mach 5dx digital color duplex printer service guide

MACH 5DX
DIGITAL COLOR
DUPLEX PRINTER
(MACH 5 PRINTER NOT INCLUDED)
SERVICE GUIDE
Revised: 11-22-17
Neopost Digital Print Group
3100 Horizon Dr., STE 100
King of Prussia, PA 19406-2660
Phone: (610) 650-9170
www.neopost.com
www.haslerinc.com
www.renausa.com
SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
OBSERVE SAFETY RULES WHEN OPERATING MACH 5DX PRINTER.
BEFORE USING PRINTER, READ THIS MANUAL CAREFULLY AND FOLLOW
RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS:

Keep hands, hair, and clothing clear of rollers and other moving parts.

Avoid touching moving parts or materials while machine is in use. Before clearing a jam, be
sure machine mechanisms come to a stop.

Always turn machine off before making adjustments, cleaning machine, or performing any
maintenance covered in this manual.

Power cord and power supply supplied with machine. Plug it into a properly grounded, easily
accessible wall outlet near machine. Failure to properly ground machine can result in severe
personal injury and/or fire.

Power cord and wall plug are primary means of disconnecting machine from power supply.

DO NOT use an adapter plug on line cord or wall outlet.

DO NOT remove ground pin from line cord.

DO NOT route power cord over sharp edges or trap it between furniture.

Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.

Make sure there is no strain on power cord caused by jamming it between equipment,
walls or furniture.

DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a
qualified service representative. Report any cover damage to your service representative.

This machine requires periodic maintenance. Contact your authorized service representative
for required service schedules.

To prevent overheating, do not cover vent openings.

Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of Neopost, its designated agents,
customers, and their employees. The information in this guide was obtained from several different
sources that are deemed reliable by all industry standards. To the best of our knowledge, that
information is accurate in all respects. However, neither Neopost nor any of its agents or
employees shall be responsible for any inaccuracies contained herein.
Memjet® is a registered trademark.
All other trademarks are the property of their respective holders.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher.
TABLE OF CONTENTS
Table of Contents
SECTION 1 – Installation
Contents of Packaging
Choose a Location
Unpack and Set-up
Remove Transport Locks
Remove Service Station Transport Tab and Shipping Tape
Install Adapter Feet on Top Printer
Install Top Printer on Duplex (Bottom) Printer
Connecting Printers
Overview: Install Firmware and Printer Driver on Top Printer
Printer Driver (Top Printer)
Uninstall Existing Printer Driver
1
1
1
1
2
3
4
5
6
7
8
8
Install Over USB Connection
Install Over Network Connection, Version A
Install Over Network Connection, Version B
Install Firmware on Top Printer
10
12
15
17
Set Up Top and Bottom Printer Communication
Install Ink Tanks
Install Printhead Cartridge
Adjust Printer Alignment
19
20
22
25
SECTION 2 – Troubleshooting
Power Problems
Interface Communication Problems
Feeding Problems
Memjet Printhead
Air in Ink Lines
Memjet Print Engine Main Printed Circuit Assembly (MPCA)
Print Engine DPCA Wire Connections
Service Station
Printing Problems
Software Problems
Errors and Warnings
Jams in Printer
SECTION 3 – Functional Operation
Sequence of Operation
Duplex Printer Control Panel Button/LED Indicators
Control Panel Button/LED Indicators (Top Printer)
Duplex Printer Driver Properties
General Tab
Layout Tab
Color Tab
Import/Export Tab
Services Tab
Using Duplex Printer Toolbox
Drop-Down Menu Options
View Drop-Down
Advanced Service Menus
Maintenance Drop-Down
Service Drop-Down
Print Drop-Down
Updating Firmware
27
27
27
28
29
29
30
34
34
35
35
36
42
43
43
44
45
46
46
48
50
50
51
52
52
52
60
62
62
63
64
i
TABLE OF CONTENTS
SECTION 4 – Disassembly/Assembly Procedures
Duplex Unit Basic Disassembly
Service Disassembly Procedures
Operator Side Door
Non-Operator Side Cover
Replace Control Panel Circuit Board
Feeder End Cover
Replacing Wire Harness Conduit Chain
Replacing Power Supply
Replacing Ethernet Switch
Replacing Duplex Feeder Position Sensor
Replacing Print Engine Entry Sensor
Replacing Print Engine Latch Sensor
Replacing Print Engine Latch
Removing Duplex Feeder Assembly
Replacing Duplex Feeder Cover Sensor
Removing Duplex Feeder Cover
Replacing Duplex Feeder Motor Assembly
Replacing Duplex Feeder Drive Belt
Adjusting Duplex Feeder Drive Belt Tension
Removing Print Engine
Replace Print Engine Slide Brackets
Print Engine Basic Disassembly
Remove 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 Pen Driver Printed Circuit Assembly (PCA)
Removing Starwheel Assemblies
Replacing Ink Tank Latches
66
66
67
68
68
69
70
72
73
74
75
76
77
78
80
81
82
82
84
85
87
88
88
89
89
90
91
93
94
94
95
95
96
Main Printed Circuit Assembly (MPCA) Cover
97
Removing Main Printed Circuit Assembly Cover
Replacing Encoder or Encoder Sensor
Replacing Service Station Lifter Arm Sensor
Replacing Paper Path Motor or Drive Belt
Adjust Paper Path Motor Drive Belt Tension
Replacing Belt Drive Gear Pulleys
Replacing Lifter Motor Assembly or Lifter Gear
Replacing Stepper Motor
97
98
98
99
100
101
102
103
Clamshell Assembly
Removing Clamshell Assembly
Replacing Service Station Sled Printed Circuit Boards
Replacing Wiper Motor Flex Cable PCA
Replacing Duplex Exit Sensor
Replacing Duplex Entry Sensor
Reinstall Main Printed Circuit Board Assembly
ii
66
105
105
106
106
107
109
110
TABLE OF CONTENTS
SECTION 5 - Maintenance
Maintenance Schedule
Replacing Ink Tanks
Cleaning Ink Tank Contacts
Cleaning/Replacing Printhead Cartridge
Cleaning/Replacing Ink Revolvers
Cleaning Ink Revolver Couplings
Replace Ink Revolvers
Cleaning Pen Driver Printed Circuit Board Contacts
Replacing Printhead Latch
Replacing Printhead Latch Solenoid
Replace Upper and Lower Clamshell Latch Pins
Replace Upper Latch Pins
Replace Lower Latch Pins
Cleaning/Replacing Service Station
Cleaning Service Station
Removing Wiper Motor Assembly
Replacing Service Station Lifting Arms
Lubricating Service Station
Reinstall/Replace Service Station
Replacing Ink Waste Tray
Cleaning
Duplex Feeder Rollers
Print Engine
Grit Rollers
Media Sensors
Capping Station Seal and Squeegee
Printing Platen
Appendices
Appendix A – Duplex Printer Specifications
Appendix B – Supplies and Optional Hardware
Appendix C – Ink Flow Diagrams
Appendix D – Duplex Print Engine Wiring Diagram
Index
111
111
112
114
116
121
121
121
123
124
127
129
129
134
136
139
140
141
142
144
146
147
147
148
148
148
148
148
149
149
150
151
153
154
iii
SECTION 1
INSTALLATION
SECTION 1 – Installation
Contents of Packaging
1.
Duplex Printer
2.
Ink Tanks – Cyan, Magenta, Yellow, Black, Black
3.
Printhead Cartridge
4.
Envelope Attachment Spacers (pkg. of 2)
5.
AC Power Cord
6.
Ethernet Cable (to connect Top Printer and Duplex Printer)
7.
Adapter Feet for Top Printer (pkg. of 2)
8.
Operator Manual
9.
Driver Software CD
Before using Printer:
•
Choose a location for Duplex Printer
•
Unpack and assemble Duplex Printer
•
Remove Print Engine Transport Locks
•
Remove Service Station Transport Tab and Shipping Tape
•
Install Adapter Feet on Top Printer
•
Install Top Printer on Bottom (Duplex) Printer
•
Plug in Printer and connect it to computer or network
•
Update/Install Firmware and Printer Driver on Top Printer
•
Set up Top and Duplex Printer communication
•
Install Ink Tanks
•
Install Printhead
•
Set up feed on Printer
Choose a Location
Position Duplex Printer at least 9" from any walls. Use the Bubble Gauge mounted on Print Engine
(or a small level) to make sure Duplex Printer is level. Protect Printer from excessive heat, dust, and moisture.
Avoid placing it in direct sunlight.
Unpack and Set-up
Remove Duplex Printer and parts from carton. Remove all packing tape.
1
SECTION 1
INSTALLATION
Remove Transport Locks
2
1.
Remove the Non-operator Side Cover.
(6 screws.)
2.
Remove 2 screws from Print Engine Support
Bracket [A].
3.
Open Print Engine Access Door.
Remove 4 screws securing Transport Locking Bracket
[B] to Frame (Under Handle). Remove Bracket and
save for future use.
4.
Remove two Duplex Feeder Transport Brackets.
Remove screws [C] securing the two Brackets to the
Duplex Feeder and Duplex Cabinet. (3 screws per
side). NOTE: Save all Transport Brackets and screws
for later use.
5.
Reinstall Non-operator Side Cover.
SECTION 1
INSTALLATION
Remove Service Station Transport Tab and Shipping Tape
1. Lower Duplex Feeder. Open Print Engine Access Door.
Unlatch and pull out Print Engine.
2. Release two latches [A] (one on either side of Print Engine).
Open top half of Clamshell by lifting both levers at same time.
CAUTION
HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING PRINT
ENGINE CLAMSHELL TO PREVENT DAMAGE.
DO NOT ALLOW CLAMSHELL TO DROP OR SLAM CLOSED.
TO PREVENT DAMAGE TO INK LINES, A STOP LIMITS RAISING
CLAMSHELL MORE THAN 60°.
3. Remove cardboard Transport Tab [A] from
Service Station.
4. Remove tape [B] securing Head Media Guide.
(If necessary, wipe off tape residue on Head Media
Guide surface [C].)
5. Carefully close and latch Upper Clamshell.
Slide and latch Print Engine into cabinet.
Close Print Engine Access Door.
Return Duplex Feeder to double-sided
printing position.
3
SECTION 1
INSTALLATION
Install Adapter Feet on Top Printer
Install two Adapter Feet on the operator side of the
Printer. These will help guide and stabilize the Top
Printer onto the Duplex (Bottom) Printer.
4
1.
Remove the two Rubber Feet from the operator
side (Control Panel side) of the Top Printer.
2.
Install two Adapter Feet (included with Duplex
Printer) on the operator side of the Top Printer.
SECTION 1
INSTALLATION
Install Top Printer on Duplex (Bottom) Printer
CAUTION Two people should lift and position the Top Printer onto the Duplex (Bottom) Printer.
1.
[A] Lower the Duplex Feeder on the
Duplex Printer.
[B] Carefully place feet on the exit end of
the Printer into the two holes located in
front of the Duplex Feeder.
[C] Place the feet on the entry end of the
Printer into the two holes located at the
exit end of the Duplex Printer.
NOTE: Make sure the Top Printer sits
flat on the Duplex (Bottom) Printer.
2.
Double-Sided Printing: Raise the Duplex Feeder [D] until it
attaches magnetically to the exit end of the Top Printer.
Single-Sided Printing: Lower the Duplex Feeder Assembly.
3.
Position the Drop Tray or
Conveyor for single or doublesided printing as shown.
5
SECTION 1
INSTALLATION
Connecting Printers
Plugging in Printer
Plug power cord (included with Duplex Printer) into receptacle [1] at rear of
Duplex Printer. Plug other end into an appropriate wall receptacle. Internal
power supplies in Top Printer and Duplex Printer are rated 115 to 240VAC,
50/60 Hz.
CAUTION
DO NOT USE ADAPTER PLUGS OR EXTENSION CORDS TO
CONNECT PRINTER TO WALL OUTLET.
DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES.
DO NOT USE OUTLETS SHARING SAME CIRCUIT WITH
LARGE ELECTRICAL MACHINES OR APPLIANCES.
CHECK POWER CORD! USE 115V POWER CORD ONLY
WITH 115 VAC OUTLETS. USE 220V POWER CORD ONLY
WITH 220 VAC OUTLETS.
Connecting to Computer or Network
IMPORTANT
For the initial (first time) installation, DO NOT connect the Top
Printer to the Duplex Printer (via Ethernet cable) until after the Top
Printer's firmware and Printer Driver have been updated/installed.
If Top Printer is connected to a computer via USB port [2]:
Plug Ethernet Cord (included with Duplex Printer) into Ethernet Port on Top Printer [3] and either
Ethernet Port on Duplex (Bottom) Printer [3A].
If Top Printer is connected to a network via Ethernet port:
[A] Plug Ethernet Cord (included with Duplex Printer) into Ethernet Port on Top Printer [3] and either
Ethernet Port on Duplex (Bottom) Printer [3A].
[B] Move the network Ethernet cable from the Top Printer to the second Ethernet port on the Duplex
(Bottom) Printer. (This connects both Printers to the network.)
See “Network Connection Setup” in “Using Duplex Printer Toolbox” section.
6
SECTION 1
INSTALLATION
Turning Power ON and OFF
Powering Up Printer:
1.
2.
Press Main Power Switch on Rear Panel.
Press Power Button on Control Panel.
Powering Down Printer:
CAUTION
WHENEVER POWERING DOWN UNIT, ALWAYS:
1. PRESS POWER BUTTON ON CONTROL PANEL.
2. WAIT FOR PRINTER TO STOP PROCESSING.
3. THEN PRESS MAIN POWER SWITCH ON REAR PANEL.
Overview: Install Firmware and Printer Driver on Top Printer
BEFORE YOU BEGIN:
The firmware and Printer Driver on the Top Printer have to be updated and/or installed. If you are using your
existing Printer as the Top Printer follow the procedure below to update the firmware and install a new Printer
Driver. If the Top Printer is new (never before installed), you can skip Step 1.
1.
If using an existing (previously installed) Top Printer: Uninstall the current Printer Driver.
See “Uninstall Existing Printer Driver.”
If the Top Printer is new (never before installed): Skip to Step 2.
2.
Install Printer Driver on Top Printer. See “Install Printer Driver (Top Printer)”.
3.
Update the firmware on the Top Printer. See “Update Firmware on Top Printer”.
4.
See “Set Up Top and Bottom Printer
CommunicationError! Reference source not
found.”:
Open the Printer Toolbox.
Open Service Menus using the password.
Open Printer Control Configuration
Check boxes for both “Enable Duplex” and
“Duplex Master” options. Click “Submit”.
5.
Use the short network cable (included) to connect
the Top and Duplex Printers.
7
SECTION 1
INSTALLATION
Printer Driver (Top Printer)
Before installing the Printer Driver on the Top Printer: If the Top Printer already has a Printer Driver installed,
you will have to uninstall the existing Printer Driver from the Top Printer. If the Top Printer is new or has never
been installed you can proceed to “Install Printer Driver”. NOTE: The Duplex Printer's software is preinstalled.
The Duplex Printer should not be connected to the Top Printer for this step.
Uninstall Existing Printer Driver
NOTE: If installing a new Top Printer, you can skip this step and proceed to “Install Printer Driver”.
8
1.
Make sure Top Printer is plugged in and turned ON,
USB is disconnected and that no jobs are pending.
The Duplex Printer should not be connected to the
Top Printer for this step.
2.
Open “All Programs”, then find and select the
Memjet Folder.
3.
Open the “M Series Driver” folder and click on “Uninstall”.
4.
Select (highlight) the desired Printer and click
“Remove One”.
NOTE: Clicking “Remove All” without selecting
a Printer will remove all listed Printers and
associated Drivers.
5.
The next window asks if you want to continue.
Click “Yes”.
6.
The Printer Driver will be uninstalled.
SECTION 1
INSTALLATION
7.
A window opens telling you the Printer was
successfully uninstalled. Click “Finish”.
8.
A window opens telling you the system must be
rebooted to complete the process. Save any open
files and close other applications. Click “Reboot”.
9
SECTION 1
INSTALLATION
Install Printer Driver
The Printer Driver can be installed using the USB connection or the Network connection. For Network connection,
there are two ways to install the Driver: Using Auto IP (network automatically assigns the IP address, this is the
default). Using Static IP (the IP address is entered manually). For Auto IP, use Network Version A. For Static IP,
use Network Version B.
For Printer software to operate properly, check that computer system meets minimum requirements:
•
Operating System: Windows 8/8.1, Windows 10 (Desktop Mode only). Windows XP, Windows Vista,
Windows 7. Supports 32 and 64 bit systems. (You must have administrative privileges on system.)
NOTE: Win 8, 8.1 and Windows 10 will only work in desktop mode. No Win 8 or 10 metro apps will be
supported (applications that work only in a Windows 8 or 10 environment).
•
•
•
•
•
•
•
Microprocessor: Pentium II, 2 GHz minimum (Pentium Dual Core, 2.5 GHz or better, is optimal)
System memory: 2 GB minimum; or as recommended for your operating system.
Free hard-disk space: At least 10 GB free.
Web Browser: Firefox recommended: Chrome, Safari, Opera also supported.
CD/DVD drive.
USB port (2.0/3.0): (Ports will be identified as “USB” or “Enhanced” in Device Manager)
Microsoft .Net Framework version 3.5 (for 32 bit systems) or Microsoft .Net Framework version 4 (for 64 bit
systems) must be installed. NOTE: Even if a higher .NET Framework version is installed; version 3.5 or 4 must
also be installed, or Toolbox will not open.
IMPORTANT: Before installing Printer software (Toolbox and Driver), temporarily disable all antivirus
programs and firewalls. In addition, you must be logged onto system with full administrative privileges
(admin rights). NOTE: If installing over USB, do not plug in USB cable until prompted.
Install Over USB Connection
This is the procedure for installing the Print Driver over the USB connection. The procedures for installing the
Print Driver over a network connection follow.
10
1.
Check that the Top Printer is plugged in and turned OFF.
Disconnect USB connection if already plugged in.
NOTE: Duplex Printer should not be connected to the Top
Printer at this time.
Install disk supplied with the Duplex Printer in your CD drive.
When AutoPlay Window opens, click “Run Setup.exe” to start.
2.
Install Printer Software. Make sure computer system
meets minimum requirements and you have followed
other instructions listed on screen.
Click “Install Printer Software”.
SECTION 1
INSTALLATION
3.
License Agreement.
Check “I accept…” then click “Next>”.
4.
Printer Connections. Click “Configure to print using
USB”. Then click “Next>”.
5.
Installing Printer Software.
Software download begins.
6.
Would You Like to Install This Device Software?
Click “Install”.
7.
Connect Device Now. Turn Printer ON and connect
USB cable. Don’t click on either button. Software will
finish installing.
11
SECTION 1
INSTALLATION
8.
Finished software installation. Do not check the Print
Test Page as Printer is not set up yet.
You can check “Set this printer as the default printer”
at this time. Click “Finish”.
9.
Install Printer Software.
Click “Exit” to close CD.
10. Restart computer to complete installation.
Install Over Network Connection, Version A
Use this procedure to install the Print Driver over the Network connection. This procedure works for almost all
networks that allow automatic assignment of the IP address (factory default).
NOTE: Copy the 12-digit Hardware ID number listed on the Printer(s) on the label located just below the
Ethernet port so you can identify the Printer(s) in a later step.
12
1.
Check that the Top Printer is plugged in and turned ON. Make
sure the Ethernet (network) cable is plugged into the Ethernet
port on the Printer. NOTE: Duplex Printer should not be
connected to the Top Printer at this time. Install disk supplied
with Duplex Printer in your CD drive. When AutoPlay Window
opens, click “Run Setup.exe” to start.
2.
Install Printer Software. Make sure computer system
meets minimum requirements and you followed other
instructions listed on screen.
Click “Install Printer Software”.
SECTION 1
INSTALLATION
3.
License Agreement.
Check “I accept…” then click “Next>”.
4.
Printer Connections. Click “Configure to print using
the Network”. Make sure the Printer is connected to the
Network. Then click “Next>”.
5.
Printers Discovered. A list of available Printers opens.
Check the Printer column to verify you have an M-Series
printer. Check the Hardware ID column and match the
number listed to the number you copied previously from
the Printer label. Select that Printer. Click “Next>”.
NOTE: If the Printer does not appear on the list, the IP
address may have to be assigned manually. See “Install
Over Network Connection, Version B”.
6.
Installing Printer Software.
Software download begins.
7.
Would You Like to Install This Device Software?
Click “Install”.
13
SECTION 1
INSTALLATION
8.
Finished software installation. Do not check the Print
Test Page as Printer is not set up yet. You can check
“Set this printer as the default printer” at this time.
Click “Finish”.
9.
Install Printer Software window.
Click “Install Print Software” again to install software
on another Printer, or click “Exit” to close the CD.
Tip: To help distinguish between multiple M-Series Drivers on your system; open the “Printers and Faxes”
(Devices and Printers) folder and rename the Printers. For example, rename a network-configured printer
“M Series (Network-1)” and a USB-configured printer “M Series (USB)”.
To open the “Toolbox” utility over an Ethernet (network) connection:
Click Start, All Programs, Memjet, M Series Driver, Toolbox.
If more than one copy of the M-Series Driver is installed,
you will have to choose which device you want the
Toolbox to connect to. To help choose the proper device,
you can identify the Printer(s) using the Hardware ID
you copied earlier or you can rename the Printer(s) as
outlined in the Tip above.
Example:
M-Series Driver configured for USB:
suggested name “M Series (USB)”
M-Series Driver (Copy 1) configured for Network:
suggested name “M Series (Network-1)”.
M-Series Driver (Copy 2) configured for Network:
suggested name “M Series (Network-2)”.
14
SECTION 1
INSTALLATION
Install Over Network Connection, Version B
Use this procedure to install the Print Driver over the Network connection on Static IP systems requiring that an IP
address is assigned manually instead of automatically. NOTE: Copy the 12-digit Hardware ID number listed on
the Printer(s) on the label just below Ethernet port so you can identify the Printer(s) in a later step.
1.
Install the Printer Software using either over a USB or Network connection to the Top Printer (see
“Install Over USB Connection” or “Install Over Network Connection Version A”). If installing over
USB, you can use a nearby computer or laptop. Once the Driver and Firmware are installed, use that same
computer to open the Printer Toolbox. NOTE: Duplex Printer should not be connected at this time.
2.
Open the “View”
drop-down menu.
Click “Service
Menus”.
Click “Network
Config” button.
The Network
Configuration
window opens.
Your IT support
person can fill in the necessary information (or
you can get it from them.)
NOTE: Make sure the “dhcp” and “autoip”
boxes are unchecked. Enter an ip_address
(Top Printer). Click “Submit”.
3.
If using the USB connection; disconnect the USB from the local computer or laptop. If not using that
computer for updating other printers or for printing, the M-Series Software can be uninstalled.
4.
Connect the network Ethernet cable to the Ethernet port on
the Top Printer and run the “Install Over Network
Connection, Version A” procedure. The Printer should
now appear on the “Printers Discovered” window. The
Printer can still be identified by its “Hardware ID”, but
the new IP address entered by your IT support person (or
operator) is shown. Follow the remaining steps.
5.
Installing Printer Software.
Software download begins.
6.
Would You Like to Install This Device Software?
Click “Install”.
15
SECTION 1
INSTALLATION
7.
Finished software installation. Do not check the Print
Test Page as Printer is not set up yet.
You can check “Set this printer as the default printer” at
this time. Click “Finish”.
8.
Install Printer Software window.
Click “Exit” to close the CD.
Tip: To help distinguish between multiple M-Series Drivers on your system; open the “Printers and Faxes”
(Devices and Printers) folder and rename the Printers. For example, rename a network-configured printer
“M Series (Network-1)” and a USB-configured printer “M Series (USB)”.
To open the “Toolbox” utility over an Ethernet (network) connection:
Click Start, All Programs, Memjet, M Series Driver, Toolbox.
If more than one copy of the M-Series Driver is
installed, you will have to choose which device you
want the Toolbox to connect to. To help choose the
proper device, you can identify the Printer(s) using
the Hardware ID you copied earlier or you can
rename the Printer(s) as outlined in the Tip above.
Example:
M-Series Driver configured for USB:
suggested name “M Series (USB)”
M-Series Driver (Copy 1) configured for Network:
suggested name “M Series (Network-1)”
M-Series Driver (Copy 2) configured for Network:
suggested name “M Series (Network-2)”
16
SECTION 1
INSTALLATION
Install Firmware on Top Printer
IMPORTANT! This procedure is for updating the firmware on the Top Printer. NOTE: The firmware on the
Duplex Printer is already installed.
IMPORTANT!
BEFORE STARTING ANY PRINTER FIRMWARE UPDATE, REMEMBER TO USE THE PRINTER
DRIVER TO FIRST EXPORT ANY CUSTOM MEDIA SIZES, WATERMARKS OR PRINT SETTINGS
YOU HAVE ADDED TO AN OUTSIDE HOLDING FILE. THIS WILL PREVENT THE LOSS OF YOUR
CUSTOM SETTINGS. SEE THE "IMPORT/EXPORT TAB" IN THE OPERATOR MANUAL FOR
MORE INFORMATION.
Make sure the Top Printer is turned ON and the USB cable or Network cable is connected from the computer or
network to the Top Printer. Duplex Printer should not be connected to the Top Printer during this procedure.
NOTE: Once started, the Firmware installation runs automatically and requires NO operator interaction
with the Printer. The Install New Firmware process takes about 5-10 minutes to complete.
1.
Open the Duplex CD.
Open the Firmware folder.
Double-click the “.bin” file.
2.
When the “Update printer firmware” window
opens, select the M-Series printer you want to update.
NOTE: You can only update one printer at a time.
3.
Click “Update”. DO NOT touch the Printer until
the firmware is loaded!
A message will appear on your screen warning you
not to unplug or shut off the Printer. The firmware
finishes loading (about 5-10 minutes).
17
SECTION 1
INSTALLATION
4.
Once the “printer firmware was successfully
updated” window appears, click “OK”.
NOTE: If the Update Software dialog box continues
to run you can close it now.
5.
“Update printer firmware” window appears again:
6.
•
If this is the only printer being updated,
click “Cancel”.
•
If other printers are being updated, select the
next printer and click “Update”.
Verify Firmware Version. (NOTE: Printer Driver
must also be installed). Open Printer Toolbox and
check “Firmware Version”. Verify that you have
firmware version “R14.3” or higher.
•
Standard Toolbox: System Information is
located in the upper left corner of the screen.
•
Duplex Toolbox: Firmware Version is located in
“Diagnostics” on the Service Menu screen
accessed using the “View” drop-down menu.
After the firmware is loaded (if using a previously
installed Printer):
•
18
Import your custom settings back using the
“Import/Export Tab” in the Printer Driver.
SECTION 1
INSTALLATION
Set Up Top and Bottom Printer Communication
Use the Printer Toolbox to select the following settings to allow
the Top and Bottom Printers to synchronize and communicate.
1.
Open the Printer Toolbox.
2.
Open the Service Menus. (Enter the password to open)
Click “Submit”.
3.
Click “Printer Control Configuration”.
“Printer Control Configuration” window opens.
4.
Check both “enable_duplex” and
“duplex_master” boxes to activate the Duplex
Printer Toolbox. This Toolbox provides status
information and controls printer functions for both
Top and Bottom Printers. NOTE: When
“duplex_master” is checked, the Top Printer is
the master and the Duplex Printer is subordinate
to the Top Printer.
5.
Click “Submit”.
6.
Printer will reset and restart. Use the short
network cable (included) to connect the Top
and Duplex Printers.
Open the Toolbox. Now there should be a
“Duplex View” menu option visible under
“Network Config”.
7.
If you click “Duplex View”, the Toolbox window should change to the
Duplex “System Status” window. (See image below).
See “Using the Duplex Toolbox” for more information about the
Duplex Toolbox windows and functions.
8.
Verify Network Configuration Settings: To ensure proper synchronization between the Top and Bottom
Printers, check the Network Configuration settings found in the Duplex Toolbox. See “Network
Configuration” in “Using the Duplex Toolbox”.
19
SECTION 1
INSTALLATION
Install Ink Tanks
Printer uses one Printhead Cartridge and five Ink Tanks
(two Black, one Cyan, one Magenta, and one Yellow).
20
1.
Open Printer Toolbox. Ink Tank Levels information (Top Row is
Top Printer, Bottom Row is Duplex Printer) appears on left side
corner of System Status window. Note that “C, K2, Y, M, K1”
boxes are empty.
2.
Select “Bottom Unit” from “Service” drop-down
menu. Click “Replace Ink Tanks”. (Disconnects
Printer communication with Ink Tanks and allows safe
installation and replacement.) Once “Confirm” screen
displays, it is safe to install Ink Tanks.
IMPORTANT: DO NOT press “Continue” until after
installing Ink Tank(s) and closing Ink Tank Latches.
3.
Lower Duplex Feeder. Open Print Engine
Access Door on Duplex Printer. Unlatch and
pull out Print Engine. Open three Latches [A].
4.
Remove Ink Tank(s) from packaging.
SECTION 1
INSTALLATION
5.
Insert Ink Tanks (labels up) into appropriate
color slots [B].
Close three Ink Tank Latches.
INSTALLATION TIP: Make sure Ink
Tanks seat properly. Insert Ink Tank into
appropriate Ink Station, then pull Ink Tank
back about an inch and push forward
firmly to insure that Ink Nozzles penetrate
seals on Ink Tanks.
6.
Click “Continue” on Confirm screen.
Click on the “Service” drop-down menu in
the Toolbox. Select “Bottom Unit” and
“Refresh Ink Levels”. On the System
Status screen, Ink colors fill in as Ink Tanks
are installed. If ink colors do not fill in after
a few seconds, click “Replace Ink Tanks” again and
reinstall Ink Tank(s).
7.
Slide and latch Print Engine into cabinet. Close Print
Engine Access Door. Return Duplex Feeder to doublesided printing position.
WARNING!
Ink in Ink Tanks may be harmful if swallowed. Keep new and used Ink
Tanks out of reach of children. Discard empty tanks immediately.
21
SECTION 1
INSTALLATION
Install Printhead Cartridge
Printhead Cartridge is a delicate precision device. Handle with extreme care to avoid damage and issues that could
degrade print quality.
CAUTION
1.
•
Use electrostatic discharge (ESD) protection when handling.
•
Hold Printhead Cartridge by handles ONLY.
•
DO NOT touch ink couplings, nozzle surfaces or electrical contacts.
•
DO NOT unpack Printhead Cartridge until Printer is ready for
installation. Once unwrapped, delays in installing Printhead Cartridge
can compromise print quality due to dehydration.
•
DO NOT place an unwrapped Printhead Cartridge on any surface before
installing. Protect Printhead from scratches, dust, fibers, dirt and other
contaminants at all times.
With Printer power ON, lower Duplex Feeder. Open
Print Engine Access Door on Duplex Printer. Unlatch
and pull out Print Engine.
Press Printhead Latch Release button [1]. Printer
runs, then Latch pops open [2].
NOTE: Remove Cap Protectors on Ink Nozzles [3].
Be sure to open Latch fully to retract Ink Nozzles.
CAUTION
DO NOT PRY OR MANUALLY LIFT
PRINTHEAD LATCH OR LATCH MAY BREAK.
ONLY OPEN LATCH USING PRINTER'S
RELEASE BUTTON OR PRINTHEAD
RELEASE COMMAND IN PRINTER TOOLBOX.
22
SECTION 1
INSTALLATION
2.
[A] Carefully remove Printhead
Cartridge from foil packaging.
Tear foil at notch or cut the end
with scissors.
[B] Remove protective plastic
cover. Hold Printhead by handle
and unclip cover from Printhead.
[C] Remove protective strip from
Printhead Electrical Contacts.
Once removed, DO NOT allow
strip to touch electrical contacts.
[D] Remove protective strip from
Printhead Nozzles. Hold Printhead
by handle. Pull strip tab and slowly
peel strip from Printhead.
DO NOT pull strip at less than a
45° angle from Printhead surface.
DO NOT allow removed strip to
touch Printhead Nozzles.
3.
Carefully insert Cartridge into compartment at an angle [4], with
Printhead surface facing down and Ink Nozzles facing Ink Hoses. Once seated, gently tilt Cartridge back
until it snaps into an upright position [5]. DO NOT FORCE Cartridge into position.
23
SECTION 1
INSTALLATION
4.
Wet Printhead Surface [A]. (Ensures that
Printhead will prime correctly.) Release and
lift two latches at same time to raise Print
Engine Clamshell. Moisten Printhead
nozzles using distilled water and a damp,
lint-free cloth, wiping end to end. (Gray
strip located below orange strip.)
Close and latch Print Engine Clamshell.
CAUTION
HOLD ONTO BOTH LATCHES WHEN
OPENING AND CLOSING CLAMSHELL
TO PREVENT DAMAGE.
DO NOT ALLOW CLAMSHELL TO
DROP OR SLAM CLOSED.
TO PREVENT DAMAGE TO INK LINES,
A STOP LIMITS RAISING CLAMSHELL
MORE THAN 60°.
5.
Close Printhead Latch [6]. Slide the Print Engine
into the cabinet and latch it. Close Print Engine
Access Door. Return Duplex Feeder to the
double-sided printing position. Printer
starts up and primes ink into Printhead.
(May take a few minutes.) Make sure
ink is flowing through hoses.
6.
Open the Printer Status screen. Notice
some information is in red. As Printer
circulates ink and primes system, these
fields should turn black. Check that the
Printhead icon [7] in Duplex image is
primed (solid color).
7.
When ONLINE [8] appears, Printer is
ready for use.
NOTE: If the Printhead icon continues to
display an outline or a question mark (?)
try the following procedures:
[1] Printhead icon shows an outline (Printhead unprimed): Click “Circulate Ink” under
“Maintenance” drop-down in Printer Toolbox. If issue persists, try the “Install Printhead”
procedure again. If the issue continues, contact technical support.
[2] Printhead icon displays a question mark (Printhead not recognized): Try the “Install
Printhead” procedure again. If the issue continues, contact technical support.
NOTE: Printer may take up to 12 minutes to set itself up during initial startup. This is normal.
24
SECTION 1
INSTALLATION
Adjust Printer Alignment
Alignment between the Top and Bottom Printers' media paths is critical for accurate printing. While minor
adjustments to media positioning can be made in the Printer Toolbox on the Printer Control Config screen or on
the Layout Tab of the Printer Driver, it may be necessary to physically align the Print Engines' media paths.
1.
Open the Duplex Printer Toolbox. Select the “Print”
dropdown menu and select “Print Setup Page”. This doublesided page prints a pattern that shows how the Top and Bottom
Printers are aligned. Hold the page up to the light to see how
much adjustment may be needed to align the Printers.
2.
Remove Non-operator Side Cover (6 screws). Open
the Print Engine Access Door on the Duplex Printer.
3.
Open the Storage Door (below the Print Engine
Access Door). From underside, loosen the two
screws securing the Print Engine Latch to the
Cabinet Frame [A]. (This will allow Latch to move
with the Print Engine when it is pulled out).
25
SECTION 1
INSTALLATION
26
4.
Remove Locking Knob from one of the Media
Guides on the Top Printer.
5.
Screw the Locking Knob into the center hole in the
Rear Transport Bracket [B].
6.
With the Print Engine pushed all the way into the
cabinet, turn the Knob clockwise in small
increments to push the Print Engine toward the
Operator Side.
7.
Open the Duplex Toolbox. From the “Print” drop-down menu,
select “Print Setup Page”. Once that prints, check the alignment
of front and back pages. Turn Knob to adjust Bottom Unit Print
Engine position. Continue printing Setup Pages after each
adjustment until the front and back pages align. Once page is
properly aligned, tighten the two Latch mounting screws. Both
Printers' media paths should now be aligned, any fine tuning
adjustments can be made in the Toolbox or Printer Driver.
8.
Reinstall Locking Knob on Top Printer.
Reinstall Non-operator side Cover.
SECTION 2
TROUBLESHOOTING
SECTION 2 – Troubleshooting
This section is arranged by first the condition that might occur, and then by possible problems,
their cause and recommended solutions.
Power Problems
CONDITION
Power is ON, nothing
happens.
PROBLEM
No power to Printer.
SOLUTION
Check that power cord is plugged in.
Check that power outlet is live.
Replace AC Adapter.
Interface Communication Problems
CONDITION
PROBLEM
SOLUTION
Printer does not respond
to software.
Connection problems.
Check that port is communicating with
Printer by using another USB cable,
replace cable if necessary.
If port cannot communicate using USB
cable, check Printer.
If port cannot communicate using USB
cable and Printer is OK, check USB port
on computer.
Printer not responding to
software.
Poor connection between
Printer and computer.
Turn Printer OFF and ON again.
Check connections.
27
SECTION 2
TROUBLESHOOTING
Feeding Problems
CONDITION
Intermittent feeding
PROBLEM
Feed Ramp not used.
Side Guides set improperly.
Dirty Feed Rollers.
Paper stuck together.
Uneven mail piece.
Feed Ramp adds a slope to stack and
helps feeding.
Loosen Side Guides slightly.
Clean Feed Roller with distilled water
and a cloth. DO NOT use any solvents
or detergents as they may damage
Feed Rollers.
Fan media before placing it in Printer.
Tap contents to front of envelopes
and retry.
Multiple feeds
Separator gap not set properly.
Media stuck together.
Side Guides too close to media.
Adjust Separators to thickness of media.
Fan media before loading in Printer.
Push Side Guides away from media.
Failure to feed
Side Guides too close to media.
No power to Printer.
Readjust Side Guides.
Check that power buttons are ON
(Control Panel and Main Power) and that
power cord is plugged in.
Adjust Separator to thickness of media.
Adjust Separator to thickness of media.
Maximum thickness is 0.020".
Check for broken Drive Belt and replace.
Check for loose set screws on Drive
Pulley or Belt Drive Roller Pulley.
Replace Clutch.
Check that motor is receiving power from
Power Supply.
See Power Problems in this Section.
Feed gap too tight.
Feed gap too loose.
Material is out of specification.
Motor on, Feed Rollers not turning.
Clutch not engaging.
Motor failure.
No power.
Jams
Paper path obstruction.
Paper not loaded properly.
Feed Ramp not used properly.
Separators improperly adjusted.
Media curled or bent.
The Separators are worn.
28
SOLUTION
Clear jam and remove pieces remaining
under Printhead.
Instruct operator in proper loading
of media.
Set Feed Ramp.
Adjust Separators to thickness of media.
Uncurl media.
Replace Separator Tip.
SECTION 2
TROUBLESHOOTING
Memjet Printhead
CONDITION
Missing parts of letters
or text.
PROBLEM
SOLUTION
Air and bubbles blocking
nozzles.
Clean Printhead using recirculation,
priming or cycles of depriming and
priming found in Driver or Toolbox*.
Printhead is dry.
Rehydrate Printhead using distilled water
and a wet, clean, lint-free cloth.
NOTE: Bubbles often disappear with
Printer use.
*If bubbles persist, try the “Air In Ink
Lines” procedure listed below.
Print shows regularly
missing or misdirected
nozzles or ink color
mixing.
Debris on Printhead.
Perform startup routine.
Clean Printhead using Cleaning Levels in
Driver or Toolbox.
Ink mixing – Mixed or
muddy colors.
Causes: Ink flooding, air in
Printhead or a dirty Printhead.
Clean Printhead using Cleaning Levels in
Driver or Toolbox.
Wipe Printhead manually with distilled
water and a wet, clean, lint-free cloth.
No print or crisp blocks
of missing drops.
Electrical failure or poor
electrical connection.
Reseat Printhead.
Replace Printhead.
System will not reprime
ink after replacing
Printhead Cartridge.
Printhead nozzles dry.
Wipe Printhead manually with distilled
water and a wet, clean, lint-free cloth.
Replace Ink Tanks.
Wipe Printhead manually with distilled
water and a wet, clean, lint-free cloth.
Replace Printhead.
Ink Tanks may be 1/3 full
or less.
Air in Ink Lines
If air bubbles appear in the Ink Lines, particularly on the input (Valve) side of the Printhead and persist even after
running “Circulate Ink” from the Toolbox, try the following procedure:
1. Open the Printer
Toolbox. Use the
password to open
Service Menus.
2.
Open Printer Control
Configuration screen.
3.
Choose the Printer to
adjust: Top Unit or
Bottom Unit.
4.
Uncheck the “dpv_fix”
box. Click “Submit”.
5.
Click on “Circulate Ink” again and check for air bubbles in the Ink Lines. If OK, leave “dpv_fix”
unchecked, exit Service Menus and continue printing. If condition persists, a worn DPV Valve or other
problem may be indicated.
29
SECTION 2
TROUBLESHOOTING
Memjet Print Engine Main Printed Circuit Assembly (MPCA)
LABEL
COMING FROM
DESCRIPTION
Driver Printed
Circuit Assembly
(DPCA)
Power Supply.
Feeder Encoder
Reader Board
Feeder Encoder
Control.
J1002
P2004
Service Station Home
Sensor,
Service Station Index
Sensor,
Lower Clamshell
Service Station Lift Up
Sensor,
Duplex Exit Sensor,
Duplex Entry Sensor,
Black Mark Sensor,
Clamshell
Open/Closed Switch
P2002
30
SECTION 2
TROUBLESHOOTING
MPCA (Continued)
LABEL
COMING FROM
DESCRIPTION
Motor PWM
Control/Encoder
signals for:
Driver Printed
Circuit Assembly
(DPCA)
(a) Print Engine
Paper Motor,
(b) Print Engine
Pump Motor,
(c) Feeder Motor,
(d) Wiper Motor
P2006
Control Panel
Power/LED/Printer
Indicator LEDs
J35
Pen Driver Printed
Circuit Assembly
(PPCA)
P1
Printhead QAI Bus and
2.5 VDC QAI power,
3.3 VDC Logic Power
for Printhead, VPOS
Enable & VPOS Power
Good Signal, DOUT
from Printhead,
Printhead Reset Lines,
5 VDC Power for
Current Sense Buffer,
Analog Current Sense
Line from PPCA,
Pushbutton (2) Inputs
to MPCA.
31
SECTION 2
TROUBLESHOOTING
MPCA (Continued)
LABEL
COMING FROM
DESCRIPTION
Ink level PCA,
Pinch Valve, Ink
Cartridge QAI
interfaces
Ink Level Optical
Sensors, Print Engine
Accelerometer (Level
Sensor), Pinch Valve
Actuator and Position
Sensors, Ink Cartridge
QAI, Temperature
Sensor.
P2005
Service Station
Lifter Motor &
Encoder, Service
Station Translation
Motor
Service Station Lifter
Arm and Translation
Drive Signals.
Pen Driver Printed
Circuit Assembly
(PPCA)
Primary 24 VDC
Supply to PPCA.
P2003
J20
32
SECTION 2
TROUBLESHOOTING
MPCA (Continued)
LABEL
COMING FROM
DESCRIPTION
Printhead Latch
Solenoid,
Upper Clamshell
Printhead Latch
Open/Closed Sensor,
Label Gap IR
Transmitter LED.
J2001
Power Button
ON/OFF Switch.
J1000
J250 (CAT-5)
PPCA
Data Input to
Printhead.
J260 (CAT-5)
PPCA
Data Input to
Printhead.
33
SECTION 2
TROUBLESHOOTING
Print Engine DPCA Wire Connections
LABEL
COMING FROM
J17A
J17B
J18C
J17E
J1
Main Transport Motor
Ink Pump
External Feeder Motor
Wiper Roller Assy. Motor
J1002 on MPCA
P1
P2006 on MPCA
Service Station
CONDITION
Motor stalls
PROBLEM
•
•
•
•
Color mixing
Service Station
cannot be removed
from Print Engine
34
•
•
SOLUTION
Jammed gear train due to
broken post or improperly
seated gears.
Squeegee blade wedged, not
seated properly.
Debris build-up on blade and
rollers, increasing friction.
Bad Motor.
1.
Wiper Roller is saturated.
Squeegee blade is wedged,
not seated properly or bowed.
1.
Wiper Roller Latches were not
completely closed when Station
was installed. Latches now hooked
on bottom of paper path.
2.
3.
2.
3.
Check each possible cause
and correct if possible:
reseat gears and/or
squeegee, clean debris from
blade and rollers.
Retest.
If Motor is still stalled,
replace Motor.
If saturated, clean or
replace roller.
Reseat squeegee.
If squeegee is bowed,
adjust squeegee blade.
Carefully unhook Latches from
bottom of paper path and lock
correctly.
SECTION 2
TROUBLESHOOTING
Printing Problems
CONDITION
PROBLEM
SOLUTION
Ink Tank installed, no Ink Level
indication in Toolbox
Ink Tank contacts dirty,
preventing Printer/Ink Tank
communication.
Remove Ink Tank(s). Clean
prism and QA Chip contacts,
see Maintenance, Cleaning Ink
Tank Contacts.
Extra lines; losing data
Database problem.
Check data in database
program.
Improper output
(address information out of order,
misfeeding, etc.)
Wrong interface settings.
Check software or database
on PC.
Close software and then turn
Printer OFF and ON.
Clean Media Sensor.
Static electricity.
Dirty Media Sensor.
Media jams
Double feeding.
Media is curled or bent.
Media is too thin.
No communication
Improper cabling /
connector.
Unit not receiving power.
Adjust Sheet Separators on
Feeder.
Uncurl media.
Minimum thickness for media
is 0.004".
Use proper cable
(see Operator Manual).
Check plug connections,
ON/OFF switch and fuse on
back panel.
Print too light or missing
character dots
Clogged or dirty Printhead.
Running out of ink.
Check Printhead.
Replace Ink Tanks.
Blurry address
Image is not sharp.
Clean Printhead using
Cleaning Levels.
Replace Ink Tanks or change
Printer resolution setting.
Check media thickness.
Split line of type
A line of type does not
match up.
Check media thickness.
Minimum thickness for media
is 0.004".
Increase resolution of print.
Feeding problems
Double sheets.
Misfeeds.
Adjust Sheet Separators.
Paper Light Flashes
Media misfeeds.
Press Pause/Resume button to
feed media into position for
printing.
Cancel Light Flashes
Ink Tank Missing
Install Ink Tank.
Software Problems
Refer to the manual for the application software being used.
35
SECTION 2
TROUBLESHOOTING
Errors and Warnings
Printer Alert Window Messages
Messages sent from Driver and displayed on PC screen in a small
popup window.
MESSAGE
Cleaning in Progress
Wait until message disappears. Printer will start printing your job once
cleaning process is complete.
Excessive Tilt Error
See details under “Toolbox System Status Messages” section.
Incompatible
Printhead
Remove and reinsert your Printhead Cartridge. Replace Printhead. Printhead
Cartridges must be purchased from authorized supplier for this printer model.
Incorrect … Ink Tank
Replace Ink Tank. Ink Tanks must be purchased from authorized supplier for
this printer model.
…. Ink Low
Example: Black Ink Low
…. Out of Ink
Example: Cyan Ink Out
Load Paper
Mechanical Jam
Reorder Ink.
Replace empty Ink Tank.
Out of Paper. Load paper into Printer and press PAPER button
to resume printing.
Check for and remove obstruction, then press PAPER button to
resume printing.
Check/Clean Sensors. If problem persists, contact technical support.
Missing Printhead
Remove Printhead Cartridge. Check/clean electrical contacts. Reinsert
Printhead. Replace Printhead. If problem persists, contact technical support.
Multiple Inks Low
Reorder Ink.
Multiple Ink Tanks
Out
Replace empty Ink Tanks.
Multiple Ink Tanks are
missing
Insert missing Ink Tanks.
Clean electrical contacts and reseat Ink Tanks.
Multiple Unauthorized
Ink Tanks
Remove and reinsert Ink Tank. Replace Ink Tank. Ink Tanks must be
purchased from authorized supplier for this printer model.
Remove jammed media. Check for proper feed setup then press the PAPER
button to resume printing.
Check/Clean Sensors. If problem persists, contact technical support.
Paper Jam
36
SOLUTION
Printhead Latch Open
Ensure that Printhead Cartridge is inserted properly, then close Printhead
Latch so it locks.
Print Zone Assembly
(Clamshell) Open
Check to be sure Clamshell is completely closed and latched.
Make sure Print Engine Latches are secure.
The … Ink Tank is
missing
Insert missing Ink Tank.
Clean electrical contacts and reseat Ink Tank.
Unauthorized … Ink
Tank Installed
Ink Tanks must be purchased from authorized supplier for this Printer model.
Unauthorized
Printhead
Printhead Cartridges must be purchased from authorized supplier for this
Printer model.
SECTION 2
TROUBLESHOOTING
Toolbox System Status Messages
(Valid for printers with firmware version 14.3 or higher installed.)
Use the Duplex Toolbox System Status screen to quickly determine and locate a problem in the Printers. Status
Indicator shows ERROR shows in red box. Printer Graphic Icon highlights which Printer and system is affected.
The System Status information on the right displays the basic problem (in red) and which of the two Printers (Top
or Bottom) is affected. Ink Levels displays ink status in both Top and Bottom Printers. Control Buttons (at screen
bottom) let you perform often used tasks without leaving the screen.
Listed below are some of the messages that may appear in System Status.
SYSTEM STATUS
SOURCE
SOLUTION
Out of Paper
Media is not reaching
Print Engine. Hesitation
in media feed.
Load media into Printer and
press Pause/Resume button to
resume printing.
If media is present; check/adjust
Guides and Separators.
Paper/Media Jam
See below
Paper/Media jam
detected.
Printer has detected
that one (or all) of
media sensors are
blocked (interrupted).
Carefully remove jammed media
from Printer and close Print
Engine. System Status message
in red should go away.
Toolbox Paperpath Sensor
indicators should change from
red to green.
After jam is cleared, you can:
Press Pause/Resume to resume
printing.
Press Cancel Job to cancel job,
then manually clear job from
computer’s print queue.
37
SECTION 2
TROUBLESHOOTING
Toolbox System Status Messages (Continued)
SYSTEM STATUS
38
SOURCE
SOLUTION
Indicates that
“Clamshell” is open.
Sensor cable
unplugged P202.
Verify that Clamshell is closed
and securely latched on both
sides. Make sure that Clamshell
switch (located on opposite side)
is activated by Clamshell Lever.
Use Scan Sensors in Toolbox
to check that Clamshell switch
is functioning.
DATA_PATH_UNDERRUN
Media is not moving
from Entry Sensor to
Exit Sensor within a
specified time.
Possible issue with
format or orientation of
job being sent.
Dirty Encoder Wheel.
Check/clean Transport Rollers.
Check/clean Sensors.
Try changing orientation setting
in software/driver or setting a
different media size.
Check/clean Encoder Wheel.
If problem persists contact
technical support.
INK _LOW
X = Color.
One or more Ink
Tanks are low on ink.
Ink Tank replacement will be
necessary soon. Reorder Ink.
X = Color.
One or more Ink
Tanks are out of ink.
Replace empty Ink Tank(s),
using “Replace Ink Tanks”
command from EWS.
Verify that Ink Tanks are
seated firmly and latches are
fully closed.
Clear error using “Refresh Ink
Levels” command in Toolbox or
just press Pause/Resume to
refresh ink levels and continue
printing.
Printer(s) performing a
maintenance
procedure.
No action required.
SECTION 2
TROUBLESHOOTING
Toolbox System Status Messages (Continued)
SYSTEM STATUS
SOURCE
SOLUTION
Ink Tank(s) missing or
not recognized
(obtained from an
unauthorized reseller).
If correct ink, check
contacts.
Insert missing Ink Tank(s) or pop
Ink Tank in and out to improve
connection.
Clear error using “Refresh Ink
Levels” command in Toolbox
or press Pause/Resume button
to refresh ink levels and
continue printing.
Printer is not level.*
Printer’s electronics
have detected that
Print Engine is too far
out of level.
Tilt Sensor needs to be
recalibrated.
P2005 unplugged.
Make sure Printer is placed on
level surface. Failure to do so
may result in severe ink mixing
and cause an inaccurate ink
level reading in Ink Tanks.
If just powered on, wait a few
minutes; error may clear by
itself. Open the Diagnostics
screen in the Duplex Printer
Toolbox to see Tilt:. Once Tilt
Level drops to 1.99 or less,
clear error using “Clear Error”
button on the System Status
screen in the Duplex Toolbox.
*NOTE: Tilt should
always be less than
±2 degrees. If Tilt
warning indicates
more than ±2
degrees FB or LR,
(even if Printer
continues to run)
Printer must be
leveled again to
prevent damage.
Make sure Printer is placed on a
sturdy, level worktable. DO NOT
move Printer while power is on.
If Tilt Level is 1.99 or less,
clear this error using
“Clear Error” feature in the
Duplex Toolbox.
Contact technical support
person to have them check level
and possibly “Zero” Tilt Sensor.
39
SECTION 2
TROUBLESHOOTING
Toolbox System Status Messages (Continued)
SYSTEM STATUS
ERROR on System Status screen.
Check the Printer Graphic to determine
what component has a problem or failed:
Service Station, Ink Valve or Printhead,
(usually indicated with a steady “?”)
SOURCE
Mechanical error
One of Printer's
mechanical
components was not
properly registered at
expected position.
Mechanical failure or
Sensor failure.
Using Scan Sensors page in
Toolbox, perform toggle test on
Sensor responsible for
registration of failed mechanical
component position.
Lifter Arm Sensor is dirty or
damaged, Lifter Motor Cable is
unplugged, operator's side
Lifting Arm is damaged, or
Lifting Arm mechanism is stuck.
Dual Pinch Valve problem:
Check Sensor board connector
and flag/sensors alignment.
Check Valve motor connector.
Check P2005 cable on MPCA.
At this point, this error may
represent an Ink Pump error,
since there is no return signal
from pump and therefore, a
separate message describing an
Ink Pump error.
Data Cables
unplugged, dirty
Printhead contacts,
dirty PPCA contacts.
Check data cables (P250,
P260), clean Printhead contacts,
and/or clean PPCA contacts.
Service Station was
ejected, Service
Station position
sensors are damaged
or malfunctioning.
Check Service Station position.
Using Scan Sensors page in
Toolbox, perform a toggle test
on the two Sensors responsible
for registration of Service Station
position.
Printhead missing and
one or more of Ink
Tanks are missing,
When this error
occurs, Multiple EWS
monitoring is disabled.
Check Printer Graphic and Ink
Levels displaying “?”.
ERROR on System Status screen.
Printer Graphic shows Top or Bottom
Printer Service Station as “?”.
40
SOLUTION
Install Printhead.
Install Ink Tanks.
SECTION 2
TROUBLESHOOTING
Toolbox System Status Messages (Continued)
SYSTEM STATUS
SOURCE
SOLUTION
No Printhead installed
or Printhead not
making proper
connections.
J2001 cable
unplugged.
Printhead Latch
is open.
If Printer was just powered on,
wait a minute; error may clear
by itself.
Install Printhead Cartridge.
Remove and reinstall Printhead.
Replace Printhead. Refer to
appropriate sections in this
manual for removing and
installing Printhead Cartridge.
PRINTHEAD_UNPRIMED
Printhead priming
process has failed.
If Printer was just powered on,
wait a minute; error may clear
by itself.
Remove Printhead Cartridge,
wet print nozzles using
deionized or distilled water and
reinstall Printhead Cartridge.
Refer to appropriate sections in
this manual for removing and
installing Printhead Cartridge. If
you continue to have trouble
priming Printhead; check for
kinked or pinched color tubes.
MECH_CANCELPAGE
Job was cancelled
by user pressing
Cancel Job button.
Wait until print job has cleared
from Printer. Then manually
clear job from computer’s print
queue. Then send new print job.
Check to be sure “Clamshell” is
securely latched, and then press
“Clear Error” button to
continue. If problem persists,
contact service support.
ERROR on System Status screen.
Printer Graphic shows Top or Bottom
Printer Printhead as “?”.
Job was interrupted by
“Clamshell” being
momentarily opened.
WIPER OVERTEMP
Wiper Motor is
overheated due to
performing a Wiper
Transfer (removing
excess ink off Service
Station Wiper) too
often or for multiple or
extended periods.
Printer will continue
maintenance after
Wiper Motor cools
down. Message will
disappear once the
temperature returns to
operating range.
Wait for Wiper Motor to cool
down, Printer will automatically
resume operation. NOTE: If
running a number of short jobs
or jobs on smaller media, reset
Mid-Job Servicing interval to a
higher number of pages.
41
SECTION 2
TROUBLESHOOTING
Jams in Printer
If a jam occurs, STOP the Printer.
Some possible causes for jamming are:
1.
2.
3.
4.
Feeding more than one piece of media (double-feeding).
Damaged media, such as dog-eared (turned down corners).
Media that is not stiff enough may not be usable. Media that meets Postal stiffness requirements for
automated feeding is acceptable in Printer.
Envelopes caught under flap of another envelope or stick to one another.
Removing Jammed Media
Clearing a jam depends on where jam occurred.
(See Top Printer Operator Manual to clear jams in Top Printer.)
Duplex Feed Section:
[A] Open Duplex Feeder (pinch two tabs together to release Duplex Feeder
Cover latch). Clear jam; close Feeder Cover.
Print Engine Area:
[B] Lower Duplex Feeder.
[C] Open Print Engine Access Door. Release latch and use handle slide
Print Engine out of Duplex Printer cabinet.
[D] Release and lift two latches (one on each side of Print Engine
Clamshell) at same time to raise Clamshell.
Clear jam, then carefully lower and relatch Clamshell. Slide Print
Engine into the cabinet and latch in place. Close Print Engine Access
Door. Raise Duplex Feeder into position.
CAUTION
HOLD ONTO BOTH LATCHES WHEN OPENING
AND CLOSING PRINT ENGINE CLAMSHELL TO
PREVENT DAMAGE.
DO NOT ALLOW CLAMSHELL TO DROP OR
SLAM CLOSED.
TO PREVENT DAMAGE TO INK LINES, A STOP
LIMITS RAISING CLAMSHELL MORE THAN 60°.
42
SECTION 3
FUNCTIONAL OPERATION
SECTION 3 – Functional Operation
Sequence of Operation
User Prepares Printer
1.
Installs Ink Tanks in proper locations.
2.
Uses a single piece of media to set Sheet Separators.
3.
Loads media and adjusts Side Guide to within 1/32" of media.
4.
Stacks media in Feeder and adjusts Feed Ramp.
5.
Turns Printer ON.
User Prepares Layout and Creates a Job
1.
Selects the database and opens layout software (such as Microsoft Word).
2.
Creates a layout consisting of the variable data from database using Merge function.
3.
Creates a layout using fixed information (such as return address) and adds graphics as required.
4.
Saves layouts.
5.
Initiates Print function through File menu in program.
6.
Selects Properties menu through M-Series Print Driver to set single- or double-sided printing, media size
and desired print resolution.
7.
Clicks Print button to start printing job.
Printing Job
1.
As soon as enough of the job is sent from computer to Printer, Control Panel Power Button begins to blink.
If this is first job of the day, Print Engine automatically runs cleaning function. Once this is complete,
Printer will begin to feed paper.
2.
After media travels to Printer, Media Sensor detects lead edge of media and will then stop feeding and
line up lead edge of media with Printhead.
3.
Print Engine then begins printing job. Media is advanced by Paper Feed Clutch to continue printing.
4.
When first piece is printed, it is ejected and next piece is moved into position and aligned for printing.
5.
When last piece in job is printed, Printer ejects it and any pieces waiting to be printed.
6.
Service Station caps Printhead and remains there until next job is sent.
Printing
Print Engine consists of a single page-width Printhead to handle four colors from five Ink Tanks (Cyan, Magenta,
Yellow, Black and Black) to provide full color CMYK printing. Printing and operation of Printer is controlled by
Printer Interface Circuit Board and Print Engine Main Circuit Board.
43
SECTION 3
FUNCTIONAL OPERATION
Printer Functional Description
1.
Photosensor (located behind Sheet Separators) sees lead edge of media, another Photosensor in Print
Engine signals Print Engine on Main Board that mailing piece is ready for printing. Feed Clutch remains
disengaged as long as a mailing piece is in view of Photosensor.
2.
When mailing piece uncovers Sensor, Clutch engages Feed Rollers and next piece of media starts
moving toward Printer section.
3.
Cycle repeats itself as long as there is media in Feeder.
4.
Cycle stops when Feeder runs out of media, operator stops process, or there are no records left
to be printed.
5.
When there are no records to be printed, Printer ejects any media that is in line for printing.
Feed Clutch is OFF at this point.
Printhead Cleaning
Printhead is cleaned at beginning of each startup of a job by Service Station and at times during a run as determined
by Printer software. The Printhead cleaning function can also be activated through the Printer Driver Services screen
or through the Maintenance dropdown menu in the Printer Toolbox. A separate motor operates the Service Station.
See also “Cleaning/Replacing the Printhead” in the Maintenance section.
Duplex Printer Control Panel Button/LED Indicators
Control Panel has one power button and a diagram with three
LED indicators.
POWER (ON/OFF): Turns Duplex Printer power ON and OFF.
Turns off power for cleaning and maintenance.
Indicator LEDs: Show readiness status in Printer, Duplex Feeder
and Duplex Printer.
White: Ready – No Job loaded
Green: Ready – Job loaded
Red: Not Ready – Action Required in area(s) showing
red. (Clear media jams, Duplex Feeder not set correctly
for type of job sent, out of media, out of ink, etc.)
44
SECTION 3
FUNCTIONAL OPERATION
Control Panel Button/LED Indicators (Top Printer)
Control Panel has 3 buttons with LED indicators.
POWER (ON/OFF) – Turns Printer power ON and OFF.
Turns off power for cleaning and maintenance
PAPER /RESUME – Press to Resume printing after a paper
feed error (such as a paper jam or running out of paper) and/or
after a job is paused with the Cancel button.
CANCEL (CANCEL JOB) – Pauses or Cancels a Job.
•
Press to Pause a Job. Printer will clear media in machine and stop.
•
Press Again to Cancel a Job. Once the Printer has stopped, pressing this button clears job from printer and
print queue in driver.
NOTE: Cancelled Jobs must be reloaded before printing can resume.
See “Section 6” for additional Troubleshooting Information.
45
SECTION 3
FUNCTIONAL OPERATION
Duplex Printer Driver Properties
Printer Driver works the same as any other Printer Driver for Windows. It does have some enhancements to help
you maximize Printer's ability to print variable addressed pieces quickly and efficiently.
Once job is set up, click File, then Print.
Window at right opens.
Make sure M Series Driver is selected Printer.
Clicking “Printer Properties” opens the
“Properties” window.
General Tab
General tab lets you select:
•
Orientation – Portrait (default), Landscape,
Rotate 180° and Mirrored.
•
Page Buffering – Loads entire print job before
printing starts.
Mask Optimization (checked is default setting)
optimizes images for printing in most applications.
NOTE: Some applications (like FlexMail) may
display image boundaries when printed.
Unchecking the Mask Optimization box
eliminates these lines. (Remember to check box
when changing applications.)
Back Page – When selected, saves processing and
printing time when printing two-sided pieces
(envelopes, postcards, flyers, etc.) where the back
page is “static” (same image printed on the back
page of every piece printed).
46
SECTION 3
FUNCTIONAL OPERATION
To create and print a job that includes a static “Back Page”: The following procedure can be used to
print a job where the Top Unit prints each page of the document (usually variable-data multi-page
document) as the front page and the Bottom Unit prints a preloaded “static” image on the “Back Page” of
each piece.
1. Create/Select a “Back Page” document that meets one of the
following parameters:
a. A two-page document; with the second page (page printed by
Bottom Unit) as the desired “Back Page”.
b. A single-page document; with the number of copies set to “2”.
c. A multi-page document; with only the desired “Back Page”
selected to print and the number of copies set to “2”.
2. Print the desired “Back Page” document with the following Printer
Driver settings:
“Back Page” option selected.
“Duplex Settings” set to “short edge” or “long edge”, as desired.
Tip: After the “Back Page” document prints, check that the Bottom Unit in the Toolbox displays the “Back
Page” icon [A]. If not, “Back Page” was not loaded/saved to the Bottom Unit – Repeat Steps 1 & 2 above.
3. Open and Print the document that will be used to print the “Front Page” (page printed by the Top Unit)
of each piece, with the following Printer Driver settings:
“Back Page” option selected.
“Duplex Settings” set to “OFF”.
Tip: You can set all other Printer Driver settings as desired.
How to Replace the current “Back Page” image:
To replace the current “Back Page” image currently stored in the Bottom Unit, repeat Steps 1 & 2 above.
How to Remove the current “Back Page” image:
To remove the current “Back Page” image currently stored in the Bottom Unit, do one of the following:
a. Reset or reboot the Printer.
b. Uncheck (turn-off) the “Back Page” option in the Printer Driver before printing your next job.
•
Copies – Enter number of copies to be printed. NOTE: Default setting (Reverse Order unchecked) prints
job starting with first page. Printing starts as soon as first page loads.
Reverse Order allows job to start printing from last page. Since entire job has to load into Printer before
printing starts, large jobs may take longer to load.
47
SECTION 3
FUNCTIONAL OPERATION
•
•
•
•
•
Media – Choose a type of media or different
MEDIA PROFILE
size media than document was originally
Plain Paper
designed for. Type: Chart at right lists media
profiles associated with type of media chosen.
Sizes: 21 sizes are available. Document is
Matte Paper
automatically resized to fit new media.
Also create and save a Custom Size to suit
your needs. NOTE: Do not exceed maximum
paper size for the Printer.
Premium Matte Coated Paper
Duplex Settings – Sets the Duplex Printer for
single or double-sided printing when attached
to the Top Printer. Also set the Binding for
Glossy Paper
the print job. NOTE: This feature is inactive
if the Top Printer is not connected to the
Premium Glossy Paper
Duplex (Bottom) Printer.
Color Selection – Set Printing for Color,
Composite Black (uses all colors to print Black), or
Black Only (uses only Black ink).
Print Quality – Select Normal or Best. Normal is 1600 x
800 dpi, checking “Half Speed” box slows printing for
higher quality on glossy stock. Best setting is 1600 x 1600
dpi, for use when high quality images are required.
My Print Settings – Access your saved custom print
settings for various jobs.
Layout Tab
Layout allows you change how document prints without
changing original document.
48
•
Resizing – Specify Original Size or Custom
Resize: Resizes original as a % of normal size.
Printer prints document in size you selected
regardless of paper size.
Print on: Specify particular size of media that you
want to print on regardless of size of original
document. Checking “Scale to Fit” automatically
resizes document to fit on new page size.
•
Printing Adjustments – Make minor positioning
changes to print area in relation to media if needed.
You can also set measurements to be in Inches,
Millimeters or Pixels.
NOTE: Printing Adjustments only works when
Print Area is less than full print width (less than
8.5"/215.9mm wide). See “Using Layout Tab
Printing Adjustments” on next page.
MEDIA TYPE
Plain Paper
Bright White Paper
Presentation Paper
Postcards Matte
Brochure Matte
Labels Matte
Other Inkjet Paper Matte
Premium Inkjet Paper
Premium Photo Paper Matte
Photo Paper Semi-gloss
Photo Paper Glossy
Labels Glossy
Postcards Glossy
Brochure Glossy
Premium Photo Paper Glossy
SECTION 3
FUNCTIONAL OPERATION
Using Layout Tab Printing Adjustments
Image Position – Left Adjustment moves image area (-3mm left to +200mm right) from left edge of
media. Top Adjustment moves image up or down (-5mm up to
+ 200mm down) from top left corner of media used. (0.1mm increments)
Max Page Width – Sets width of actual print area. (0.1mm increments) This shuts off nozzles in nonprinting area (not used for printing) and saves ink. NOTE: Can be no larger than maximum print
width for Printer (8.5"/215.9mm).
Purge Bar Position* – In operation, Printhead spits a small amount of ink in gap between pieces to
keep nozzles refreshed. For irregular-shaped pieces (like an envelope flap), Sensor may “read” lower
end as the edge and spray on tip of flap instead of actual gap between pieces. This feature allows you
to manually set gap (in 0.1mm increments) to account for extra length needed to reach actual gap.
* See also “Purge Bar Position” in Printer Toolbox section.
•
Watermark – Prints a light background watermark in paper while printing original document. When this
option is selected, “First page only” option prints watermark on first page, but not subsequent pages,
unchecking prints watermark on all pages. Custom button lets you create a new watermark or edit an
existing watermark, including font selection, color, size and printing angle.
49
SECTION 3
FUNCTIONAL OPERATION
Color Tab
Color is used to adjust the color output of the Printer.
Use the sliders to adjust Color Tone, Brightness and
Saturation. The C, M, Y, K sliders adjust individual
colors. Use Defaults to reset to 0 settings.
Import/Export Tab
Import/Export is used to preserve any custom Media
Sizes, Watermarks and/or Print Settings you may have
developed and saved for various jobs when you update
Printer firmware.
• Export – Send custom settings to a holding file
before downloading new firmware.
• Import – Return custom settings after firmware
installation is complete.
This tab is also used to import custom media size packages
or watermarks from your dealer if they are available.
IMPORTANT!
BEFORE STARTING ANY PRINTER FIRM-WARE
UPDATE, REMEMBER TO FIRST EXPORT ANY
CUSTOM MEDIA SIZES, WATERMARKS OR PRINT
SETTINGS YOU HAVE ADDED TO AN OUTSIDE
HOLDING FILE. THIS WILL PREVENT LOSS OF
YOUR CUSTOM SETTINGS.
50
SECTION 3
FUNCTIONAL OPERATION
Services Tab
Services allows you to:
•
•
•
•
•
Print Configuration Page – Prints out current
configuration of Printer including current
Firmware Version, Network Connection, printer
Serial Number and more.
Print Colorbar Page – Prints type and color bands
to check print quality.
Print Diagnostic Page – Displays basic Printer
information, memory, Network Settings, Event
Log and RAM partitions.
Clean Printhead Buttons: Provide 3 levels of
cleaning for Printhead Cartridge.
Quick Clean Printhead – Circulates ink, wipes
and cleans Printhead Cartridge.
Normal Clean Printhead – Runs cleaning
and wiping routine twice for better flushing
and cleaning.
Full Clean Printhead – Runs cleaning routine
multiple times for most thorough flushing and
cleaning of Printhead.
NOTE: If Printer is connected to a network and Driver buttons fail to activate cleaning process, you
can perform same functions from Toolbox User Interface.
Wipe Printhead – Wipes and cleans excess ink from Printhead Cartridge.
51
SECTION 3
FUNCTIONAL OPERATION
Using Duplex Printer Toolbox
Once Printer Driver is installed, you can access the Duplex Printer Toolbox. You can check Printer status, monitor
ink usage, perform diagnostic checks, print reports and run maintenance tasks on both Top and Duplex Printers from
your computer.
To open the Duplex Toolbox:
Open Start Menu; then click on Toolbox. If the standard M-Series Toolbox opens and there is no “Duplex View”
selection under “Network Config”, see “Set Up Top Printer and Bottom Printer Communication” in the
Installation section. When the Duplex Toolbox window opens:
[A] System Status Indicator and Drop-Down Menu Options (at top of screen).
[B] Check Printer Status of both Printers (across middle of screen).
[C] Four often-used control buttons (at bottom of screen).
Drop-Down Menu Options
There are four Drop-Down Menus:
View, Maintenance, Service and
Print. The drop-down menus are
available on every Toolbox screen,
allowing you to toggle between menus and
select different Printer features and functions.
View Drop-Down
The View drop-down gives you four choices:
System Status, User Interface, Ink Usage and Service Menus.
52
SECTION 3
FUNCTIONAL OPERATION
System Status
This screen opens when you access the Toolbox.
It provides information about both Printers.
Left side:
Status Indicator shows Printer activity as
ONLINE, ERROR, MAINTENANCE,
PRINTING or PAUSED. Gray box (below
Status Indicator) shows the name of the job
being processed.
Page shows the page count for a given job.
Job shows number of jobs printed (resettable),
Session shows the total number of pages printed
by the Printers (resettable) over the length of
a Session (shift, day, week, etc).
Ink Levels displays percentage of ink remaining
in each of the Ink Tanks in both Printers.
Printer Icon: Shows status of Media Sensors
located in the media feed path of both Printers.
Also shows status of Ink Valves, Service Station,
and Printhead. These can alert the operator to the
type and location of a problem. (See icon key
image at right.) Another icon shows when Back
Page is activated (see Printer Driver Properties,
General Tab for more information).
Rolling over any of the status icons with your cursor pops up a description of that icon.
Right side:
Shows basic operating information about both Printers.
CONTROL BUTTONS (located along bottom of screen): Pause/Resume, Cancel a Job, Clear Error, and
Quick Clean Printhead. Provide quick access to often-used functions.
53
SECTION 3
FUNCTIONAL OPERATION
User Interface
SET-UP SETTINGS: Adjust automated
service and cleaning intervals, adjust
feeder speed for a job, manually set gap
between pieces and adjust Printer for
pre-printed media.
KWS Setting – (Keep Wet Spitting)
Keeps Printhead hydrated while
running a job.
Select from 3 settings: None, Light
(default), and Heavy to determine how
much ink will “spit” from Printhead
Nozzles. Set in conjunction with “MidJob Servicing” which determines frequency of Printer stopping for self-servicing during a job.
Cutsheet Feeding Mode – Change how Printer feeds media depending on type of job you are running:
Safe Feed – Leaves a larger gap between pieces to reduce overprinting onto next piece. This setting is useful
for more intricate printing jobs or jobs requiring the best print quality.
Max_Throughput – Allows fastest printing speed. Printer works like a stream feeder. This setting is useful
for simple printing jobs. NOTE: A few extra blank pieces may run through at end of job.
NOTE: These two settings can be changed without stopping job. Example: While running a job in
“Max-Throughput” you find that media is jamming excessively due to speed. Open Toolbox, check
“Safe Feed” and click “Submit”. Printer automatically adjusts without having to pause or stop job.
Mid-Job Servicing – Sets frequency of automatic maintenance cycles run during a job after a set amount of
media is run. Settings are: 50 Pages* (Default), 100 Pages, 250 Pages, 500 pages, 1000 Pages and 2500 Pages.
NOTE: Changing setting from “Default” may cause print quality issues and reduce Printhead life.
*Use 50 Pages (Default) setting only with media at least letter-sized or A4 length or longer.
Purge Bar Position – In operation, Printhead spits a small amount of ink in gap between pieces to keep nozzles
refreshed. For irregular-shaped pieces (like an envelope flap), Sensor may “read” lower end as the edge and spray
on the tip of flap instead of actual gap between pieces. This feature allows you to manually set gap (1 micron
increments) to account for extra length needed to reach actual gap.
Ignore Exit Sensor – Checking this box turns Exit Sensor OFF. Sensor may not detect trailing edge of a piece of
pre-printed media if back of that media is dark or black. (Example: adding addresses to a pre-printed postcard.)
This may cause Sensor to react as if a jam has occurred. Turning Sensor OFF prevents these “false jams” from
stopping job.
Overlap Detection – Detects differences in media thickness and stops the Printer if two or more single sheets pass
through the sensor stacked on top of each other. Default is not activated (box not checked). If running envelopes or
media with varying thickness (such as folded), turn this feature OFF (uncheck box).
NOTE: Remember to turn feature back ON if running single sheets again.
Click “Submit” to apply settings.
54
SECTION 3
FUNCTIONAL OPERATION
DISPLAY LANGUAGE:
Selects language EWS (Toolbox) will display.
Click “Submit” after selecting language.
FIRMWARE DOWNLOAD:
Get the latest version of firmware for your
Printer. Two types of firmware files are
normally provided: “.bin” files and “.fbf”
files. “.fbf” files are loaded using the Printer
Toolbox. Using the Toolbox and “.fbf” files
gives you the option of choosing to update
both Top and Bottom Printers at the same
time, or selecting Top Unit or Bottom Unit to
update the Printers individually.
NOTE: Using the “.fbf” file procedure is an
alternative method for downloading
firmware. See “Updating Firmware” for the recommended
procedure using “.bin” files and the procedure using “.fbf” files.
WARNING: Firmware download procedure using the “.fbf” file should only be performed by qualified service
personnel. In some cases firmware must be loaded using “Firmware Migration Tool”.
If this process is not performed properly, Printer is rendered inoperable.
55
SECTION 3
FUNCTIONAL OPERATION
Ink Usage
Allows you to monitor estimated amount of ink
left in each Ink Tank. Monitor ink use and
consumption and schedule Tank changes
(saving down-time during a print run.)
NOTE: Ink Usage only works when a new
Ink Tank is installed and left in the Printer.
INK ESTIMATION MODE – Lets you
predetermine how much ink a given job may
use prior to printing a job. This is useful for
determining per piece costs. Job is sent to
Printer and loads, but does not print. Once job is loaded, click
“Refresh” to show amount of ink (by color) that job will use.
Mode selection:
Off – Feature is disabled.
Continuous – Ink Estimation Mode
continues running (Printer will not print),
until feature is turned “OFF”.
Single Pass – Ink Estimation Mode
runs once, then turns off. Printer will
then be ready to print.
Click “Submit” to activate Mode
setting selected.
NOTE: Estimating process takes as long as
job would take to print (i.e., if job would take
1 hour to print, estimate will take 1 hour to
display. Track progress on the Counter
located in the System Status window).
JOB COST SETTINGS – Enter your ink cost and printhead
cost and media size preference (inches or mm).
Set a minimum of at least 100 pcs. to ensure a large enough
sample size. Click “Submit”. In Ink Estimation Mode, this
feature estimates per page cost and job cost without printing
job. With Ink Estimation Mode disabled, Printer still tracks
estimated per page cost and estimated job cost as job is being
printed. Once costs are entered, they will remain until changed
again, even if Printer is turned OFF.
NOTE: This is only an estimate and does not include other factors such as Printer maintenance routines,
(printhead wiping and cleaning, power up/down, etc.) that may affect overall result.
56
SECTION 3
FUNCTIONAL OPERATION
Service Menus
Clicking Service Menus opens the Service Menus screen.
Diagnostics button. Click to check the status of both Top Printer
and Bottom (Duplex) Printer. (See Diagnostics below.)
Network Config button. Click to view, enter or change settings
to connect Printer to your network.
(See Network Configuration below.)
Scan Sensors button. Provides status and a log on Sensors
located throughout the Printer. (See Scan Sensors below.)
Service Menus, Password: Entering the Service Menu
password provides access to more advanced Printer control and
maintenance menus. For authorized service personnel only.
Diagnostics
From this screen you can see current status of
both Printers. You can also:
Serial Debug Log – Download and save a log
of the Printer status (for each Printer) to send
to a technician to help diagnose a problem.
Clicking this button creates a snapshot log
showing everything going on with the Printer
since powering up. (See Sample Log at right).
NOTE: If a problem arises, try to recreate the
problem, then press Upload the Debug Log
without performing any other actions to make it
easier for the technician to determine the problem.
If this is not possible, include any actions you may have taken
after the problem started.
Other information provided in the Diagnostics window:
Event Log – Displays significant events occurring on the
Printer (such as firmware updates, errors, power off, etc.)
Useful for troubleshooting Printer problems.
NVM Settings – Displays Printer's current NVM
(Non-Volatile Memory) settings. (Once settings are saved,
they remain even when Printer is turned off, until they are
manually changed.)
VARS Settings – Displays Printer's current VARs
(Variable) settings. (Settings that are set for a particular
job that automatically revert to the default settings when
the Printer is turned off or rebooted.)
57
SECTION 3
FUNCTIONAL OPERATION
Network Configuration
Permits you to view, enter or change settings to connect Printer to your network.
Network Connection Set Up:
NOTE: If Top Printer is connected to a computer via USB, skip to Step 2. If the Top Printer is connected to a
network via the Ethernet Port, see Step 1 below.
1.
If Top Unit is connected to the network via the Ethernet port
[A]: Switch the network Ethernet cable from the Ethernet port on
the Top Printer [A] to network Port on Rear Panel of Bottom
(Duplex) Printer [B].
2.
To connect Printer to a network, open the Duplex Toolbox.
Select “View”; then select “Service Menus”.
Click “Network Config”.
3.
Network Configuration screen opens.
Three addresses are listed: The network
ip_address for the Top Printer. There are
also different internal communication
addresses for both the Top Printer and
Bottom (Duplex) Printer.
NOTE: If manually making a change to
the ip_address, make sure the “dhcp”
and “autoip” boxes are unchecked.
(Default is checked.) Enter changes in the
appropriate boxes. Click “Submit”.
58
SECTION 3
FUNCTIONAL OPERATION
Scan Sensors
Provides status and log on Sensors located throughout
both Printers. (See chart at right.)
Click “Stop” button to stop scanning or click out of
“Scan Sensors”.
SENSOR
DESCRIPTION
Entry Sensor
(Paper Path Entry)
Interrupted (media present) = 0-60
Uninterrupted (no media) = 255
Blackmark Sensor
NOTE: Not applicable for this model. Blackmark Sensor's output is for printers
designed to run a “continuous” web of media (i.e. labels).
Exit Sensor
(Paper Path Exit)
Uninterrupted = 0
Interrupted (blocked) = 1
Tip: If media has dark colors on underside, you may experience “paper jam”
conditions when there is no physical media in machine. If Exit Sensor appears to be
operating normally, select “Ignore Exit Sensor”; then click “Submit” in User
Interface screen to bypass Exit Sensor.
Clamshell Switch
Clamshell Open = 1
Clamshell Closed = 0
Printhead Latch
Closed = 0
Open = 1
Lifter Arm
Up = 1
Down = 0
Sled Index
Cap Position = 0
Print/Wipe Positions = 1
Sled Home
False = 0
True = 1
Paper Feed Sensor
Covered (media present, sensor dirty) = 1
Uncovered (no media) = 0
Valve Position
Displays operating positions of Dual Pinch Valve: “OpenAir,” “OpenInk,” and
“Closed”. “Unknown” will display as Valve transitions between positions. NOTE: If
“Unknown” displays for more than a few seconds, it may indicate a problem.
TX Closed
Duplex Feeder (Transport) is open (lowered) = 1
Duplex Feeder (Transport) is closed (in duplex print position) = 0
TX Cover
Duplex Feeder (Transport) Cover is open = 1
Duplex Feeder (Transport) Cover is closed = 0
DX Engine
Duplex Print Engine is open (print engine pulled out) = 1
Duplex Print Engine is closed (latched in place) = 0
59
SECTION 3
FUNCTIONAL OPERATION
Advanced Service Menus
Enter the Service Menu password and click
“Submit” for access to more advanced Printer control
and maintenance menus.
Printer Control Config
Allows you to make fine
adjustments as to how a job is
fed into and through the Printers
and how it will print. Settings for
both the Top Unit and Bottom
Unit are displayed.
Checking the enable_duplex and
duplex_master boxes and
clicking “Submit” will reboot
the Printer, allows the Top
Printer and Duplex Printer to
communicate and opens the
Duplex Printer Toolbox. When the duplex_master box is checked in the Top Unit column, the Top Unit is the
master printer and the Bottom Unit (Duplex Printer) is subordinate. Note that duplex_master should be unchecked
in the Bottom Unit column.
You can also return to the default Printer settings by pressing the “Reset to Factory Defaults” button.
NOTE: Changes made in the Printout Control columns are permanent until changed or the “Reset to Factory
Defaults” button is pressed. Changes made in Printing Parameters columns revert to default settings when the
Printers are turned off or rebooted.
60
SECTION 3
FUNCTIONAL OPERATION
Top Unit and Bottom Unit
Top Unit switches back to the Standard Printer Toolbox view and shows
information for the Top Unit (Top Printer).
Bottom Unit switches to the Standard Printer Toolbox view but shows
information for the Bottom Unit (Duplex Printer).
NOTE: Printer Maint Config and Printer Commands Help (see below) are
only available in the both the Top and Bottom Unit Standard Toolbox view:
Exit Service Menus
Click to exit the Service Menus.
NOTE: (The two menus below are only accessible by opening the Standard Printer Toolbox.)
Printer Maintenance Configuration
Enables or disables certain maintenance functions.
“Zero Tilt Sensor” can reset Tilt Warning in Printer Status column.
You can also “Print Setup Page,” “Print Configuration,” “Print
Diagnostics,” “Print Printhead Test,” “Print Ink Channels” and
“Print Color Bars” without returning to the Diagnostics screen.
You can also return the Printer to the default settings by pressing the
“Reset to Factory Defaults” button.
Printer Commands Help
Provides a list and descriptions of available EWS (Embedded
Web Server) service commands.
61
SECTION 3
FUNCTIONAL OPERATION
Maintenance Drop-Down
Perform maintenance tasks. Select drop-down menus for Top Unit or Bottom Unit.
Circulate Ink – Purges air from lines and primes system after
replacing Ink Tanks or Printhead Cartridge.
Quick Clean Printhead – Circulates ink; wipes and cleans
Printhead Cartridge. (Also available in the System Status window.)
Normal Clean Printhead – Runs cleaning and wiping routine twice
for better flushing and cleaning.
Full Clean Printhead – Runs cleaning routine multiple times for
the most thorough flushing and cleaning.
Wipe Printhead – Activates Service Station to wipe Printhead.
Wiper Preemptive Maintenance – Re-saturates Wiper with ink to
remove dried residue if Printer is inactive for long periods of time.
Service Drop-Down
Control functions that require the Printer to be out of service for
extended periods of time while they are being performed.
Top Unit and Bottom Unit: Select the desired Printer to open a
submenu of functions to perform on that Printer.
Shutdown: Turns off both Printer and Duplex Printer.
Restart: Restarts both Printer and Duplex Printer without having to
perform the startup routine (purging ink tanks, priming, etc.)
Top Unit and Bottom Unit submenus: Using these features affects
only the specified Printer. (Bottom Unit Printer in this example.)
Replace Ink Tanks – Disconnects Printer communication with Ink
Tank Sensor. Allows safe removal of Ink Tanks.
Refresh Ink Levels – Updates or confirms ink levels
(shown at left of screen).
Eject Service Station – Releases Service Station for removal for
cleaning, repair or replacement.
Install Service Station – Pulls Service Station back into place after
cleaning, repair or replacement.
System Deprime – Pumps ink back into Ink Tanks prior to replacing
Printhead Cartridge or transporting Printer.
Release Printhead – Pumps ink back into Ink Tanks and opens Printhead Latch to remove or install Printhead
Cartridge. NOTE: Function can also be performed by pressing Printhead Release button on Print Engine.
Zero Tilt Sensor – Allows you to reset the Tilt Sensor if the Printer is level within tolerances
(Tilt Level is 1.99 or less).
Shutdown – Turns specified Printer OFF. For best system performance, it is recommended to keep Print Engine
powered-up (ON/OFF light illuminated) at all times. If turning Printer off, first power-down Print Engine using
“Shutdown” button in Toolbox or ON/OFF button on Control Panel. Wait until all Control Panel buttons go out
before turning off Main Power Switch.
Restart – Restarts the specified Printer without having to perform the startup routine
(purging ink tanks, priming, etc.)
62
SECTION 3
FUNCTIONAL OPERATION
Print Drop-Down
Print various reports and Printer tests.
Each printout displays information about both Printers.
Print Setup – Prints a printing pattern used for positioning image on
the page. (Duplex Printer: the same page is printed on both units to
help align top and bottom Printers.)
Print Configuration –
Prints current Printer configuration including Firmware Version,
Network Connection, Printer Serial Number and more for Printer
and Duplex Printer.
Print Diagnostics – Prints basic Printer information, memory,
Network Settings, Event Log and RAM partitions.
Print Printhead Test – Prints color bands, text and patterns to
check condition of Printhead's ink nozzles. NOTE: Uses less ink
than Print Ink Channels or Print Color Bars.
Print Ink Channels – Prints 5 bars per Printer (1 bar from each ink
tank) to indicate how well Printhead Nozzles are working.
NOTE: Function can also be accessed by pressing “Print Ink
Channels” button on right side of Print Engine.
Print Color Bars – Prints a series of 7 color bars (per Printhead) to
indicate how well Printheads are mixing colors and printing.
63
SECTION 3
FUNCTIONAL OPERATION
Updating Firmware
Get latest version of firmware for your Printer. This may be in the form of a CD or download. In many cases the
Firmware and Printer Driver are updated at the same time. Two types of firmware files are normally provided:
“.bin” files and “.fbf” files. “.fbf” files are loaded using the Printer Toolbox. NOTE: Use the firmware update
procedure AFTER you have updated the Printer Driver. The Printer Driver update procedure is included with
an “Update Package” which includes both updated Printer Drivers and firmware updates.
Download new firmware using “.bin” files:
1.
2.
3.
4.
5.
6.
64
When you are notified that new firmware is available
for your Printer, download “*.bin” file and save it to
your desktop.
From Start Menu, open All Programs.
Open “Memjet” folder, then “M Series Driver”.
Click “Update Firmware”.
Click “Browse” button. Find and select file you just
saved to your desktop. Click “Open”.
When “Update printer firmware” window opens,
select M-Series printer you want to update.
NOTE: You can only update one printer (Top or
Bottom) at a time.
Click “Update”. DO NOT touch Printer until
firmware is loaded! A message appears on screen
warning you not to unplug or shut off Printer.
Once firmware finishes loading (about 5-10 minutes),
Control Panel lights and Printer shuts OFF, then
restarts automatically to complete installation.
SECTION 3
FUNCTIONAL OPERATION
Download new firmware using the Printer Toolbox and “.fbf” files:
WARNING: Firmware download procedure using the “.fbf” file should only be performed by qualified service
personnel. In some cases firmware must be loaded using “Firmware Migration Tool”.
If this process is not performed properly, Printer is rendered inoperable.
1.
When you are notified that new firmware is
available for your Printer, download the *.fbf file
and save it to your desktop.
2.
Open Printer Toolbox. On the “User Interface”
screen, find “Firmware Download”.
3.
Click “Browse” button; then select the “.fbf” file
just saved to your desktop.
4.
Click Unit (Printer) to be updated:
Both, Top, or Bottom.
5.
Click “Submit”. DO NOT touch the Printer(s)
until firmware is loaded!
A message appears on screen warning you not to
unplug or shut off Printer.
6.
Once firmware finishes loading (about 5-10 minutes), the Control Panel lights and Printer shuts OFF, then
restarts automatically to complete the installation.
65
SECTION 4
DISASSEMBLY AND ASSEMBLY
SECTION 4 – Disassembly/Assembly Procedures
Duplex Unit 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 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).
• DISPOSE OF ALL MAINTENANCE WASTE IN ACCORDANCE WITH
LOCAL REGULATIONS.
CAUTION
USE ELECTROSTATIC DISCHARGE (ESD) PROTECTION WHEN WORKING
AROUND ELECTRONIC DEVICES:
• USE STATIC-FREE WORKSTATIONS WHEN UNIT COVERS ARE REMOVED.
• WEAR GROUNDED WRIST STRAPS WHEN WORKING ON UNIT.
• TRANSPORT ELECTRONIC SUBASSEMBLIES IN SEALED STATICSHIELDING PACKAGING.
66
SECTION 4
DISASSEMBLY AND ASSEMBLY
Operator Side Door
1.
Open Print Engine Access Door [A].
Components behind Operator Side Door
1.
Print Engine
2.
Print Engine Release
Latch and Print Engine
Latch Sensor
3.
Wire Harness Conduit Chain
4.
Duplex Feeder
5.
Indicator Panel Printed
Circuit Board
6.
Power On/Off Switch
67
SECTION 4
DISASSEMBLY AND ASSEMBLY
Non-Operator Side Cover
1.
Upper Non-Operator Side
Cover: Remove (3) screws at
top and (3) screws from bottom
of Cover.
Major Components under Upper Non-Operator Side Cover
1.
Print Engine
2.
Ethernet Switch
3.
Ethernet Ports (2)
4.
Ethernet Switch
Power Receptacle
5.
Main Power Switch, Fuse
and Power Receptacle
6.
Power Supply
Replace Control Panel Circuit Board
68
1.
Open Print Engine Access Door.
2.
Disconnect wiring harness [A].
3.
Remove 2 screws securing Circuit Board to
Cabinet Frame [B].
4.
Reinstall in reverse order.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Feeder End Cover
Remove Feeder End Cover:
[A] Remove 3 screws across bottom of Cover.
[B] Remove 2 screws (one on each side
inside Cabinet.)
[C] Remove 2 screws on top. Remove Cover.
Major Components under Feeder End Cover
1.
Print Engine
2.
Duplex Feeder
3.
Duplex Feeder Cover Sensor
(Open/Closed)
4.
Duplex Entry Sensor
5.
Wire Harness Conduit Chain
6.
DPCA
7.
Peristaltic Pump
8.
Dual Pinch Valve Assembly
69
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Wire Harness Conduit Chain
70
1.
Open Print Engine Door.
Remove upper Non-Operator Side Cover
(6 screws) and Feed End Cover [A], [B]
and [C].
2.
Remove MPCA
Cover. (4 screws).
SECTION 4
DISASSEMBLY AND ASSEMBLY
3.
Disconnect these Wire
Harnesses:
From MPCA:
[A] Ethernet,
[B] P1000 (Power
Supply),
[C] J1000,
[D] P2004,
[E] Control Panel
Indicator wire harness,
From DPCA:
[F] DPCA-J18C
Cut cable ties securing wiring harnesses to
chain as necessary. Carefully pull the
disconnected wire harnesses free of other
wiring, the MPCA and the Print Engine.
4.
Remove 2 screws securing chain to upper
mounting bracket [A].
5.
Remove 2 screws securing chain to lower
mounting bracket [B].
6.
From the upper chain mount, carefully unroll
chain and disconnected ends of wiring harnesses
toward the Operator Side. Slide chain off of
wiring harnesses.
7.
Reinstall in reverse order.
NOTE: Make sure chain ends or positioned
correctly during installation.
71
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Power Supply
72
1.
Remove upper Non-Operator Side Panel.
(6 screws)
2.
Disconnect wire harnesses [A] from Power Supply.
NOTE: Wires are labelled to simplify reconnection.
3.
Remove 2 mounting screws and washers [B].
(Access screws from exit end of Duplex Printer.)
4.
Reinstall in reverse order.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Ethernet Switch
1.
Remove upper Non-Operator Side Panel.
(6 screws)
2.
Disconnect Ethernet Cables [A] from
Ethernet Switch.
3.
Unplug Power Cord from Switch [B]. Unplug
Power Cord plug from outlet [C]. Unclip Power
Cord and remove.
4.
Switch is attached with hook and loop strip.
Pull Switch away from cabinet.
5.
Center and attach the new hook and loop strip
onto the new Switch as shown [D].
6.
Align and attach the Switch to the hook and loop
strip on the Printer Cabinet [E].
7.
Reconnect Ethernet cables. Plug in Power Cord.
73
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Duplex Feeder Position Sensor
74
1.
Lower Duplex Feeder (6 screws).
2.
Remove Duplex Feeder Sensor mounting screws
(2 screws). Disconnect wire harness.
3.
Reinstall in reverse order.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Print Engine Entry Sensor
The Entry Sensor (Emitter) is located on the upper clamshell at the media entry end of the Duplex Print Engine.
NOTE: To remove the Receiver component of this Sensor, you must first remove the Print Engine's Upper
Clamshell Assembly. See “Removing the Print Engine”, “Removing the Upper Clamshell Assembly”, then
“Replacing the Entry Sensor” later in this section.
1.
Lower Duplex Feeder.
2.
Open Print Engine Access Door. Unlatch and pull out
Print Engine.
3.
Remove 2 screws [A] securing Sensor to
mounting bracket.
4.
Reinstall in reverse order.
75
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Print Engine Latch Sensor
76
1.
Lower Duplex Feeder.
2.
Open Print Engine Access Door. Unlatch and pull out
Print Engine.
3.
Remove 2 screws [A] securing Sensor to
Print Engine Latch Assembly.
4.
Disconnect NC and COM wire harnesses.
5.
Reinstall in reverse order.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Print Engine Latch
1.
Lower Duplex Feeder.
2.
Open Print Engine Access Door. Unlatch and pull out
Print Engine.
3.
Remove 2 screws [A] securing Sensor to Print
Engine Latch Assembly. Move Sensor away from
Latch Assembly
4.
Open the Storage Door (below the Print Engine
Access Door). From underside, remove the two
screws securing the Print Engine Latch to the
Cabinet Frame [B]. Remove the Latch.
5.
Reinstall in reverse order.
NOTE: Latch location will have to be adjusted
to ensure both Top and Bottom Print Engine
media paths are properly aligned.
See Section 1, Adjust Printer Alignment.
77
SECTION 4
DISASSEMBLY AND ASSEMBLY
Removing Duplex Feeder Assembly
1.
Disconnect and remove the Top Printer.
2.
Remove Non-operator Side Cover. (6 screws.)
Open Print Engine Access Door.
3.
Remove Feeder End Cover:
[A] Remove 3 screws across bottom of cover.
[B] Remove 2 screws (one on each side
inside Cabinet.)
[C] Remove 2 screws on top.
Remove Cover.
78
SECTION 4
DISASSEMBLY AND ASSEMBLY
4.
Disconnect SW2, ENCOD and MOTOR wire
connectors and unsnap wires from wire clip.
5.
Support Assembly. Remove
2 screws (one on each side)
holding Feeder Pivot Arm to
Duplex Printer Cabinet.
6.
Continue to support
Assembly. Remove 2 screws
(one on each side) holding
Feeder Arms to Duplex
Printer Cabinet.
7.
Carefully remove Duplex
Feeder Assembly from the
Duplex Cabinet.
8.
Reinstall in reverse order.
79
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Duplex Feeder Cover Sensor
1.
80
Remove Upper Non-Operator Side
Cover: Remove (3) screws at top of
Cover. Remove (3) screws from
bottom of Cover.
2.
Remove 1 mounting screw [A]
securing the Sensor to side of
Duplex Feeder.
3.
Cut cable ties [B] as needed to
remove SW2 wiring harness.
4.
Disconnect SW2 wiring harness at SW2
connector [C].
Remove Sensor Assembly.
5.
Reinstall in reverse order.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Removing Duplex Feeder Cover
1.
Remove 4 mounting screws (2 on each
side). Remove Cover.
2.
Reinstall in reverse order.
NOTE: When reinstalling Feeder
Cover, pull up on the Cover as you
tighten screws or Cover may rub
against the Drive Belt and/or not
contact the Feeder Sensor Switch.
Major Components under Duplex Feeder Cover
1.
Roller Shaft Assemblies
2.
Motor Assembly
3.
Duplex Feeder Drive Belt
81
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Duplex Feeder Motor Assembly
1.
Remove Duplex Feeder Cover
(4 screws).
2.
Remove Motor mounting screws [A]
(2 screws).
3.
Disconnect wire harnesses [B].
Cut cable tie if necessary.
Remove Motor Assembly.
4.
Reinstall in reverse order.
NOTE: When reinstalling Feeder Cover, pull up
on the Cover as you tighten screws or Cover
may rub against the Drive Belt and/or not
contact the Feeder Sensor Switch.
Replacing Duplex Feeder Drive Belt
82
1.
Remove Duplex Feeder Cover
(4 screws).
2.
Remove Motor mounting screws [A]
(2 screws). Move Motor Assembly aside.
SECTION 4
DISASSEMBLY AND ASSEMBLY
3.
Remove Bearing Housing Assemblies [B] for the
four Roller Shafts (4 per side).
4.
Remove four Roller Shafts.
5.
Remove Drive Belt.
6.
Install new Drive Belt around Roller Shaft Pulleys
and Idler Pulleys [C] on Roller Shaft Assemblies.
7.
Reinstall the Roller Shaft Bearing Housing
Assemblies.
8.
Install the Feeder Motor Assembly so that the
Motor Pulley is on top of the Drive Belt [D].
Reinstall the Feeder Motor mounting screws.
9.
See “Adjusting Duplex Feeder Drive Belt
Tension” to properly tension the Drive Belt.
83
SECTION 4
DISASSEMBLY AND ASSEMBLY
Adjusting Duplex Feeder Drive Belt Tension
84
1.
Remove Duplex Feeder Cover.
2.
Loosen Idler Roller mounting screw [A].
3.
Slide Idler Roller Assembly up or down to adjust
Belt tension [B].
(Approximately 1/8" of deflection.)
4.
Hold Idler Roller Assembly in place while
retightening Idler Roller mounting screw.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Removing Print Engine
1.
Remove Upper Non-Operator Side Cover:
Remove (3) screws at top of Cover.
Remove (3) screws from bottom of Cover.
2.
Disconnect Network (Ethernet) cable [1] and power
supply cable [2] from MPCA.
3.
Carefully disconnect Wire Harness Connectors
(wire harnesses are labelled):
To MPCA: A, B, C
To DPCA: D
4.
Open Print Engine Access Door [A].
85
SECTION 4
DISASSEMBLY AND ASSEMBLY
86
5.
Lower Duplex Feeder. Unlatch and pull
out Print Engine.
6.
Reach under Print Engine to access and remove
(4) screws securing bottom of Print Engine to
Base Plate.
7.
Carefully lift Print Engine out of
Printer. (Print Engine is entire unit
including Ink Station.)
NOTE: Make sure no wire harnesses
get snagged or pulled while
removing Print Engine.
8.
Reassemble in reverse order.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replace Print Engine Slide Brackets
Remove Print Engine, upper NonOperator side Cover, and Rear Cover.
1.
Remove Print Engine Tray:
Open Print Engine Access Door.
Slide Print Engine Tray out.
Remove screws securing
Mounting Plate to Sliding
Bracket. (3 screws per side.)
2.
Remove Sliding Brackets:
Remove the screws securing the
Sliding Bracket to the Mounting
Bracket. (3 screws per side.)
NOTE: Sliding arms may have
to be extended/retracted to
access all 3 screws.
3.
Install in reverse order.
87
SECTION 4
DISASSEMBLY AND ASSEMBLY
Print Engine Basic Disassembly
Print Engine must be removed from Printer for these procedures. See “Removing Print Engine” on previous pages.
It is also assumed that Ink Tanks, Printhead and Service Station are also removed.
Remove Print Engine Base
Provides access to parts located underneath
Print Engine.
1.
Remove Ink Waste Tray (located below Ink Tanks)
and set aside.
2.
Remove Engine Base. Remove (6) T-10 screws,
(3 on each side) of Print Engine Assembly.
(Set aside for reassembly.)
Print Engine Components – Underside
[A] Peristaltic Pump
[B] Dual Pinch Valve
[C] DPCA Board
[D] Buffer Boxes (3 Sets of 2)
[E] Q/A Chip Assembly for Ink Tanks
(3 – one per Buffer Box).
88
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.
IMPORTANT! Make sure you know where each
Ink Hose connects.
Remove old Pump Assembly.
Install new Pump Assembly:
Plug wire connector into new Pump Assembly Motor
Circuit Board [C].
Attach to Chassis with (4) screws [A].
Cable tie wire harness to assembly (as shown in [B] above).
Attach Ink Hoses in order shown to hose splice connectors
(included with kit) [D].
IMPORTANT! Make sure you know where each
Ink Hose connects for reassembly.
Replacing Dual Pinch Valve Assembly
Remove old Valve Assembly:
[A] Remove (4) screws that secure the Bracket
to the Chassis.
[B] Cut cable tie holding wiring harness to
top flange on Bracket Assembly.
[C] Unplug (2) connectors from Valve Assembly.
[D] Disconnect Ink Hoses.
IMPORTANT! Make sure you know where each
Ink Hose connects.
Remove old Pinch Valve Assembly.
Install new Pinch Valve Assembly:
Plug wire connectors into new Pinch Valve
Assembly [C].
Attach to Chassis with (4) screws [A].
Cable tie wire harness to top flange on Pinch Valve Assembly (as shown in [B] above).
Reattach Ink Hoses in to same connector they were removed from. NOTE: Check that Hoses were not
stretched or damaged when they were disconnected. If damaged, or you have any doubt, cut the damaged
or stretched portion off before installing.
89
SECTION 4
DISASSEMBLY AND ASSEMBLY
Cleaning Dual Pinch Valve Sensors
If “Ink Valve: Unknown” (displays as “?”) appears for
more than a few seconds in the Printer icon on the Status
screen in the Duplex Toolbox, it may indicate that the
Dual Pinch Valve (DPV) Sensors are dirty or blocked.
Print Engine must be removed and turned upside down
for this procedure. See “Removing Print Engine” on
previous pages. It is also assumed that Ink Tanks, Ink
Waste Tray, Printhead and Service Station are removed.
1.
Use canned air to blow debris off
two Sensors [A & B] located on
DPV Sensor PC Board.
2.
As a preventive measure, apply a
small amount of Super Lube Grease
(or Teflon®-based lubricant equivalent) to space
between springs and DPV Adaptor [C & D].
(Requires a small brush or toothpick to reach
these small, tight areas.)
CAUTION
DO NOT GET GREASE ON SURROUNDING
AREAS INCLUDING DPV SENSOR PC
BOARD, SENSORS OR SENSOR FLAGS.
90
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Dual Pinch Valve Sensor PC Board
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. Inserts prevent Sensor PC Board from being misaligned during replacement.
Pinch Valve Wrench holds spring-loaded Pinch Valve Shaft in place while replacing PC Board.
Remove Dual Pinch Valve Assembly.
[A] Remove (4) screws that hold Bracket to the
Print Engine Chassis.
[B] Cut cable tie holding wiring harness to top
flange on Bracket Assembly.
[C] Unplug (2) connectors from
Valve Assembly.
IMPORTANT! Ink hoses are still attached.
Carefully pull Pinch Valve Assembly away from
chassis without kinking or pulling out hoses.
Clean Pinch Valve Sensors PC Board
1.
Secure spring-loaded shaft using Dual Pinch
Valve Wrench included in Kit. Position wrench
exactly as shown.
NOTE: Wrench fits around shaft (as shown).
See that Wrench head and screw head [A] fit
around Pinch Valve housing rib (as shown).
IMPORTANT! This Step keeps spring-loaded
shaft in position when Pinch Valve Motor
Assembly is removed. Make sure Wrench is
positioned correctly before proceeding.
91
SECTION 4
DISASSEMBLY AND ASSEMBLY
92
2.
Remove Motor Assembly. Remove three (3) screws
[A] holding Pinch Valve Motor Assembly on Pinch
Valve Body.
Remove Motor Assembly.
3.
Remove one (1) screw to remove
Pinch Valve Sensor PC Board.
4.
Install new Pinch Valve Sensor PC Board using
screw removed in Step 3.
NOTE: Make sure PC Board is installed flush
against Pinch Valve body.
5.
Install (3) Metal Inserts into Motor Assembly
mounting holes. With rounded end of insert facing
down, press three (3) inserts into Motor Assembly
mounting holes (as shown).
NOTE: Insert is self-aligning, but to ensure it is
evenly aligned with mounting hole, and to prevent
accidental damage, use a flat surface (a flat metal
bar for example) to provide even pressure to press
insert in partially. Use pliers or another tool to
press insert the rest of the way in.
6.
Reinstall Pinch Valve Assembly in
reverse order.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing DPCA Board
[A] Remove (2) screws on outside of Chassis that attach Circuit
Board Bracket to Chassis.
[B] Carefully move DPCA Assembly out to unplug wire harness
connectors. NOTE: Make sure you know which connectors go
with which socket.
[C] Remove (3) screws attaching DPCA to Bracket.
Remove DPCA Board.
Install in reverse order.
93
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Buffer Boxes (3 per machine)
[A] Each Buffer Box is held in place by (2) screws accessed through
Ink Tank Station. Use a long Phillips screwdriver to remove screws
and pull up on box to remove it from chassis.
[B] If necessary, remove
Tubing Inserts (2) from
used Buffer Box and insert
into new Buffer Box.
NOTE: One or both
inserts may stay on Print
Engine or in Buffer Box,
simply make sure you
have both. Put each one in
same color chamber it
came from, ie; blue to
blue, black to black, etc.
[C] Push new Buffer Box down onto ink ports. Attach with (2)
screws from inside Ink Tank Station.
Replacing QA Chip Assembly (3 per machine)
[A] Each QA Chip Assembly is held in place by (1) screw accessed
through center of Chip Assembly. Unplug wire harness from Printed
Circuit Boards.
[B] Remove mounting screw.
Install in reverse order. NOTE: Make sure wire harnesses are
plugged into correct Printed Circuit Board.
Buffer Boxes and QA Chip Assemblies
94
SECTION 4
DISASSEMBLY AND ASSEMBLY
Removing Pen Driver Printed Circuit Assembly (PCA)
Location: Upper Clamshell next to Printhead Cartridge bay.
[A] Remove Pen Driver PCA Cover
(lightly glued in place).
[B] Disconnect (2) Ethernet data cables, then unplug power
connector and Main PCA harness connectors.
[C] Remove (3) screws holding Head Board Mount.
[D] Remove Pen PCA.
[E] Remove (2) screws attaching PCA
to Head Board Mount.
Install in reverse order.
Removing Starwheel Assemblies
Location: Upper Clamshell. Open Print Engine Clamshell
to access two Starwheel Assemblies. One is just inside exit
end of the Clamshell, other one is mounted externally on
Clamshell Frame over Exit Center Plate Assembly.
Removal procedure is similar for both.
External:
[A] Remove (2) screws from the top of the Exit
Wheel Bracket.
[B] Carefully release locking tabs holding Starwheel
Assembly to Clamshell.
NOTE: Locking tabs break easily!
Remove Starwheel Assembly.
Install in reverse order.
95
SECTION 4
DISASSEMBLY AND ASSEMBLY
Internal:
[A] Remove Pen Driver Printed Circuit Board Cover.
[B] Remove (2) screws from bottom of Pen Driver
Printed Circuit Board bay.
[C] Locate and carefully release (2) black locking tabs
holding Starwheel Assembly to metal bracket.
NOTE: Locking tabs break easily!
Remove Starwheel Assembly.
Install in reverse order.
Replacing Ink Tank Latches
Remove Ink Tanks before replacing latches. See “Replacing Ink Tanks” in Maintenance Section.
Printer must be flat on a level surface.
[A] Lift latch.
[B] Remove (2) screws located on underside of
latch hinge block. (May require a mirror to
find screw heads.) Remove Latch Assembly.
CAUTION
SPRING-LOADED LATCHES.
WATCH THAT SPRINGS
DO NOT FLY OFF.
96
SECTION 4
DISASSEMBLY AND ASSEMBLY
Main Printed Circuit Assembly (MPCA) Cover
Removing Main Printed Circuit Assembly Cover
To access parts on Print Engine Clamshell, MPCA Panel Cover must be removed and Panel folded out of the way.
1.
Remove (4 or 5) screws to remove Cover.
Set Cover aside.
NOTE: End Panel screws intentionally left
off to improve accessibility.
2.
Remove two (2) mounting screws from
bottom of MPCA Panel.
3.
Fold Main Printed Circuit Assembly down
out of the way.
NOTE: Be Careful! DO NOT pull, pinch or
strain wiring harnesses.
97
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Encoder or Encoder Sensor
[A] Remove (3) screws holding Encoder Cover.
[B] Unplug wire harness from Encoder Sensor.
[C] Carefully pivot Cover away from Encoder Wheel.
Be careful of spring.
[D] Remove (2) screws holding Encoder Sensor in place and
pull away from Encoder Wheel.
NOTE: Be careful not to damage Wheel.
[E] Remove single screw holding Encoder Wheel to Roller
Shaft. Remove Encoder Wheel Assembly.
NOTE: Be careful of tension spring and washers located on
Shaft behind Encoder Assembly.
Install in reverse order.
Replacing Service Station Lifter Arm Sensor
[A] Unplug wire harness from Lifter Arm Sensor.
[B] Remove (1) screw holding Sensor to Print Engine Frame.
[C] Slide Sensor out of retainer clip. Remove Sensor.
Install in reverse order.
98
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Paper Path Motor or Drive Belt
[A] Remove (2) screws that attach Motor Assembly to lower Print
Engine Clamshell. Pull Motor straight out so Motor Pulley clears
Drive Belt.
NOTE: If removing Motor, unplug two wire connectors.
[B] If removing Drive Belt, remove Encoder Assembly (see
“Replacing Encoder or Encoder Sensor”). Remove Drive Belt.
[C] Install Drive Belt and/or Motor in reverse order.
See “Adjusting Paper Path Motor Drive Belt Tension” on next
page. NOTE: Make sure that Belt stays inside raised edges of
Motor Pulley and Roller Studs.
99
SECTION 4
DISASSEMBLY AND ASSEMBLY
Adjust Paper Path Motor Drive Belt Tension
[A] Loosen Drive Belt Tensioner Locking Screw.
[B] Push and release Belt Tensioner Roller to release
tension on Drive Belt.
[C] Use your finger to push belt clockwise
one full revolution around rollers.
NOTE: This equalizes tension around full length of
Drive Belt.
[D] Use Drive Belt Tension Tool
(P/N 42-110-54).
Position Tool between two pulleys as shown
(so point presses on Drive Belt.)
NOTE: In place of tool, you can use your finger to
deflect belt 1-2mm (3/64-5/64").
[E] With Tool in place (or while applying pressure
with your finger), tighten Drive Belt Tensioner
Locking screw.
100
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Belt Drive Gear Pulleys
There are three. One is mounted on Exit Grit Roller Shaft, one is located behind Encoder Assembly on another
Grit Roller Shaft and one is mounted on Entry Grit Roller Shaft. First, you may need to loosen or remove
Drive Belt, see “Replacing Paper Path Motor or Drive Belt”.
Exit Grit Roller Gear Pulley
[A] Remove Paper Path Motor.
See “Removing Paper Path Motor”.
[B] Remove screw, washer, C-clip and plastic washer from end of
Exit Grit Roller Shaft. (Note order for reassembly.)
[C] Remove Pulley from Shaft.
Install in reverse order.
NOTE: Align slot on Pulley with pin in Shaft before installing.
Encoder Grit Roller Gear Pulley
[A] Disconnect and remove Encoder Assembly.
See “Removing Encoder and Sensor Assembly”.
[B] Remove washer, tension spring, thin washer, washer and
plastic washer from end of Grit Roller Shaft.
(Note order for reassembly.)
[C] Remove Pulley from Shaft.
Install in reverse order.
NOTE: Align slot on Pulley with pin in Shaft before installing.
Entry Grit Roller Gear Pulley
[A] Remove screw, washer, C-clip and plastic washer from end of
Grit Roller Shaft. (Note order for reassembly.)
[B] Remove Pulley from Shaft.
Install in reverse order.
NOTE: Align slot on Pulley with pin in Shaft before installing.
101
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Lifter Motor Assembly or Lifter Gear
Remove Lifter Motor Assembly Only
[A] Unplug wire harness from Lifter Motor Assembly.
[B] Remove (2) screws holding Motor Assembly to Motor
Assembly Bracket.
[C] Gently remove Motor Assembly. Take care that Worm Gear
does not damage Lifter Gear.
Install in reverse order. NOTE: Make sure Worm Gear and
Lifter Gear are engaged correctly. Apply a small amount of gear
lube to Lifter Gear.
Remove Lifter Motor Assembly and Lifter Gear
[A] Remove (2) screws holding Lifter Motor
Assembly Bracket.
[B] Unplug wire harness from Lifter Motor.
[C] Remove C-clip located on end of shaft.
[D] Unpin pegs and turn (2) plastic bayonet
bearings to release Motor Bracket.
[E] Remove (2) C-clips (one on either side) of
Lifter Gear.
[F] Slide Lifter Motor Assembly and Lifter Gear
off of shaft.
Install in reverse order.
NOTE: Make sure Worm Gear and Lifter Gear are
engaged correctly. Apply a small amount of
synthetic gear lube to Lifter Gear
(Super Lube 21030 or equivalent).
102
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Stepper Motor
[A] Remove (2) screws.
[B] Unplug wire harness from Stepper Motor
Printed Circuit Board.
[C] Note position of motor gears to make sure
gears will mesh with Service Station gear
(if Service Station is installed.)
Install in reverse order.
103
SECTION 4
DISASSEMBLY AND ASSEMBLY
Lubricating Grit Roller Ground Clips
Three Ground Clips are located on right side of Print Engine, at ends of Grit Roller Shafts.
To access them, remove Lifter Motor and Stepper Motor. See “Replacing Lifter Motor” and
“Replacing Stepper Motor” on previous two pages.
104
1.
Once Stepper Motor is removed, carefully
remove Stand and Gear mounted behind it.
2.
Loosen, but do not remove, T10 mounting
screw on all (3) Ground Clips.
[A] Two behind Stepper Motor.
[B] One behind Lifter Motor.
3.
Use a small, flathead screwdriver to remove
e-clip, washer and spring from end of shaft(s).
4.
Use a foam swab to apply a thin film of
conductive grease (Loctite 38650 or equivalent)
to washers and ground spring.
5.
Reinstall washers, spring and e-clip on Roller Shafts.
6.
Align Stepper Motor with Gear and Stand hardware.
7.
Reinstall Stepper and Lifter Motors.
SECTION 4
DISASSEMBLY AND ASSEMBLY
Clamshell Assembly
Provides access to parts under Clamshell Assembly.
Removing Clamshell Assembly
1.
Remove (4) screws attaching Clamshell to
Chassis (1 at each corner).
2.
Gently lift Clamshell from Chassis.
Take care not to pinch or damage any
wires or Ink Hoses.
NOTE: Remember to reinstall ground cable
when reattaching Clamshell Assembly to
Chassis. Check that no wires or hoses are being
snagged or pinched.
IMPORTANT
Check Clamshell Assembly Alignment:
[1] Check that the Clamshell Assembly is
properly aligned on the Print Engine Base.
[2] Measure that the distance from the front
edge of Print Engine Base to both front
corners of the Clamshell Assembly are
equal. [3] Loosen the Clamshell mounting
screws and adjust as necessary.
Clamshell Assembly Components – Underside
[A] Service Station PCA Sled
[B] Wiper Motor PCA and Flex Cable
[C] Wiper Lifter Arms (Left & Right)
[D] Segmented Grit Shaft
[E] Service Station Drive Shaft
[F] Cam Shaft Assembly
105
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Service Station Sled Printed Circuit Boards
[A] Remove (2) screws.
[B] Carefully disconnect (2) connectors.
[C] Swing Sled away from Clamshell and turn over. Carefully
unclip two Printed Circuit Boards.
Install reverse order. NOTE: Make sure wire harnesses are
plugged into correct Printed Circuit Board.
Replacing Wiper Motor Flex Cable PCA
[A] Carefully unclip Printed Circuit Board from Holder and turn it
over. NOTE: Tabs break easily.
[B] Disconnect Ribbon Cable. Slide Latch open on Circuit Board
to release Ribbon Cable.
[C] Disconnect Wiring Harness.
Install in reverse order. NOTE: Make sure ribbon cable and
wiring harness are plugged in correctly.
106
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Duplex Exit Sensor
Located under left side exit end of the Print Engine.
1.
Open the Print Engine Access Door.
2.
Lower the Duplex Feeder.
3.
Unlatch and pull out Print Engine.
4.
[A] Release two Latches.
Open Print Engine Clamshell.
[B] Remove (2) screws from Operator side of
Exit Center Plate Assembly.
[C] Loosen (1) screw.
5.
[A] Remove (1) screw from non-operator side of
Exit Center Plate Assembly.
[B] Loosen (1) screw.
107
SECTION 4
DISASSEMBLY AND ASSEMBLY
6.
Detach Exit Roller from Operator side.
NOTE: Be careful not to drop or lose bearing.
Then pivot Exit Center Plate up out of the way.
(Sensor is on underside of Center Plate).
7.
[A] Remove Exit Sensor mounting screw (1 screw).
[B] Carefully pull Exit Sensor away from mounting
bracket. DO NOT strain or damage the Sensor
wire harness.
[C] Turn Exit Sensor over and disconnect the
wiring harness.
Install in reverse order.
108
SECTION 4
DISASSEMBLY AND ASSEMBLY
Replacing Duplex Entry Sensor
Entry Sensor consists of a Receiver
(located in lower Clamshell) and an
Emitter (on upper Clamshell).
NOTE: For easier access to the
Sensors, remove the Print Engine
Media Entry Assembly [A] (2
screws). Cut the wire tie holding the
upper and lower sensor wire
harnesses together. Carefully move
Assembly away from the Print Engine.
DO NOT strain or damage the Sensor wire harnesses.
Receiver (Located under the Media Entry Assembly):
[A] Remove (2) screws.
[B] Carefully pull Receiver away from the
mounting bracket.
[C] Disconnect wiring harness.
Install in reverse order.
Emitter (Located on top of the Media Entry Assembly):
[A] Remove mounting screws (2 screws).
[B] Carefully pull Emitter away from mounting bracket.
[C] Turn Emitter over and unplug wiring harness.
Install in reverse order.
109
SECTION 4
DISASSEMBLY AND ASSEMBLY
Reinstall Main Printed Circuit Board Assembly
110
1.
Gently lift up Wiring Panel. NOTE: DO NOT pinch or
cut wires running through Frame.
2.
Reinstall two (2) mounting screws into bottom
of MPCA Panel.
3.
Reinstall Cover (4 screws).
SECTION 5
MAINTENANCE
SECTION 5 - Maintenance
General, periodic maintenance is needed to keep 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. NOTE: High volume usage may require more frequent maintenance.
Maintenance Supplies & Equipment: Flashlight, small telescoping mirror, hard-bristled toothbrush, tweezers,
small flathead screwdriver, powder-free nitrile gloves, protective clothing and eyewear, vacuum with wand,
deionized/distilled water, Super Lube 21030 synthetic grease (or equivalent), Loctite 38650 copper anti-seize
(or equivalent), can of compressed air, foam or lint-free cotton swabs, lint-free wipes, disposable shop towels.
AS NEEDED MAINTENANCE (Depending on Printer usage)
Cleaning (Remove media fibers and ink residue):
Media path, Service Station (Wiper Roller, Platen)
Ink Revolver Couplings
Inspect and clean after every Printhead removal.
Printhead
Wipe as needed to maintain print quality.
Printhead Pen Driver PCA
Clean contacts after every Printhead removal.
Lubrication
Service Station (Cams, Lifting Arm pivot points and Guide Tracks),
Lift Motor Gear
Replacement
Wiper Roller, Ink Waste Tray, Ink Revolver Couplings, Tubing, Belts.
DAILY MAINTENANCE
Media Path
Clean manually prior to installing, after paper jams and when
automated servicing does not clear nozzles.
Clean to remove excess ink residue and debris.
Print Engine: System Components, Paper Path
surfaces (upper and lower)
Clean to remove excess ink residue and debris.
NOTE: DO NOT wipe Starwheel Assemblies.
Printhead
Clean after: Installing and priming, removing and replacing, priming
or repriming, contamination.
Service Station:
Capping Station and Platen
Empty/clean excess ink residue and debris.
Ink Cartridge(s)
BI-WEEKLY MAINTENANCE
Encoder Disk (Z2i Print Engines with exposed
Encoder Disks only)
Media Sensors
Clean spattered ink or residue.
Clean to remove excess ink residue and debris.
Print Engine
Clean to remove excess ink residue and debris.
Wiper Roller, Cap Station Seal
Inspect for proper operation and wear.
MONTHLY MAINTENANCE
Grit Rollers
Inspect for proper operation and residue build-up.
Ink Tubing, Connections, Peristaltic Pump,
Pinch Valve & Vents, Buffer Boxes, Ink
Revolver Couplings
Ink Waste Tray
Lift Motor Gear
Inspect for leaks, kinks, pinches, proper operation.
Inspect for excessive ink saturation or leakage.
Inspect for proper operation, debris and wear.
YEARLY MAINTENANCE
Check Firmware Version
Verify latest version and update if needed.
Grit Rollers
Clean to remove excess ink residue and debris.
Ink Tank Latches/Ink Tank Bay
Inspect for proper operation, wear, debris, leakage.
Inspect Moving Parts: Media Path, Pump, Pinch
Valves and Service Station
Verify smooth operation. Listen for unusual noise indicating damage
or wear.
Lubrication
Lifter Motor Gear, Grit Roller Ground Springs and Washers,
Service Station (Cams, Lifting Arm pivot points, Wiper Roller Gears,
Guide Tracks)
Service Station: Wiper Roller, Sled Assembly,
Clean to remove excess ink residue and debris.
111
SECTION 5
MAINTENANCE
WARNING!
ALWAYS POWER DOWN 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.
• DISPOSE OF ALL MAINTENANCE WASTE IN ACCORDANCE WITH LOCAL REGULATIONS.
Replacing Ink Tanks
Replace Ink Tanks when ink runs out.
112
1.
Open Printer Toolbox. System Status information
appears on right side of System Status window.
Ink Cartridge status boxes “C, K2, Y, M, K1” are
on the left. The boxes may be low or empty.
2.
Click “Service” drop-down menu. Select “Bottom Unit” and
“Replace Ink Tanks”. (Disconnects Printer communication
with Ink Tanks and allows safe installation and replacement.)
Once “Confirm” screen displays, it is safe to remove Ink Tanks.
IMPORTANT: DO NOT press “Continue” until after you
have removed and replaced Ink Tank(s) and closed Ink
Tank Latches.
3.
Lower Duplex Feeder.
Open Print Engine Access Door on Duplex
Printer. Unlatch and pull out Print Engine.
Open three Latches [A] and pull Ink Tank(s)
out of Printer.
4.
Remove new Ink Tank(s)
from packaging.
SECTION 5
MAINTENANCE
5.
Insert new Ink Tanks (labels up) into
appropriate color slots [B].
Close three Ink Tank Latches.
INSTALLATION TIP: Make sure
Ink Tanks seat properly. Insert Ink Tank
into appropriate Ink Station, then pull Ink
Tank back about an inch and push forward
firmly to insure that Ink Nozzles penetrate
seals on Ink Tanks.
6.
Click “Continue” on Confirm screen. Click
“Service” drop-down menu. Select “Bottom
Unit” and “Refresh Ink Levels”. Ink colors fill
in as Ink Tanks are installed. If ink colors do not
fill in after a few seconds, click “Replace Ink
Tanks” again and reinstall Ink Tank(s).
NOTE: If Ink Tank is installed, but Ink Tank indicator
still does not refresh, see “Cleaning Ink Tank Contacts”
on next page.
7.
When Printer stops processing and all fields in System Status
are black, Printer is ready for use.
8.
Slide and latch Print Engine back into cabinet.
Close Print Engine Access Door. Return Duplex
Feeder to double-sided printing position.
WARNING!
Ink in Ink Tanks may be harmful if swallowed. Keep new and used Ink
Tanks out of reach of children. Discard empty Ink Tanks immediately.
113
SECTION 5
MAINTENANCE
Cleaning Ink Tank Contacts
When reinstalling or replacing Ink Tanks; Ink Level indicator in Toolbox may not refresh. This may be due to a
dirty Ink Tank Level Prism and/or QA Chip contacts on that Ink Tank(s).
Clean contacts as follows:
114
1.
Remove Ink Tank(s). Open Toolbox. Click “Service”
drop-down menu. Select “Bottom Unit” and “Replace
Ink Tanks”. Once “Confirm” window opens, it is safe
to remove Ink Tanks.
IMPORTANT: DO NOT press “Continue” until
after removing and replacing Ink Tank(s) and
closing Ink Tank Latches.
2.
Lower Duplex Feeder. Open Print Engine Access Door on Duplex Printer. Unlatch and pull out Print
Engine. Release Ink Tank Latch(es) [A]. Remove Ink Tank(s) [B] that did not refresh.
3.
Clean Ink Level Prism [A] and QA Chip contacts [B] with a
clean, dry, lint-free cloth.
NOTE: Dampen cloth with distilled water to wipe Prism,
but DO NOT get QA Chip contacts wet.
SECTION 5
MAINTENANCE
4.
Click “Service” drop-down
menu. Select “Bottom Unit” and
“Refresh Ink Levels”. Ink colors
fill in as Ink Tanks are installed.
If ink colors do not fill in after a
few seconds, click the “Replace
Ink Tanks” again and reinstall
Ink Tank(s).
5.
Slide and latch Print Engine back into cabinet.
Close Print Engine Access Door. Return Duplex
Feeder to the double-sided printing position.
Storage
New Ink Tanks should be stored in original packaging and kept away from heat.
Opened Ink Tanks should remain in Printer.
Nominal Ink expiration date: 24 months following date of manufacture (ink fill date).
Disposal
Safely dispose of Ink and Ink Tanks in accordance with local/national regulations.
Clean up spills with soap and water. Abrasive soap is effective in cleaning ink off your hands.
115
SECTION 5
MAINTENANCE
Cleaning/Replacing Printhead Cartridge
Cleaning
Printhead Cartridge is cleaned automatically each time Printer is turned on or when “Quick Clean Printhead”
routine is performed. (Found under Service Tab, “Quick Clean Printhead” in Printer Driver or “System Status”
screen in Printer Toolbox.) “Normal Clean Printhead” and “Full Clean Printhead” can be used to more
thoroughly clean or clear Printhead.
If using the automated Cleaning Levels doesn’t help improve print quality, the Printhead Cartridge can also be
cleaned manually:
1.
Lower Duplex Feeder.
Open Print Engine Access Door on Duplex Printer.
Unlatch and pull out Print Engine.
2.
Release and lift up two latches at same time to raise Print
Engine Clamshell.
3.
Moisten Printhead nozzles [A] using deionized/distilled
water (reference ASTM D5127-90 Type E-II Electronic Grade
Water) and a damp, lint-free cloth, wiping end to end. (Gray
strip located below orange strip.) Take care not to damage
copper contacts, metal plate, or gold Printhead surface.
4.
Close and relatch Print Engine Clamshell.
Generally, when ink supply is adequate and print quality remains poor, or when automated cleaning processes or
manually cleaning Printhead does not help image quality, replace Printhead.
CAUTION
116
•
Use electrostatic discharge (ESD) protection when handling.
•
Hold Printhead Cartridge by handles ONLY.
•
DO NOT touch ink couplings, nozzle surface or electrical contacts.
•
DO NOT unpack Printhead Cartridge until Printer is ready for
installation. Once unwrapped, delay in installing Printhead can
compromise print quality due to dehydration.
•
DO NOT place an unwrapped Printhead on any surface before
installing. Protect Printhead from scratches, dust, fibers, dirt and
other contaminants at all times.
SECTION 5
MAINTENANCE
Replacing Printhead Cartridge
1.
Open Duplex Toolbox. On System Status
screen, System Status information appears
on the right side.
2.
Lower Duplex Feeder. Open Print Engine Access Door on
Duplex Printer. Unlatch and pull out Print Engine. Press
Printhead Latch Release button [1]. Printer pumps any ink in
system back into Tanks. Then Printhead Latch pops open [2].
NOTE: Perform this same function from your computer
by clicking “Printhead Release” in the “Service” dropdown menu on the System Status screen.
CAUTION
DO NOT PRY OR MANUALLY LIFT PRINTHEAD
LATCH OR LATCH MAY BREAK. ONLY OPEN
LATCH USING PRINTER'S RELEASE BUTTON
OR PRINTHEAD RELEASE COMMAND IN
PRINTER TOOLBOX.
3.
Make sure Printhead Latch is fully opened to retract ink lines.
Remove used Printhead Cartridge by tilting it toward ink lines
[3], then carefully lifting it out of Printhead Compartment.
117
SECTION 5
MAINTENANCE
4.
[A] Carefully remove Printhead
Cartridge from foil packaging.
Tear foil at notch or cut the end
with scissors.
[B] Remove protective plastic
cover. Hold Printhead by handle
and unclip cover from Printhead.
[C] Remove protective strip from
Printhead electrical contacts.
Once removed, DO NOT allow
strip to touch electrical contacts.
[D] Remove protective strip from
Printhead Nozzles. Hold Printhead
by handle. Pull strip tab and slowly
peel strip from Printhead.
DO NOT pull strip at less than a
45° angle from Printhead surface.
DO NOT allow removed strip to
touch Printhead Nozzles.
NOTE: Keep foil packaging to
store/dispose of old Printhead Cartridge.
5.
118
Carefully insert Cartridge into compartment at an angle
[4], with Printhead surface facing down and Ink Nozzles
facing Ink Hoses. Once seated, gently tilt Cartridge back
until it snaps into an upright position [5].
DO NOT FORCE Printhead Cartridge into position.
SECTION 5
MAINTENANCE
6.
Wet Printhead Surface [A]. (Ensures that Printhead
will prime correctly.)
Release and lift two latches at same time to raise
Print Engine Clamshell. Moisten Printhead nozzles
using distilled water and a damp, lint-free cloth,
wiping end to end. (Gray strip located below orange
strip.) Close and latch Print Engine Clamshell.
CAUTION
HOLD ONTO BOTH LATCHES WHEN
OPENING AND CLOSING PRINT ENGINE
CLAMSHELL TO PREVENT DAMAGE.
DO NOT ALLOW CLAMSHELL TO DROP
OR SLAM CLOSED.
TO PREVENT DAMAGE TO INK LINES, A
STOP LIMITS RAISING CLAMSHELL
MORE THAN 60°.
7.
Close Printhead Latch [6]. Slide the Print Engine into
the cabinet and latch it. Close Print Engine Access Door.
Return Duplex Feeder to the double-sided printing position.
Printer starts up and primes ink into Printhead.
(May take a few minutes.) Make sure
ink is flowing through hoses. If air bubbles
appear, you may have to tap lines or click
“Circulate Ink” in Printer Toolbox under
“Maintenance” to clear them.
8.
Watch Printer Status screen. Notice
some information is in red. As the
Printer circulates ink and primes system
these fields should all turn black. Check
that the Printhead icon [7] in Duplex
image is primed (solid color).
9.
When ONLINE [8] appears, Printer is
ready for use.
NOTE: If the Printhead icon continues
to display an outline or a question mark
(?) try the following procedures:
[1] Printhead icon shows an outline (Printhead unprimed): Click “Circulate Ink” under
“Maintenance” drop-down in Printer Toolbox. If issue persists, try the “Install Printhead”
procedure again. If the issue continues, contact technical support.
[2] Printhead icon displays a question mark (Printhead not recognized): Try the “Install
Printhead” procedure again. If the issue continues, contact technical support.
IMPORTANT!
CHECK INK TANKS. PRINTER MAY NOT FULLY
REPRIME IF TANKS ARE LESS THAN 1/3 FULL.
NOTE: Printer may take up to 12 minutes to set itself up during initial startup. This is normal.
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SECTION 5
MAINTENANCE
Printhead Storage
Store and transport cartridge as indicated by “this side up” arrow symbol
on packaging.
Cartridge and ink supply must be within operating temperature range before
attempting to prime cartridge with ink and starting to print. When stored at
temperatures below operating range it may take up to 3 hours for a cartridge
in its packaging to reach operating temperature. NOTE: Additional
packaging will increase time needed to reach operating temperature.
Storage Life: 12 months from date of manufacture (printed on shipping box).
Storage Temperature Range:
Long Term: 14° F to 86° F (-10° C to 30° C)
Short Term: -11° F to 140° F (-25° C to 60° C)
NOTE: Cumulative storage duration above 86° F (30° C)
must not exceed 72 hours.
Humidity Range:
5% to 95% Relative Humidity, non-condensing
Atmospheric Pressure Range:
70 kPa to 106 kPa
Electrostatic Discharge:
8 kV air discharges or 4 kV contact discharges*
*When tested in accordance with IEC 61000-4-2
Printhead Service Life
Projected: 50,000,000 ejections per nozzle. Printhead has a total of 70,400 nozzles (14,080 per color channel.)
Since printing does not use entire length of Printhead, some nozzles do not fire as often. The most often used
Nozzles will degrade more quickly. Noticing effects of failing nozzles depends partly on the relative position of
those nozzles to each other. In simple terms, number of images printed and amount of ink that will pass through
printhead prior to printhead degradation will depend on make-up of the images printed, operating environment,
servicing, media characteristics (including cleanliness) and other factors.
120
SECTION 5
MAINTENANCE
Cleaning/Replacing Ink Revolvers
First Deprime system and remove 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 (labeled).
IMPORTANT! Make sure you replace Valve side Ink Revolver in
Valve side and Pump side in Pump side.
1.
Remove Cover by squeezing sides to release tabs.
Lift Cover out and set aside.
NOTE: Cover does not have to be removed to clean Ink
Revolver Couplings.
Cleaning Ink Revolver Couplings
1.
Moisten a foam swab in distilled water.
2.
Insert swab into an ink channel and rotate swab
to clean chamber.
3.
Use a new swab for each of remaining ink channels
until all 10 openings are clean.
(5 on Valve side, 5 on Pump side)
Replace Ink Revolvers
1.
Route hose leads from new Revolver through same frame cutout
as existing hoses.
2.
Work one hose at a time: Carefully match, cut and connect
existing Ink Hoses to hose leads on new Ink Revolver. Trim hose
leads to fit as needed. Use hose connector barbs included in kit.
IMPORTANT! Do not mix colors! Ink Hoses, including two
black Ink Hoses, are NOT interchangeable!
121
SECTION 5
MAINTENANCE
122
3.
Once all hoses have been connected to new Ink Revolver, remove
C-Clip from hinge pin holding Ink Revolver. Remove pin.
4.
Slide old Ink Revolver forward in its track and remove.
5.
Slide new Ink Revolver back in its track and align yoke
on rear with hinge bracket. Make sure new Revolver is
turned correctly.
6.
Reinstall Pin and C-clip.
7.
Reinstall Ink Revolver Cover.
SECTION 5
MAINTENANCE
Cleaning Pen Driver Printed Circuit Board Contacts
Clean Printed Circuit Board contact pins that
connect with Printhead Cartridge.
1.
Remove Printhead Cartridge.
Locate contact pins along base of
Pen Driver Printed Circuit Board.
(Positioned opposite Ink Revolvers.)
2.
Dampen a new, lint free cloth in
deionized/distilled water.
3.
Use a very gentle up and down
motion to clean contact pins.
NOTE: Hold down plastic cover to keep
moisture away from rest of Circuit Board.
CAUTION
CONTACT PINS ARE EASILY BENT
OR DAMAGED!
USE ONLY A VERY GENTLE UP AND
DOWN MOTION FOR CLEANING.
BENT PINS CAN DAMAGE
PRINTHEAD AND CIRCUIT BOARD.
123
SECTION 5
MAINTENANCE
Replacing Printhead Latch
Printhead Latch is easily broken if forced open manually. Tools & Supplies needed: nitrile powder-free gloves,
needle nose pliers or tweezers, small flathead screwdriver.
Remove Printhead Latch
124
1.
Open Printer Toolbox.
Open “Service” drop-down menu.
Select “Bottom Unit” and click
“System Deprime”.
2.
Click “Release Printhead” to release the
Printhead Latch.
3.
Once Latch pops up, click “Shutdown” to
shut down the Duplex Printer.
4.
Lift Latch manually to access two
Latch Springs.
5.
Remove Printhead Cartridge by tilting it
toward ink lines, then carefully lifting it out
of Printhead Compartment. Place in a
protective packaging cap.
SECTION 5
MAINTENANCE
6.
Use needle-nose pliers or tweezers to gently pull
rounded end of Spring out from beneath plastic tab in
housing and remove Spring. Repeat procedure to
remove second Spring.
7.
Gently insert a small, flathead screwdriver between blue
Printhead Latch Pin and black plastic hinge [A] and
rotate to pop Printhead Latch out of hinge without
damaging either piece.
CAUTION
BE CAREFUL. Black Plastic Hinge breaks
easily. Use only gentle pressure when
removing/installing Printhead Latch Pin.
8.
Other side should easily slide out of hinge.
9.
Discard Printhead Latch according to
local regulations.
Install new Printhead Latch:
1.
Align right tab of Latch with right hinge and gently press into place.
Repeat for left side.
2.
[A] Use needle-nose pliers to install right Spring into
plastic tab in base of housing.
NOTE: Be sure to position Spring (as shown).
[B] Use needle-nose pliers to position other end of Spring into notch
in Printhead Latch.
3.
Repeat Steps 2A and 2B for left side.
4.
Remove Printhead from protective cap. Wipe Printhead surface
according to standard installation procedure, then install.
5.
Restart Printer.
6.
Manually close Printhead Latch until it clicks. Printer will
automatically prime and be ready for testing.
NOTE: If Printhead Latch is closed with system powered down, Printer will not prime automatically.
125
SECTION 5
MAINTENANCE
Testing
126
1.
Restart Printer if necessary.
2.
Open Printer Toolbox. Select “Print” drop-down
menu. Click “Print Color Bars” to confirm that unit
is functioning properly.
SECTION 5
MAINTENANCE
Replacing Printhead Latch Solenoid
To replace Lever Latch Solenoid:
Remove Printhead Latch Solenoid
1.
Open Printer Toolbox. Open the “Service”
drop-down menu. Select “Bottom Unit” and
click “System Deprime”.
2.
Click “Release Printhead” to release Printhead Latch.
3.
Once Latch pops up, click “Shutdown” to shut down
the Duplex Printer.
4.
Lift Latch manually to access Solenoid and Latch
Support Base.
5.
Remove Printhead Cartridge by tilting it toward ink lines,
then carefully lifting it out of Printhead Compartment.
Place in protective packaging cap.
6.
Remove five (5) screws securing
Latch Support Base Assembly to Print
Engine frame.
127
SECTION 5
MAINTENANCE
7.
Remove two (2) screws securing Solenoid to
Base Assembly.
8.
Cut two cable ties [A]. Unplug Solenoid connector [B]
from wiring harness.
9.
Carefully lift Base Assembly just enough to remove
Solenoid assembly from under Base Assembly.
10. Install new Solenoid.
Reassemble in reverse order.
128
SECTION 5
MAINTENANCE
Replace Upper and Lower Clamshell Latch Pins
Upper and Lower Latch Pin Kits replace Print Engine Clamshell Latch Pins that may be bent or broken.
Replace Upper Latch Pins
Upper Latch Pin Kit consists of:
(1) Latch Pin, (1) 5/64 Allen screw.
NOTE: Check that Latch Pins are pressed in on
your Printer. Some versions have welded pins that
cannot be replaced.
Tools Needed: Small T10 x 80 screwdriver, 5/64 hex head screwdriver, small
wire clippers, small semi-round file and (2) small cable ties.
1.
Power down and and unplug Printer.
Open Print Engine Access Door. Unlatch and pull out Print Engine.
2.
Release two Latches and open Print Engine Clamshell.
3.
Remove Upper Exit
Wheels Assembly.
Remove (1) T-10
screw on each side.
Remove mounting
blocks and Wheel
Assembly.
4.
Remove Pen Driver Cover. Cover is glued in place along top
edge of Print Engine frame crossmember. Carefully slide tip of a
small flat blade screwdriver under Cover lip to separate it from
crossmember. Remove Cover.
129
SECTION 5
MAINTENANCE
130
5.
Cut and remove 2 cable ties holding wire harness to Print Engine
Frame Crossmember.
6.
Remove Latch Levers (both sides). Carefully remove C-clip
holding Latch Lever onto Upper Latch Pin.
DO NOT LOSE! Must be reinstalled later.
Repeat procedure for Latch Lever on other side.
7.
Slide Latch Lever and Spring off of Upper Latch Pin.
NOTE: (May have to separate Lever from Spring.)
Repeat procedure on other side.
8.
Remove Print Engine Frame Crossmember.
Remove 3 screws securing crossmember to Print Engine Side
Frame. Repeat procedure for other side.
9.
Carefully pull Side Frames away from crossmember to slide it
off lower mounting pins. Pivot bottom of crossmember up.
Then carefully remove crossmember from upper mounting pins.
SECTION 5
MAINTENANCE
10. Use small file to enlarge
and round out cutouts
located on upper edge of
cross-member.
NOTE: This is done so
crossmember will fit
around mounting
screw for new Latch
Pin. If only replacing
one Latch Pin, you
only need to modify
that side of crossmember.
CAUTION
DO NOT allow any metal filings to fall inside Print Engine or Printer.
11. If necessary, remove old Latch Pin with pliers.
12. Install new Upper Latch Pin using socket head screw supplied
with kit. (Make sure Pin stays straight as you install it.)
13. Reinstall crossmember. Remember to
install crossmember over upper side frame
pins first; then pivot crossmember down to
fit over lower side frame pins.
NOTE: If enlarged cutout(s) do not fit
over new Latch Pin screw head(s),
remove crossmember and continue filing
as needed. Once crossmember fits
correctly, reinstall 3 mounting screws on
each side.
131
SECTION 5
MAINTENANCE
14. Slide Latch Lever Spring onto Latch Pin. Then slide Latch
Lever for that side onto Pin.
Repeat procedure for other side.
15. Maneuver spring so upper arm fits under tab on Side Frame.
Lower spring arm fits over tab on Latch Lever.
NOTE: This can be tricky, you may require two small flat
blade screwdrivers or other tools to snap lower spring end
over Lever tab.
Repeat procedure for other side.
16. Reinstall C-clip that secures Latch Lever to Upper Latch Pin.
Repeat procedure for other side.
17. Replace two cable ties that secure wire harness to crossmember
(removed in Step 5.) Trim excess.
132
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MAINTENANCE
18. Reinstall Pen Driver PCA Cover.
NOTE: If adhesive on Cover lip no longer sticks, you can use
thin double-sided tape or adhesive transfer tape secure it to top
of crossmember.
19. Reinstall mounting
blocks and Exit
Wheels Assembly.
20. Close Upper Clamshell.
Slide and latch Print Engine into cabinet.
Close Print Engine Access Door.
133
SECTION 5
MAINTENANCE
Replace Lower Latch Pins
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 Latch Pins are pressed in on your Printer.
Some versions have welded pins that cannot be replaced.
8.
Open the Print Engine Access Door.
9.
Lower the Duplex Feeder.
10. Unlatch and pull out Print Engine.
INSTALL LOWER LATCH PIN
11. [A] Release two Latches.
Open Print Engine Clamshell.
[B] Remove (2) screws from Operator side of
Exit Center Plate Assembly.
[C] Loosen (1) screw.
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SECTION 5
MAINTENANCE
12. [A] Remove (1) screw from non-operator side of
Exit Center Plate Assembly.
[B] Loosen (1) screw.
13. Detach Exit Roller from Operator side.
NOTE: Be careful not to drop or lose bearing.
Then pivot Exit Center Plate up out of the way.
14. Remove C-clip from Latch Roller, then slide Latch Roller off old Latch
Pin. Keep C-clip and Latch Roller for reinstallation.
15. Remove Latch Pin with pliers.
NOTE: Only works if Latch Pin is press fit. If Latch Pin is welded,
this procedure will not work.
16. Align new Latch Pin with existing hole.
Attach with Allen screw.
17. Reinstall Latch Roller and secure with C-clip.
18. Reinstall Exit Roller and Exit Center
Plate screws.
135
SECTION 5
MAINTENANCE
Cleaning/Replacing Service Station
Service Station [A] (located above Ink Tank Station) cleans Printhead Cartridge of excess ink and debris, keeps
Printhead hydrated and protected when not in use, captures ink used to keep nozzles clear, and acts as a base to
support media during printing. It is designed to provide a long service life.
To remove Service Station when Printer is powered ON and connected to a computer*:
(*See next page to remove Service Station manually).
1.
Lower Duplex Feeder. Open Print Engine
Access Door on Duplex Printer. Unlatch and
pull out Print Engine.
Release two latches and open Print Engine
Clamshell. (Service Station will not fully
eject with Clamshell closed.)
2.
Open Printer Toolbox. Open “Service” drop-down menu.
Select “Bottom Unit” and click “Eject Service Station”
button. Once Printer pushes Service Station out, turn Duplex
Printer OFF.
TURN PRINTER POWER OFF.
CAUTION
WHENEVER POWERING DOWN UNIT, ALWAYS:
1. PRESS POWER BUTTON ON CONTROL PANEL.
2. WAIT FOR PRINTER TO STOP PROCESSING.
3. THEN PRESS MAIN POWER SWITCH ON REAR PANEL.
136
SECTION 5
MAINTENANCE
3.
Slide Service Station out of Service Station port.
NOTE: DO NOT pull Station all the way out until you
disconnect Ribbon Cable.
NOTE: Place an absorbent towel under Service Station before
removing it to catch any drips or leaks.
4.
Disconnect Ribbon Cable. Slide Latch open on Service
Station Circuit Board to release Ribbon Cable.
Remove Service Station.
To remove Service Station with power OFF and/or Printer not
connected to a computer:
1.
Lower Duplex Feeder.
Open Print Engine Access Door on Duplex
Printer. Unlatch and pull out Print Engine.
2.
Release two latches and open
Print Engine Clamshell.
(Service Station will not fully eject with
Clamshell closed.)
137
SECTION 5
MAINTENANCE
3.
Insert a small Allen wrench into end of worm
gear on Stepper Motor [A]. Turn until Capping
Station retracts to its lowest point.
4.
Place an absorbent towel under Service Station
before removing it to catch any drips or leaks.
GENTLY pull Service Station while turning
large Gear on right side of Print Engine
counterclockwise. Gear should engage gear on
Service Station Roller and push it out. Once
Service Station stops moving; gently pull it out
of Print Engine.
DO NOT force Service Station out if it sticks
or gets caught! Gears and small parts may
break. Make sure the Capping Station is
fully retracted.
NOTE: DO NOT pull Station all the way out
until you disconnect Ribbon Cable.
5.
138
Disconnect Ribbon Cable. Slide Latch open on
Service Station Circuit Board to release Ribbon
Cable. Remove Service Station.
SECTION 5
MAINTENANCE
Cleaning Service Station
1.
Wiper Roller. Lift up Wiper
Roller Assembly. Carefully
loosen two small screws retaining
Wiper Roller Latches. DO NOT
remove screws. Release the two
latches holding Roller.
Remove Roller.
Cleaning: Wipe with distilled
water or immerse for 10 minutes
and pat dry with absorbent towel.
Replace Roller: Make sure gear
on Roller engages gear in the
Service Station Tray. Carefully
close latches. NOTE: Make sure
latches are fully locked and the
screws are tightened.
2.
Wiper Motor Assembly.
See “Removing and Cleaning
Wiper Motor Assembly” on next page.
3.
Printing Platen and Capping Station. Both simply lift out for removal from Service Station. Clean off
ink buildup and debris with distilled water and replace in Service Station Tray.
4.
Service Station Tray. Remove Wiper Roller, Printing Station and Capping Station. Wipe Tray with a
clean, damp, lint-free cloth.
NOTE: Be careful not to get Printed Circuit Board or connections wet.
139
SECTION 5
MAINTENANCE
Removing Wiper Motor Assembly
Remove Service Station.
(See Maintenance Section if not already removed.)
[A] Disconnect Wiper Module cable from Service Station Printed
Circuit Board.
[B] Lift out Wiper Motor Assembly.
[C] Loosen two small screws retaining Wiper Roller Latches just
enough to release (2) Latches.
DO NOT remove screws!
[D] Remove Wiper Roller.
Install in reverse order. Use a foam swab to lightly lubricate
Wiper Gears (3) with Teflon®-based grease (Super Lube 21030 or
equivalent). NOTE: Make sure Wiper Roller Latch Screws are fully
tightened and Latches are fully closed before installing Service
Station into Printer.
Cleaning Wiper Motor Assembly
Remove as specified in “Removing Wiper Motor Assembly” above.
1.
Pour distilled water into a flat-bottom container
about 17mm deep.
2.
Carefully immerse Wiper Assembly, Motor side up, into water.
WARNING!
DO NOT IMMERSE MOTOR OR GET
MOTOR WET TO AVOID DAMAGE.
140
3.
If vents are showing, carefully add more water until they are
covered. Allow Wiper Assembly to soak for 10 minutes.
4.
Carefully remove Wiper Assembly. Inspect vents and remove
any debris with tweezers. Pat dry with an absorbent towel.
SECTION 5
MAINTENANCE
Replacing Service Station Lifting Arms
Replacement Kit includes two Lifting Arms and two C-Clips (one each for operator and non-operator Side
installation.) Service Station must be removed prior to servicing Lifting Arms (see “Removing Service Station”).
1.
2.
3.
Remove C-Clip. Slide Lifting Arm and Spring from stud.
Slip on new Lifting Arm and Spring Assembly. Secure with C-Clip.
Apply a standard silicone or Teflon®-based grease or lubricant (Super Lube 21030 or equivalent) to
Lifting Arm pivot.
141
SECTION 5
MAINTENANCE
Lubricating Service Station
Lubricate friction points on Service Station to ensure optimum performance and reduce wear.
This maintenance should be performed when installing a new Service Station or at least monthly
(after printing about 50,000 pieces.) Use a standard silicone or Teflon®-based grease or lubricant
(Super Lube 21030 or equivalent).
CAUTION
DO NOT USE PETROLEUM-BASED LUBRICANTS OR GREASE.
Removing Service Station provides easier access and reduces chance of excess lubricant
getting into mechanism.
Lubricate Lifting Arm Cams
1.
Open Print Engine Clamshell by releasing and lifting
two locking levers.
2.
Apply lubricant to Lifting Arm Cam through opening
(as shown). (1 on each side.)
Lubricate Service Station Tracks
1.
142
Apply lubricant along full length of Tracks Service
Station moves on (as shown). (1 on each side.)
SECTION 5
MAINTENANCE
Lubricate Service Station Guide
1.
Apply lubricant to Service Station
Guide (as shown). (If Printer is
equipped with this type of Guide.)
Lubricate Lifting Arm Pivot Points
1.
Apply lubricant to Lifting Arm Pivot
(as shown). (1 on each side.)
143
SECTION 5
MAINTENANCE
Reinstall/Replace Service Station
1.
Carefully unwrap 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 LATCHES ON WIPER ROLLER
ARE FULLY LOCKED BEFORE INSTALLING
SERVICE STATION.
144
2.
Slide Latch open on Service Station Circuit Board.
3.
[1] Plug Ribbon Connector (blue side up) into space
under Latch.
[2] Close Latch.
SECTION 5
MAINTENANCE
4.
[1] Slide Service Station into Service Station port until it
touches bar. Align with tracks along sides and Guide on
Service Station dock floor.
[2] Look down through Top Cover to make sure Service
Station is aligned with bar.
IMPORTANT! Service Station must be perfectly
aligned with bar to prevent misalignment and
operating problems.
5.
GENTLY push Service Station while turning large
Gear on right side of Print Engine clockwise. Gear
should engage gear on Service Station Roller and
pull it in. Once Service Station starts moving, stop
turning gear.
145
SECTION 5
MAINTENANCE
6.
Power up unit. Open Toolbox. Click “Service” drop-down
menu. Select “Bottom Unit” and click “Install Service
Station” to pull Service Station in.
NOTE: Make sure wick (hanging below Service Station)
is inside plastic trough inside Ink Tank Station to prevent
ink seepage.
NOTE: Service Station should operate smoothly. If it binds,
chatters or grinds, reinstall Service Station. Lubricate Side
Tracks and Guide if necessary.
7.
Close Clamshell Cover. Slide and latch Print Engine into
cabinet. Close Print Engine Access Door. Return Duplex
Feeder to double-sided printing position.
CAUTION
HOLD ONTO BOTH LATCHES WHEN
OPENING AND CLOSING PRINT ENGINE
CLAMSHELL TO PREVENT DAMAGE.
DO NOT ALLOW CLAMSHELL TO DROP OR
SLAM CLOSED.
Replacing Ink Waste Tray
Ink Tray soaks up any excess ink that may drip from Print Engine during operation. After a period of time it may
become saturated and need replacement.
146
1.
Lower Duplex Feeder.
Open Print Engine Access Door on Duplex
Printer. Unlatch and pull out Print Engine.
2.
Push in on Tabs to release Ink Waste Tray and
remove it from unit.
3.
Replace with a new Ink Waste Tray.
SECTION 5
MAINTENANCE
Cleaning
WARNING!
PRINTER IS A PRECISION MACHINE. CLEAN REGULARLY TO INSURE MANY
YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE,
DISCONNECT MACHINE FROM ITS POWER SOURCE!
DO NOT REMOVE SIDE COVERS! HIGH VOLTAGES PRESENT.
Clean Printer regularly to remove accumulated paper dust and ink. Depending on types of media run, paper dust
may accumulate inside Printer and on Transport.
1.
Turn Printer OFF and unplug it from power receptacle. Then open or remove Covers.
2.
Interior: Use a vacuum with a soft brush attachment or a can of compressed air to help loosen dust
particles. NOTE: Be careful around ink tray and capping station in Print Engine area as accumulated
ink may splash onto other parts of Printer. Take care not to damage PC Boards or electrical wiring.
3.
Exterior: Wipe clean with a lint-free cloth using any standard nonabrasive household cleaner that does not
contain plastic-harming solvents.
CAUTION
NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO PRINTER.
EXCESS LIQUID COULD HARM ELECTRONIC PARTS.
DAMPEN A LINT-FREE CLOTH WITH CLEANER TO CLEAN PARTS.
Duplex Feeder Rollers
Feed Rollers can become glazed with paper lint and ink from media.
Clean Rollers regularly with a mild abrasive household cleaner on a
damp lint-free cloth.
Open the Duplex Feeder Cover [A] to access the Rollers (pinch two
tabs together to release Duplex Feeder Cover latch).
NOTE: Avoid using solvents on Rubber Rollers.
147
SECTION 5
MAINTENANCE
Print Engine
Areas in Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and have to be
cleaned regularly. Open Top Cover. Open Clamshell Assembly by releasing two latches. Use a vacuum to pick up
any loose debris.
NOTE: Be careful around Ink Tray and Capping Station in the Print Engine area as accumulated ink may splash
onto other parts of Printer. Take care not to damage PC Boards or electrical wiring.
CAUTION
USE ONLY DEIONIZED/DISTILLED WATER TO CLEAN PRINT ENGINE
COMPONENTS. AVOID CONTAMINATING PRINTHEAD WITH CLEANERS,
LUBRICANTS OR OTHER CHEMICALS.
[A] Grit Rollers: Clean as needed by moistening
a small hard-bristled brush or toothbrush with
distilled water.
DO NOT use anything other than distilled water to
clean Rollers.
[B & B1] Media Sensors: Paper lint and dust may
build up on the Media Sensors. Use a can of
compressed air or a damp (not wet) foam or lintfree cotton swab to gently swab Exit Sensor [B].
Take care not to drip water into the Circuit Boards.
Use a clean, dry swab to dab surfaces dry.
NOTE: Use compressed air to blow dust and debris
off of clear panel over Sensor Receiver at entry end
of Print Engine [B1] (see inset).
[C] Capping Station Seal and Squeegee. Clean as
needed with distilled water on a damp, lint-free cloth.
Be careful not to splash or drip ink on other parts of the Printer.
[D] Printing Platen. Wipe with distilled water on a damp, lint-free cloth.
Pat dry with a lint-free cloth.
148
APPENDICES
Appendix A – Duplex Printer Specifications
®
PRINT CARTRIDGE
Memjet Replaceable Printhead
SPEED
Up to 3600 letter size pages
(6 ips & 12 ips speeds are the same for single-sided
and double-sided printing)
PRINT QUALITY
(Dots Per Inch)
Best: 1600 x 1600 DPI
Normal: 1600 x 800 DPI
IMAGE AREA
8.5" W x 30" L (216 mm x 762 mm)
INK MONITOR
Viewable in M-Series Toolbox
FONTS
All TrueType fonts available on PC
MEDIA SIZE
(Double-Sided Printing)
Minimum: 3" W x 5" L (76 mm x 127 mm)
Maximum: 9" W x 17" W (228.6 mm x 431 mm)
MEDIA SIZE
(Single-Sided Printing)
Minimum: 3" W x 4.2" L (76 mm x 107 mm)
Maximum: 9.5" W x 17" L (241 mm x 431 mm)
MEDIA THICKNESS
Minimum: 0.004" (0.1 mm)
Maximum: 0.020" (0.5 mm)
FEEDER CAPACITY
Up to one ream of paper (500 sheets) or 500 No. 10 envelopes
INK
Water-based Ink. Five 250 ml Ink Reservoirs (CMYKK).
INK MONITOR
Viewable in M-Series (EWS) Toolbox
DIAGNOSTICS
Viewable in M-Series (EWS) Toolbox
FIRMWARE UPDATE
Flash update through M-Series (EWS) Toolbox
SOFTWARE
Windows
PC INTERFACE
USB 2.0
NETWORK INTERFACE
Ethernet Port
COUNTERS
Permanent lifetime and job counter viewable in M-Series (EWS) Toolbox
DUTY CYCLE
350,000 letter-sized/A4 sheets per month
TM
Printer Drivers for Windows
TM
8, 8.1, 10. RIP available
MACH 5: 20" W x 24" L x 17.25" H (50 cm x 61 cm x 44 cm)
DIMENSIONS
MACH 5DX (w/o MACH 5):
Double-Side Mode: 28.25" L x 33" H x 21.5" W
(71.8 cm x 84 cm x 54.6 cm)
Single-Side Mode: 48" L x 33" H x 21.5" W
(122 cm x 84 cm x 54.6 cm)
MACH 5DX (w/MACH 5 mounted):
Double-Side Mode: 39" L x 54.5" H x 21.5" W
(99 cm x 138.4 cm x 54.6 cm)
Single-Side Mode: 48" L x 54.5" H x 21.5" W
(122 cm x 138.4 cm x 54.6 cm)
WEIGHT
MACH 5: 75 lbs. (34 kg)
MACH 5DX: 72 lbs. (32.6 kg)
MACH 5DX (w/MACH 5 mounted): 147 lbs. (66.6 kg)
ELECTRICAL
115-240 VAC, 50/60 Hz
SUPPLIES
Memjet Printhead
250 ml Ink Tanks: Black (x2), Cyan, Magenta & Yellow
OPTIONS
Conveyor/Stacker, Conveyor Drop Tray, Printer Drop Tray
®
All Specifications Subject To Change Without Notice
149
APPENDICES
Appendix B – Supplies and Optional Hardware
The following supply items and optional hardware are available from your Dealer/Distributor:
Supplies
DESCRIPTION
PART NO.
Printhead Cartridge
M5 PRINT
Wiper Roller
123-2480
Cyan Ink Tank (250 ml)
M5 C250
Magenta Ink Tank (250 ml)
M5 M250
Yellow Ink Tank (250 ml)
M5 Y250
Black Ink Tank (250 ml)
- printer requires two
M5 K250
Waste Ink Tray Pad (pad only)
123-2491
Waste Ink Tray
(Tray with absorbent pad material)
123-2487
Optional Hardware
Conveyor/Stacker with Drop Tray
NOTE: The use of a conveyor is highly recommended.
150
APPENDICES
Appendix C – Ink Flow Diagrams
151
APPENDICES
152
APPENDICES
Appendix D – Duplex Print Engine Wiring Diagram
153
INDEX
INDEX
A
D
Adjust
Feeder Drive Belt ............................................ 84
Paper Path Drive Motor Belt ......................... 100
Alignment, Adjust Printer ........................................ 25
Assemble Printer.................................................... 4, 5
Diagnostics, Toolbox ............................................... 57
Diagrams
Ink Flow ........................................................ 151
Print Engine Wiring ...................................... 153
Disassembly
Print Engine .................................................... 88
Printer.............................................................. 66
Procedures ....................................................... 66
Disposal, Ink Tanks ............................................... 115
Door, Print Engine ................................................... 67
Download Firmware ................................................ 65
DPCA ...................................................................... 93
Remove/Replace ............................................. 93
Wire Connections ............................................ 34
Drive Belt
Adjust Paper Path Motor ............................... 100
Duplex Feeder ................................................. 82
Paper Path Motor ............................................ 99
Drop-Down Menu
Maintenance .................................................... 62
Options ............................................................ 52
Print ................................................................. 63
Service ............................................................ 62
View ................................................................ 52
Dual Pinch Valve, Replace ...................................... 89
Duplex Feeder
Adjust Belt Tension ........................................ 84
Cover ............................................................... 81
Cover Sensor ................................................... 80
Drive Belt ........................................................ 82
Motor .............................................................. 82
Position Sensor, Replace ................................. 74
Remove/Replace ............................................. 78
B
Base, Print Engine ................................................... 88
Belt Tension, Adjust ................................................ 84
Bottom Unit Button, Toolbox .................................. 61
Buffer Boxes, Replacing.......................................... 94
C
Cartridges
Ink Tank .................................................. 20, 112
Printhead ........................................... 22, 44, 116
Chain, Wire Harness Conduit .................................. 70
Choose Location ........................................................1
Circuit Board, Control Panel ................................... 68
Clamshell Assembly .............................................. 105
Clamshell Latch Pins ............................................. 129
Cleaning
Capping Station Seal & Squeegee................. 148
Dual Pinch Valve Sensors ............................... 90
Feeder Rollers ............................................... 147
Grit Rollers.................................................... 148
Ink Revolvers ................................................ 121
Ink Tank Contacts ......................................... 114
Media Sensors ............................................... 148
Pen Driver PCA Contacts ............................. 123
Print Engine .................................................. 148
Printer............................................................ 147
Printhead ................................................. 44, 116
Printing Platen ............................................... 148
Service Station ...................................... 136, 139
Wiper Motor Assembly ................................. 140
Color Tab, Printer Driver......................................... 50
Commands Help, Toolbox ....................................... 61
Connect
Computer...........................................................6
Network ............................................................6
Printers ..............................................................6
USB ............................................................. 6, 11
Control Panel
Indicators................................................... 44, 45
Power Button .................................................. 44
Control Panel Circuit Board .................................... 68
E
Encoder/Encoder Sensor .......................................... 98
Entry Sensor .......................................................... 109
Entry Sensor ............................................................ 75
Error Messages ........................................................ 36
Ethernet Switch ....................................................... 73
Exit Sensor............................................................. 107
Exit Wheels ............................................................. 95
F
Feeder Motor ........................................................... 82
Firmware
Download ........................................................ 65
Install .............................................................. 17
Update ............................................................. 64
154
INDEX
Gear Pulleys, Belt Drive ........................................ 101
General Tab ............................................................. 46
Ground Clips, Lubricate ........................................ 104
Lubricate
Grit Roller Ground Clips............................... 104
Lifter Motor Gear .......................................... 102
Service Station .............................................. 142
Wiper Motor Assembly ................................. 140
I
M
Import/Export Tab, Printer Driver ........................... 50
Indicators, Control Panel ................................... 44, 45
Ink Flow Diagrams ................................................ 151
Ink Lines, Air Bubbles............................................. 29
Ink Revolvers
Cleaning ........................................................ 121
Replace.......................................................... 121
Ink Tanks
Cleaning Contacts ......................................... 114
Disposal ........................................................ 115
Install .............................................................. 20
Latches ............................................................ 96
Remove/Replace ........................................... 112
Storage .......................................................... 115
Ink Usage, Toolbox ................................................. 56
Ink Waste Tray ...................................................... 146
Install
Adapter Feet, Mach 5 Printer ............................4
Firmware ......................................................... 17
Firmware, Top Printer .......................................7
Ink Tanks ........................................................ 20
Printer Communication ................................... 19
Printer Driver .................................................. 10
Printer Driver Over USB ................................. 10
Printer Driver, Network Version A ................. 12
Printer Driver, Network Version B ................. 15
Printhead ......................................................... 22
Service Station .............................................. 144
Main PC Assembly .................................................. 97
Main PC Board Assembly ..................................... 110
Maintenance .......................................................... 111
Maintenance Drop-Down Menu .............................. 62
Maintenance Schedule ........................................... 111
Media Profiles Chart ................................................ 48
Minimum Requirements, System ............................ 10
Motors
Duplex Feeder ................................................. 82
Lifter ............................................................. 102
Paper Path ....................................................... 99
Stepper .......................................................... 103
Wiper .................................................... 139, 140
MPCA Board, Troubleshooting ............................... 30
G
J
Jams, Media ............................................................. 42
L
Latch Pins
Replace Lower Clamshell ............................. 134
Replace Upper Clamshell .............................. 129
Latch, Print Engine .................................................. 77
Latches, Ink Tank .................................................... 96
Layout Tab............................................................... 48
Lever Latch
Replace.......................................................... 124
Replace Solenoid .......................................... 127
Lifter Arm Sensor .................................................... 98
Lifter Motor ........................................................... 102
Lifter Motor/Gear Assembly ................................. 102
Lifting Arms, Service Station ................................ 141
Location, Choose .......................................................1
N
Network Configuration, Toolbox ............................ 58
Network Connect .......................................................6
O
Operation, Printer .................................................... 43
Operator Side Door.................................................. 67
Optional Hardware ................................................ 150
P
Package Contents .......................................................1
Pen Driver PC Assembly ......................................... 95
Pen Driver PC Assembly Contacts, Cleaning ........ 123
Peristaltic Pump, Replace ........................................ 89
Power Supply........................................................... 72
Print Drop-Down Menu ........................................... 63
Print Engine
Access Door .................................................... 67
Base, Remove ................................................. 88
Basic Disassembly .......................................... 88
Buffer Boxes ................................................... 94
Clamshell Assembly ..................................... 105
Cleaning ........................................................ 148
DPCA Board ................................................... 93
Dual Pinch Valve Assembly ........................... 89
Dual Pinch Valve Sensor PC Board ................ 91
Dual Pinch Valve Sensors, Cleaning............... 90
Encoder/Encoder Sensor ................................. 98
Entry Sensor .................................................. 109
Exit Sensor .................................................... 107
Gear Pulleys, Belt Drive ............................... 101
Ink Revolvers ................................................ 121
Latch Pins, Replace ....................................... 129
Lifter Arm Sensor ........................................... 98
155
INDEX
Lifter Motor/Gear Assembly ......................... 102
Main PC Assembly ......................................... 97
MPCA Board .................................................. 30
Paper Path Motor/Drive Belt........................... 99
Pen Driver PC Assembly ................................ 95
Pen Driver PCA Contacts ............................. 123
Peristaltic Pump .............................................. 89
QA Chip Assembly ......................................... 94
Remove/Replace ............................................. 85
Sliding Brackets .............................................. 87
Starwheel Assembly ........................................ 95
Stepper Motor ............................................... 103
Wire Connections ............................................ 34
Printer
Adjust Alignment ............................................ 25
Assembly...........................................................5
Basic Disassembly .......................................... 66
Cleaning ........................................................ 147
Conduit Chain ................................................. 70
Connect .............................................................6
Disassembly Procedures ................................. 66
Duplex Feeder Assembly ................................ 78
Duplex Print Engine Wiring Diagram........... 153
Ethernet Switch ............................................... 73
Feeder End Cover............................................ 69
Feeder Rollers ............................................... 147
Ink Flow Diagrams........................................ 151
Install Mach 5 Adapter Feet ..............................4
Jams, Removing .............................................. 42
Maintenance .................................................. 111
Media Profiles Chart ....................................... 48
Non-Operator Side Cover ............................... 68
Operation......................................................... 43
Optional Hardware ........................................ 150
Power Supply .................................................. 72
Printer Communication ................................... 19
Replace Duplex Feeder Position Sensor ......... 74
Replace Print Engine Latch Sensor ................. 76
Replacing Entry Sensor ................................... 75
Replacing Print Engine Latch ......................... 77
Service Station Transport Tab ...........................3
Set-up ................................................................1
Specifications ................................................ 149
Supplies ......................................................... 150
Top Printer, Install Firmware ............................7
Troubleshooting .............................................. 35
Unpack ..............................................................1
Update Firmware............................................. 64
Printer Driver
Color Tab ........................................................ 50
General Tab ..................................................... 46
Import/Export Tab........................................... 50
Install .............................................................. 10
Layout Tab ...................................................... 48
Network Install, Version A ............................. 12
156
Network Install, Version B ............................. 15
Properties ........................................................ 46
Services Tab .................................................... 51
Top Printer ........................................................8
Uninstall ............................................................8
USB Install ...................................................... 10
Printer Toolbox
Commands Help.............................................. 61
Diagnostics ...................................................... 57
Drop-Down Menu ........................................... 52
Ink Usage ........................................................ 56
Network Configuration ................................... 58
Printer Control Config .................................... 60
Printer Maintenance Config ............................ 61
Scan Sensors ................................................... 59
Service Menu .................................................. 57
System Status .................................................. 53
Top and Bottom Unit Switches ....................... 61
User Interface .................................................. 54
Using ............................................................... 52
Printhead
Cleaning .................................................. 44, 116
Installing ......................................................... 22
Latch Replace................................................ 124
Lever Latch Solenoid, Replace ..................... 127
Remove/Replace ........................................... 116
Service Life ................................................... 120
Storage .......................................................... 120
Troubleshooting .............................................. 29
Q
QA Chip Assembly.................................................. 94
R
Remove/Replace
Buffer Boxes ................................................... 94
Clamshell Assembly ..................................... 105
Control Panel Circuit Board ............................ 68
DPCA Board ................................................... 93
Dual Pinch Valve Assembly ........................... 89
Dual Pinch Valve PC Board............................ 91
Duplex Feeder Assembly ................................ 78
Duplex Feeder Cover ...................................... 81
Duplex Feeder Position Sensor ....................... 74
Encoder/Encoder Sensor ................................. 98
Entry Sensor ............................................ 75, 109
Ethernet Switch ............................................... 73
Exit Sensor .................................................... 107
Feeder Drive Belt ............................................ 82
Feeder End Cover............................................ 69
Feeder Motor................................................... 82
Gear Pulleys, Belt Drive ............................... 101
Ink Revolvers ................................................ 121
Ink Tanks ...................................................... 112
Ink Waste Tray .............................................. 146
Latch Pins, Clamshell ................................... 129
INDEX
Lifter Arm Sensor ........................................... 98
Lifter Motor/Gear Assembly ......................... 102
Main PC Assembly Cover............................... 97
Non-Operator Side Cover ............................... 68
Paper Path Motor/Drive Belt........................... 99
Pen Driver PC Assembly ................................ 95
Peristaltic Pump .............................................. 89
Power Supply .................................................. 72
Print Engine .................................................... 85
Print Engine Base ............................................ 88
Print Engine Latch .......................................... 77
Print Engine Latch Sensor............................... 76
Printer Jams ..................................................... 42
Printhead ....................................................... 116
Printhead Latch ............................................. 124
Printhead Latch Solenoid .............................. 127
QA Chip Assembly ......................................... 94
Sensor, Feeder Cover ...................................... 80
Service Station ...................................... 136, 144
Service Station Lifting Arms ........................ 141
Service Station Sled PC Boards .................... 106
Service Station Tab ...........................................3
Shipping Tape ...................................................3
Sliding Brackets .............................................. 87
Starwheel Assembly ........................................ 95
Stepper Motor ............................................... 103
Transport Locks ................................................2
Wiper Motor Assembly ................................. 140
Wiper Motor Flex Cable PCA....................... 106
Wiper Roller.................................................. 139
Wire Harness Conduit Chain .......................... 70
Rollers, Cleaning ................................................... 147
S
Scan Sensors, Toolbox ............................................ 59
Schedule, Maintenance .......................................... 111
Sensors
Dual Pinch Valve ............................................ 90
Duplex Entry ................................................... 75
Duplex Feeder Cover ...................................... 80
Duplex Feeder Position ................................... 74
Encoder ........................................................... 98
Entry.............................................................. 109
Exit ................................................................ 107
Lifter Arm ....................................................... 98
Media ............................................................ 148
Print Engine Latch .......................................... 76
Sequence of Operation............................................. 43
Service Drop-Down Menu....................................... 62
Service Life, Printhead .......................................... 120
Service Menus
Advanced ........................................................ 60
Basic................................................................ 57
Bottom Unit .................................................... 61
Exit .................................................................. 61
Printer Commands Help .................................. 61
Printer Control Config .................................... 60
Printer Maintenance Configuration ................. 61
Top Unit .......................................................... 61
Service Station
Cleaning ................................................ 136, 139
Install ............................................................ 144
Lifting Arms.................................................. 141
Lubricate ....................................................... 142
PC Boards, Sled ............................................ 106
Remove Transport Tab......................................3
Remove/Replace ........................................... 136
Troubleshooting .............................................. 34
Wiper Motor Assembly ................................. 140
Wiper Motor Flex Cable PCA....................... 106
Wiper Roller.................................................. 139
Services Tab ............................................................ 51
Set-up
Network Configuration ................................... 58
Printer................................................................1
Printer Communication ................................... 19
Shipping Tape, Remove ............................................3
Starwheel Assemblies .............................................. 95
Stepper Motor ........................................................ 103
Storage
Ink Tanks ...................................................... 115
Printhead ....................................................... 120
Supplies ................................................................. 150
System Requirements, Minimum ............................ 10
System Status, Toolbox ........................................... 53
T
Top Unit Button, Toolbox ....................................... 61
Transport Locks .........................................................2
Troubleshooting ..................................................... 27
Air in Ink Lines ............................................... 29
DPCA Wire Connections ................................ 34
Errors and Warnings ....................................... 36
Feeding Problems ............................................ 28
Interface Communication ................................ 27
Main Printed Circuit Assembly (MPCA) ........ 30
Power .............................................................. 27
Printhead ......................................................... 29
Printing Problems ............................................ 35
Service Station ................................................ 34
Software Problems .......................................... 35
U
Uninstall Printer Driver .............................................8
Unpack.......................................................................1
Update Firmware ..................................................... 64
USB Port.............................................................. 6, 11
User Interface, Toolbox ........................................... 54
Using Printer Toolbox ............................................. 52
157
INDEX
V
View Drop-Down Menu .......................................... 52
W
Warning Messages ................................................... 36
Waste Tray, Ink ..................................................... 146
Wiring
Duplex Print Engine Diagram ....................... 153
MPCA Connections ........................................ 30
Print Engine Connections ................................ 34
158
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