Memjet MACH 8 Service Manual
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Memjet MACH 8 Service Manual

High capacity digital color printer
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MACH 8
(HJ/AS-1180C)
HIGH CAPACITY
DIGITAL COLOR PRINTER

SERVICE MANUAL

Rev 05-27-14
PRELIMINARY

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Summary of Contents for Memjet MACH 8

  • Page 1: Service Manual

    MACH 8 (HJ/AS-1180C) HIGH CAPACITY DIGITAL COLOR PRINTER SERVICE MANUAL Rev 05-27-14 PRELIMINARY...

  • Page 2: Safety Precautions

    SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE MACH 8 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 SECTION 2 – Troubleshooting Print Quality Issues: Examples of Print Quality Issues (including possible causes and solutions) Air in Printhead Nozzle Area: Clogged/Damaged/Dead Nozzles: Color Mixing Issues:...
  • Page 4 TABLE OF CONTENTS Removing the Print Engine Base Replacing Peristaltic Pump Assembly Replacing Dual Pinch Valve Assembly Cleaning Dual Pinch Valve Sensors Replacing Dual Pinch Valve Sensor PC Board Replacing DPCA Board Replacing Buffer Boxes (3 per machine) Replacing QA Chip Assembly (3 per machine) Removing the Pen Driver Printed Circuit Assembly (PCA) Removing the Starwheel Assemblies Replacing the Ink Tank Latches...
  • Page 5 TABLE OF CONTENTS Cleaning Other Items inside the Print Engine Grit Rollers (Media Transport Rollers) Media (Paperpath) Sensors Capping Station Lip Paperpath Surfaces Printing Platen Surface Cleaning the Ink Revolver Couplings Preparing Printer for Transport Local relocation Remote relocation or shipping Lubricating the Service Station Reinstalling or Replacing the Service Station Lubricating the Media Table Lift Assembly...

  • Page 6: 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 7: Minimum Computer System Requirements

    SECTION 1 BEFORE YOU BEGIN Minimum Computer System Requirements • Windows XP, Windows Vista, Windows 7 & *Windows 8/8.1 Supports 32 & 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 8: Section 2 - Troubleshooting

    SECTION 2 TROUBLESHOOTING SECTION 2 – 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. The best advice we can offer is to make sure that the system is set up properly, plugged in, and that it has an adequate supply of ink before attempting to troubleshoot any problem.

  • Page 9: 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, dehydrated or clogged.

  • Page 10: Clogged/Damaged/Dead Nozzles

    SECTION 2 TROUBLESHOOTING Clogged/Damaged/Dead 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 11: Color Mixing Issues

    SECTION 2 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 12: Scuff Marks And Smudging Issues

    SECTION 2 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 13 SECTION 2 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 14: Fuzzy/Distorted Print

    SECTION 2 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 15: The Ink Tank(S)

    SECTION 2 TROUBLESHOOTING The Ink Tank(s) CONDITION PROBLEM SOLUTION One or more of the “septum Try removing and re- Installed New Ink Tank and shortly after the related Ink needles” didn’t fully puncture the installing the Tank. See Channel (color) stopped septum seal on the new Ink Tank.

  • Page 16: 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 very tiny size of each nozzle and the high number of nozzles;...
  • Page 17 SECTION 2 TROUBLESHOOTING The Printhead Cartridge (continued) CONDITION PROBLEM SOLUTION Printhead nozzles dry (air pulled Wet the Printhead nozzles System will not prime the through nozzles; not allowing using distilled water and a printhead after installing system to create vacuum) wet, lint-free cloth.

  • Page 18: The Printer

    SECTION 2 TROUBLESHOOTING The Printer NOTICE: The printer will not print if any of the five ink tanks are empty or missing. Dots or Lines Printed on Media CONDITION PROBLEM SOLUTION Heavy, horizontal black lines You have exceeded Reduce paper width to 8.5” to avoid exceeding are printed down the length the maximum print the max print width of printer.

  • Page 19: Power (Power-Up) Problems

    If output is bad, replace Power Supply. 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.

  • Page 20: Service Station Problems

    SECTION 2 TROUBLESHOOTING Service Station Problems CONDITION PROBLEM SOLUTION Service Station was not installed Eject Service Station. Cycle print Service Station (SS) Drive properly. engine off/on. If drive motor turns Motor stalls. without stalling then motor is OK. Make sure SS is installed squarely. Check for physical resistance to movement.

  • Page 21: Interface Communication Problems

    SECTION 2 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 22: Feeding Problems

    SECTION 2 TROUBLESHOOTING Feeding Problems CONDITION PROBLEM SOLUTION Side Guides set too tight to media. Readjust Side Guides. Intermittent feeding Dirty Feed Rollers. Clean the Feed Roller with distilled water and a cloth. Do NOT use any solvents as they may damage Rollers. Paper stuck together Fan media before placing it in Printer.

  • Page 23: Feeding Problems (Continued)

    SECTION 2 TROUBLESHOOTING Feeding Problems (continued) Blank piece(s) fed at Toolbox “Cutsheet Feeding In the Max Throughput mode the printer Mode” is set to Max Throughput. will feed 1 or 2 blanks at end of job. Set to end of job and or last piece does not exit the “Safe Feed”...

  • Page 24: Errors And Warnings

    SECTION 2 TROUBLESHOOTING Errors and Warnings Printer Alert Window Messages Messages sent from the driver and displayed on PC screen in a small popup window. MESSAGE SOLUTION Wait until the message disappears. The printer will start printing your job Cleaning in Progress once the cleaning process has completed.

  • Page 25: Toolbox System Status Messages

    SECTION 2 TROUBLESHOOTING Toolbox System Status Messages Displayed, in red, in the M Series Toolbox utility. SYSTEM STATUS PROBLEM SOLUTION PAPERPATH_FEED_TIME Out of Paper Load media into printer and press the Media is not reaching PAPER/RESUME button. the print engine. If media is present;...
  • Page 26 SECTION 2 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. X = Color. Ink Tank replacement will be necessary X_INK_LOW One or more Ink Tanks soon. Reorder Ink Example: CYAN_ INK_LOW are low on ink. INK_OUT_X X = Color or MULTI Replace empty Ink Tank(s).
  • Page 27 SECTION 2 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. SYSTEM STATUS PROBLEM SOLUTION TILT_ERROR The printer’s electronics If just powered on, wait a few minutes; have detected that the error may clear by itself. Once Tilt EXCESSIVE_TILT_ERROR print engine is too far level drops to 1.99 or less you can clear...
  • Page 28 SECTION 2 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. Service Station was just Re-install the Service Station (as System Status: ONLINE Reason: Uncapped printhead ejected (using Eject outlined in this manual) or clamshell open Service Station button).

  • Page 29: Ink Accumulating In The Wrong Areas Of The Printer

    SECTION 2 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 30: Jams In The Printer

    SECTION 2 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 31 SECTION 2 TROUBLESHOOTING Forwarding Roller Section: Release the Forwarding Roller Guide Assembly by opening the Latch [C]. Slide the Assembly toward the Control Panel [D]. Carefully lift the Assembly up [E]. Remove jammed media. Reinstall the Assembly. CAUTION DO NOT BEND, PINCH OR CUT THE INK LINES LOCATED DIRECTLY IN FRONT OF THE ASSEMBLY.

  • Page 32: Section 3 - Toolbox Service Features

    SECTION 3 FUNCTIONAL OPERATION SECTION 3 – Toolbox Service Features Using 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 33 SECTION 3 FUNCTIONAL OPERATION [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. 2.

  • Page 34: Service Menu

    SECTION 3 FUNCTIONAL OPERATION 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 Menu For authorized service personnel only. Provides access to more advanced Printer Control and Maintenance menus.
  • Page 35 SECTION 3 FUNCTIONAL OPERATION You will notice that several new menu options are available: “Printer Maint Config,” “Printer Control Config,” “Scan Sensors,” “Commands Help,” and “Exit Service Menu.” Printer Maintenance Configuration Screen: Allows you to enable or disable certain maintenance functions. “Zero Tilt Sensor” can reset the Tilt Warning in the Printer Status column.
  • Page 36 SECTION 3 FUNCTIONAL OPERATION 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 37 SECTION 3 FUNCTIONAL OPERATION Printer Commands Help Screen: Provides a list and descriptions of available EWS service commands. Clicking “Exit Service Menus” closes the Service Menu options and takes you back to the User Interface screen.

  • Page 38: Section 4 - Disassembly/Assembly Procedures

    SECTION 4 DISASSEMBLY AND ASSEMBLY SECTION 4 – Disassembly/Assembly Procedures Printer Basic Disassembly • Turn off Power • Disconnect Power Cord • Disconnect Interface Cable Service Disassembly Procedures WARNING! THE FOLLOWING DISASSEMBLY SHOULD ONLY BE DONE BY A QUALIFIED, TRAINED SERVICE REPRESENTATIVE. WARNING! ALWAYS POWER DOWN THE PRINTER BEFORE CONNECTING OR DISCONNECTING ANY WIRING HARNESSES OR CABLE CONNECTIONS TO...

  • Page 39: Left-Hand Side (Operator Side) Covers

    SECTION 4 DISASSEMBLY AND ASSEMBLY Left-hand Side (Operator Side) Covers 1. Left Side Front Cover: Remove (3) screws on the end of the Cover, (2) screws inside Storage Door frame and (1) screw at the top front of the Cover. Remove Cover.

  • Page 40: Right-Hand Side (Non-Operator Side) Cover

    SECTION 4 DISASSEMBLY AND ASSEMBLY Right-hand Side (Non-Operator Side) Cover 1. Remove the (3) screws at both ends of the Cover. Then remove the (2) screws at the top front of the Cover. Major Components under Right-hand Side (Non-Operator Side) Cover 1.

  • Page 41: Replacing The Feed Sensor

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing the Feed Sensor 1. Remove Right-hand Side Cover (8 screws). 2. Unplug the Sensor from the Interface PC Board [A]. Unclip the wire from any mounting clips. 3. [A] Remove (2) screws attaching the Sensor to the Sensor Bracket.

  • Page 42: Adjusting The Feed Sensor

    SECTION 4 DISASSEMBLY AND ASSEMBLY Adjusting the Feed Sensor A new Feed Sensor may have to be adjusted once it is installed. 1. Remove the Right-hand Side Cover. Make sure that no media is covering the Feeder Sensor and that the reflective plate is installed.

  • Page 43: Replacing Feed Motor Drive Belt Or Motor

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Feed Motor Drive Belt or Motor 1. Remove Right-hand Side Cover. NOTE: To remove the Motor, access it from inside the storage compartment. 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 44: Replacing The Feeder Encoder And/Or Encoder Sensor

    SECTION 4 DISASSEMBLY AND ASSEMBLY 3. Push the Clutch in toward the Pulley to get access to the retaining 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 45: Replacing The Upper Limit Switch Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing the Upper Limit Switch Assembly 1. Unplug the Printer from power. 2. Open the Feed Head Roller Assembly. Loosen the two thumbscrews [A] and slide latches back [arrows]. Open the Feed Roller Assembly [B]. 3.
  • Page 46 SECTION 4 DISASSEMBLY AND ASSEMBLY 4. Remove (2) screws securing Upper Limit Switch Assembly located on top of Feed Head Shell. 5. Carefully pull Switch and Bracket Assembly away from Feed Head Shell. 6. Disconnect red wire connector [A]. Disconnect black wire connector [B]. (Both located under Right Hand Feed Head Nest Assembly behind Control Panel.) Remove Switch Assembly.

  • Page 47: Replacing The Feed Height Switch Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing the Feed Height Switch Assembly 1. Unplug the Printer from power. 2. Open the Feed Roller Assembly. Loosen the two thumbscrews [A] and slide latches back [arrows]. Open the Feed Roller Assembly [B]. 3. Remove Feed Roller Assembly. [A] Remove the E-clip.
  • Page 48 SECTION 4 DISASSEMBLY AND ASSEMBLY 4. Remove (2) screws securing Feed Height Switch Assembly located on top of Feed Head Shell. 5. Carefully pull Switch and Bracket Assembly away from Feed Head Shell. 6. Disconnect Sensor wire connector. (Located under Control Panel.) Remove Switch Sensor Assembly.

  • Page 49: Replacing The Hold Down Roller Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing the Hold Down Roller Assembly 1. Unplug the Printer from power. 2. Open the Feed Roller Assembly. Loosen the two thumbscrews [A] and slide latches back [arrows]. Open the Feed Roller Assembly [B]. 3. Remove Feed Roller Assembly. [A] Remove the E-clip.

  • Page 50: Remove Media Table Lift Assembly Motor And Drive Belt

    SECTION 4 DISASSEMBLY AND ASSEMBLY 4. Remove Hold Down Roller Assembly. Remove (2) screws securing the Hold Down Roller Assembly from inside the Feed Head Shell. Remove the Roller Bracket Assembly. Remove Media Table Lift Assembly Motor and Drive Belt 1.

  • Page 51: Replacing Media Table Lift Assembly Belt

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Media Table Lift Assembly Belt 1. Remove the Left-hand Front Side Cover by removing the (3) screws on the side of the Cover. Remove (2) screws from inside the Storage Door frame. Remove (1) screw from the top center of the Cover.
  • Page 52 SECTION 4 DISASSEMBLY AND ASSEMBLY 3. Remove Bottom Divider: [A] Remove (2) top screws. [B] Remove (3) screws from each side frame. 4. Remove Bottom Media Table Lift Pulley. Remove (1) Allen screw and lock washer. Slide Pulley off of Shaft. 5.
  • Page 53 SECTION 4 DISASSEMBLY AND ASSEMBLY 6. Remove the Bottom Bar Assembly. Remove the Belt. 7. Reassemble in reverse order. Remember to reinstall the Motor Drive Belt.

  • Page 54: Remove Media Table Lift Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Remove Media Table Lift Assembly 1. Remove the Left-hand Front Side Cover by removing the (3) screws on the side of the Cover. Remove (2) screws from inside the Storage Door frame. Remove (1) screw from the top center of the Cover.
  • Page 55 SECTION 4 DISASSEMBLY AND ASSEMBLY 3. Raise the Rear Media Support Assembly. 4. Remove the Media Table Assembly: [A] Remove (4) screws/(2) lock washers securing Media Table to the Media Table Brackets (located under the Table). [B] Carefully lift rear of Table up (be careful not to pull too hard on sensor wiring).
  • Page 56 SECTION 4 DISASSEMBLY AND ASSEMBLY 5. Remove the Threaded Rod Guard (located on Control Panel side). Remove (2) screws. 6. Remove the Rear Side Closure (located on non-operator side): [A] Remove (1) screw and (2) Allen screws. Remove (1) screw from the Media Table Bracket.
  • Page 57 SECTION 4 DISASSEMBLY AND ASSEMBLY 7. Remove Bottom Divider: [A] Remove (2) top screws. [B] Remove (3) screws from each side frame. 8. Loosen Motor Assembly screws. Move Motor Assembly in slots to remove Belt. 9. Remove Bottom Media Table Lift Pulley. Remove (1) Allen screw and lock washer.
  • Page 58 SECTION 4 DISASSEMBLY AND ASSEMBLY 10. Remove Lift Table Assembly: [A] Remove (2) top and (2) bottom Allen screws per side. NOTE: You may have to cut any cable ties securing the Sensor Wiring Harness to a Lift Table Assembly Bracket Stud. [B] Slide Media Table Lift Assembly up and out of Guide Tracks.

  • Page 59: Replacing The Feed Rollers

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing the Feed Rollers 1. Unplug the Printer from power. 2. Open the Feed Roller Assembly. Loosen the two thumbscrews [A] and slide latches back [arrows]. Open the Feed Roller Assembly [B]. 3. Remove Feed Roller Assembly. [A] Remove the E-clip.
  • Page 60 SECTION 4 DISASSEMBLY AND ASSEMBLY IMPORTANT BEFORE DISASSEMBLING FEED ROLLERS, NOTE ORDER AND POSITION OF PARTS FOR REASSEMBLY. STEPS 4, 5 AND 6 CAN BE PERFORMED SINGLY OR TOGETHER AS NEEDED. 4. Remove Feed Roller Drive Belt. Slide Belt off of Front Feed Roller Shaft Pulley. Remove Belt. 5.

  • Page 61: Replacing Pull Out Rollers

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Pull Out Rollers 1. Remove the Left-hand Front Side Cover by removing the (3) screws on the side of the Cover. Remove (2) screws from inside the Storage Door frame. Remove (1) screw from the top center of the Cover.
  • Page 62 SECTION 4 DISASSEMBLY AND ASSEMBLY 4. Remove the Encoder Sensor from the Rear Side Frame. [A] Remove the (2) screws holding the Encoder Circuit Board to the two standoffs. [B] Remove the Encoder Sensor by carefully moving the Sensor down and away from the Encoder Wheel.
  • Page 63 SECTION 4 DISASSEMBLY AND ASSEMBLY 8. Remove the Bearing Housing (2 screws). 9. Reach through the Side Frame or reach up through the Storage Compartment and pull the Pull Out Roller Shaft toward the non-operator side [A]. Make sure the Shaft clears the Delivery Roller Shaft Belt [B].

  • Page 64: Replacing Delivery Center Plate Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Delivery Center Plate Assembly 1. Remove Side Covers and Pull Out Shaft. See "Replacing Pull Out Shaft" on previous pages. 2. Open the Feed Roller Assembly. Loosen the two thumbscrews [A] and slide latches back [arrows].
  • Page 65 SECTION 4 DISASSEMBLY AND ASSEMBLY From Operator Side: 4. [A] Unplug the Network Connector if necessary. [B] Remove (2) screws (Be careful of Pause/Resume Control Button wiring). [C] Remove (1) small mounting screw. 5. Nest Head Assembly. Remove (1) screw (see photo at right) and pivot assembly up.
  • Page 66 SECTION 4 DISASSEMBLY AND ASSEMBLY Non-Operator Side: 6. Unplug Feed Sensor Connector (J10) from Interface Board. Separate wire from bundle. 7. Remove (2) mounting screws (access through cutouts in the side frame). 8. Carefully remove Delivery Center Plate Assembly. 9. Reassemble in reverse order.

  • Page 67: Removing Delivery Rollers

    SECTION 4 DISASSEMBLY AND ASSEMBLY Removing Delivery Rollers The Delivery Rollers are part of the Deliver Center Plate Assembly located at the feed end of the Print Engine. See "Replacing Delivery Center Plate Assembly" on previous pages. 1. Remove the Delivery Center Plate Assembly. 2.

  • Page 68: Removing Separator Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Removing Separator Assembly 1. Remove the Left-hand Front Side Cover by removing the (3) screws on the side of the Cover. Remove (2) screws from inside the Storage Door frame. Remove (1) screw from the top center of the Cover. 2.
  • Page 69 SECTION 4 DISASSEMBLY AND ASSEMBLY 3. Open the Feed Roller Assembly. Loosen the two thumbscrews [A] and slide latches back [arrows]. Open the Feed Roller Assembly [B]. 4. Remove (4) mounting screws: [A] Remove (2) screws from non- operator side Side Frame.

  • Page 70: Replacing Interface Pc Board

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Interface PC Board 1. Remove the Right-hand Side Cover. 2. Unplug (4) Connectors for Clutch and Sensors. NOTE: Wires are labeled for easy reconnection. CAUTION DO NOT DAMAGE THE WIRES DURING REMOVAL. 3. Remove the (2) screws that attach the PC Board to the Side Frame and remove the PC Board.

  • Page 71: Replacing The Main Pc Board (Mpca)

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing the Main PC Board (MPCA) WARNING THE FOLLOWING PROCEDURE SHOULD ONLY BE DONE BY A QUALIFIED, TRAINED SERVICE REPRESENTATIVE. Before you Begin: • When ordering a new board; please be sure to provide the serial number of the printer and the print-engine with your order.
  • Page 72 SECTION 4 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 73 SECTION 4 DISASSEMBLY AND ASSEMBLY 6. Unplug: [1] USB, [2] Network, [3] Power Supply and [4] PuTTY cables from Print Engine’s Main PCB. NOTE: The PuTTY connection is used during the manufacturing and system flushing (removing ink from system) process. These processes, and the use of the PuTTY interface, require special tools, software and training that are not available to the field.
  • Page 74 SECTION 4 DISASSEMBLY AND ASSEMBLY 9. Remove the T10 screws that secure the Main PCB to the frame. 10. Carefully remove the Main PCB. 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 order shown on the following pages.
  • Page 75 SECTION 4 DISASSEMBLY AND ASSEMBLY a. J1002 Cable J1002 Socket Location (Connection)
  • Page 76 SECTION 4 DISASSEMBLY AND ASSEMBLY b. J1000 Cable J1000 Socket Location (Connection)
  • Page 77 SECTION 4 DISASSEMBLY AND ASSEMBLY c. J551 Cable J551 Socket Location (Connection)
  • Page 78 SECTION 4 DISASSEMBLY AND ASSEMBLY d. J703 Cable J703 Socket Location (Connection)
  • Page 79 SECTION 4 DISASSEMBLY AND ASSEMBLY e. P2002 Cable P2002 Socket Location (Connection)
  • Page 80 SECTION 4 DISASSEMBLY AND ASSEMBLY f. P2004 Cable P2004 Socket Location (Connection)
  • Page 81 SECTION 4 DISASSEMBLY AND ASSEMBLY g. P2006 Cable P2006 Socket Location (Connection)
  • Page 82 SECTION 4 DISASSEMBLY AND ASSEMBLY h. J35 Cable J35 Socket Location (Connection)
  • Page 83 SECTION 4 DISASSEMBLY AND ASSEMBLY i. P1 Cable P1 Socket Location (Connection)
  • Page 84 SECTION 4 DISASSEMBLY AND ASSEMBLY j. P2005 Cable P2005 Socket Location (Connection)
  • Page 85 SECTION 4 DISASSEMBLY AND ASSEMBLY k. P2003 Cable P2003 Socket Location (Connection)
  • Page 86 SECTION 4 DISASSEMBLY AND ASSEMBLY l. J20 Cable J20 Socket Location (Connection)
  • Page 87 SECTION 4 DISASSEMBLY AND ASSEMBLY m. J2001 Cable J2001 Socket Location (Connection)
  • Page 88 SECTION 4 DISASSEMBLY AND ASSEMBLY n. J250 Data Cable J250 Data Cable Socket Location (Connection) o. J260 Data Cable J260 Data Cable Socket Location (Connection)
  • Page 89 SECTION 4 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 90 SECTION 4 DISASSEMBLY AND ASSEMBLY 14. Reinstall the Main PCB Cover with 4 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 91: Mpca (Main Printed Circuit Assembly) Connections

    SECTION 4 DISASSEMBLY AND ASSEMBLY MPCA (Main Printed Circuit Assembly) Connections 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). LABEL COMING FROM DESCRIPTION Driver Printed Circuit Power Supply.

  • Page 92: Removing The Print Engine

    SECTION 4 DISASSEMBLY AND ASSEMBLY Removing the Print Engine 1. Open the Top Cover. Open the Toolbox, click 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 93 SECTION 4 DISASSEMBLY AND ASSEMBLY 6. Remove Ink Tank Door (Front Cover). Carefully unhook the (2) springs (one each side) [A], then remove the mounting screw [B] from the left-hand side (Control Panel side). Remove Door and set aside. 7. Remove Top Cover. Remove mounting screw [A] from left-hand side (Control Panel side, above Main Printed Circuit Board).
  • Page 94 SECTION 4 DISASSEMBLY AND ASSEMBLY 9. Disconnect Power, Paper & Cancel control panel switches. 10. Disconnect FRONT and BACK wiring bundles (on Control Panel side). 11. Disconnect Feed Drive Motor wiring (access from inside the storage compartment). NOTE: When reconnecting make sure black goes to black connector and red goes to red connector.
  • Page 95 SECTION 4 DISASSEMBLY AND ASSEMBLY 12. Unclip wiring and cut wire tie (located on non-operator side of the Printer.) NOTE: Make sure wires are clear of other wires so they won't catch or snag when Print Engine is removed. 13. Disconnect the following wires from the Interface Printed Circuit Board (located on the non-operator side of the Printer): •...
  • Page 96 SECTION 4 DISASSEMBLY AND ASSEMBLY 15. Remove the (2) screws and (2) adjusting knobs attaching the base of the Print Engine to the cabinet (Access via the Storage Compartment). NOTE: Knobs are closest to Storage Door. When reinstalling the (2) mounting screws, DO NOT tighten fully –...

  • Page 97: Print Engine Basic Disassembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Print Engine Basic Disassembly The Print Engine must be removed from the Printer for these procedures. See “Removing the Print Engine” on previous pages. It is 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 98: Replacing Peristaltic Pump Assembly

    SECTION 4 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 99: Cleaning Dual Pinch Valve Sensors

    SECTION 4 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. The Print Engine must be removed and turned upside down for this procedure.

  • Page 100: Replacing Dual Pinch Valve Sensor Pc Board

    SECTION 4 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, (3) inserts and a Pinch Valve Wrench. The Inserts prevent the Sensor PC Board from being misaligned during replacement.
  • Page 101 SECTION 4 DISASSEMBLY AND ASSEMBLY 2. Remove 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 one (1) screw to remove the Pinch Valve Sensor PC Board.

  • Page 102: Replacing Dpca Board

    SECTION 4 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 103: Replacing Buffer Boxes (3 Per Machine)

    SECTION 4 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 104: Removing The Pen Driver Printed Circuit Assembly (Pca)

    SECTION 4 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 105 SECTION 4 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 106: Replacing The Ink Tank Latches

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing the Ink Tank Latches Ink Tanks must be removed prior to replacing latches. See “Replacing Ink Tanks” in the Maintenance Section. Printer must be flat on a level surface. [A] Lift the latch. [B] Remove (2) screws located on underside of the latch hinge block.
  • Page 107 SECTION 4 DISASSEMBLY AND ASSEMBLY 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. Place in a moistened packaging cap to avoid dehydration.
  • Page 108 SECTION 4 DISASSEMBLY AND ASSEMBLY 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 109: Replacing The Printhead Lever Latch Solenoid

    SECTION 4 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 110 SECTION 4 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 111: Replacing Upper And Lower Clamshell Latch Pins

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Upper and Lower Clamshell Latch Pins The Upper and Lower Latch Pin Kits replace Print Engine Clamshell Latch Pins that may have become bent or broken. Replacing Upper Latch Pins The Upper Latch Pin Kit consists of: (1) Latch Pin, (1) 5/64 Allen screw.
  • Page 112 SECTION 4 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 113 SECTION 4 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 114 SECTION 4 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 115 SECTION 4 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 116: Replacing Lower Latch Pins

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Lower Latch Pins The Lower Latch Pin 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. NOTE: Check that the Latch Pins are pressed in on your Printer. Later versions have welded pins that cannot be replaced.
  • Page 117 SECTION 4 DISASSEMBLY AND ASSEMBLY INSTALL LOWER LATCH PIN 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 118 SECTION 4 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 119: Replacing The Ink Revolvers

    SECTION 4 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 120 SECTION 4 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 121: Replacing Lifter Motor Assembly Or Lifter Gear

    SECTION 4 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 122: Replacing Stepper Motor

    SECTION 4 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 123 SECTION 4 DISASSEMBLY AND ASSEMBLY Lubricating the Grit Roller Ground Clips Three Ground Clips are located on the right side of the Print Engine, at the ends of the Grit Roller Shafts. To access them you must remove the Lifter Motor and Stepper Motor. See “Replacing Lifter Motor” and “Replacing Stepper Motor”...

  • Page 124: Accessing Items Behind The Main Printed Circuit Assembly (Mpca)

    SECTION 4 DISASSEMBLY AND ASSEMBLY Accessing Items Behind the Main Printed Circuit Assembly (MPCA) Creating Access 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.

  • Page 125: Replacing Encoder Or Encoder Sensor

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Encoder or Encoder Sensor [A] Remove (3) screws holding Encoder Cover. [B] Unplug wire harness from the Encoder Sensor. [C] Carefully pivot the Cover away from the Encoder Wheel. Be careful of the spring. [D] Remove the (2) screws holding the Encoder Sensor in place and pull away from Encoder Wheel.

  • Page 126: Replacing Paper Path Motor Or Drive Belt

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Paper Path Motor or Drive Belt [A] Remove (2) screws that attach the Motor Assembly to the lower Print Engine Clamshell. Pull the Motor straight out so the Motor Pulley clears the Drive Belt. NOTE: If removing Motor, unplug the two wire connectors.

  • Page 127: Replacing Belt Drive Gear Pulleys

    SECTION 4 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 128: Reinstall Main Printed Circuit Board Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Reinstall Main Printed Circuit Board 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 129: Accessing Items Under The Clamshell Assembly

    SECTION 4 DISASSEMBLY AND ASSEMBLY Accessing Items Under the Clamshell Assembly Provides access to parts under the Clamshell Assembly. Removing Clamshell Assembly 1. Remove the (4) screws attaching the Clamshell to the Chassis (1 at each corner). 2. Gently lift the Clamshell from the Chassis. Take care not to pinch or damage any wires or Ink Hoses.

  • Page 130: Replacing Label Web Sensor

    SECTION 4 DISASSEMBLY AND ASSEMBLY Replacing Label Web Sensor The Label Web 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 131: Replacing Service Station Sled Printed Circuit Boards

    SECTION 4 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 132: Replacing Service Station Lifting Arms

    SECTION 4 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 133 SECTION 4 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 134 SECTION 4 DISASSEMBLY AND ASSEMBLY 4. Remove Spring, located at the bottom of the encoder assembly (Z3, Z4 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.
  • Page 135 SECTION 4 DISASSEMBLY AND ASSEMBLY 7. Turn the lifting arm motor (worm gear) to raise the lifting arms to their highest position. Tip: A 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 136 SECTION 4 DISASSEMBLY AND ASSEMBLY 10. Remove the Service Station Side Rails. 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 137 SECTION 4 DISASSEMBLY AND ASSEMBLY ® 13. Apply a standard silicone or Teflon based grease or lubricant 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 138 SECTION 4 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 139 SECTION 4 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 140: Section 5 - Maintenance

    SECTION 5 MAINTENANCE SECTION 5 - 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 141: Replacing The Ink Tanks

    SECTION 5 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 142: Cleaning Ink Tank Contacts

    SECTION 5 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 143 SECTION 5 MAINTENANCE 2. Open the Front Cover, 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 144: Cleaning/Replacing The Printhead Cartridge

    SECTION 5 MAINTENANCE Cleaning/Replacing the Printhead Cartridge Cleaning 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 145: Replacing The Printhead Cartridge

    SECTION 5 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 146: Printhead Storage & Shelf Life

    SECTION 5 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 147: Cleaning Pen Driver Printed Circuit Board Contacts

    SECTION 5 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 148: Inspecting & Cleaning The Lip Of The Capping Station

    SECTION 5 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 149: Inspecting The Wiper Roller

    SECTION 5 MAINTENANCE Inspecting the Wiper Roller The Wiper Roller should be routinely inspected for signs of wear and debris. NOTICE! If you have not been trained or are uncomfortable performing this task, please contact your service support representative. Directions: 1.

  • Page 150: Cleaning/Replacing Service Station Items

    SECTION 5 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 151 SECTION 5 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 152: Cleaning The Service Station

    SECTION 5 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 153: Wiper Motor Assembly Removal And Cleaning

    SECTION 5 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 154: Printing Platen And Capping Station Removal And Cleaning

    SECTION 5 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 155: Installing The Service Station

    SECTION 5 MAINTENANCE Installing the Service Station CAUTION THIS PROCESS MUST BE PERFORMED BY A QUALIFIED/TRAINED PERSON. NOTICE: Due to the technical nature of this procedure; it should only be performed by a qualified technical support person or someone that has been properly trained on this procedure. Please contact your technical support representative.
  • Page 156 SECTION 5 MAINTENANCE 6. Slide the Cable Securing Latch open on the Service Station Circuit Board; as shown below. Closed Opened 7. 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 157 SECTION 5 MAINTENANCE 9. 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 158: Still Experiencing Print Quality Issues

    SECTION 5 MAINTENANCE 11. 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 159: Inspecting/Replacing The Waste Ink Tray

    SECTION 5 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 160: Replacing The Sheet Separators

    SECTION 5 MAINTENANCE Replacing the Sheet Separators The sheet separators (43-106-10) insure separation of the pieces as they are being fed. If you experience double sheet feeding, and adjusting for Media Thickness (See Feed Setup) does not prevent this, it may be time to replace the separators.

  • Page 161: Cleaning The Printer Body

    SECTION 5 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 162: Cleaning The Feed Sensor

    SECTION 5 MAINTENANCE Cleaning the Feed Sensor The Feed Sensor is located between the Feed Roller Assembly and the Print Engine. It is used to control the delivery of media to the print engine. TIP: If the Toolbox, Cutsheet Feeding Mode is set to “Safe Feed” and you are getting blanks fed at the end of every job (last piece may stop inside print engine), then the Feed Sensor may not be working properly (dusty/dirty).

  • Page 163: Cleaning Other Items Inside The Print Engine

    SECTION 5 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 Capping Station Lip...
  • Page 164 SECTION 5 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 165: Cleaning The Ink Revolver Couplings

    SECTION 5 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 166: Preparing Printer For Transport

    SECTION 5 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 167 SECTION 5 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 168: Lubricating The Service Station

    SECTION 5 MAINTENANCE Lubricating the Service Station 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 monthly (after ® printing about 50,000 pieces.) Use a standard silicone or Teflon -based grease or lubricant (Super Lube 21030 or equivalent).
  • Page 169 SECTION 5 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 170: Reinstalling Or Replacing The Service Station

    SECTION 5 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 5 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 5 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: Lubricating The Media Table Lift Assembly

    SECTION 5 MAINTENANCE Lubricating the Media Table Lift Assembly Before lubricating the Threaded Rod and Wheel Guides on the Media Table Lift Assembly it is a good idea to wipe the surfaces to clean off any accumulated grit and dirt. 1.
  • Page 174 SECTION 5 MAINTENANCE 4. Remove the Rear Side Closure (located on Non-operator side): [A] Remove (1) screw and (2) Allen screws. NOTE: Be careful of any wiring. [B] Remove (2) screws from non- operator Side Frame. Lift Closure up and out. (Located below the Main Power Switch Assembly.) 5.

  • Page 175: Appendix A - Ink Delivery System (Ids)

    APPENDICES Appendix A – 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 176 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 177: Index

    INDEX INDEX Adjusting ............40 Cleaning ............160 Belt, Media Table Lift Assembly ......49 Buffer Boxes, Replacing ........101 Replacing ............39 Feeder Encoder & Sensor ........42 Clamshell Assembly ..........127 Firmware Download ..........31 Clamshell Latch Pins ..........109 Forwarding Rollers Removal/Install ..........
  • Page 178 INDEX MPCA Board, Connections ........89 Media Table Lift Assembly Motor & Drive Belt ..............48 Preparing for Transport ......... 164 Paperpath Sensors ..........162 Pull Out Rollers ..........59 Pen Driver PC Assembly ........102 Pen Driver PC Assembly Contacts, Cleaning ..145 Replacing Feed Sensor ........
  • Page 179 INDEX Media Table Lift Assembly ......52 Removing ............148 Media Table Lift Assembly Belt ..... 49 Replacing ............148 Media Table Lift Assembly Motor & Drive Belt Wiper Motor Flex Cable PCA ....... 129 ..............48 Service Station Installation ........153 Paper Path Motor/Drive Belt ......
  • Page 181 Copyright © Neopost USA 2014...

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