove the Solenoid assembly from under the Base Assembly.

  • Page 107: Replacing The Clamshell Latch Pins

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing the Clamshell Latch Pins The Upper and Lower Latch Pin Kits replace Print Engine Clamshell Latch Pins that may have become bent or broken. TIP: It is possible to perform these procedures without removing the Print Engine from the printer. However, when replacing the Lower Latch Pins;...
  • Page 108 SECTION 5 DISASSEMBLY AND ASSEMBLY 5. Cut and remove the (2) cable ties holding the wire harness to the Print Engine Frame Crossmember. 6. Remove Latch Levers (both sides). Carefully remove the C-clip holding the Latch Lever onto the Upper Latch Pin.
  • Page 109 SECTION 6 DISASSEMBLY AND ASSEMBLY 10. Use the small file to enlarge and round out the cutouts located on the upper edge of the Crossmember. NOTE: This is done so the Crossmember will fit around the mounting screw for the new Latch Pin.
  • Page 110 SECTION 5 DISASSEMBLY AND ASSEMBLY 14. Slide the Latch Lever Spring onto the Latch Pin, then slide the Latch Lever for that side onto the Pin. Repeat the procedure for the other side. 15. Maneuver the spring so the upper arm fits under the tab on the Side Frame.
  • Page 111 SECTION 6 DISASSEMBLY AND ASSEMBLY 18. Reinstall the Pen Driver PCA Cover. NOTE: If the adhesive on the Cover lip no longer sticks, you can use thin double-sided tape or adhesive transfer tape secure it to the top of the Crossmember. 19.

  • Page 112: Lower Clamshell Latch Pin Replacement Kit

    SECTION 5 DISASSEMBLY AND ASSEMBLY Lower Clamshell Latch Pin Replacement Kit (42-900-30) This kit and procedure is used to replace Lower Latch Pins that may have become bent or broken. The 42-900-30 Kit consists of: (1) Latch Pin, (1) Allen screw. Tools Needed: Small Phillips screwdriver, small long shaft Phillips screwdriver, 1/16 Allen head screwdriver, and Pliers.
  • Page 113 SECTION 6 DISASSEMBLY AND ASSEMBLY PROCEDURE: 1. [A] Release the two Latches and open the Print Engine Clamshell. [B] Remove (2) screws from Operator side of Exit Center Plate Assembly. [C] Loosen (1) screw. 2. [A] Remove (1) screw from non-operator side of Exit Center Plate Assembly.
  • Page 114 SECTION 5 DISASSEMBLY AND ASSEMBLY 4. Remove the C-clip from the Latch Roller, then slide the Latch Roller off the old Latch Pin. Keep C-clip and Latch Roller for reinstallation. 5. Remove Latch Pin with pliers. NOTE: Only works if Latch Pin is press fit, if Latch Pin is welded, this procedure will not work.

  • Page 115: Replacing The Ink Revolvers

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing the Ink Revolvers First Deprime the system and remove the Printhead Cartridge. New Ink Revolver includes attached leader hoses and hose connectors. NOTE: Procedure is similar for both Valve side Ink Revolver and Pump side Ink Revolver (they are labeled). IMPORTANT! Make sure you replace the Valve side Ink Revolver in the Valve side and Pump side in the Pump side.
  • Page 116 SECTION 5 DISASSEMBLY AND ASSEMBLY 5. Slide the new Ink Revolver back in its track and align the yoke on rear with the hinge bracket. Make sure the new Revolver is turned correctly. 6. Reinstall the Pin and C-clip. 7. Reinstall the Ink Revolver Cover.

  • Page 117: Replacing Lifter Motor Assembly Or Lifter Gear

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing Lifter Motor Assembly or Lifter Gear Remove Lifter Motor Assembly Only: [A] Unplug the wire harness from the Lifter Motor Assembly. [B] Remove the (2) screws holding the Motor Assembly to the Motor Assembly Bracket. [C] Gently remove the Motor Assembly.

  • Page 118: Replacing Stepper Motor

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Stepper Motor [A] Remove (2) screws. [B] Unplug the wire harness from the Stepper Motor Printed Circuit Board. [C] Note the position of the motor gears to make sure gears will mesh with the Service Station gear (if Service Station is installed.) Install in reverse order.

  • Page 119: Accessing Items Behind The Main Printed Circuit Assembly (Mpca)

    SECTION 6 DISASSEMBLY AND ASSEMBLY Accessing Items Behind the Main Printed Circuit Assembly (MPCA) To get access to parts on the Print Engine clamshell, the MPCA Panel Cover must be removed and the panel folded out of the way. 1. Remove (4) screws to remove the Cover.

  • Page 120: Replacing Encoder Or Encoder Sensor

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Encoder or Encoder Sensor Printers with Z3/Z4/MR Print Engines have an enclosed Encoder Assembly (see picture at below). [A] Remove (3) screws holding Encoder Cover in place. [B] Unplug the wire harness from the Encoder Sensor.

  • Page 121: Replacing Paper Path Motor Or Drive Belt

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing Paper Path Motor or Drive Belt 1. Loosen (do not remove) the screw that secures the Belt Tensioner [A]. Pivot the Belt Tensioner “clockwise”, to release the belt tension. While holding it in this position, secure the screw. 2.

  • Page 122: Replacing Belt Drive Gear Pulleys

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Belt Drive Gear Pulleys There are three. One is mounted on the Exit Grit Roller Shaft, one is located behind the Encoder Assembly on another Grit Roller Shaft and one is mounted on the Entry Grit Roller Shaft. First, you may need to loosen or remove the Drive Belt, see "Replacing the Paper Path Motor or Drive Belt".

  • Page 123: Reinstall The Main Printed Circuit Assembly

    SECTION 6 DISASSEMBLY AND ASSEMBLY Reinstall the Main Printed Circuit Assembly 1. Gently lift up the Wiring Panel. NOTE: DO NOT pinch or cut wires running through Frame. 2. Reinstall the two (2) mounting screws into bottom of MPCA Panel. 3.

  • Page 124: Accessing Items Under The Clamshell Assembly

    SECTION 5 DISASSEMBLY AND ASSEMBLY Accessing Items Under the Clamshell Assembly Provides access to parts under the Clamshell Assembly. 1. Remove the (4) screws attaching the clamshell to the chassis (1 at each corner). 2. Gently lift the Clamshell Assembly from the chassis –...

  • Page 125: Replacing Paperpath Entry Sensor

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing Paperpath Entry Sensor The Paperpath Entry Sensor consists of a Receiver located in the upper Clamshell and an Emitter located in the lower Clamshell. Receiver (Under Upper Clamshell): [A] Remove (2) screws. [B] Disconnect wiring harness. Install in reverse order.

  • Page 126: Replacing Service Station Sled Printed Circuit Boards

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Service Station Sled Printed Circuit Boards [A] Remove (2) screws. [B]. Carefully disconnect the (2) connectors. [C] Swing Sled away from Clamshell and turn over. Carefully unclip the two printed circuit boards. Install reverse order. NOTE: Make sure wire harnesses are plugged into correct printed circuit board.

  • Page 127: Replacing Service Station Lifting Arms

    SECTION 6 DISASSEMBLY AND ASSEMBLY Replacing Service Station Lifting Arms Replacement Kit (42-900-05) includes two Lifting Arms and two C-Clips (one each for Operator and Non-Operator Side installation.) Before you begin: • Prepare the printer ready for service. Tip: Depriming is not possible if lift arms are broken. In this case leave the printhead and tanks installed, to reduce the chance of ink leakage.
  • Page 128 SECTION 5 DISASSEMBLY AND ASSEMBLY 1. Remove the four screws that secure the clamshell to the deck. 2. Disconnect the Transport Motor on the Print Engine. Note: This is a picture of an older Print Engine. On current Print Engines the Main PCB cover will need to be removed before you can access the motor wire connections.
  • Page 129 SECTION 6 DISASSEMBLY AND ASSEMBLY 4. Remove Spring, located at the bottom of the encoder assembly (Z3/Z4/MR Print Engines Only) 5. Carefully maneuver the top section of the print engine so the motor clears the board housing. Tilt the top section of the print-engine back to expose the underside. Be careful not to damage wires or kink/pinch ink tubes.
  • Page 130 SECTION 5 DISASSEMBLY AND ASSEMBLY 7. Turn the lifting arm motor (worm gear) to raise the lifting arms to their highest position. Tip: A long, straight, 5/64”Allen wrench can be pushed into the round hole at the end of the worm gear and used to spin the gear.
  • Page 131 SECTION 6 DISASSEMBLY AND ASSEMBLY 10. Remove the Service Station Side Rail Tracks. NOTE: The Service Station Drive Shaft will be removed with the Service Station Side Rail on the Non-Operators side. 11. Remove the Lifting Arm Spring(s) 12. Remove c-clip that secures each of the Lifting Arm(s). Then remove the Lifting Arm(s)
  • Page 132 SECTION 5 DISASSEMBLY AND ASSEMBLY 13. Apply a plastic-safe synthetic grease or lubricant (Super Lube 21030 or equivalent) to the Lifting Arm pivot pin and the area of the lifting arm that contacts the Lifting Arm Cam. Super Lube 21030 or equivalent is suggested.
  • Page 133 SECTION 6 DISASSEMBLY AND ASSEMBLY 15. Reinstall the Service Station Servo Motor, Bracket and Gears. 16. Lower the Lifting Arms. If the Lift Arms are not lowered, turn the lifting arm motor (worm gear) to lower the lifting arms to their lowest position. 17.
  • Page 134 SECTION 5 DISASSEMBLY AND ASSEMBLY 18. Remove the Service Station from the print engine. 19. Re-install print engine and other components in reverse order. Realign outline marks, from step 1, before securing the Clamshell to the deck (Ink Tank section). Tip: Leave the side covers off until you are sure the printer is fully operations.

  • Page 135: Section 6 - Service Maintenance

    SECTION 6 MAINTENANCE Section 6 – Service Maintenance General, periodic maintenance is needed to keep the Printer in good working order. Many tasks can be performed by operators with basic supplies, no special tools needed. Other tasks should only be performed by trained service personnel.

  • Page 136: Replacing The Ink Tanks

    SECTION 6 MAINTENANCE WARNING! ALWAYS POWER DOWN THE PRINTER BEFORE CONNECTING OR DISCONNECTING ANY WIRING HARNESSES OR CABLE CONNECTIONS TO AVOID SERIOUS SHOCK OR INJURY. CAUTION • ALWAYS USE APPROPRIATE PERSONAL PROTECTION EQUIPMENT (PPE). • USE ELECTROSTATIC DISCHARGE (ESD) PROTECTION WHEN MAINTAINING EQUIPMENT. •...

  • Page 137: Cleaning Ink Tank Contacts

    SECTION 6 MAINTENANCE 6. Click “Continue” on the Confirm screen, then “Refresh Ink Levels” on the User Interface screen. The ink colors fill in as the Ink Tanks are installed. If the ink colors do not fill in after a few seconds, click “Replace Ink Tanks”...
  • Page 138 SECTION 6 MAINTENANCE 2. Open the Ink Tank Door, release the Ink Tank Latch(es) [A] needed and remove the Ink Tank(s) [B] that did not refresh. 3. Clean the Ink Level Prism [A] and QA Chip contacts [B] with a clean, dry, lint-free cloth. NOTE: You can dampen the cloth with distilled water to wipe the Prism, but DO NOT get the QA Chip contacts wet.

  • Page 139: Cleaning The Printhead Cartridge

    SECTION 6 MAINTENANCE Cleaning the Printhead Cartridge The Printhead Cartridge in the Printer is cleaned automatically each time the machine is turned on or when the “Quick Clean Printhead” routine is performed by the operator. This can be found under the Service tab, “Quick Clean Printhead”...

  • Page 140: Replacing The Printhead Cartridge

    SECTION 6 MAINTENANCE Replacing the Printhead Cartridge ATTENTION If you experienced fuzzy print quality or an abrupt failure in a particular area of nozzles on the previous printhead; we recommend that you have the service station inspected/cleaned and the wiper roller replaced, before installing the new printhead. If not; the chance of damage to the new printhead is greatly increased.

  • Page 141: Printhead Storage & Shelf Life

    SECTION 6 MAINTENANCE Printhead Storage & Shelf Life Properly stored, unopened, Printhead Cartridges have a shelf life of up to 1 year. ° Long Term: 14° F to 86° F (-10 C to 30° C Short Term: -11° F to 140° F (-25° C to 60° C) Storage Temperature Range: NOTE: Cumulative storage duration above 86°...

  • Page 142: Cleaning Pen Driver Printed Circuit Board Contacts

    SECTION 6 MAINTENANCE Cleaning Pen Driver Printed Circuit Board Contacts Clean the Printed Circuit Board contact pins that connect with the Printhead Cartridge. 1. Remove the Printhead Cartridge. Locate the contact pins along the base of the Pen Driver Printed Circuit Board.

  • Page 143: Inspecting & Cleaning The Lip Of The Capping Station

    SECTION 6 MAINTENANCE Inspecting & Cleaning the Lip of the Capping Station The Capping Station (Cap) is part of the Service Station. When the printer is idle, the Service Station automatically caps the printhead to keep the nozzles hydrated. Excess ink can accumulate on the Lip of the Cap. This commonly occurs after a printhead cartridge is installed and the system is primed.

  • Page 144: Inspecting The Wiper Roller

    SECTION 6 MAINTENANCE Inspecting the Wiper Roller The Wiper Roller should be routinely inspected for signs of wear and debris. Directions: 1. Power ON the printer and power-up the print engine. 2. After the printer has finished performing maintenance, carefully release the Latches and Open the Clamshell.

  • Page 145: Cleaning/Replacing Service Station Items

    SECTION 6 MAINTENANCE Cleaning/Replacing Service Station Items The Service Station contains separate areas/devices that are used to perform the following tasks. • Cleaning. The Wiper Roller cleans the Printhead nozzles of excess ink and debris. • Printing/Purging. The Printing Platen acts as a base to support media during printing. It also contains a purging area;...
  • Page 146 SECTION 6 MAINTENANCE 3. Power-up the printer. 4. Open the Printer Toolbox. In the User Interface window, press the “Eject Service Station” button. 5. Once the Service Station has ejected; power OFF the printer. Press the ON/OFF button once and wait about 45 seconds for the print engine to power off (all control panel light’s off).

  • Page 147: Cleaning The Service Station

    SECTION 6 MAINTENANCE Cleaning the Service Station Caution: Please be sure that you are using proper cleaning techniques to clean items that come in contact with the printhead. Use only distilled or deionized water and lint free cloths. If you don’t follow this rule, you will introduce contamination into the printhead;...

  • Page 148: Wiper Motor Assembly Removal And Cleaning

    SECTION 6 MAINTENANCE Wiper Motor Assembly Removal and Cleaning Removal: 1. Disconnect (unplug) the wiper motor cable from the Service Station Printed Circuit Board [A]. 2. Remove the Printed Circuit Board [A] from the Service Station Tray. Carefully release clips to remove board.

  • Page 149: Printing Platen And Capping Station Removal And Cleaning

    SECTION 6 MAINTENANCE completed the Service Station Tray cleaning process. Printing Platen and Capping Station Removal and Cleaning Removal: Both of these items simply lift out for removal from the Service Station. Cleaning: 3. Rinse off ink using tap water. Tip: Make sure the valve, located on the bottom of the Capping Station, is clear of debris and working.

  • Page 150: Installing The Service Station

    SECTION 6 MAINTENANCE Installing the Service Station CAUTION THIS PROCESS MUST BE PERFORMED BY A QUALIFIED/TRAINED PERSON. Please use nitrile powder-free gloves and have plenty of paper towels on-hand for these procedures. The Service Station fits in the slot immediately above the Ink Tank slots. PROCEDURE: 1.
  • Page 151 SECTION 6 MAINTENANCE 7. Slide the Cable Securing Latch open on the Service Station Circuit Board; as shown below. Closed Opened 8. Locate the Ribbon Cable (from within the Service Station Slot). Insert the Ribbon Cable (blue side up) into the space under the Cable Securing Latch [1].
  • Page 152 SECTION 6 MAINTENANCE 10. Look down through open area, in the Print Engine, to make sure the Service Station is aligned with the “Bar”; (Service Station Drive Shaft) as shown. If the Printhead Cartridge is not installed (has been removed), you can look down through the top of the Print-Engine, through the Printhead Cartridge opening.

  • Page 153: Still Experiencing Print Quality Issues

    SECTION 6 MAINTENANCE 12. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button. After printer initialization (~45 seconds) the Print Engine will automatically pull the Service Station the rest of the way in. NOTICE: If the Service Station should get jammed during this process (you hear motor stall noise or gear slipping noise);...

  • Page 154: Inspecting/Replacing The Waste Ink Tray

    SECTION 6 MAINTENANCE Inspecting/Replacing the Waste Ink Tray The Waste Ink Tray (123-2487) is filled with an absorbent material, used to capture the waste ink that drains from the Service Station. 1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45 seconds until the system shuts down (all control panel lights will go off).

  • Page 155: Replacing The Sheet Separators

    SECTION 6 MAINTENANCE Replacing the Sheet Separators The Sheet Separators insure separation of the pieces as they are being fed. If you experience double sheet feeding and cannot adjust the Separators to prevent it, they should be replaced. Replacement of the Sheet Separators is not difficult.

  • Page 156: Cleaning The Printer Body

    SECTION 6 MAINTENANCE Cleaning the Printer Body WARNING THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THE MACHINE FROM ITS POWER SOURCE! DO NOT REMOVE SIDE COVERS! HIGH VOLTAGES PRESENT. Clean the Printer regularly to remove accumulated paper dust and ink.

  • Page 157: Cleaning The Feed Sensor

    SECTION 6 MAINTENANCE Cleaning the Feed Sensor This sensor is located between the media hopper and the print engine. It has two functions. It is used to control the delivery of media to the print engine and it also drives the LCD counter; located on the entrance side of the printer.

  • Page 158: Cleaning The Ink Revolver Couplings

    SECTION 6 MAINTENANCE Cleaning the Ink Revolver Couplings This process should be performed just before a printhead cartridge is installed or re-installed; to remove contaminated/dry ink and other debris from the Ink Revolver Couplings. If this step is skipped; the printhead and or ink system could become contaminated resulting in an increase in print quality issues.

  • Page 159: Cleaning The Lift Arm Sensor

    SECTION 6 MAINTENANCE Cleaning the Lift Arm Sensor The lift arm sensor is used to detect the position of the shaft/cams that drive the lift arms. The lift arm cup/flag rotates counter-clockwise through the lift arm sensor. About 1/3 of the cup is open. •...

  • Page 160: Cleaning The Encoder Wheel On The Lift Motor

    SECTION 6 MAINTENANCE Cleaning the Encoder Wheel on the Lift Motor The encoder, on the Lift Motor, is responsible for motor speed control (speed of lift arm movement). If the encoder wheel or sensor gets dusty/dirty, the arms will be driven very quickly (up/down). This can result in improper arm positioning ;...

  • Page 161: Cleaning Other Items Inside The Print Engine

    SECTION 6 MAINTENANCE Cleaning Other Items inside the Print Engine Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and need to be cleaned regularly. This section covers the procedures for cleaning the following items. Grit Rollers (Media Transport Rollers) Media (Paperpath) Sensors Paperpath Surfaces...
  • Page 162 SECTION 6 MAINTENANCE 5. Use the procedures, as outlined below, to clean the following items. Grit Rollers [A]: Entry Mark Clean as needed using a small stiff-bristled brush (toothbrush), lightly moistened with distilled water. Do NOT use anything other than distilled water to clean the Rollers.

  • Page 163: Preparing Printer For Transport

    SECTION 6 MAINTENANCE Preparing Printer for Transport Please use this procedure if you ever need to transport the printer to a new location or ship the printer. Please refer to the appropriate sections in the manual for details on installing/removing items from the printer.
  • Page 164 SECTION 6 MAINTENANCE 9. Remove the Printhead Cartridge and install protective covers on printhead. Be careful to avoid ink spills (drips) and stains during this process. Store Printhead Cartridge in a sealed plastic bag with a damp cloth. CAUTION: Make sure the cartridges electrical contacts are dry before re-installing printhead. 10.

  • Page 165: Lubricating The Service Station Friction Points

    SECTION 6 MAINTENANCE Lubricating the Service Station Friction Points Friction points on the Service Station should be lubricated to ensure optimum performance and reduce wear. This maintenance should be performed when installing a new Service Station or as needed. Use a plastic-safe synthetic grease or lubricant (Super Lube 21030 or equivalent). CAUTION DO NOT USE PETROLEUM-BASED LUBRICANT/GREASE.
  • Page 166 SECTION 6 MAINTENANCE Lubricate the Worm Gear on the Lifting Arm Motor 1. Apply lubricant (Super Lube 21030 or equivalent) to the Worm Gear. Lubricate Service Station Sled Rails and Service Station Side Rail Tracks 1. Eject the Service Station. 2.
  • Page 167 SECTION 6 MAINTENANCE Lubricate Service Station Guide 1. Apply lubricant to the Service Station Guide (42-900-25) as shown. (If your printer is equipped with this type of Guide). Newer Print Engines will have a different type of guide (42-900-26) installed; as shown. This guide is to be used in conjunction with RevC Service Stations.
  • Page 168 SECTION 6 MAINTENANCE Lubricate Lifting Arm Pivot Points 1. Apply lubricant to the Lifting Arm Pivot as shown. (1 on each side). CAUTION: Spray Lubricants can get into the wrong areas and cause damage. A safer way to lubricate is to use a small paint brush and grease (Super Lube 21030 or equivalent).

  • Page 169: Lubricating The Grit Roller Ground Clips/Springs

    SECTION 6 MAINTENANCE Lubricating the Grit Roller Ground Clips/Springs NOTE: The Ground Clips and Thrust Springs provide a path for static energy to discharge from the Grit Rollers to earth-ground. They must be periodically lubricated with a conductive grease to reduce spring wear and provide a good earth-ground connection.

  • Page 170: Reinstalling Or Replacing The Service Station

    SECTION 6 MAINTENANCE Reinstalling or Replacing the Service Station 1. Carefully unwrap the new Service Station. (Or reuse cleaned Service Station.) NOTE: Loose parts may fall out. Keep roller side facing up when removing packaging. CAUTION MAKE SURE THE LATCHES ON THE WIPER ROLLER ARE FULLY LOCKED BEFORE INSTALLING THE SERVICE STATION.
  • Page 171 SECTION 6 MAINTENANCE 4. [1] Slide the Service Station into the Service Station port until it touches the bar. Align with tracks along sides and Guide on Service Station dock floor. [2] Look down through the Top Cover to make sure Service Station is aligned with the bar.
  • Page 172 SECTION 6 MAINTENANCE 6. Power up the unit, then press “Install Service Station” in the Printer Toolbox to pull the Service Station in. NOTE: Make sure the wick hanging below the Service Station is inside the plastic trough inside the Ink Tank Station to prevent ink seepage.
  • Page 173 SECTION 6 MAINTENANCE NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________...

  • Page 174: Appendix Section

    Maximum: 0.020" (0.5 mm / 430 gsm / 160# Cover / 240# Index) PRINT QUALITY Normal: 1600 x 800 DPI @ 12 ips Best: 1600 x 1600 DPI @ 6 ips Memjet® Thermal Inkjet TECHNOLOGY Cyan (250 ml); Yellow (250 ml); Magenta (250 ml); Black (500 INK CAPACITY PRINT AREA 8.5"...

  • Page 175: Appendix B - Supplies And Optional Hardware

    Conveyor /Stacker Drop Tray NOTE: The use of a TB-390 conveyor with the Mach 5 printer is highly recommended. For this application; please be sure to order the Riser Legs for the TB-390 (part # TB-390 M5 FEET). Mach 5 Digital Color Printer and optional TB-390 Conveyor with Riser Legs installed.

  • Page 176: Appendix C - Service Station Guide Installation Instructions

    APPENDICES Appendix C – Service Station Guide Installation Instructions The original Service Station Guide (42-900-25) was designed/developed to help prevent Service Station misalignment during installation. NOTE: Starting with S/N 100029449; all printers were shipped with a Service Station Guide pre-installed. Before You Begin: Newer Print Engines (MR) will have a different type of guide (42-900-26) installed;...

  • Page 177: Remove The Service Station

    APPENDICES REMOVE THE SERVICE STATION 1. Using the M Series Toolbox, Eject the Service Station. Press the Eject Service Station button located in the User Interface window. 2. Once the printer has ejected the Service CAUTION Station; Power-down the printer using the ON/OFF button.
  • Page 178 APPENDICES INSTALL THE SERVICE STATION GUIDE 10. Release the two latches and open the Clamshell. 11. Remove the two existing screws [A] from Service Station Slot floor: [A] Use the T10 screwdriver to remove the innermost screw. Access to this screw cab be obtained through the Printhead area (top of print-engine);...
  • Page 179 APPENDICES 13. While holding the Guide into position; install the two longer T10 Screws and the Washers that were included in the kit. Note: Two washers are used on each screw to prevent the screw from bottoming out before it is able to secure the Guide.
  • Page 180 APPENDICES REINSTALL THE SERVICE STATION, ALIGN & SECURE THE GUIDE 1. Reconnect the Ribbon Cable to the Service Station [1] Plug the Ribbon Connector (blue side facing out) into the space under the cable securing Latch. [2] Make sure the cable is square with the connector, then close the Latch. Open Close 2.
  • Page 181 APPENDICES 4. Drive the Service Station into the slot, just far enough that you have access to the T10 Torx screw, which is located closest to the exit end of the Guide and printer. Since the screws that secure the Guide are only slightly snug; this process should allow the Guide to self-align.

  • Page 182: Appendix D - Ink Delivery System (Ids)

    APPENDICES Appendix D – Ink Delivery System (IDS) Theory of Operation Dual Pinch Valve (DPV) and Pump Control Sequences Dual Pinch Valve (DPV) STOP INK FLOW PUMP: OFF DPV: CLOSED • No Ink Flow • Printer Powered-Down ALLOW INK FLOW PUMP: ON DPV: OPEN INK •...
  • Page 183 APPENDICES DEPRIME SYSTEM DPV: OPEN AIR PUMP: ON • Dual Pinch Valve opens air inlet and closed ink flow from Tanks. • As pump runs, air is pulled into the system and ink travels back into the Ink Tanks. NOTE: When Head Release button is pressed the system only does a partial deprime.

  • Page 184: Appendix E - Z2I Wiring Diagram

    APPENDICES Appendix E – Z2i Wiring Diagram...

  • Page 185: Appendix F - Z3/Z4/Mr Wiring Diagram

    APPENDICES Appendix F – Z3/Z4/MR Wiring Diagram...

  • Page 186: Appendix G -Interface (I/O) Board (42-500-30) Schematic

    APPENDICES Appendix G –Interface (I/O) Board (42-500-30) Schematic...

  • Page 187: Appendix H -Interface (I/O) Board (42-500-30 Rev B) Schematic

    APPENDICES Appendix H –Interface (I/O) Board (42-500-30 Rev B) Schematic...

  • Page 188: Appendix I -Side Frame Modification

    APPENDICES Appendix I –Side Frame Modification To Accommodate the Z3/Z4/MR Print Engine in a printer that was built for the Z2i Print Engine. Valid for Printer S/N 100027598 or lower. IMPORTANT: After installing a Z3/Z4/MR Print Engine into a printer that originally had a Z2i engine installed; please be sure to replace the too small (short) rubber feet with two large (tall) rubber feet (35-117-04 foot and screw), so that all the feet are the same size.

  • Page 189: Index

    INDEX INDEX Adjustments ..............39 Tilt Error ................31 Appendices Specifications ............172 Ink Flow Diagrams ............180 Supplies/Opt. Hardware ........173, 174 Ink Revolvers ..............113 Z2i Wiring Diagram ..........182 Cleaning ..............156 Z3/Z4/MR Wiring Diagram ........183 Ink Tank Door ..............
  • Page 190 INDEX Dual Pinch Valve Sensors, Cleaning ......93 Service Station ............168 Encoder/Encoder Sensor .......... 118 Stepper Motor ............116 Gear Pulleys, Belt Drive ........... 120 Removing Media Jams ............30 Ink Revolvers ............ 113, 156 Removing the Lifter Arm Sensor ............. 118 Ink Tank Door ............
  • Page 191 INDEX Side Covers Troubleshooting, Communication Problems ....20 Left-hand ..............53 Troubleshooting, Dust Exhaust Fans ........ 45 Right-hand ..............54 Troubleshooting, Errors and Warnings ......23 Smudging ................11 Troubleshooting, Feeding Problems ......21, 22 Specifications ..............172 Troubleshooting, Interface Board Test Points ....50 Starwheel Assemblies ............
  • Page 192 Copyright © 2014 All rights reserved...

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