Page 1 Service Manual P/N 1-960470-00 Edition 1 August1999 ColorCoder V4 Color Label Printer...
Page 2: Table Of Contents
Control Panel ................74 A. Outline ..................74 B. Operation ................. 75 Power Supply ................77 A. Power Supply ................77 Intermec ColorCoder V4 Service Manual Edition 1, August 1999 Part No. 1-960470-00 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 3 A. Outline .................. 211 B. Operation of Service Mode ............ 211 C. Functions of Service Mode ............ 212 D. List of Service Mode ............. 213 E. Service Mode Menu Hierarchy Diagram ....... 223 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 4 Information in this manual is subject to change without prior notice and does not represent a commitment on the part of Intermec Printer AB. © Copyright Intermec Printer AB 1999. All rights reserved. Published in Sweden. ColorCoder is a registered trademark of Intermec Technologies Corp.
Page 5: Notices And Approvals
A prescrites dans le règlement sur brouillage radioélectrique édicté par le Ministère des Communications du Canada. VDE Notice Germany ALLGEMEINE VORSCHRIFT: Reparaturen oder sonstige Eingriffe, die sich nicht auf normale Bedienung der Maschine beziehen, dürfen ausschließlich nur von einem ausgebildeten, zuständigen Fachmann vorgenommen werden. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 6 ..............Mats Gunnarsson President /. Intermec assumes no responsibility as regards fulfilling the CE Directive if the printer is handled, modified or installed in other manners than those described in the manuals. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 7: Preface
• Intermec ColorCoder V4; User's Guide (multilingual) • Intermec ColorCoder V4; Installation & Operation manual • Intermec ColorCoder V4; Spare Parts Catalogue • Intermec ColorCoder V4; Installation Instructions (for various options)
Page 8: Features
9. A roll unit is provided for the paper feeding. By setting a large roll of paper, consecutive mass-printing is possible. By remov- ing the roll unit drive system, fan-fold paper can also be used. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 9: Specifications
When printing: 60 dB (excluding peak period). Service life 1 year or 5,000,000 sheets, whichever comes first. Operating modes On line: Prints connected to host computer via Windows printer driver or with ColorCoder LSW. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 10 1. Total count (indicated on the operation panel in the service mode) 2. Mechanical counter (positioned at the back of the main unit inside) Options Cutter unit, Rewinder, Fan-fold kit The above information is subject to change. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 11: Parts Of The Machine
2. PHS (Printer Head Station) unit 3. Roll cover 4. Power switch 5. Front cover 1.3:B Rear View 1. Sub cover 2. Power cord connector 3. Parallel interface connector 4. Manual cutter Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 12: Internal View
9. Right cursor key 3. PAUSE key 10. READY lamp 4. STOP key 11. ON LINE lamp 5. FEED key 12. DATA lamp 6. MENU key 13. ERROR lamp 7. Left cursor key Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 13: Cross Sectional View
10. Engine 2 PCB 11. Delivery roller 12. Drive roller 13. TOF outlet sensor 1 14. TOF outlet sensor 2 15. Engine 1 PCB 16. Formatter PCB 17. DC power supply unit Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 14: Menu Hierarchy Diagrams
* O N L I N E S TA R T S TA R T- U P O P T I O N O F F L I N E S TA R T Next Page Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 15 I / F S E T. * PA R A L L E L * T Y P E 1 T Y P E 2 T Y P E 3 Next Page Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 16 L A B E L G A P = 0 3 M A R K W I D T H S E T. M A R K W I D T H Next Page Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 17 M O D E ( B ) N V R A M R E S E T N V R A M N V R A M N V R A M S AV E Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 18: Basic Operation
Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 19: Outline Of Electrical Circuit
Inside the PHS unit are arranged two motors and one solenoid, which control the UP and DOWN motion of the head holder unit and capping and wipe evacuation operation of the recovery unit. These are controlled by the engine 2 PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 20 Array CG-ROM Counter Memory J109 card holder Counter Option J104 connector Roll holder PCB Gate Array DC power supply unit Roll motor Power control Circuit Control voltage circuit Power switch Figure 2-2 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 21: Input From And Output To Formatter Pcb
2.1:C Input from and Output to J106 Formatter PCB Formatter PCB Control panel Memory J109 card Parallel J102 External device J104 Cutter unit (Option) J307 J105 Engine 1 J601 J103 Roll holder Figure 2-3 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 22: Input From And Output To Engine 1 Pcb (1/2)
When front door is open, "L." Front door sensor J7-1 J309-1 [PHS SLND1] When "H," PHS unit is released. PHS lock solenoid [PHS SLND2] When "H," PHS unit is locked. Figure 2-4 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 23: Input From And Output To Engine 1 Pcb (2/2)
GND is measured with connector (J304) CTRG disconnected, if a new ink cartridge is set, "infinity (Ω)." CTRG Ink cartridge sensor (Y) J105 J307 Formatter PCB J406 J308 J412 J312 Engine 2 PCB Counter Counter Figure 2-5 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 24: Input From And Output To Engine 2 Pcb
When head holder is past Head position sensor 2 home position, "H." +24V J411-1 PHS open/close detection switch When PHS unit is closed, "H." J308 J406 J312 J412 Engine 1 PCB Figure 2-6 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 25: Input From And Output To Roll Holder Pcb
When paper 4 inches wide is Paper width sensing set, voltage is approx. 4V. slide rheostat When paper 2 inches wide is set, voltage is approx. 0V. J103 J601 Formatter PCB Figure 2-7 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 26: Input From And Output To Dc Power Supply Unit
While power is on, "H". VM-CONT VM-CONT While power is on, "H". J107 J002 J306 J001 Engine 1 PCB J405 J002 Engine 2 PCB Shut-down is going Power SW Switching SW SNS Sleep Figure 2-8 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 27: Basic Sequence
Cam pressure release clutch PHS unit initialization Sequence Head position sensor 2 Head position sensor 1 86 pulse Head motor Cap position sensor 1 Cap position sensor 2 Cap motor Figure 2-9 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 28 HDCL Head cleaning processing MVPR Printing position movement operation HDPRT BJ head printing operation Delivery operation after printing MVCP BJ head/recovery system cap position movement SWBK Paper back feed operation Table 2-1 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 29: Motor Control
Drives recovery unit Pump motor (M2) Drives suction pump, pressure pump, and recovery pump Roll motor (M5) Drives roll drive shaft Fan motors (FM1–3) Cools head while its temperature is in- creasing Table 2-2 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 30 +24V +12V Q348 Q313 Q317 FEEDMA J301-1 FEEDMB FEEDMC Motor Gate Driver driver array FEEDMD Control FEEDME Circuit Feeder motor Q318 Driver +24V Q338 PUMPMA J302-13 Driver PUMPMB Pump motor Figure 2-11 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 31 CAPMB CAPMCOMB CAPMB Cap motor +24V Q402 HDMA J407-14 HDMCOMA HDMA Motor driver HDMB HDMCOMB HDMB Head motor +24V J408-2 Fan motor 1 Q421 Fan motor 2 Fan motor 3 Figure 2-12 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 32 Formatter PCB Roll holder PCB J602-7 OPIMT1 J103-A8 J601-6 Gate motor controller array driver OPIE/B -A12 Roll motor J602-3 Roll sensor output detection circuit Roll sensor J602-6 Roll paper end sensor Figure 2-13 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 33: Image Formation System
See Figure 2-14 for the basic construction of the image formation system. Head motor Cap motor Tube connector Tube station BJ head Absorber Restoration tub unit Recovery unit Figure 2-14 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 34 The restoration tub unit is driven by the cap motor (M4), and the capping position and the evacuated position are controlled by the cap home position sensor 1 and the cap position sensor 2. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 35 Third paper Fourth paper Fifth paper Sequence Feeder motor TOF inlet sensor BJ line head (K) BJ line head (C) BJ line head (M) BJ line head (Y) TOF outlet sensor Figure 2-17 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 36: Bubblejet Line Head
Block 1 Block 2 Block 3 Block 4 Block 5 Block 6 Block 7 Block 8 Block 9 Block 10Block 11 1 2 3 1 1 1 2 2 2 6 7 8 Figure 2-18 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 37 7. Supply of ink The ink is again supplied to the nozzle by the capillary tube phenomenon. Bubble volume (relative value) Heater drive pulse (main heat section) 2 3 4 Figure 2-19 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 38: Recovery Unit
While the power supply is off or the printer is standby state, the head is moved to the capping position, and covered by the restoration tub. BJ head Cleaner blade Absorber Restoration tub Figure 2-20 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 39 When the head is in the capping position, driving the pressure pump and the suction pump to feed ink from the sub-tank to the head. (See “III. INK SUPPLY SYSTEM, 1. Outline of Operation, B. Operation of the Circulation Mode.”) Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 40 The restoration tub evacuates to the printing position, the head nozzle face moves downward to about 2.9 mm above the platen (about 1.5 mm from the paper), and then printing operation starts. BJ head Restration Platen Figure 2-23 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 41 1 and the cap position sensor 2. • Capping position Position of preliminary discharge, capping, and pressurizing • Evacuated position Position of printing Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 42 Head motor (M3) Cap position sensor 1 (PS6) Cap position sensor 2 (PS7) 20 pulse 21 pulse Cap motor (M4) MVWP : Wipe position movement : Wipe MVCP : Cap position movement Figure 2-25 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 43 4. When more than 12 hours have elapsed after the previous cleaning 4: ink supply → cleaning 4 When less than 12 hours have elapsed after the previous cleaning 4: Cleaning 3 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 44 Recovery before printing before the printing process is restarted. • When the interval to restart of printing is less than 20 seconds: No cleaning process takes place before the printing process is restarted. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 45 (printing density 12.5%) is completed, cleaning 4 takes place. However, if paper has exhausted during the printing process, and printing on paper equivalent to 2,000 sheets has already completed, cleaning 4 takes place. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 46 Recovery pump position sensor (PS5) 30sec 40sec 3.0sec 1.6sec 15sec Pump motor (M2) Cam pressure release clutch (CL1) 1.6sec Pressure clutch (CL2) Motor running forward, sensor light blocking, clutch ON Motor running backward Figure 2-28 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 47 Pressure cam position sensor (PS4) Recovery pump position sensor (PS5) Pump motor (M2) Cam pressure release clutch (CL1) Pressure clutch (CL2) Motor running forward, sensor light blocking, clutch ON Motor running backward Figure 2-30 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 48: Ink Supply System
Ink remaining quantity detection sensor Restoration tub unit Sub tank Suction pump Pressure pump Pressure release Needle block Cartridge detection contact Ink cartridge Recovery pump Pump retainer Ink room (lower) Figure 2-31 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 49 Latch lever (Up) Filter unit Pump retainer Ink cartridge Pressure Pressure clutch Needle block pump Ink tank Sub tank Pump retainer One way clutch Recovery pump Recovery pump home position Figure 2-32 sensor Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 50 Latch lever (Down) Filter unit Pump retainer Ink cartridge Pressure Pressure clutch Needle block pump Ink tank Sub tank Pump retainer One way clutch Recovery pump Recovery pump home position sensor Figure 2-33 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 51 Latch lever (Down) Filter unit Pump retainer Ink cartridge Pressure Pressure clutch Needle block pump Ink tank Sub tank Pump retainer One way clutch Recovery pump Recovery pump home position sensor Figure 2-34 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 52 • Ink overflow error: “26 SERVICEMAN CALL” takes place, when the ink leaks inside the printer and reaches the ink leak sensor. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 53: Pump Unit
With the recovery pump home posi- tion sensor, the pump always stops at the position of the released condition without no roller. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 54 Pressure pump pressure Suction pump release clutch Suction clutch Pressure clutch Pressure cam home position sensor Pump retainers Pressure release cam Pump motor Recovery pump Recovery pump home position sensor Figure 2-37 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 55 Pressure pump pressure Suction pump release clutch Suction clutch Pressure clutch Pressure cam home position sensor Pump retainers Pressure release cam Pump motor Recovery pump Recovery pump home position sensor Figure 2-38 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 56 Pressure pump pressure Suction pump release clutch Suction clutch Pressure clutch Pressure cam home position sensor Pump retainers Pressure release cam Pump motor Recovery pump Recovery pump home position sensor Figure 2-39 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 57 Pressure pump pressure Suction pump release clutch Suction clutch Pressure clutch Pressure cam home position sensor Pump retainers Pressure release cam Pump motor Recovery pump Recovery pump home position sensor Figure 2-40 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 58 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 59: Ink Cartridge
• Slots to prevent misinsert Slots to ensure that the ink cartridge is inserted into the fixed position for each colour. The cartridge can not be inserted into wrong position. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 60: Pick Up/Feeder System
TOF outlet sensor 2 TOF inlet sensor 2 TOF outlet sensor 1 Roll paper end sensor Roll sensor Roll motor Roll paper Feed belt Roll drive shaft Slide rheostat unit Figure 2-42 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 61: Motor Control
If it does not catch up with a given speed for developing image data, the feeding of paper pauses every print of 1 page. See Chapter 2.1 Basic Operation, I Motor Control for the drive and control of the feeder motor. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 62: Pick Up Operation
Slide rheostat unit Roll paper end sensor Roll sensor lever Roll sensor Roll drive shaft Roll paper Roll holder PCB Figure 2-43 Slide rheostat unit Roll holder PCB Fan fold paper Figure 2-44 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 63 When the roll holder PCB detects the roll sensor OFF, the roll motor drive signal is stopped and the roll drive shaft stops rotating. Above procedure is repeated so that the roll unit feeds required quantity of paper. Figure 2-46 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 64 PAUSE key and then restarted, unprinted paper in the feed unit or paper being printed is returned to the printing start position to avoid waste. This process is called feedback process. Figure 2-48 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 65 When the top of the next paper returns to the position of the TOF inlet sensor 1 or 2, paper pick up and feeding operation is started. TOF inlet sensor Feed belt Figure 2-50 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 66 PCB through the roll holder PCB and “NO PAPER” is indicated on the operation panel. Roll sensor lever Roll sensor Roll paper end sensor Roll paper Roll drive shaft Figure 2-51 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 67: Feeding Operation
(an equivalent of one line of 360 dpi) paper fed, an equivalent of one line of the ink of the BJ head is ejected. Rowels Delivery rowel Feeder motor Pinch roller Roll paper Feed belt Roll drive shaft Figure 2-52 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 68 HDCL Head cleaning processing MVPR Printing position movement operation HDPRT BJ head printing operation Delivery operation after printing MVCP BJ head/recovery system cap position movement SWBK Paper back feed operation Table 2-4 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 69: Checking For Paper Errors
Normal condition Abnormal condition PWR ON PRINT START PWR ON PRINT START WAIT PRINT WAIT PRINT ERROR Paper feed motor Inlet TOF sensor TOF outlet sensor or Abnormal cutter TOF sensor 1.3sec 1.3sec Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 70 PRINT PRINT ERROR Paper feed motor Abnormal Inlet TOF sensor Approx. 2 sec Approx. 2 sec (When the 3 inch length (When the 3 inch length paper is used) paper is used) Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 71: Control/Interface System
The control/interface system which controls overall operation of the printer and interface system consists primarily of a formatter PCB. Host computer Memory card Parallel interface Control system Formatter PCB Engine 1 PCB Engine 2 PCB BJ head Figure 2-54 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 72: Outline Of Operation
Likewise, when the printing position reaches each head position of cyan, magenta, and yellow, printing data of each colour are printed to form color images. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 73: Memory Card
The printer can print the data by using the memory card. Note: Although the printer is capable of using memory cards, Intermec does not support this facility. Neither does Intermec provide any means for programming memory cards. Formatter PCB...
Page 74: Parallel Interface
RAM in accordance with the information of the data ( printing position, direction, character size, and character code). When the development of the image data to the bit map RAM completes, the printing operation starts. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 75: Control Panel
Pause key Error lamp Menu key READY DATA ERROR PAUSE MENU ON LINE STOP FEED ENTER On-line key Stop key Right cursor key Left cursor key Enter key Feed key Figure 2-57 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 76: Operation
Indicates that whether the signal on the data bus line is the display data or the control signal. Formatter PCB LCDECK DC+5V READY DATA ERROR D8 ~ D15 PAUSE MENU ON LINE CSLED STOP FEED ENTER CSKEY Figure 2-58 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 77 The on-line, pause, and stop keys are effective. 3. Off-line and in normal mode The on-line and feed keys are effective. 4. Off-line and in setup mode The on-line, right cursor, left cursor, menu, and enter keys are effective. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 78: Power Supply
Engine 1 PCB Engine 2 PCB +24V (Cyan) Counter PCB Counter BJ head +24V (Magenta) Battery BH301 +24V Motor +12V BJ head +24V (Yellow) Roll holder +24V Sensor DC power supply unit Figure 2-60 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 79 Even while the power is off, the power has to be supplied to maintain this function. The battery supplies the power to the clock IC. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 80: Mechanical System 3.1 Externals
Detach the covers as necessary to clean, inspect, or repair the inside of the printer. Those that can be detached by mere removal of the mounting screws without detaching any others in advance are omit- ted from the discussions. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 81 Figure 3-3 See Chapter 3.1:B Control Panel as to how to detach the control panel. 2. Remove the two mounting screws (3) from the left cover (1) and manual cutter (2). Figure 3-4 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 82 Figure 3-5 4. Open the front cover. 5. Remove the two mounting screws (2) from the inner cover (1), and then slide the inner cover in the left direction to detach. Figure 3-6 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 83: Control Panel
Figure 3-8 1. Control panel PCB 2. Screws (8 pieces) 3. Conductive rubber sheet 4. Key top A 5. Key top B 6. Key top C 7. LED lens (3 pieces) 8. Housing Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 84: Image Formation System
1. Detach the PHS cover (see Chapter 3.1. Externals). 2. Loosen the one mounting screw (2) on the head upper plate (1), and slide the head upper plate in the right direction to disengage the claw (3). Figure 3-9 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 85 Never open the tube release lever, if it’s not necessary. If opened, carry out the procedure for initial ink fill after re-assembling in compliance with Chapter 3.3:B Punp Unit, Precautions in assembling (last page). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 86 (1-901807-00). 7. Hold the heat sink (1) of the BJ head by both hands, and holding the head holder (2), detach the BJ head from the head holder (2) upward. Figure 3-13 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 87 (1-901800-00) and clear ink (1-901805-00). Wipe off the face at a stroke slightly with the lint-free sponge moistlned with a trace of the clear ink. Head face Figure 3-14 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 88 (1). Figure 3-16 3. Select the tube connector, matching with the colour of the BJ head to be used. Colour P/N of Tube Connector Black 1-901216-00 Cyan 1-901221-00 Magenta 1-901214-00 Yellow 1-901220-00 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 89 (1-901800-00) before connecting. 2. When the rubber packing comes off from the connector, re-fix it in the proper position and clean it with the lint-free sponge (1-901800-00). Projecting surface is the outside. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 90 3. Peel off the protective tape on the head face. Temporarily place the BJ head (1) on the head holder unit by putting on it along the guides naturally. In so doing, never force the BJ head in. Figure 3-20 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 91 [Head Print/Cap] menu. 7. Push into the temporarily placed BJ head, and bring the both sides of the BJ head (1) to the bottom face (2) of the head holder. Figure 3-22 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 92 Figure 3-24 14. Close the tube release lever. Attach the PHS cover. 15. Execute “SETUP CLEANING”. 16. Finish the service mode, and transfer to the normal mode (see Chapter 6.5 Service Mode). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 93 17. Execute Cleaning (B). 18. Execute Cleaning (A). 19. Check the image quality with [NOZ ADJ. PAT-TERN] and [NOZ CHK. PATTERN]. Execute adjustment of the registra- tion, if necessary (see Chapter 6.3 Test Print/Test Pattern). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 94: Recovery Unit
5. Remove the three screws (2) from the PHS right under cover (1), and detach the cover. Remove the mounting screw (4) and disconnect the connector (5) from the right fan unit (3), and detach the fan unit. Figure 3-26 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 95 When the recovery tubing is removed, suck the waste ink in the tubing with the paper towel and, if leaving the recovery tubing removed, put paper towel around the edge of the tubing. Figure 3-29 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 96 2. To clean the blade, use a new lint free sponge (1-901800-00) moistened with traces of clear ink (1-901805-00). Figure 3-33 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 97 2. Run the recovery tubes (2) of the recovery unit (1) to the rear side through between the PHS unit and the feeder unit, and connect it to the recovery pump (3). Figure 3-35 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 98 Figure 3-36 4. Insert the claws (1) of the further side of the recovery unit in the holes (2) of the recovery support plate and push it to the bottom. Figure 3-37 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 99 6. Insert the recovery tube into the recovery pump completely and connect with recovery pump. 7. Install the pinch roller unit (1) to the position marked, and fix with the two screws (2). Marking Figure 3-39 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 100 8. Install the right fan unit (1), and fix with one screw (2). Connect with the connector (3). Install the lower-right PHS cover (4) with three screws (5). Figure 3-40 9. Install the BJ head (see Chapter 3.2:A Installing the BJ head ). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 101: Fan Unit
2. Be sure to attach the transportation connectors (1-901809-00) to the tube stations; otherwise the ink may flow out of the tube when the tube station is detached or during the initial ink filling. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 102 5. Remove the two mounting screws (2) from the tube station (1), and detach the tube station. Figure 3-42 6. Disconnect the connectors J20 and J21 (1). Detach the tie-wraps (2), and then remove the wiring cable. Figure 3-43 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 103 8. Disconnect the connectors J20 and J21 (1) from the back side of the fan mounting plate, and disengage the claw (3) of the fan rear duct (2), and then detach the fan rear duct. Figure 3-45 9. Detach the fan motor. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 104 2. Disconnect the connector J22 (1), disengage the claws (3) of the fan right holder 2 (2), and then detach the fan right holder 2. Figure 3-46 3. Detach the fan motor. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 105: Motor Unit
4. Remove the three mounting screws (2) from the motor unit (1), and detach the motor unit. Figure 3-48 Caution: Install the motor unit properly so that the head holder, the recovery unit and gear back lash of two motors work precisely. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 106 1. Remove the one mounting screw (2) from the gear cover (1), and detach the gear cover. Figure 3-49 2. Pull out the gears (1) and (2), while expanding the claw. Figure 3-50 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 107 3. Disengage the two E-rings (1), and pull out the two gears (2). Figure 3-51 4. Remove the two mounting screws (2) from the cap motor (1), and detach the motor. Figure 3-52 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 108 Chapter 3 Mechanical System 3.2 Image Formation System, cont'd. 3.2:D Motor Unit, cont'd. Detaching the Motor, cont'd. 5. Remove the two mounting screws (2) from head motor (1), and remove the motor. Figure 3-53 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 109: Ink Supply System
2. Remove the two mounting screws (2) from the upper ink room (1), and pull out the upper ink room to the near side. Figure 3-54 3. Disconnect the connector J78 (1). Figure 3-55 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 110: Pump Unit
Never open the tube release lever , if it’s not necessary. If opened, carry out the procedure for initial ink fill after re-assembling in compliance with Chapter 3.3:B Pump Unit/Precautions in assembling (last page). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 111 (J71, J76, J77, and J79A)(2). Figure 3-58 6. Remove the mounting screw (2) and toothed washer (3) from the grounding wire of the rear crossmember (1), and remove the grounding wire (4). Figure 3-59 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 112 Detaching the Pump Unit, cont'd. 7. Remove the two mounting screws (2) from the tube station (1), and detach the tube station. Figure 3-60 8. Remove four recovery tubes (1) from the recovery pump. Figure 3-61 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 113 (1), and disconnect the wire clip (3) and wiring cable, and then detach the rear crossmember. Figure 3-62 10. Remove the two mounting screws (2) from the lower ink room (1). Figure 3-63 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 114 Do not tilt the pump unit more than necessary, because the ink in the pump unit may leak out of the unit. 12. Remove the two mounting screws (2) from the lower ink room (1), and detach the pump unit from the lower ink room. Figure 3-65 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 115 To clean the tip, use clear ink (1-901805-00) put in another container. After cleaning, be sure to dispose of the used clear ink. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 116 (4) from the claw, and detach the pump cover. Figure 3-66 3. Detach the recovering tube (1). 4. Remove the screw (2), detach the filter unit (3). Figure 3-67 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 117 1. Remove the latch solenoid. 2. Remove the spring (1). 3. Disconnect the connector (2). 4. Remove the breather joint (3) for 4 places. 5. Remove two screws (4) and detach the breather unit. Figure 3-69 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 118 (4) from the claw, and detach the pump cover. Figure 3-70 3. Remove the eight tubes (3) which are extending from the needle block (1) to the sub-tanks (2). Figure 3-71 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 119 And always put the needle cover on the tips of the needle block, when detached. When disposing of it, careful action should be carried out to make sure the safety, such as, crushing the tips and wrapping it with durable protection. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 120 (1). Figure 3-73 Detaching the pressure cam home position sensor 1. Disconnect the connector J14 (2), unhook the claw, and then detach the pressure cam home position sensor (1). Figure 3-74 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 121 5-4) are tied up together with a bundle of wires of the pump unit, not too strong, the leading edge of the tube should be arranged to run into the inside of the lower ink room. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 122 9. Execute [Cleaning(A)]. 10. Check the image quality in the modes [NOZ ADJ. PATTERN] and [NOZ CHK. PATTERN], and then adjust the position of the nozzles (see Chapter 6:3 Test Print, Test Pattern). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 123: Pick-Up/Feeder System
2. Remove the two screws (2) fixing the roll right cover (1) and remove the cover. Figure 3-76 3. Remove the three screws (2) from the roll rear cover (1) and remove the cover. Figure 3-77 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 124 4. Disconnect the connector J65 (2) of the roll harness (1). Figure 3-78 5. Remove the three screws (2) from the roll unit and remove the roll unit (1) from the printer. Figure 3-79 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 125 3. Remove the spacer (6) from the roll drive shaft. Figure 3-80 4. Remove four screws (2) fixing the roll motor cover (1) and remove the cover. Figure 3-81 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 126 When installing the roll drive shaft (1), push the drive gear (2) against the motor bracket (3) (in arrow mark direction) to eliminate play in the drive shaft, and then fix the roll drive shaft holding the roll retainer (inner) (4). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 127 2. Remove the grip ring (2) from the roll motor drive gear (1) and detach the gear. 3. Remove three mounting screws (4) from the roll motor (5) and detach the motor. Figure 3-84 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 128 Removing the paper guide (front) 1. Remove the mounting screw (2) from the roll lower cover (1) and detach the cover. 2. Remove the mounting screw (3) from the paper guide. Figure 3-86 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 129 2. Remove the three mounting screws (6) from the roll sensor mount (5) and detach the roll sensor and roll paper end sensor from the mount, removing the claws of the sensors. Figure 3-88 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 130 (1). Figure 3-89 2. Remove the mounting screw (2) from the paper width detection slide rheostat unit (1) and detach the paper width detection slide rheostat unit. Figure 3-90 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 131 1. Disconnect the connectors J601-J603 (2) from the roll holder PCB (1), and detach the roll holder PCB from the roll holder removing the claws of the four locking card spacers (3). Figure 3-91 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 132: Feeder Unit
(3). Figure 3-92 4. Open the wire clip (2) of the rear crossmember (1), remove the four mounting screws (3), and detach the rear crossmember. Figure 3-93 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 133 3.4:B Feeder Unit, cont'd. Detaching the Feeder Unit, cont'd. 5. Disconnect the two connectors J8 and J73 (1). Figure 3-94 6. Remove the four mounting screws (2) of the feeder unit (1). Figure 3-95 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 134 (BJ head, recovery unit, etc.) are detached, the PHS unit may jump up violently, because the PHS unit becomes light in weight. Work with the PHS unit open. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 135 2. Disengage the spring (1) and remove the E-ring (2), remove the two mounting screws (4) of the solenoid (3) and the spring pin (5), and detach the solenoid out of the locking hook (6). Figure 3-98 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 136 (1) with a hex wrench. 2. Disconnect the connector J8 (3). Figure 3-99 3. Remove the four mounting screws (2) of the feed motor (1), and detach the feed motor. Figure 3-100 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 137 2. Remove the delivery belt (3), disengage the E-ring (4), and remove the pin (5) and the drive pulley (6). Figure 3-101 3. Disengage the two E-rings (1), disengage the bushings (2), and detach the delivery roller (3). Figure 3-102 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 138 (3), and detaching the bearing retainer plate (4) and the bearing (5). Figure 3-103 2. Remove the four mounting screws (2) of the platen plate (1), and pull out the platen plate to detach it. Figure 3-104 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 139 (2) and the pin (3), remove the askew feed pulleys (4), remove the E-ring (5), and detach the whole bearing (6). Remove the E-ring (8), and detach the drive roller (7) on the delivery side along with the bearing (9). Figure 3-105 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 140 (4), and then detach the feed motor mount. Figure 3-106 2. Disengage the claw, disconnect the two connectors J9 and J10 (2), and detach the TOF inlet and outlet sensor 2 (1). Figure 3-107 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 141 When attaching the joint of the feed motor and the drive roller shaft, be sure to tighten one of screw of the joint at the D-cut side of the shaft. Figure 3-109 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 142: Rowels And Rollers
Caution in Attaching the Rowel unit When attaching the rowel (1), be sure that the washers (2) are on the outside of the bushing. Figure 3-111 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 143 3. Remove the two screws (1), and detach the pinch roller unit (2). Marking Figure 3-113 4. Mount the pinch roller unit to meet the marking by adjusting the screw and fix it with the screw. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 144 3. Remove the four screws (2) on the left side plate (1), and detach the left side plate. Figure 3-114 4. Remove the two screws (1), and detach the upper delivery roller unit (2). Figure 3-115 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 145: Pcbs
J306, J307, J308, J309, J312, and J314 (2) of the engine 1 PCB. Figure 3-116 3. Remove the two mounting screws (2) of the engine 1 PCB (1), and take off the PCB with the face down. Figure 3-117 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 146: Formatter Pcb
2. Remove the screws (2) of the interface connector J102. 3. Remove the screws (4) of the PCB supports (3). 4. Pull out the formatter PCB rearward (in the direction indicated by the arrow). Figure 3-118 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 147: Counter Pcb
1. Disconnect the connectors CN1and CN2 (2) from the counter PCB (1). 2. Remove the two mounting screws (3) from the counter PCB (1) and pull out the counter PCB. Figure 3-119 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 148: Engine 2 Pcb
J411, and J412 (2) of the engine 2 PCB (1). Figure 3-120 2. Remove the claw from the six locking card spacers (2) and detach the engine 2 PCB (1). Figure 3-121 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 149: Dc Power Supply Unit
Figure 3-122 4. Remove the two mounting screws (2) from the lower front side of the DC power supply unit cover (1), and detach the DC power supply unit cover. Figure 3-123 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 150 5. Remove the three mounting screws (2) from the DC power supply unit (1), and detach the DC power supply unit by pulling it toward the front side. Figure 3-124 Figure 3-125 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 151: Installation
6. The machine should be at least 10 cm (4") away from the wall and there should be ample space to operate it. 7. When placing the machine on a desk or table, use one that is stable and sturdy enough to withstand the load. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 152: Unpacking And Installation
• Head shading data floppy disk Cleaning sticks • Bottle of clear ink Collux ink cartridges • Cleaning sheets (2 x 100 ml) Collux ink cartridges • Cleaning sticks (2 x 100 ml) Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 153: Installation (Roll Type)
Install the sub cover Detaching the PHS cover: Remove two screws (1) of the PHS cover and detach the PHS cover (2). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 154 3. After all the cartridges have been set in place, close the front • If the attached positions of the cartridges are cover. wrong, the cartridges cannot be properly set in place. • Push in the cartridges right up to the end. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 155 If the machine is to be relocated inside rooms after installing the covers, raise the opening/ closing arm as described in Chapter 4.2:F. Relocation and Transportation before moving the machine. After relocating, push the opening/ closing arm down. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 156 Connect the power cord to the power cord connector at the back of the machine. Insert the power cord connected to the machine into an outlet. Turn the power on in service mode. (See Chapter 6.5 Service Mode) Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 157 5. About 1 minutes after the completion of the set up cleaning process, operation sound stops. Then turn OFF the power switch. Turn the power off. Open the PHS unit and remove the taped lint-free towel (1). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 158 5. Set a roll paper to the roll drive shaft and fit the roll paper core into the roll retainer (inner). 6. Set the roll retainer (front) to the roll drive shaft and tighten the fixing screw pushing it lightly against the roll paper. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 159 Position the paper guide match the paper edge correctly to the mark. watching from the window so that the paper edge is matched to the mark on the paper guide. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 160 “ENTER” key. Then the error is reset and printing is started. 11. Set the roll cover. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 161: Installation (Fan-Fold Type)
3. Remove the mounting screw (2) from the lever fixing arm (1) and take out the roll sensor lever (3) and spring (4). 4. Remove the two mounting screws (2) from the roll frame (1). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 162 6. Remove the harness (4) from the edge saddle (3). 7. Turn ON the No.1 dip switch (SW1) (5). 8. Remove the seven mounting screws (2) from the roll frame (1) and detach the roll unit drive system. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 163 10. Insert the roll harness connector (1) into J65 (2). 11. Install the rear cover. 12. Unpack the fan fold kit and take out the fan fold roll right cover (1) and fan fold guide (2). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 164 14. Install the fan fold guide (1) to the fan fold guide frame (2) with two binding screws (M3x6) (3). Follow the steps from No.8 to 13 in chapter 4.2:B Installation (roll type). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 165 3. Open the paper box and fold down the vinyl bag and box lid outward. 4. Untighten the screw fixing the paper guide (front) and move the paper guide frontward until coming to a stop. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 166 “ENTER” key. Then the error is reset and printing is started. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 167: Check Of Image And Operation
Check the image quality by the nozzle check “NOZZELE CHECK PATTERN” pattern and carry out the head cleaning if neces- appears on the display panel. sary. 7. Press the ENTER key. The “NOZZLE CHECK PATTERN” will be printed. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 168: Head Shading
Copy the head shading data file into the “HS_DATA” folder in the where XXXXX indicates the last five digits of host computer from the HS data floppy disk packed with the the printer's serial number. printer. C:\WINDOWS\HS_DATA\XXXXX.HS Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 169: Relocation And Transportation
1. mentioned. Do not tilt the machine too much. Also, avoid bumpy road so as not to expose the machine to excessive vibration. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 170 Use a lint free sponge to clean the connection areas and wipe off the ink adhered there. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 171 Set the four transport cartridges into the ink room. Place the upper head plate packing (1) on top of the upper head plate and secure with filament tape (2). Attach the PHS cover. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 172 (green coloured lever) to “TRANSPORTA- TION MODE”. 1. Close the PHS unit. 2. Secure the front side (3 positions), rear sub-cover (1 position) and roll cover rear (1 position) with filament tape. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 173: Daily Care By Customer
2. When white streaks still exist in spite of Cleaning (A) carried out sometimes. 3. When many white streaks appear on the image. When color loss or color blanks appears over in a wide areas of the image. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 174: Image Maintaining Functions
1. When printing an image with variable data or variable bar codes. 2. When printing an image a part of which is a high density printing area. 3. When printing a large amount of about 10,000 sheets per day. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 175: Cleaning
2. Have the customer fully understand not to touch the rowel units on top of the feeder system or another sharp parts , etc., as they could cause injury or be damaged. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 176: Maintenance And Servicing
1,500,000 sheets 12.5% driven using 4"x3" paper Pump Unit 1-901311-00 Recycle pump operating 250 hours PHS Unit 1-901300-00 1,500,000 sheets Roll motor 1-901228-00 1,500,000 sheets Roll motor drive gear 1-901175-00 1,500,000 sheets Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 177: Maintenance
800,000 sheets age for both sensors Check whether output voltage of the both sensors meet required value or not, and adjust it, if not. Figure 5-2 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 178 (2) or not. Replace the breath ink tub if necessary. semble and clean around 700,000 – Remove and clean ink around the pump unit. pump unit 1,000,000 sheets Figure 5-3 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 179 Large volume of waste ink stained into specially the BJ head 1,000,000 sheets absorber (1) or the blade cleaner (2) [the absorber] in the restoration tub is to be sucked with the pump set. Figure 5-5 Figure 5-6 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 180: Troubleshooting 6.1 Preface
In the winter season, particularly when installing the machine, if it is suddenly moved from a cold warehouse, etc. into a warm room, condensation forms on various parts of the machine and may cause all sorts of trouble. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 181: Others
Is the power plug properly connected to the Reconnect the power plug printer and inserted to the printer and reinsert into the outlet? into the outlet. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 182: Specifications And Adjustments
J313-1 pin (–) falls in the specification given below. ± Specification: 3.4 V 0.1 V When no specification is indicated in the transparent chart, adjust using the following values. ± Specification: 2.7V 0.1 V Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 183 • TOF Outlet Sensor 2 (PST2) Adjust VR 305 so that the voltage of J313-6 pin (+) against J313-1 pin (–) falls in the specification given below. ± Specification: 2.5 V 0.1 V Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 184: Test Print
32°C. If the head temperature does not reach 32°C in 2 minutes, start printing. /. If paper smaller than that listed above is used, image may not be wholly printed or printing may not take place. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 185: Test Patterns
2. K-C, C-M, M-Y Gap Adjustment Method Read the number where the straight lines coincide, and add that number to the currently set value. (1) Pattern for vertical registration adjustment Outer frame Figure 6-3 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 186 2. The third pattern (latest one) of three “NOZ.ADJ.” should be taken into account to judge the printing position and decide set value. (2) Pattern for horizontal registration adjustment (2) Pattern for checking the result of the adjustment Figure 6-4 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 187 There shall be no nozzle that has not printed or that is greatly out of position. (1) Solid colouring pattern (2) Dot omission checking pattern Figure 6-5 (2) Font type and style indication Description of font types Description of font styles Figure 6-6 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 188 MARK WIDTH Interface setting ............. : INTERFACE ACK/BUSY setting ............: ACK/BUSY /. “STOP ADJUST” is printed when cutter unit is not connected. /. “CUTTER ADJUST’ is printed when cutter unit is connected. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 189 Chapter 6 Troubleshooting 6.3 Test Print, cont'd. 6.3:B Test Patterns, cont'd. SET. VALUE. PRINT (Internal Set Values), cont'd. (1) Set value indication pattern Figure 6-7 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 190 Caution: Since the adjustment is partially made, rtegistration may get out of position in other portions after the change. Figure 6-7 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 191 “4-INCH FEED PATTERN”, print the “NOZ. ADJ. PATTERN 2”, read the values of the portions 2, on previous page. Vertical linearity check pattern Horizontal linearity check pattern Figure 6-9 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 192 TERN”. Objective and method of registration adjustment are the same as in the “4-INCH FEED PATTERN”. (See Chapter 6.3:B 4- Inch Feed Pattern.) Vertical linearity check pattern Horizonal linearity check pattern Figure 6-10 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 193: Head Cleaning
Required time marked with * is just for your reference, The time required for the cleaning operation becomes longer than the time above, in consideration of additional operations of ink supply and suction for waste ink before cleaning operation start. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 194: Cleaning Of Head Face
2. Open the PHS unit and clean the ejection face where non-fire or • Refer to the test print for points where you misaligmment is going with the lint-free sponge. should clean off. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 195 “Cleaning (A)”, and check for the effect by test printing. eject correctly, clean the head face repeatedly. Print the head shading test chart using head shading data and collect the HS data again if necessary. (See Chapter 6.4 Head shading.) Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 196: Head Shading
Vertical streaks (uneven shade) Improved image after HS Figure 6-11 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 197 HS data file and copy it to a floppy disk. Carry the floppy disk into the customers’ site to copy it to the customers host computer and then, perform the process of the HS data. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 198: Procedure To Make Hs Data
• Click the button of “Basic printer setting”. • Select “Label printer”. 7. Install the TWAIN driver attached for the image scanner. (Installation method refers to the Installation manual or the Users’ manual for each) Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 199 When clicking “New”, confirmation message to delete existing file appears in the display and the file is deleted by clicking “OK”. When clicking “Continue”, continue the process with the HS file stored. Figure 6-13 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 200 Make sure that a printed image position is within the range below. If it is not, adjust the registration to make it fall within the range. 3.4±0.5 mm 4±2 mm Figure 6-15 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 201 (When using a flatbed scanner, place the test chart in alignment with the home position as shown figure 6-18.) Start/Stop button Figure 6-18 Figure 6-17 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 202 4. Select your scanner and Click “All colors”. “One color” is clicked for making the HS data for part of the colors registered (a given BJ head). Figure 6-20 5. Press the START/STOP button of the scanner. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 203 “\WINDOWS” folder. HS data file is saved into “\HS_DATA” folder as named “HSTEST **.HS”. When message of “New data file successfully created under file name hstest **.hs” appears on the display, click “OK”. Figure 6-23 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 204 Figure 6-25 12. Click “OK”. 13. “Insert the disk for hs” appears on the display, insert the floppy disk for HS data and click “OK”. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 205 “OK”. Figure 6-26 15. Click “Exit” in the HS utility menu. 16. When “Terminating execution of HS utility.” appears on the display, click “OK” to finish the HS utility. Figure 6-27 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 206 (Cyan, Magenta and Yellow) which are already copied in a customer’s host computer. 1. Copy HS data file in a customer’s host computer to “WIN- DOWS \HS-DATA” folder in a personal computer for HS. Figure 6-28 2.Click “One color”. Figure 6-29 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 207 - This is used to extract the colour data needs to be modified from another HS file already created. B: “Read-in from scanner” - This is used to print a new test chart and read it on a scanner. Figure 6-31 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 208 Execute test printing and confirm that it is printed properly. B. “Read in from scanner” 1. Set the test chart into the inlet of the scanner. Press the START/ STOP button of the scanner. Click in the twain display. Figure 6-33 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 209 Figure 6-34 3. Click “Test print”. When “Performing test print” appears on the display, click “Execute”. Make sure the efficiency of the HS with the test chart output. Figure 6-35 Figure 6-36 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 210 6. Copy the new HS data file to the customer’s host computer, (Replacement with the old data.) and finish the setting-up work. Execute test printing and confirm that it is printed properly. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 211 • Click the tag of “Details” • Click the button of “Set up” • Click the button of “Option” • If “Shading output” is unclicked, click it to output with the HS. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 212: Service Mode
2. In this state, when the “STOP” key is kept pressed, a warning beep sounds for about three seconds after which “SHUTTING DOWN” is displayed, and the machine will go into normal initializing operation. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 213: Functions Of Service Mode
Cleaning 4) and ink feed. 5. Keeping the TOF sensor drive current present. The TOF sensor drive current is kept present on. In the normal mode, the current flows only during print opera- tion. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 214: List Of Service Mode
Executes ink supplying operation. Items marked with execute ink remaining check before starting operation, and if there is no ink in the sub-tanks, execute ink suppling operation and then execute each operation. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 215 Indicates read value of total counter. SERIAL No. Serial number read Indicates serial number of the machine. Note: When “M. CARD CHECK” is executed, the data stored in the memory card is lost. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 216 The printer judges the absence of the label. 32 – C5 The printer judges the presence of the liner. 06 – FF The printer judges the presence of the label on the liner. Table 6-2 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 217 Cross-reference table for the environmental temperature ° ° ° Indication Temperature ( Indication Temperature ( Indication Temperature ( Table 6-3 Cross-reference table for the paper width Indication Width (mm) Indication Width (mm) Indication Width (mm) Table 6-4 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 218 “LABEL GAP=” 2–99 mm. MARK WIDTH SET. Sets the width of the mark on the reverse side of the paper or the width of the cut in the range of “MARK WIDTH=” 2–9 mm. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 219 /. Number of sheets is when 4" x 3" standard size paper is used. /. Number of sheets is when 4" x 8" size paper is used. /. Number of sheets is when 2" x 8" size paper is used. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 220 ~ +2.0 mm. This item is indicated when cutter unit is connected. /. When C, M, or Y horizontal registration is adjusted, check for the head shading effect and prepare new data, if necessary. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 221 How to stop the Aging Mode Aging menu can be paused while the “beeping” sound is on, once it has been paused, the aging process can be stopped by pressing the stop button. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 222 Set Values of Paper Type Table After NVRAM Reset Paper Type Setting of Kind Paper Paper Label Marker Setting of Paper Width Length Width TYPE 1 A:LABEL/GAP TYPE 2 C:TAG/MAKER TYPE 3 A:LABEL/GAP TYPE 4 C:TAG/MAKER TYPE 5 A:LABEL/GAP Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 223 Control Panel Indication Description of Operation DATE SET Date (year-month-day) set. TIME SET Time (hour-minute-second) set. Indicated language select (DISPLAY MODE) Control Panel Indication Description of Operation Set to indicate English. JAPAN Set to indicate Japanese. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 224: Service Mode Menu Hierarchy Diagram
DRAM check M. CARD CHECK Memory card check F. CARD CHECK Font card check CG-ROM CHECK CG-ROM check A/D DATA READ A/D value read-in TOTAL COUNT Total count SERIAL No. Serial number Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 225 =XXX Input 3 digit figure (38-406) PAPER LENGTH SET PAPER LENGTH =XXX Input 2 digit figure (02-10) LABEL GAP SET. LABEL GAP Input 2 digit figure (02-09) MARK WIDTH SET. MARK WIDTH Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 226 Y NOZZLE POS. STOP POS. ADJ. STOP POS. =0.0 When the cutter unit Stop position adjustment is not used. CUTTER POS. ADJ. CUTTER POS. =0.0 When the cutter unit is used. Cutter position adjustment Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 227 2-Inch size feed pattern Date set DATE SET DATE & TIME SET y-m-d 00-00-00 Time set TIME SET h:m:s 00:00:00 DISPLAY MODE Set indicated language *JPN NVRAM NVRAM SAVE NVRAM Save NVRAM RESET NVRAM Reset Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 228 To head printing position To Cap Pos. To head cap position Phs Holder Phs Lock PHS lock Phs Unlock PHS lock release Fan Motor Fan ON Fan motor drive Fan ON Fan motor stop Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 229 AIR TEMP . Temperature A/D value in the machine Paper width A/D PAPER WIDTH Paper width A/D value TOTAL COUNT Total count indication T.CUT = ???????? Serial number indication SERIAL NO. Ser.No.= ????? Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 230: Diagnosis
Carry out Cleaning (B) and eliminate ture discharge of ink. High duty print- non-discharge. Switch off power and ing was carried out for a long leave standing for a while. time, etc. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 231 Replace Engine 1 PCB or Formatter lithium battery PCB or Formatter PCB abnor- PCB. mality, defective connection. PHS lock abnormality PHS lock solenoid malfunction, Check wiring connection, replace sole- wiring connection abnormality, noid. etc. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 232 Formatter PCB, wire breakage of address bus or data bus, etc. Formatter system RAM abnor- Malfunction of system RAM in Replace Formatter PCB. mality Formatter PCB, wire breakage of address bus or data bus, etc. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 233 PCB. Host system hardware error Communication abnormality Check host, check interface cable con- with host. Interface cable abnor- nection, replace SCSI interface PCB. mality, SCSI interface PCB ab- normality, faulty connection, etc. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 234: Warning Indications
CHECK CART.(K) Displayed when machine senses that Set black cartridge. When cartridge is black cartridge is not set. properly set, replace it with a new one. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 235 (Depending on the type of memory card, control panel. there are some that cannot detect that the battery is low). Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 236 Ser. No. ERROR Displayed when serial number of the Check correct serial number and press printer sent from host computer is differ- any key on the control panel. ent from practical number. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 237: Image Troubleshooting
Engine 2 PCB Is the problem corrected when Engine 2 Finished. PCB is replaced? Engine 1 PCB Is the problem corrected when Engine 1 Finished. PCB is replaced? Formatter PCB Replace the Formatter PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 238 Is the problem corrected when the rowel Finished. cleaner unit is replaced? Paper delivery Is the paper delivery rowel deformed or Replace the paper delivery rowel unit scratched? rowel. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 239 Is the problem corrected when the En- Finished. gine 1 PCB is replaced? Formatter PCB Is the problem corrected when the Finished. Formatter PCB is replaced? Pump unit Replace the pump unit. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 240 Is the feeder motor (M1) in order? Check Replace the feeder motor (M1). by pressing the Feed key. Engine 2 PCB Is the problem corrected when the En- Finished. gine 2 PCB is replaced? Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 241 Is there any paper dust or dirt attached to Clean the TOF inlet sensors 1 or TOF inlet sensors 1 or 2? Are TOF inlet sensors 1 or 2 working Replace the TOF inlet sensors 1 properly? or 2. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 242 Is the feed belt properly attached? Reattach the feed belt in the prop- Feeder unit erly adjusted position. Are the tension roller and tension spring Reattach the tension roller and properly attached? tension spring properly. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 243: Function Troubleshooting
Is the attachment to the IC socket (If Reattach properly to the IC used) of the CPU (Q301) in order? socket of the CPU (Q301). Is the problem corrected when Engine 1 Finished. PCB is replaced? Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 244 Is the problem corrected when the BJ Finished. head corresponding to the error indica- tion is replaced? Engine 2 PCB Is the problem corrected when Engine 2 Finished. PCB is replaced? Engine 1 PCB Replace Engine 1 PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 245 Is the problem corrected when the BJ Finished. head corresponding to the error indica- tion is replaced? Engine 2 PCB Is the problem corrected when Engine 2 Finished. PCB is replaced? Engine 1 PCB Replace Engine 1 PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 246 BJ head head corresponding to the error indica- tion is replaced? Is the problem corrected when Engine 2 Finished. Engine 2 PCB PCB is replaced? Engine 1 PCB Replace Engine 1 PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 247 (orange-blue, red-yellow) of the con- nectors on the motor side about 3 ohms? Engine 2 PCB Is the problem corrected when Engine 2 Finished. PCB is replaced? Engine 1 PCB Replace Engine 1 PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 248 (PHS unit). Engine 2 PCB Is the problem corrected when Engine 2 Finished. PCB is replaced? Engine 1 PCB Replace Engine 1 PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 249 Replace the recover pump HP working properly? sensor (PS5). Is the pump working properly? Replace the pump unit. Engine 1 PCB Is the problem corrected when Engine 1 Finished. PCB is replaced? Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 250 PHS unit in the closed state, and placing the + probe of the tester on J411-2 and the – probe on J405-2 of Engine 2 PCB, is it about 24V? Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 251 Reattach the latch solenoid (SL2) attached? properly. Is the latch solenoid (SL2) working Replace the latch solenoid (SL2). properly? Engine 1 PCB Is the problem corrected when Engine 1 Finished. PCB is replaced? Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 252 Is the problem corrected when Engine 2 Finished. PCB is replaced? Engine 1 PCB Is the problem corrected when Engine 1 Finished. PCB is replaced? BJ Heads Replace the BJ head correspond- ing to the error indication. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 253 Replace the fuse of the DC power blown? unit. After that, find the cause of the fuse blowing, and take cor- rective action. DC power unit Is the problem corrected when the DC Finished. power unit is replaced? Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 254 Engine 2, Roll Holder board, or following terminals as prescribed? the DC load system, and remove the cause of the over-current. + Probe - Probe Voltage J002-12 J002-4 Approx. 24V J002-10 J002-1 Approx. 24V Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 255 Control panel PCB Is the problem corrected when the Con- Finished. trol panel PCB is replaced? Formatter PCB Replace Formatter PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 256 Is the problem corrected when the Roll Finished. Holder PCB is replaced? Engine 1 PCB Is the problem corrected when the En- Finished. gine 1 PCB is replaced? Formatter PCB Replace Formatter PCB. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 257 Is the sensor plate stopping position of Replace pump unit. the pressure cam home position sensor in order? Engine 1 PCB Is the problem corrected when Engine 1 Finished. PCB is replaced? Pump Unit Replace pump unit. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 258: Layout/Functions Of Electrical Parts
PS11 Roll Paper End Sensor PS12 Latch Solenoid Position Sensor Photosensor TOF Inlet Sensor 2 TOF Outlet Sensor 2 Slide rheostat VRU1 Paper Width Sensing Slide Rheostat Switch PHS Open/Close Detection Swirch Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 259: Motors And Solenoids
Cap Motor Roll Motor Fan Motor Head Cooling Fan Motor Head Cooling Fan Motor Head Cooling Fan Motor Solenoid PHS Lock Solenoid Latch Solenoid Clutch Cam Pressure Release Clutch Pressure Clutch Suction Clutch Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 260: Printed Circuit Boards
TOF Inlet Sensor 1 Sensing of paper position TOF Outlet Sensor 1 Sensing of paper position DC Power Unit DC power supply Counter PCB Counter control Counter Counting the number of printed sheets Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 261: List Of Variable Resistors (Vr) And Check Pins By Pcbs
Legend: May be adjusted in the field. Must NOT be adjusted in the field. Formatter PCB Designation Function Control system power supply GND Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 262 For checking TOF Inlet Sensor 1 (transmitting type sensor) J313-5 For checking TOF Outlet Sensor 1 (transmitting type sensor) J313-6 For checking TOF Inlet Sensor 2 (reflecting type sensor) J313-7 For checking TOF Outlet Sensor 2 (reflecting type sensor) Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 263 (P GND) (GND) J407 J406 J409 J412 Designation Function LED401 Lights when VH24V (head power source) is being supplied TP412 Control system power supply GND Roll Holder PCB J502 J503 J504 J501 Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 264: Overall Circuit Diagram
Appendix Appendix A.1 Overall Circuit Diagram Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 265: List Of Packaging Parts
– 11 Polyethylene bag – Upper head plate packing – 12 Shipping connector – 13 Prevent rub sheet – Recovery unit packing – 1-13 Compete Packaging Set 1-901251-00 Lint free towel – Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 266: List Of Special Purpose Tools
B: A tool that should suffice if one was assigned to a group of about 5 service engineers. C: A tool that should suffice if one is kept in a work shop. Used for putting the wasted ink. Intermec ColorCoder V4 – Service Manual Ed. 1...
Page 267 B: A tool that should suffice if one was assigned to a group of about 5 service engineers. C: A tool that should suffice if one is kept in a work shop. Intermec ColorCoder V4 – Service Manual Ed. 1...

Intermec ColorCoder V4 Service Manual

Mechanical System 3.1 Externals

Installation

Maintenance and Servicing

Troubleshooting 6.1 Preface

Appendix

Quick Links

Troubleshooting

Need help?

Questions and answers

Related Manuals for Intermec ColorCoder V4

Summary of Contents for Intermec ColorCoder V4

Table of Contents